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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to intensified treatment of wastewater containing excreta that is contaminated with highly concentrated Nitrogen and dissolved organic matter (COD). More particularly, plants such as algae and diatoms cultivated under a special environment are adopted to effectively remove the insoluble residues of Nitrogen and COD in nature.
[0003] 2. Related Prior Art
[0004] There are three essential needs, i.e., water, air, and soil, for life to survive in this world. However, our environment is contaminated year by year to such a point that we have to worry about the drinking water and breathing air. Due to increasing pollutants, such as carbon dioxide (CO2), oxides of nitrogen (NOx) or dioxin in the air, the global weather becomes unstable. Furthermore, the toxic wastewater discharged from the industrial plants or farmland without sufficient treatment pollutes our reservoirs.
[0005] The facts listed below are a few of many life threatening water pollution issues stemming from livestock farms:
[0006] California officials identify agriculture, including cattle farms, as the major source of nitrate pollution in more than 100,000 square miles of polluted groundwater.
[0007] Huge open-air waste lagoons, often as big as several football fields, are prone to leaks and spills. In 1995 an eight-acre hog-waste lagoon in North Carolina burst its banks, spilling 25 million gallons of manure into the New River. The spill killed about 10 million fish and closed 364 , 000 acres of coastal wetlands to shell fishing.
[0008] From 1995 to 1998, 1,000 spills or pollution incidents occurred at livestock feedlots in 10 states and 200 manure-related fish kills resulted in the death of 13 million fish.
[0009] Ammonia, a toxic form of nitrogen released in gas form during waste disposal, can be carried more than 300 miles through the air before being dumped back onto the ground or into the water, where it causes algal blooms and fish kills.
[0010] These examples are only part of countless water pollution problems that current livestock farms face. Even with the current technology, the amount of COD and nitrogen generated are still large enough to cause pollution.
[0011] The tertiary treatment for the swine farm waste matters were evaluated in the laboratory and in full-scale micro-algal ponds and achieved the removal of COD, BOD, inorganic nitrogen and orthophosphate up to 57%, 69%, 79% and 74%, respectively. Despite much research, a complete treatment for swine excreta has not yet been developed. As a result, it still causes pollution in the water reservoirs.
[0012] Further research is ongoing to develop a bio-filter for lowering the highly concentrated nitrogen. Other research is being performed for developing a bio-film to lower COD concentrations. A study has reported that the removal rate of the COD is up to 65% (from 1500 to 380 mg/L) by using the bio-film.
[0013] Even though many studies are ongoing in the field of wastewater treatment, there are no perfect solutions developed to prevent water pollution.
[0014] Despite the tremendous efforts to reduce pollutants, the current technology is inadequate to effectively prevent the increasing pollution.
SUMMARY OF THE INVENTION
[0015] In order to overcome the aforementioned problems, a biological treatment means for completely removing the final residues discharged from dissolved organic matter (COD) is provided.
[0016] An objective of the present invention is to employ algae and diatoms that are cultivated under special conditions to treat wastewater containing animal or human excreta, applying Calcium Salt and Silica Salt to develop a competent cell in the algae and diatoms, removing un-dissolved residues after decomposing the dissolved organic matter (COD) contained in the wastewater and animal excreta, removing pollutants contained in the wastewater through a series of multiple stage treatment tanks consisting of 3˜1,000 steps, each 4˜8 inches in width, and sequentially diluting the wastewater under different cultivating conditions.
[0017] Another objective of the present invention is to provide an elevating means for efficiently cultivating the algae and diatoms by using artificial illumination, a means for insulating the cultivation site of the algae and diatoms with vinyl or glass to maintain optimum temperature, and a means for photosynthesizing nitrate gas without forcibly expelling nitro-nutrition dissolved in the wastewater to the air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a series of multi-stage treatment tanks of the present invention.
[0019] FIG. 2 is an UV scanning for comparing the swine wastewater treatments.
[0020] FIG. 3 is a visible ray scanning for comparing the swine wastewater treatment methods.
[0021] FIG. 4 is an UV scanning of the swine wastewater treated by the algae and diatoms to show progressing for a week interval.
[0022] FIG. 5 is an UV scanning of Humic Acid (compost comes from the pine trees and oak trees) treated by the algae and diatoms to show progressing for a week interval.
[0023] FIG. 6 a is an UV scanning of wastewater containing coffee residues treated by the algae and diatoms to show progressing for a week interval.
[0024] FIG. 6 b is an UV scanning of wastewater containing coffee residues treated by the bacteria and fungi.
[0025] FIG. 7 shows Table 1 for a result of the swine wastewater treatments and Table 2 for comparing the treatment results of the new and old technologies.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Ecosystems are dynamic entities composed of the biological community and the abiotic environment. The composition and structure of biotic and abiotic members of the ecosystem are determined by the state and numbers of interrelated environmental factors.
[0027] The natural ecosystem made up of abiotic factors and biotic factors, i.e., plants, animals, and microorganisms. The flow of energy and matter through the ecosystem is regulated by the complex interactions of the energy, water, carbon, oxygen, nitrogen, phosphorus, sulfur, and other cycles that are essential to the functioning of the biosphere. Biotic factors consist of three kinds: Plants, such as algae, diatoms, and photo-bacteria belong to the production class, animals belong to the consumer class, while bacteria and fungi belong to the decomposer class. The elements composed of the plant and animal in nature are decomposed for circulation by the bacteria and fungi class. Even though the decomposer class decomposes the production and consumer classes, there always remains some Humic acid. Plenty of Humic substances, which are ubiquitous in the environment, are built up in the forest or soil. They may constitute as much as 95% of the total dissolved organic matter in aquatic systems and often are equal to or greater than the concentrations of inorganic ions present.
[0028] Over the last 150 years much has been learned about the chemistry of organic matter. Some of the earliest work by Sprengel on the fractionation of organic matter still forms the basis of methods currently in use. These methods utilize dilute sodium hydroxide (2 percent) to separate humus as a colloidal sot from alkali-insoluble plant residues.
[0029] The environmental contaminants of recent concern are pharmaceuticals, estrogens and other endocrine disrupting chemicals (EDC) such as degradation products of surfactants, algal and cyanobacterial toxins, disinfection by-products (DBPs) and metalloids. In addition, pesticides, especially their transformation products, microorganisms, and Humic substances (HS), in their function as vehicles for contaminants and as precursors for by-products in water treatment, traditionally play an important role.
[0030] If the Humic acid were combined with iodine, it would be a serious problem for the tap water.
[0031] After treating the wastewater containing the human or animal excreta, the Humic acid still remains in the treated water. In the case of human, when the human eats and digests the food to absorb nutrition, the remaining substance is discharged by the bowel movement. Then, a lot of bacteria are proliferated to further decompose the remaining substance. The process of producing Humic acid in the animal case is similar to the case of human. Because the dissolved organic matters cannot be completely removed during the wastewater treatment process, it will cause a water pollution problem.
[0032] Since a century ago, bacteria and fungi have been used for decomposing the wastewater containing excreta. The food in the human's stomach and intestinal tract is decomposed by digestive enzymes, and the human bowel movements are decomposed by bacteria and fungi in nature.
[0033] For the general case, most dissolved organic matters in the influent wastewater are decomposed by the bacteria and fungi and the black colored residues of the insoluble organic matters remain. To remove such insoluble organic matters, it will require the huge, costly, and complicated facilities.
[0034] In the active sludge method, the bacteria and fungi decompose the dissolved organic matters in the wastewater. At the same time, plenty of final product remains, which is known as compost, consisting of insoluble organic matter (BOD, COD). Such compost in the wastewater consists of a hundred species of low molecular substances that are hard to decompose by the bacteria and fungi.
[0035] The objective of the present invention is to provide a new technology to treat the compost that is insoluble organic matter in the wastewater at relatively lower cost. Under the special environment, the cultivated algae and diatoms will absorb the insoluble organic matters in the wastewater, which originally belongs to the plant species.
[0036] Up to the present time, the scientist understands that the bacteria or fungi belong to and act as a decomposer in the Ecosystem. Therefore, the scientist uses the bacteria and fungi for decomposing excreta. Nevertheless, a new discovery through the present research shows that the bacteria and fungi act as not only the decomposer, but also a consumer similar to the role of the human being in the Ecosystem. The compost which remains after decomposing by the bacteria or fungi are analogous to the bowel movement of the human being.
[0037] The foods in our stomach are decomposed by the digestive enzymes for absorbing the nutrition into our body. The nutrition absorbed in our body is further decomposed in the blood cells by enzymes or hormones and finally the remaining residues are discharged through the urine. The food decomposed in our body by the digestive bacteria turns to a bowel movement. The mixture of urine and bowel movement is further decomposed by the stronger bacteria in the septic tank.
[0038] Accordingly, the scientist uses the bacteria or fungi for treating the waste material. Up to the present time, the algae and diatoms are rarely used to treat the waste material. Furthermore, since animal excreta have already decomposed once in the animal's stomach, it takes a longer time to be further decomposed by the stronger bacteria and fungi and insoluble organic matters remain in the nature quite a longer time.
[0039] Even though the commercialized treatment of the swine excreta includes a biological treatment after separating the solid stuff, the effluent of the treated water still contains COD in concentrations of 100˜500 ppm, which is not suitable to discharge into the environment. The Total Nitrogen (TN) has a level of 10-40 ppm, which is high enough to pollute the water reservoir.
[0040] The conventional treatment method uses a flocculant to separate the solid portion and the liquid portion from the collected swine farm excreta. The separated liquid portion is primarily treated by the active sludge treatment method, and then the treated liquid portion is discharged through ultra filtration.
[0041] It is also hard to treat the wastewater or sewage containing human excreta. Due to the composts, which are insoluble COD, it causes water pollution. The sewage disposal plant uses the active sludge treatment method to remove the organic substance and nitrogen components. However, the treatment efficiency is very poor because the wastewater contains too many insoluble organic substances. Therefore, the scale of the treatment facility is getting larger to remove the large amount of BOD and nitrogen.
[0042] The treatment facility comprises a series of 3 to 1,000 multiple stage treating tanks, each approximately 4˜8 inches in width. While the wastewater being treated is flowing down the series of stages, the effluent of wastewater is treated by the photosynthesis of the algae. Each tank is filled with a mixture of soil 70%, oyster powder 25% and phosphate rock 5%.
[0043] Once the city sewage water, or the wastewater separated from the solid stuff, has passed through the collecting basin, Calcium salt (50 ppm of Ca(OH)2) is added to the water being treated.
[0044] Due to the Calcium salt reaction, the cell membrane of the algae and diatoms will change to increase the permeability and easily absorb the residues of the dissolved organic matters in the wastewater being treated. Once the algae and diatoms absorb the residues of the dissolved organic matters, it will be used to photosynthesize in their cells.
[0045] Under a special environment, plants such as algae and diatoms have a tendency to form excellent solubility cells. Those plants are able to absorb the insoluble organic matter, which the bacteria could not decompose. Even though the Calcium Salt is not added in the treating tanks, the algae and diatom flourish. But, it is found that the COD substances are not significantly diminished.
[0046] The soil is used as a filtering material because the diatom requires Silica to proliferate.
[0047] As presently known, the algae and diatoms belong to a class of independent nutrition species that produces carbohydrates, which are necessary to proliferate and survive, by photosynthesis.
[0048] According to the present research, it is newly discovered that the algae and diatoms are absorbing the insoluble organic substances in the wastewater while the algae and diatoms are photosynthesizing with nitrogen and carbonate. It is also verified that more than 95% of the dissolvable organic substances known as Humic acid are consumed as the algae and diatoms grow.
[0049] The Humic acid is a residue that is left over after the bacteria and fungi have decomposed the dissolved organic matters in the wastewater over a long period of time.
[0050] The residues of the sewage, animal excreta and human bowel movement are the remaining insoluble organic matter after decomposition by the bacteria or fungi for a long time. Through the present research, it is discovered that the algae and diatoms have the capability to absorb the residues that remain after the bacteria and fungi have decomposed the dissolved organic matters in the wastewater. This discovery is applied to the new concept of treatment. However, this concept extends the current understanding that organic matter is decomposed by the bacteria and fungi.
[0051] By virtue of the present discovery, it becomes possible to employ algae and diatoms to effectively decompose the insoluble organic substances in wastewater.
[0052] The treating process is as follows: the sewage water or wastewater flows down through a series of multi-stage filtering tanks, which contain transplanted algae and diatoms along with filtering materials. It will take 5 to 7 days to fully grow the transplanted algae and diatoms.
[0053] Each filtering tank has a compartment wall to sequentially over-flow the wastewater along the flow stream. There are several different kinds of algae and diatoms being cultivated depending on the concentration of pollutants in the wastewater, from a higher level to a lower level. In order for the algae and diatoms to survive in the highly concentrated wastewater, the highly concentrated wastewater at the initial stage may be diluted by mixing with the finally treated wastewater. It is recommended that the wastewater being treated must have COD levels of 60 ppm at the initial stage of the treatment.
[0054] Due to the varying concentration of the wastewater along the flow stream, the environmental conditions of the cultivated algae and diatoms are different along the treatment stages.
[0055] The algae and diatoms transplanted from natural streams are easily enriched while the algae and diatoms are in contact with the wastewater.
[0056] Daylight is good to cultivate the algae and diatoms. However, it may be needed to install artificial illumination and thermal insulation for the night time hours. A glass, plastic or vinyl cover could be used for protection or thermal insulation of the cultivating algae and diatoms. In order to stimulate the photosynthesis of the cultivating algae and diatoms, a small amount of air may be supplied in the treatment tanks. Such a treatment method of the present invention results in wastewater that is clean enough to solve pollution problems.
[0057] Regarding the structure of the New Treatment Method, a new technology uses a combination of the conventional wastewater treatment with the algae and diatoms to complement the insufficient wastewater treatment and bring the water treatment technology to near perfection. The conventional wastewater treatment uses the method of de-nitrification to convert the toxic substances, such as NO2 and NH4, into a stable nitrate. This process requires a highly expensive treatment facility. However, the amount of nitrate reduction by the conventional de-nitrification method is not sufficient to cut down the current pollution levels. The new method could solve both high cost issues and insufficient wastewater treatment technology.
[0058] The new treatment process incorporates the idea of ecosystem balancing. Total nitrogen (TN) is eliminated through a decomposition process in the ecosystem while the synthesis process is performed by the water plants and microorganisms in the water. The microorganisms use (absorb) the waste products in the wastewater such as NO3, NH4 and CO2, as their nutrition resources. As microorganisms and water plants grow, NO3, NH4 and CO2 are eliminated from the wastewater. Therefore, the major water pollutants, NO3 and NH4 are naturally eliminated while CO2 is removed from the air.
[0059] Additives are used to balance the wastewater being treated. From the conventional wastewater treatment system, the water flows through the final process still containing high COD which creates a “dead zone” where there is not enough oxygen to support aquatic life. Since the new treatment process will reduce the remaining high COD and nitrate from the water, “dead zone” issues will be resolved. Therefore, the treated water is nearly equal to spring water at the end of the treatment process.
[0060] As shown in FIG. 1 , the bottle marked “0” contains swine wastewater treated by the conventional biological treatment. After applying the new method, slight improvement was made in the bottle marked number “1”. After several steps, the bottle marked number “4” became significantly clear, to a quality level near that of pre-processed tap water.
[0061] The wastewater of hog's excreta, which is three times more toxic than that of human, causes a serious polluting problem to the water. As previously mentioned, the conventional technology can remove only 98 or 99% of the contaminants in wastewater. However, using the new technology, almost all contaminants were removed in the fully treated wastewater.
[0062] The experimental data is shown in Table 2, representing the most highly effective method found in the conventional wastewater treatment. In this research, the test medium was collected from a swine wastewater treatment facility in South Korea. The wastewater sample was collected from the water that had undergone the complete treatment process, which has COD level of 350 mg/l, total nitrogen (TN) level of 60 mg/l, and biological oxygen demand (BOD) level of 20 mg/l.
[0063] Even though the wastewater had been fully treated by the conventional technology, it still contained levels of COD and nitrogen high enough to threaten the water reservoirs. It is prohibitively expensive to lower the contaminants in the wastewater to the level of pre-processed tap water.
[0064] As shown in FIG. 2 , the UV ray analysis of influent and effluent wastewater in the present experiment is presented. UV analysis shows more peaks whenever there is some kind of substance in the wastewater. The peak and enclosed area is the scanning result of swine wastewater after conventional biological treatment. The blue area shows the scanning result of the treated sample undergoing the new method of this research. Most residue contaminants are removed, as shown in the brown area. Further, the blue portion of the remaining residue contaminants can be reduced further by increasing the duration of the treatment.
[0065] This research has discovered an advanced method to fully treat water that still contains high levels of residue contaminants to the level of pre-processed tap water, reducing the amount of residue contaminants to less than 1 to 3 mg/l at an optimal cost. Although the new technology requires 10% additional cost compared to a conventional treatment system, the new technology will eliminate a system of higher cost in the current treatment system. Consequently, the overall cost is significantly reduced compared with the conventional wastewater processing system.
[0066] As shown in FIG. 3 , visual ray analysis of influent and effluent wastewater in this experiment is presented. The visual ray analysis represents how many opaque particles are present in the water. The figure shows the influent having an absorbency of 1.500 at a wavelength of 400.0 nm. At the same wavelength, the absorbency of the effluent is significantly reduced, down to 0.020. The entire yellow area was reduced down to the tiny blue area along the horizontal axis after adopting the new treatment method. The most purified water (double distilled water) would be just a line along the horizontal axis.
[0067] When the new highly effective wastewater treatment is applied to current wastewater facilities throughout the world, the current water pollution crisis can be resolved.
[0068] The present research addresses the current insufficient wastewater treatment process providing the following results:
[0000] 1. Significant reduction of chemical oxygen demand (COD) and nitrate in wastewater that had been already processed through a conventional treatment system up to 99%.
[0000] 2. The reduction of the large amount of COD and nitrate in the water helps to prevent algal bloom and red tide in the long term.
[0000] 3. Reduction of a significant amount of carbon dioxide in the air.
[0000] Accordingly, the present research results reveal the following:
[0069] 1. The current swine wastewater treatment level is limited to COD 100-500 mg/l, TN 10-40 mg/l. Through this research, it was found that it is possible to treat the final product once more to achieve a 99% reduction, which is down to COD<3 mg/l, TN<1 mg/l, and BOD<1 mg/l. This contaminant level can be improved further by lengthening the process period.
[0070] 2. It was found that non-decomposition materials found in swine wastewater were perfectly decomposed by algae and diatoms. Many other contaminant products that can be seen by UV ray had been mostly eliminated as well as those seen by visible ray (refer to attached test data graph).
[0000] 3. As the population of algae and water plant increases using TN as their nutrition resource, mineral substances are eliminated to the point of pre-processed tap water condition.
[0000] 4. The additional cost to further reduce the amount of contaminants in conventionally treated wastewater up to 99% is minimal compared to the current treatment system/equipment.
[0000] 5. In the long term, as this new method of wastewater treatment is applied, algal bloom and red tide issues will be resolved.
[0000] 6. Algae and plant products collected from the water treatment process can be used as alternative resources such as fertilizer or alternative energy material.
[0071] Currently in S. Korea, over five hundred thousand tons of treated wastewater containing nitrogen is discharged through rivers to the ocean per year. Thus, by collecting this amount of nitrogen as plants can result in collecting 50 million tons of CO2 from the air. This amount is five times the target rate of ten million tons for the current South Korean government. (Assuming C:N ratio of Algae as 30:1 then converting to CO2 will bring about 100 times.)
[0072] Therefore, if the new technology is applied, the impacts on water and air environments are tremendous. This research found that improvement on current wastewater treatment processes could resolve both water and air pollution. This new method will bring nearly perfectly treated water at a much lower cost. Thus, tremendous positive results can be achieved by combining elimination of water pollutants such as COD and nitrate with air pollutants such as CO2.
IMPLEMENTING EXAMPLE 1
[0073] An animal farm employs a facility to treat the animal excreta of 5,000 swine. The collected animal excreta of 30 tons per day are pre-treated to separate the solid portion and liquid portion by adding precipitants. The liquid portion is pre-treated 24 hours to be COD 542 ppm, TN 96 ppm by the active sludge treatment. Then 50 ppm of Ca++ (calcium) salt is added to the pre-treated wastewater. Then, the pre-treated wastewater is sequentially flowed through the multi-filtering tanks, in which are cultivated the algae and which are filled with a mixture of soil, oyster powder and phosphate rock. The filtering tank has a 30 ton capacity and consists of 5˜10 stages. The UV scanning analysis of the fully treated effluent water is shown in FIGS. 2 and 4 .
[0074] As seen in FIG. 2 , the comparison of the before and after treatments for the swine wastewater, it is shown that many kinds of organic substances are evident before the treatment. However, most of the organic substances are nonexistent after the treatment with below 3 ppm of COD.
[0075] In the analysis by the visible ray, the comparison of before and after treatments of the swine wastewater shows that most of the brownish colored organic substances are eliminated after treatment.
[0076] For example, the result of the wastewater treatment is shown in Table 1 for the swine excreta in the United States. Even though most pollutants (98˜99%) are removed, the remaining pollutants (1˜2%) in the effluent cause serious problems as they accumulate.
[0077] As shown in Table 1, an example of a current swine waste treatment result is presented that:
[0078] In order to prevent polluting water from such swine wastewater, the remaining 1˜2% of pollutants must be further processed before dumping into nature. Unfortunately, the current technology of the biological treatment cannot completely remove the remaining COD and Nitrogen. As shown in FIG. 1 , the chemical oxygen demand (COD) is composed of several hundred organic compounds. These organic compounds cannot be decomposed by the bacteria or fungi.
[0079] Throughout the current research, the organic compounds that cannot be degraded by bacteria or fungi are found to be easily removed by the algae and diatoms cultivated under a special condition. Algae and diatoms utilize COD and nitrogen as their growth nutrients. Such removal is up to a point where there is hardly any trace of COD and nitrogen compared to the conventional technology.
[0080] Such a technology may seem improbable and very expensive, but it is proven to be extremely successful and very effective at lowering the cost during the research. Applying the breakthrough technology could be more than enough to stop accumulating residual pollutants in the water. In addition to reducing water pollution, the new method will also help reduce air pollution and soil pollution.
IMPLEMENTING EXAMPLE 2
[0081] For treating the urban sewage water, the solid substance in the wastewater is settled out in the precipitation tanks. Then, calcium salt (Ca) is added to the primarily treated wastewater. Then, the primarily treated sewage water is sequentially flowed through the multi-filtering tanks (same as in example 1). A small amount of air is supplied for diluting the carbon dioxide. For stimulating the photosynthesis of the algae and diatoms, artificial illumination is installed under or above the water being treated.
IMPLEMENTING EXAMPLE 3
[0082] For treating the runoff wastewater from a garbage dumpsite, calcium salt (Ca) is added into the runoff wastewater. Then, the primarily treated wastewater is sequentially flowed through the multi-filtering tanks (same as in example 1). A small amount of air is supplied for diluting the carbon dioxide. For stimulating the photosynthesis of the algae and diatoms, artificial illumination is installed under or above the water being treated.
IMPLEMENTING EXAMPLE 4
[0083] For treating the sewage stream of wastewater, calcium salt (Ca) is added into the sewage stream. Then, the primarily treated sewage water is sequentially flowed through the multi-filtering tanks (same as in example 1). A small amount of air is supplied for diluting the carbon dioxide. For stimulating the photosynthesis of the algae and diatoms, artificial illumination is installed under or above the water being treated.
IMPLEMENTING EXAMPLE 5
[0084] For treating colored wastewater, which contains the residue of coffee or red tea, calcium salt (Ca) is added into the colored wastewater. Then, the primarily treated wastewater is sequentially flowed through the multi-filtering tanks (same as in example 1).
[0085] The scanning tests of the Implementing Examples 1 to 5 are shown in FIGS. 4 to 6 b.
[0086] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A method of biological treatment is developed for completely removing the compost remaining after decomposing the dissolved organic matter (COD) in wastewater by the bacteria or fungi. It comprises the steps of: adopting the algae and diatoms cultivated under the special conditions to treat wastewater containing excreta, applying Calcium Salt and Silica Salt to develop a competence cell in the algae and diatoms, removing insoluble composts after decomposing the dissolved organic matter (COD), removing pollutants in the wastewater by flowing through a series of multi-stage filtering tanks consisting of 3˜1,000 stages each 4˜8 inches in width and sequentially treating the wastewater through the algae and diatoms cultivated under different conditions, improving the cultivation efficiency of the algae and diatoms by installing artificial illumination, insulating the cultivation place of the algae and diatoms to maintain optimum temperature, and stimulating the algae to photosynthesize with nitrate-gas without forcibly expelling to the air. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a vehicle steering system with a device for changing the gear ratio, and with an electrical auxiliary drive.
A series of vehicle steering systems is known, for which the function of rotational speed conversion and an auxiliary drive are realized in separate devices.
Accordingly, in the DE 19823721 A1, a rotational speed superimposition is introduced. A housing, in which there are gearings of an internal gear wheel of two planetary gear trains, is driven here by a driving wheel. An electric motor, disposed in the housing, drives the sun wheel of the second planetary gear train. The planet carrier of the first planetary gear train drives the sun wheel of the second planetary gear train. The planet gears of the second planetary gear train are supported at the internal gear wheel of the housing and the planet carrier is connected with the transmission output shaft. In the embodiments shown, the driving mechanism of the sun wheel of the first planetary gear train is realized directly by the rotor of the electric motor. The desired rotational speed gear ratios can be represented by an appropriate control of the electric motor. However, this solution, shown in the state of the art, has some decisive disadvantages. When the steering wheel is turned, the whole unit is turned along with it. Therefore, when turning the steering wheel, the driver must employ the whole driving torque for turning the steering pinion and, additionally, overcome the inertia of the whole unit. In order to equalize this, such systems are equipped with an additional auxiliary power support at a different place. In addition, such a transmission unit is afflicted with play. As a result, the driving shaft and driven shaft must be mounted, so that the whole unit is held and a connection with a high positional stability between the steering wheel and the driven shaft is attained. This represents a not inconsiderable structural expense. Furthermore, the coupling of electric energy into the electric motor, which rotates along with the steering wheel, is expensive.
In a further state of the art, the DE 19852447 A1, a solution for the rotational speed conversion is introduced, for which the electric motor is coupled over a worm drive with the speed-changing transmission constructed as a planetary gear train. The transmission unit is fixed to the car body here, so that the driver does not have to support the whole of the torque, which is introduced by the electric motor. However, a series of disadvantages is also associated with this solution. The coupling-in over a worm transmission leads to very low efficiencies in the rotary speed conversion. Furthermore, the arrangement requires appreciable space, which, due to the geometrically determined positions of the components with respect to one another, is not very flexible. Here also, an additional auxiliary power support is required at a different place.
Moreover, the above-mentioned state of the art jointly has even further disadvantages. All steering systems require the highest degree of safety in the event of a failure of the electrical components. For example, it must be possible to steer the vehicle even if the electric motors fail. For the state of the art shown above, this means that, in the event of a power failure or other disorder, the torque, introduced by the steering wheel, must not be introduced into the electric motor. For this purpose, the transmissions with high conversions are designed with self-locking. However, this leads to low efficiencies and slow response times of the electric motor driving mechanisms. Independently of the change in the rotational speed conversion, an additional driving mechanism is required as power support for the steering (power steering).
It is an object of the invention to eliminate the disadvantages of the state of the art and, at the same time, to make a compact component available, the reaction force on the steering wheel not being increased noticeably if at all. At the same time, the system shall offer in a simple way the necessary redundancy in the event of a malfunction of the electrical units.
Pursuant to the invention, the whole of the steering device has only one electric motor, which, at the same time, introduces the energy for the desired rotational speed conversion and the auxiliary power support into the system. This inventive, new device, in which the change in the conversion ratio as well as the introduction of the auxiliary power is realized, is referred to in the following as steering differential. The torques from the steering wheel and from the electric motor are introduced into the steering differential and the whole of the torque is passed on to the steering adjustment. In so doing, it is unavoidable that the torque, introduced by the electric motor, must be supported at least partially at the torque, introduced by the steering wheel.
In contrast to the state of the art, however, the housing of the conversion ratio device is fastened to be body of the vehicle. However, by selecting suitable mechanical conversions in the superimposed gear mechanism between the driving mechanism of the electric motor, of the drive shaft driven by the steering wheel and the drive shaft, the torques, which become noticeable at the steering wheel and the torques, which are made available for adjusting the wheels, can be adjusted largely as desired to a fixed ratio to one another. In this connection, it should be noted that, for steering a vehicle, a driver requires a torque Ma. Due to this configuration, the number of components of the steering device is reduced significantly, because only one electric motor and, with that, only one crank mechanism is required in the steering device.
Pursuant to the invention, the electric motor, the drive shaft, which is connected non-rotationally with the steering wheel, and the driven device assigned to the wheels, such as a driven shaft or steering rack, are disposed coaxially with one another. The steering differential consists of two planetary gear trains, which are mounted in one housing and with the help of which the appropriate transmission conversions are realized. As a result, the construction becomes very compact.
In a special, preferred embodiment, a permanently energized synchronous motor is used as electric motor. For this electric motor, the stator with the energizing coils is connected permanently with the housing of the device and the rotor is disposed coaxially in the interior, surrounds the driven device and transfers its torque to the planet carrier of the first planetary gear train and, with that, causes the first planet carrier to rotate. By these means, the planet gear wheels are caused to rotate and, at the same time, are supported at the half of the internal gear wheel fastened to the housing. As a consequence, the torque is transferred to the second rotatable half of the internal gear wheel with a number of teeth different from that of the first internal gear wheel that is fastened to the housing. This second, rotatable half of the internal gear wheel is coupled non-rotationally with a first half of an internal gear wheel of the second planetary gear train. In this way, the torque is transferred from the first to the second planetary gear train. The torque is transferred from this half of the internal gear wheel to the planet gear of the second planet carrier. If the number of teeth of the first half of the internal gear wheel and the number of teeth of the second half of the internal gear wheel of the second planetary gear train are different, the torque is transferred to the second planet carrier. At the same time, the second planet carrier, in the coupled state, is connected non-rotationally with the drive shaft, which is connected non-rotationally with the steering wheel. By these means, the torque of the drive shaft is transferred to the second planet carrier. Moreover, the torques, introduced by the electric motor into the second planet carrier, are supported by the steering wheel.
The planet gears of the second planet carrier transfer the torque to the second half of the internal gear wheel. Due to the arrangement, the torque, introduced by the electric motor, and the torque, introduced by the steering wheel, are introduced as a sum into the second half of the internal gear wheel of the second planetary gear train.
The second half of the internal gear wheel of the second planetary gear train introduces the torque directly into the non-rotationally connected driven device. The driven device may be a driven shaft or a conversion transmission for converting the rotational movement into a translational movement, for example, a ball-type linear drive.
The arrangement of the stator of the electric motor with the energizing coils, the stator being fixed to the housing, makes it easily possible to couple the electric motor electrically to the vehicle.
Moreover, the arrangement of the steering differential, attached to the body of the car, increases the positional stability between the steering wheel and the power take-off in a structurally simple manner.
Pursuant to the invention introduced, the steering differential can be disposed between the steering gear and the steering wheel, as well as between the steering gear and the steering tie rod. The selection is made in accordance with the respective circumstances of the available space and according to other technical and commercial requirements. In the event that the steering differential is disposed between the steering gear and the steering tie rod, the drive shaft will usually be connected directly with a conversion transmission for converting a rotational movement into a translational movement. For example, a ball-type linear drive is driven directly here.
Advantageously for the further development of the invention, a safety clutch or a circuit, which forces a direct mechanical coupling between the driving shaft and the driven shaft in the event of a fault or of special driving situations, such as a power failure, a computer defect or, when the ignition is switched off, etc., is integrated in the steering differential. The torque, introduced by the electric motor, is then without effect and the driver, due to the mechanical coupling, has complete control of the steering system.
The same coupling may be provided with a different step, for which the drive shaft and, with that, the steering wheel are uncoupled or also locked in position against rotation under pre-tension. However, the driven shaft is controlled by the electric motor by a control device. This last case may be used, for example, for automated parking. In this way, even functions, which otherwise can be represented only with a steer-by-wire system, may be realized.
In an alternative embodiment, the electric motor is disposed parallel to the axis of the steering differential and is coupled over a spur gear or belt drive or chain drive to the conversion transmission or driving transmission.
The inventive transmission may also be operated with a hydraulic driving mechanism, such as an orbital engine or a “reversed” vane-type pump.
As an alternative to using planetary gear trains, it is also possible to use other planetary gearing, such as a harmonic drive transmission. The transmissions may also be constructed as friction drives.
BREIF DESCRIPTION OF THE DRAWINGS
An example of the invention is shown in the following. In the drawing
FIG. 1 shows a diagrammatic construction of a steering system with auxiliary power support,
FIG. 2 shows a longitudinal section through a preferred embodiment of a steering differential with an integrated safety clutch and an integrated “automatic operation”, the “manual operation” being shown above the center line of the switch setting and “operation with power support” being shown below the center line of the switching setting,
FIG. 3 shows a longitudinal section corresponding to FIG. 2 ; in this case, however, the “manual operation” switch setting is shown above the center line and the “automatic operation” switch setting is shown below the center line and
FIG. 4 shows a cross-section along the cutting plane IV-IV in FIG. 2 or FIG. 3 .
DESCRIPTION OF THE INVENTION
The diagrammatic construction of a steering device 29 , shown in FIG. 1 as steer-by-wire arrangement or steering device 29 with electrical auxiliary power support, corresponds essentially to the state of the art. Among other things, it consists of a steering wheel 20 , a steering column 21 , the steering transmission 22 and the two steering tie rods 24 . The steering tie rods 24 are driven by the steering rack 23 . The inventive steering differential 1 or 27 , the details of which are shown in FIGS. 2 and 3 , serves as driving mechanism Depending on the embodiment, the steering differential is located either between the steering wheel 20 and the steering transmission 22 (position 1 ) or between the steering transmission 22 and the steering tie rods 24 (position 27 ). The steering differential 27 contains then a conversion transmission for converting the rotational movement into a translational movement, for example, a ball-type linear drive. In the normal case, the wishes of the driver are transferred by the steering wheel 20 over a sensor system, which is not shown here, as a signal to 281 to a control device 28 . In the control device 28 , optionally with the help of a sensor signal of the driving unit (not shown here) and further signals describing the driving state, the appropriate control voltage 282 for the electric motor or servo motor, which is disposed in the steering differential 1 or 27 , is put out.
FIGS. 2 and 3 show an embodiment of the steering differential 1 , disposed between the steering wheel 20 and the steering transmission 22 with an integrated safety clutch and an integrated reversing clutch in the “automatic operation” position.
The drive shaft 2 is shown, which is connected non-rotationally with the pinion of the steering transmission 22 , the drive shaft 3 , which is connected non-rotationally with the steering wheel 20 , the excitation windings 4 of the driving motor, the permanent magnets 5 of the driving motor, which are disposed non-rotationally at the rotor, as well as the two planetary gear trains and the multiple connection.
The multiple connection has the switching positions a, b or c, which are controlled by an indicated switching lever 30 . In switching position a, the coupling 17 is engaged and an “automatic operation”, which may also correspond to “steer-by-wire mode”, is realized, that is, an automatic steering mode without driver intervention is realized at the steering wheel 20 . The steering wheel is locked, but can be rotated by force if the coupling 18 is designed appropriately. In the switching position b, power-assisted operation is realized. The torque from the electric motor and the torque from the steering column are superimposed here. The steering force, exerted on the steering wheel 20 , is reinforced by the electric motor. At the same time, with appropriate control of the motor, the rotational speed is converted, so that, when the steering wheel 20 is rotated by a small amount, an electrically adjustable, basically arbitrarily large rotation of the drive shaft 2 becomes possible. In the switching position c, the drive shaft 3 is connected mechanically directly with the drive shaft 2 and the electric motor is uncoupled. This switching position c is intended as a mechanical backup solution in the event that the electronic system or the voltage supply fails, when the ignition is switched off or in the case of other special situations of the vehicle.
The multiple connection is actuated by the switching sleeve 19 by means of the switching lever 13 . In the embodiment introduced, the switching sleeve 19 is connected non-rotationally with the drive shaft 3 . In the switching position a, the couplings 18 and 33 are engaged and the coupling 17 is uncoupled. In the switching position b, the coupling 17 and 18 are uncoupled and the coupling 33 is engaged. In the switching position c, the coupling 17 is engaged and the couplings 18 and 33 are uncoupled. All couplings in the embodiment shown are realized by appropriate gearings.
Starting out from the electric motor and the drive shaft 3 , the torque flows over the two planetary gear trains into the drive shaft 2 .
Moreover, the torque flows from the rotor of the electric motor over a first planet carrier 7 , which is connected non-rotationally with the rotor of the driving motor, into a first planetary gear train. In each case, this planetary gear train has axially divided planet wheels, consisting of planet wheel halves 8 , 10 , which are coupled non-rotationally with one another, and internal gear wheels, consisting of internal gear wheel halves 9 , 11 . The planet wheel halves 8 , mounted on the first planet carrier 7 , are supported in the internal gear wheel halves 9 , which are connected permanently with the housing 31 . Over the planet wheel halves 10 , which may also be constructed in one part with the planet wheel half 8 , the torque is passed into the rotatably mounted internal gear wheel half 11 , which, in turn, passes the torque into a similarly constructed second planetary gear train. An internal gear wheel half 12 of the second planetary gear train is tied non-rotationally to the internal gear wheel half 11 of the first planetary gear train. The torque is passed over the planet wheel halves 14 into the planet carrier 13 of the second planetary gear train. Alternatively to the non-rotational coupling or the one-part construction of the planet wheel halves 8 and 10 or 14 and 15 , freely rotating sun wheels (not shown here), over which the torque is transferred from the respectively first planet wheel half 8 or 15 to the second planet wheel half 9 or 14 , may also be disposed in the respective planetary gear train. The flow of the torque changes depending on the switching position a, b or c.
In the switching position a, the “automatic operation”, the steering wheel 20 is connected non-rotationally over the coupling 18 with the housing 31 and, at the same time, over the coupling 33 with the planet carrier 13 of the second planetary gear train, so that the planet carrier 13 cannot rotate with respect to the housing 31 and, with that, the vehicle. Consequently, the whole of the torque is passed directly over the planet wheel halves 14 into the planet wheel halves 15 , which may also be constructed in one piece with the planet wheel half 14 , into the internal gear wheel half 16 and, with that, in to the driven device 32 . The torque from the driven device 32 is passed directly, for example, over a gearing to the driven shaft 2 and, with that, into the steering gear.
In the switching position b, the “operation with power support”, the torque, starting out from the driver, is introduced by the drive shaft 3 over the coupling 33 into the planet carrier 13 . The sum of the torques of the electric motor and of the drive shaft 3 are introduced, as in switching position a, over the planet wheel halves 14 , 15 into the internal gear wheel half 16 and the driven element 32 , connected with it, and from there into the driven shaft 2 . Corresponding to the number of teeth of the planet wheel halves 8 , 10 , 14 , 15 and internal gear wheel halves 9 , 11 , 12 , 16 of the participating planetary gear trains, the torque is divided with respect to the drive shaft 3 , the driven shaft 2 and the rotor of the electric motor.
In the switching position c, the “manual operation”, the drive shaft 3 is coupled directly with the driven shaft 2 over the coupling 17 . Because the coupling 33 is uncoupled, the planet carrier 13 rotates completely freely. No torque whatsoever is introduced into the steering transmission from the rotor of the electric motor. The driver has complete control over the direction, in which the vehicle is steered.
In the embodiment shown, the steering differential 1 is disposed between the steering wheel 20 and the steering transmission 22 . It may be disposed at any convenient place, for example, also within the steering column 21 or the guide box (which is not specifically shown here).
In a further embodiment, the steering differential 27 is disposed between the steering transmission 22 and the steering tie rod 24 . In this case, the driven device 32 is constructed as a conversion transmission for converting a rotational movement into a translational movement. In the simplest case, preferred pursuant to the invention, a recirculating ball screw nut is selected directly here as a driven device 32 . In this case, the driven shaft 2 caries out a translational movement and not a rotational movement.
LIST OF REFERENCE SYMBOLS
1 steering differential
2 driven shaft
3 driving shaft
4 energizing coils
5 permanent magnets
6 stator
7 first planet carrier
8 planet wheel half
9 internal gear wheel half
10 planet wheel half
11 internal gear wheel half
12 internal gear wheel half
13 planet carrier
14 planet wheel half
15 planet wheel half
16 internal gear wheel half
17 coupling
18 coupling
19 switching sleeve
20 steering wheel
21 steering column
22 steering gear
23 steering rack
24 steering tie rod
27 steering differential
28 control device
29 steering device
30 switching lever
31 housing
32 driven element
33 coupling gearing
281 signal driver's desire
282 control voltage for electric motor
a switching position for “automatic operation”
b switching position for “operation with power assisted steering”
c switching position for “manual operation”. | A vehicle steering device has a single electric motor which, at the same time, introduces energy for desired rotational speed conversion and auxiliary power support into the system. Steering interventions by a driver of the vehicle, in the form of a driving moment exerted by a vehicle steering wheel, are superimposed with a driving movement of the electric motor, and these two motors are initiated jointly onto a driving element. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to printer paper collection baskets and, more particularly, to a continuous feed printer paper collection basket adapted for automatically stacking the continuous feed paper therein.
2. History of the Prior Art
The advent of the computer and continuous feed paper for use therewith has revolutionized the business world. Today reams of paper are produced by continuous feed printers and are collected adjacent the printer for subsequent review, analysis or other uses. Although such uses often require separation of individual sections of the continuous feed paper, the advantages of a continuous feed discharge process are widely accepted and appreciated. Sequential pages from the printer are collected in an organized fashion and may be handled and transported without concern for misjoinder of pages. Of course the most advantageous aspect of the continuous feed discharge is the fact that paper may be fed into the printer and received from the printer with a minimum of handling and a high degree of reliability as to both the feed and the discharge relative thereto.
Paper which is being fed into a continuous feed and discharge printer is easily controlled. The paper comes from a pre-arranged folded stack and few problems, if any, result from the transfer of said paper from the paper feed area. The same cannot be said in all instances for the collection end. When printer paper is discharged from the printer it has been, by definition, unfolded, and it may or may not have a tendency to properly fold itself back upon discharge from the printing unit. In many instances boxes or baskets are simply placed in a region below the printer discharge area for collection, and the printer paper is simply allowed to collect and fold upon itself therein. Misalignment of the collection basket relative to the printer, interruptions in the operation of the printer and/or mishandling of the discharged paper itself can lead to irregularities in the folding process. Any of these events can result in a disorganized array of continuous feed paper received within conventional basket areas. It would be an advantage, therefore, to provide a collection basket that virtually assures the proper folding of the continuous feed printer paper across the perforated sides thereof following discharge from the printer to facilitate proper stacking and organization thereof.
The present invention addresses such improved printer paper collection systems by providing a basket which may be integrally formed with, or disposed adjacent to, a continuous feed printer stand for the collection of paper therefrom. The improved collection structure includes adjustable side walls and an adjustable breaker bar which engages the printer paper during the discharge from the printer to ensure the proper folded configuration thereacross. In this manner physical interruptions of the printer paper itself will not adversely effect the organized folding and stacking of the discharged paper. Maximum effectiveness of the continuous feed system can then be realized.
SUMMARY OF THE INVENTION
The present invention relates to a continuous feed paper collection basket having means formed therewith for passive folding of the paper therein. More particularly, one aspect of the invention comprises a continuous feed printer paper basket adapted for positioning adjacent a continuous feed printer for the collection of paper therefrom, which basket includes a breaker bar adjustably mounted therein for positioning intermediately thereof to receive the continuous feed paper thereupon. The breaker bar causes an arcuate roll to be formed upon the received paper. The breaker bar produces an arch upon the paper received within the basket which arch is supported by the breaker bar and further induces adjacent layers of continuous feed paper to fold thereupon in sequentially induced folding steps commensurate with the organized stacking of the printer paper. The basket may be formed integrally with the printer stand or may be separately constructed for positioning adjacent thereto. In either configuration, the size and shape of the basket may be adjusted in conjunction with the breaker bar for facilitating utilization with various continuous feed paper sizes and preferential folding configurations thereof.
In yet another embodiment, the above described collection basket further includes a paper chute disposed adjacent the printer platform and angled downwardly toward the base. A tray assembly is disposed relative to a leg assembly and beneath the paper chute for collecting the paper from the chute. The leg assembly may be part of, or separate from, the printer stand. Means are disposed within the tray for inducing the paper to fold upon itself and stack therein. The folding means may comprise at least one bar adjustably mounted within the tray for select positioning relative to the leg assembly and beneath the platform. The bar may also be supported on opposite ends by adjustable linkage affording height and lateral position adjustment thereof.
In another aspect, the above described invention includes the adjustable linkage having first and second slotted arms, the arms being pivotally engaged one to the other on a first end and opposite ends of the first and second arms being pivotally secured to laterally disposed portions of the leg assembly of either the printer stand or the basket itself.
In yet another aspect, the invention includes an improved printer paper collection basket of the type wherein a container is disposed beneath a continuous feed paper printer platform for receipt of paper discharged therefrom, the improvement comprising first and second upstanding walls adjustably disposed one to the other for facilitating the size of paper to be received from the printer and means disposed between the adjustable walls for inducing the paper to fold upon itself and stack therein. The folding means may comprise at least one bar adjustably mounted between the walls for select positioning relative thereto and beneath the platform. The bar may also be supported on opposite ends by adjustable linkage affording height and lateral position adjustable thereof, and the linkage may comprise first and second slotted arms, the arms being pivotedly engaged one to the other on a first end of each with opposite ends of the first and second arms being pivotedly secured to laterally disposed portions of the basket.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference may now be had to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a printer paper collection structure constructed in accordance with the principles of the present invention and integrally formed with a printer stand illustrating the receipt of continuous feed paper therein;
FIG. 2 is a side elevational view of the paper collection structure of FIG. 1 illustrating the folding of the continuous feed paper therein;
FIG. 3 is an enlarged, fragmentary, side elevational view of the collection structure of FIG. 2 illustrating in more detail the means for passively folding the paper therein and the adjustability thereof; and
FIG. 4 is a perspective view of an alternative embodiment of the printer paper collection structure separately formed for positioning adjacent a printer stand.
DETAILED DESCRIPTION
Referring first to FIG. 1, there is shown a perspective view of a continuous paper feed printer stand and paper collection basket, integrally formed therewith, constructed in accordance with the principles of the present invention. The collection basket 10 is connected to the printer stand 12 in the lower region 14 thereof. With this particular assembly, effective and improved paper stacking is provided with enhanced stacking features capable of handling an entire box of any type of continuous feed forms or labels with an assembly that will adjust both height and depth positioning to assure proper refolding of such continuous feed paper as described below.
Still referring to FIG. 1, the printer stand 12 includes a platform 18 supported by vertical legs 20 and 22, which legs are each secured to underlying, horizontal base members 24 and 26, respectively. The base members 24 and 26 provide the necessary balance to the platform 18 for the placement of a conventional printer thereon. The platform 18 has an end surface for positioning behind the printer to provide means for passing continuous feed printer paper discharged from the printer downwardly toward the collection basket 10. The collection basket 10, described above, is then assembled between the legs 20 and 22 and base members 24 and 26 outwardly therefrom and in a configuration beneath platform 18 to thereby effectively receive, guide and refold continuous feed paper in a manner most efficiently handled and adaptable to a variety of printers and types of continuous feed paper. In this configuration, the collection basket 10 includes a plurality of upstanding wire members 28 which form a paper chute comprising a rear wall 30 of the collection basket 10. The rear wall panel 30 continues upwardly beyond the platform 18 with angulated wall section 32 likewise comprised of extended, angulated wire members 28. In this embodiment the rear wall 30 is stationary. The wire members 28 are joined across the upper region by top wire member 34 to effectively provide an end piece and structural integrity thereto. The lower region of the collection basket 10 includes a tray or floor panel 36 adapted for receiving the continuously fed paper thereupon.
The collection basket 10 further includes a frontal wall panel 40 likewise comprised of a plurality of wire members 28 formed in an angular orientation and upstanding from floor panel 36 in a moveable, adjustable configuration. Wire members 28 of panel 40 are connected across the top most region by a wire section 42 and are connected across the floor panel 36 by wire 44. Each of the vertical wire members 28 of panel 40 are constructed in an angular configuration with each wire member 28 of panel 40 having a first base section 46 formed at right angle to an upstanding wall section 48. This particular assembly then provides an adjustable wall for the alignment and containment of varying sizes of foldable paper.
Still addressing to the frontal panel wall 40, the adjustability thereof is provided by locking or coupling members 41 upstanding from the base panel 36. The locking members 41 are, in this particular embodiment, conventional threaded fasteners that may be loosened and tightened about selected wire members 46 that form the above described base section of frontal wall 40. Although a threaded adjustment is shown herein any conventional form of a demountable coupling would be in accordance with the principles of the present invention.
Referring still to FIG. 1, the key to properly folding continuous feed paper into the basket area that is adjustably positioned by the front wall 40 is breaker bar assembly 50. Breaker bar assembly 50 includes elongate breaker bar 52 disposed between first and second adjustable linkages 54 and 56. Linkages 54 and 56 are disposed on opposite lateral sides of floor panel 36 as will be described in more detail below. Said linkages may be seen to effectively permit both the height and the lateral adjustment of breaker bar 52 relative to rear wall 30 and front wall 40 to therein provide precise adjustability.
Referring now to FIG. 2 there is shown a side-elevational view of the collection basket 10 and printer stand 12 of FIG. 1. A conventional printer 60, shown in phantom, is illustrated resting atop panel 18 with continuous feed paper 62 being discharged therefrom. It may be seen in this particular illustration that backwall section 32 engages the paper 62 as it arches over the rear portion of the printer and is directed downwardly toward the lower region of the basket 10. The rear wall 30 of the collection basket 10 guides the paper 62 downwardly toward the bottom panel 36 where the paper is folded into stack 64. The folding of the paper in stack 64 occurs across the breaker bar 50, the position of which is controlled by the linkages 54 and 56 to be described hereafter. As illustrated in FIG. 2 the linkages 54 and 56 adjust the breaker bar by moving in the direction of arrows 55, 55A and 57. Likewise, the frontal wall 40 may be adjusted in the direction of arrows 58 and 59 to precisely define the lateral size of the collection basket 10 for receipt of the paper 62 from the printer 60 disposed thereabove. It may also be seen in this view that frontal wall securement means 41 is likewise illustrated from a side elevational view further showing the securement of the base section of frontal wall 40 for proper securement of the folded paper 64 therein.
Referring now to FIG. 3 there is shown an enlarged side-elevational, fragmentary view of the breaker bar 50 of the collection basket 10 and the positioning linkage 54 thereof. The linkage 54 includes a first lateral adjustment member 70 which is coupled at a first end to leg 20 and slidably engaged at a second end to vertical linkage member 71. The engagement between linkage members 70 and 71 is in association with the breaker bar 50, which has a threaded end section 73 created by the securement of a T-Nut 77 thereto. In the present embodiment, the breaker bar 50 is welded to the linkage member 70 and T-nut 77 is likewise welded thereon. In this regard, it may be seen that linkage members 70 and 71 are each comprised of elongate wire members formed by bending or the like into elongated loops. The threaded section 73 of T-Nut 77 is axially aligned between the sides of linkage members 70 and 71 as shown in the drawings. The securement of breaker bar 50 and T-Nut 77 relative to the angular engagement between linkage members 70 and 71 is thus seen to be effected by a threaded fastener, such as 1/4-20 knob bolt 77A with washer 77B shown for reference purposes. The knob bolt 77A extends through washer 77B and into threaded section 73 of T-nut 77 to sandwich linkage member 71 between it and linkage member 70. The same assembly of knob bolt 77A with a T-nut and linkage assembly 56 is utilized on the other end of breaker bar 50. In this manner, the angular relationship between linkage members 70 and 71 and the resulting lateral and height position of the breaker bar 50 may be rigidly secured.
In operation, the lateral position of linkage member 70 is first secured relative to leg 20. This lateral securement of linkage member 70 is provided by another knob bolt 78 which engages a T-nut (not shown) mounted within the leg 20. The knob bolt 78 then extends through the loop of linkage member 70 into the recessed T-nut for securement in the manner shown for knob bolt 77. In this manner it may be seen that linkage member 70 may slide beneath knob bolt 78 and pivot thereabout. In similar manner, linkage 71 pivots about base member 24 across pivot mounting 79. The mounting 79 is not adjustable in this particular embodiment, simply providing a point upon the leg 24 allowing linkage member 71 to arcuately move in the direction of arrow 55. No height, or vertical, adjustment is facilitated, due to the fact that breaker bar 50 may slide upwardly and downwardly within the loop of linkage member 71. Arrow 55A illustrates the arcuate movement of the linkage member 70 about pivot point 78 while arrow 57 illustrates the lateral movement afforded thereby. It may be seen with such adjustability that the position of breaker bar 50 within the basket 10 can be precisely located for the most appropriate folding of paper thereover. The same adjustment assembly is provided in the linkage 56 oppositely disposed from linkage 54.
Referring now to FIG. 4, there is shown an alternative embodiment of the collection basket 10 of the present invention. A portable collection basket 110 shown in FIG. 4 comprises a frontal wall 130 formed out of a plurality of wire members 128. The frontal wall 130 is disposed oppositely, and in a generally parallel spaced relationship with, a second wall 140 likewise comprised of wire members 128. The walls. 130 and 140 are disposed about a base member 136 that is itself mounted to a frame having bottom leg members 124 and 126 and upstanding leg members 122 and 124, respectively. It may be seen that portable collection basket 110 is not assembled directly to a printer stand 12, as shown in FIGS. 1-3, but instead, provides a separate assembly that is yet fully adjustable with a breaker bar 150 that may be disposed adjacent a variety of printers and printer stands not having a self-contained stacking region.
Still referring to FIG. 4, it may be seen that the position of the breaker bar 150 is effected exactly as described above in that a linkage assembly 154 controls the position of breaker bar 150 as described in FIG. 3. For structural purposes a separate, solid wall panel 111 may be disposed adjacent wall 140 and secured to upstanding leg members 120 and 122 as shown herein. The collection basket 110 may there be positioned directly upon a floor, upon a printer stand base, or it may be constructed with casters 113 as shown herein. The casters 113 permit the collection basket 110 to be rolled into and out of position relative to a printer stand.
In operation, the collection baskets 10 and 110 described above may be positioned beneath a variety of continuous feed paper printers and may be utilized to adjustably fold either standard computer paper, forms or labels secured thereto in a variety of sizes. Size may be accommodated by the adjustable wall members described herein as well as the adjustable breaker bar fully described above. Because the collection basket 110 may be separately formed, its utilization with casters 113 will allow it to be rolled from one printer stand to another for ease in handling, and it may easily facilitate the collection of paper from a variety of printers with a few minor adjustments of the type described above.
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method, apparatus and system shown and described has been characterized as being preferred, it will be readily apparent that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the following claims. | A computer paper printer collection basket constructed with an adjustable bar facilitating the automatic folding of continuous feed printer paper thereacross during the discharge thereof for purposes of stacking. The printer basket may formed with or separately from a discharge area of a conventional printer and disposed immediately therebeneath. The adjustable bar's position to intercept the paper intermediate the fold lines thereof. In this manner, the printer paper will automatically fold thereacross during the collection thereof. | 1 |
BACKGROUND OF INVENTION
The invention relates to a method for writing software are into electric erasable programmable read only memory (EEPROM) or flash memory.
The mask read only memory (Mask ROM) or erasable programmable read only memory (EPROM) has been widely utilized as apparatus for storing software which operates a peripheral device. As shown in FIG. 1, in a conventional approach, the microcontroller 11, e.g. 80C32, executes the instructions of software, inputted via signal lines 131, in EPROM 13, i.e. IC 27512. The signal lines 131 are also inputted to the latch 15. The microcontroller 11, via signal lines 110, connects a CD-ROM pickup head 17. The microcontroller 11 outputs the address latch enable (ALE) signal, address signals (A8-A15), program strobe enable (PSEN) signal to latch 15 and EPROM 13 respectively. The signal lines 131 (AD0-AD7) are multiplexed between address information and data information in a conventional manner. The address latch enable (ALE) signal is used to latch the address information (A0-A7) by the latch 15. In the following, a CD-ROM player is used as an example of the peripheral device.
Under different situations, e.g. within a developing period of a CD-ROM player, the routine within the ROM of the CD-ROM player has to be updated. One of the conventional approaches uses the Mask ROM or EPROM as the software storage device. Conventionally, when update of the routine is required, one has to open the peripheral device and replace the EPROM or Mask ROM with one which has an update version of the software. The following drawbacks are observed with the conventional approaches.
(1) The Mask ROM, which needs a longer lead time when placing an order, is not suitable for peripheral devices of shorter life time.
(2) The programming operation of an EPROM involves a lot of labors.
(3) The Mask ROM or EPROM of the old version is useless and has to be discarded.
(4) When there is a bug within the old version of Mask ROM or EPROM, one has to open the peripheral device, retrieve the old version and insert in the new version of the Mask ROM or EPROM. As a result, the labor cost associated with the replacement of the Mask ROM or EPROM within the peripheral device is high.
Therefore, another conventional approach uses an EEPROM instead of a Mask ROM or EPROM as an alternative storage device for software. However, at the present time, when there is a bug within the old version of the EEPROM, the same replacement procedure as with the Mask ROM or EPROM should be applied and, therefore, the labor cost associated with the replacement of the EEPROM within the peripheral device is still high.
SUMMARY OF INVENTION
To overcome the mentioned drawbacks, this invention provides a method which may program the software into the EEPROM or flash memory via the peripheral's bus interface under control of a host computer.
The method involves a host computer issuing a command, via a standard interface, e.g. Integrated Drive Electronic (IDE), RS 232 or Small Computer System Interface (SCSI), to a CD-ROM player which has a flash memory or EEPROM for storing the control routine.
In the first embodiment, the microcontroller within the CD-ROM player must have a built-in supervisory routine responsible for the programming operation of software into the flash memory or EEPROM.
The supervisory routine includes a "software write" instruction. Afterwards, the microcontroller executes the software write instruction and receives the software from the host computer via the interface. Subsequently, via the microprocessor bus lines, the method performs the programming operation of the control software into the EEPROM or flash memory.
In the second embodiment, there is no need to build any supervisory routine in the microcontroller within the CD-ROM player. Instead, the supervisory routine and the control routine both reside in the EEPROM or flash memory. Other than this, the supervisory program in the second embodiment does the same function as in the first embodiment.
The second embodiment dramatically reduces the cost of hardware implementation, since there is no need to provide a microcontroller of mask ROM type with supervisory software built within the microcontroller.
BRIEF DESCRIPTION OF THE APPENDED DRAWINGS
FIG. 1 discloses the internal functional blocks in a conventional CD-ROM player.
FIG. 2 discloses a circuit of the first embodiment of the invention.
FIG. 3 discloses the flow chart of the first embodiment of invention.
FIG. 4 discloses a circuit of the second embodiment of invention.
FIG. 5 discloses the arrangement of the flash memory 19 in accordance with the second embodiment.
FIG. 6 discloses the flow chart of the second embodiment of invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There are several types of software mentioned in this invention:
(a) The "control software" means that software used to control the normal operations of a CD-ROM player, like: read CD-ROM disk, load/unload CD-ROM disk, . . . etc.
(b) The "supervisory software" means the special software proposed in this invention, which is used to perform the programming operations of software into the EEPROM/flash memory.
(c) In this patent specification, the "software" means a program still in the software data form, and the program already programmed into the hardware is named as a "routine".
The First Embodiment
As shown in the circuit of FIG. 2, a supervisory routine is provided within the microcontroller 12 which is responsible for down-loading the control software for the peripheral device, via a standard interface, from the host computer 10 to the flash memory 19 or EEPROM 19. The microcontroller 12 of the peripheral device connects to the memory 19 via signal lines 191 and operates according to the instructions of the control routine already stored within the memory 19. The signal lines 191 (AD0-AD7) are multiplexed between address information and data information in a conventional manner. The signal lines 191 are also inputted to the latch 15. The microcontroller 12 connects to the CD-ROM pickup head 17 via the signal lines 120 and outputs address latch enable (ALE), address signal (A8-A15) and program strobe enable (PSEN) signals to latch 15 and EEPROM 19, via OR gate 20, and AND gate 22 respectively. The control signal WR from the microcontroller 12 is inputted to the WE pin of the memory via OR gate 23 to perform the write operation. The gates 21, 23 are also OR gates. The microcontroller 12 asserts a RD signal to read data from the memory 19, and asserts Program Strobe Enable signal to strobe the memory 19 outputting the routine therein.
As shown in FIG. 3, the operation of the first embodiment of the present invention starts at block 301. After the power-on period of the system at block 301, in which the EA line in FIG. 2 is logic high, the microcontroller 12 executes the instructions therein starting at address value 0, i.e. program counter equal to 0, which detects an update command from host computer 10. If the microcontroller 12 does not receive the update command from host computer 10 at block 305, the microcontroller 12 pulls the EA line to logic low, via the I/O pin connected also to the EA line in FIG. 2, at block 307. Thereafter, the microcontroller 12 sets program counter to value B at block 309. Starting from address value B, a plurality of Non Operation Codes (NOP) are provided and executed to smooth the program switching recited hereinafter. As switching from the supervisory routine in the microcontroller 12 to the control routine in the memory 19 is completed, the operation of peripheral device follows the instructions of the control routine in the memory 19 at block 311. During predetermined operation of the control routine in memory 19, if the microcontroller 12 receives the update command from host computer 10 at block 313, execution path goes to block 315 in which the EA line is raised to logic high, via I/O pin, and the program counter is set to value A which is the starting address of the software write instruction within the microcontroller 12. In block 319, downloadinig of the new version of the control software is performed.
When requiring down-loading or update of the control program of the peripheral device, the host computer 10, via the standard interface, gives associated commands to the microcontroller 12. As the microcontroller 12 receives the update command at block 305 after power-on of block 301, the microcontroller 12 then sets the program counter to value A at block 317 which is the starting point of the update routine within the microcontroller 12. Thereafter, down-loading operation within the update routine by the microcontroller 12 is performed at block 319. At block 321, the host computer 10 sends the new version of the software to the microcontroller 12 via the interface. At block 323, via signal lines 191 and address lines (A8-A15), programming operation of memory 19 is performed. At block 325, it is decided whether the programming operation is completed. If not, go to block 321 to continue operation. If complete, at block 327, reset the system, and the peripheral device thereafter operates in accordance with the new version software just programmed into the memory 19.
The I/O pin of microcontroller 12 is also used to control the operation of memory 19. As I/O line is logic low during the time microcontroller 12 executes the routine within the memory 19, the PSEN signal is outputted to the OE pin of the memory 19 by microcontroller 12 strobing the output of the codes from the memory 19. As EA is logic high during the time microcontroller 12 executes the resident routine within the microcontroller 12 to perform the programming operation, OE and I/O pins are logic high prohibiting the output of the codes from the memory 19. During this period, the programming control signal WR from the microcontroller 12 is inputted to the WE pin of the memory via OR gate 23 enabling programming of software codes.
The Second Embodiment
As shown in FIG. 4, the microcontroller 12 connects to the memory 19 via signal lines 191 and operates according to the instructions already programmed within the memory 19. The signal lines 191 (AD0-AD7) are multiplexed between address information and data information in a conventional manner. The signal lines 191 are also inputted to the latch 15. The microcontroller 12 connects to the CD-ROM pickup head 17 via the signal lines 120 and outputs address latch enable (ALE), address (A8-A15), program strobe enable (PSEN) and WR signals to latch 15 and EEPROM 19 respectively. The microcontroller 12 asserts the Program Strobe Enable signal to strobe the memory 19 outputting the routine therein. Different from the first embodiment, a supervisory routine is programmed within the flash memory or EEPROM 19 which functions to detect any software update command from the host computer 10.
As shown in FIG. 5, assume the pre-program supervisory routine has a size of 1K bytes which is loaded and located at the lowest 1K bytes address of memory 19. The locations higher than those of the supervisory routine are used as the main memory space, e.g. 63K, for storing the peripheral device's control routine which is to be programmed. When pre-programming the supervisory routine, one predetermined location, e.g. the last addressable location within the 1K byte space is programmed with a preset identification code (PSID), e.g. a value of 00 (Hex). This identification code may, alternatively, also include information regarding the version number, e.g. V. 2.0. In the main memory space storing the peripheral device's control software there is also reserved a corresponding location for storing a program identification code (PGID) embedded within the downloaded control software. During the download operation of the control software, this PGID value is written into this PGID location. If the PSID code includes information regarding the software version number, the PGID information should also have the corresponding information.
Referring to FIG. 6, the second embodiment starts at block 70. At block 72, PSID is compared to PGID to decide their identity. If they are the same, at block 74, test if the control routine exists in the main memory space mentioned regarding FIG. 5. If it exists, at block 76, the control routine is executed to operate the peripheral device. During the execution of the control routine, detection of the programming command from the host computer 10 is performed at block 78, by either a conventional polling scheme or interrupt scheme. If the programming command is detected, at block 71, perform the programming, e.g. writing of the update version of the software. Also, the new PGID value is programmed into the PGID location in block 71. After the programming operation, at block 79, (1) PGID the value is stored in the local RAM (not shown) of the microcontroller 12, (2) locations corresponding to PSID, and PGID are cleared to value "1" first and afterwards set to value "0", and (3) the value within the local RAM is written back into the locations storing PSID and PGID respectively. It is well known flash memory or EEPROM has limited times of programming operation. The main purpose of operations at block 79 is to program these two locations more frequently than other memory cells. As a result, these two locations will extinguish earlier than other locations. In addition, when PSID is not equal to PGID at block 72, this indicates the flash memory or EEPROM 19 might have already been not usable due to its limited times of programming operation. The error message is outputted at block 77 and then there is checking whether the programming command is requested in block 73. | A method for writing software into a programmable memory within a peripheral apparatus initiated by a host computer is provided. The host computer issues a software write command and the peripheral apparatus includes a microcontroller connected to the host computer via an interface. A data line and an address line are provided to connect the microcontroller and the programmable memory. The method comprises the following steps: (1) providing a supervisory program within the programmable memory or the microcontroller, the supervisory program including a software write instruction; (2) the microcontroller executing the software write instruction and down-loading the software from the host computer via the interface; and (3) via the data and address line, performing the write operation of the control software to the programmable memory. | 7 |
This is a continuation-in-art of application Ser. No. 415,485, filed Nov. 13, 1973 for "Method Of Stretching A Tow", now abandoned, which was a continuation-in-part of application Ser. No. 244,195 filed Apr. 14, 1972 for "Method Of Stretching A Tow", now abandoned, which was a continuation-in-part of application Ser. No. 50,485 filed June 29, 1970 for "Method Of Stretching A Tow", now abandoned, in the names of David F. Bittle and Arnold L. McPeters.
BACKGROUND OF THE INVENTION
a. Field of the Invention
This invention relates to methods for stretching tows of filaments.
B. Description of the Prior Art
A number of man-made filaments of various known types are made by forcing a spinning solution through a spinnerette to form a tow of filaments. In almost all of the various types of man-made filaments it is necessary at one point or another to stretch the filaments to obtain desired properties. In order to obtain best results the tow is usually heated in some manner and is stretched while hot. The heating of the tow is usually accomplished by passing the tow over heated rolls or through a steam chamber or by other known methods such as the use of sprays or cascades.
Apparatus other than cascades and sprays may be used for stretching a tow. U.S. Pat. No. 3,267,704 issued to H. G. Mueller and U.S. Pat. No. 3,353,383 issued to E. A. Taylor, Jr., for example, show apparatus for washing a tow wherein the washing liquid is continually passed back and forth through the tow. Such apparatus can be used for stretching a tow if the apparatus is sufficient in length and the liquid is sufficiently hot. In fact, a simple bath can be used if it is long enough. The requirement which must be met is that the tow must be wet and at a sufficiently high temperature.
The disadvantage of most of the known methods of heating and stretching tow is that the heating operation is inefficient and slow, especially when sprays or baths are used. Either the tow must have a long dwell time in the heating zone or excessive temperatures must be used to raise the temperature of the filaments to a point where they can be stretched. Further, it is very difficult in conventional stretching processes to heat the inner filaments of the tow to the same temperature as the outer filaments, since the outer layers of filaments shield the inner filaments from the heated liquid.
SUMMARY OF THE INVENTION
In the method of this invention tow is stretched by passing it under tension through a chamber having openings at the ends thereof for passage of the tow into and out of the chamber and forcing a heated liquid transversely through the tow at the chamber openings at a rate in excess of a predetermined critical value, the liquid being maintained at a temperature within a predetermined range. The rate at which the heated liquid is passed through the tow in the chamber openings must be at least as great as
x = 3,000T√(WN/h) (μ/ρ)
where x is the heated liquid flow rate in gallons per minute through each chamber opening, T is the thickness in inches of the streams of heated liquid flowing through the openings, W is the width in inches of the openings and the liquid streams, h is the thickness in inches that the tow is free to assume in passing through the openings, N is the number of filaments in the tow, μ is the viscosity of the heated liquid in pounds per foot-second and ρ is the density of the heated liquid in pounds per cubic foot.
DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic cross-sectional view of an apparatus or tow heater useful for carrying out the process of the present invention.
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1 showing the cross-sectional area of the openings through which the tow is passed, and
FIG. 3 is a diagrammatic view of apparatus used with the tow heater in carrying out the process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in detail to the drawing there is shown, in a more or less diagrammatic manner, a tow heater 10 which is useful in carrying out the method of the present invention. The apparatus 10 is made up of upper and lower units 11 and 12 which are held in a spaced relationship by side plates 13, the side plates 13 being secured to the upper and lower units 11 and 12 by screws 14. The upper unit is recessed and with the lower unit 12 forms a chamber 22 through which a tow 15 passes. The lower face 18 of the upper unit 11 and the upper face 19 of the lower unit 12 and the inner faces of the side plates 13 define openings 23 at the ends of the chamber through which the tow 15 passes, the tow entering the chamber through one opening and exiting through the other. The cross-sectional areas of the openings at the ends of the chamber is best shown in FIG. 2 where "h" is the height or thickness of the opening and "W" is the width of the opening, the opening thus having a cross-sectional area of Wh, as best shown in FIG. 2. The area Wh is the area that the cross section of the tow is free to assume in passing through the openings at the ends of the chamber.
The lower unit 12 is provided with an inlet 21, near the midpoint of the chamber, through which a heated liquid is admitted to the chamber. The inlet 21 extends across the lower unit 12 from one of the side plates 13 to the other, so that it has a width W.
The chamber 22 directs the heated liquid back through the tow at the openings 23 is streams having a thickness T (FIG. 1). The value for the dimension T should be within the range of 2h to 5h. The heated liquid entering the inlet 21 passes through the tow 15 and is divided into substantially equal portions which pass back through the tow 15 at the openings 23. The chamber 22 completely fills with liquid under pressure. This pressure forces the liquid through the openings 23, and the tow 15, at a high velocity.
As shown in FIG. 3, the tow heater 10 is mounted over a vat 30 containing a heated liquid 31, such as water. Spaced pairs of driven rolls 32 and 33 feed the tow 15 through the tow heater 10 at a uniform speed, with the rolls 33 being driven at a higher peripheral speed than the rolls 32 to thereby stretch or draw the tow. By adjusting the speed of the rolls 33 relative to the speed of the rolls 32, and thereby adjusting the tension applied to the tow in the chamber, the draw ratio can be adjusted. The speed of the rolls 32 and 33 will determine the dwell or residence time of the tow in the chamber, i.e., the time that it takes a point on the tow to pass through the chamber. Since it is not known at what point the tow stretches in the chamber, approximation of the dwell time can be determined by assumming that the tow stretches at the midpoint of the chamber and then computing the dwell time. The following equation can be used,
Dwell time = (L/2Vi) + (L/2Vo)
where L is the length of the chamber in inches, Vi is the speed of the tow, in inches per second, entering the apparatus and Vo is the speed of the tow, in inches per second, leaving the apparatus.
A pump 34 connected to the vat or reservoir 30 and the inlet 21 of the heater 10 pumps the liquid from the vat 30 through the heater via the inlet 21. The liquid exiting from the heater 10 falls back into the vat 30 and is recirculated. Additional liquid may be added to the vat or reservoir 30 from a supply 38 to maintain a uniform level. An overflow line 39 drains off excess water from the reservoir 30. Pairs of stripper bars 36 positioned in contact with the tow as shown in FIG. 3 are used to prevent liquid from overflowing beyond the edges of the vat 30.
The denier of the filaments in the tow is not a factor in this process. Larger filaments require more heat for stretching than do smaller filaments. However, with a constant flow rate into the chamber the actual flow rate between filaments at the openings will be higher with large filaments than with small filaments. The reason for this is that larger filaments occupy more space in the openings 23, leaving less space for passage of the liquid and thereby increasing the velocity of the liquid through the tow.
Of course, a portion of the heated liquid will, in an apparatus such as described above, not pass completely through the tow but will travel along the voids in the tow to the openings 23. Since it would be very difficult to actually measure the liquid flow rate inside the tow, an easier way of determining whether the minimum critical flow rate is exceeded is desired. If the openings 23 are held within the limits set out above one half the flow rate into the inlet 21 can be compared with the minimum critical flow rate of
3,000T √WN/h (μ/ρ)
to determine whether minimum critical flow rate is exceeded, without regard for actual flow rate in the tow or the fact that some of the liquid will travel along voids in the tow.
The table below shows values of μ and ρ for water at various temperatures.
______________________________________Temperature° C. lbs/ft-sec lbs/cu.ft.______________________________________30 5.38 × 10.sup.-4 62.1635 4.85 × 10.sup.-4 62.0640 4.40 × 10.sup.-4 61.9545 4.02 × 10.sup.-4 61.8250 3.69 × 10.sup.-4 61.6855 3.40 × 10.sup.-4 61.5460 3.15 × 10.sup.-4 61.3865 2.92 × 10.sup.-4 61.2270 2.72 × 10.sup.-4 61.0475 2.55 × 10.sup.-4 60.8680 2.39 × 10.sup.-4 60.6785 2.25 × 10.sup.-4 60.4790 2.12 × 10.sup.-4 60.2795 2.01 × 10.sup.-4 60.05100 1.90 × 10.sup.-4 59.83______________________________________
EXAMPLE I
A copolymer of 93% acrylonitrile and 7% vinyl acetate was spun into a spin bath made up of 55% dimethylacetamide and 45% water. The tow formed was made up of 40,000 filaments, 15 denier per filament. The tow was withdrawn from the spin bath, washed to remove dimethylacetamide and then passed through a tow heating apparatus such as that described above. The apparatus had a chamber 5.2 inches long and the dimensions: T = 9/16"; h = 3/16" and W = 37/8". Water at a temperature of 100° C was circulated through the apparatus at a rate of 30 gallons per minute. The tow was fed into the stretch zone at 26.5 feet per minute and withdrawn at 132.5 feet per minute, giving a stretch or draw ratio of 5 to 1. The dwell or residence time was approximately 0.6 seconds. No broken filaments were observed.
EXAMPLE II
Example I was repeated using water temperatures of 50° C, 60° C, 70° C, 80° C, 90° C, 100° C, 102° C, 104° C, 106° C and 108° C in order to determine the temperature range in which the stretching of this acrylic tow could be accomplished. The temperatures above 100° C were accomplished by constructing the apparatus in such a manner that the heated water made 20 passes back and forth through the tow in order to obtain a sufficient back pressure to raise the temperature of the water above 100° C. It was found that, in order to obtain a 4X stretch the temperature of the water had to be at least 80° C. Preferably, the water temperature is maintained at a value above 90° C.
EXAMPLE III
Modacrylic fibers were spun from a spin dope comprised of 65.9% acrylonitrile, 19% vinylidene chloride, 10% vinyl bromide, 1.9% sodium sulfonate, 1.2% styrene and 2% antimony trioxide dissolved in dimethylacetamide to give a solution containing about 20% solids. A tow bundle of 18,000 filaments was spun into a spin bath made up of 55% dimethylacetamide and 45% water. The tow was withdrawn from the spin bath and washed to remove dimethylacetamide and was then passed through a tow stretching apparatus such as that described above. The apparatus had a chamber 5.2 inches long and the dimensions: T = 9/16"; h = 7/32" and W = 31/2". Water at a temperature of 100° C was circulated through the apparatus at the rate of 30 gallons per minute. The dwell time of the tow in the chamber was 1.4 seconds. The speeds of the rolls 32 and 33 were adjusted to give the tow a stretch of 3.4×. No broken filaments were observed.
EXAMPLE IV
A tow bundle of acrylic filaments of a copolymer of 93% acrylonitrile and 7% vinyl acetate was spun and washed as described in the above examples, the tow bundle containing 160,000 filaments. The filaments denier entering the stretching apparatus was 16.5 dpf. The apparatus had a chamber 77/8" long and the following dimensions: T = 0.63"; h = 0.34" and W = 6". Water at a temperature of 95° C was forced through the tow at the openings 23 at a rate of 50 gallons per minute. The preferred minimum flow rate in accordance with the invention was 10.5 gallons per minute. The tow was stretched 4.2× and was in the chamber for a dwell time of 0.9 seconds. No breaks in the filaments were observed.
EXAMPLE V
A number of runs were made using filaments of different chemical composition wherein the filaments were stretched in accordance with the process of the present invention. Fiber types included in these runs were polyvinyl chloride, polyester, nylon 66 and rayon, all well known to those skilled in the art. The treatment liquid was 98% water and 2% of a conventional finish, at a temperature of 100° C.
The chamber had the following dimensions: W = 3/16"; h = 3/16"; and T = 9/16", with an overall chamber length of 8 inches. The flow rate through the openings was 1.2 gallons per minute. The following table shows the conditions under which these runs were made and the amount of stretch applied to the various filaments.
__________________________________________________________________________Fiber Polyvinyl Chloride Nylon Rayon Polyester__________________________________________________________________________Run No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14__________________________________________________________________________No. ofFilaments 100 140 3,000 192__________________________________________________________________________Tow speedenteringchamber(Ft/min) 39.5 20.0 59.0 10 40 50 60 10 40 20 40 10 40 40Tow speedleavingchamber(Ft/min) 156 78.0 235 56.8 180 205 240 45 180 25 45 52 162.5 202.5Time inchamber(seconds) 0.6 1.3 0.4 2.4 0.6 0.5 0.4 2.4 0.6 1.8 0.9 2.4 0.6 0.6StretchRatio 4 4 4 5.6 4.5 4.0 4.0 4.5 3.5 1.25 1.1 5.2 4 5__________________________________________________________________________
From the foregoing examples it can be seen that the dwell time of the tow in the treatment zone varies from less than one-half second to several seconds. A practical lower limit on the dwell time would probably be about 0.1 to 0.25 seconds, preferably 0.25 seconds. The dwell times shown in the examples are not the minimum but are those which actually resulted from the entrance and exit speeds of the tow from the treatment zone in the runs made.
It will be noted from the drawing that the chamber has an opening 23 at each end and that the dimensions W, h and T are dimensions of the openings. The dimensions W and h define an area Wh which is a cross-sectional area that the filaments are free to assume in passing through the openings. The dimensions W and T define an area WT which the cross section of the liquid stream is free to assume in passing through the openings 23. In other words, at the critical point of the operation the tow has a cross-sectional area Wh, and the liquid stream has a cross-sectional area WT.
It is not necessary that the heating fluid be water. For example, the heated fluid may be ethylene glycol, polyethylene glycol or other high boiling alcohols. The advantage of using one of these liquids is that temperatures higher than 100° C can easily be utilized. | A method for stretching a tow of filaments wherein the tow is passed under tension through a chamber, the chamber having openings at the ends thereof for passage of the tow, and streams of heated liquid are forced transversely through the tow at the chamber openings at a critical minimum rate at least as great as
x = 3,000T√(WN/h(μ/ρ)
where x is the heated liquid flow rate in gallons per minute through each opening, T is the thickness of the streams of heated liquid in inches at said openings, W is the width of the openings and the liquid streams in inches, h is the height or thickness in inches that the tow is free to assume in passing through the openings, N is the number of filaments in the tow, μ is the viscosity of the heated liquid in pounds per foot-second and ρ is the density of the heated liquid in pounds per cubic foot. | 3 |
FEDERALLY SPONSORED RESEARCH
Not Applicable.
SEQUENCE LISTING OR PROGRAM
Not Applicable.
BACKGROUND
1. Field of Invention
This invention relates to modular enclosures for components of redundant array of inexpensive disk (RAID) electronic data storage systems.
2. Prior Art
The acronym RAID refers to systems which combine disk drives for the storage of large amounts of data. In RAID systems the data is recorded by dividing each disk into stripes, while the data are interleaved so the combined storage space consists of stripes from each disk. RAID systems fall under 5 different architectures RAID 1-5, plus one addition type, RAID-0, which is simply an array of disks with data striping and does not offer any fault tolerance. RAID 1-5 systems use various combinations of redundancy, spare disks, and parity analysis to achieve conservation in reading and writing of data in the face of one, and, in some cases, multiple intermittent or permanent disk failures. Ridge, P. M. The book of SCCSI: A guide for Adventurers. Daly City Calif., No Starch Press. 1995. P. 323-329.
In order to increase reliability of RAID systems, conventional systems often have two or more controllers which control two or more arrays of direct access storage devices (DASD), each array often containing 6 or more DASDs, generally hard disks. Such RAID systems are arranged so that if one controller fails, another controller will take control of the other's DASD. In particular, in typical conventional RAID systems two controllers are arranged in a single chassis with a common backplane or cables and a common cooling system and a common power supply. The DASD are arranged in a multiple of chassis, each of which contains several individual DASD units (termed a “rack” of DASD). In conventional systems the controllers may share a common backplane or cables. Problems arise when there is a failure affecting the backplane or cables. When that occurs, both of the controllers may become inactivated or DASD may not be accessible, causing failure of the RAID system.
A backplane (termed a midplane if located near the middle of the chassis containing the controller or channel of DASD) is a circuit board with electronic components such as capacitors, resistors, chips, and connectors. A controller backplane serves to connect the two controllers, so that if one controller fails the other controller can detect the failure and communicate with the failed controller's DASD. A DASD backplane provides connectors into which several DASD can be inserted. The DASD may be connected to each other through one or more busses on the backplane.
Failure of a backplane or cable may be due to physical displacement of connectors, to physical failure of chips, to physical failure of traces on the boards, or to faults in cables or on computer boards. Failure of a common backplane which serves two controllers disrupts communications between the controllers and the DASD. Such an occurrence, while unexpected, has a catastrophic effect on the function of the RAID system, especially when two controllers share a single backplane or midplane, as in conventional RAID systems. In that case the entire RAID system becomes inactive. If data are striped within a single channel of direct access storage devices, the failure of a backplane serving the channel results in loss of data.
An active-active RAID system uses two RAID controllers that simultaneously process input and output (I/O) requests from host computers. The two RAID controllers communicate with one another, so that when one RAID controller fails, the surviving RAID controller takes over the identity of the failed RAID controller, takes over communication to the disks to which the failed RAID controller communicated, and takes over processing all the I/O operations for the RAID system.
After this automatic failover process, the failed RAID controller can be hot swapped, i.e., replaced with a functional RAID controller. The RAID controllers then perform a failback operation and restore the system to its original configuration. Thus, just as redundant disks enable a RAID system to continue operation after a disk fails, redundant RAID controllers in an active-active RAID system enable the system to continue operation after a RAID controller fails.
While an active-active RAID system can survive the failure of a disk or failure of a RAID controller, there are several other system components whose failure causes loss of data. This is a fundamental problem with prior art active-active systems.
For example, when a disk channel fails, the disks attached to that channel become unavailable. For RAID systems that have two disk channels and use parity RAID (such as RAID 5), the loss of the disks on a channel means the loss of data. This is a catastrophic failure of a RAID system to protect the integrity of data. There are a variety of problems that cause disk channel failure. The disk channel controller chip in a disk can fail and lock the disk channel. The disk channel controller chip in a RAID controller can fail and lock the disk channel. The physical disk channel itself can fail, e.g. as a result of the failure of a cable, a trace, a connector, or a terminator. In addition to these hardware failures, firmware in the disk channel controller chips in the disks or in the RAID controllers can lock a disk channel and cause catastrophic system failure.
In addition to disk channel failures, there are other single points of failure in RAID systems. A common example is the blackplane into which the RAID controllers are inserted. In the design of most active-active systems each RAID controller plugs into a common backplane. There are many ways in which a backplane can fail that cause the system to fail. Although some backplanes have only passive components to reduce the probability of failure, it is still the case that in most designs an active-active RAID system that uses a single backplane has multiple single points of failure that cause catastrophic data loss.
The communication link between controllers is another site for problems in an active-active RAID system. A link between controllers, sometimes called a heartbeat connect, is used to inform each controller of the status of the other controller. Should one RAID controller fail to send or respond to a signal, the other controller initiates failover activities. If the heartbeat connection fails while both controllers are operating properly, the system can become dysfunctional as both controllers attempt to take over the identification of the other controller and its disks.
The RAID system of the present invention avoids the failure of the RAID system or the loss of the data when there is a failure of any board, cable, power supply or cooling system in the controller chassis. In this invention, the two or more controllers which control the RAID system each have independent boards, cables, cooling, and power supply. Loss of one board, cable, cooling or power supply to one controller does not inactivate the entire RAID system or cause data loss. Similarly, loss of a board, cable, cooling or power supply to one direct access storage device DASD chassis results in inactivation of the affected DASD, but, since there is adequate redundancy in the racks of DASD units, the RAID system continues to function. In addition, this invention allows hot replacement of a failed controller along with associated backplanes, cables, power supply, or cooling system without interrupting the function of the RAID system.
The present invention insures the function of a RAID 1-5 system despite any single point of failure.
U.S. Pat. No. 5,761,032 discloses a removable media library unit with a frame structure with modular housing. A robot inserts media into the library and removes media no longer needed. There is continual access to one or more good storage devices while one or more failed drives of the library are repaired.
U.S. Pat. No. 5,871,264 discloses a drawer type computer housing with two sliding rails attached to the housing.
U.S. Pat. No. 6,018,456 discloses an enclosure system having a front and rear cages separated by a backplane. Connectors on either side of the backplane are used to connect trays containing drives in the front cage and sub-modules in the rear cage.
U.S. Pat. No. 6,025,989 discloses a modular node assembly for a rack mounted microprocessor computer. The assembly contains a power supply, fans, and removable chassis.
U.S. Pat. No. 6,061,250 discloses a full enclosure chassis system containing hot-pluggable circuit boards. A double height unit, such as a RAID controller, is combined with single height devices such as hard disk drives. The system allows the replacement of a controller circuit board without shutting down the system.
U.S. Pat. No. 6,097,604 discloses a carrier for installing electronic devices into an enclosure. An electronic device is attached to the carrier. Pushing the carrier into an enclosure causes metal surfaces on the carrier to be pushed outward contacting the enclosure side walls for electrical grounding.
U.S. Pat. No. 6,148,352 discloses a RAID system with provisions for adding a module or replacing a module without affecting host system access to existing online storage. Each storage module contains two sets of disk drives along with electronics for operating the disk drives. FIG. 10 shows storage systems with a power supply and a controller, in addition to the disks. In this system, one power supply serves one controller and 8 storage hard disk drives.
None of the prior art references provide the advantages of the present invention, that of the reliability of operation associated with an independent backplane board, cables, power supply and cooling system for each controller and for each rack of DASD. Conventional methods insure function of RAID systems despite failure of a single controller or DASD. With the innovations of the present invention, RAID systems are disclosed which function despite any failure of controller, DASD, backplane, or cable. The RAID systems of this invention eliminate the sharing of backplanes by more than one controller or more than one channel of DASD.
OBJECTS AND ADVANTAGES
The objective of this invention is to provide a RAID system of enhanced reliability.
Another objective is to provide a RAID system which functions despite any single point of failure.
Another objective is to provide a RAID system which functions despite failure of any single power supply or cooling system.
Another objective is to provide a modular RAID system which functions despite failure of any single module.
Another objective is to provide a modular RAID system wherein any failed module can be replaced without disruption to the function of the system.
Another objective is to provide a modular RAID system which is inexpensive, easy to construct, and capable of construction and operation without deleterious effects on the environment.
SUMMARY
The RAID data storage system of this invention comprises greater than one controller and a multiplicity of direct access storage devices. The direct access storage devices are arranged in one or more channels. Each channel comprises a multiplicity of direct access storage devices. Each controller is electrically connected to each direct access storage device of each channel, and each controller has a backplane component electrically connected to the electronic components of the controller. The backplane of each controller is a component of only one controller. Each channel of direct access storage devices has a backplane component electrically connected to each of the direct access storage devices. The backplane of each channel of direct access storage devices is a component of only one channel of direct access storage devices.
The RAID data storage system of this invention comprises greater than one controller, a multiplicity of direct access storage devices, the direct access storage devices arranged in racks of a multiplicity of direct access storage devices, each controller electrically connected to each direct access storage device, each controller and each rack of direct access storage devices having a power supply and a cooling system independent of each other power supply and cooling system, and no power supply or cooling system serving more than one controller or one rack of DASD.
DRAWINGS
—Figures
FIG. 1 is a schematic depiction of a first embodiment RAID system of this application.
FIG. 2 is a schematic depiction of a second embodiment RAID system of this application.
FIG. 3 is a diagrammatic side view of the modules of a RAID system of this application.
FIG. 4 is a top view of a storage array controller module of this application.
FIG. 5 is a side view of a storage array controller module of this application.
DETAILED DESCRIPTION
FIG. 1 is a schematic of the external view of a preferred RAID system of this invention 10 . This RAID system comprises two storage array controllers 175 and 275 , and three racks of DASD or storage units 310 - 380 , 410 - 480 , and 510 - 580 . A host computer is electrically connected to the storage array controllers 175 and 275 by connectors 125 and 225 , respectively.
Any suitable connector may be used, such as a wire, copper wire, cable, optical fiber, or a SCSI bus.
In all of the Figures the convention is followed of depicting connectors which are not electrically connected as lines which cross perpendicularly. An electrical connection is indicated by a line which terminates perpendicularly at another line or at a symbol for a component. Thus in FIG. 1 a host computer (not shown in FIG. 1 ) is electrically connected to storage array controller 175 by connector 125 . The host computer is not considered part of the RAID system and is not shown in FIG. 1 .
DASD may be disks, tapes, CDS, or other suitable storage device. A preferred DASD is a disk.
All the storage units or DASD and connectors in a system taken as a whole is referred to as an “array” of storage units or DASD, respectively. In the example here the DASD are arranged in channels which consist of a number of DASD which are electrically connected to each other and to the storage array controller by connectors. The channels associated with controller 175 are designated in FIG. 1 as 112 , 122 , and 132 . The number of channels may vary. A preferred number of channels is 6 .
A channel, for example channel 112 , consists of connector 110 , DASD 310 , DASD 320 , DASD 330 , DASD 340 , DASD 370 , and DASD 380 . Although only 6 DASD are depicted in channel 112 of FIG. 1 , there may be as many as 126 DASD in a channel. A preferred number of DASD in a channel is five.
The DASD are dual ported, with each DASD electrically connected to two controllers. For example, in FIG. 1 , channel 212 consists of connector 210 , DASD 310 , DASD 320 , DASD 330 , DASD 340 , DASD 370 , and DASD 380 .
Channel 122 consists of connector 120 , DASD 410 , DASD 420 , DASD 430 , DASD 440 , DASD 470 , and DASD 480 .
Channel 222 consists of connector 220 , DASD 410 , DASD 420 , DASD 430 , DASD 440 , DASD 470 , and DASD 480 .
Channel 132 consists of connector 130 , DASD 510 , DASD 520 , DASD 530 , DASD 540 , DASD 570 , and DASD 580 .
Channel 232 consists of connector 230 , DASD 510 , DASD 520 , DASD 530 , DASD 540 , DASD 570 , and DASD 580 .
The storage array controllers 175 and 275 are supported by and enclosed by chassis 100 and 200 , respectively. Also supported and contained by chassis 100 and 200 are power supply and cooling systems 150 and 250 , which serve storage array controllers 175 and 275 , respectively with electrical power and cooling. Connector 160 connects power supply and cooling system 150 to the mains or other source of electrical power. Connector 260 connects power supply and cooling system 250 to the mains or other source of electrical power.
Storage array controller 175 is connected to storage array controller 275 by connectors 102 and 104 .
DASD chassis 300 supports and encloses DASD 310 , 320 , 330 , 340 , 370 and 380 , and also supports and encloses DASD power supply and cooling system 350 , which provides electrical power and cooling to the DASD enclosed in DASD chassis 300 . Connector 360 connects power supply and cooling system 350 to the mains or other source of electrical power
DASD chassis 400 supports and encloses DASD 410 , 420 , 430 , 440 , 470 and 480 , and also supports and encloses DASD power supply and cooling system 450 , which provides electrical power and cooling to the DASD enclosed in DASD chassis 400 . Connector 460 connects power supply and cooling system 450 to the mains or other source of electrical power
DASD chassis 500 supports and encloses DASD 510 , 520 , 530 , 540 , 570 and 580 , and also supports and encloses DASD power supply and cooling system 550 , which provides electrical power and cooling to the DASD enclosed in DASD chassis 500 . Connector 560 connects power supply and cooling system 550 to the mains or other source of electrical power.
A group of DASD in separate channels across which data are striped is referred to as a “tier” of DASD. A DASD may be uniquely identified by a channel number and a tier letter, for example DASD 310 is the first DASD of channel 112 and is in tier A, along with DASD 410 of channel 122 , and DASD 510 of channel 132 .
Data are striped across a tier of DASD in parity groups. A parity group is created when a binary digit is appended to a group of binary digits to make the sum of all the digits, including the appended binary digit, either odd or even, as preestablished. In this invention, each parity group extends over several tiers of DASD. Failure of any single channel of DASD therefore does not result in loss of data.
Additional tiers of DASD may be used.
A preferred storage array controller is the Fibre Sabre 2100 Fibre Channel RAID storage array controller manufactured by Digi-Data Corporation, of Jessup, Md.
Any suitable power system capable of converting electrical power from the mains or other supply of to power of suitable voltage and amperage for a storage array controller or for DASD can be used.
Any suitable cooling system capable of providing necessary cooling to a storage array controller or a channel of DASD can be used.
Any suitable host computer may be used. A preferred host computer is a PENTIUM microchip-based personal computer available from multiple vendors such as IBM, Research Triangle Park, N.C.; Compaq Computer Corp., Houston Tex.; or Dell Computer, Austin, Tex. PENTIUM is a trademark for microchips manufactured by Intel Corporation, Austin, Tex.
Although a specific example of a RAID system has been described here, this invention is applicable to any RAID system which comprises two or more storage array controllers and one or more channels of DASD.
FIG. 2 is a diagrammatically representation of the second embodiment RAID system of this invention 20 . The elements of the second embodiment are identical to those of the first embodiment with the following exceptions. In the second embodiment, the channels span more than one DASD chassis. Such chassis are said to be “daisy-chained”.
For example, channel 612 consists of connector 610 , DASD 310 , DASD 320 , DASD 330 , DASD 340 , DASD 370 , DASD 380 , DASD 410 , DASD 420 , DASD 430 , DASD 440 , DASD 470 , DASD 480 , DASD 510 , DASD 520 , DASD 530 , DASD 540 , DASD 570 , and DASD 580 .
Channel 712 consists of connector 710 , DASD 310 , DASD 320 , DASD 330 , DASD 340 , DASD 370 , DASD 380 , DASD 410 , DASD 420 , DASD 430 , DASD 440 , DASD 470 , DASD 480 , DASD 510 , DASD 520 , DASD 530 , DASD 540 , DASD 570 , and DASD 580 .
FIG. 3 diagrammatically shows a preferred arrangement of the storage array controller and DASD chassis of the RAID system of this invention.
A rack 700 is used to support the chassis of the RAID system. The rack 700 comprises the left vertical end 715 , and right vertical end 705 , which are connected by horizontal shelves 710 , 720 , 730 , 740 , 750 , and 760 . The storage array controller chassis 100 rests on shelf 710 , and storage array controller chassis 200 rests on shelf 720 . DASD chassis 300 rests on shelf 730 , DASD chassis 400 rests on shelf 740 , DASD chassis 500 rests on shelf 750 , and DASD chassis 600 rests on shelf 760 . The connectors associated with the RAID system are not shown in FIG. 3 .
The term “module” is used to designate a self contained system component. A controller module consists of a chassis, a RAID controller, a power supply and a cooling system. Similarly, a DASD module consists of a DASD chassis plus the DASDs, a power supply, and a cooling system. Similarly, each cable used to connect one chassis with another chassis is a module.
FIG. 4 is a diagrammatic representation of the top view of a storage array controller module 101 with the top panel removed. A chassis 100 encloses the internal components. Visible in FIG. 4 is the front panel 118 of the chassis, the back panel 126 , left panel 122 , right panel 124 , and bottom panel 128 . Also visible is the storage array controller 175 , power supply 150 , and cooling system 250 . A connector 160 which provides power to the module is also shown. A plurality of connection sites 162 , 164 , 166 , 168 extend through the back panel 126 and are used to provide electrical connections between the storage array controller board 175 and host computers, channels of DASD, storage array controllers, and loop connector means for communicating with storage array controllers and host computers.
FIG. 5 is a side view of a storage array controller module 100 with the right panel removed. Visible in FIG. 5 is the front panel 118 of the chassis, the back panel 126 , bottom panel 128 and top panel 130 . The storage array controller 175 is supported by pegs 116 and 114 . Also visible is a connection site 168 and the power connector 160 .
—Operation
A RAID system of this invention will continue operation despite any single point of failure. Unlike conventional RAID systems, there are no shared components such as backplanes or midplanes, power supplies, cooling systems, or cables between the individual storage array controllers and the DASD channels which are controlled.
Failure of any single module, i.e. failure of any single storage array controller module, DASD module, or connector module does not halt the RAID system.
—Conclusions, Ramifications, and Scope
The RAID systems of this invention are able to function without loss of data despite the inactivation or loss of any one module. The inactive module may be hot swapped without halting the operations of the RAID system and without losing data.
It will be apparent to those skilled in the art that the examples and embodiments described herein are by way of illustration and not of limitation, and that other examples may be used without departing from the spirit and scope of the present invention, as set forth in the appended claims. | A RAID system which functions despite any single point of failure is disclosed. The system has two or more controllers, a multiplicity of direct access storage devices arranged in racks, redundant connectors throughout, and an independent backplane, cables, power supply, and cooling system for each controller and for each rack of direct access storage devices. In a second embodiment, no backplane or midplane is included in the RAID system; rather each controller is connected directly with the direct access storage devices. | 6 |
[0001]
[0000]
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TECHNICAL FIELD OF THE INVENTION
[0002] The field of the invention generally relates to systems for heating swimming pools and retaining heat in swimming pools
BACKGROUND OF THE INVENTION
[0003] With the high cost of oil, gas and electricity, the heating of swimming pools is expensive. Various types of inventions have been proposed to use solar radiation to heat the water. Some solar heaters require permanent installation of coils of pipe and which require pumps to circulate the heated water, and which are expensive.
[0004] Other proposed to use a sheet of cover to cover the swimming pools. The sheet of cover may utilize light weight thermoplastic film layers, having features like reflective integral air-pockets (U.S. Pat. No. 5,511,536). The cover must be removed from the pool before the pool can be used. The cover is expensive as it must be custom made for each pool. The cover requires large storage space, when it is not used.
[0005] The Lockshaw U.S. Pat. No. 4,103,368 illustrates a pool cover having solar energy heating capability is provided comprising sheet material adapted to furl about a reel less locus in a storage position and to be deployed in an extended position. The cover must be removed from the pool before the pool can be used. The cover is expensive as it must be custom made for each pool. The cover requires large space to store, when it is not used.
[0006] The Pelehach U.S. Pat. No. 3,949,095 illustrates a solar heating device for swimming pools comprising an inflatable raft having a thermally reflective bottom surface and a thermally transparent top surface, and means for elevating at least a fraction of said reflective surface above the swimming pool surface during periods of diminished solar radiation to reduce heat loss from the water. The Pelehach structure requires a pump to circulate the water. It is expensive, hard to use and suffers from other shortcomings.
[0007] The Acker U.S. Pat. No. 4,222,366 illustrates a solar pool heater which has a submersible tubular ring attached to the perimeter of a transparent or translucent sheet. The Acker structure does not provide for efficient heat collection. The Acker structure is expensive to construct, store, shipping and maintain.
[0008] The McCluskey U.S. Pat. No. 4,284,060 illustrates a floating solar heater which includes a top cover; a vertical outer side wall with inclined inner side wall segments connected thereto, an outside rim and a bottom wall. The inner side wall segments are octagonal, coated with light reflective material, and aid in reflecting the sun's rays to heat the space inside the walls formed by the cover which dead air space also provides for floatation of the heater. The bottom wall is heated by direct sun impingement and by the air in contact with it and is formed of a material having high heat conductivity. The McCluskey structure is expensive to manufacture, store, shipping and maintain. It does not require removal from the pool for pool use. However it is expensive to construct, store, shipping and maintain.
[0009] The Rosene U.S. Pat. No. 7,093,593 illustrates a solar pool heater for floating on water which uses an inflatable ring to support the pool heater, which has a center hole serves to permit egress of air from under the heater. Rosene's heaters hold together by the magnets on the edge. Heaters must be removed entirely or partially before use. The hole in the center does not efficiently permit egress of air. The Rosene's structure is soft in the ring with valves, which is easy to cause air leakage. When deploy on water, the rings are easy to overlap to each other and are easy to be blown off by wind.
[0010] The pool heater of my invention does not require removal before the pool is used. It has a hard frame. It is inexpensive, easy to construct, shipping and store and it is energy efficient.
SUMMARY OF THE INVENTION
[0011] These and other objects of the invention to become apparent hereinafter are accomplished in accordance with the present invention by the provision of the cover structure hereinafter to be described.
[0012] The invention is a solar heater for floating on water and it comprises a flexible pipe or a plurality of pipes, a coupling or a plurality of couplings and a multi layers cover, which has a dark color to absorb solar radiation, and which has layer to preserve heat, and which has a reflective film at the bottom side to reflect heat radiates from swimming pool.
[0013] The pipes and couplings can construct a closed shape. In the preferred embodiment of design, the solar heater is a ring shape, which is constructed of one pipe and one coupling. In another embodiment of design, the solar heater is a square shape, which is constructed of four pipes and four couplings, with each coupling having ninety degrees angle. In another embodiment of design, the solar heater is a hexagon shape, which requires six pipes and six couplings, with each coupling having one hundred and twenty degrees angle.
[0014] The bottom cover has multi layers films. In one embodiment of design, the bottom cover has one transparent upper film and one dark color lower film. The upper film and lower film form a thermo sheet with a plurality of bubble chambers in between. The embodiment of design allows solar radiation to pass through upper film, while the lower film absorbs the radiation to heat water. Air bubble chambers between upper film and lower film provide an effective and enhanced insulation barrier against heat loss from the pool.
[0015] The holes on the multi layers cover permit flow of rain from above the cover and egress of air from under the cover, when the heater is placed on the surface of water.
[0016] The object of the invention is to provide a durable low cost floating solar pool heater that is energy efficient, easy to store, easy to construct and require low maintenance.
[0017] Other features and advantages of the present invention will become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional features and advantages be included herein within the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which:
[0019] FIG. 1 is a top plan view of the preferred embodiment of the invention, before construction
[0020] FIG. 2 is a top plan view of the preferred embodiment in FIG. 1 , after construction.
[0021] FIG. 3 is a side view of the preferred embodiment in FIG. 2 .
[0022] FIG. 4 is an enlarged cross session taken on line 2 - 2 of FIG. 2 .
[0023] FIG. 5 is an enlarged cross session taken on line 3 - 3 of FIG. 2 .
[0024] FIG. 6 is a top plan view of second embodiment of the invention, before construction.
[0025] FIG. 7 is a top plan view of second embodiment of the invention, after construction.
DETAILED DESCRIPTION
[0026] Throughout the several Figures, identical call outs are used to identify identical structure. FIG. 1 is a top view of the preferred embodiment of the solar pool heater of the invention before construction. Flexible plastic pipe 101 , typically varies from 1 / 2 inch in diameter to 2 inches as a maximum diameter. Depending upon the end use of the solar pool heater, the length thereof will also vary. Flexible plastic coupling 102 , typically the outer diameter of 102 is a little less than the inner diameter of 101 . Hence, 102 can be placed into 101 to connect two ends of 101 to form a closed ring shape. Different means of method could be used to connect 101 and 102 . One method would be to use plastic glue to glue 101 and 102 to ensure the ring shape will last. Plastic coupling 102 , typically varies from 3 inches long to 6 inches. The length of plastic coupling 102 is much shorter than the length of plastic pipe 101 . Bottom cover 103 is a multilayers thermo material. The upper side of 103 is transparent or semitransparent plastic film. The lower side of 103 is a dark color film, which absorbs solar radiation. There is a plurality of small air pockets 105 between upper side film and lower side film. A plurality of small air pockets 105 enable solar heater to reduce heat lost when the pool water temperature is higher than air temperature. Bottom cover 103 includes air escape means, such as a plurality of through holes 104 , for allowing rain to flow from the top of bottom cover 104 and air to escape from below the bottom cover 104 , when solar heater is placed on water. Through-hole 104 also allows water on the bottom cover 104 to drain down to pool.
[0027] FIG. 2 is a top view of the preferred embodiment of the solar pool heater of the invention after construction; In FIG. 2 coupling 102 has been installed into plastic pipe 101 . A portion of 102 residues in one end of plastic pipe 101 , while the other portion of 102 residues in the other end of plastic pipe 101 . Connection line 201 is where the two ends of plastic pipe 101 meet. Coupling 102 connects both ends of 101 to form a plastic ring 200 . Bottom cover 103 has been attached to outer ring 200 . The upper side of bottom cover 103 has contacts with outer ring 200 .
[0028] FIG. 3 is a side view of the embodiment in FIG. 2 . It shows the outer ring 200 , the bottom cover 103 and the connection line 201
[0029] FIG. 4 is an enlarged cross session taken on line 2 - 2 of FIG. 2 . The dark shade area 401 is the cross session of plastic pipe 101 . The dark shade area 402 is the cross session of the coupling 102 . 403 is the cross session of bottom cover 103 , which has two films, the upper film 405 and the lower film 404 . Lower film 404 is made of dark color thermo material, allowing the solar pool heater to absorb solar radiation. Upper film 405 is made of transparent or light color thermo material. 406 is the cross session of air pocket 105 , air pocket 105 enable solar heater to reduce heat lost when the pool water temperature is higher than air temperature.
[0030] FIG. 5 is an enlarged cross session taken on line 3 - 3 of FIG. 2 . The dark shade area 401 is the cross session of plastic pipe 101 . FIG. 5 . shows one embodiment of cross session that only has plastic pipe 101 , but not has coupling 102 . The bottom cover has two films, the upper film 405 and the lower film 404 . Lower film 404 is made of dark color thermo material, allowing the solar pool heater to absorb solar radiation. Upper film 405 is made of transparent or light color thermo material. 406 is the cross session of air pocket 105 , air pocket 105 enable solar heater to reduce heat lost when the pool water temperature is higher than air temperature.
[0031] FIG. 6 is a top plan view of second embodiment of the invention, before construction. Flexible plastic pipe 601 , typically varies from ½ inch in diameter to 2 inches as a maximum diameter. Depending upon the end use of the solar pool heater, the length thereof will also vary. Flexible plastic coupling 602 , which has a 90 degree angle, typically has outer diameter a little less than the inner diameter of 601 . Four plastic pipe 601 and four right 602 can connect together to form a closed square shape. Different means of method could be used to connect 601 and 602 . One method would be to use plastic glue to glue 601 and 602 to ensure the square shape will last. Bottom cover 603 is a square shaped, multilayers thermo material. The upper side of 603 is transparent or semitransparent plastic film. The lower side of 603 is a dark color film, which absorbs solar radiation. There is a plurality of small air pockets 105 between upper side film and lower side film. A plurality of small air pockets 105 enable solar heater to reduce heat lost when the pool water temperature is higher than air temperature. Bottom cover 603 includes rain draining means and air escape means, such as a plurality of through holes 104 , for allowing air to escape from below the bottom cover 104 , when solar heater is placed on water. Through-hole 104 also allows water on the bottom cover 104 to drain down to pool.
[0032] FIG. 7 is a top plan view of second embodiment of the invention, after construction. Square shape floating solar pool heater 700 is made from four plastic pipes, four connect couplings and one bottom cover. | A solar heater for floating on water generally comprises a flexible outer ring and a bottom cover. The ring and the cover can absorb solar radiation, reduce pool water evaporation and preserve heat in pool. Holes through the cover permit drain of rain from above the cover and egress of air from under the cover. | 4 |
CLAIM OF PRIORITY
This application is Continuation-in-Part of U.S. application Ser. No. 13/029,336 filed Feb. 17, 2011 and claiming priority to U.S. Ser. No. 61/305,255 filed Feb. 17, 2010, the contents of both of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to the installation of building siding, and more particularly to insulation board and processes related to installing the insulation.
BACKGROUND OF THE INVENTION
Houses in America often have their exterior walls clad with siding to protect the predominately wooden construction from the elements. Vinyl siding has become particularly popular over the last several decades as it is inexpensive, relatively easy to clean and relatively durable. However, in recent years, fiber cement siding has begun to replace vinyl siding. Fiber cement is a product made of sand, cement and cellulose. As a siding material, fiber cement has advantages over both wood and vinyl in that it is rot resistant, termite resistant and non-combustible. Because of these properties fiber cement siding has become widely used in bush fire regions of Australia, and is now becoming a material of choice for new construction in the United States also. Fiber cement siding can also be painted and can be made to look like wood. Its one significant disadvantage is that the fiber cement planks used in the siding are relatively heavy and need to be placed one at a time. Any method of making their alignment easier is, therefore, of great practical utility.
On the other hand vinyl and other types of building siding remain common and insulation at the times of high energy costs has become an important consideration. Therefore, there is a need of insulation practical to use with vinyl and other types of building sidings as well as fiber cement siding.
The system and method of this invention provide both increased thermal insulation and significantly simple installation of the insulation. Furthermore the invention provides an alignment of the fiber cement planks when fiber cement siding is used. The simplified insulation does not compromise the thermal insulation but makes the system more affordable and time saving.
DESCRIPTION OF THE RELATED ART
The relevant patent literature involving siding alignment and insulation products and processes include:
U.S. Patent Publication Number 2009/0019814 is directed to a panelized cladding system including a plurality of battens securable to a building structure, each batten having a structure engaging surface and an integrally formed finish ready panel supporting surface. Fiber cement cladding panels are secured to or through the battens such that the finish ready panel supporting surface of each batten forms an external recessed surface of an expressed joint formed thereon.
U.S. Pat. No. 6,418,610 relates to a method for using a support backer board system and siding. The support backer board system comprises at least a first layer. The first layer is made from a material selected from the group consisting of alkenyl aromatic polymers, polyolefins, polyethylene terephthalate, polyesters, and combinations thereof. The board system is thermoformed into a desired shape with the desired shape being generally contoured to the selected siding. The siding is attached to the board system so as to provide support thereto. In one process, the siding may be vinyl.
U.S. Pat. No. 8,091,313 discloses an apparatus and method for a drainage system of an exterior wall of a building comprising insulation having a rear face for contact with the exterior wall of the building and a drainage plane positioned on the rear face for removal of water from the exterior wall.
CA 2,742,046 discloses an insulation system for securing cladding to the exterior surface of a building. An insulated panel has a front face and a rear face. Joining elements are defined in horizontal edges of the panel for connecting adjacent panels to each other. A horizontal attachment member, such as a nailing hem, is mounted to the rear face of the panel for attaching the insulated panel to the exterior surface. Receiving members are present on the front face of the panel, and can be located in receiving channels. The receiving member is generally made from a material that is better at retaining fasteners, such as nails, than the material of the insulated panel itself.
U.S. Pat. No. 7,762,040 discloses a method for installing siding panels to a building including providing a foam backing board having alignment ribs on a front surface and a drainage grid on a back surface and then establishing a reference line at a lower end of the building for aligning a lower edge of a first backing board an tacking thereon. The system includes tabs and slots along vertical edges of the foam backing board to align and secure adjacent backing boards to each other. A siding panel is butted against one of the lower alignment ribs and secured thereto. Another siding panel is butted against and secured to the adjacent alignment rib to form a shadow line between the adjacent siding panels on the building.
U.S. 20100251648, 2011021073, 20110271622, and US20110271624 disclose foam backing panels for use with lap siding and configured for mounting on a building. The foam backing panels comprise a rear face configured to contact the building, a front face configured for attachment to the lap siding, alignment means for aligning the lap siding relative to the building, means for providing a shadow line, opposing vertical side edges, a top face extending between a top edge of the front face and rear face and a bottom face extending between a bottom edge of the front face and rear face.
The existing art does not provide sufficient protection against moisture drainage of building structures, sufficient aeration between the building surface and the insulation, nor a method or means to easily align drainage panels or attach the insulation boards.
Various implements are known in the art, but fail to address all of the problems solved by the invention described herein. One embodiment of this invention is illustrated in the accompanying drawings and will be described in more detail herein below.
SUMMARY OF THE INVENTION
The present invention relates to an apparatus that forms an insulating barrier behind building siding. The siding may be of any material, vinyl siding, wood siding, fiber cement siding or any other siding material.
In U.S. patent application Ser. No. 13/029,336 and corresponding provisional application 61/305,255, the contents of both of which are incorporated herein by reference, the inventor provided an easy to install shaped insulation board with a separate two sided water drainage panel. The inventor has now developed the product further, and provides here an insulation board that in it self may act as two sided water drainage panel and simultaneously allows aeration between the board and the building surface.
According to one preferred embodiment the siding is fiber cement siding and the insulation also acts as an installation guide that aids in attaching fiber cement planks or boards that form the siding.
In a preferred embodiment, a rectangular insulating board made of a suitable thermal insulating material has a substantially flat, rectangular back surface including multiple drainage areas for water draining.
The substantially flat back surface of the insulation board has a plurality of molded drainage areas. The drainage areas consist of vertically positioned drainage grooves and ridges and the drainage areas are separated from each other by inner stud ridges that are designed to coincide with the building studs for attachment of the board. The inner stud ridges may also be designed to be higher than the drainage ridges, whereby the system leaves an aeration space between the drainage areas and building surface when the board is attached on the building studs.
The front surface has preferably one or more stud marking areas. The stud marking areas may contain vertically running stud marking grooves that may also act as water drainage channels but also enable easy lining of the boards plus guide attachment to the studs. The stud marking areas may contain other markings for attachment to the studs as well, such a nail spots, letters, numbers, or color codes.
The front surface may be shaped to form a number of flat-faced, protruding horizontal ridges. The protruding ridges are preferably aligned substantially parallel to an edge of the rectangle. A cross-section, taken orthogonal to the alignment of the protruding ridges, has a saw-tooth shape. The front side of the board also includes means to guide attachment to the building studs.
The protruding horizontal ridges are shaped and sized so that the following may be done. A standard-size, fiber cement plank, or board, may be placed face-down on a long face of a protruding ridge of the shaped insulating board. The fiber cement board may be positioned to have its long edge abutting the short face of an adjacent protruding ridge. A second fiber cement board of a similar size may then be placed face-down on a long face of the adjacent protruding ridge. When the second fiber cement board is positioned to have its long edge abut the short face of the next adjacent ridge, the second board may then overlap the first fiber cement board. The overlap is such that the underside face of the overlap of the second board lies flat on the upper face of the first board. The invention of this disclosure also comprises shaped flashing elements that are sandwiched between the insulation board and the fiber cement boards to provide water protection in areas where two insulation boards are abutting either horizontally or vertically. The shaped insulating board is aligned on the wall to a required orientation. The required orientation is preferably the orientation in which the protruding ridges are aligned in the same direction as the desired orientation of the length of the fiber cement board when it is attached.
An aspect of the instant invention in addition to provide a guidance system for installation of the cement boards is to provide an insulation board that allows efficient water drainage and aeration. Furthermore, the instant invention not only provides guidance for installing the cement boards, but provides guidance to easily align the drainage channels and to attach the insulating boards on the building studs.
Once the shaped insulating board is attached to the wall, it may then serve as a guide for positioning the fiber cement board. The fiber cement board may be positioned by abutting its long side against a short edge of one of the protruding ridges, with the fiber cement board's face against the long face of an adjacent protruding ridge. The fiber cement board is then correctly aligned and may be slid along the ridge edge until it is in place for attaching to the wall. The attachment may, for instance, be by means of a fastener such as, but not limited to, nails, screws, bolts or some combination thereof.
Therefore, the present invention succeeds in conferring the following, and others not mentioned, desirable and useful benefits and objectives.
It is an object of the present invention to provide a shaped insulating board for attachment on building studs, having a vertical cross section, a horizontal cross section, a front surface and a substantially flat back surface, wherein the back surface is forming a molded drainage panel, said drainage panel comprising a multitude of drainage areas, each drainage area being formed by vertical drainage ridges and drainage grooves, and each drainage area being separated from each other by an inner stud ridge, said vertical ridges and grooves running from an upper end of the back surface to a lower end of the back surface, and said stud ridges located from each other at distance such that a multiplication of the distance equals to the distance between building studs, whereby each building stud coincides with one stud ridge, and the front surface comprising markings for attachments on building studs, said markings coinciding with stud ridges on the back surface.
It is another object of the present invention to provide fiber cement siding system comprising:
a multitude of fiber cement boards; a shaped insulating board, having a vertical cross section, a horizontal cross section, a shaped front surface and a substantially flat back surface,
the front surface being formed of horizontally aligned ridges having a short face and a long face, the short face of one ridge being joined in an angle to the long face of an adjacent ridge, whereby the vertical cross section has a substantially saw tooth like edge toward the front surface and a flat edge toward the back surface, the front surface further comprising a plurality of stud marking areas, each stud marking area consisting of vertically oriented stud marking grooves running across the horizontally aligned ridges from an upper end of the front surface to a lower end of the front surface, said vertically oriented grooves being separated from each other by an outer stud ridge, and the stud marking areas being separated from each other by clearance ridges, said clearance ridges having a width equaling to a distance between building studs, the back surface having a molded drainage panel, said drainage panel comprising a multitude of drainage areas, each drainage area being formed by vertical drainage ridges and drainage grooves, and each drainage area being separated from each other by an inner stud ridge, said vertical ridges and grooves running from an upper end of the back surface to a lower end of the back surface, and said inner stud ridge coinciding with the outer stud ridge, whereby the horizontal cross section of the insulating board has non grooved stud ridge areas in between of grooved drainage areas, and said non grooved stud ridge areas locate from each other at distance equaling to the distance between building studs; and a multitude of flashing elements, said flashing elements consisting of a first rectangle having a short edge substantially equal in length to the width of the short face of the protruding ridge of the front surface of the shaped insulating board, a second rectangle having a long edge longer than the long face of the protruding ridge of the shaped insulating board, and a short edge having a length substantially equal to a long edge of the first rectangle, and wherein the long edge of the first rectangle forms a substantially contiguous join with the short edge of the second rectangle in an angle matching the angle of the joint of the short and the long face of adjacent protruding ridges of the front side of the shaped insulating board.
It is an object of the present invention to provide a thermal insulation including an efficient drainage system.
It is another object of the present invention to provide thermal insulation with drainage panels that allows proper aeration between the insulation and the building surface.
It is a further object of the present invention to provide a system to align the drainage channels of abutting insulation boards.
Another object of the present invention is to easily enable attachment of the insulation board onto the building studs.
It is an object of the present invention to provide additional thermal insulation to houses.
It is an object of the present invention to prevent water damage to building structures.
It is another object of the present invention to provide a tool for rapid positioning of fiber cement boards.
Yet another object of the present invention is to provide quicker, and therefore less expensive, installation of fiber cement siding.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view of a preferred embodiment of a shaped insulating board of the present invention.
FIG. 2 shows a vertical cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention.
FIG. 3A shows a horizontal cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention.
FIG. 3B is an enlarged detail of the grooves and ridges on the cross section shown in FIG. 3A .
FIG. 4 A. shows an isometric view of the substantially flat back surface of one embodiment of the shaped insulating board of the present invention having a series of drainage areas separated by stud ridges. The vertical cross section in this embodiment is saw tooth like.
FIG. 4 B shows an isometric view of the substantially flat back surface of another embodiment of the shaped insulating board of the present invention having a series of drainage areas separated by stud ridges. The vertical cross section in this embodiment is not saw tooth like.
FIG. 5 shows an isometric view of a shaped flashing element of the present invention.
FIG. 6 shows an isometric view of shaped flashing elements placed to cover a horizontal gap between two adjacent shaped insulating boards.
FIG. 7 shows an isometric view of shaped flashing elements sandwiched between fiber cement boards and shaped insulating board and covering a vertical gap between two adjacent shaped insulating boards.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
Reference will now be made in detail to embodiments of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
FIG. 1 shows an isometric view of a preferred embodiment of a shaped insulating board of the present invention. FIG. 1 shows the shaped insulating board 100 , the front surface 155 , the upper end of the front surface 156 , the lower end of the front surface 157 , the back surface 200 , the upper end of the back surface 202 , the lower end of the back surface 204 , protruding ridges of the front surface 150 , vertical stud marking areas 190 , the front surface, stud marking grooves 192 , clearance ridge 196 between the stud marking areas, outer stud ridge 195 separating the stud marking grooves 192 , and markings for attachment 198 on the outer stud ridges.
FIG. 2 shows a vertical cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention. The figure shows the shaped insulating board 100 , the front surface 155 , the back surface 200 , and the saw-tooth shaped vertical cross section 160 . The long face of protruding ridges 185 and the short face of the protruding ridges are also shown.
FIG. 3 A shows a horizontal cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention. The figure shows the building studs 125 , the building surface 105 , the horizontal cross section 170 , the back surface 200 , the front surface 155 , the stud marking grooves 192 , the outer stud ridge 195 , the clearance ridges 196 between the stud marking areas, the drainage areas 300 , the inner stud ridges 305 , the drainage grooves 310 , and the drainage ridges 320 .
FIG. 3B shows an enlarged detail of the horizontal cross-section of the shaped insulating board of FIG. 3A . The figure shows the back surface 200 , the front surface 155 , the stud marking grooves 192 , the inner stud ridge 195 , the clearance ridge 196 , drainage groove 310 , drainage ridge 320 and inner stud ridge 305 .
FIG. 4 A shows an isometric view of the back surface with stud markings according to one embodiment. The figure shows the back surface 200 , the vertical saw tooth like cross section 160 , the horizontal cross section 170 , the drainage areas 300 , the drainage grooves 310 , the drainage ridges 320 and the inner stud ridges 305 .
FIG. 4 B shows an isometric view of the back surface with stud markings of another embodiment where the front side does not have the protruding ridges and accordingly the vertical cross section is not saw tooth like. The figure shows the back surface 200 , the vertical cross section 160 , the horizontal cross section 170 , the drainage areas 300 , the drainage grooves 310 , the drainage ridges 320 , an optional diagonal groove 303 , and the inner stud ridges 305 .
FIG. 5 shows an isometric view of a shaped flashing element of the present invention. The figure show the flashing element 420 , the first rectangle 440 , the second rectangle 450 , the long edge of the second rectangle 455 , the short end of the second rectangle 460 , the short end of the first rectangle 442 , and the long end of the first rectangle 445 .
FIG. 6 shows the shaped flashing elements placed to cover a horizontal gap between two adjacent shaped insulating boards. The figure shows the horizontal gap 500 between the boards, the flashing element 420 , the first rectangle 440 , the second rectangle 450 , the short end of the first rectangle 442 , the long end of the first rectangle 445 , the long end of the second rectangle 455 , the short end of the second rectangle 460 , the protruding ridges of the front surface 150 , the long face of protruding ridges 185 , and the short face of protruding ridges 180 .
FIG. 7 shows the flashing elements sandwiched between fiber cement boards 110 and shaped insulating board 100 and covering a vertical gap 550 between two adjacent shaped insulating board. The figure shows the vertical gap 550 , fiber cement boards 110 , flashing element 420 , the first rectangle 440 , the second rectangle 450 , the long end of the first rectangle 445 , the short end of the first rectangle 442 , the long end of the second rectangle 455 , the short end of the second rectangle 460 , the protruding ridges of the front surface 150 , the long face of protruding ridges 185 , and the short face of protruding ridges 180 .
Now referring to FIGS. 1 and 2 , the shaped insulating board 100 has a rectangular, substantially flat back surface 200 . In one preferred embodiment the vertical cross section 160 is saw tooth-like and on the front surface 155 , the shaped insulating board 100 is shaped to have a series of substantially identical, flat-faced protruding ridges 150 . The size and shape of these protruding ridges 150 is largely defined by the dimensions of the standard fiber cement boards 110 typically used for exterior wall siding, for instance, on domestic houses. Further, the front surface 155 of the shaped insulating board 100 has vertical stud marking areas 190 . A stud marking area 190 consists preferably of two vertically running stud marking grooves 192 separated by an outer stud ridge 195 . Alternatively, only one stud marking groove 192 may be used. It is also possible to have more than two stud marking grooves. A skilled artisan would understand that it is in the spirit of this invention to have an insulating board where the front surface does not have the protruding ridges 150 but only the stud marking areas (shown in FIG. 4B ). Such a board would be practical to use for example with vinyl- or wood sidings. The width of the outer stud ridges 195 when measured from the middle of one stud marking groove 192 to middle of the second stud marking groove 192 , is determined by the width of the building studs 125 and is between 1 and 4 inches, preferably between 1 and 2 inches, and most preferably 1.5″ (3.81 cm), but the width may also be larger or smaller. The stud marking areas 190 are separated by clearance ridges 196 . The width of the clearance ridge 196 is determined by the distance between building studs 125 . The standard distance between building studs is 16 or 24 inches (40.64 or 60.96 cm) from stud center to stud center. Accordingly, in the preferred embodiment the width is such that a multiplication of the width would equal with the distance between building studs. In a most preferred embodiment the with of the clearance ridges 196 is 2, 4, 8, 16, or 24 inches, whereby there is always one stud ridge 195 coinciding with each building stud 125 and therefore guide installation of the shaped insulating board 100 . One skilled in the art would appreciate that it is within the scope of this invention to vary the width of the clearance ridges long as there is one stud ridge 195 coinciding with each building stud 125 . According to a preferred embodiment the width of the clearance ridges is 16 inches for buildings where the distance between studs is 16 inches, and 24 inches where the distance between the studs is 24 inches. The stud marking areas 190 of the instant invention also helps aligning horizontally abutting insulation boards so that drainage areas and drainage grooves on the back side of the boards are aligned. Furthermore the stud marking areas 190 enable to position the insulation boards 100 so that they are easy to attach with nails or other means to the studs 125 . According to one preferred embodiment, the outer stud ridges 195 have markings for the attachment 198 . In the embodiments where the width of the clearance area is smaller than the distance between the studs, the markings for attachment 198 are so designed that they locate only on those stud ridges that are to be attached to the studs. The markings may be, but are not limited to spots, lines, crosses, colored areas or other codes. According to one embodiment the front of the board may have letters or numbers and certain numbers or letters serve as markings for attachment 198 . Certain codes may guide attachment to studs that are 16 inches apart from each other, while other codes may guide attachment to studs 24 inches apart from each other. According to one embodiment the codes may be letters which may be part of advertisement or other information.
Now referring to FIGS. 4 A and B, the back surface 200 of the shaped insulating board has several drainage areas 300 , each drainage area comprising several vertical drainage grooves 310 separated by drainage ridges 320 . The drainage areas 300 are separated from each other by inner stud ridges 305 . FIG. 4 A shows an embodiment where the front surface has the protruding ridges whereby the vertical cross section 160 is saw tooth like. FIG. 4 B shows another embodiment where the front surface does not have the protruding ridges and the vertical cross section 160 accordingly does not have the saw tooth like character. FIG. 4B also shows a diagonal groove 303 . According to one embodiment the inner stud ridge 305 may contain one or more diagonal grooves 303 connecting the drainage areas.
Referring now to FIGS. 3A and 3B , the inner stud ridges 305 preferably coincide in location with the outer stud ridges 195 , thereby the inner stud ridge and the corresponding outer stud ridge form a non grooved stud area 302 and the non grooved stud areas coincide with the location of the building studs 125 . When the shaped insulating boards are attached to the building they can be easily attached along the non grooved stud areas 302 to the studs 125 for example with nails, screws or other similar means. As is shown in FIG. 3B , which shows the stud area 302 in details, it can be seen that the inner stud ridge 305 is preferably higher than the drainage ridges 320 . This feature would allow an air space between the building surface 105 and the installed shaped insulating board 100 , because the lower height of drainage ridges 320 would not allow them to touch the building surface 105 when the higher inner stud ridges 305 is aligned along and attached to the building studs 125 . According to a preferred embodiment the height a drainage ridge 320 when measured from the bottom of adjacent drainage groove 310 to the top of the inner drainage ridge 320 is between 1/16 and ¼ inches, more preferably about ⅛ inches and most preferably ⅛ inches (3.18 mm). An inner stud ridge 305 may be 1/16 to ¼ inches higher than the drainage ridge, but preferably is 1/16 inches higher than the drainage ridge 320 . Accordingly, preferably when the height of an inner drainage ridge 320 is measured from the bottom of a drainage grove 310 to the top of the inner drainage ridge 320 , it would be 3/16 inches (4.76 mm) high, and the air space between the building surface 105 and the shaped insulating board 100 would be approximately 1/16 inches (1.18 mm). It is understood by a skilled artisan that the measures may be changed without departing the spirit of the invention.
According to one embodiment the board may contain one or more diagonally positioned grooves 303 across the inner stud ridge. Such diagonal grooves may connect the drainage grooves that locale on both sides of the inner stud ridge. Such an embodiment would provide improved water drainage.
The cross section of the stud marking grooves 192 and the drainage grooves 310 is preferably V-shaped, but it can also be U-shaped, or partially square shaped.
The shaped insulating board 100 may be made from any suitable thermal insulation that is also sufficiently rigid to support standard-sized fiber cement boards 110 during installation. Suitable materials are insulation such as, but not limited to, polyolefin, polyethylene terephithalate, polyester, alkenyl aromatic polymer, polystyrenic resin and polystyrene, or some combination thereof. Preferably the insulation board is made of polystyrene foam. The board may be up to 2″ (5.08 cm) thick. The size of the boards may vary. According to one preferred embodiment the board is about 4×4 feet (121×121 cm), but any other feasible size is within the scope of the invention.
The shaped insulating board 100 with the optional flat faced protruding ridges, stud markings and drainage areas is preferably shaped by using molding techniques but may be shaped by any method suitable to the material used including hot wire forming techniques such as, but not limited to preformed wire manufacture.
Now referring to FIGS. 5 , 6 and 7 , the instant invention comprises a shaped flashing element 420 to waterproof the horizontal 500 and vertical 550 gaps that are between adjacent shaped insulating boards 100 . According to a preferred embodiment the shaped flashing element 420 is made of coated aluminum, but instead of aluminum other malleable materials such as copper, bronze, tin, or steel may also be used. The flashing element may also be made of plastic or polyethene. Preferably the flashing element is made of aluminum coated with an anticorrosion coating from both sides to avoid corrosion caused by the fiber cement. The shaped flashing element 420 may, for instance, be made by a process such as, but not limited to, molding, machining, bending or some combination thereof.
FIG. 5 illustrates the flashing element according to a preferred embodiment. The flashing element 420 has a first rectangle 440 and a second rectangle 450 . The first rectangle 440 has a short edge 442 substantially equal in length to the width of the short face 180 of the protruding ridge 150 . The second rectangle 450 has a long edge 455 . The long edge 455 may be substantially equal in length to the width of the long face 185 of the protruding ridge 150 of the shaped insulating board 100 , but according to a preferred embodiment the long edge 455 is longer than the width of the long face 185 . According to a most preferred embodiment the long edge 455 is substantially equal in length to the width of the cement board 110 . The short edge of the second rectangle 460 has a length substantially equal to the long edge of first rectangle 440 . The long edge of the first rectangle 442 forms a substantially contiguous join with the short edge of the second rectangle 450 in an angle that matches the angle between adjacent protruding ridges 150 of the shaped insulating board 100 .
FIG. 6 shows an isometric view of shaped flashing elements 420 placed to cover a horizontal gap 500 between two adjacent shaped insulating boards 100 . FIG. 7 shows an isometric view of shaped flashing elements 420 placed to cover a vertical gap 550 between adjacent shaped insulation boards 100 . As shown in FIGS. 6 and 7 , the next step after attaching the shaped insulation board 100 on the building surface is a sandwich flashing elements between the insulation board 100 and the fiber cement boards 110 to cover horizontal 500 or vertical 550 gaps between two adjacent insulation boards 100 . Once the fiber cement boards 110 are secured, the shaped flashing element 420 is held in place without any fastening elements. An advantage in this is to save material and on the other hand to save the flashing elements from any holes that would be created by nails or pins or other fastening means.
In a preferred embodiment, the shaped flashing element 420 may have a width in a range of 0.5 to 12 inches (1.27 cm to 30.48 cm) and a thickness in a range of less than 0.5 inches (1.28 cm). More preferably, the shaped flashing element 420 may have a width in a range of 1 to 3 inches (2.54 to 7.62 cm) and a thickness in a range of less than 0.125 inches (3.18 mm). According to a preferred embodiment the long edge of the second rectangle 455 is preferably between 5 and 8 inches (12.70 to 20.32 cm), but the length primarily depends on the width of the fiber cement planks.
According to one embodiment of this invention, a water proof sheet may be attached on the building surface 105 before attaching the shaped insulating boards 100 . Such water proof sheet may be made of any suitable waterproof or water-resistant for creating a vapor barrier such as, but not limited to, aluminum foil, paper-backed aluminum, polyethylene plastic sheet, a metalized film, or some combination thereof.
Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. | A shaped insulating board is disclosed for enabling lining of fiber cement boards and simultaneously enabling attachment of the insulating board on the building studs. Furthermore, the shaped insulating board provides a water drainage panel that allows water to drain downward on both sides of the board. The shaped insulating board also provides aeration between the board and the building surface. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to digital processing apparatus, and more particularly to a digital processing apparatus having a distributed architecture.
A classical Digital Signal Processor (DSP) has two major parts, namely a core architecture and the peripherals.
The major blocks of the core architecture are:
Program/Data Memory
Arithmetic/Logic Unit (ALU)
Multiplier/Accumulator (MAC)
Barrel Shifter (BS)
Data Address Generator (DAG)
Program Address Generator (PAG)
Registers (used to hold intermediary results, addresses, and speed up access to the previous five blocks)
Buses
Some of the peripheral blocks are:
Serial Port(s)
Host Interface Port (parallel port)
Timer(s)
Somewhere between these two blocks are:
DMA controller
Interrupt(s) controller
Various DSPs may use distinct ALU, MAC and BS computational blocks or may blend them into multifunctional units.
The new generation of DSPs take advantage of:
newer technologies allowing faster clocking of old architectures and consequently higher processing power
faster memories that allow improvements in the internal architecture of various blocks
multiple internal buses
new peripherals
One of the common problems associated with the traditional DSP architectures is the uneven loading of the processors in a multiprocessor design. To cope with this problem, more recently, new DSP architectures have been proposed and implemented that have parallel processing capabilities.
At the heart of their design is the concept of inter-processor communication via external interface ports, globally shared memory, and shared buses. The complexity of these designs, however, translates into extremely high cost IC implementations.
Parallel Computing (PC) increases processing power by permitting parallel processing at the routine (task) level. When a program has to execute two different routines that are independent at the data level (i.e. the data written by one routine is not read by the other routine), the two routines can be executed in parallel. This is referred to herein as macro parallelism.
Congestion can also occur at the instruction level. When a program has to execute a sequence of instructions that are independent, at data level, these instructions could be executed in parallel. Executing these instructions in parallel (herein referred to as micro parallelism) on the same processor, however, would require multiple buses and instruction words large enough to handle multiple operands.
An object of the invention is alleviate this problem.
SUMMARY OF THE INVENTION
According to the present invention there is provided digital processing apparatus comprising a microprocessor, said microprocessor comprising at least one external interface for connection to a respective parallel like microprocessor having a similar interface; a plurality of internal registers including a respective internal register shareable with each said parallel like microprocessor, an internal bus accessing said internal registers, and an external bus connectable to each said parallel like microprocessor through said at least one external interface to permit the exchange of data said control signals; a multiplexer connecting said internal bus and the or each said external bus to the or each said shareable internal register so that said microprocessor and the or each said external like microprocessor can co-operatively share in the execution of a single instruction represented by a large instruction word; and an inter-processor status register for maintaining the current status of said microprocessor and said least one parallel like microprocessor.
The invention handles macro parallelism by allowing a processor to start a task (and be notified on its completion) on a neighboring parallel processor.
The invention can also handle parallel processing of single instruction words (micro parallelism) without the need for multiple buses and the like. Instead of requiring a complex processor, the invention locks together multiple simpler processors to achieve a similar result, and at the same time obtain the benefit of the power of multiple processing units. When multiple processors are locked together, the instructions they execute can be seen as the equal length segments of a Large Instruction Word (LIW). Depending on how many processor are locked together, the length of the Large Instruction Word could vary.
The invention thus permits the handling of micro parallelism through LIW, as well as macro parallelism through Parallel Computing.
The invention thus employs a processor interface and changes to the architecture of a DSP that make both Parallel Computing and Large Instruction Word possible. The new distributed processing architecture is particularly suited for the case when the processors share the silicon space of a single integrated circuit.
The invention also provides a distributed architecture parallel processing apparatus, comprising a microprocessor having at least one external interface connected to a similar interface of a neighboring parallel processor, said processors exchanging data and control signals through said interfaces to cooperatively share in the execution of a program; and an inter-processor status register in each processor for maintaining the current status of said processors.
The invention still further provides a method of executing a comprising the steps of providing an least two parallel processors; interconnecting said processors through an external interface so that they can exchange data and control signals to cooperatively share in the execution of a program; providing internal registers in each said processor, at least one said register being shareable with a said parallel processor; providing in each said processor an internal bus and an external bus connected to a said parallel processor through said interface; permitting two said processors to access said shareable register by multiplexing said internal and external buses so that said parallel processors can co-operatively share in the execution of a single instruction represented by a large instruction word; and maintaining the status of the cooperating processors in a inter-processor status register provided therein.
It should be understood that each processor in a multiprocessor configuration has the potential to be a master/and or slave. For example, if processor A starts a job on processor B, A and B are in a master-slave relationship. However, B can "sub-contract" some part of the job to C, in which case B and C are in a master-slave relationship. B is a slave to A, but a master to C. At a different moment in time, which is software dependent, this relationship can totally reverse itself.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail, by way of example, only with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic illustration of a microprocessor with an external interface in accordance with the invention;
FIG. 2 shows the organization of the inter-processor status register;
FIG. 3 shows the control and status lines of the interface in more detail;
FIG. 4 shows the internal registers and bus structure of a processor in accordance with the invention;
FIG. 5 illustrates conflict resolution in a multiple processor system; and
FIG. 6 is a more detailed diagram explaining the architecture of a processor in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the central digital signal processor 1 includes a program/data memory; an arithmetic/logic unit (ALU); a multiplier/accumulator (MAC); a barrel shifter (BS); a data address generator (DAG); a program address generator (PAG); registers for holding intermediate results, addresses, and speed up access to the previous five blocks); and buses. As these components are conventional, they are not illustrated in the drawings and will not be described in detail.
The processor 1 also includes an interprocessor register 2 (IPSR) described in more detail with reference to FIG. 2 and right and left register banks 3, 4, and central register 130. Right and left dual Port data memory 12, 13 provides a memory window accessible both to the central processor and the associated neighboring parallel processor.
The central processor 1 has right and left external interfaces 5, 6 for communicating with respective parallel processors 7, 8 in a symmetrical scheme, referred to as the Left processor and Right processor. The external interface is presented in FIG. 1. The Left and Right Processors are similar microprocessors to the central processor and are not illustrated in detail.
In the above scheme, the processor 1 is viewed as the `Middle processor`, having a similar left and a right neighbor presenting and controlling an identical interface.
The external signals are separated in three main groups of signals 9, 10, 11 as shown in more detail in FIG. 3, namely the Control and Status Lines--eight lines, (6 outgoing and two bi-directional as shown in more detail FIG. 3 for details); bi-directional Data Bus Lines; the number of which is implementation dependent (16 in one embodiment); and bi-directional Register Select Lines, the number of which is implementation dependent (3 in one embodiment).
As shown in FIG. 1, two adjacent processors share data through a dual port RAM 12, 13, mapped in the data memory space of both processors, and via two banks of dual port registers (accessed from both internal Data Bus and external Left or Right Data Bus), each processor with its own set (see FIG. 3).
The central processor has an Inter-Processor Status register (IPSR) 2 that describes its state and functional mode with respect to the left and right processors. The IPSR register is shown in FIG. 2.
There are four possible states and thus two bits needed to describe them:
1. Independent
2. Parallel Computing (PC)
3. Large Instruction Word (LIW)
4. Suspended
There are 2 possible modes (1 bit needed):
Master
Slave
A central processor can be in a Master mode with respect to both neighboring processors, or a Master mode with respect to one and a Slave mode with respect to the other, but it can never be in a Slave mode with respect to both (left and right) processors simultaneously.
Any central processor can interrupt a left or/and right them (status and interface line condition permitting) and bring it/them into a Master-Slave mode in which the Slave does work on behalf of the Master.
Depending on the state and mode bits in the status register 2, a processor has various access rights to the dual port data memory window and to the register bank of the neighboring processor(s). Table 1 describes the access rights and the functionality of a processor based on the state and mode bits configuration. In Table 1, the `Symmetry state` column is used to label those situations where a symmetric situation could occur.
TABLE 1__________________________________________________________________________Access rights and functionality based on status bits.Left Side Bits Right Side Bits Symm.State Mode State Mode Access Executed programs state__________________________________________________________________________Indep. Master Indep. Master Restricted to its own regs. Executes its own job. NO and data spaceIndep. Master PC Master Restricted to its own regs. Executes its own job. YES and data space Started job on right processorIndep. Master PC Slave Own regs. and data space + Executes job on behalf of YES RDMWA.sup.1 Right proc.Indep. Master LIW Master Own regs. and data + Executes own job locking Right YES RRA2 + RDMWA proc.Indep. Master LIW Slave Own regs. and data + Executes locked by YES RRA + RDMWA Right procIndep. Master Suspend Slave Own regs. and data + PC is frozen while YES RRA + RDMWA NOPs are executedPC Master PC Master Restricted to its own regs. Executes its own job. NO and data space Started II jobs on left & right processors.PC Master PC Slave Own regs. and data + Executes job on behalf of Right YES RDMWA proc. Started II job on left.PC Master LIW Master Own regs. and data + Executes its own job locking YES RRA Right proc. Started job on Left proc.PC Master LIW Slave Own regs. and data + Executes locked by YES RRA + RDMWA Right proc. Started job on Left proc.PC Master Suspend Slave Own regs. and data + Started job on Left YES RRA + RDMWA proc. Suspended while locked by rightPC Slave LIW Master Own regs. and data + Executes job on behalf of Left YES LDMWA + RRA proc. + locking Right proc.PC Slave Suspend Master Own regs. and data + Suspended while YES LDMWA + RRA locking Right proc. Now executes ∥ job for Left processor.LIW Master LIW Master Own regs. and data + Executes its own job NO LRA3 + RRA locking both Left and Right procs.LIW Master LIW Slave Own regs. and data + Executes on behalf of and YES LRA + RRA + locked by RDMWA Right, locking Left.Suspend Master Suspend Slave Own regs. and data + While in the above state has YES LRA + RRA + received (and passed to Left) RDMWA the Suspend command__________________________________________________________________________ .sup.1 RDMWA -- Right processor Data Memory Window Access .sup.2 RRA -- Right processor Register Access .sup.3 LRA -- Left processor Register Access The state and mode bits in the IPSR 2 uniquely determine the condition of the external interface status line. The mapping of the state and mode bit onto external status lines is given in Table 2.
TABLE 2__________________________________________________________________________Internal status bits to external status lines mappingLeft Side Bits Right Side Bits Left state lines Right state lines Symm.State Mode State Mode State Mode State Mode states__________________________________________________________________________Indep. Master Indep. Master Indep. Master Indep. Master NOIndep. Master PC Master PC Master PC Master YESIndep. Master PC Slave pC Slave PC Slave YESIndep. Master LIW Master LIW Master LIW Master YESIndep. Master LIW Slave LIW Slave LIW Slave YESIndep. Master Suspend Slave Suspend Slave Suspend Slave YESPC Master PC Master PC Master PC Master NOPC Master PC Slave PC Slave PC Slave YESPC Master LIW Master LIW Master LIW Master YESPC Master LIW Slave LIW Slave LIW Slave YESPC Master Suspend Siave Suspend Slave Suspend Slave YESPC Slave LIW Master LIW Slave LIW Slave YESPC Slave Suspend Master Suspend Slave Suspend Slave YESLIW Master LIW Master LIW Master LIW Master NOLIW Master LIW Slave LIW Slave LIW Slave YESSuspend Master Suspend Slave Sus end Slave Suspend Slave YES__________________________________________________________________________
The possible actions of a processor with respect to the left/right processors, based on its left/right status bits and external status lines and left/right processor status lines are given in Table 3.
TABLE 3______________________________________Possible actions of a processor based on its status bits andexternal status lines RightRight Side Bits Right Side Lines Status Lines PossibleState Mode State Mode State Mode actions______________________________________Indep. Master Indep. Master Indep. Master Force Right to PC PC PC Force Right to LIW LIWIndep. Master Indep. Master LIW Master Force Right to PC PCIndep. Master PC Slave Indep. Master Force Right to PC PC Force Right to LIWIndep. Master LIW Slave Indep. Master Force Right to PC PC Force Right to LIWPC Slave PC Slave PC Master Report task comletedLIW Master LIW Master LIW Slave Exit LIW state unlock______________________________________
As will be apparent, there are four possible states and two possible modes. From all eight possible combinations only one is invalid, (Independent, Slave) combination.
The two pairs of status bits in the IPSR 2 determine what is the relation of the processor with respect to the processor on that side. Only a combination of both sides status bits could determine the real state of the processor.
Whenever a processor enters a Slave mode, almost all its registers get saved, such that the work can be resumed when the Master mode is re-entered. This can occur quickly with the use of shadow registers in this embodiment.
The situation that arises in various valid combinations will now be described, although it will be apparent to one skilled in the art that other valid combinations are possible.
1. (Independent, Master)
A processor is in this state when the status bits on both sides of the IPSR 2 show it in this state. In this case the external status lines will show the same thing (see Table 2).
In this state a processor executes code on behalf of itself and can access only its own registers and data memory.
2. (Parallel Computing, Master)
When one side of the IPSR register 2 shows this configuration and the other side shows the Independent-Master case, the central processor 1 is in a Master-Slave relationship with the processor on that side, has already started a parallel task on the processor on that side, and can check on the state of that task by polling the corresponding Task Completed bit in IPSR 2 or by executing a Wait until Task Completed on Left/Right instruction. In this last case the processor will stay idle until the corresponding bit is set.
In this state the processor has the same access right as in (Independent, Master) state.
3. (Large Instruction Word, Master)
When one side of the IPSR register 2, shows this configuration (while the other side shows the Independent-Master case), the central processor 1 is in a Master-Slave relation with the processor on that side, and has already locked to that processor to so as to process Large Instruction Words in parallel. The processor that has been locked can, in turn lock to another one, and so on in cascade. Whenever the LIW-Master processor jumps as a result of a control instruction (conditional/unconditional branches or looping instructions,) the take-the-branch condition is passed as a signal through the interfaces to all the processors locked in the chain. In this way, synchronized jumps are ensured, making assisted loop executions possible. When the processor executes a Release Left/Right processor instruction, the locked processor becomes unlocked and the Master can enter a state dependent on the status bits on the other side of IPSR 2.
In this state, the processors have access not only to the dual port data memory window separating them from the Slave but also to the correspondent register bank of processor locked. The instruction set will be extended with instructions capable of accessing the left or right processor.
4. (Suspended, Master)
Only one side of a processor can show this combination of state and mode bits. However, the status bits on the opposite side of IPSR determine what the processor really does.
If the opposite status bits show (PC, Slave), the processor in fact is not suspended but is rather executing a parallel task forced by the processor on that side. Before being forced into a (PC, Slave) situation the processor was in a (LIW, Master) situation. When the switch occurred the processor had to suspend LIW activity itself and the processors locked up with it.
If the opposite status bits show (LIW, Slave), the processor is in fact suspended. In this situation the processor has frozen its own PC and executes NOP instructions. Before being in this state the processor was in a (LIW, Slave) situation with one of its sides and in a (LIW, Master) situation with the other side. The processor it has received a SUSPEND signal from the Slave side that it has past to the processor on the Master side. In this way, when the head of LIW link is suspended, all the processors in the chain will get suspended.
5. (Parallel Computing, Slave)
When one side of the IPSR register 2 shows this configuration (while the other side shows the Independent-Master case), the processor is in a Slave-Master relation with the processor on that side, on behalf of which it executes a task. The starting address of the task is passed to the processor when the Slave-Master relation has been established. At the end of the task, the processor executes an End-Of-Task instruction that gets locked in the corresponding status bits of the Master. When the End-Of-Task instruction is executed, the processor enters a state that is dependent on the status bits on the other side of the IPSR 2.
In this state, a processor has access to its own registers and data memory space and to the dual port memory window into the data space of the Master processor.
6. (Long Instruction Word, Slave)
When one side of the IPSR register shows this configuration, (while the other side shows the Independent-Master case), the processor is in a Slave-Master relation with the processor on that side. In this situation, the processor still has the ability to put itself into a Master situation with respect to the processor on the other side.
As mentioned before, when multiple processors run in a locked state, synchronism is essential. All processors should have the same master clock and they all should take (or not take) a conditional branch based on the decision of the Master processor. In this case, the Master drives the Jump interface line and all the Slaves in the chain execute a Branch on External Decision instruction that takes the jump based on the state of the line.
A processor locked in a Slave mode has access not only to its own registers and data memory space but to the register banks of the other neighboring processor it is running locked with and the dual port data memory windows into their data space.
7. (Suspended, Slave)
In this case the processor that was locked executes only an NOP instruction, freezes the Program Counter (PC), and waits for the Release signal.
The internal register access and structure of a central processor will now be described with reference to FIG. 4. Data memory data bus 20 is connected through multiplexers 21 to Left, Middle and Right registers 22, 23, 24 which in turn are connected through muliplexer 25 to processing unit 26 including the ALU/MAC, BS, and DAG. Because any processor in this architecture is interruptible, almost all internal registers except for the IPSR 2 should be shadowed.
The MAC/ALU (Multiplier/Accumulator)architecture is shown in more detail in FIG. 6, in which for brevity only the input data flow is shown. The left DMD bus 40 is connected through the interface to a corresponding bus in the left processor 8. In operation, data flows from the left hand processor through MUX 22 to registers ALH, ALL (Accumulator Left High, Accumulator Right Low) from where it passes through Mux 23 to Multiplier and Accumulator and logic circuit 24, which is connected to the right barrel shifter 25. Similarly, data from the right processor 7 arrives over the right DMD bus 26 and passes through Mux 27, registers ARH, ARL, and Mux 28 to MAC unit 24. Internal register bus 29 is connected through Mux units 30, 31, 32, 33 to pairs of registers ALH, ALL; ARH, ARL; AAH, AAL; ABH, ABL connected through Mux 34 and left barrel shift register to MAC unit 24. It will be apparent that this arrangement allows instruction words to be shared between the adjacent processors.
When a processor becomes slave to another processor, it uses the shadow registers to preserve the last contents of its registers as a Master. The shadow registers are back-propagated to the main registers when the processor re-enters a master mode (with respect to both left and right processor).
For all three computational units (ALU, MAC and BS) a register relationship as presented in FIG. 4 is valid.
The ALU and the MAC require two operands (usually) while the BS requires only 1. Depending on the architecture, the DAG requires 1 to 3 input registers. The set of registers available to a computational block is symmetrically divided into three groups, namely a set of n registers that can be loaded from their own DMD bus or some other local bus, and two sets/banks of m registers that can be accessed not only from the local buses but from the adjacent (left or right) processors.
The access to an internal register from the left or the right processor, in a symmetrical arrangement, is a significant aspect of the present invention. This change facilitates the taking advantage of the Large Instruction Word functional state. When one DSP can perform an operation on the already existent registers, the neighboring DSPs can use the additional buses to read/write access other internal registers. The dual port memory is 3 used in this case to enhance the access of the neighboring DSPs to the data space of the middle processor.
The m and n values should be relatively small (1 and 2 in one embodiment) because otherwise the propagation delays through various levels of multiplexing could add up to significant values. The totality of all registers accessible from the left (or right) processor forms the bank of registers used for communicating with the left (or right) processor.
Because of the symmetry of the register distribution, similar banks of registers are available in the left and right processor, and as such, in any two processor LIW interaction two banks of registers will be always available for communication and speeding up each others computations when needed.
The instruction set of a processor will be enhanced with instructions capable of addressing the left or right processor. These instructions are operational and useful only when a processor functions locked with another processor (in LIW state).
Tables 4 to 19 present the state and mode transition. It should be noted that due to the symmetrical properties of the architecture, the cases that are not covered can be derived from those that are given.
TABLE 4__________________________________________________________________________Initial status bits Left: Indep Master Right: Indep Master Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: force Right to PC Indep. Master PC Master Saved PC Master PC MasterInt.: force Right to LIW Indep. Master LIW Master Saved LIW Master LIW MasterRight: Enter PC Indep. Master PC Slave Saved PC Slave PC SlaveRight: Enter LIW Indep. Master LIW Slave Saved LIW Slave LIW Slave__________________________________________________________________________
TABLE 5__________________________________________________________________________Initial status bits Left: Indep. Master Right: PC Master Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: force Right to PC PC Master PC Master Saved PC Master PC MasterInt.: force Left to LIW LIW Master PC Master Saved LIW Master LIW MasterRight: task completed lndep. Master Indep. Master Saved Indep. Master Indep. MasterLeft: Enter PC PC Slave PC Master Saved PC Slave PC SlaveLeft: Enter LIW LIW Slave PC Master Saved LIW Slave LIW Slave__________________________________________________________________________
TABLE 6__________________________________________________________________________Initial status bits Left: Indep. Master Right: PC Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: force Left to LIW LIW Master PC Slave Saved LIW Slave LIW SlaveInt.: force Left to PC PC Master PC Slave Saved PC Slave PC SlaveInt.: task completed Indep. Master Indep. Master Saved Indep. Master Indep. Master__________________________________________________________________________
TABLE 7__________________________________________________________________________Initial status bits Left: Indep Master Right: LIW Master Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: force Left to LIW LIW Master LIW Master Saved LIW Master LIW MasterInt.: force Left to PC PC Master LIW Master Saved PC Master LIW MasterRight: exit LIW Indep. Master Indep. Master Saved Indep. Master Indep. MasterLeft: enter PC PC Slave Susp. Master Saved PC Slave Susp. Slave__________________________________________________________________________
TABLE 8__________________________________________________________________________Initial status bits Left: Indep Master Right: LIW Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: force Left to LIW LIW Master LIW Slave Saved LIW Slave LIW SlaveInt.: force Left to PC PC Master LIW Slave Saved LIW Slave LIW SlaveRight: exit LIW Indep. Master Indep. Master Saved Indep. Master Indep. MasterRight: suspend Indep. Master Susp. Slave Saved Susp. Slave Susp. Slave__________________________________________________________________________
TABLE 9__________________________________________________________________________Initial status bits Left: Independent Master Right: Suspend Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Right: exit Suspend Indep. Master LIW. Slave Saved LIW. Slave LIW. Slave__________________________________________________________________________
TABLE 10__________________________________________________________________________Initial status bits Left: PC Master Right: PC Master Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Left: task completed Indep. Master PC Master Saved PC Master PC MasterRight: task completed PC Master Indep. Master Saved PC Master PC Master__________________________________________________________________________
TABLE 11__________________________________________________________________________Initial status bits Left: PC Master Right: PC Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Left: task completed Indep. Master PC Slave Saved PC Master PC SlaveInt.: task completed PC Master Indep. Master Saved PC Master PC Master__________________________________________________________________________
TABLE 12__________________________________________________________________________Initial status bits Left: PC Master Right: LIW Master Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Left: task completed Indep. Master LIW Master Saved LIW Master LIW MasterInt.: exit LIW (unlock) PC Master Indep. Master Saved PC Master PC Master__________________________________________________________________________
TABLE 13__________________________________________________________________________Initial status bits Left: PC Master Right: LIW Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Left: task completed Indep. Master LIW Slave Saved LIW. Slave LIW. SlaveRight suspend PC Master Susp. Slave Saved Susp. Slave Susp. SlaveRight exit LIW PC Master Indep. Master Saved PC Master PC Master__________________________________________________________________________
TABLE 14__________________________________________________________________________Initial status bits Left: PC Master Right: Suspend Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Right: exit Suspend PC Master LIW Slave Saved LIW Slave LIW SlaveLeft: task completed Indep. Master Susp. Slave Saved Susp. Slave Susp. Slave__________________________________________________________________________
TABLE 15__________________________________________________________________________Initial status bits Left: PC Slave Right: LIW Master Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: task completed Indep. Master Indep. Master Saved Indep. Master Indep. MasterInt.: exit LIW unlock PC Slave Indep. Master Saved PC Slave PC Slave__________________________________________________________________________
TABLE 16__________________________________________________________________________Initial status bits Left: LIW Master Right: LIW Master Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: task completed Indep. Master LIW Master Saved LIW Master LIW Master__________________________________________________________________________
TABLE 17__________________________________________________________________________Initial status bits Left: LIW Master Right: LIW Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: exit LIW Left Indep. Master LIW Master Saved LIW. Master LIW. MasterInt.: exit LIW Right LIW Master Indep. Master Saved LIW Master LIW Master__________________________________________________________________________
TABLE 18__________________________________________________________________________Initial status bits Left: LIW Master Right: LIW Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Int.: exit LIW Left Indep. Master LIW. Slave Saved LIW. Slave LIW. SlaveRight: exit LIW Indep. Master Indep. Master Saved Indep. Master Indep. MasterRight: suspend Susp. Slave Susp. Master Saved Susp. Slave Susp. Slave__________________________________________________________________________
TABLE 19__________________________________________________________________________Initial status bits Left: Suspend Master Right: Suspend Slave Left status bits Right status bits Regs Left state lines Right state linesAction State Mode State Mode state State Mode State Mode__________________________________________________________________________Right: exit Suspend LIW Master LIW Slave Saved LIW Slave LIW Slave__________________________________________________________________________
The following table present all the software commands required to perform the various actions described in the previous tables.
TABLE 20______________________________________Command Description______________________________________XTR address execute Task starting at `address` on Right processorXTL address execute Task starting at `address` on Left processorLCKR address LoCK Right processor (force right to LIW state) starting at `address`LCKL address LoCK Left processor (force left to LIW state) starting at `address`EOT End Of Task (reported to the processor on the slave side)RELR RELease (unlock) Right processorRELL RELease (unlock) Left processorBED address Branch on External DecisionWTCL Wait for Task Completed on Left processorWTCR Wait for Task Completed on Right processor______________________________________
In one embodiment, the first four instructions in Table 20 (XTR,XTL,LCKR,LCK1) are blocking. This ensures that if the processor they are trying to bring to a Master-Slave relation is in a state that does not permit the desired state transition, then the processor will enter a state where it will keep on trying to execute the mentioned instructions. In a different embodiment, these instructions can be made non blocking. In this situation, the program needs code that is compatible with a successful attempt and code that is compatible with a failed attempt.
Besides the specific instructions given in the table, some of the usual instructions of a DSP are extended to handle external register bank access rights.
The instructions XTR,XTL,LCKR,LCK require at least two cycles to execute. During the first cycle, the processor executing one of these instructions will try, based on its own status bits and other processor status lines, to force a neighboring processor into a Slave situation. If this attempt is successful, during the second cycle an address will be passed over the Data Bus lines to the other processor. In many cases, a third cycle is required for the second processor to fetch the instruction found at the address passed.
A conflict arises when two processors attempt to put each other in a Master-Slave relation simultaneously. One solution to this situation is to always give priority to the processor on the right side of the couple. To solve this conflict, in one embodiment, an extra interface line is added (the ACKnowledgment line) and an Arbitration block that is biased to the right. This arrangement is shown in FIG. 5, where central processor 1 is shown connected to Right and Left processors 7, 8. The IPSR 2 of each processor has an arbitration block 30.
Where the software can guarantee that such conflicts do not occur, the Arbitration block and the additional interface line are not required.
The present invention thus offers a powerful technique for evenly distributing the processing power of complex applications over multiple DSPs, using Parallel Computing and Large Instruction Word methods, which can be of variable length.
Because of the processing power and additional buses made available by multiple processors through this new distributed architecture method, it can be used with slower master clocks or slower memories.
The new distributed architecture is particularly suited for the case where the processors are sharing the silicon space of the same integrated circuit.
Due to its symmetrical properties, the distributed architecture can be easily scaled up to provide the necessary computational power for very complex DSP tasks even at low master clock rates or slow memory access time. | A distributed architecture parallel processing apparatus, includes a central microprocessor having at least one external interface connected to a similar interface of a neighboring parallel processor. The processors exchange data and control signals through the interfaces to cooperatively share in the execution of a program. An inter-processor status register in each processor maintains the current status of the processors. | 6 |
FIELD OF THE INVENTION
[0001] The present invention is directed to novel compounds of formula I and their use as intermediates in the synthesis of asenapine. The invention provides a process for the preparation of these novel compounds of formula I and their conversion to asenapine.
BACKGROUND OF THE INVENTION
[0002] Asenapine or trans-5-chloro-2-methyl-2,3,3a,12b -tetrahydro-1H-dibenz[2,3:6,7]oxepino[4,5-c]pyrrole is described in U.S. Pat. No. 4,145,434 to van der Burg and it is represented by the following chemical structure:
[0000]
[0003] Asenapine has CNS-depressant activity and it has antiserotonin activity. Asenapine exhibits potential antipsychotic activity and may be useful in the treatment of depression (see international patent application WO 99/32108). It has been established that the maleate salt of asenapine is a broad spectrum, high potency serotonin, noradrenaline and dopamine antagonist. A pharmaceutical preparation suitable for sublingual or buccal administration of asenapine maleate has been described in the international patent application WO 95/23600. Asenapine maleate is launched in the USA for two related indications. It is indicated for the acute treatment of schizophrenia in adults as well as for the treatment of manic or mixed episodes associated with bipolar I disorder, with or without psychotic features also in adults.
[0004] The synthetic approach for the preparation of asenapine is derivable from the teaching of U.S. Pat. No. 4,145,434 and disclosed in full Example 9 of EP 1 710 241. The last steps of this methodology are shown in the following scheme.
[0000]
[0005] In Scheme 1, the double bond in the enamide, 11-chloro-2,3-dihdyro-2-methyl-1H-dibenzo[2,3;6,7]oxepino[4,5-c]pyrrol-1-one (1), is reduced to produce a mixture of a desired trans-2-isomer and an unwanted cis-2-isomer, in a 1:4 ratio. The unfavourable product ratio can be improved by subsequent partial isomerisation of the unwanted cis-2-isomer into the trans-2-isomer using DBN, leading to a thermodynamic equilibrium ratio of trans to cis of 1:2. Separation of the trans-isomer and the cis-isomer is done by chromatography over silica gel. The cis-isomer can be isomerized again using DBN and the resulting trans-isomer is again separated by chromatography. The drawback of this process is that it is extremely elaborate and time-consuming, while the final yield of the trans-isomer is only moderate.
[0006] European patent EP 1 710 241 discloses preparation of asenapine which avoids the separation of the cis-trans isomers through chromatography over silica gel. In Scheme 2, the cis-trans mixture of the compound 2 and/or its regio-isomer, 2a, preferably without separating the enantiomers, undergoes the ring-opening reaction by an excess of strong base in an alcoholic medium, yielding, predominantly, a trans-isomer of the amino-acid of the formula 3 or 3a in an approx. ratio 10:1 (trans:cis), respectively.
[0000]
[0007] The trans-3 or the trans-3a may be isolated and subjected to re-cyclisation yielding the desired trans-2 or trans-2a with the overall yield of about 60% in respect of compound 1. Alternatively, compounds trans-3 or trans-3a may be converted to asenapine directly, by cyclisation with a reducing agent, optionally with a combination with a Lewis acid. In conclusion, in order to obtain the desired trans-isomer it is necessary to carry out a complex procedure involving first ring-opening to the trans-form and then re-cyclisation.
[0008] International patent application WO 2009/008405 provides a process for the production of asenapine in which reduction, leaving group conversion, hydrogenation and methylation are carried out in that order (see Scheme 3; X 1 and X 2 are the same or different and each independently represents hydrogen or halogen atom; R represents an alkyl group optionally substituted; Y represents a leaving group).
[0000]
[0009] There is a need for an industrially efficient process for the preparation of asenapine with good esteroselectivity and yields.
BRIEF DESCRIPTION OF THE INVENTION
[0010] The present inventors have surprisingly found that the process of the invention provides asenapine with a good yield which makes it appropriate for the preparation of asenapine or salts thereof in an industrial scale.
[0011] Thus, a first aspect of the present invention relies on a compound of formula I
[0000]
wherein X and X′ are different and each independently represents hydrogen or chlorine atom and R is selected from hydrogen or a substituted or unsubstituted C 1 -C 6 alkyloxy group.
[0013] A second aspect of the invention relates to process for preparing compound of formula I comprising reacting an amino alcohol compound of formula II
[0000]
wherein X and X′ have the same definitions as above with a formic acid anhydride of formula III or a chloroformate of formula IV
[0000]
wherein R 1 is a substituted or unsubstituted C 1 -C 6 alkyl.
[0016] Another aspect of the invention is a process for preparing asenapine or its salts
[0000]
[0000] comprising:
(a) reducing the carbonyl moiety of a compound of formula I
[0000]
wherein X, X′ and R have the same definitions as above to give a methylamino compound of formula V
[0000]
wherein X and X′ have the same definitions as above
(b) optionally, converting the hydroxyl moiety of compound V into a leaving group to give a compound of formula VI
[0000]
wherein X and X′ have the same definitions as above and LG is a leaving group
(c) cyclising the compound of formula V or VI to give asenapine; and
(d) optionally, converting the asenapine to a salt thereof, or
(a-i) converting the hydroxyl moiety of compound of formula I into a leaving group to give a compound of formula VIII
[0000]
wherein LG is a leaving group
(b-i) reducing and cyclising the compound of formula VIII to give asenapine; and
(c-i) optionally, converting the asenapine to a salt thereof.
[0021] Another aspect of the invention relies on a process for preparing asenapine or its salts comprising treating compound of formula I with a reducing agent.
[0022] An aspect of the invention relates to amino alcohol compound of formula II:
[0000]
wherein X and X′ have the same definitions as above.
[0024] Another aspect of the invention is directed to a compound of formula V:
[0000]
wherein X and X′ have the same definitions as above.
[0026] Another aspect is a compound of formula VI:
[0000]
wherein X, X′ and LG have the same definitions as above.
[0028] Another aspect of the invention is directed to compound of formula VIII
[0000]
wherein LG is a leaving group.
[0030] Another aspect of the invention is a process for the preparation of compound I wherein amino alcohol compound of formula II, is prepared by reduction of both the nitro and ester functions of a compound of formula VII
[0000]
wherein X and X′ have the same definitions as above and R 2 represents a substituted or unsubstituted C 1 -C 6 alkyl.
[0032] The invention also relies on the use of novel intermediates I, V, VI and VIII in the preparation of asenapine or salts thereof.
[0033] The invention also relies on the use of compound II in the preparation of compound of formula I.
DESCRIPTION OF THE INVENTION
Definitions
[0034] In the context of the present invention, the following terms have the meaning detailed below:
[0035] The term “leaving group” refers to a group that can easily be replaced by another group. In J. March Advanced Organic Chemistry, 4th edition, 1992, are listed some typical leaving groups. In the context of the present invention, the leaving groups are preferably selected from halogens and activated alcohols, such as sulfonyloxy groups. The halogens include fluorine, chlorine, bromine and iodine. The sulfonyloxy group is represented by —OSO 2 R′, wherein R′ is a substituted or unsubstituted alkyl, a substituted or unsubstituted aryl, a fluorinated hydrocarbon or a halogen. By the term “substituted or unsubstituted alkyl” it is understood a linear hydrocarbon radical consisting of carbon and hydrogen atoms, which does not contain unsaturation, having one to twelve carbon atoms and which is joint to the rest of the molecule by a single bond. Alkyl radicals may be optionally substituted by one or more substituents such as an aryl, halo, hydroxy, alkoxy, carboxy, cyano, carbonyl, acyl, alkoxycarbonyl, amino, nitro, mercapto, alkylthio, etc. The term “substituted or unsubstituted aryl” relates to an aromatic hydrocarbon radical containing from 1 to 3 separated or fused rings and from 6 to about 18 carbon ring atoms, such as phenyl, naphthyl, indenyl, fenanthryl or anthracyl radical. The aryl radical may be optionally substituted by one or more substituents such as hydroxy, mercapto, halo, alkyl, phenyl, alkoxy, haloalkyl, nitro, cyano, dialkylamino, aminoalkyl, acyl, alkoxycarbonyl, etc.
[0036] The term substituted or unsubstituted alkyl- or aryl-sulfonyl halide is understood as containing a sulfonyloxy group, represented by —OSO 2 R′, as defined above, and a halide ion selected from fluoride, chloride, bromide and iodide.
[0037] By the term “C 1 -C 6 substituted or unsubstituted alkyloxy” it is understood a linear hydrocarbon radical consisting of carbon and hydrogen atoms, which does not contain unsaturation, having one to six carbon atoms and which is joint to the rest of the molecule by an oxygen atom. Alkyloxy radicals may be optionally substituted by one or more substituents such as an aryl, halo, hydroxy, alkoxy, carboxy, cyano, carbonyl, acyl, alkoxycarbonyl, amino, nitro, mercapto, alkylthio, etc. Examples of “C 1 -C 6 substituted or unsubstituted alkyloxy” are methoxy, ethoxy, propoxy, butoxy, sec.-butoxy, tert.-butoxy, trichloromethoxy, 1-phenylpropoxy, 2-phenylethoxy and phenylmethoxy.
[0038] By the term “C 1 -C 6 substituted or unsubstituted alkyl” it is understood a linear hydrocarbon radical consisting of carbon and hydrogen atoms, which does not contain unsaturation, having one to six carbon atoms and which is joint to the rest of the molecule by a single bond. Alkyl radicals may be optionally substituted by one or more substituents such as an aryl, halo, hydroxy, alkoxy, carboxy, cyano, carbonyl, acyl, alkoxycarbonyl, amino, nitro, mercapto, alkylthio, etc.
[0039] The term “one-pot process” means two or more reactions that take place without isolating intermediate compounds, wherein all the reactants are added at the beginning of the first reaction or adding all reactants sequentially during the course of the reaction.
[0040] Ether solvents include diethyl ether, tert-butyl methyl ether, 1,2-dimethoxyethane, cyclopentyl methyl ether, diglyme and tetrahydrofuran. Amide solvents are selected from N, N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone and 1,3-dimethyl-2-imidazolidinone. Ketone solvents are selected from methyl isobutyl ketone, methyl ethyl ketone, 2-propanone, cyclohexanone, and cyclopentanone. Ester solvents are selected from ethyl acetate and butyl acetate. Alcohol solvents are selected from methanol, ethanol, 1-propanol, 2-propanol, 1-butanol and 2-butanol. Halogenated solvents are selected from dichloromethane, 1,2-dichloroethane, and chloroform. Aromatic hydrocarbon solvents are selected from toluene, xylene, chlorobenzene and nitrobenzene.
[0041] As organic bases there may be mentioned tertiary amines (trimethylamine, triethylamine, diisopropylethylamine, tributylamine, N-methylmorpholine and 1,4-diazabicyclo[2.2.2]octane), aromatic amines (pyridine, 2-methyl-5-ethylpyridine, 2,6-di-tert-butylpyridine, 4-dimethyl aminopyridine, imidazole and 1-methylimidazole), cyclic amidines (1,8-diazabicyclo[5.4.0]-7-undecene, 1,5-diazabicyclo[4.3.0]-5-nonene), alkali metal alkoxides (lithium methoxide, sodium methoxide, potassium methoxide, lithium ethoxide, sodium ethoxide, potassium ethoxide and lithium tert-butoxide) and alkali metal amides (lithium diisopropylamide, lithium hexamethyldisilazide, potassium hexamethyldisilazide).
[0042] As examples of inorganic bases there may be mentioned alkali metal hydroxides (lithium hydroxide, sodium hydroxide, potassium hydroxide and cesium hydroxide), alkali metal carbonates (lithium carbonate, sodium carbonate, potassium carbonate and cesium carbonate), alkali metal hydrogenocarbonates (sodium hydrogenocarbonate, potassium hydrogenocarbonate), ammonia, ammonium carbonate and the like.
[0043] The term “purification” refers to the process wherein a purified drug substance can be obtained. Therefore, term “purification” comprises solvent extraction, filtration, slurring, washing, phase separation, evaporation, centrifugation, column chromatography or crystallisation.
DESCRIPTION
[0044] According to a first aspect, the present invention is directed to novel compounds of formula I
[0000]
wherein X and X′ are different and each independently represents hydrogen or chlorine atom and R is selected from hydrogen or a substituted or unsubstituted C 1 -C 6 alkyloxy group.
[0046] Examples of compounds of formula I are trans-N-(8-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-formamide, trans-(8-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-carbamic acid benzyl ester, trans-(2-Chloro-11-hydroxymethyl 10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-carbamic acid benzyl ester, trans-(8-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-carbamic acid ethyl ester or trans-(2-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-carbamic acid ethyl ester.
[0047] The second aspect of the invention is directed to a process for the preparation of compounds of formula I comprising reacting an amino alcohol compound of formula II
[0000]
wherein X and X′ have the same definitions as above with a formic acid anhydride of formula III or a chloroformate of formula IV
[0000]
wherein R 1 is a substituted or unsubstituted C 1 -C 6 alkyl.
[0050] Formic acid anhydrides of formula III are selected from formic acetic anhydride, formic propionic anhydride or formic isobutyric anhydride.
[0051] The reaction may be performed by the addition of a solution of compound II in an organic solvent to a solution of the formic acid anhydride of formula III in an organic solvent, with no particular restriction on the order of addition and mixing. As examples of organic solvents, there may be mentioned ether solvents, acetonitrile, ester solvents, halogenated solvents, aromatic hydrocarbon solvents, ketones and formic acid. These solvents may be used alone or two or more may be used simultaneously. The reaction temperature for the reaction is 0-150° C. and preferably 0-100° C.
[0052] As examples of chloroformates of formula IV they may be mentioned methyl chloroformate, ethylchloroformate or benzylchloroformate.
[0053] The reaction is carried out by conventional methodologies. The resulting compound of formula I may be prepared by reaction of amine compound II with a chloroformate of formula IV. The reaction may be carried out in a mixture of water and organic solvents. Suitable organic solvents include ether solvents, amide solvents, ketone solvents, ester solvents, halogenated solvents and/or aromatic hydrocarbon solvents. The reaction also requires the addition of an inorganic base. Alternatively, the reaction may be carried out in a non-protic organic solvent. Examples of non-protic organic solvents are ethyl acetate, acetonitrile, acetone, methyl ethyl ketone, tetrahydrofuran, dioxane, toluene, xylene, etc. These solvents may be used alone or two or more may be used simultaneously. The reaction also requires the presence of an organic base.
[0054] Another aspect of the invention is a process for preparing asenapine or its salts
[0000]
[0000] comprising:
(a) reducing the carbonyl moiety of compound of formula I
[0000]
wherein X, X′ and R have the same definitions as above to give a methylamino compound of formula V
[0000]
wherein X and X′ have the same definitions as above
(b) optionally, converting the hydroxyl moiety of compound V into a leaving group to give a compound of formula VI
[0000]
wherein X and X′ have the same definitions as above and LG is a leaving group
(c) cyclising the compound of formula V or VI to give asenapine; and
(d) optionally, converting the asenapine to a salt thereof, or
(a-i) converting the hydroxyl moiety of compound of formula I into a leaving group to give a compound of formula VIII
[0000]
wherein LG is a leaving group
(b-i) reducing and cyclising the compound of formula VIII to give asenapine; and
(c-i) optionally, converting the asenapine to a salt thereof.
[0059] The reducing agent used for reducing the carbonyl moiety of compound I may be boron hydrides or aluminum hydrides. As examples of boron hydride compounds there may be mentioned alkali metal borohydrides such as lithium borohydride, sodium borohydride and potassium borohydride; and borane compounds such as diborane and borane. In most cases, the reducing agent is sodium borohydride. Examples of aluminum hydrides are lithium aluminum hydride, sodium bis-(2-methoxyethoxy)aluminum hydride, lithium tri-tert-butoxyaluminum hydride and aluminum hydride. The amount of reducing agent used is 1-10 mol with respect to 1 mol of compound I.
[0060] Aluminum hydride, also referred to as “alane”, is usually prepared as an alane•etherate complex by the reaction of lithium aluminum hydride with a Lewis acid such as aluminum trichloride, zinc chloride or with beryllium chloride. In an alternative synthesis, lithium aluminum hydride is reacted with sulphuric acid to give the alane•eherate complex.
[0061] When an alkali metal borohydride is used as the reducing agent, a Lewis acid such as boron trifluoride, a Bronsted acid such as sulphuric acid may also be used as an additional reducing agent. Preferably, the boron trifluoride is used as additional reducing agent. In most cases, boron trifluoride can be used as a complex with tetrahydrofuran or the like. The amount used is 1-3 with respect to 1 mol of the alkali metal borohydride.
[0062] The reduction is carried out in the presence of a solvent. The solvent may be selected from ether solvents, preferably, tetrahydrofuran. The reaction temperature for the reduction is 0-100° C. and preferably 25-60° C. The reaction time is 1-24 hours.
[0063] Step (b) of the process consists of converting the hydroxyl group of compound V into a leaving group. This step can be optional, this means that, compound I can be synthesized with or without conversion of the hydroxyl group into a leaving group.
[0064] In an embodiment of the invention, asenapine is synthesized directly by cyclisation of compound V without performing step (b). This cyclisation is achieved by heating a solution of compound V in an organic solvent. The reaction temperature of the cyclisation is between 0° C. and 150° C. Examples of organic solvents are ether solvents, aromatic hydrocarbon solvents, ester solvents, ketone solvents, alcohol solvents, amide solvents, acetonitrile, halogenated solvents and aromatic hydrocarbon solvents.
[0065] Sometimes, addition of acid may be required. The acid used may be an organic acid such as para-toluensulfonic acid, methanesulfonic acid, camphorsulfonic acid, benzensulfonic acid or naphtalensulfonic acid. Alternatively, an inorganic acid can be used. Examples of inorganic acids are sulfuric acid, phosphoric acid, hydrochloric acid, etc.
[0066] In an embodiment of the invention, step (b) is performed to transform the hydroxyl group of compound V into a leaving group before cyclisation to give asenapine. As indicated before, the leaving group is preferably selected from halogens and activated alcohols, such as sulfonyloxy groups. More preferred are the halogens which include fluorine, chlorine, bromine and iodine. Preferably, the halogen is chlorine or bromine. Introduction of desired halogens is achieved by using specific reagents like thionyl chloride, phosphoryl chloride or carbon tetrachloride or carbon tetrabromide in combination with triphenylphosphine, or triphenylphosphine dibromide or triphenylphosphine diiodide. The amount of leaving group conversion reagent used is 1-5 mol and preferably 1-3 mol with respect to 1 mol of compound V.
[0067] The leaving group conversion is usually carried out in the presence of a solvent. The solvent is not particularly restricted. Examples of solvents that can be used are ether solvents, ester solvents, aromatic hydrocarbons and halogenated solvents as those specifically mentioned before.
[0068] The reaction temperature for leaving group conversion is between −30° C. and 100° C. and preferably −10° C. to 70° C.
[0069] According to an embodiment of the invention, compound V, when treated with a leaving group conversion reagent may undergo cyclisation to yield asenapine. In this case, steps (b) and (c) are performed in a one-pot procedure. That is, compound VI is not isolated and it is subjected to cyclisation in the same reaction vessel.
[0070] In these circumstances, the mixture obtained upon completion of the reaction normally contains asenapine as the main product which is subjected to a post-treatment such as filtration, neutralization, washing and extraction. Asenapine may also be isolated by ordinary isolating treatment of the mixture and then it may be purified by ordinary purification means. Then it may also be converted into a salt by conventional procedures known by the skilled person in the art.
[0071] Alternatively, compound VI may be isolated and, optionally, purified before being cyclised to give asenapine. This cyclisation may, optionally, be carried out by further allowing compound VI to contact with an organic or inorganic base.
[0072] The cyclisation is usually performed in the presence of a solvent. The solvent is not particularly restricted. Examples of solvents that may be used in the cyclisation are ether solvents, amide solvents, ketone solvents, acetonitrile, alcohol solvents, halogenated solvents and aromatic hydrocarbon solvents. These solvents may be used alone or two or more may be used simultaneously. The reaction temperature for cyclisation is between 0° C. to 120° C.
[0073] Step (d) of the process consists of the preparation of a salt of asenapine. The mixture obtained upon completion of the cyclisation contains asenapine which may be isolated by ordinary isolating treatment. Asenapine may also be transformed in an acid addition salt. The isolated asenapine or its acid addition salt may be purified by ordinary purification means such as column chromatography or recrystallization, respectively. Moreover, asenapine can be further purified via an acid addition salt thereof that, after being isolated and, optionally, purified is transformed again into asenapine by treatment with an organic or inorganic base.
[0074] The acid used to obtain an acid addition salt of asenapine may be for example an organic acid (oxalic acid, fumaric acid, maleic acid, succinic acid, tartaric acid, etc.) or an inorganic acid (hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid or nitric acid).
[0075] Another aspect of the invention is directed to an alternative process for the preparation of asenapine or its salts which comprises treating compound of formula I with a reducing agent. This one-pot reaction provides asenapine in acceptable yield, reduced number of chemical steps and without isolating intermediate methylamino compound V. The one-pot reaction is performed in the same reaction vessel.
[0076] The reducing agent used in that process may be selected from aluminium hydrides, also referred as “alane” or boron hydrides as described above. The amount of reducing agent used is usually 1-3 with respect to 1 mol of the alkali metal borohydride.
[0077] The reduction is carried out in the presence of a solvent. The solvent may be selected from ether solvents, preferably, tetrahydrofuran. The reaction temperature for the reduction is usually 0-100° C. and preferably 25-60° C. The reaction time is 1-24 hours.
[0078] The invention also refers to intermediate compounds of the process.
[0079] In one aspect, the invention is directed to an amino alcohol compound of formula II:
[0000]
wherein X and X′ have the same definitions as above.
[0081] In another aspect, the invention is directed to a compound of formula V
[0000]
wherein X and X′ have the same definitions as above.
[0083] Another aspect of the invention is directed to compound of formula VI
[0000]
wherein X, X′ and LG have the same definitions as above. Preferred LG are halogen atoms, more preferably, chlorine and bromine. Another aspect of the invention is directed to compound of formula VIII
[0000]
wherein LG is a leaving group.
[0086] In another aspect, the invention provides a process for the preparation of compound of formula I wherein the amino alcohol compound of formula II, is prepared by reduction of both the nitro and ester functions of a compound of formula
[0087] VII
[0000]
wherein X and X′ have the same definitions as above and R 2 represents a substituted or unsubstituted C 1 -C 6 alkyl, preferably R 2 is methyl.
[0089] The above process for the preparation of compound I is depicted below in Scheme 4
[0000]
[0090] The inventors have discovered that the treatment of compound of formula VII with Lithium aluminum hydride (LAH) yields compound of formula II with optimal yields. In most cases, the hydride used is as a complex with tetrahydrofuran, diethyl ether or the like. The amount of reducing agent is 1-10 mol and preferably 1-5 mol with respect to 1 mol of compound II. The mixture obtained upon completion of the reduction of compound VII may be used directly to the next step. However, usually, the mixture is used in the next step after post-treatment such as filtration, neutralization, washing and extraction. Resulting compound II may be isolated and purified by conventional means like crystallization or column chromatography and further converted into compound I.
[0091] The process of the invention may be used for the preparation of asenapine and its salts as depicted in the following Scheme 5
[0000]
[0092] The process of the invention alternatively may be used for the preparation of asenapine and its salts as depicted in the following Scheme 6
[0000]
[0093] Step (a-i) of the process is performed to convert the hydroxyl group of compound of formula I into a leaving group, before reduction and cyclisation to give asenapine. As previously defined, the leaving group is preferably selected from halogens and activated alcohols, such as sulfonyloxy groups. The most preferred leaving groups are mesylate (CH 3 SO 3 − ), tosylate (CH 3 C 6 H 4 SO 3 − ), chlorine and bromine. Introduction of desired halogens is achieved by using specific reagents like thionyl chloride, phosphoryl chloride, carbon tetrachloride or carbon tetrabromide in combination with triphenylphophine, triphenylphosphine dibromide or triphenylphosphine diiodide. The preferred reagents are carbon tetrachloride or carbon tetrabromide in combination with triphenylphophine. Introduction of desired sulfonyloxy groups is achieved by using a substituted or unsubstituted alkyl- or aryl-sulfonyl halide, preferably methanesulfonyl chloride (CH 3 SO 3 Cl) or toluenesulfonyl chloride (CH 3 C 6 H 4 SO 3 Cl). This step is carried out in the presence of a solvent and an organic base. The solvent may be selected from the groups of ethers, amides, ketones, esters, halogenated and aromatic hydrocarbons, as previously defined, preferably, halogenated solvents, most preferably dichloromethane. The organic base may be selected from tertiary amines, aromatic amines, cyclic amidines, alkali metal alkoxides and alkali metal amides, as previously defined. The preferred organic bases are tertiary amines, most preferably triethylamine. The reaction temperature for the derivatization process is between −10° C. and 50° C. and preferably 0° C. to 25° C.
[0094] The reduction and cyclisation of the compound of formula VIII to give asenapine, as described in step (b-i), are carried out under the same conditions as previously described for steps (a) and (b).
[0095] The reducing agent is selected from boron hydrides or aluminium hydrides, preferably the reducing agent is alkali metal borohydride. The amount of reducing agent used is from 1-10 mol with respect to 1 mol of compound VIII. When alkali metal borohydride is used, as the reducing agent, boron trifluoride tetrahydrofuran complex may also be used, as an additional reducing agent. The amount of additional reducing agent used such as boron trifluoride tetrahydrofuran is 1 to 3 fold the amount of the alkali metal borohydride.
[0096] The reaction is carried out in the presence of a solvent. The solvent may be selected from ether solvents, preferably, tetrahydrofuran. The reaction also requires the addition of an inorganic base that may be selected from alkali metal hydroxides, alkali metal carbonates, alkali metal hydrogenocarbonates, ammonia, ammonium carbonate and the like, preferably an alkali metal carbonate. The reaction temperature is between −30° C. and 100° C. and preferably from 0° C. up to 100° C.
[0097] Asenapine maleate obtained according to the process of the present invention corresponds to asenapine monoclinic form as described by Funke et al (Arzneim.-Forsch./Drug Res. 40 (1999), 536-539).
[0098] The present invention is illustrated in more detail by the following Examples but should not be construed to be limited thereto.
EXAMPLES
Example 1
Preparation of trans-(11-Aminomethyl-2-chloro-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (5)
[0099]
[0100] A solution of trans-2-Chloro-11-nitromethyl-10,11-dihydro-dibenzo[b,f]oxepine-10-carboxylic acid methyl ester (4) (4.6 g, 13.23 mmol) in dry THF (23 ml) is added at—15° C. to a mixture of THF (23 ml) and 3.5 M Lithium aluminum hydride (LAH) suspension in THF/Toluene (15.1 ml, 52.9 mmol).
[0101] The mixture is stirred at 30° C. for 30 minutes, cooled to −15° C. and sequentially quenched with H 2 O (2 ml), 15% NaOH (2 ml) and H 2 O (6 ml).
[0102] The solid is filtered, washed with THF (2×23 ml) and the filtrate evaporated to dryness to give 3.60 g (95%) of trans-(11-Aminomethyl-2-chloro-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (5) as a pale yellow solid.
[0103] 1- H-RMN (CDCl 3 , 200 MHz): 1.64 (br s, 3H, exchg. D 2 O), 2.70-2.80 (m, 1H) 2.87-2.97 (m, 1H), 3.12-3.18 (m, 1H) 3.19-3.36 (m, 1H), 3.44-3.54 (m, 1H), 3.63-3.72 (m, 1H), 7.03-7.26 (m, 7H).
Example 2
Preparation of trans-N-(8-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-formamide (6)
[0104]
[0105] A mixture of Acetic Anhydride (2 ml, 20.7 mmol) and Formic Acid (1.6 ml, 41.4 mmol) is heated to 50° C. for 2 hours. After cooling to 25° C. the mixture is diluted with dichloromethane (15 ml). Next, reaction is cooled to 0° C. and trans-(11-Aminomethyl-2-chloro-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (5) (3.00 g, 10.4 mmol) is added and is stirred at 25° C. for one hour.
[0106] Reaction is quenched with 10% K 2 CO 3 (20 ml) and organic layer is washed with 10% K 2 CO 3 until pH 9.
[0107] Methanol (3 ml) and solid K 2 CO 3 (0.72 g, 5.21 mmol) are added to the organic layer and stirred for 2 hours at room temperature (r.t.). Water (30 ml) is then added and stirred for additional 15 min. Organic layer is then separated, washed with water (2×20 ml) and brine (20 ml) and evaporated to dryness to give 2.45 g (76%) of trans-N-(8-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-formamide (6) as a white solid.
[0108] 1 H-RMN (CDCl, 200 MHz): 2.23 (br s, 1H, exchg. D 2 O), 3.30-3.67 (m, 6H), 5.78 (br s, 1H), 7.06-7.23 (m, 7H), 8.10 (s, 1H).
Example 3
Preparation of trans-(2-Chloro-11-methylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (7)
[0109]
[0110] Sodium Borohydride (0.80 g, 21.2 mmol) is added at 0° C. to a solution of trans-N-(8-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-formamide (6) (2.25 g, 7.1 mmol) in dry THF (15 ml). The mixture is stirred for 10′. Next Boron trifluoride tetrahydrofuran complex (4 ml, 34.6 mmol) is added dropwise maintaining temperature below 5° C. Reaction is then stirred at 35° C. for 15 h.
[0111] Reaction is then cooled to 0° C. and 3N HCl (15 ml) is added, then is heated to 100° C. and stirred for 30 minutes, during heating about 15 ml of tetrahydrofuran are distilled.
[0112] Next is cooled to room temperature and 10% K 2 CO 3 is added until pH 9, followed by ethyl acetate (30 ml). Organic layer is separated and washed with water, 1M NaOH and brine and evaporated to dryness to obtain 1.85 g (87%) of trans-(2-Chloro-11-methylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (7) as a colorless oil. 1 H-RMN (CDC1 3 , 200 MHz): 1.64 (br s, 2H, exchg. D 2 O), 2.34 (s, 3H) 2.62-2.78 (m, 1H), 2.80-2.92 (m, 1H) 3.21-3.58 (m, 3H), 3.62-3.74 (m, 1H), 7.03-7.26 (m, 7H).
Example 4
Preparation of Asenapine
[0113]
[0114] A solution of Carbon Tetrabromide (2.86 g, 8.64 mmol) in Dichloromethane (5 ml) is added at 0° C. to a mixture of trans-(2-Chloro-11-methylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (7) (1.75 g, 5.8 mmol) and Triphenylphosphine (2.26 g, 8.64 mmol) in dichloromethane (10 ml). Reaction is stirred at room temperature overnight.
[0115] Reaction is then evaporated and 10 ml of diethylether are added and is stirred for 1 hour at room temperature and 1 hour at 0° C. Triphenylphosphine oxide is then filtered and washed with cold diethylether and organic layers were evaporated to dryness.
[0116] Product is purified by flash chromatography (Heptane:Ethyl Acetate 7:3). 1.42 g (86%) of trans-(5-Chloro-2-methyl-2,3,3a,12b-tetrahydro-1H-dibenz[2,3:6,7]oxepino-[4,5-c]pyrrole (Asenapine) are obtained as a slightly yellow oil. 2,1% of cis isomer is observed by HPLC.
[0117] 1 H-RMN (CDCl 3 , 200 MHz): 2.56 (s, 3H), 3.12-3.18 (m, 4H), 3.61-3.64 (m, 2H), 7.05-7.26 (m, 7H).
Example 5
Preparation of Asenapine Maleate
[0118]
[0119] trans-(5-Chloro-2-methyl-2,3,3a,12b-tetrahydro-1H-dibenz[2,3:6,7] oxepino-[4,5-c] pyrrole (Asenapine) (1.3 g, 4.5 mmol) is dissolved in absolute ethanol (6,5 ml) at room temperature. Maleic Acid (0.634 g, 5.46 mmol) is then added and stirred until complete dissolution. The solution is seeded with Asenapine Maleate monoclinic form and is stirred overnight at r. t.
[0120] Suspension is stirred at 0° C. for one hour, filtered and washed with cold Absolute Ethanol (1 ml). Product is dried for 24 hours at 45° C. 1,63 g of Asenapine Maleate monoclinic form (89%) were obtained as a white solid. No presence of cis isomer is observed by HPLC.
[0121] 1 H-RMN (CD 3 OH, 200 MHz): 3.14 (s, 3H), 3.79-3.82 (m, 2H), 3.91-3.94 (m, 2H), 4.06-4.11 (m, 2H), 6.23 (s, 2H), 7.16-7.31 (m, 7H).
Example 6
Preparation of Asenapine
[0122]
[0123] Concentrated sulfuric acid (618 mg, 6.3 mmol) is added carefully at −10° C. to a suspension of lithium aluminum hydride (478 mg, 12.6 mmol) in dry THF (20 mmol). Then a solution of (6) (1.0 g, 3.1 mmol) in THF (5 mL) is added dropwise and the mixture stirred at 40° C. for 6 hr. After quenching sequentially with H 2 O (0.5 mL), 15% NaOH (0.5 mL) and H 2 O (1.5 mL), the white precipitate is filtered and the filtrate evaporated. The residue is purified by flash chromatography (Heptane:Ethyl Acetate 7:3) giving 612 mg (69%) of trans-(5-Chloro-2-methyl-2,3,3a,12b-tetrahydro-1H-dibenz[2,3:6,7]oxepino-[4,5-c]pyrrole (Asenapine) as a slightly yellow oil.
[0124] 1 H-RMN (CDCl 3 , 200 MHz): 2.56 (s, 3H), 3.12-3.18 (m, 4H), 3.61-3.64 (m, 2H), 7.05-7.26 (m, 7H).
Example 7
Preparation of trans-(11-Aminomethyl-8-chloro-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (C 16 H 16 ClNO 2 )
[0125]
[0126] A solution of trans-8-Chloro-11-nitromethyl-10,11-dihydro-dibenzo[b,f] oxepine-10-carboxylic acid methyl ester (8) (5.0 g, 13.23 mmol) in dry THF (25 ml) is added at −15° C. to a mixture of THF (25 ml) and 3.5 M LAH suspension in THF/Toluene (16.4 ml, 57.5 mmol).
[0127] The mixture is stirred at 30° C. for 30 minutes, cooled to −15° C. and sequentially quenched with H 2 O (2 ml), 15% NaOH (2 ml) and H 2 O (6 ml).
[0128] The solid is filtered, washed with THF (2×30 ml) and the filtrate evaporated to dryness to give 3.88 g (93%) of trans-(11-Aminomethyl-2-chloro-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (9) as a yellow solid.
Example 8
Preparation of trans-N-(2-Chloro-11-hydroxymethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-formamide (C 17 H 16 ClNO 3 )
[0129]
[0130] A mixture of Acetic Anhydride (2.3 ml, 24.8 mmol) and Formic Acid (1.9 ml, 49.7 mmol) is heated to 50° C. for 2 hours. After cooling to 25° C. the mixture is diluted with dichloromethane (20 ml). Next, reaction is cooled to 0° C. and trans-(11-Aminomethyl-8-chloro-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (9) (3.60 g, 12.4 mmol) is added and is stirred at 25° C. for one hour.
[0131] Reaction is quenched with 10% K 2 CO 3 (20 ml) and organic layer is washed with 10% K 2 CO 3 until pH 9.
[0132] Methanol (4 ml) and solid K 2 CO 3 (0.86 g, 6.22 mmol) are added to the organic layer and stirred for 2 hours at room temperature. Water (30 ml) is then added and stirred for additional 15 min. Organic layer is then separated, washed with water (2×20 ml) and brine (20 ml) and evaporated to dryness to give 3.20 g (81%) of trans-N-(2-Chloro-11-hydroxymethyl -10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl)-formamide (10) as a white solid.
Example 9
Preparation of trans-(8-Chloro-11-methylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (C 17 H 18 ClNO 2 )
[0133]
[0134] Sodium Borohydride (1.11 g, 29.27 mmol) is added at 0° C. to a solution of trans-(2-Chloro-11-methylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (10) (3.10 g, 9.8 mmol) in dry THF (15 ml). The mixture is stirred for 10 min. Next Boron trifluoride tetrahydrofuran complex (5.4 ml, 48.8 mmol) is added dropwise maintaining temperature below 5° C. Reaction is then stirred at 35° C. for 15 h.
[0135] Reaction is then cooled to 0° C. and 3N HCl (10 ml) is added, then is heated to 100° C. and stirred for 30 minutes, during heating about 19 ml of tetrahydrofuran are distilled. Next is cooled to room temperature and 10% K 2 CO 3 is added until pH 9, followed by ethyl acetate (30 ml). Organic layer is separated and washed with water, 1M NaOH and brine and evaporated to dryness to obtain 2.48 g (84%) of trans-(8-Chloro-11-methylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (11) as a slightly yellow oil.
Example 10
Preparation of Asenapine
[0136]
[0137] A solution of Carbon Tetrabromide (3.92 g, 11.8 mmol) in Dichloromethane (5 ml) is added at 0° C. to a mixture of trans-(8-Chloro-11-methylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-yl)-methanol (11) (2.40 g, 7.9 mmol) and Triphenylphosphine (3.10 g, 11.8 mmol) in dichloromethane (10 ml). Reaction is stirred at room temperature overnight.
[0138] Reaction is then evaporated and 10 ml of diethylether were added, then is stirred for 1 hour at room temperature and 1 hour at 0° C. Triphenylphosphin oxide is then filtered and washed with cold diethylether and organic layers were evaporated to dryness.
[0139] Product is purified by flash chromatography (Heptane:Ethyl Acetate 7:3). 2.06 g (91%) of trans-(5-Chloro-2-methyl-2,3,3a,12b-tetrahydro-1H-dibenz[2,3:6,7]oxepino-[4,5-c]pyrrole (Asenapine) are obtained as a slightly yellow oil. 1.8% of cis isomer is observed by HPLC.
[0140] 1 H-RMN (CDCl 3 , 200 MHz): 2.56 (s, 3H), 3.12-3.18 (m, 4H), 3.61-3.64 (m, 2H), 7.05-7.26 (m, 7H).
Example 11
Preparation of Methanesulfonic acid trans-2-chloro-11-formylamino methyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl Ester
[0141]
[0142] Triethylamine (2.05 g, 20,27 mmol is added to a suspension of trans-N-(8-Chloro-11-hydroxymethyl-10,11-dihydrodibenzo[b,f]oxepin-10-ylmethyl)-formamide (2.30 g, 7.24 mmol) in dichloromethane (23 ml). The suspension is then cooled to 0° C. and methanesulfonyl chloride (1.66 g, 14.48 mmol) is added during 20 minutes, keeping temperature below 5° C. Reaction is then stirred at 5° C. for 30 minutes, until all starting material is dissolved.
[0143] Reaction is quenched with 4% NaHCO 3 (50 ml) and stirred at 20-25° C. for 30 minutes. After phase separation, the organic layer is washed with water (25 ml) and brine (25 ml) and evaporated to dryness to yield 2.46 g (86%) of methanesulfonic acid trans-2-chloro-11-formylaminomethyl-10,11-dihydro-dibenzo[b,f]oxepin-10-ylmethyl ester as a pale yellow solid that can be used without further purification.
[0144] 1 H-RMN: (CDCl3, 200 MHz): 2.86 (s, 3H), 3.49-3.52 (m, 4H), 4.03 (q, 1H) 4.24 (m, 1H), 6.73 (s, 1H, exchg. D 2 O), 7.06-7.38 (m, 7H), 8.13 (s, 1H, exchg. D 2 O).
Example 12
Preparation of Asenapine
[0145]
[0146] Sodium Borohydride (0.70 g, 18,19 mmol) is added at 0° C. to a solution of methanesulfonic acid trans-2-chloro-11-formylaminomethyl-10,11-dihydro-dibenzo [b,f]oxepin-10-ylmethyl ester (2.40 g, 6.06 mmol) in dry THF (14.4 ml). The mixture is stirred for 10 minutes. Next, boron trifluoride tetrahydrofuran complex (3.3 ml, 30.31 mmol) is added dropwise keeping temperature below 5° C. The reaction is then stirred at 20-25° C. for 15 h.
[0147] After cooling to 0° C., 3N HCl (8 ml) is added. The mixture is heated to 100° C. and stirred for 30 minutes, allowing about 15 ml of tetrahydrofuran to distill. Next, it is cooled to 25° C., diluted with Ethyl Acetate (12 ml) and a solution of 10% K 2 CO 3 (25 ml) is added keeping the temperature below 25° C. The reaction is stirred for 1 hour at 20-25° C., filtered and layers separated. The organic layer is washed with 1M NaOH (2×10 ml) and evaporated to dryness to yield 1.65 g (95%) of Asenapine as a clear oil that can be used without further purification. HPLC purity: 92.2%. No presence of cis isomer is observed 1 H-RMN: (CDCl 3, 200 MHz): 2.56 (s, 3H), 3.12-3.18 (m, 4H), 3.61-3.64 (m, 2H), 7.05-7.26 (m, 7H).
Example 13
Preparation of Asenapine Maleate
[0148]
[0149] trans-(5-Chloro-2-methyl-2,3,3,12b-tetrahydro-1H-dibenz[2,3;6,7] oxepino-[4,5-c]pyrrole (Asenapine) (1.65 g, 5.77 mmol) is dissolved in absolute ethanol (8.25 ml) and stirred at room temperature for 10 minutes. Maleic Acid (804 mg, 6.93 mmol) is added and stirred until complete dissolution. The solution is seeded with Asenapine Maleate monoclinic form and stirred overnight at room temperature. The obtained suspension is cooled down to 0° C. in an ice bath and stirred for one hour, filtered and washed with cold absolute ethanol (1.65 ml). The obtained product is dried for 24 hours at 45° C.
[0150] 2.11 g of Asenapine Maleate monoclinic form (91%) is obtained as a white solid. HPLC purity: 99.1%. No presence of cis isomer is observed. 1 H-RMN: (CDOH, 200 MHz): 3.14 (s, 3H), 3.79-3.82 (m, 2H), 3.91-3.94 (m, 2H), 4.06-4.11 (m, 2H), 6.23 (s, 2H), 7.16-7.31 (m, 7H).
Example 14
Recristalization of Asenapine Maleate
[0151] 2.11 g (5.25 mmol) of Asenapine Maleate are dissolved in absolute ethanol (8.5 ml) at 65° C. Afterwards, the solution is allowed to cool and seeded with Asenapine Maleate monoclinic form at 40° C. The obtained suspension is cooled to room temperature and stirred for 12 hours, cooled down to 0° C., stirred for 2 hours, filtered and washed with cold absolute ethanol (2.1 ml). The obtained solid is dried for 24 h at 45° C. 1.96 g of Asenapine Maleate monoclinic form (93%) is obtained, as a white solid. HPLC purity: 99.,93%. No presence of cis isomer is observed. 1 H-RMN: (CDOH, 200 MHz): 3.14 (s, 3H), 3.79-3.82 (m, 2H), 3.91-3.94 (m, 2H), 4.06-4.11 (m, 2H), 6.23 (s, 2H), 7.16-7.31 (m, 7H). | The present invention is directed to novel compounds of formula (I) as well as to the process for their preparation. Novel compounds of formula (I) can be converted into asenapine through an efficient process. The invention also relates to novel intermediates used in this process and their use in the preparation of compounds of formula (I). | 2 |
SUMMARY OF THE INVENTION
The present invention relates to an apparatus and a method for forming, filling and sealing closed individual pinch pouches. A support holds a supply of web material in a roll which material has a heat sealable surface on one side and printed indicia on the other side. The web of material engages a plow for folding the material onto itself with one portion of the heat sealable surface facing another portion of the heat sealable surface with the indicia on the exterior of the folded material. A gusset is formed at the fold between the folded portions of the heat sealable surface. Drive rollers pull the material from the roll of material. A pair of preheating sealing bars engage the folded material to preheat a portion of the heat sealable surface, and a second pair of heat sealing bars engage the preheated portion to fuse the heat sealable material at a selected location to form a seal extending from the gusset across the direction of movement of the material. A blade is positioned between the margins of the material to provide an extended opening between sealed portions. The material is mounted in a transfer clamp. A cutter cuts the material through a seal to form a folded blank having opposed sealed edges extending to the gusset and an open margin opposite the gusset. A hammer pushes the gusset inward to spread apart opposed surfaces. A vacuum opener holds apart the open margins of the blank, and an injector forces a flowable substance including liquid into the blank through the open margins. Heat sealing bar engages the blank at the margins opposite the gusset to seal closed the open portion. A cooling bar engages the sealed margins, and a cutter cuts the sealed margins to form a nozzle in the blank and complete the pinch pouch.
DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a side elevation view of an apparatus for forming, filling and sealing closed individual pinch pouches embodying the herein disclosed invention;
FIG. 2 is an enlarged fragmentary portion of a portion of the apparatus of FIG. 1 showing a hammer in engagement with a blank for pushing a portion of a gusset inward to open interiorly the blank;
FIG. 3 is an end view of the portion of the apparatus shown in FIG. 2;
FIG. 4 is an enlarged fragmentary view showing a filling station of the apparatus shown in FIG. 1;
FIG. 5 is an end view of a portion of the filling station of FIG. 4;
FIG. 6 is a perspective view of a completed pinch pouch made on the apparatus shown in FIG. 1;
FIG. 7 is a diagrammatic illustrative view showing the effects of various steps of the subject method after the web material is folded by displaying the various forms which the material takes as it goes through the apparatus of FIG. 1 going from the folded web material to a blank to a completed pinch pouch; and
FIG. 8 is a cross sectional view through the completed pinch pouch of FIG. 6 taken on line 8--8 of FIG. 6.
DETAILED DESCRIPTION
Referring now to the drawings and especially to FIG. 1, an embodiment of the present invention, namely, an apparatus for forming, filling and sealing closed individual pinch pouches is shown therein and is generally indicated by numeral 10. Apparatus 10 generally includes a power assembly 12, a stock assembly 14, a sealing section 16, a cutting section 18, a forming section 20, a filling assembly 22, a carrier assembly 24, a closure section 26, and a final die cutting section 28.
A web material 29 is formed and cut to make individual pinch pouches 30. The web material is a continuous roll of board including solid bleached sulfate board or paper board material having on one side a heat sealable surface which is a layer of polyethylene 32. Printing indicia 33 is on the other side of the cardboard. The thickness of the web material is greater than 7 mils, and in this instance, is 13 mils which is more than twice as thick as the material which is used heretofore for similar pinch pouches. The advantages of the thicker material will become readily apparent to those skilled in the art upon a consideration of the pinch pouch end product of the subject apparatus and method. The stock material is provided in a roll 34 which is mounted on a conventional power driven web feed device 35. The material comes off the roll and passes through a conventional plow 36 so that the web material is folded substantially in half along its length in its direction of movement. The polyethylene layer 32 has one portion facing another portion and forming a fold 37 at the bottom as viewed in FIG. 1. The top portion has opposed free margins 39 of the material adjacent to each other. The web of material is drawn from the roll and through the plow by a pair of conventional drive rollers 40.
Printing indicia 33 on the SBS board or paper board material includes a plurality of spaced identifying or advertising matter blocks 41 extending along the length of the web. A register mark 42 is printed along the upper margin of the web of stock material above and between each pair of adjacent identifying or advertising matter blocks 41. Register mark 42 provides a means or indicia for a conventional optical scanner or detector 43 to detect the mark and control movement of the web material and parts of the apparatus.
Optical scanner 43 controls the output of the power assembly 12 so that the web material moves intermittently through sealing section 16. Sealing section 16 includes a pair of conventional preheaters or preheating bars 44 which are engageable with the web material. Heating and sealing bars 46 are spaced from the preheating bars 44. The web material moves from preheating bars 44 to heating and sealing bars 46. The optical scanner interrupts the movement of the web so that a register mark 42 is aligned with each of the bars. When the web stops moving, preheater bars 44 move toward the web to heat the material in the spaced section between adjacent identifying or advertising matter blocks 41 and thereby heat the polyethylene at that section of the heat sealable surface between the spaced blocks. Heating and sealing bars 46 also engage the web at the same location where the preheating bars had previously engaged the web. Heating and sealing bars 46 further heat the web material and apply a force to the opposed portions of the heat sealable surface of the web material to cause the opposed portions to seal to each other to form a sealed portion 47 extending from the fold toward the free margins of the web material substantially perpendicular to and across the direction of movement of the web material. A blade 48 is positioned between the free margins 39 of the web material parallel to the direction of movement of the web material to prevent the free margins from being sealed to each other and thereby provide an opening to the space defined by the fold and two sealed portions 47. The movement of the web is controlled so that the sealing occurs between the identifying or advertising matter blocks 41.
The web material with a plurality of elongated sealed portions 47 extending across the direction of movement of the web is delivered to cutting station 18. The end of the web is placed into engagement with a blank carrier 50 of the carrier assembly which includes a plurality of blank carriers 50 mounted on a conventional driven chain 52. The movement of the web and the chain is interrupted when stock material is placed into engagement with the carrier. A conventional and well known knife (not shown herein) cuts the web material through the middle of a sealed portion 47 to form two separate sealed edges 56 and 58, thereby forming a blank 54 which has material folded on itself with the polyethylene surface on the interior of the fold. The blank has a rectangular configuration defined by opposed sealed edges 56 and 58 on the sides, the top being a free edge 60 formed by the free margins 39 and the bottom, and a gusset 62 which is formed by the fold and is opposite free edge 60.
Blank 54 is carried to the forming section 20. The blade 48 has an air port 66 which provides into the blank a supply of compressed air from a conventional compressed air source being means for blowing air through the blade. The blank ends at the forming section. A pair of upper retainers 70 and 71 hold the side walls 72 and 73, respectively, in place at the margins 39. A pair of lower retainers 74 and 76 holds the lower portion of the blank in position. A hammer 77 engages the bottom of the gusset to push the gusset inward thereby expand the side walls of the blank.
The chain moves the formed blank to filling station 22. A pair of opposed vacuum heads 78 engages the upper portion of the blank adjacent to the margins 39. The vacuum heads are moved apart to open the free end of the blank thereby providing an open end. A suitable flowable substance, such as a liquid, is injected into the open end of the blank through a conventional nozzle 80 which is connected to a conventional liquid filler (not shown herein). The blank continues its intermittent movement to a second position of the filling section where a second pair of vacuum heads 82 engages the upper portion of the blank adjacent to the margins 39. Vacuum heads 82 are moved apart to insure that the upper portion of the blank is open. An additional amount of flowable substance is injected into the open blank by a second liquid filler (not shown herein) through a second nozzle 84.
The blank with its contents of the flowable substance is then carried by the chain to the closure section 26. Free margins 39 at the upper portion of the blank are heated by a pair of preheater bars 88. The chain moves the blank to a pair of upper edge heating and sealing bars 90 to seal off the open end. Clamps 90 further heat and squeeze the margins 39 to form a sealed portion 92 which is bounded by the generally arrow shaped dotted lines as is shown in FIG. 7. Sealed portion 92 extends into the two sealed edges 56 and 58. Sealed portion 92 includes a nonsealed portion 94 which communicates with the main portion of the interior of the blank. The blank moves to a cooler 96 where sealed portion 92 is cooled.
The blank with the contents sealed therein is carried into the die cutting assembly 28. A die 98 cuts off a trim portion 100. Removal of the trim portion from the blank completes pinch pouch 30. Pinch pouch 30 includes a nozzle 104 with a pair of notches 106 and 108 formed in opposite sides of the nozzle. Nonsealed portion 94 extends above notches 106 and 108 to allow the edge of the nozzle to be torn off at the notches and thereby provide an egress from the interior of the pinch pouch through the unsealed portion of the nozzle. Each completed pinch pouch is moved to a discharge assembly 110 where each pinch pouch is disengaged from its respective carrier and delivered to a conventional container which is not shown herein.
FIG. 7 is a condensed illustration of the transition of the web material from a folded web material to a completed pinch pouch 30 filled with flowable substance. Viewing the illustration from left to right, the first portion 111 shows a side view of the web material folded and with sealed portions 47. The next portion 112 illustrates the resulting formation of the blank by cutting through the middle of the sealed portion. The following part 113 shows the blank after the gusset has been forced inward. The succeeding part 114 depicts the blank ready to receive the flowable substance. The next part 115 is an example of the blank filled with the flowable substance and the sealed portion 92 closing the open end extending to the margin. The following portion of the illustration shows a completed pinch pouch and the trim portion 100 separated from the pinch pouch. The succeeding portion of the illustration shows a completed pinch pouch 30.
Power assembly 12 includes a conventional electric motor 116 which drives a pair of conventional shafts 118 and 120. The power to the shafts is delivered through conventional clutches. The optical scanner 43 controls the clutches so that the optical scanner can selectively interrupt the delivery of power to each of the shafts 118 and 120. The movement of the web material and the individual blanks is controlled by the optical scanner. When movement of the web and the blanks is interrupted, the various other parts of the apparatus are energized, that is, the heaters and the sealers squeeze the blanks as described above. The cutting operation is done at the same time. The blanks are also filled at the same time. Once the sealing, filling, forming operations are completed, the various elements disengage the blank in its various forms and the web of material and the blanks move to the next incremental station. The use of the two shafts allows the various operations to be effectively synchronized.
Pinch pouch 30 formed by the present apparatus and method is an improvement over those made heretofore from a continuous web of material. The instant pinch pouch is made of a stock having a thickness of 13 mils which is more than twice as thick as the material heretofore used in a continuous web of operation. The web material has a thickness of at least 7 mils. One of the advantages which flows from using the heavier web material is that when the pinch pouch is opened by tearing off the upper portion of nozzle 104 at the two notches 106 and 108 to expose the unsealed portion 94, material contained in the pinch pouch may be expelled by squeezing the pinch pouch. However, if all of the material is not used, or is not necessary, the mere release of pressure from the sidewalls of the pinch pouch allows the resilience of the material to close the opening. The natural resilience of the heavy material provides a resilient closure for the pinch pouch, thereby preventing unneeded and unnecessary dripping or oozing of the contents of the pinch pouch.
Although a specific embodiment of the herein disclosed invention has been shown in the accompanying drawings and described in detail above, it is readily apparent that those skilled in the art may make various modifications and changes in the herein disclosed apparatus and method without departing from the spirit and scope of the present invention. It is to be expressly understood that the instant invention is limited only by the appended claims. | A machine and method for forming, filling and sealing closed individual pinch pouches includes a support for holding a continuous supply of material having a solid bleached sulfate board or paper board surface and a heat sealable plastic coating on one side. A folding apparatus folds the web material onto itself with the heat sealable surface facing itself with a gusset at the fold. Drive rollers pull the material from the source through the folding apparatus. Heating bars form a seal between selected portions of the material by sealing the heat sealable surfaces at intermittent portions. A cutter cuts the material through the seal and forms a blank having opposed sealed edges extending to the gusset and an open edge opposite the gusset. A hammer pushes the gusset of the blank inward to spread apart opposed surfaces of the blank. An injector forces a flowable substance into the blank through the open edge. A sealer engages the open edge opposite the gusset to force a selected area of the edge together to form a sealed closed pinch pouch. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a polymeric material solution for electrospinning and a method of fabricating nano-fibers by electrospinning using the same.
[0003] 2. Description of Related Art
[0004] The development of nanotechnology has enhanced great evolution of the industry, but also causes great impacts to many traditional manufacturers. Among numerous nano-scaled materials, nano-fiber can be extensively applied into various industries such as the textile industry, biotechnology industry, optical industry etc, and thus is of particular interest to researchers.
[0005] Among various artificial fibers, though nylon has acted as a pilot in the history of fiber development, the rigid-rod like polymers, such as polybenzoxazole (PBO), polyimide and Kevlar, fibers is advanced in its outstanding mechanism properties and excellent heat resistance. Among them, the PBO fiber has also been named as “Super Fabric of the 21st Century”.
[0006] In 1998, PBO fiber was first presented with the name of“ZYLON” in the international fiber congress by Japan Toyobo Company. PBO fiber has higher tensile properties than other tensile fibers such as UHMWPE (Ultra High Molecular Weight Polyethylene) or Kevlar, and simultaneously has the same high thermo stability as Meta Aramid Fiber.
[0007] PBO fiber is advanced in many characteristics including thermo stability, heat resistance, impact resistance, fatigue bending resistance, and chemical resistance. PBO fiber has about twice the tensile strength of Kevlar. Besides, PBO fiber has great heat resistance, so it is incombustible and unshrinking when ignited. Many manufacturing methods of fabricating PBO fibers have been developed; some are by dissolving PBO or PHA into PPA (polyphosphoric acid) or other solvents such as MSA (methanesulfonic acid) followed by spinning to produce fibers. However, the solution used for spinning must be prepared with a determined high temperature heat treatment and mixed for a long time period, because the viscosity of the PBO solution should be lowered otherwise the spinning process cannot be proceeded. Meanwhile, the sizes (diameters) of the fibers obtained using prior spinning techniques can only be reduced to micro scale, and cannot further be lowered.
[0008] Table 1 shows some research results on PBO fiber manufacture during the present years. Most of the methods use PPA (polyphosphoric acid) or other solvent (e.g. MSA) as the solvent system for PBO or the precursor of PBO and PHA (polyhydroxyamide). It was tried to spin the solution into fibers, but an extremely large effort was involved in preparing the spinning solution because the raw PBO solution has such high viscosity that must be reduced by both high temperature treatment and a mixing process over a long period of time. Besides, the limitation of the spinning head and the later processing both may increase the difficulties in reducing the diameter of the fibers. For example, Kumar et al. proposed a method of dissolving the PBO material in the MSA solvent with high temperature following by spinning the PBO solution into fibers in a high temperature environment. However, the diameter of the fibers produced from such solvent system is still at micro scale (e.g. 25 μm).
[0009] Others such as Li, Chae, Hu (2006, 2005, 2003) used PPA (poly phosphoric acid) as a solvent for the PBO spinning solution. The PBO fiber produced from such solvent system has a diameter of several micros (25˜30 μm), and all of the process during the manufacturing of the PBO fiber must be carried out at a high temperature i.e., between 100-200° C.
[0010] In recent years, Lin and Wang (2005) tried using PHA, the precursor of PBO, for electro-spinning to produce fibers, and then applied high temperature to the PHA fibers to cyclize into PBO fibers having nano-scaled sizes (643±212 nm). However, some unreacted PHA residues remaining after the cyclization reaction may affect the characteristic of the PBO fibers. Furthermore, the shrinking of volume or loosening of the molecule bonding related to the temperature factor may cause severe influence on the polymerization, which needs additional high temperature treatment for reworking. Thus, such method is still improper for the producing of nano PBO fibers.
[0011] According to the various disadvantages mentioned above, such as demands of high temperature treatment, long pretreatment time, irreducible diameter sizes, undesirable residues, etc, the method utilizing PBO as raw material directly and processing in a single way to fabricate PBO fibers is a present need for the development of PBO fibers productions.
[0000]
TABLE 1
the development of PBO fibers in the recent years.
reference
Lin, 2005
Li, 2006
Chae, 2006
Hu, 2003
Kumar, 2002
Solution for
polymer
20 wt. % PHA
9-10 wt. %
10-15 wt %
8.6 wt. %
14 wt. % PBO
electrospinning
solvent
THF/DMAc =
PPA
PPA
MSA
PPA
9/1
% of the
—
2-8%
—
—
—
carbon
Mixing
temperature
—
160
—
100-150
160-190
condition
(° C.)
time(Hr)
—
24 hr
—
—
20
Electrospinning
temperature
—
—
—
—
—
(° C.)
injecting
0.3 mL/h
—
—
—
—
pump
voltage(V)
11
—
—
—
—
distance(cm)
7
—
—
—
—
Wet
temperature
—
200
100-170
—
100-150
spinning
(° C.)
After
treatment
Cyclization at
Washed with
Water bath
—
Washed with
spinning
100~300° C.
water for
at various
water for
5 days→
temperature
5 days→
Vacuum dry
Vacuum dry
at
at 80° C. (24 hr)
100° C. (24 hr)
Product
diameter
643 ± 212 nm
25~30 μm
—
—
25 μm
(Fiber)
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to provide a novel solvent system for polymeric materials, specifically, the rigid-rod like polymers (such as PBO, Kevlar, polyimide, etc). With such solvent system, the problems such as high viscosity, high temperature treatment, long pretreatment time, irreducible diameter sizes, and undesirable residues can be overcome. The solvent system of the present invention is the first that enables polymer solution applied to electrospinning process, and enables the production of nano-fibers with well-organized structure and ordered molecular arrangement.
[0013] Besides, the application of the electrospinning methods in the present invention enhances high distribution uniformity of the polymer fiber sizes, and provides a better selectivity for the diameter of the polymer fiber.
[0014] In order to obtain the above object, the present invention provides a polymeric material solution for electrospinning, which comprises: a solvent system comprising an alkylsulfonic acid and a flouro-substituted organic acid; and a polymeric material. The solvent system of the present invention enables PBO to be easily dissolved at room temperature, and has higher evaporating ability than the solvent containing only alkylsulfonic acid. Consequently, the polymeric material solution of the present invention has been a first polymeric material solution applied into electrospinning under room temperature to produce PBO nano-fiber, which has excellent metallic luster, and the molecular structure thereof is well arranged.
[0015] If MSA is used singly, the solvent will be too sticky, i.e. the viscosity will be too high, and thus a long time period heat treatment will be needed to dissolve the polymer. Besides, the traditional polymer fiber fabrication usually takes place in a high temperature environment by using wet spinning, which cannot proceed at room temperature. However, the solvent system for polymeric materials of the present invention enables polymers to be dissolved at room temperature, and provides a better evaporating character. With the use of the solvent system of the present invention, PBO solution can firstly be applied into electrospinning under room temperature to produce PBO nano-fiber, which is a significant advance in the development of the electrospinning.
[0016] According to the solution of the present invention, the ratio of the alkylsulfonic acid and the flouro-substituted organic acid is preferably from 7:3 to 2:8, but is not limited thereto.
[0017] According to the solution of the present invention, the polymeric material may be any polymeric material that can be dissolved in the solvent system of the present invention, preferably the polymeric material is rigid-rod like polymers such as polybenzoxazole (PBO), Kevlar, polyimide or polybenzoxazole mixed with Kevlar, silk, poly lactic acid (PLA), or chitosan, but is not limited thereto. When a mixture of polybenzoxazole and poly lactic acid is used, a bio-acceptable polymer fiber may be produced, which can be further applied into biomedical material development.
[0018] According to the solution of the present invention, the content of the polymeric material is preferably 0.1%-10%, but is not limited thereto.
[0019] According to the solution of the present invention, the number of carbon atoms of the alkylsulfonic acid is preferably 1-3, but is not limited thereto.
[0020] According to the solution of the present invention, the alkylsulfonic acid is preferably methanesulfonic acid (MSA), but is not limited thereto.
[0021] According to the solution of the present invention, the number of flouro atoms of the flouro-substituted organic acid is preferably 1-3, but is not limited thereto.
[0022] According to the solution of the present invention, the flouro-substituted organic acid is preferably trifluoroacetic acid (TFA), but is not limited thereto.
[0023] According to the solution of the present invention, the viscosity of the solution is preferably 1000-35000 cSt, and more preferably 4000-20000 cSt, but is not limited thereto.
[0024] Another object of the present invention is to provide a method of electrospinning, comprising: (A) providing an electrospinning instrument; (B) dissolving a polymeric material in a solvent system to provide an electrospinning solution, wherein the solvent system comprises an alkylsulfonic acid and a flouro-substituted organic acid; and (C) electrospinning the electrospinning solution with the electrospinning instrument to provide nano-fibers.
[0025] The method of the present invention is the first method applying polymer solution into electrospinning process to produce nano-fibers having well-organized structure and ordered molecular arrangement. The fibers produced by the present invention have diameter of nano scale, but the fibers produced by the conventional method have diameter of micro scale instead. In addition, with the characteristic such as heat resistance, flame retardance, and chemical environmental resistance held by the polymer itself, the fibers produced by the present invention can be applied to a wide usage, e.g. bulletproof clothing, fireproof clothing, conveyor belts with high wear-resistance, sports equipment, medical materials, filtrating film, etc. Therefore, the electrospinning method of the present invention is practical and has been an innovation in the field of nano fiber fabrication.
[0026] According to the method of the present invention, the ratio of the alkylsulfonic acid and the flouro-substituted organic acid is preferably from 7:3 to 2:8, but is not limited thereto.
[0027] According to the method of the present invention, the polymeric material may be any polymeric material that can be dissolved in the solvent system of the present invention, preferably the polymeric material is rigid-rod like polymer such as polybenzoxazole (PBO), Kevlar, polyimide, or polybenzoxazole mixed with Kevlar, silk, poly lactic acid (PLA), or chitosan, but is not limited thereto.
[0028] According to the method of the present invention, the content of the polymeric material in the electrospinning solution is preferably 0.1%-10%, but is not limited thereto.
[0029] According to the method of the present invention, the number of carbon atoms of the alkylsulfonic acid is preferably 1-3, but is not limited thereto.
[0030] According to the method of the present invention, the alkylsulfonic acid is preferably methanesulfonic acid (MSA), but is not limited thereto.
[0031] According to the method of the present invention, the number of flouro atoms of the flouro-substituted organic acid is preferably 1-3, but is not limited thereto.
[0032] According to the method of the present invention, the flouro-substituted organic acid is preferably trifluoroacetic acid (TFA), but is not limited thereto.
[0033] According to the method of the present invention, the viscosity of the solution is preferably 1000-35000 cSt, and more preferably 4000-20000 cSt, but is not limited thereto.
[0034] Still another object of the present invention is to provide a nano-fiber prepared from the method described above. The nano-fiber of the present invention has well-organized structure and ordered molecular arrangement, and the diameter of the nano-fiber of the present invention is preferably 50 nm-500 nm.
[0035] Therefore, by using the electrospinning method and the solvent system for polymeric materials of the present invention, problems such as high viscosity, high temperature treatment, long pretreatment time, irreducible diameter sizes, and undesirable residues can be overcome. The solvent system of the present invention is the first solvent system that enables polymer solution to be applied to an electrospinning process, and enables the production of nano-fibers with well-organized structure and ordered molecular arrangement. Besides, the application of the electrospinning methods in the present invention enhances high distribution uniformity of the polymer fiber sizes, and provides a better selectivity for the diameter of the polymer fiber.
[0036] Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is the result of the X-ray diffraction analysis of the nano fiber provided from Example 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] The present invention will be apparent from the following detailed description.
EXAMPLE 1
[0039] In the present example, the method of preparing PBO (polybenzoxazole) nano-fibers includes the preparation of the PBO solution and the electrospinning process.
[0040] (A) Preparation of the Polymer Solution
[0041] Add PBO (MW=110000) to the mixture solvent of methanesulfonic acid (MSA) and trifluoroacetic acid (TFA)(MSA:TFA=5:5) to afford 1 wt % PBO solution with a viscosity of 16100 cSt. Electrospinning the PBO solution is performed as below.
[0042] (B) Electrospinning
[0043] Perform electrospinning process. The key spinning conditions are as follows: voltage, 13.6 kV; flowing rate, 0.4 ml/hr; and air gap, 7 cm. A variety of tools are used for collecting the product (nano-fibers), including a flat-plate and net-spool. Using a flat-plate to collect fibers is less preferred because the fibers collected are not well-aligned, and the solvent may remain on the surfaces of the product. The net-spool is better than the flat-plate for collecting process because the rotating spool may collect the fibers in a single direction, thus the output fibers are able to be well-aligned. In addition, the net-included spool provides a better condition, i.e. large evaporating area, for the evaporating of the solvent.
[0044] From the optical microscope (OM) picture result of the PBO fibers obtained from the Example 1 of the present invention, it is shown that PBO fibers fabricated by the present invention have good outer appearance.
[0045] In the present example, no heating is needed for the process of dissolving PBO into the MSA/TFA (=5/5) solvent system (it can be done at room temperature), in which PBO can be dissolved rapidly. After applying the method of electrospinning, the yield can be improved with high efficiency. On the contrary, in the use of conventional solvent, heating and long-time stirring is needed for dissolving of PBO, and only wet spinning can be applied due to the high viscosity. Therefore, with the conventional solvent system, not only is longer time needed and the yield is low, but also other problems are caused, such as the diameter of the fiber cannot be decreased, and the pollution by contaminants is increased.
EXAMPLE 2
[0046] PBO (MW=105000) is added to a mixture solvent of methanesulfonic acid (MSA) and trifluoroacetic acid (TFA)(MSA:TFA=7:3) to afford 1 wt % PBO solution with a viscosity of 32200 cSt. The PBO solution is electrospun as described in Example 1, except that the spinning conditions are as follow: voltage, 15 kV; flowing rate, 0.2 ml/hr; and air gap, 3 cm. The fibers are collected by the same method as described in Example 1.
EXAMPLE 3
[0047] PBO (MW=26000) is added to a mixture solvent of methanesulfonic acid (MSA) and trifluoroacetic acid (TFA)(MSA:TFA=4:6) to afford 1 wt % PBO solution with a viscosity of 3630 cSt. The PBO solution is electrospun as described in Example 1, except that the spinning conditions are as follow: voltage, 11 kV; flowing rate, 0.8 ml/hr; and air gap, 4 cm. The fibers are collected by the same method as described in Example 1.
EXAMPLE 4
[0048] PBO (MW=105000) is added to a mixture solvent of methanesulfonic acid (MSA) and trifluoroacetic acid (TFA)(MSA:TFA=5:5) to afford 1 wt % PBO solution with a viscosity of 1480 cSt. The PBO solution is electrospun as described in Example 1, except that the spinning conditions are as follow: voltage, 11 kV; flowing rate, 0.5 ml/hr; and air gap, 5 cm. The fibers are collected by the same method as described in Example 1.
EXAMPLE 5
[0049] PBO (MW=110000) is added to a mixture solvent of methanesulfonic acid (MSA) and trifluoroacetic acid (TFA)(MSA:TFA=5:5) to afford 7 wt % PBO solution with a viscosity of 341000 cSt after heating to 60° C. for 24 hours. The PBO solution is electrospun as described in Example 1, except that the spinning conditions are as follow: voltage, 11 kV; flowing rate, 0.4 ml/hr; and air gap, 6 cm. The fibers are collected by the same method as described in Example 1.
EXAMPLE 6
[0050] The purpose of the present example is to provide a polymer fiber of PBO and Kevlar. Except that, in the step (A), the PBO is replaced by the mixture of PBO and Kevlar to afford the polymer solution, the other processing conditions are the same as in Example 1 to provide a PBO/Kevlar nano-fiber.
EXAMPLE 7
[0051] The purpose of the present example is to provide a polymer fiber of PBO and silk. Except that, in the step (A), the PBO is replaced by the mixture of PBO and silk to afford the polymer solution, the other processing conditions are the same as in Example 1 to provide a PBO/silk nano-fiber.
EXAMPLE 8
[0052] The purpose of the present example is to provide a polymer fiber of PBO and PLA (poly lactic acid). Except that, in the step (A), the PBO is replaced by the mixture of PBO and PLA to afford the polymer solution, the other processing conditions are the same as in Example 1 to provide a PBO/PLA nano-fiber.
EXAMPLE 9
[0053] The purpose of the present example is to provide a polymer fiber of PBO and chitosan. Except that, in the step (A), the PBO is replaced by the mixture of PBO and chitosan to afford the polymer solution, the other processing conditions are the same as in Example 1 to provide a PBO/chitosan nano-fiber.
[0054] SEM (Scanning Electron Microscope) Analysis
[0055] From the SEM picture of the PBO fiber produced from Example 1, it can be seen that the PBO fiber of the present invention has a diameter of nano-sizes (about several hundred nanometers or less), and the surface of the PBO fiber is clean without residues remaining. Therefore, the PBO fiber of the present invention has fine widths and excellent quality (without residues on the surfaces) that cannot be realized in the prior methods.
[0056] X-Ray Diffraction Analysis
[0057] The nano fiber provided from Example 1 is taken into X-ray diffraction analysis with the conditions as below:
[0058] a. Scan rate: 1 o/min
[0059] b. Scan angle: 2-40 o
[0060] c. Sample width: 0.05 o/S
[0061] d. Div Slit: ½ o
[0062] e. Div H.L.Slit: 5 mm
[0063] f. Sct Slit: auto
[0064] g. Rec Slit: 0.3 mm
[0065] FIG. 1 shows a result of the X-ray diffraction analysis of the nano fiber provided from Example 1. As can be seen from FIG. 1 , peaks appearing at 2θ=14.15 o·16.9 o·18.3 o·25.5 o represent an excellent molecular alignment of the nano fiber of the present invention, which also means a strong bonding of the molecules. Such properties enhance high strength and tensile of the nano-fibers. Therefore, the nano fiber of the present invention can be applied to a wide usage, e.g. bulletproof clothing, fireproof clothing, conveyor belts with high wear-resistance, sports equipment, medical materials, filtrating film, etc.
[0066] Furthermore, the solvent system of the present invention, which comprises the mixture of methanesulfonic acid (MSA) and trifluoroacetic acid (TFA), can be applied to the coating process (making thin films of nano-fibers) and polymer recycling process (recycling of the PBO fibers) without high temperature heating and/or long dissolving time. Therefore, the solvent system of the present invention can be more widely used and has high efficiency of dissolving compared with the traditional solvent system.
[0067] Dissolving and Electrospinning Test
[0068] Mixed solvents with different ratios of methanesulfonic acid (MSA) and trifluoroacetic acid (TFA), and with different concentrations of PBO are applied into the present electrospinning test. The results are shown in Table 2 as below.
[0000]
TABLE 2
Solvent
TFA
10
8
7
6
5
4
3
2
0
ratio
MSA
0
2
3
4
5
6
7
8
10
PBO
7
⊙*
w/v %
6
5
◯
⊙X
⊙X
⊙*
⊙X
⊙X
⊙X
4
3
⊙*
2
1
⊙X
0.5
◯PBO cannot be dissolved;
⊙PBO can be dissolved;
Xcannot be electrospun;
fibers produced from electrospinning at room temperature;
*fibers produced from electrospinning after heating
[0069] As can be seen from the results shown in Table 2, in the conditions that the ratio of MSA:TFA is 7:3 to 2:8 and the concentration of PBO is 0.1 wt % to 10 wt %, electrospinning can be easily performed, which means the ratio of MSA:TFA is preferably in a range from 7:3 to 2:8 and the concentration of PBO is preferably in a range from 0.1 wt % to 10 wt %. By using such solvent system, the polymer solution can be electrospun directly without heating. Herein, the viscosity of the polymer solution is ca. 1000-35000 cSt. If the viscosity of the polymer solution is out of the range, electrospinning may not be carried out.
[0070] If the content of the TFA of the solvent system is too high, fast evaporating phenomenon may occur, also the spinning head may be easily stocked, thus hinders the proceeding of the electrospin. If the content of the TFA of the solvent system is too low, PBO may not be completely dissolved, the output product cannot be solidified into fibers or the fibers are produced with weak tensile strength because the slow evaporation of the solvent. Besides, the concentration of PBO in the solution also affects the feasibility of the electrospinning process. Therefore, it should be noted that the ratio between TFA and MSA, and the concentration of PBO in the solution are both very important and need to be controlled in a proper range.
[0071] Moreover, any solution having viscosity without the range described above can be further processed with additional heating, pressurizing, cooling, or pressure-reducing to adjust the viscosity to be in the range, thus enabling the solution to be applied to electrospinning for the fabrication of the nano fibers.
[0072] As mentioned above, the solvent system for polymeric materials of the present invention enables polymers to be dissolved at room temperature, and provide a better evaporating character, thus the solvent system of the present invention can solve the problems such as high viscosity, high temperature treatment, long pretreatment time, irreducible diameter sizes, and undesirable residues. Besides, with the use of the solvent system of the present invention, PBO solution can firstly be applied into electrospinning at room temperature to produce PBO nano-fibers, which have excellent metallic luster, and the molecular structure thereof is well arranged. The PBO nano-fiber fabricated from the present invention is well-organized in molecular arrangement, and has the advantages of heat resistance, flame retardance, and chemical environmental resistance, and thus may be widely used in several applications. Moreover, the application of the electrospinning methods in the present invention enhances high distribution uniformity of the polymer fiber sizes, and provides a better selectivity for the diameter of the polymer fiber. Therefore, the electrospinning method and the solvent system for polymeric materials of the present invention are practical and are innovations in the field of nano fiber fabrication.
[0073] Although the present invention has been explained in relation to its preferred embodiment, 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 novel solvent system for dissolving rigid-rod like polymers, such as polybenzoxazole (PBO), is disclosed, wherein said solvent system includes: a methanesulfonic acid (MSA) and a trifluoroacetic acid (TFA). Therefore, the rigid-rod like polybenzoxazole (PBO) can be easily dissolved in said solvent system without extra heat treatment. Besides, the polybenzoxazole (PBO) solution of said solvent system is firstly able to apply into electrospinning at room temperature to produce PBO nano-fiber, which has metallic luster and high thermal stability. Evident supported by the WAXD suggested these fibers have their molecular chains well aligned along the fiber spinning direction and has the advantages of heat resistance, flame retardance, and chemical environmental resistance, thus can be applied to a wide usage. | 3 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention is directed to a system and method for notifying and dispatching employees. The notification system and method of the present invention may also be used as an accessory or addition to existing dispatch systems.
[0003] 2. Background of the Invention
[0004] Existing employee dispatch systems and methods include either a dispatcher (a person who receives and processes requests for services), or an automated dispatch system. These existing dispatch systems suffer from shortcomings and limitations that significantly detract from their usefulness and their efficient management of resources.
[0005] The limitations of current dispatch systems can be demonstrated by considering an example of a large public utility, such as a local telephone company that provides telephone services. Local telephone companies typically have tens of millions of customers, and those customers request new services or changes in services. These requests require the telephone company to dispatch technicians to service locations to make the requested changes in service.
[0006] On average, a local telephone company will make two and a half to three million service order dispatches per year. Generally, the productivity per task is about 2 hours, in other words, the requests for service generally take 2 hours to resolve. With this level of productivity, the local telephone company can only assign around four items per day per technician. Thus each truck dispatch is extremely costly to the local telephone company. It therefore becomes imperative that each dispatch is effective, i.e., each dispatch either actually resolves the problem or obtains information needed to resolve the problem.
[0007] Conventional automated dispatch systems very often assign tasks on a first-come, first-serve basis to the first available technician. As a technician completes or close out a job, the next job in the queue is automatically assigned to that technician. Occasionally, by happenstance, this first-come first-serve priority system would produce efficiencies where a second job would come to the technician after the first job was completed and the second job would happen to be in the same location as the first job. This would allow the technician to quickly complete a second job without having to drive to another location. Unfortunately, these efficiencies seldom occur and then only by pure chance. Oftentimes, in fact, that was not the case, and it would be very likely that a technician would leave the first location to travel to the next job site and a second technician would drive up to that first location to complete a second job there.
[0008] Moreover, in some cases a single problem causes multiple customers to lose service or experience poor service. For example, damage to pedestals that provide telephone service to multiple customers could cause several customers to report problems or loss of service. The pedestal often is located on the side of the road and provides a connection between a customer's location and serving centers. These pedestals are subject to damage, for example, from cars or even from state highway mowers. When damage to these pedestals occurs, the result is often that multiple outages occur in one locality. Generally, conventional reporting and dispatch systems address this problem by setting a certain tolerance threshold to indicate a probable common problem. For example, if the threshold were set at five, the system would require five or more similar complaints or reports of problems received from a common location to assume that a common problem was causing all of the problems reported by customers. If that threshold number of complaints or reports were met, then only a single technician would be dispatched to resolve the problem.
[0009] However, in those cases where the threshold for a system wide or regional problem is not met, as many (in the example provided above) as four technicians may be deployed to a single site causing enormous waste of resources and extreme expense to the company.
[0010] Also, customers often cancel appointments or request a modification in service. Sometimes these changes can occur at the last minute and existing systems have no way of informing the technician of these changes. These cancellations and modifications also waste technician resources, because technicians waste time waiting for customers or are required to return to the same location to make the modifications in service that the customer later requested.
[0011] Another source of ineffective use of technician resources is the lack of knowledge of customer service representatives. These representatives often lack an understanding of the costs associated with technician deployment and of the logistical complexities of managing and assigning a large number of technicians. They are generally trained to meet the customer's needs and to generate service orders. However, customer service representatives may occasionally create two different service orders for related or similar tasks. This could cause two dispatches to be generated and result in two technicians being deployed to the same location to fix what the service representative thinks are two different problems, but is instead only a single problem that could be handled by a single technician.
[0012] Dispatch systems that use a human dispatcher may permit real time modification of tasks and assignments. However, these dispatch systems, generally employed by taxicab companies, suffer significant drawbacks that would prevent them from being employed in large-scale environments. These dispatcher-based dispatch systems rely on a human dispatcher who is given information regarding demand (customers that need rides). The dispatcher uses this information combined with his or her knowledge of where all of the cabs are to assign the customer pick up to the nearest available cab. First, these dispatch systems are very expensive because a staff of well trained dispatchers are required to work around the clock, 24 hours a day, to match resources with demand. Second, the dispatcher-based systems are not practical for large-scale deployment because human dispatchers cannot accurately track hundreds, much less thousands, of technicians and their daily assignments. Finally, human dispatcher-based systems rely heavily dependent on the performance of the dispatcher or the dispatcher staff. Human error may produce an unacceptable level of errors.
[0013] Thus there is currently a need for a system that accommodates real time or near real time changes in load or demand by adjusting or reallocating resources to meet those changing needs. There is also need for such a system that is also automated, can handle a large number of technicians and requests for services, and inexpensively delivers information to the technician.
SUMMARY OF THE INVENTION
[0014] The present invention is designed to overcome the shortcomings of the prior art and to provide an effective and efficient dispatching system that can adjust resources to meet and accommodate real time changes in demand or load. The invention provides a system that notifies technicians of real time changes in their scheduled work. The system can determine if a real time intervention in a technician's schedule is necessary and can notify the technician in near real time of changes in assigned tasks. In this way, the invention adjusts the allocation of resources to meet real time changes in demand.
[0015] Once a technician has been dispatched to complete a task, the system monitors cancellations and changes that may be requested by the customer for that task. The system sends information to adjust the assignment of the technician to efficiently utilize the technician's time in situations where the customer has requested late or last minute cancellations or changes.
[0016] The system allows real time or near real time instructions to be sent to the technician. These instructions can include changes or modifications to the task assigned to the technician. The instructions can also include notices that the task has been canceled, or that the technician should complete the assigned task and then remain at that location to receive the next assignment.
[0017] The invention may include a system that considers the following information in determining if a real time intervention is necessary: information regarding the work history of the technician or the number of hours the technician has worked in a pay period, including the number of overtime hours, the availability of the technician, the qualifications of the technician, and the suitable locations where the technician is most beneficially dispatched.
[0018] An object of the present invention is to reduce or eliminate the inefficient use of technicians.
[0019] Another object of the present invention is to maximize the utilization of technicians.
[0020] Another object of the present invention is to provide a system that adjusts and reallocates resources to meet real time changes in load or demand.
[0021] Another object of the present invention is to provide real time or near real time information to a technician regarding the status of his assignments.
[0022] Additional features and advantages of the invention well be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practicing the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims as well as the appended drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0023] FIG. 1 is a schematic diagram of a preferred embodiment of the present invention.
[0024] FIG. 2 is a schematic diagram of another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a schematic representation of a preferred embodiment of the present invention. When a problem 102 arises and is reported to a notification system 104 , according to the present invention, notification system 104 reviews the qualifications of a number of technicians 106 , and selects the most suitable technician 108 to dispatch to the problem 102 .
[0026] Once the suitable technician 108 has been dispatched or is en route 110 to the problem, the invention allows real time or near real time instructions to be sent to the technician. These instructions can include changes or modifications to the task assigned to the technician 108 . Preferably, those instructions also include notices that the task technician 108 is currently heading towards has been canceled, or that the technician should complete the assigned task and then remain at that location to receive the next assignment.
[0027] In a preferred embodiment, the system 104 includes information regarding the work history of the technician or the number of hours the technician has worked in a pay period, including the number of overtime hours, the availability of the technician, the qualifications of the technician, and suitable locations to which the technician is most beneficially dispatched. In addition to considering all of these factors in deciding to send information to the technician 108 , the system 104 also monitors problem information and requests for service sent to the system by customers and customer service representatives. The system 104 analyzes requests for modifications to existing assignments and determines if a real time intervention is required. If a real time intervention is required, the system 104 sends a message to the technician 108 and informs the technician 108 of that information.
[0028] FIG. 2 is a preferred embodiment of the present invention in which various components have been assembled and linked together to provide a notification system 200 . The notification system 200 includes a dispatch unit 202 , a centralized call-out system (CCS) 206 , an employee scheduling program (ESP) 208 and a paging system 210 . The system 200 can communicate with various other devices, for example, an access unit 204 via access system 203 and pagers 212 via paging system 210 .
[0029] The dispatch unit 202 serves several functions. Dispatch unit 202 , according to this embodiment, receives information 201 about problems or requests for service from customers directly or through customer service representatives. These problems could include reports of downed lines, loss of service, poor service and other problems that affect the services rendered. Examples of requests for service include requests to modify or change the services rendered. In the specific context of a local telephone company, this could include requests to add additional telephone lines, to add DSL lines, to install additional telephone jacks, and other types of service. Preferably, the dispatch unit 202 receives information regarding problems or requests for service through customer service representatives who complete an interactive computerized form. Preferably, this information, which may include the customer's name, address, telephone number, billing information, and nature of problem, is communicated to the dispatch system 202 when a technician intervention is required.
[0030] Dispatch unit 202 communicates with one or more access units 204 via an access system 203 . The access system 203 , which is capable of wireless or wireline communications with access units 204 , also communicates with dispatch unit 202 . The access system 203 conveys information from the access units 204 to dispatch unit 202 . In an exemplary embodiment of the present invention, the Tech Plus system is used as the access system 203 . The Tech Plus system is disclosed in U.S. patent application Ser. No. 09/343,815, which is assigned to the same assignee as the present application, and is incorporated by reference herein. The access units 204 are preferably each associated with a technician. Preferably, each technician is assigned an access unit 204 and can use the access unit 204 to communicate with the dispatch unit 202 . For purposes of clarity, this disclosure will describe a single access unit 204 , but it should be kept in mind that many other access units 204 may be in communication with dispatch unit 202 . Dispatch unit 202 sends information regarding work assignments to the access unit 204 via access system 203 , which is capable of wireless or wireline communication with access unit 204 . In an exemplary embodiment of the invention, the dispatch system 202 is an LMOS™ (Loop Maintenance Operating System) created by Lucent Technologies.
[0031] Dispatch system 202 sends assignment information to access unit 204 via access system 203 and technicians use access unit 204 to retrieve assignment information. Access unit 204 is preferably equipped with a display 220 and an input portion 222 . Preferably, only one assignment is sent to the access unit 204 at a time and a second assignment is only sent after the first assignment has been completed or closed by the technician. Access unit 204 may also include provisions that allow technicians to retrieve infrastructure information. For example, in the context of a local telephone company, infrastructure information could include the number of lead pairs available to a particular location, the number of switches available and other information related to infrastructure. Access unit 204 may also include provisions that allow technicians to run tests on the customer's equipment.
[0032] The employee scheduling program (ESP) 208 communicates with dispatch unit 202 and centralized call-out system (CCS) 206 . ESP 208 contains a database that associates each technician with an employee or technician number and a system number. Preferably, the system number is an LMOS™ system number. The use of a system number is optional, but may be helpful where systems allow only three digit employee numbers and those same employee numbers must be used over again for different employees in different regions. Adding a regional designation or a system number allows each employee to have a unique identification. ESP 208 also includes a detailed database that contains schedule information for some or all of the technicians. ESP 208 preferably stores the scheduling information for all or some of the technicians for up to one year. Maintenance personnel preferably maintain, enter, and modify the schedules of technicians using the ESP 208 .
[0033] ESP 208 provides information regarding the availability of technicians to dispatch unit 202 . Preferably, ESP 208 provides technician numbers, system numbers, and scheduling information to dispatch unit 202 . The dispatch unit 202 preferably stores a detailed, but shorter time span of information regarding scheduling. While the preferred ESP may store a year of scheduling information, the preferred dispatch unit 202 may store only about three to five days of scheduling information. In addition to providing information to dispatch unit 202 , ESP 208 also provides information to CCS 206 . Preferably, ESP 208 provides technician numbers, system numbers, and scheduling information to CCS 206 .
[0034] Once CCS 206 receives information from ESP 208 , CCS 206 constructs a table or database that includes technician numbers, system numbers, pager numbers, and pager types. The pager numbers and pager types that are carried by the technicians are stored in CCS 206 , and CCS 206 associates these pager numbers and pager types with the additional information sent to it by ESP 208 . The pager numbers are associated with pagers worn or carried by technicians. CCS 206 is in communication with both the dispatch unit 202 and a paging system 210 .
[0035] In order to maximize the efficient use of resources, namely, the technicians and their time, the system 200 can dynamically adjust technician deployment to accommodate real time changes in load or demand for services. Notification system 200 accomplishes this by rapidly notifying technicians of information that could affect their work schedule as soon as possible, and by diverting technicians away from inefficient situations to locations where their talents and skills will be more effectively utilized. These notices to technicians can occur in near real time and even during the critical period after the technician has been dispatched to a job site.
[0036] In order to accomplish this near real time adjustment in technician deployment, system 200 preferably uses a number of different components. The following example of an adjustment demonstrates how system 200 can dynamically adjust technician deployment in near real time.
[0037] Initially, dispatch unit 202 is functioning in its normal routine. It receives problems or requests for service 201 , matches technicians based on the factors mentioned above, then transmits tasks and assignments to access unit 204 via access system 203 . As noted above, the dispatch unit 202 may assign tasks in any suitable manner. However, the preferred method of assignment considers several factors including commitment dates and time, severity of the outage, the revenue generated by the service order, and the availability of a close-by technician. Technicians are preferably assigned based upon geographic regions, which are areas bound by natural geographic barriers. Technicians who are geographically located closer to the task being the preferred dispatch technician. The technicians read the tasks and drive to those destinations to make the necessary repairs or changes in service. Occasionally, dispatch unit 202 will retrieve additional information from the ESP 208 and update its technician work schedules.
[0038] Dynamic adjustments occur when dispatch unit 202 is notified of a modification or change to a technician's schedule, or learns of a situation that could result in more efficient use of resources. Customers sometimes call their customer service representatives to notify them that they need to cancel, postpone or change a work request they had previously submitted. When this occurs, the customer service representative relays the information to dispatch unit 202 .
[0039] When the dispatch unit 202 receives the notification that a work request has been changed or modified, the dispatch unit 202 determines if an intervention by CCS 206 would be helpful. Any desired situation or condition that helps to prevent waste of technician resources or maximize technician utilization may be used by the dispatch unit 202 to determine if a CCS 206 intervention would be helpful.
[0040] Preferably, a condition where a technician has already been dispatched to a job site to an assigned task combined with a request for modification of that task is the condition used to determine a CCS 206 intervention. After dispatch unit 202 has determined that a CCS 206 intervention would be helpful, dispatch unit 202 communicates appropriate information to CCS 206 so that CCS 206 can provide real time adjustment information to the technician. Preferably, dispatch unit 202 communicates geographic information, that is, where in the service region the technician must go to respond to the request and where the technician is located or assigned; information associated with the technician, like the employee number and the technician's system number; and information related to the modification or change in schedule or task.
[0041] This information is used by CCS 206 to determine which technician should receive the information and what information that technician should receive. Once the identity of the technician and the adjustment information to be sent to the technician has been determined, CCS 206 communicates this information to a paging system 210 . Preferably, the information communicated to the paging system 210 includes the technician's pager number and an information code. CCS 206 can also preferably send a text message, if the technician's pager is capable of receiving text messages.
[0042] The paging system 210 receives the information from CCS 206 and sends a page to the technician's pager 212 . After the technician has been paged, the technician can review the information displayed on pager 212 and act accordingly.
[0043] Some of the preferred messages that are sent to technicians include codes that inform the technicians that a job has been canceled or modified. Another code that can be sent to the technician informs the technician that the next job will be at the same or nearby location. In essence, this code is a “remain where you are and standby for the next job” command. Obviously, if a customer wants to cancel a previously scheduled service order, the cancel code will be transmitted. Similarly, if a customer wants to change or modify a previously scheduled service order, the change or modify code will be transmitted to the technician. When the technician receives the change or modify code, the technician is preferably trained to retrieve the new job from the access system 204 . Finally, if the system 200 determines that it would be beneficial for the technician to remain at a certain location after a job has been completed, the remain code will be transmitted. In an exemplary embodiment of the present invention, the cancel code is 333, the modify or change code is 444 and the remain code is 555.
[0044] Any of the various components or sub-steps disclosed above can be used either alone, or with other existing components, or with components or features of the present invention.
[0045] It will be apparent to those skilled in the art that various modifications and variations can be made to the dynamic carrier selection system of the present invention without departing from the spirit or scope of the invention.
[0046] The foregoing disclosure of embodiments of the present invention has been presented for purposes of illustration and description. It is not exhaustive or intended to limit the invention to the precise forms disclosed herein. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents. | A dispatching system adjusts resources to meet real-time changes in demand. When a customer requests service, a work assignment is generated and sent to an employee. When a customer cancels the requested service, a cancelation code is sent to the employee. The cancelation code informs the employee that the work assignment has been canceled. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2012/054374, filed Mar. 13, 2012, which designated the United States and has been published as International Publication No. WO 2012/136449 and which claims the priority of European Patent Application, Serial No. 11160956.6, filed Apr. 4, 2011, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present invention relates to a method for installing an electric machine, in particular a generator for a wind turbine generator system. The present invention also relates to such an electric machine with a stator and a rotor.
Wind turbine generator systems are generally equipped with relatively large generators. These generators are often not installed until they are on site. This applies in particular to two components of the generator, namely the rotor and the stator. This is irrespective of whether an external stator and internal rotor are used, or an external rotor and internal stator.
Since the rotor is normally equipped with permanent magnets it constantly exerts a magnetic force on the stator components. The consequence is that the components of the stator are difficult to position and install opposite the components of the rotor. These problems are particularly severe for direct-drive wind turbines that have a very large diameter.
Up to now, there have been installation methods in which the rotor is preinstalled as a complete unit and, in the case of an internal rotor, is then surrounded on site with stator segments which together constitute a complete stator ring. Such segmented machines have a joint between the segments. Before the segments are bolted the joints have to be padded out with plates of appropriate thickness to produce a continuous ring. This padding of the joints calls for great skill and experience. It often presents problems on site in the open air.
SUMMARY OF THE INVENTION
The object of the present invention is to propose a method for assembling an electric machine which is easy to implement and enables the various components to be easily transported to the assembly site. In addition, a suitable electric machine is proposed.
According to the invention, this object is achieved by a method for assembling an electric machine, in particular a generator for a wind turbine generator system, by
assembling one inner segment on multiple outer segments with the aid of at least one fixing element in each case so that multiple segment modules are produced, in which there is a predefined air gap between the inner segment and the outer segment, and in which the inner segments and outer segments are ring segments and are assigned to the rotor or stator of the generator, fastening the inner segments of the multiple segment modules to an inner assembly device so that the segment modules form a complete ring, fastening the outer segments of the multiple segment modules to an outer assembly device, and removing the fixing elements between the inner segments and the outer segments.
In addition, according to the invention an electric machine is provided in particular for a wind turbine generator system with
a stator and a rotor, in which the rotor and stator of the electric machine each have inner segments that can be separated from each other or outer segments that can be separated from each other, the inner segments and outer segments are ring segments, each inner segment is assigned to one of the multiple outer segments, between the inner segments and the outer segments there is a predefined air gap, the inner segments are fastened to an inner assembly device to form a ring, and the outer segments are fastened to an outer assembly device to form a ring.
The method according to the invention beneficially fixes inner and outer segments to one another in pairs in a pre-assembly stage, in which the two are separated from one another by a predefined air gap. This produces a ring-segment-shaped segment module which has a rotor segment and a stator segment. Such segment modules are easier to handle than a completely preassembled rotor, for example. In addition, the segments have a fixed spacing from one another so there is automatically the correct air gap between the rotor and the stator when the segment modules are then assembled to form a complete ring. By contrast, constant checks are needed in the conventional assembly method to ensure that the desired air gap is maintained.
The inner segments and/or the outer segments are preferably fixed to one another in the circumferential direction. This direct assembly in the circumferential direction means that they are coupled to one another not only indirectly via the inner and outer assembly devices. This improves the strength of the rotor and stator.
In addition, the inner segments and/or outer segments may have a flange for fixing to the inner assembly device (e.g. hub) or outer assembly device. For example, such a flange enables the inner segments to be fixed to the hub of the electric machine. In this case, the flange protrudes radially inwards from the inner segments. In the case of the outer segments the flange can protrude radially outwards so that they can be fastened to an appropriate outer ring.
According to a development, there is provision that each of the inner segments and outer segments extends in the circumferential direction across a first angle range, each of the inner segments and outer segments has a flange, and each flange extends across a smaller angle range than the first angle range. This ensures that the flange segments do not strike one another during assembly and do not therefore lead to undesired large joints between the segment modules.
In addition, the segment modules can be fastened to the inner assembly device and the outer assembly device so that a gap remains between neighboring segment modules in the circumferential direction. This intentional gap serves to offset any tolerances. As a result, less precise tolerances can be maintained in manufacturing the segment modules, i.e. the stator segments and rotor segments. There are cost benefits in manufacture here.
A connecting element can be inserted in each gap between the segment modules to connect the adjacent segments to one another. Each connecting element may comprise several components, e.g. plates. This enables gaps of different widths due to manufacturing tolerances to be filled precisely.
A sealing element may also be inserted in each gap from the outside. Such sealing elements ensure that for example no moisture or dirt can enter the air gap of the electric machine through the tolerance gap.
BRIEF DESCRIPTION OF THE DRAWING
The present invention is explained below with reference to the appended drawings where:
FIG. 1 shows a side view of a segment module according to the invention;
FIG. 2 shows a section through a hub on which multiple segment modules are assembled; and
FIG. 3 shows an enlarged section of a joint between two segment modules.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The exemplary embodiments described below are preferred embodiments of the present invention.
A direct-drive wind generator, for example, is to be manufactured with a large inner rotor and a correspondingly large outer stator. The manufacturing process can be used however for any other electric machine, irrespective of whether it has an inner rotor or outer rotor.
The core concept of the present invention is that both the stator and the rotor are segmented and the segments are preassembled in pairs to form a module. The purpose of this segmentation and preassembly is to simplify transport and final assembly at the intended location, which is beneficial in particular for offshore wind turbine generator systems.
FIG. 1 shows a side view of a segment module 1 according to the invention. Eight such segment modules form a complete ring. Consequently each segment module extends across an angle range of 45°. Obviously the segment modules can be larger or smaller in terms of the angle dimensions. In particular, a segment module may extend over 90° or 180°.
The segment module 1 here has an outer segment 2 and an inner segment 3 . Since the electric machine in this example has an inner rotor, the outer segment 2 here is a stator segment and the inner segment 3 is a rotor segment. The rotor or inner segment 3 in FIG. 1 has permanent magnets 4 , shown symbolically. An annular air gap 5 lies concentrically between the ring-segment-shaped outer segment 2 and the ring-segment-shaped inner segment 3 .
The outer segment 2 and the inner segment 3 are fixed to one another by fixing elements 6 in order to ensure an air gap 5 . In the present case, two fixing elements 6 can be seen. In order to achieve a stable segment module there are two such fixing elements, for example, on both faces of the segment module. More than two fixing elements per face may be provided. It is also possible for the fixing elements 6 to extend axially through the segment module 1 so that in this case only two such fixing elements 6 are necessary.
The fixing elements 6 can be moved in the axial direction from the segment module 1 . They not only provide retention during transport but also ensure a defined air gap width.
A flange segment 7 is attached to the inside of the inner segment 3 . The flange segment protrudes radially inwards and extends essentially across the same angle range as the outer segment 2 and the inner segment 3 . It also has axial holes 8 for fastening purposes.
Such segment modules 1 are now fastened to a hub 9 for example according to FIG. 2 . In the view here only half of the hub 9 is shown so only a half-ring can be seen. The hub 9 may for example be a hollow shaft. On its face here it has holes 10 evenly distributed in the circumferential direction. They are used for bolting on the flanges 7 of the inner segments 3 of the segment modules 1 . During assembly, the individual segment modules 1 are mounted radially on the hub 9 according to the arrows 11 so that ultimately a complete electric machine with a rotor and a stator is produced.
The entire assembly procedure for the electric machine consists of the following four basic steps:
a) The segment modules 1 including the outer segment 2 and inner segment 3 and fixing elements 6 and possibly including the flange 7 are preassembled and transported to the final destination. b) The segment modules 1 are mounted on an inner assembly device, e.g. hub. c) The segment modules 1 are fastened to an outer assembly device, e.g. a stator support unit. d) The fixing elements 6 are removed so that the rotor (hub 9 and inner segments 3 ) can rotate with respect to the stator (outer segments 2 ).
The preassembly and provision of segment modules 1 has the advantage that the air gap 5 can be set at the factory. It is maintained during assembly by the fixing elements 6 and is retained at the end of assembly after removal of the fixing elements 6 . The fixing elements 6 absorb in particular the forces that the permanent magnets 4 of the rotor segment 3 exert on the stator segment 2 .
Both the stator segment 6 and the rotor segment 3 extend across the same angle range here, e.g. 45°. The flange 7 attached radially inwards on the inner rotor or inner segment 3 is also arc-shaped and, in a special embodiment, does not extend across the entire angle range covered by the inner segment 3 , which means that excessively large gaps between the individual segment modules 1 cannot arise in the assembled state as a result of different tolerances.
During assembly the paired segments, i.e. the segment modules 1 , as mentioned, are first positioned on the hub and fixed. In the case of an inner rotor the hub 9 rotates; in the case of an outer rotor this hub 9 is part of the supporting structure. In each case the inner segments 3 are centrically aligned. Since the outer segments 2 (stator in the case of an inner rotor, or rotor in the case of an outer stator) are fixed via the air gap 5 precisely on the inner segments 3 (fixing elements 6 ), these are also aligned and an air gap 5 of constant size is ensured. Manufacturing tolerances are compensated by the joints 12 between the segment modules 1 . FIG. 3 is an enlarged view of such a joint 12 .
An outer flange, not shown in FIG. 2 , on each segment module 1 does not have a centering property so there is no redundancy. Instead, the outer segments 2 are connected with the central flange in a force fit (stationary component of the turbine in the case of an inner rotor; rotating component in the case of an outer rotor). All the tolerances in the tangential direction are compensated by the joints 12 between the segment modules 1 .
The individual segment modules 1 are connected directly with one another in the circumferential direction via a force-fit or form-fit connection. The joints 12 between the segment modules 1 are padded with plates for example for this purpose and the neighboring segment modules are then bolted together.
To ensure that the outer segments 2 for a tight casing the joints 12 can be sealed. A rubber sealant or similar with sufficient elasticity can be provided between the outer segments 2 . During preassembly of the segment modules 1 , for example, O-rings can be inserted in the outer segments 2 at the edges and fixed with adhesive.
On the basis of the assembly concept and the design details described here it is possible to assemble a segmented electric machine (for example a direct-drive wind turbine generator) away from the actual production site (for example immediately at the erection site for the wind turbine) without having to conduct the time-consuming alignment of the stator and rotor segments with respect to one another which would otherwise be needed with segmented electric machines, There is also no need to pad the joints between the segments or segment modules. | In a method an inner segment is first pre-assembled on each of a number of outer segments by at least one fixing element, so as to produce a plurality of segment modules having each a predetermined air gap between the inner segment and the outer segment. The inner segments and the outer segments are assigned to the rotor or stator of the electrical machine. The inner segments of the plurality of segment modules are fastened to an inner assembly device (for example a hub). The outer segments of the plurality of segment modules are fastened to an outer assembly device (for example a supporting structure). Finally, the fixing elements between the inner segments and the outer segments are removed. | 8 |
BACKGROUND OF THE RELATED ART
[0001] 1. Field of the Invention
[0002] The present invention relates to a device and a method for identifying a human face.
[0003] 2. Description of the Related Art
[0004] A conventional method for identifying a person (i.e. determining whose face is included) involves comparing registered information, such as feature values and performing a comparison between this information and a identification image. However, if conditions are not suitable for identification, that is, if a subject wears an article covering all or a part of the face such as sunglasses or a mask (hereinafter referred to as a “worn article”), or the lighting environment is too dark or too bright, or the subject faces sideways, the identification accuracy decreases.
[0005] In order to solve such a problem, it has been proposed that face identification devices corresponding to various face directions be prepared, that the face direction be detected in an identification image, and that a suitable face identification device be used (see to Pose Invariant Face Recognition, by F. J. Huang, Z. Zhou, H. Zhang, and T. Chen, Proceedings of the 4 th IEEE International Conference on Automatic Face and Gesture Recognition, Grenoble, France, 2000, pp. 245-250.) Further, Laid-Open Japanese Patent Application No. 2000-215308 proposes providing an illumination sensor that senses the light intensity at the time of photography and also proposes that algorithms for extracting feature values and algorithms for identification are selected based on the light intensity previously determined. As such, for a plurality of functions relating to extraction of feature values and identification provided as mentioned above, image registration, algorithm tuning, studying of various parameters etc., must be performed for each of the functions.
[0006] Further Japanese Patent Publication No. 2923894, Laid-Open Japanese Patent Application No. 2002-015311 and 2003-132339 all discuss methods for maintaining identification accuracy in which an image or feature value determined when there are no unfavorable conditions is used to restore an image in which there are unfavorable conditions. However, with these methods, additional processing time is necessary and the accuracy of the restoration procedure is not guaranteed.
SUMMARY
[0007] A first embodiment according to the invention is a face identification device, including a storage unit, a face detection unit, a feature value obtainment unit, a reliability determination unit and a identification unit. The storage unit stores a plurality of feature values previously obtained from a face image of a registrant. The storage unit may be configured to store feature values of one registrant or feature values of a plurality of registrants. The face detection unit detects the face of a person from the input image. The feature value obtainment unit obtains a plurality of feature values from the detected face.
[0008] The reliability determination unit determines reliability of each feature value from the input image. Reliability is a value indicating how reliable the result obtained from identification processing is, when identification processing is performed by using the feature value. That is, if the subject in the input image faces sideways or wears a worn article such as sunglasses for example, it is difficult to accurately obtain specific feature values from the image. In such a case, if all feature values are used with similar weighting in identification processing, deterioration in identification accuracy may be caused. Therefore, the reliability determination unit decides reliability for each feature value, and hands over the reliability to the identification unit, which performs identification to prevent the identification accuracy from deteriorating. Note that a specific processing example of the reliability determination unit will be described later.
[0009] The identification unit identifies the detected face with the face of the registrant stored on the storage unit, by comparing the feature values stored on the storage unit with the feature values obtained from the detected face while taking into account the reliability of each feature value. That is, the identification unit performs identification while performing weighting based on the reliability of each feature value.
[0010] In a face identification device configured as described above, identification is performed based on the reliability determined for each feature value. Therefore, even when a specific feature value cannot be obtained with high accuracy, it is possible to prevent the identification accuracy from deteriorating by reducing the weighting or disregarding the feature value when performing identification.
[0011] The face identification device according to a second embodiment of the present invention may be configured to further include a partial area deciding unit for deciding a plurality of partial areas in an area including the detected face. In such a case, the storage unit may store a plurality of feature values previously obtained for respective partial areas from the face image of the registrant. Further, in such a case, the feature value obtainment unit may obtain the feature value from each partial area of the input image. Additionally, the identification unit may calculate a score of each partial area for the registrant by comparing the feature value of the registrant stored on the storage unit with the feature value obtained by the feature value obtainment unit for each partial area, and based on the score and the reliability, may identify the detected face with the face of the registrant stored on the storage unit.
[0012] The face identification device according to a third embodiment of the present invention may be configured to further include a direction determination unit for determining the direction of the detected face. In such a case, the reliability determination unit may determine the reliability of each feature value corresponding to the direction of the detected face.
[0013] The face identification device according to a fourth embodiment of the present invention may be configured to further include a brightness determination unit for determining the brightness of a part in which each feature value is to be obtained or the surrounding thereof. In such a case, the reliability determination unit may determine the reliability of each feature value corresponding to the brightness.
[0014] The face identification device according to a fifth the present invention may be so configured as to further include a worn article determination unit for determining whether a worn article is included with the detected face. In such a case, the reliability determination unit may determine the reliability of each feature value corresponding to whether a worn article being worn and a part where the worn article is worn.
[0015] The face identification device according to a sixth embodiment of the present invention may be so configured as to further include a direction determination unit for determining the direction of the detected face. In such a case, the partial area deciding unit may decide a range of each partial area corresponding to the direction of the detected face.
[0016] Several embodiments of the present invention may be implemented as a program for causing processing performed by each unit described above to be executed with respect to an information processor, or a recording medium on which the program is written. Further, a seventh embodiment according to the present invention may be specified as a method in which processing performed by each unit described above is executed by an information processor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows a function block examples of a face identification device;
[0018] FIG. 2 shows a specific example of partial areas;
[0019] FIGS. 3A to 3 E show examples of face directions;
[0020] FIG. 4 shows an example of a reliability table corresponding to the face directions of the subject;
[0021] FIGS. 5A to 5 C show examples of effects of lighting environment;
[0022] FIG. 6 shows an example of a reliability table corresponding to the effects of lighting environment;
[0023] FIGS. 7A to 7 C show examples of effects of worn articles;
[0024] FIG. 8 shows an example of a reliability table corresponding to the effects of the worn articles;
[0025] FIG. 9 shows a flowchart showing an exemplary operation of a face identification device; and
[0026] FIG. 10 shows an example of distortion corresponding to a face direction.
DETAILED DESCRIPTION
[0027] FIG. 1 shows function block examples of a face identification device 1 . The face identification device 1 obtains feature values (e.g., brightness distribution and histogram) of a face from an image (identification image) in which a human who is the identification subject is captured, and compares them with the feature values of each person having been registered to determine who the person in the identification image is. The face identification device 1 includes, as hardware, a CPU (Central Processing Unit) connected via a bus, a main memory (RAM) and an auxiliary memory.
[0028] The face identification device 1 includes an image input block 2 , an image storage block 3 , a face detection block 4 , a feature point detection block 5 , a state determination block 6 , a partial area deciding block 7 , a reliability storage block 8 , a reliability determination block 9 , a registered information storage block 10 and a face identification block 11 . Various programs (OS, applications, etc.) stored on the auxiliary memory are loaded to the main memory and executed by the CPU. The face detection block 4 , the feature point detection block 5 , the state determination block 6 , the partial area deciding block 7 , the reliability determination block 9 and the face identification block 11 are realized when the programs are executed by the CPU. Further, the face detection block 4 , the feature point detection block 5 , the state determination block 6 , the partial area deciding block 7 , the reliability determination block 9 and the face identification block 11 may be configured as a dedicated chip. Next, respective functional blocks included in the face identification device 1 will be described.
[0029] The image input block 2 works as an interface for inputting data of a identification image to the face identification device 1 . By the image input block 2 , data of a identification image is input to the face identification device 1 . The image input block 2 may be configured by using any existing technique for inputting data of a identification image to the face identification device.
[0030] For example, data of a identification image may be input to the face identification device 1 over a network (e.g., local area network or the Internet). In such a case, the image input block 2 is configured by using a network interface. Further, data of a identification image may be input to the face identification device 1 from a digital camera, a scanner,. a personal computer, a recording device (e.g., hard disk drive) or the like. In such a case, the image input unit 2 is configured corresponding to a standard (e.g., standard for a wire connection such as USB (Universal Serial Bus) or SCSI (Small Computer System Interface) or wireless connection such as Bluetooth (registered trademark)) for connecting the face identification device 1 with a digital camera, a scanner, a personal computer, a recording device or the like in a manner enabling data communications. Further, data of a identification image written on a recording medium (e.g., any kind of flash memory, flexible disk, CD (Compact Disk), DVD (Digital Versatile Disc, Digital Video Disc)) may be input to the face identification device 1 . In this case, the image input unit 2 is configured by using a device for reading out data from the recording medium (e.g., flush memory reader, flexible disc drive, CD drive or DVD drive).
[0031] Further, the face identification device 1 may be incorporated in an image capturing apparatus such as a digital camera or any kind of apparatus (e.g., PDA (Personal Digital Assistant) or mobile telephone), and data of a captured identification image may be input to the face identification device 1 . In this case, the image input block 2 may be configured using a CCD (Charge-Coupled Device), a CMOS (Complementary Metal-Oxide Semiconductor) sensor or the like, or configured as an interface for inputting data of a identification image captured by a CCD or a CMOS sensor to the face identification device 1 . Moreover, the face identification device 1 may be incorporated in an image output device such as a printer or a display, and image data input into the image output device as output data is input into the face identification device 1 as an identification image. In this case, the image input block 2 is configured using a device for converting the image data input to the image output device into data which can be handled in the face identification device 1 .
[0032] Further, the image input block 2 may be configured to be able to cope with the multiple cases mentioned above.
[0033] The image storage block 3 is configured using a memory. As a memory used as the image storage block 3 , any specific technique may be applied such as a volatile memory or a nonvolatile memory.
[0034] The image storage block 3 stores data of a identification image input via the image input block 2 . Data of an identification image stored on the image storage block 3 is read out by the face detection block 4 , the feature point detection block 5 , and the partial area deciding block 7 . The image storage block 3 holds data of the identification image, which is the subject of the processing, until processing at least performed by the face detection block 4 , the feature point detection block 5 , the state determination block 6 , the partial area deciding block 7 and the face identification block 11 has been completed.
[0035] The face detection block 4 reads data of a identification image from the image storage block 3 , and detects the human face from the identification image, and specifies the position and the size of the detected face. The face detection block 4 may be configured so as to detect the face by template matching using a reference template corresponding to the contour of the whole face, or configured so as to detect the face by template matching based on organs (eyes, nose, ears, etc.) of the face. Alternatively, the face detection block 4 may be configured so as to detect the vertex of the head or the like by chroma-key processing to thereby detect the face based on the vertex. Alternatively, the face detection block 4 may be configured so as to detect an area of a color similar to the skin color to thereby detect the area as the face. Alternatively, the face detection block 4 may be configured so as to perform learning by teacher signals using a neural network to thereby detect a face-like area as the face. Further, face detection processing by the face detection block 4 may be realized by applying any other existing techniques.
[0036] Further, if faces of multiple people are detected from an identification image, the face detection block 4 may decide which face is to be the subject of processing according to predetermined criteria. Predetermined criteria include face size, face direction, and face position in an image.
[0037] The feature point detection block 5 detects a plurality of feature points for a face detected by the face detection block 4 . Any of the existing feature point detection technique may be applied to the feature point detection block 5 . For example, the feature point detection block 5 may be configured so as to previously learn patterns showing the positions of face feature points and perform matching using the learned data to thereby detect feature points. Alternatively, the feature point detection block 5 may be configured so as to detect edges and perform pattern matching inside the detected face to thereby detect end points of the organs of the face, and by using them as references, detect feature points. Alternatively, the feature point detection block 5 may be configured so as to previously define shapes or texture models such as AAM (Active Appearance Model) and ASM (Active Shape Model), and by deforming them corresponding to the detected face, detect feature points.
[0038] The state determination block 6 determines, relating to the face detected by the face detection block 4 , whether any unfavorable condition for identification has been caused, and if caused, determines the level. For example, the state determination block 6 may determine the angle of the direction of the detected face. Such a determination can be performed in the following manner, for example. First, the state determination block 6 obtains corresponding relationships between face images or parts thereof and face directions and corresponding relationship between arrangements of feature points of the face and face directions, for example, by learning them previously, to thereby be able to know the angle of the direction of the corresponding face. Such a determination of angle may be performed by applying another technique.
[0039] Further, the state determination block 6 may determine the effect of a lighting environment. Such a determination can be performed in the following manner for example. First, the state determination block 6 obtains the brightness for each partial area decided by the partial area deciding block 7 described later. Then, the state determination block 6 determines for each partial area that to what degree it is dark or bright. Alternatively, the state determination block 6 may perform processing in the following manner. First, the state determination block 6 sets a point or an area corresponding to each partial area in the detected face, and obtains the brightness for each of them. The state determination block 6 may be configured to determine darkness or brightness for each partial area based on the obtained brightness. Further, determination of the effect of such a lighting environment may be performed by applying another technique.
[0040] Further, the state determination block 6 may determine whether there is any worn article. Such a determination can be performed in the following manner, for example. First, the state determination block 6 previously performs learning based on an image in which a worn article, such as sunglasses or a mask, is worn. Then, the state determination block 6 performs detection processing based on the learning in the face detected by the face detection block 4 , and if any worn article is detected, determines that the worn article is worn. Alternatively, the state determination block 6 may be configured so as to obtain templates and color information about worn articles and perform detection by obtaining the correlation thereto. Alternatively, based on an empirical rule that entropy and dispersion deteriorate if the subject wares a worn article such as sunglasses or a mask, the state determination block 6 may be configured so as to detect by using a substitute index such as entropy. Further, if a worn article is detected, the state determination block 6 may be configured so as to obtain a value (concealment ratio) to what degree the face is concealed by the worn article. The concealment ratio can be obtained by examining to what degree the feature points of an organ likely to be concealed can be detected near the part where the worn article is detected, for example.
[0041] Further, the state determination block 6 may be configured to obtain the information amount included in the image of each partial area, for each partial area decided by the partial area deciding block 7 described later. The information amount can be shown as entropy for example. Alternatively, the information amount may be shown as relative entropy or KL (Kullback Leibler) divergence of the same partial area in an ideal image having sufficient information amount.
[0042] The partial area deciding block 7 designates partial areas based on positions of the plural feature points detected by the feature point detection block 5 . A partial area is an area which is a part of a face image. For example, the partial area deciding block 7 may be configured so as to designate a polygon such as a triangle having feature points at the respective vertexes as a partial area.
[0043] FIG. 2 shows specific examples of partial areas. In FIG. 2 , three partial areas 101 , 102 and 103 indicated by rectangles are designated by the partial area deciding block 7 . The partial area 101 is a part including the right eye and the surrounding thereof of the subject. The partial area 102 is a part including the left eye and the surrounding thereof of the subject. The partial area 103 is a part including the nose and the surrounding thereof of the subject. The partial area deciding block 7 may be configured to designate partial areas different from them, or to designate more partial areas.
[0044] The reliability storage block 8 is configured by using a storage device. The reliability storage block 8 stores a reliability table. The reliability table contains reliability values for respective partial areas in various conditions. Reliability is a value showing to what degree the result obtained from identification processing is reliable when identification processing is performed using the feature value of the partial area. In the following description, the reliability value is indicated as a value in a range of 0 to 1, in which the reliability is lower as the value becomes close to 0, and the reliability is higher as the value becomes close to 1. Note that values of the reliability may be continuous values or discrete values.
[0045] First, reliability corresponding to a face direction of the subject will be described. FIGS. 3A to 3 E show examples of face directions. As shown in FIGS. 3A to 3 E, in the present embodiment, angle is expressed such that the right side for whom viewing the identification image indicates positive value and the left side indicates negative value. FIGS. 3A to 3 E show examples of the face of the subject facing − 60 °, 30 °, 0 °, + 30 ° and +60°, respectively. FIG. 4 shows a specific example of a reliability table 8 a corresponding to the face directions of the subject. The reliability table 8 a in FIG. 4 shows reliabilities in the respective partial areas 101 to 103 for the respective face directions (θ).
[0046] Explanation will be given exemplary for the case of −60°. Almost all part of the left eye of the subject appears in the image, but the half of the right eye is hidden. Therefore, compared with the reliability of the partial area 102 corresponding to the left eye, the reliability of the partial area 101 corresponding to the right eye is set substantially lower. Further, in the case of −30°, the right eye appears in the image to some extent, compared with the case of −60°. Therefore, for the reliability in the partial area 101 , the case of −30° is set higher than the case of −60°. Further, the feature value used in identification (feature value stored on the registered information storage block 10 described later) is generally a feature value obtained from a full-face image. Therefore, if the face of the subject faces sideways in the identification image, the accuracy deteriorates due to distortions being caused or the like, irrespective of all feature points in the partial area appearing on the image or not. Accordingly, the reliability of each partial area 101 to 103 is set lower as the angular absolute value increases.
[0047] Next, explanation will be given for a reliability table corresponding to effects of lighting environments. FIGS. 5A to 5 C show specific examples of effects of lighting environments. In FIG. 5A , the whole face of the subject is lighted uniformly. On the other hand, in FIG. 5B , the left side of the face of the subject is lighted but the right side is shadowed. Therefore, in FIG. 5B , the surrounding part of the right eye is shadowed, so it is difficult to obtain the accurate feature value in the partial area 101 . Further, in FIG. 5C , the right side of the face of the subject is lighted properly but the left side is lighted excessively, causing halation. Therefore, in FIG. 5C , halation is caused in the part of the left eye, so it is difficult to obtain the accurate feature value in the partial area 102 .
[0048] FIG. 6 shows a specific example of a reliability table 8 b corresponding to the effects of lighting environments. In this example, relationship between lighting environment and reliability is defined for all partial areas in common. In any partial area, reliability is decided depending on how many percentages of the area being shadowed or caused halation (e.g., may be expressed by using concealment ratio).
[0049] Next, explanation will be given for a reliability table corresponding to effects of worn articles. FIGS. 7A to 7 C show specific examples of the effects of worn articles. In FIG. 7A , the subject does not have a worn article on the face, so the features in all partial areas appear on the image. On the other hand, in FIG. 7B , the subject wares sunglasses, so the right and left eyes are concealed, making it difficult to obtain the accurate feature value in the partial areas 101 and 102 . Further, in FIG. 7C , the subject wares a mask, so the nose, mouth, cheeks etc., are concealed, whereby it is difficult to obtain the accurate feature value in the partial area 103 .
[0050] FIG. 8 shows a specific example of a reliability table 8 c corresponding to the effects of worn articles. In this example, if sunglasses are worn, the reliability of the partial areas 101 and 102 is 0, and the reliability of the partial area 103 , not affected by the sunglasses, is 1. On the other hand, if a mask is worn, the reliability of the partial area 103 is 0, and the reliability of the partial area 101 and 102 , not affected by the mask, is 1. Values in the reliability table 8 c are not necessarily limited to “0” and “1”, but may be expressed by using other values (e.g., “0.1” and “0.9”).
[0051] Next, explanation will be given for a reliability table corresponding to the information amount obtained for each partial area. In this case, the reliability table is configured so that the reliability becomes closer to 1 as the information amount increases, and the reliability becomes closer to 0 as the information amount decreases.
[0052] The reliability determination block 9 determines the reliability of each partial area decided by the partial area deciding block 7 , based on the determination results by the state determination block 6 and the reliability tables stored on the reliability storage block 8 . If it is determined by the state determination block 6 that a plurality of adverse effects exist, the reliability determination block 9 may be configured so as to calculate statistics (average, center of gravity, etc.) of the reliabilities corresponding to the respective conditions and decide them as the reliabilities. Further, priority may be set for the respective conditions, and the reliability determination block 9 may be configured so as to decide the reliability obtained for the condition of the highest propriety as the reliability of the partial area.
[0053] The registered information storage block 10 is configured using a storage device. The registered information storage block 10 stores a registered information table. The registered information table includes the feature value of each partial area for each ID of a person who is to be the subject of identification. In the registered information table, for the feature value corresponding to an ID “A” for example, the feature value of the partial area 101 , the feature value of the partial area 102 and the feature value of the partial area 103 are associated.
[0054] The face identification block 11 performs identification processing based on the feature values obtained from the respective partial areas, the feature values stored on the registered information storage block 10 , and the reliabilities decided by the reliability determination block 9 . Hereinafter, processing by the face identification block 11 will be described specifically. In the following description, the number of partial areas is not limited to three but is assumed as N pieces.
[0055] First, the face identification block 11 calculates the final scores for all IDs stored on the registered information storage block 10 . The final score is calculated by executing score calculation processing and final score calculation processing using the calculated scores.
[0056] In the score calculation processing, the face identification block 11 calculates scores of respective partial areas (j=1, 2, . . . , N). A score is a value calculated based on the feature value obtained from each partial area, indicating the possibility that the subject having the partial area is a specific subject. For example, a large score is obtained if the possibility is high and a small score is obtained if the possibility is low.
[0057] The score of each partial area can be calculated according to Equation 1 for example. Equation 1 indicates the probability P(ψ j |x j , θ) that the person (face) is the subject person when a feature value x j in a partial area j is obtained under a condition θ. However, ξ is a hyper parameter, which is a probability variable indicating how much the feature value obtained under the condition θ deviates from a feature value which should be obtained originally under an ideal condition (deviance). ψ is a probability variable indicating the ID of a registrant. Although the deviance ξ is treated as a discrete variable in Equation 1, it may be a continuous variable. Further, although a common condition θ is used for all partial areas in Equation 1, a different condition θ j may be used for each partial area of course.
P ( ψ j | x j , θ ) = ∑ ξ P ( ψ j | x j , ξ ) P ( ξ | θ ) ( Equation 1 )
[0058] P(ψ j |x j , ξ) indicates a value (score not taking into account the condition θ) which can be obtained by comparing the feature values obtained from partial areas of the image with the feature values stored on the registered information storage block 10 . This value is, for example, the similarity between both feature values. The similarity can be obtained by applying a face identification technique conventionally used. For example, normalized correlation of brightness distribution and histogram intersection of color histogram can be obtained as similarity.
[0059] On the other hand, P(ξ|θ) indicates reliability decided by the reliability determination block 9 . That is, it is a value indicating reliability (or accuracy) of the feature value x j obtained in a partial area j under the condition θ (or similarity calculated from the feature value x j thereof). The reliability takes a smaller value as the condition θ becomes worse.
[0060] In other words, P(ψ j |x j , θ) in Equation 1 can be a value (adjusted score) obtained by adjusting the similarity P(ψ j |x j , ξ) between the feature value of the subject and the feature value of the registrant, based on the state of the subject (reliability) P(ξ|θ). In the final score calculation processing described later, the final score used for final evaluation is calculated from the adjusted scores of the respective partial areas. For the final score, a greater effect is given to a score having high reliability. Therefore, the reliability P(ξ|θ) can be considered to be “weighting” when the final score is calculated.
[0061] When the score calculation processing has been completed, the face identification block 11 then performs the final score calculation processing. In the final score calculation processing, the face identification block 11 calculates the final score on the basis of the scores obtained from the respective partial areas. Equation 2 is an equation for calculating the final score in the case where the respective partial areas are considered as independent. Equation 3 is an equation for calculating the final score based on Bagging model or Mixture of Experts model, from which the final score can be obtained as the average of the scores of a local area. The face identification block 11 calculates the final score by using Equation 2 or 3, for example. Equations 2 and 3 are specific examples of processing capable of being applied in calculating the final score. The final score may be obtained by another processing. For example, the face identification block 11 may be so configured as to obtain the maximum value of the scores obtained from the respective partial areas as the final score.
P ( ψ | x , θ ) = ∏ j N P ( ψ j | x j , θ ) ( Equation 2 ) S ( ψ | x , θ ) = 1 N ∑ j N P ( ψ j | x j , θ ) ( Equation 3 )
[0062] When the final scores are calculated for all IDs, the face identification block 11 determines who the subject in the identification image is, that is, whether the person has an ID or not. For example, if the largest final score exceeds a prescribed threshold, the face identification block 11 determines that the subject is a person with an ID corresponding to the final score. On the other hand, if the largest final score does not exceed a prescribed threshold, the face identification block 11 determines that the subject in the identification image is not a person with an ID stored on the registered information storage block 10 , that is, an unregistered person. Then, the face identification block 11 outputs the determination result as the result of face identification.
[0063] FIG. 9 is a flowchart showing an operating example of the face identification device 1 . Next, an operating example of the face identification device 1 will be explained. First, an identification image is input into the face identification device 1 via the image input block 2 (S 01 ). The image storage block 3 stores data of the input identification image. The face detection block 4 detects the face of a person from the identification image stored on the image storage block 3 (S 02 ). Next, the feature point detection block 5 detects a plurality of feature points from the detected face, and based on the feature points, the partial area deciding block 7 decides partial areas (S 03 ).
[0064] Next, the state determination block 6 determines whether any unfavorable condition is caused in the detected face, and if caused, determines the degree thereof (S 04 ). The reliability determination block 9 obtains the reliabilities of the respective partial areas based on the determination results by the state determination block 6 (S 05 ).
[0065] Next, the face identification block 11 performs score calculation processing (S 06 ) and final score calculation processing (S 07 ) for each ID (each registrant) stored on the registered information storage block 10 . This processing is repeated until processing for all registrants are completed (S 08 -NO). When the processing is performed for all registrants (S 08 -YES), the face identification block 11 decides the identification result based on the final score obtained for each registrant (S 09 ). Then, the face identification block 11 outputs the identification result.
[0066] In the identification processing by the face identification block 11 , degrees of effects of the feature values according to the respective partial areas are determined based on the reliabilities, which prevents deterioration in the accuracy of face identification processing in a identification image in which an unfavorable condition is caused.
[0067] Further, since it is configured so that the reliability determined from the image is multiplied with the similarity (score), functions such as face detection, feature value extraction, and similarity calculation can be performed commonly in all conditions. Therefore, it is possible to reduce the development cost, the program size, and used resources, which is extremely advantageous in implementation.
[0068] The face identification block 11 may be so configured as to perform score normalization processing after the final scores for all IDs are calculated. Score normalization processing can be performed in order to collect the values in a certain range if the range of the obtained final scores is too broad.
[0069] Further, if the face of the subject in the input identification image does not face the front, partial areas decided by the partial area deciding block 7 may be distorted depending on the direction. Further, the feature value used in identification by the face identification block 11 is generally a feature value obtained from a face image facing the front. Therefore, a distortion caused by the direction may cause an error in identification processing by the face identification block 11 . FIG. 10 shows a specific example of a distortion corresponding to a face direction. Conventionally, there is a case where the distance between the both eyes is used in deciding partial areas. However, since the distance between the eyes depends largely on the face direction, in such a method of deciding partial areas, accuracy in identification deteriorates significantly according to the face direction of the subject. In the case of FIG. 10 , it is also found that the distance between the eyes (t 1 ) when facing sideways and the distance between the eyes (t 2 ) when facing the front are significantly different. When the face direction is detected by the state determination block 7 , the partial area deciding block 7 may change the size or the range of each partial area corresponding to the direction, that is, perform normalization corresponding to the direction. More specifically, when the face direction is determined by the state determination block 6 , the partial area deciding block 7 may perform processing such as affine conversion to the partial area corresponding to the direction. Further, the partial area deciding block 7 may be configured to prepare templates corresponding to a plurality of face directions, and to designate the partial area by using a template corresponding to the determined direction. With such a configuration, it is possible to obtain a feature value under a condition closer to the feature value stored on the registered information storage block 10 to thereby prevent the accuracy of face identification from deteriorating due to face directions.
[0070] Further, the face identification device 1 may be configured so as to enable processing to register feature values in the registered information storage block 10 by inputting an image capturing the face of registrant (hereinafter referred to as registered images) into the face identification device 1 , rather than inputting feature values into the face identification device 1 . In such a case, the registered image input via the image input block 2 is stored on the image storage block 3 . Then, through cooperation between the face detection block 4 , the feature point detection block 5 , the partial area deciding block 7 and the face identification block 11 , feature values of the respective areas are obtained from the registered image, and are stored on the registered information storage block 10 . In this case, the face identification device 1 may be configured such that the state determination block 6 determines the presence or absence of an unfavorable condition and its level in the registered image, and if it is in a certain level, registration will not be performed. With this configuration, it is possible to prevent feature values obtained under unfavorable conditions from being stored on the registered information storage block 10 . Further, since face identification based on the feature values of low accuracy will not be performed, it is possible to prevent deterioration in the accuracy of the face identification processing thereafter.
[0071] In the embodiment described above, identification processing of “one to many”, that is, to which ID's registrant face and the face of the subject coincides, is performed. However, the face identification device can be applied to identification processing of “one to one” in which it is determined whether the face photographed is the subject's face. | A method for identifying a person includes the steps of detecting the face of a person in an input image, determining the reliability of each feature value from the input image, and obtaining a plurality of feature values from the detected face. Based on the feature values obtained from the detected face, the feature values stored on a storage unit, and the reliability of each feature value, an identification result according to the detected face is decided. A device includes the components for implementing said method. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 07/857,689 filed Mar. 31, 1992.
FIELD OF THE INVENTION
The present invention relates to patterned spunlaced fabrics and a process of making the same. More particularly, the invention relates to patterned spunlaced fabrics formed of synthetic fibers and woodpulp and/or woodpulp-like fibers, which fabrics exhibit very low wet and dry particle counts and good absorbency.
BACKGROUND OF THE INVENTION
Fabric wipers used in cleanroom applications require low particle generation when tested in air and water environments. In addition, cleanroom wipers must exhibit adequate absorbency rates and capacities. Unfortunately, particle generation and absorbency properties for many fabrics are many times mutually exclusive of each other. For example, untreated 100% polyester fabrics generate very low wet and dry particle counts but provide almost no absorbency. On the other hand, cotton fabrics or fabrics containing woodpulp exhibit high absorbency rates and capacity but typically generate unacceptably high wet and dry particle counts.
In the past, commercially available non-patterned spunlaced woodpulp/polyester fabrics (55 wt. % woodpulp/45 wt. % polyester) have proved adequate when used in Class 100 cleanroom environments. Federal Standard 209E, Sept. 11, 1992, defines airborne particulate cleanliness classes of air in cleanrooms using both English and metric units, and specifies that Class 100 air shall have no more than 100 particles (0.5 micrometer or larger) per cubic foot, or the equivalent metric designation of no more than 3530 particles (0.5 micrometer or larger) per cubic meter for Class M 3.5 air. Although Class 100 environments may be currently acceptable for non-sensitive operations, it has become increasingly desirable to have even lower particle counts for sensitive high-tech cleanroom applications.
U.S. Pat. No. 3,485,706 (Evans) discloses hydroentangling fibrous webs to produce textile-like patterned nonwoven fabrics. The hydroentanglement process calls for imparting high energy water jets (i.e., usually between about 200 and 2,000 psi) to a fibrous web to entangle the web and produce a spunlaced fabric. In FIG. 40 of Evans, a continuous commercial process is depicted wherein the fabric is subsequently dewatered by one or more squeeze rollers. Unfortunately, the application of high impact energy and squeeze roll dewatering produces fabrics which are typically unacceptable for sensitive high-tech cleanroom wiper applications.
Numerous examples in Evans disclose patterned spunlaced fabrics. Typically, the patterned spunlaced fabrics are fabricated of 100% synthetic textile staple fibers (e.g., polyester). Patterning takes place during hydroentanglement treatment by supporting the fibers on an apertured patterning member and then passing the fibers through a series of water jet banks. In addition, there are a few samples disclosed in Evans which demonstrate the use of relatively short cellulosic fibers in combination with synthetic staple fibers. These samples were made on table washers where the belt speed was very slow. Moreover, some of these samples were formed using predominantly cellulosic fibers (i.e., less than 50 wt. % synthetic fibers).
However, when a continuous commercial process was considered for making patterned spunlaced fabrics formed of synthetic fibers and woodpulp and/or woodpulp-like fibers, the conventional wisdom was that, although webs of 100% synthetic fibers could be successfully hydroentangled and patterned at commercial speeds, webs containing woodpulp and/or woodpulp-like fibers could not be formed on an apertured patterning member without destroying web integrity and/or generating large amounts of wet and dry particles. The wisdom was that supporting a synthetic/woodpulp web on an apertured patterning member would cause the woodpulp fibers to be washed out of the web through the openings in the patterning member when the web was treated with high energy water jets during hydroentanglement. In addition, it was believed that low process speeds (i.e., speeds below about 135 yds/min) would be required in order to overcome the problem of fabric wrinkling caused by excessive water carryover. Therefore, synthetic/woodpulp spunlaced fabrics were not patterned by high speed commercial hydroentanglement processes for fear that the web would lose its integrity during hydroentanglement treatment and/or that the fabric would exhibit numerous post-treatment wrinkles due to water carryover.
Due to the problems inherent in the prior art, the applicant recognized the need for a spunlaced fabric which provides an adequate degree of absorbency yet very low wet and dry particle counts. In this regard, the applicant has surprisingly found that patterned spunlaced fabrics formed of synthetic fibers and woodpulp and/or woodpulp-like fibers provide low wet and dry particle counts yet good absorbency when processed under certain conditions. These conditions allow such patterned spunlaced fabrics to be made at commercial speeds without woodpulp washout or fabric wrinkling. Other objects and advantages of the present invention will become apparent to those skilled in the art upon reference to the attached drawings and to the detailed description of the invention which hereinafter follows.
SUMMARY OF THE INVENTION
In accordance with the invention, there are provided patterned spunlaced fabrics formed of synthetic fibers and woodpulp and/or woodpulp-like fibers having very low wet and dry particle counts and good absorbency.
The patterned spunlaced fabrics of the invention comprise 5-50 wt. % woodpulp fibers, woodpulp-like fibers, or combinations thereof and 50-95 wt. % synthetic fibers. Preferably, the synthetic fibers are textile staple fibers or spunbonded fibers made of polyester. However, the synthetic fibers may also be made of polypropylene, polyamide, polyacrylonitrile resins, or combinations thereof. The inventive spunlaced fabrics contain a pattern on predominantly one surface of the fabric and exhibit a dry particle count no greater than 8000 particles/ft 3 , a wet particle count no greater than 6.5×10 7 particles/m 2 , an absorbency rate of at least 0.10 g/g/sec and an absorbency capacity of at least 300%. The patterned spunlaced fabrics of the invention are extremely well-suited for sensitive high-tech wiper applications.
In a more preferred embodiment, the inventive patterned spunlaced fabrics have a dry particle count no greater than 5000 particles/ft 3 , a wet particle count no greater than 5.0×10 7 particles/m 2 , an absorbency rate of at least 0.15 g/g/sec and an absorbency capacity of at least 350%.
The invention also provides a process for making absorbent, low-linting, patterned spunlaced fabrics formed from a web of synthetic fibers and woodpulp and/or woodpulp-like fibers. Preferably, the initial web comprises a layer of synthetic fibers and a layer of woodpulp and/or woodpulp-like fibers such that the web has a predominantly woodpulp side and a predominantly synthetic fiber side. (Composite structures are also possible wherein the woodpulp and/or woodpulp-like fibers are sandwiched between synthetic fiber layers.) The process comprises, as a first step, supporting the synthetic fiber side of the web on a smooth foraminous screen. Thereafter, the unsupported side of the web is traversed by high velocity jets of water providing a total impact energy of at least 2×10 -3 Hp-hr-lb f /lb m for this process step to entangle the fibers of the woodpulp layer with the fibers of the synthetic layer. Thereafter, the hydroentangled web, preferably the woodpulp side of the web, is supported on an apertured patterning member having from about 40 to about 10 openings per inch. Then, the unsupported side of the web, preferably the synthetic side of the web, is traversed by high velocity jets of water providing a total impact energy for this process step of at least 2×10 -3 Hp-hr-lb f /lb m to move the fibers laterally and vertically from their original positions toward the apertures of the patterning member to form a spaced apart pattern on the surface of the supported side of the fabric. The pattern is determined by the pattern of openings in the apertured patterning member.
To the applicant's surprise, patterning a hydroentangled web of synthetic fibers and woodpulp and/or woodpulp-like fibers on an apertured patterning member does not cause the woodpulp fibers to be washed out of the web during subsequent hydroentanglement treatment, but rather that patterning drastically decreases the amount of wet and dry particles present in the final spunlaced fabric. As a result, patterning is a critical element in producing spunlaced fabrics of synthetic fibers and woodpulp and/or woodpulp-like fibers that will satisfy the requirements necessary for sensitive high-tech cleanroom applications.
Patterned spunlaced fabrics of the invention are useful as cleanroom wipers, robotic covers, food service wipers, coverstock for sanitary napkins, diapers, surgical body part bags, and other end-use applications where low-linting and absorbency properties are important.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood with reference to the following figures:
FIG. 1 is a schematic view of a continuous hydroentanglement process of the invention depicting belt and drum washers for water jetting both sides of a fabric web and a conventional squeeze roll for dewatering the resulting fabric following water jetting.
FIG. 2 is a schematic view of a preferred continuous hydroentanglement process of the invention depicting belt and drum washers for water jetting both sides of a fabric web and a vacuum dewatering extractor for improving the absorbency properties of the resulting fabric following water jetting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures, wherein like reference numerals represent like elements, schematic representations are shown of two continuous processes of the invention. FIG. 1 depicts a continuous process wherein a web of fibers 10 (e.g., synthetic textile staple fibers and woodpulp and/or woodpulp-like fibers) is air-laid onto a conveyor 12 having a smooth mesh screen and conveyed towards a belt washer 14. The web is air-laid such that the synthetic textile staple fibers are supported by the smooth mesh screen and the woodpulp fibers are supported by the synthetic textile staple fibers. Belt washer 14 contains a series of banks of water jets which treat the woodpulp side of the fiber web and cause the woodpulp fibers to become entangled with the synthetic textile staple fibers. Thereafter, the hydroentangled web is passed underneath another series of banks of water jets while it is supported on an apertured patterning member of a drum washer 16 so that the other side of the web (i.e., the synthetic textile staple fiber side) can receive hydroentanglement treatment. Although it is not depicted in FIG. 1, the synthetic textile staple fiber side of the hydroentangled web can be supported by the apertured patterning member instead of the woodpulp side of the hydroentangled web. Subsequently, the resulting patterned spunlaced fabric is passed through a pair of squeeze rolls 18 to dewater the fabric. Thereafter, the patterned spunlaced fabric may be further treated by a padder 20, a dryer 22 and a slitter 24 before it is wound up on roll 26.
FIG. 2 is identical to FIG. 1, except that the squeeze rolls 18 have been replaced by a vacuum dewatering extractor 19. Both of these dewatering techniques are useful in the invention, but as will be shown hereinafter, vacuum extraction provides patterned spunlaced fabrics which have improved absorbency properties over those spunlaced fabrics which have been squeeze rolled. The vacuum extractor 19 is positioned between the apertured patterning member of the drum washer 16 and the dryer 22.
As indicated above, the web is made up of a mixture of synthetic fibers and woodpulp fibers, woodpulp-like fibers or combinations thereof. The web should be formed so that there is a distinct layer of synthetic fibers and a distinct layer of woodpulp and/or woodpulp-like fibers (i.e., a woodpulp fiber side and a synthetic fiber side). Such webs may be produced by any conventional dry or wet method. Particularly preferred are the air-laid webs depicted in the Figures and produced according to U.S. Pat. No. 3,797,074 (Zafiroglu), the entire contents of which are incorporated by reference herein.
The woodpulp and/or woodpulp-like fibers used in preparing the web should be relatively short (i.e., on average less than about 7 mm), thin and flexible. (It will be understood that any reference to woodpulp fibers in this application is also a reference to any naturally occuring woodpulp-like fibers or combinations of both woodpulp fibers and woodpulp-like fibers). Specifically, woodpulp-like fibers include plant fibers of thin and flexible character that may not strictly be considered a part of the woodpulp family but can be easily formed into paper. Preferred woodpulp fibers include those obtained from northern softwoods, such as redwood, western red cedar or eastern white pine. Preferred woodpulp-like fibers include abaca fibers, fibers obtained from the leafstalk of a banana (Musa textilis) native to the Philippines and tropical regions of Ecquador. Abaca fibers are also often commonly referred to as "Manila hemp".
The amount of woodpulp and/or woodpulp-like fibers in the web may vary from about 5% to 50%, by weight, of the total weight of the final fabric, but preferably less than about 45% is used. Most preferably, the amount of woodpulp and/or woodpulp-like fibers present in the web is in the range of 15 to 45 wt. %. It is the applicant's belief that an untreated (i.e., no surface treatments or agents applied) woodpulp and/or woodpulp-like fiber content greater than 50 wt. % cannot be used to make an adequately low-linting spunlaced fabric, whether the fabric is patterned or not. Thus, woodpulp and/or woodpulp-like fiber contents greater than 50 wt. % are excluded from the applicant's invention.
The synthetic fibers may be of any suitable material such as polypropylene, polyamide, polyester, polyacrylonitrile resins or combinations thereof. Preferably, the length of such fibers is between 0.375 and 1 inch (0.95 to 2.54 cm), and the denier is between 0.7 and 5 d.p.f. (0.78 to 5.6 dtex). Of the above-listed materials, polyester is particularly preferred. The polyester may be in the form of textile staple fibers or as a spunbonded sheet.
The amount of synthetic fibers in the web may vary between 50% to about 95% by weight, of the total weight of the final fabric, but preferably more than about 55% is used. Most preferably, the amount of synthetic fibers present in the web is in the range of 55 to 85 wt. %.
In use, the layered web is initially supported on a smooth foraminous screen (i.e., 75 mesh or finer) such that the synthetic fiber side is in contact with the screen. Thereafter, the woodpulp side of the web is traversed by high velocity streams of water jetted under relatively high pressure, e.g., from about 100 to 2000 psig, to hydraulically entangle the fibers of the woodpulp layer with the fibers of the synthetic layer. Thereafter, the hydroentangled web is supported on an apertured patterning member having from about 40 to about 10 openings per inch. Preferably, the woodpulp side of the hydroentangled web is supported on the apertured patterning member such that the resulting pattern predominantly appears on the woodpulp side of the spunlaced fabric. Then, the supported web (preferably the synthetic side of the hydroentangled web) is traversed by high velocity streams of water jetted under relatively high pressure to move the fibers laterally and vertically from their original positions toward the apertures of the patterning member to form a pattern on the resulting fabric. This pattern is determined by the apertures in the patterning member.
As used herein, "apertured patterning member" means any screen, perforated or grooved plate, or the like, on which the hydroentangled web of fibers is supported during processing and which by reason of its apertures and/or surface contours influences the movement of the fibers into a pattern in response to water jet streams. The patterning member may have a planar or nonplanar surface or a combination of planar and nonplanar areas. Greater detail regarding suitable patterning members is provided in U.S. Pat. No. 3,485,706 (Evans).
Various weaves and patterns may also be selected for the apertured patterning member according to the fabric pattern desired. For example, woven screens suitable for forming the fabrics of the invention are described in Widen, C.B., "Forming Wires for Hydroentanglement Systems", Nonwovens Industry, pp. 39-43 (1988). Perforated cylinders suitable for this invention are also disclosed in U.S. Pat. No. 4,704,112 (Suzuki et al.).
During fabric manufacture, the fibrous web is subjected to jets of water delivered through closely-spaced small orifices. The jets used in each of the process steps impart to the web a total impact-energy product ("I×E") of at least 2×10 -3 Horsepower-hour-pounds force/pounds mass (HP-hr-lb f /lb m ), preferably 2×10 -3 to 10×10 -3 Hp-hr-lb f /lb m most preferably 2×10 -3 to 5×10 -3 Hp-hr-lb f /lb m , according to the general process of U.S. Pat. No. 3,485,706 (Evans), the entire contents of which are incorporated herein by reference. In addition, equipment of the general type described above, and mentioned in U.S. Pat. No. 3,485,706 (Evans) and U.S. Pat. No. 3,403,862 (Dworjanyn), is suitable for the water-jet treatment.
The energy-impact product delivered by the water jets impinging upon the fabric web is calculated from the following expressions, in which all units are listed in the "English" units from measurements originally made or from units converted from measurements originally made (e.g., pounds per square inch converted to pounds per square foot) so that the "I×E" product is in 10 -3 foot-pounds force-pounds force per pounds mass. This expression can then be divided by 1.98×10 6 foot-pounds force per horsepower-hour to ultimately obtain an "I×E" product in 10 -3 horsepower-hour-pounds force per pounds mass.
I=PA
E=PQ/wzs
wherein:
I is impact in pounds force
E is jet energy in foot-pounds force per pound mass
P is water supply pressure in pounds per square foot
A is cross-sectional area of the jet in square feet
Q is volumetric water flow in cubic feet per minute
w is web weight in pounds mass per square yard
z is web width in yards and
s is web speed in yards per minute
Although the general process of hydrolacing a fabric web is not new, the spunlaced fabrics of the invention formed by water jetting and patterning woodpulp/synthetic fiber webs display unexpected and surprising physical properties and product features than those exhibited by prior art fabrics. These specific differences are set forth in the Tables below for fabrics of the invention and for fabrics of the prior art.
The following test procedures were employed to determine the various characteristics and properties reported below:
Dry particle count and wet particle count were determined by the test methods described in Kwok et al., "Characterization of Cleanroom Wipers: Particle Generation" Proceedings-Institute of Environmental Sciences, pp. 365-372 (1990) and "Wipers Used In Clean Rooms And Controlled Environments", Institute of Environmental Sciences, IES-RP-CC-004-87-T, pp. 1-13 (October, 1987). In brief, the spunlaced fabric is flexed in air on a Gelbo Flexer and the particles generated are measured with a laser counter as dry particle count. The wet particle count (i.e., number of particles suspended in water) is also measured with a laser counter after the fabric has been washed in water. Dry particle count is recorded as particles/ft 3 of air while wet particle count is recorded as particles/m 2 of fabric.
Absorbent characteristics were determined using a Gravametric Absorbency Testing System (GATS), available from M/K Systems, Danvers, Mass. In this test, a dry fabric specimen is placed onto a flat surface that is connected by a liquid bridge to a reservoir of water sitting on a top-loading balance. As liquid is taken up by the fabric, the amount transferred from the reservoir to the fabric is recorded as a loss in weight at the balance. The corresponding time interval from test initiation is likewise recorded automatically. The uptake rate is obtained from the rate of change of the balance reading. Typical fabrics absorb liquid most rapidly at the initiation of the test and more slowly as they reach their sorptive limit (absorptive capacity). The rate data reported herein is the rate of liquid uptake when the fabric has reached 50% of its total capacity (Rate @50% in g of water sorbed/g of fabric/sec). Total capacity is reported herein as the weight of liquid sorbed by the fabric, expressed as a percentage based on the sample weight.
The following non-limiting examples illustrate the differences in physical properties of the inventive patterned spunlaced woodpulp and/or woodpulp-like/synthetic fabrics compared to both patterned and non-patterned spunlaced fabrics of the prior art:
EXAMPLES
Example 1
In this example, a patterned spunlaced woodpulp/polyester fabric was made with mixtures of western red cedar woodpulp and polyester textile staple fibers in the form of an air-laid web. Commercially available "Dacron" polyester staple fibers (Type T612) from E. I. du Pont de Nemours and Co., Wilmington, Del., having a denier of 1.35 (1.5 dtex) and a length of 0.85 inch (2.16 cm), were combined with western red cedar woodpulp fibers (commercially available in roll form from E. B. Eddy Paper Co. of Port Huron, Mich. having a fiber length less than about 0.12 inches (0.30 cm). The cedar woodpulp was used in roll form and had a weight of 20 lbs/3300 ft 2 ream. The polyester staple fibers were air-laid according to the process described in U.S. Pat. No. 3,797,074 (Zafiroglu) and combined with the woodpulp fibers to form a 1.68 oz/yd 2 (57.0 g/m 2 ) web (woodpulp fibers on top of the polyester fibers). Based on the weight of the web, the web had a measured woodpulp content of about 44 wt. % and a polyester content of about 56 wt. %.
In a continuous operation, the web was supported on a smooth foraminous screen (approximately 76 mesh) such that the polyester side of the web was in contact with the screen. Thereafter, the web was passed along at a belt washer speed of 169 yds/min (155 m/min) and then passed underneath a series of banks of belt washer jets under conditions as shown in Table I. The water used for the jets was once-through water that had not been recirculated. In a continuous operation, the web was wrapped around a drum washer having an apertured patterning member so that the back side of the web (i.e., the woodpulp side of the web contacted the apertured patterning member) could be passed underneath a series of banks of drum washer jets under conditions as shown in Table II. It should be noted that the wind-up speed of the fabric was 185 yds/min (169 m/min) and this value was used, along with certain standardized process variables, to calculate the "I×E" product provided in the Tables below. The apertured patterning member had 24 wires per inch (i.e., 24 warp wires). Following patterning, the spunlaced fabric was dewatered using a pair of squeeze rolls.
TABLE I______________________________________Belt Washer Treatment Orifice # ofJet Diameter Jets per Pressure I × ENo. inch (mm) inch (cm) psi 10.sup.-3 Hp-hr-lb.sub.f /lb.sub.m______________________________________1 0.005 (0.127) 40 (15.7) 100 0.0012 0.005 (0.127) 40 (15.7) 300 0.013 0.005 (0.127) 40 (15.7) 500 0.044 0.005 (0.127) 40 (15.7) 800 0.145 0.005 (0.127) 40 (15.7) 1400 0.566 0.005 (0.127) 40 (15.7) 1800 1.067 0.005 (0.127) 40 (15.7) 1800 1.068 0.005 (0.127) 40 (15.7) 1800 1.069 0.005 (0.127) 40 (15.7) 1800 1.0610 0.005 (0.127) 60 (23.5) 300 0.02Total I × E = 5.011 × 10.sup.-3 Hp-hr-lb.sub.f /lb.sub.m______________________________________
TABLE II______________________________________Drum Washer Treatment Orifice # ofJet Diameter Jets per Pressure I × ENo. inch (mm) inch (cm) psi 10.sup.-3 Hp-hr-lb.sub.f /lb.sub.m______________________________________1 0.005 (0.127) 40 (15.7) 300 0.012 0 0 03 0.005 (0.127) 40 (15.7) 1800 1.044 0 0 05 0.005 (0.127) 40 (15.7) 1800 1.046 0 0 07 0 0 08 0 0 09 0 0 010 0 0 0Total I × E = 2.09 × 10.sup.-3 Hp-hr-lb.sub.f /lb.sub.m______________________________________
The inventive fabric was tested for dry particle generation using a Gelbo Flex Test Apparatus. The inventive fabric was also tested for wet particle generation using a Biaxial Shake Test using the test procedure described in IES-RP-CC-004-87-T. The results of the wet and dry particle tests are tabulated below in Table III and are compared to results obtained for: (A) a non-patterned spunlaced 1.65 oz/yd 2 (55.9 g/m 2 ) cedar woodpulp/polyester (Cedar WP/PET) fabric; and (B) a non-patterned spunlaced 2.04 oz/yd 2 (69.1 g/m 2 ) pine woodpulp/polyester (Pine WP/PET) fabric. The pine WP/PET (eastern pine woodpulp and "Dacron" polyester) is commercially available as "Sontara" Style 8801 from E. I. du Pont de Nemours and Co., Wilmington, Del. The jet profile and pressures for the comparative samples were the same as for the inventive patterned spunlaced fabric, except that the drum washer was not used for making the non-patterned fabrics. Absorbency rates and capacities according to the GATS method described above are also provided for the inventive fabric, the non-patterned cedar WP/PET fabric and the non-patterned pine WP/PET fabric. Both the non-patterned cedar WP/PET and non-patterned pine WP/PET fabrics are currently recommended for use in wiper applications.
TABLE III______________________________________ (A) Patterned Non-patterned (B) Inventive Cedar Non-patternedProperties Fabric WP/PET Pine WP/PET______________________________________Woodpulp 44 48 56Content (wt. %)Particle counts(≧0.5 micrometers)Dry particles/ft.sup.3 1600 5574 45,200of airWet particles/m.sup.2 4.6 × 10.sup.7 8.4 × 10.sup.7 1.01 × 10.sup.8of fabricAbsorbencyRate @ 50% 0.21 0.25 0.25(g/g/sec)Capacity (%) 401 408 346______________________________________
The fabrics of the invention generate surprisingly much lower particle counts than non-patterned cedar WP/PET fabrics and non-patterned pine WP/PET fabrics. In addition, comparative sample (B) exhibits much higher particle counts than does comparative sample (A) due to the increased woodpulp content in sample (B) (i.e., greater than 50 wt. %).
In Table IV, the physical properties of two additional prior art samples (comparative samples C and D) are reported for further purposes of comparison. These samples are of the 100% synthetic fiber type disclosed in the Evans patent. In Table IV, a 2.77 oz/yd 2 (94.2 g/m 2 ) patterned spunlaced fabric sample of 100% polyester staple fibers was made and dewatered by vacuum extraction. In addition, a 1.97 oz/yd 2 (67.0 g/m 2 ) non-patterned spunlaced fabric sample of 100% polyester staple fibers was made and dewatered by squeeze rollers. The results are as follows:
TABLE IV______________________________________ (C) (D) Non-patterned PatternedProperties 100% PET 100% PET______________________________________Dewatering Method Squeeze Roll Vacuum ExtractionParticle counts(≧0.5 micrometers)Dry particles/ft.sup.3 914 907of airWet particles/m.sup.2 4.0 × 10.sup.6 4.1 × 10.sup.6of fabricAbsorbencyRate @ 50% 0 0(g/g/sec)Capacity (%) 0 0______________________________________
Table IV shows that although the particle count for 100% polyester staple fibers is very low there is no associated absorbency measured by the GATS test for up to 10 minutes. Woodpulp and/or woodpulp-like fibers as used in this invention are what provide the necessary absorbency in the applicant's fabrics.
Example 2
In this example, an inventive fabric was made according to Example 1 except that the apertured patterning member had 13 openings per inch (13 warp wires) instead of 24 openings per inch. The resulting patterned spunlaced fabric exhibited a dry particle count of 600 particles/ft 3 a wet particle count of 6.2 ×10 7 particles/m 2 , an absorbency rate @50% of 0.17 g/g/sec and an absorbency capacity of 405%.
Example 3
In this example, a 1.73 oz/yd 2 patterned spunlaced fabric of the invention was vacuum dewatered instead of squeezed rolled. The same blend of fibers as described in Example 1 was formed into a web using the conditions, equipment and air-lay process described in Example 1. The sample was dewatered with a vacuum dewatering extractor at 17 inches of mercury vacuum after passing the drum washer jets. The results are summarized in Table V below. The results show that vacuum dewatering clearly increases the absorbency properties of the patterned spunlaced fabric. Therefore, in order to optimize the absorbency properties of a low-linting patterned spunlaced fabric of the invention, vacuum extraction should take the place of squeeze rolls.
TABLE V______________________________________ Example 1 Example 3 (Squeeze roll) (Vacuum extractor)______________________________________Particle count(≧0.5 micrometers)Dry particles/ft.sup.3 1600 1931of airWet particle/m.sup.2 4.6 × 10.sup.7 4.6 × 10.sup.7of fabricAbsorbencyRate @ 50% 0.21 1.16(g/g/sec)Capacity 401 934______________________________________
Example 4
In this example, two variants of a patterned three-layered spunlaced fabric were made by sandwiching a woodpulp fiber layer between two synthetic fiber layers.
In the first variant (4A), a "Reemay" spunbonded polyester fabric (commercially available from Reemay, Inc., Old Hickory, Tenn. as a 1.0 oz/yd 2 (34 g/m 2 ) consolidated web (lightly bonded) of 2.2 dpf round continuous filaments, Style T503) was placed on top of layers of polyester staple fibers and woodpulp fibers, and the resultant three layered composite web (PET staple/woodpulp/"Reemay") was passed under the water jets of Example 1 (washer belt) such that the jets traverse the "Reemay" side of the composite web. The web is entangled from the "Reemay" side and then subsequently entangled from the PET staple side using the drum washer of Example 1. The drum washer used apertured patterning members having 24 wires per inch (i.e., 24 warp wires).
In the second variant (4B), the polyester staple layer (PET staple) was replaced with a "Reemay" spunbonded polyester fabric so that the resulting three layered composite was comprised of "Reemay"/woodpulp/"Reemay". The composite was treated and patterned the same as the first variant. Similar properties for the first and second variant were obtained as shown in Table VI.
TABLE VI______________________________________Composites Utilizing Continuous Filament Scrims Example 1 Example 4A Example 4B______________________________________FabricWeight (oz/yd.sup.2) 1.68 2.77 2.95Wt. % PET 56 71 77Woodpulp (lbs/ 20 20 203300 ft.sup.2 ream)Particle Count(≧0.5 micrometers)Dry particles/ft.sup.3 1600 407 219of airWet particles/m.sup.2 4.6 × 10.sup.7 3.3 × 10.sup.7 3.0 × 10.sup.7of fabricAbsorbencyRate @ 50% (g/g/sec) 0.21 0.24 0.18Capacity (%) 401 439 370______________________________________
As can be seen from Table VI, the resulting variant spunlaced fabrics exhibit exceptional properties, particularly dry particles. The composite sandwich structure is believed to inhibit the release of dry particles upon flexing while retaining good absorptive properties. The improvement in dry particles is not believed to be due to a compositional increase in wt. % PET, since the woodpulp weight was the same per unit area for all three examples in Table VI. The tactile "hand" is also more similar to 100% polyester fabrics than typical WP/PET fabrics by virtue of polyester being exposed on each side.
Example 5
In this example, abaca fibers (i.e., woodpulp-like fibers) were used in combination with softwood woodpulp fibers to make a patterned spunlaced fabric similar to that described in Example 1. In particular, 70 wt. % abaca fibers/30 wt. % softwood woodpulp fibers (commercially available in paper roll form from J. R. Crompton of Bury, England as type PV 221) were used without any wet strength resins added to the fibers. The abaca/woodpulp combination paper had a weight of 17.4 lbs/3300 ft 2 ream. The polyester staple fibers were air-laid according to the process described in U.S. Pat. No. 3,797,074 (Zafiroglu) and combined with the abaca/woodpulp fibers to form a 1.73 oz/yd 2 (58.6 gm/m 2 ) web (abaca/woodpulp fibers on top of the polyester fibers). Based on the weight of the web, the web had a measured abaca/woodpulp content of about 38 wt. % and a polyester content of about 62 wt. %.
The belt washer jets were used to apply a total impact energy of 6.0×10 -3 Hp-hr-lb f /lb m and the drum washer jets were used to apply a total impact energy of 4.0×10 -3 Hp-hr-lb f /lb m (Total "I×E"=10.0 Hp-hr-lb f /lb m ). The patterned spunlaced fabric was squeeze roll dewatered.
The inventive abaca-based fabric was tested for dry particle generation using a Gelbo Flex Test Apparatus. The inventive fabric was also tested for wet particle generation using a Biaxial Shake Test using the test procedure described in IES-RP-CC-004-87-T. The results of the wet and dry particle tests are tabulated below in Table VII. Absorbency rates and capacities according to the GATS method described above are also provided for the inventive fabric.
TABLE VII______________________________________ Patterned Abaca-BasedProperties Inventive Fabric______________________________________Abaca/Woodpulp 38Content (wt. %)Particle counts(≧0.5 micrometers)Dry particles/ft.sup.3 848of airWet particles/m.sup.2 2.3 × 10.sup.7of fabricAbsorbencyRate @ 50% 0.153(g/g/sec)Capacity 477______________________________________
The resulting abaca-based fabric had excellent low-linting properties and very good absorptive properties.
Example 6
In this example, type PV 221 abaca/woodpulp combination paper from J. R. Crompton was again used. The paper did not have any wet strength resins added to the fibers. The abaca/woodpulp paper had a weight of 17.4 lbs/3300 ft 2 ream. The polyester staple fibers were air-laid according to the process described in U.S. Pat. No. 3,797,074 (Zafiroglu) and combined with the abaca/woodpulp fibers to form a 1.49 oz/yd 2 (50.5 g/m 2 ) web (abaca/woodpulp fibers on top of the polyester fibers). Based on the weight of the web, the web had a measured abaca/woodpulp content of about 35 wt. % and a polyester content of about 65 wt. %.
The belt washer jets were used to apply a total impact energy of 22.0×10 -3 Hp-hr-lb f /lb m and the drum washer jets were used to apply a total impact energy of 23.0×10 -3 Hp-hr-lb f /lb m (Total "I×E"=45.0×10 -3 Hp-hr-lb f /lb m ). The resulting patterned spunlaced fabric was dewatered by vacuum extraction.
The inventive abaca-based fabric was tested for dry particle generation using a Gelbo Flex Test Apparatus. The inventive fabric was also tested for wet particle generation using a Biaxial Shake Test using the test procedure described in IES-RP-CC-004-87-T. The results of the wet and dry particle tests are tabulated below in Table VIII. Absorbency rates and capacities according to the GATS method described above are also provided for the inventive fabric.
TABLE VIII______________________________________ Patterned Abaca-BasedProperties Inventive Fabric______________________________________Abaca/Woodpulp 35Content (wt. %)Particle counts(≧0.5 micrometers)Dry particles/ft.sup.3 2270of airWet particles/m.sup.2 2.1 × 10.sup.7of fabricAbsorbencyRate @ 50% 0.725(g/g/sec)Capacity (%) 933______________________________________
The resulting abaca-based fabric had excellent low-linting properties and very good absorptive properties.
Example 7
In this example, a patterned three-layered spunlaced fabric was made by sandwiching an abaca/woodpulp fiber layer between two synthetic fiber layers, namely a polyester scrim layer and a polyester staple fiber layer.
Type PV 222 abaca/woodpulp paper from J. R. Crompton was used without any wet strength resins added to the fibers. The abaca/woodpulp combination paper had a weight of 22.0 lbs/3300 ft 2 ream. The abaca/woodpulp combination paper was sandwiched between a layer of polyester staple fibers, which were air-laid according to the process described in U.S. Pat. No. 3,797,074 (Zafiroglu), and a 1.0 oz/yd 2 polyester scrim ("Sontara" Style S8001 commercially available from E. I. du Pont de Nemours and Company of Wilmington, Del.). The resultant three-layered composite web (PET staple/abaca-based paper/PET scrim) was passed under belt washer water jets operating such that the jets traversed the polyester scrim side of the composite web and provided an "I×E" of 8.0 Hp-hr-lb f /lb m . The web was entangled from the polyester scrim side and then subsequently entangled from the polyester staple side using drum washer water operating jets such that the jets traverse the polyester staple side of the composite web and provided an "I×E" of 9.0×10 -3 Hp-hr-lb f /lb m (Total "I×E"=17.0×10 -3 Hp-hrlb f /lb m ). The drum washers used apertured patterning members having 24 wires per inch (i.e., 24 warp wires). After patterning, the composite web was dewatered by vacuum extraction. The resulting composite web had a basis weight of 2.77 oz/yd 2 (93.8 g/m 2 ) and a measured polyester content of about 70 wt. % and an abaca/woodpulp content of about 30 wt. %.
The inventive abaca-based composite fabric was tested for dry particle generation using a Gelbo Flex Test Apparatus. The inventive fabric was also tested for wet particle generation using a Biaxial Shake Test using the test procedure described in IES-RP-CC-004-87-T. The results of the wet and dry particle tests are tabulated below in Table IX. Absorbency rates and capacities according to the GATS method described above are also provided for the inventive fabric.
TABLE IX______________________________________Composite Utilizing polyester ScrimPET Scrim/Abaca-Based Paper/PET Staple______________________________________Abaca/Woodpulp 30Content (wt. %)Particle Count(≧0.5 micrometers)Dry particles/ft.sup.3 48of airWet particles/m.sup.2 2.5 × 10.sup.7of fabricAbsorbencyRate @ 50% (g/g/sec) 0.231Capacity (%) 611______________________________________
As can be seen from Table IX, the resulting three-layered spunlaced fabric exhibits exceptional properties, particularly dry particles. As noted before, the composite sandwich structure is believed to inhibit the release of dry particles upon flexing while retaining good absorptive properties. This embodiment utilizes many preferred features of the invention, features that tend to optimize particle counts and absorbency properties.
Although particular embodiments of the present invention have been described in the foregoing description, it will be understood by those skilled in the art that the invention is capable of numerous modifications, substitutions and rearrangements without departing from the spirit or essential attributes of the invention. Reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | Patterned spunlaced fabrics formed of synthetic fibers and woodpulp and/or woodpulp-like fibers are disclosed having very low wet and dry particle counts and good absorbency. The patterned spunlaced fabrics according to the invention are particularly useful as cleanroom wipers, robotic covers, food service wipes, and as coverstock for sanitary napkins, diapers, surgical body part bags, and the like. The invention also comprises a process of making the patterned spunlaced fabrics.. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to cooperative identification systems in which the identifying agency and the object to be identified cooperate in the identification process according to a prearranged scheme. More specifically, the invention relates to systems consisting generically of an interrogator-responsor (or "reader") inductively coupled to a transponder (or "tag") where the reader is associated with the identifying agency and the tag is associated with the object to be identified.
Such systems are being used or have the potential of being used for identifying fish, birds, animals, or inanimate objects such as credit cards. Some of the more interesting applications involve objects of small size which means that the transponder must be minute. In many cases it is desirable to permanently attach the tag to the object which means implantation of the device in the tissues of living things and somewhere beneath the surfaces of inanimate objects.
In most cases, implantation of the tag within the object forecloses the use of conventional power sources for powering the tag. Sunlight will usually not penetrate the surface of the object. Chemical sources such as batteries wear out and cannot easily be replaced. Radioactive sources might present unacceptable risks to the object subject to identification.
One approach to powering the tag that has been successfully practiced for many years is to supply the tag with power from the reader by means of an alternating magnetic field generated by the reader. This approach results in a small, highly-reliable tag of indefinite life and is currently the approach of choice.
Tags typically use programmable read-only memories (PROMs) for the storage of identification data to be communicated to readers. The PROMs are programmed either by the manufacturer of the tags at the time of manufacture or by the user prior to implantation in the objects to be identified. Once the PROMs are programmed and the tags are implanted, the PROMs usually cannot be reprogrammed. Thus, tampering with the information stored in a tag is essentially impossible.
There are situations, however, where the user would like to reprogram the tag PROMs in situ because the identification scheme has become known to unauthorized individuals or organizations or certain data associated with the object to be identified needs to be revised or updated. The utilization of reprogrammable PROMs in tags would permit the user to exercise a reprogramming option when the need arose: for example, to store and/or update information which is specific to the object or animal to be identified such as sex, weight, or medical treatment information.
The exclusive utilization of reprogrammable PROMs would, however, prevent the manufacturer from offering after-sale diagnostic and/or warranty services since the tags would no longer have unique and permanent identifying codes.
Thus, the need exists for tags which carry two kinds of information: (1) a manufacturer's serial number and perhaps other data which is permanently associated with a tag and cannot be altered and (2) object-identifying nonvolatile data that is alterable by the user.
BRIEF SUMMARY OF INVENTION
The multi-memory electronic identification tag comprises a means for receiving data, a means for transmitting data, and up to three types of memory where the data to be transmitted is stored.
A portion of the data to be transmitted is stored permanently in a non-reprogrammable type of memory wherein the stored-data cannot be altered. Examples of this type of memory are the fusible-link diode-array read-only memory, the anti-fuse memory, and the laser-programmable read-only memory.
Another portion of the data to be transmitted is stored permanently in a reprogrammable type of memory wherein the stored data can be altered even after the tag has been implanted in the object that is subject to identification. Examples of this type of memory are the electrically-erasable-programmable read-only memories (EEPROMs). The multi-memory tag further comprises the means for receiving data from a remote reprogramming unit and the means for programming such reprogrammable memory with the newly-received data.
A third portion of the data to be transmitted is stored temporarily in a type of memory which can be written to and read from with alacrity and which typically utilizes an array of capacitors as the storage media. The type of data appropriately stored in this type of memory is data that has their origins in sensors contained in or attached externally to the tag.
An object of the invention is to provide a permanent and unalterable means for storing data that uniquely identifies a tag and can thereby be used by the tag manufacturer in providing diagnostic and warranty services.
Another object of the invention is to provide permanent but alterable means for storing data that a user may wish to associate with the object being tagged. The user may require that this data, particularly the association of the data with the tagged object, be kept private. In case of compromise, the user may utilize the reprogrammable memory option to recode the data assigned to particular objects.
Still another object of the invention is to provide a temporary storage facility in which the outputs of sensors embedded in or associated with the tag may be stored until they are transmitted to the user.
It is also an object of the invention to provide a means for transmitting from the user to a tag the data that is to be substituted for the data stored in reprogrammable memory.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is the functional block diagram of the preferred embodiment of an electronic identification system that comprises a conventional reader and the multi-memory tag.
FIG. 2 is the flow diagram associated with the main program that governs the operations of the controller in the multi-memory electronic identification tag.
FIG. 3 is the flow diagram associated with the routine performed by the controller in the multi-memory electronic identification tag when the bit rate interrupt occurs.
FIG. 4 is the functional block diagram of the preferred embodiment of the programing unit that is used to program the multi-memory electronic identification tag.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The electronic identification system that utilizes multi-memory tags is comprised of a reader that is capable of interrogating and receiving information from a multi-memory tag, a programming unit that is capable of reprogramming the reprogrammable portion of the memory of the multi-memory tag, and a multi-memory tag that is capable of transmitting data to the reader and receiving data and commands from the programming unit.
The functional block diagrams of the preferred embodiments of the reader and the multi-memory tag are shown in FIG. 1. The reader 100 interrogates the tag 200 by generating a reversing magnetic field 10 by means of the wound wire coil 110 that is inductively coupled to a similar coil 220 in the tag 200. The coil 110 in series with capacitor pair 120 is driven by the double-ended balanced coil driver 135 with a periodic signal of appropriate frequency supplied by the clock generator 140. Typically, the driving frequency is in the range from 100 kHz to 400 kHz.
A typical design for balanced drivers suitable for driving the coil 110 and capacitors 120 is the commercially-available integrated circuit SI995ODY which comprises a complementary pair of power metal oxide silicon field effect transistors (power MOSFETS), the output ports of the two transistors being connected to opposite ends of the coil 110 through the two capacitors 120. The two transistors are driven by complementary waveforms, the second waveform being an inverted version of the first.
The two capacitors 120 have equal capacitances, the capacitance being chosen so that the combination of the coil and capacitor pair constitutes a series resonant circuit at a desired driving frequency.
The clock generator 140 is comprised of a crystal-controlled oscillator and divider chains of conventional design. The oscillator frequency is chosen such that all required driving frequencies can be obtained by integer divisions.
The clock generator 140 includes a duty cycle timer which generates a square-wave timing signal that causes the reader coil 110 to be energized when the signal is high. The signal remains high for a time long enough to receive the information to be communicated by a tag on the particular driving frequency being used. The signal remains low for a time long enough for the reader 100 to be moved to a new reading position.
The purpose of operating the reader coil 110 with a duty cycle is to conserve battery power and achieve longer operating periods between battery rechargings or replacements.
The duty cycle timer is set to low by the microprocessor 170 whenever the microprocessor recognizes a condition that indicates failure of the read process.
The duty cycle timer turns on only when the reader power switch is on and the user-activated "read" trigger switch 142 is closed. Releasing the "read" trigger does not disable the duty cycle timer until the normal transition from high to low occurs.
Time T is maintained in the clock generator 140 by a counter that counts cycles of the driving frequency when the duty cycle timer signal is high. The counter is reset each time the duty cycle timer signal goes from high to low. The T counter can be accessed by the microprocessor 170 by means of the control bus 187 and data bus 190.
The T counter supplies an interrupt signal to the microprocessor 170 when T equals T 1 where T 1 is the time required for the reader coil voltage to approach within say 0.1% of its steady-state voltage. When the T 1 interrupt occurs, signal processing in the reader begins.
In response to an interrogation by the reader 100, the tag 200 causes the variable load 230 that is inductively coupled to the reader coil 110 by means of coil 210 to vary in accordance with one or the other of two patterns, one pattern being associated with the transmission of a 0 and the other being associated with the transmission of a 1. The loading pattern is manifested at the reader by a variation in the voltage across the reader coil 110. The demodulator 150 performs those operations necessary to determine whether the voltage pattern during a bit period corresponds to a 0 or a 1 and periodically communicates this determination to the microprocessor 170 by means of the data bus 190.
The tag data that derives from this information together with operational information is caused by the microprocessor 170 to be visually displayed on alphanumeric display 175. This same information is made available audibly to the user in the form of audio signals and/or artificial speech by means of the audio interface 180 and the speaker 185.
The microprocessor 170 exercises control over the clock generator 140, the demodulator 150, the alpha-numeric display 175, and the audio interface 180 by means of the control bus 187. Data is exchanged between the microprocessor 170 and the clock generator 140, the demodulator 150, the alpha-numeric display 175, and the audio interface 180 by means of the data bus 190.
An external digital computer 195 can exercise control over and exchange data with the microprocessor 170 by means of the standard RS-232 data link 197.
The circuits and devices which provide the basis for the reader design are conventional and are fully described in a number of textbooks having to do with the design of . communication systems and equipment. Specific examples of reader designs are contained in U.S. Pat. No. 4,333,072 to Beigel and U.S. Pat. No. 4,730,188 to Milheiser which are hereby incorporated by reference.
The tag 200, when in the proximity of and inductively-coupled to the reader 100, extracts power from the alternating magnetic field 10 established by the reader coil 110 by means of the multi-turn coiled conductor 210 in parallel with the capacitor 220, the combination constituting a resonant circuit at one of the reader's driving frequencies.
The variable load 230 is connected across the coil-capacitor combination thereby providing a means for varying the load on the balanced coil driver 135 in the reader 100 resulting from the inductive coupling of the reader and tag coils. The variable load 230 is resistive in the preferred embodiment thereby achieving the greatest possible effectiveness in absorbing power from the reversing magnetic field and in communicating with the reader. Other less desirable embodiments could use loads that are inductive, capacitive, or some combination of inductive, capacitive, and resistive.
The communication capability of the reader 100 and the tag 200 are critically dependent on the characteristics of the reader coil 110 and the tag coil 210. The number of turns for the reader coil should be as large as possible so that the magnetic field created by the reader coil is as large as possible. On the other hand, the resistance of the reader coil 110 (proportional to the number of turns) must not become so large as to be a substantial mismatch to the driving impedance and thereby impede the transfer of power to the tag. The preferred embodiment of the reader coil is wound on an oval plastic core approximately 45/8 inches long by 33/4 inches wide. The coil is wound with 90 to 100 turns of 28-gauge wire yielding a coil with approximate inductance of 2.3 mH and approximate resistance of 7.6 ohms.
The number of turns on the tag coil 210 also should be as large as possible in order to maximize the inductively-generated voltage across the coil. Again caution must be exercised in choosing the number of turns so that the power transfer between reader and tag is not adversely affected.
The alternating voltage appearing across the coil 210 as a result of being inductively coupled to the reader coil 110 is converted to direct current by means of the AC/DC converter and voltage regulator 235 which supplies all of the power required by the tag circuitry.
The alternating voltage appearing across the coil 210 provides a reference frequency for the clock generator 240 which supplies all of the clocking signals required by the tag circuitry. Another embodiment utilizes the alternating coil voltage to stabilize a voltage-controlled oscillator which would then act as the source for all clocking signals.
The controller 245 controls all of the operations performed by the tag circuitry by means of control bus 246 and data bus 248. A clock signal for the controller 245 is supplied by the clock generator 240.
The threshold detector 250 produces a signal when the voltage from the AC/DC converter and voltage regulator 235 reaches the level required for reliable operation of the tag circuitry. The threshold detector 250 is a simple comparison circuit that uses a Zener diode as a reference voltage.
The signal from the threshold detector 250 serves to reset the controller 245 which waits for a first predetermined period of time (measured by a clock cycle counter in the controller) for the purpose of allowing the voltage transient associated with the inductive coupling of an externally-generated magnetic field to the tag coil 210 to die down to the point where either power absorption by the tag can be detected by the reader or amplitude modulation by the programming unit can be detected by the tag.
After waiting for the transient to die down, the controller 245 waits for a second predetermined period of time (also measured by a clock cycle counter in the controller) for the purpose of allowing the demodulator 244 time enough to discover whether the interrogation is by the programming unit rather than the reader.
The demodulator 244 is enabled by the controller 245 at the expiration of the first predetermined time period. The demodulator 244 first extracts the modulating signal (if such exists) in the same manner as the reader demodulator 150 by taking the difference between two smoothed versions of the rectified coil signal, one of the smoothed versions being obtained by smoothing the rectified coil signal over a time period that is long compared to the period of the coil signal and short compared to the period of the bits that are transmitted by the programming unit, the other of the smoothed versions being obtained by smoothing the rectified coil signal over a time period that is long compared to the bit period.
Typically, the coil signal has a frequency of a few hundred kHz and the bit rate is a few kHz. These numbers suggest a smoothing time somewhere in the range of 10 to 20 coil signal periods for the first smoothed version. The smoothed version should be smoothed for at least 10 bit periods.
The programming unit initially transmits an alternating series of "0's" and '1's" for the purpose of allowing the demodulator 244 to recognize the presence of a modulating signal. The demodulator recognizes the modulating signal presence by smoothing the rectified difference signal for at least ten bit periods and comparing the smoothed rectified difference signal with a predetermined threshold voltage which is three to five times the standard deviation of the noise appearing across the coil 210 and the capacitor 220. If the smoothed rectified difference signal is greater than the threshold voltage, the demodulator concludes that a modulating signal is present and sets the "modulation present" flag which can be read by the controller 245.
The threshold voltage is preferably established at such a level that the probability of falsely recognizing the presence of a modulating signal is less than 0.01 and the probability of recognizing the presence of a modulating signal that is truly present is greater than 0.99.
The demodulation process continues with the demodulator 244 identifying the peaks and valleys of the difference signal and thereby generating a bit rate clock signal which is a square wave having a frequency equal to the bit rate and having low-to-high transitions that coincide with the peaks and valleys of the difference signal. The demodulator identifies a bit by observing the sign of the difference signal when a positive transition of the bit rate clock signal occurs. If the difference signal is negative, the received bit is a "0". If the difference signal is positive, the received bit is a "1".
The demodulator 244 can be implemented in a number of ways. An example of a suitable implementation is given in the aforereferenced Beigel patent in connection with the description of the preferred embodiment of the reader amplitude demodulator.
The bit rate clock signal alerts the controller 245 each time a bit decision is made whereupon the controller retrieves the bit and saves it in memory. The programming unit transmits a "start message" code following the alternating series of "0's" and "1's". If a "start" message code is not received by the end of the second predetermined time period, the controller 245 concludes that the interrogation is by a reader rather than a programming unit and proceeds to transmit the data stored in memory to the reader.
A message is transmitted by the controller 245 by applying a square wave signal of appropriate frequency to the variable load 230 for each bit of the message.
The controller 245 retrieves for transmission all but the sensor data portion of the message from the nonvolatile memories 252 and 258.
The electrically-erasable programmable read-only memory (EEPROM) 252 contains data that the user of the tag may wish to change sometime in the future. The user changes the data by transmitting an appropriate message via the programming unit to the tag whereupon the controller 245 causes the EEPROM programmer 254 to reprogram the EEPROM 252 with data included in-the message. The EEPROM 252 can also be reprogrammed by using standard reprogramming circuitry that connects directly to contacts on the device, when such contacts are accessible.
The reprogramming of the EEPROM can be permanently inhibited during initial programming, prior to implantation in or attachment to the object to be identified, by breaking a fused connection (i.e., "blowing" a fuse) in the EEPROM by the application of a voltage of sufficient magnitude to the input port 256 of the EEPROM.
The laser-programmable read-only memory (laser PROM) 258 contains data which uniquely identifies the tag and is unalterable because of the nature of the laser PROM. The manufacturer utilizes this data in providing warranty and diagnostic services to the user. The laser PROM is permanently programmed at the time of manufacture by utilizing a laser beam to make or break connections in the device.
In the embodiment shown in FIG. 1 the controller 245 obtains the sensor data from a first-in/first-out (FIFO) memory device 259 where the data was stored as a result of the sensor selector 260 connecting the A/D converter 265 sequentially first to temperature sensor 270 and then to PH sensor 275.
In the absence of a message transmission from the controller 245, the variable load 230 is dormant and does not appreciably load the resonant circuit 210, 220. When the controller transmits a message over line 238 to the variable load 230, the variable load applies a load to the resonant circuit 210, 220 in accordance with a frequency-shift-keying (FSK) technique. A message bit "1" causes a "mark" frequency signal to be selected. A "0" selects a "space" frequency signal. The selection of the "mark" frequency signal causes the load to be turned on or off depending on whether the "mark" frequency signal is high or low. Similarly, the "space" frequency signal causes the load to be turned on or off depending on the high and low states of the "space" frequency signal. The "mark" and "space" square-wave signals are derived from the reader driving frequency and supplied by the clock generator 240 to the variable load 230 over lines 242.
Since the "mark" and "space" frequencies are phase-coherent with the magnetic field driving frequency, the reader may advantageously extract the information from the power absorption signal by means of a coherent demodulation technique thereby realizing the increased communication efficiency of coherent frequency-shift keying (CFSK) as compared to non-coherent frequency shift keying (NCFSK).
The "mark" and "space" frequencies are chosen small enough that the sidebands resulting from the amplitude modulation of the driving-frequency signal are not attenuated by more than say 3 dB with respect to the driving frequency by the reader resonant circuit 110, 120. The spacing of the "mark" and "space" frequencies should ideally be an integer times the bit rate where the integer is preferably equal to or greater than two. For a driving frequency of 400 kHz and a bit rate of 5 kHz and 40 kHz respectively. Note that the difference 10 kHz is equal to the integer 2 times the bit rate.
It will be obvious to one skilled in the art that other modulation techniques could be used in both the tag 200 and the reader 100. For example, the tag could utilize on-off-keying (OOK) whereby the variable load 230 turns the load off when a "0" is transmitted and turns the load on and off when a "1" is transmitted (or vice versa) in accordance with whether a square wave of predetermined frequency supplied by the clock 240 is high or low.
Phase-shift-keying (PSK) in either the fully-coherent (CPSK) or differentially-coherent (DCPSK) versions could also be used. Coherent phase-shift-keying would result if the variable load 230 turned the load on or off in accordance with whether the square wave described above was high or low respectively when a "0" was transmitted and turned the load on or off when the square wave was low or high respectively when a "1" was transmitted (or vice versa).
Differentially-coherent phase-shift-keying would result if the variable load 230 turned the load on and off in the same way as it was during the previous bit period when a "0" is transmitted and in the opposite way when a "1" is transmitted.
The operations performed by the controller 245 in the tag 200 are detailed in the flow diagram shown in FIG. 2. The reset of the controller 245 (FIG. 1) by the threshold detector 250 (FIG. 1) causes the controller registers to be cleared and directs the controller to perform the sequence of operations beginning at the main program address 300.
The controller first performs operations 305. It waits for a predetermined time long enough for the voltage transient that results from the coupling of a magnetic field to the coil 210 (FIG. 1) to die down to a level low enough to permit the demodulation of coil signals by either the reader 100 or the tag 200 (FIG. 1). It then enables the demodulator 244 (FIG. 1) and waits for a predetermined time that is long enough for the demodulator to determine whether the coil signal is modulated.
The controller reads the "modulation present" flag in the demodulator to determine whether the coil signal is modulated 310. If modulation is not present, the controller transmits 315 a message consisting of the data stored in the laser PROM, the EEPROM, and the FIFO memory.
If modulation is present, the controller enables 320 the bit rate interrupt, the bit rate signal being supplied by the demodulator. The controller then waits 325 for the bit rate interrupt to be disabled in the bit rate interrupt routine.
When the controller determines 325 that the bit rate interrupt has been disabled, it performs test 330. If the "EEPROM data" flag was set, the controller reprograms the EEPROM in accordance with the data received from the programming unit. If the "EEPROM data" flag was not set 330, the controller closes down until the next interrogation.
When the bit rate interrupt is enabled, a positive transition of the bit rate clock signal supplied by the demodulator 244 (FIG. 1) causes the main program shown in FIG. 2 to be interrupted and the controller is directed to the address in memory of the bit rate interrupt routine shown in FIG. 3. The registers identified in this routine were cleared and the flags reset when the controller 245 was reset by the threshold device 250 when an interrogation first occurred (see discussion in connection with FIG. 1).
The controller begins the routine by reading 340 the bit just demodulated by the demodulator. The controller then determines whether the "reprogram" flag is set 345.
If the "reprogram" flag is not set, the 1 register is | Multi-memory electronic identification tags (200) are utilized in short-range cooperative electronic identification systems comprised of readers (100) and tags (200) wherein a reader (100) may communicate with the tag (200) if the tag belongs to a certain class of tags. Communication is accomplished by a reader (100) establishing a reversing magnetic field (10) in the vicinity of a tag (200) and the (200) varying its absorption of power from the field (10) in accordance with the information to be transmitted. A first type of memory (258) is permanent and unalterable and used for storing data that is unique to the tag (200) and never needs to be changed. A second type of memory (252) is permanent but alterable and used for storing data that characterizes the object to which the tag (200) is attached. A third type of memory (259) is for the temporary storage of data produced by tag sensors (270,275). | 6 |
FIELD
The present disclosure relates to a system for managing the temperature of an automatic transmission and more particularly to a two valve system for managing the temperature of fluid within an automatic transmission.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
Modern automatic motor vehicle transmissions utilize a several quart or liter fill of transmission fluid (hydraulic oil). The transmission fluid serves several purposes. First and most obvious is the lubrication of the numerous rotating and moving parts within the transmission. Second is the transfer of heat out of the transmission to maintain an appropriate operating temperature and third is use in the pressurized hydraulic control system of the transmission.
To achieve proper heat transfer to the ambient, a transmission oil cooler remote from the transmission is provided with a flow of transmission fluid. The oil cooler may be mounted within the vehicle radiator in which case heat is first transferred to engine coolant within the radiator and thence to the ambient or the oil cooler may be directly exposed to air flow, for example, through the engine compartment.
Such a device addresses only one aspect of transmission fluid temperature control however: ensuring that the transmission fluid temperature and thus the internal components of the transmission do not exceed design operating limits. While such a purpose is of great importance, there are other operating considerations relating to transmission fluid temperature. For example, when a vehicle and its transmission are started in cold weather, the viscosity of the cold transmission fluid can cause significant parasitic frictional losses. Depending upon the temperature, it can be several minutes before the transmission fluid temperature rises into a range where frictional losses become negligible. This delay is primarily due to the fact that only frictional heating from the rotation of parts heats the transmission fluid. During this time, fuel economy can be significantly degraded.
It is therefore apparent that improved control of automatic transmission fluid temperature is desirable.
SUMMARY
The present invention provides an active/passive system for managing the temperature of fluid within an automatic transmission. The system receives a flow of transmission fluid from the transmission and includes a first heat exchanger for transferring heat from engine coolant to the transmission fluid, a second heat exchanger for transferring heat from the transmission fluid to the ambient, a first, two position, diverter spool valve for directing transmission fluid to a first path which includes the first heat exchanger or a second path which includes a second, bypass valve which directs fluid flow to either the second heat exchanger the or bypasses it and returns the fluid to the transmission. The first, two position valve is solenoid operated by a signal from a transmission control module (TCM) or engine control module (ECM) and the second, bypass valve is preferably controlled by a passive wax motor.
When the transmission and transmission fluid is cold or below a threshold design temperature, the solenoid of the first, two position diverter valve is activated and fluid flow is directed to the first heat exchanger where heat in the engine coolant is transferred to the transmission fluid to assist its warming up. As the temperature of the transmission and transmission fluid rises and passes the same or a related threshold design temperature, the solenoid is deactivated and the first valve directs fluid flow to the second path. Typically at this time, the wax motor will be cold and the flow of transmission fluid will be returned to the transmission. As the temperature of the transmission and the transmission fluid continue to rise, the wax motor will sense this and translate the bypass valve to direct fluid flow to the second heat exchanger which will transfer heat to the ambient and lower the temperature of the transmission fluid.
An alternate embodiment system for managing the temperature of fluid within an automatic transmission includes two solenoid operated valves that may be controlled by two outputs from a transmission control module and which provide the three states of operation: transmission fluid circulation without heat transfer, circulation with heat transfer in from the engine coolant and circulation with heat transfer out to the ambient.
Thus it is an aspect of the present invention to provide a system for managing the temperature of fluid within an automatic transmission.
It is a further aspect of the present invention to provide an active/passive system for managing the temperature of fluid within an automatic transmission.
It is a still further aspect of the present invention to provide a system for managing the temperature of fluid within an automatic transmission having a first heat exchanger for transferring heat from engine coolant.
It is a still further aspect of the present invention to provide a system for managing the temperature of fluid within an automatic transmission having a second heat exchanger for transferring heat to the ambient.
It is a still further aspect of the present invention to provide a system for managing the temperature of fluid within an automatic transmission having a two position solenoid operated valve.
It is a still further aspect of the present invention to provide a system for managing the temperature of fluid within an automatic transmission having a bypass valve operated by a wax motor.
It is a still further aspect of the present invention to provide a system for managing the temperature of fluid within an automatic transmission having a pair of heat exchangers and a pair of valves each having a inlet and a pair of outlets.
It is a still further aspect of the present invention to provide a system for managing the temperature of fluid within an automatic transmission having a pair of heat exchangers and a pair of solenoid valves.
Further advantages, aspects and 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
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a schematic view of a temperature management system according to the present invention associated with an automatic transmission; and
FIG. 2 is an enlarged, cross sectional view of a logic or spool valve showing the non-overlapping operation of the pistons.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
With reference now to FIG. 1 , a temperature management system which is illustrated in association with an automatic transmission is generally designated by the reference number 10 . The temperature management system 10 is utilized in conjunction with an automatic transmission 12 which, in turn, is utilized in conjunction with a prime mover 14 such as an internal combustion gas, Diesel or flex fuel engine or other power plant, e.g., hybrid.
The temperature management system 10 includes a hydraulic supply line 18 which receives a flow of hydraulic fluid (transmission oil) under pressure from the automatic transmission 12 and provides it to an inlet port 20 A of a first, three way, two position diverter spool valve 20 . The three way spool valve 20 includes a spool 22 having spaced apart lands or pistons 22 A and 22 B which translate within a circular bore 24 defined by a cylindrical housing 26 . The spool 22 is connected to and translated by a plunger 28 of a solenoid assembly 30 which is disposed and translates within a solenoid coil 32 . When the solenoid coil 32 is energized, the plunger 28 and the spool 22 translate to the left, to the position illustrated in FIG. 1 . When the solenoid coil 32 is de-energized, the plunger 28 , the spool 22 and the lands or pistons 22 A and 22 B translate to the right, to the positions illustrated in dashed lines in FIG. 1 .
Note that in the energized (left) position of the spool 22 , the land or piston 22 B fully closes off the port 20 C and in the right (de-energized) position of the spool 22 , the land or piston 22 A fully closes off the port 20 B. A compression spring 34 is disposed between the end of the spool 22 opposite the solenoid assembly 30 and an end of the cylindrical housing 26 and biases the spool 22 and the plunger 28 to the right in FIG. 1 .
The cylindrical housing 26 also defines a first outlet port 20 B and a second outlet port 20 C as well as two exhaust or vent ports 20 D and 20 E. When the solenoid coil 32 is energized oil or fluid flows from the inlet port 20 A out through the first outlet port 20 B. The first outlet port 20 B communicates through a first oil or fluid line 36 to an oil inlet 38 of a first heat exchanger 40 . The first heat exchanger 40 includes a first plurality of tubes or passageways (not illustrated) that communicate between the oil inlet 38 and an oil outlet 42 . The oil outlet 42 of the first heat exchanger 40 communicates through a fluid return line 44 with the automatic transmission 12 .
The first heat exchanger 40 also includes a second plurality of tubes or passageways (also not illustrated) which are interleaved and in thermal communication with, but provide flow isolated from, the first tubes or passageways. A coolant inlet 46 communicates through the second plurality of tubes or passageways with a coolant outlet 48 . The coolant inlet 46 and the coolant outlet 48 are connected by a coolant supply line 52 and a coolant return line 54 , respectively, to appropriate coolant passageways in the prime mover 14 .
When the solenoid coil 32 in de-energized, a flow path from the inlet port 20 A to the second outlet port 20 C is established and a second oil or fluid line 56 to an inlet port 60 A of second, three way diverter or bypass valve assembly 60 . The second diverter valve assembly 60 includes a housing 62 which defines the inlet port 60 A as well as a first outlet port 60 B and a second outlet port 60 C. The second, bypass valve assembly 60 also includes a wax motor 64 that preferably senses the temperature of the transmission fluid or oil in the second fluid line 56 by, for example, exposing the housing of the wax motor 64 to flow in the second fluid line 56 or a similar method of heat transfer. The wax motor 64 drives a linearly translating valve member 66 that directs transmission fluid or oil flow through the second outlet port 60 C to a bypass or return line 44 A which may be an extension of the return line 44 when the transmission fluid is relatively cool. As the temperature rises in the second fluid line 56 , wax in the wax motor 64 heats, translates and repositions the valve member 66 to close off the second outlet port 60 C and the bypass or return line 44 A and open the first outlet port 60 B and an extension of the second fluid line 56 , designated 56 A. The extension of the second fluid line 56 A communicates with an oil inlet 68 of a second heat exchanger 70 . The second heat exchanger 70 includes a first plurality of tubes or passageways (not illustrated) that communicate between the oil inlet 68 and an oil outlet 72 . The oil outlet 72 of the second heat exchanger 70 communicates through the fluid return line 44 with the automatic transmission 12 .
The second heat exchanger 70 also includes a second plurality of tubes or passageways (also not illustrated) which are interleaved and in thermal communication with, but flow isolated from, the first tubes or passageways. An air inlet 76 communicates through the second plurality of tubes or passageways with an air outlet 78 . Thus, when the wax motor 64 repositions the valve member 66 to direct transmission fluid flow through the extension of the second fluid or oil line 56 , the second heat exchanger 70 transfers heat from the transmission fluid to the ambient air, thereby cooling the transmission fluid.
A transmission control module or TCM 80 which is typically associated with and which controls the automatic transmission 12 is provided with data, e.g., internal temperature, from the transmission 12 and provides an electrical signal to the solenoid coil 32 when the temperature of the transmission 12 is below a predetermined threshold valve. Alternatively, such control may be provided and commanded by an engine control unit (ECU) or a body control unit (BCU).
As an additional alternative, the second valve assembly 60 and specifically the wax motor 64 may be replaced with a second, electrically driven solenoid valve having the same configuration, namely, one inlet 60 A and two outlets 60 B and 60 C which is under the control of the transmission control module, the engine control unit or the body control unit 80 .
As illustrated in FIG. 2 , the first, two position spool valve 20 includes the spool 22 having axially spaced apart lands or pistons 22 A and 22 B which translate within the circular bore 24 defined by the cylindrical housing 26 . The axial spacing “A” between the adjacent (inner) faces of the lands or pistons 22 A and 22 B is greater than the adjacent edge distance “B” between the first outlet port 20 B and the second outlet port 20 C in the cylindrical housing 26 . As such, the lands or pistons 22 A and 22 B cannot close off both of the outlet ports 20 B and 20 C at the same time. Stated somewhat differently, at least one of the outlet ports 20 B or 20 C will always be at least partially open, thereby providing a fail-safe feature by ensuring that there will always be a flow of transmission fluid through the valve 20 and one of the heat exchangers 40 or 70 . This same axial distance relationship may, and preferably will be, utilized in the second diverter valve 60 .
The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An active/passive system for managing the temperature of fluid within an automatic transmission includes two heat exchangers, an active solenoid valve and a passive wax motor valve. A first heat exchanger provides transmission fluid heating and receives a flow of engine coolant. A second heat exchanger provides transmission fluid cooling and is exposed to ambient air. The solenoid valve which is preferably driven by a signal from a transmission control module (TCM) and the wax motor valve cooperate to provide three states of operation: transmission fluid heating, that is, heat added, cooling, that is, heat removed and pass-through or bypass (without heating or cooling). | 5 |
This appln is a cont of Ser. No. 08/793,444 filed May 9, 1997, abnd.
FIELD OF THE INVENTION
The present invention relates to the construction of interior works. More particularly, the invention is concerned with any construction method, involving flat prefabricated elements, especially boards, and at least one joint-pointing coat which can be used especially for the finishing of a joint. The flat prefabricated elements comprise a plaster board and at least one sheet of lining paper, at least one outer layer of which has a visible outer face ready to be decorated. The said flat elements are assembled together, especially with a coat, and the joints are finished with the said joint-pointing coat, so as to obtain an overall visible outer surface which is relatively uniform or plane, including in the region of the joints. Such a method is employed, for example, when plasterboards covered with a cardboard lining having a joint-pointing coat are assembled, for the purpose of defining spaces within a building, especially partitions.
DESCRIPTION OF RELATED ART
According to the document EP-A-0,521,804, the lining paper may comprise an upper layer, called an upper web, comprising white cellulose fibres, mainly synthetic, and a mineral filler of light colour, preferably white, and a pigment layer covering the upper layer, comprising a mineral filler of light colour, preferably white, and a binder.
In general the overall visible outer surface obtained according to the above-defined method needs to be prepared, before receiving any surface decoration, such as one or more layers of a film covering of the paint or lacquer type or a wallpaper. This preparation is necessitated especially by the shade or colour differences existing between the visible outer surface of the flat prefabricated elements, for example plasterboards, and the visible outer surface of the joints. After the interior work has been completed, this preparation involves covering the overall surface obtained, i.e. the lining of the flat prefabricated elements plus the joints, with one or more layers of a paint or priming or finishing coat.
The preparation operation represents an appreciable additional cost, for example in a complete process for the construction of a building. And in some cases, it is still insufficient for obtaining an overall decorated surface of uniform appearance, particularly in view of the physico-mechanical differences prevailing between the joints and the flat prefabricated elements.
SUMMARY OF THE INVENTION
The object of the present invention is to overcome the abovementioned disadvantages. More specifically, the object of the invention is a construction method breaking with the traditional approach adopted for solving the problem explained above, that is to say avoiding the need for a preparation of the overall surface, before any decoration. However, the object of the invention is a method which remains compatible with the practices of the professionals in the construction industry, especially those involved in interior works.
According to the present invention, the method differs from the traditional approach in that, the structure and/or composition of the sheet of lining paper and the composition of the joint-pointing coat are coordinated with one another in order, in the dry state of the joint-pointing coat, to obtain an overall surface having one or more physical characteristics, including colour or shade, which are substantially homogeneous in virtually the entire overall surface, including in the region of the visible outer face of the joints.
According to other objects of the invention a construction assembly for interior works is provided, comprising, flat prefabricated elements, especially boards, and, a joint-pointing coat capable of being used especially for the finishing of a joint. The flat prefabricated elements comprise a plaster body and at least one sheet of lining paper, at least one outer layer of which has a visible outer face ready to be decorated. In this assembly, the structure and/or composition of the sheet of lining paper and the composition of the joint-pointing coat are coordinated with one another in order, in the dry state of the joint-pointing coat, to obtain an overall surface having one or more physical characteristics, including colour or shade, which are substantially homogeneous in virtually the entire overall surface, including in the region of the visible outer face of the joints.
A joint-pointing coat, intended to be used in the method or the assembly according to the invention, is also provided.
The present invention affords the following decisive advantages which result from the surface homogeneity of the overall surface obtained according to the present invention, not only in terms of colour or shade, but also in terms of particular physical or physico-chemical characteristics.
Thus, by homogenizing the surface absorption capacity of the lining paper and of the joint-pointing coat, a virtually perfect appearance of the paint layer or paint layers and a virtually uniform adhesion of a wallpaper can be obtained. This subsequently is conducive to the homogeneous detachment of the wallpaper.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred version of the invention, there is a sealing coat intended for forming essentially the joints between the various flat elements, with the joint-pointing coat being a finishing coat which can be applied to the sealing coat.
According to an advantageous embodiment of the invention, when there are preexisting flat prefabricated elements, the composition of the joint-pointing coat is coordinated with the structure and/or composition of the sheet of lining paper.
According to another version of the invention, and converse to the foregoing, for a preexisting joint-pointing coat, the composition of the sheet of lining paper is coordinated with the composition of the joint-pointing coat.
Moreover, the method is more preferably characterized in that, in addition to the colour or shade, at least any one of the following physical characteristics is homogenized or matched between flat prefabricated elements and the joint-pointing coat, namely:
the surface appearance, including reflectance;
the absorption of surface water;
decoloration or coloration under the effect of natural light.
Advantageously, these various physical characteristics are defined as follows:
the reflectance factor of the overall surface, including that of the visible outer face of the joints, is between 70% and 80%, and preferably between 72% and 76%, for a wavelength of 457 nm;
the decoloration or coloration of the overall surface, including that of the visible outer face of the joints, has a colour deviation (delta E * ) at most equal to 3 after exposure for 72 hours to a source of UV radiation arranged at 15 cm from the surface and having a wavelength at least equal to 290 nm;
the surface water absorption of the overall surface, including that of the visible outer face of the joints, is not less than 60 minutes and/or is at most equal to 15 g/m 2 according to the COBB test, at 23° C.
In practice, and by means of routine tests, the average person skilled in the art knows how to coordinate the structure and/or composition of a sheet of lining paper and/or the composition of a coat, so as to satisfy the above-defined technical principles. As a result, the examples described below are in no way limiting.
The present invention will now be described by taking flat prefabricated elements, plasterboards, as an example. These boards are typically composed of a factory-cast plaster body between two sheets of paper forming both its lining and its reinforcement.
Conventionally, one of the sheets of paper used for making the plasterboards has a dark colour which can vary between a grey colour and a chestnut colour, since it is composed of cellulose fibres which have not undergone any particular purifying treatment. Traditionally, this so-called grey paper is obtained from unbleached chemical pulp and/or from mechanical pulp, and/or from thermomechanical pulp and/or from semi-chemical pulp. By mechanical pulp, it is usually meant a pulp obtained entirely by mechanical means from various raw materials, essentially wood, which can be provided by salvaged products originating from wood, such as old cardboard boxes, trimmings of kraft paper and/or old newspapers. Thermomechanical pulp means a pulp obtained by thermal treatment followed by a mechanical treatment of the raw material. By semi-chemical pulp is meant a pulp obtained by eliminating some of the non-cellulose components from the raw material by means of chemical treatment and requiring a subsequent mechanical treatment in order to disperse the fibres.
The other sheet of plasterboards has a visible face, called a lining face, of a colour generally lighter than the grey sheet. To obtain this lighter colour, the layer or layers of this face are based on chemical pulp, if appropriately bleached, composed of recycled and/or new cellulose fibres, and/or on mechanical pulp, if appropriately bleached. By chemical pulp is meant a pulp obtained by eliminating a very large proportion of the non-cellulose components from the raw material by chemical treatment, for example, by cooking in the presence of suitable chemical agents, such as soda or bisulphites. When this chemical treatment is completed by bleaching, a large part of the coloured substances is eliminated, as well as the substances which risk decomposing by ageing and giving unpleasant yellow shades associated with the presence of, for example, lignin.
In a preferred embodiment of the method of the invention, and according to the document EP-A-0 521 804, the content of which is incorporated by reference, the lining paper comprises an upper layer, called an upper web, comprising white cellulose fibres, mainly synthetic, a mineral filler of light colour, preferably white, and a pigment layer covering the upper layer. The pigment layer comprises a mineral filler of light colour, preferably white, and a binder. Correspondingly, according to the present invention, the joint-pointing coat comprises a mineral filler of light colour, preferably white, the grain size of which is between 5 and 35 μm.
The fineness of the grain size of the mineral filler of the joint-pointing coat makes it possible to obtain a smooth surface corresponding to that of the lining of the board. Too large a grain size of the filler gives rise to overall surface defects, such as a reflection of light radiation on the surface of the coat which is different from that on the surface of the board, bringing about differences in tone and brightness of the shade. Too large a grain size also gives rise to differences in physical appearance which are associated with the differences in roughness between the board and the coat.
The mineral filler represents preferably between 50% and 85% of the total weight of the joint-pointing coat.
Moreover, the coat can comprise a hydrophobic agent, for example between 0.2% and 5%, and preferably between 0.5% and 3%, of the total weight of the coat, for example a silicone derivative. This agent slows the drying kinetics of the coat, which is conducive to the non-cracking of the coat. Also, this agent has higher resistance to the attack of steam during operations for the removal of wallpaper, so that the removal can be achieved without thereby impairing the good bonding of a paint or paper adhesive on the overall surface, including the visible surface of the joints. In fact, this hydrophobic agent makes it possible to level off the absorbent capacities of the surfaces of the coat and of the lining paper of the board. Thus, all paints or paper adhesives applied to the overall surface obtained exhibit little shift in absorption kinetics between the coat and the board, thus making it possible to avoid the appearance of spectra or of defects in shade homogeneity.
The coat also comprises an organic binder dispersible in aqueous phase, in a proportion of between 1 and 20%, and preferably between 2 and 12%, of the total weight of the joint-pointing coat, for example polyvinyl acetates and/or acrylic acid esters. The choice of this binder is important, since it must impart sufficient flexibility to the coat to withstand mechanical stresses, and it must have both an adhesive capacity for obtaining a good bond on the overall surface and good resistance to the attacks of UV light.
Moreover, a handling agent is provided in the composition of the coat, especially a water-retaining and thickening agent, for example methylhydroxyethyl-cellulose, in a proportion of 1 to 15%, and preferably of 2 to 12%, of the total weight of the joint-pointing coat.
Finally, at least one slipping agent can be included in the composition of the coat, especially a clay, in the proportion of 0.1 to 2%, and preferably of 0.1 to 0.6%, of the total weight of the joint-pointing coat. These clays are preferably silicate derivatives and more preferably clays of the attapulgite type.
Other components, such as biocides, dispersants, anti-foaming agents and pigments can also be incorporated in the composition of the coat in the conventional way.
The invention will be understood better from the following detailed example given as a non-limiting indication.
We proceed from plasterboards similar to Example 5 of document EP-A-0 521 804, which are assembled by means of a conventional sealing joint, for example a joint coat sold under the registered trade mark of "PREGYLYS"® of the Company PLATRES LAFARGE. The upper web of the lining of the board is obtained from 65% bleached synthetic cellulose fibres and 35% talcum and is covered with a pigment layer comprising, as mineral filler, 85% by weight of CaSO 4 , 2H 2 O in the form of needles of a length of between 3 and 5 μm and, as a binder, 10.3% by weight of styrene-butadiene copolymer. The sealing joint subsequently receives a thin layer of a joint-pointing coat according to the invention, having the following composition:
50 to 85% by weight of calcium carbonate, grain size from 5 to 35 μm, as a mineral filler;
2 to 12% by weight of a binder comprising polyvinyl acetates and acrylic acid esters in aqueous dispersion;
0.5 to 3% by weight of a silicone derivative as a hydrophobic agent;
0.1 to 0.9% of a cellulose derivative of the methylhydroxyethylcellulose type;
0.1 to 0.6% of a slipping agent of the attapulgite type;
1 to 12% of another silicate derivative as an additional slipping agent;
0.1 to 5% of a polycarboxylic acid ammonium salt as a dispersant;
0.001 to 0.015 of an iron oxide as a pigment;
0.1 to 0.3% of a preparation of N-formoles and isothiazolinones as a biocide;
0.1 to 0.3% of a conventional anti-foaming agent;
water up to 100%.
The weight percentages given are in relation to the total weight of the coat, unless indicated otherwise.
For comparison requirements, standard boards conforming solely to French standard NF P 72-302 and not comprising the above-defined upper web and pigment layer are assembled by means of a joint coat for a plasterboard of the range of coats "PREGYLYS"®, sold by the Company PLATRES LAFARGE.
The characteristics of the two overall surfaces thus formed are compared by applying the following tests:
(A) Degree of whiteness or reflectance factor R obtained according to standard NFQ 03038 with a wavelength of 457 nm. This degree represents the percentage ratio between of a reflected radiation of the body in question and that of a perfect diffuser under the same conditions.
(B) Surface water absorption obtained, for example, according to the COBB test. In this test, a ring defining an area of 100 cm 2 is filled with distilled water at 23° C. to a height of approximately 10 mm. The water is left in contact with the overall surface forming the bottom of the ring for one minute, and then the water is emptied and the excess spin-dried. The weight gain of the surface is subsequently determined and brought back to an area of 1 m 2 . In an alternative version, a drop of distilled water of a volume of approximately 0.05 cm 3 at 23° C. is deposited on the surface. It is important that the drop be deposited and not allowed to fall from a variable height which consequently would crush it to a greater or lesser extent, thus falsifying the result. The duration in minutes represents the surface absorption of the tested area.
(C) UV radiation resistance obtained by exposing the overall surfaces, in a cabinet comprising eight high pressure mercury vapour lamps, each of 400 watts, to a wavelength which is not less than 290 nm. The surfaces are maintained at a distance of 15 cm from the lamps and at a temperature of 60° C. for 72 hours. The colour deviations delta E * are measured on a spectro-colorimeter according to the standard DIN 6174 at an angle of 8°, illuminant D65 as a bright specular, included in the system L * , a * , b * , in which L * is the luminance, a * represents the transition from green to red, and b * represents the transition from blue to yellow. A point E * in this system, the said point being a function of L * , a * , b * , defines the colorimetry of a sample and the deviation is measured in relation to a reference point. In general terms, a colour deviation beyond 2 becomes discernible to the naked eye.
The results of the tests (A) and (B) are collated in Table I and those of the test (C) are collated in Table II below.
TABLE I______________________________________ Overall surface Standard according to overall the surface invention______________________________________Reflectance R (%) Board: 50 to 60 Board: 72 to 76 Coat: 65 to 85 Coat: 72 to 76Absorption 19 13COBB (g/m.sup.2) Board: 50 Board: > = 60Alternative (min) Coat: 15 Coat: > = 60______________________________________
This shows that the overall surface according to the present invention is clearly more homogeneous than that of an assembly according to the conventional technique. Moreover, the more homogeneous absorption time of the overall surface makes it possible to use a paint having less covering capacity than that necessary with traditional boards and coats and is also beneficial to the painting operation.
TABLE II______________________________________Before Exposure Standard Invention______________________________________Initial measure- L* = 82.94 L* = 90.41ments of the board a* = -0.43 a* = -0.03 b* = 4.64 b* = 3.13Initial measure- L* = 90.70 L* = 89.70ments of the joint a* = 0.73 a* = 0.50 b* = 5.28 b* = 3.60 Board/Joint Board/Joint col- colour devi- our deviation ation delta E* = delta E* = 1 7.87Exposure to UV for72 hoursMeasurements of the L* = 81.10 L* = 90.38board after exposure a* = 0.69 a* = -0.91 b* = 12.93 b* = 7.40 Colour devia- Colour deviation tion delta E* = delta E* = 4.36; 8.56; very substantial substantial yellowing yellowing plus chestnut spotsMeasurements of the L* = 88.90 L* = 89.17joint after exposure a* = 0.91 a* = 0.50 b* = 3.83 b* = 3.19 Colour devia- Colour deviation tion delta E* = delta E* = 0.67; 2.32; slight very slight col- yellowing plus our deviation a few chestnut spots______________________________________
This table shows that the colour deviation before exposure to UV is much slighter for an overall surface according to the invention than for an overall surface such as is obtained traditionally.
This table also shows that the change in the colour deviation after exposure to UV is much less pronounced in the overall surface according to the invention than traditionally. In fact, the colour deviation before exposure and after exposure must be as little as possible, so that the overall surface does not give the impression to the naked eye of being spotted or being covered with zones of different shade and brightness.
This is not possible with an overall surface obtained by means of traditional plasterboards and products, but the very slight deviation of the overall surface according to the invention makes it possible to mitigate this disadvantage. | A construction assembly for interior works, comprising:
(1) plaster boards, each of which plaster boards comprises a plaster body and at least one sheet of lining paper, wherein the lining paper comprises
(a) an upper layer or web comprising white cellulose fibers and a mineral filler of light color, and
(b) a pigment layer covering said upper layer or web, wherein the pigment layer comprises a mineral filler of light color and a binder,
wherein said plaster boards are assembled creating at least one joint; and
(2) a joint-pointing coat jointing said plaster boards to form a substantially plane outer surface comprising the visible surface of said at least one joint and the visible surface of said pigment layer, wherein the composition of which joint-pointing coat is adapted for the finishing of said at least one joint, wherein said joint-pointing coat comprises a mineral filler of white color;
wherein the composition of said joint-pointing coat is similar to the composition of said upper layer or web and/or said pigment layer, whereby said joint-pointing coat in a dry state and the upper web and/or pigment layer form a substantially homogeneous outer surface having similar coloration, reflectance factors and surface water absorbability, wherein said outer surface is ready to be decorated. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 14/022,384, filed Sep. 10, 2013 (issued as U.S. Pat. No. 8,776,875 on Jul. 15, 2014), which was a continuation of U.S. patent application Ser. No. 13/663,609, filed Oct. 30, 2012 (issued as U.S. Pat. No. 8,528,631 on Sep. 10, 2013), which was a continuation of U.S. patent application Ser. No. 13/438,053, filed Apr. 3, 2012, (issuing as U.S. Pat. No. 8,297,348 on Oct. 30, 2012), which was a continuation of U.S. patent application Ser. No. 13/074,327, filed Mar. 29, 2011 (issued as U.S. Pat. No. 8,146,663 on Apr. 3, 2012), which was a continuation of U.S. patent application Ser. No. 12/724,846, filed Mar. 16, 2010, (issued as U.S. Pat. No. 7,913,760 on Mar. 29, 2011), which application was a continuation of U.S. patent application Ser. No. 11/778,956, filed Jul. 17, 2007 (issued as U.S. Pat. No. 7,681,646 on Mar. 23, 2010) which was a continuation-in-part of U.S. patent application Ser. No. 11/751,740, filed May 22, 2007 (issued as U.S. Pat. No. 7,533,720 on May 19, 2009) which was a non-provisional of U.S. Provisional Patent Application Ser. No. 60/829,990, filed Oct. 18, 2006 and U.S. Provisional Patent Application Ser. No. 60/803,055, filed May 24, 2006.
[0002] Each of these applications are incorporated herein by reference. Priority of each of these applications is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0004] Not applicable
BACKGROUND
[0005] In top drive rigs, the use of a top drive unit, or top drive power unit is employed to rotate drill pipe, or well string in a well bore. Top drive rigs can include spaced guide rails and a drive frame movable along the guide rails and guiding the top drive power unit. The traveling block supports the drive frame through a hook and swivel, and the driving block is used to lower or raise the drive frame along the guide rails. For rotating the drill or well string, the top drive power unit includes a motor connected by gear means with a rotatable member both of which are supported by the drive frame.
[0006] During drilling operations, when it is desired to “trip” the drill pipe or well string into or out of the well bore, the drive frame can be lowered or raised. Additionally, during servicing operations, the drill string can be moved longitudinally into or out of the well bore.
[0007] The stem of the swivel communicates with the upper end of the rotatable member of the power unit in a manner well known to those skilled in the art for supplying fluid, such as a drilling fluid or mud, through the top drive unit and into the drill or work string. The swivel allows drilling fluid to pass through and be supplied to the drill or well string connected to the lower end of the rotatable member of the top drive power unit as the drill string is rotated and/or moved up and down.
[0008] Top drive rigs also can include elevators are secured to and suspended from the frame, the elevators being employed when it is desired to lower joints of drill string into the well bore, or remove such joints from the well bore.
[0009] At various times top drive operations, beyond drilling fluid, require various substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as the top drive unit is rotating and/or moving the drill or well string up and/or down, but bypassing the top drive's power unit so that the substances do not damage/impair the unit. Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movement by the top drive unit of the drill or well string.
[0010] A need exists for a device facilitating insertion of various substances downhole through the drill or well string, bypassing the top drive unit, while at the same time allowing the top drive unit to rotate and/or move the drill or well string.
[0011] One example includes cementing a string of well bore casing. In some casing operations it is considered good practice to rotate the string of casing when it is being cemented in the wellbore. Such rotation is believed to facilitate better cement distribution and spread inside the annular space between the casing's exterior and interior of the well bore. In such operations the top drive unit can be used to both support and continuously rotate/intermittently reciprocate the string of casing while cement is pumped down the string's interior. During this time it is desirable to by-pass the top drive unit to avoid possible damage to any of its portions or components.
[0012] The following U.S. patents are incorporated herein by reference: U.S. Pat. Nos. 4,722,389 and 7,007,753.
[0013] While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”
BRIEF SUMMARY
[0014] The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner. One embodiment relates to an assembly having a top drive arrangement for rotating and longitudinally moving a drill or well string. In one embodiment is provided a swivel apparatus, the swivel generally comprising a mandrel and a sleeve with a packing configuration, the swivel being especially useful for top drive rigs.
[0015] In one embodiment the sleeve can be rotatably and sealably connected to the mandrel. The swivel can be incorporated into a drill or well string, enabling string sections both above and below the sleeve to be rotated in relation to the sleeve. Additionally, the swivel provides a flow path between the exterior of the sleeve and interior of the mandrel while the drill string is being rotated and/or being moved in a longitudinal direction (up or down). The interior of the mandrel can be fluidly connected to the longitudinal bore of the casing or drill string thereby providing a flow path from the exterior of the sleeve to the interior of the casing/drill string.
[0016] In one embodiment is provided a method and apparatus for servicing a well wherein a swivel is connected to a top drive unit for conveying pumpable substances from an external supply through the swivel for discharge into the well string and bypassing the top drive unit.
[0017] In another embodiment is provided a method of conducting servicing operations in a well bore, such as cementing, comprising the steps of moving a top drive unit rotationally and/or longitudinally to provide longitudinal movement and/or rotation in the well bore of a well string suspended from the top drive unit, rotating the drill or well string and supplying a pumpable substance to the well bore in which the drill or well string is manipulated by introducing the pumpable substance at a point below the top drive power unit and into the well string.
[0018] In other embodiments are provided a swivel placed below the top drive unit can be used to perform jobs such as spotting pills, squeeze work, open formation integrity work, kill jobs, fishing tool operations with high pressure pumps, sub-sea stack testing, rotation of casing during side tracking, and gravel pack or frack jobs. In still other embodiments a top drive swivel can be used in a method of pumping loss circulation material (LCM) into a well to plug/seal areas of downhole fluid loss to the formation and in high speed milling jobs using cutting tools to address down hole obstructions. In other embodiments the top drive swivel can be used with free point indicators and shot string or cord to free stuck pipe where pumpable substances are pumped downhole at the same time the downhole string/pipe/free point indicator is being rotated and/or reciprocated. In still other embodiments the top drive swivel can be used for setting hook wall packers and washing sand.
[0019] In still other embodiments the top drive swivel can be used for pumping pumpable substances downhole when repairs/servicing is being done to the top drive unit and rotation of the downhole drill string is being accomplished by the rotary table. Such use for rotation and pumping can prevent sticking/seizing of the drill string downhole. In this application safety valves, such as TIW valves, can be placed above and below the top drive swivel to enable routing of fluid flow and to ensure well control.
[0020] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0022] FIGS. 1A and 1B are a schematic views showing a top drive rig with one embodiment of a top drive swivel incorporated in the drill string;
[0023] FIG. 2 is a perspective view of one embodiment of a top drive swivel;
[0024] FIG. 3 is a sectional view of a mandrel which can be incorporated in the swivel of FIG. 2 ;
[0025] FIG. 4 is a perspective view of a sleeve, clamp, and torque arm which can be incorporated into the swivel of FIG. 2 ;
[0026] FIG. 5 is an exploded view of the sleeve, clamp, and torque arm of FIG. 4 ;
[0027] FIG. 6 is a cutaway perspective view of the swivel of FIG. 2 ;
[0028] FIGS. 7A and 7B include a sectional view of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
[0029] FIG. 8 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 2 ;
[0030] FIG. 9 is a perspective view of a spacer;
[0031] FIG. 10 is a top view of the spacer of FIG. 9 ;
[0032] FIG. 11A is a sectional side view of the spacer of FIG. 9 ;
[0033] FIG. 11B is an enlarged sectional side view of the spacer of FIG. 9 ;
[0034] FIG. 12 is a perspective view of a female backup ring;
[0035] FIG. 13 is a top view of the female backup ring of FIG. 12 ;
[0036] FIG. 14A is a sectional side view of the female backup ring of FIG. 12 ;
[0037] FIG. 14B is an enlarged sectional side view of the female backup ring of FIG. 12 ;
[0038] FIG. 15 is a perspective view of a seal ring;
[0039] FIG. 16 is a top view of the seal ring of FIG. 15 ;
[0040] FIG. 17A is a sectional side view of the seal ring of FIG. 15 ;
[0041] FIG. 17B is an enlarged sectional side view of the seal ring of FIG. 15 ;
[0042] FIG. 18 is a perspective view of a rope seal;
[0043] FIG. 19 is a top view of the rope seal of FIG. 18 ;
[0044] FIG. 20A is a sectional side view of the rope seal of FIG. 18 ;
[0045] FIG. 20B is an enlarged sectional side view of the rope seal of FIG. 18 ;
[0046] FIG. 21 is a perspective view of a seal ring;
[0047] FIG. 22 is a top view of the seal ring of FIG. 21 ;
[0048] FIG. 23A is a sectional side view of the seal ring of FIG. 21 ;
[0049] FIG. 23B is an enlarged sectional side view of the seal ring of FIG. 21 ;
[0050] FIG. 24 is a perspective view of a seal ring;
[0051] FIG. 25 is a top view of the seal ring of FIG. 24 ;
[0052] FIG. 26A is a sectional side view of the seal ring of FIG. 24 ;
[0053] FIG. 26B is an enlarged sectional side view of the seal ring of FIG. 24 ;
[0054] FIG. 27 is a perspective view of a male backup ring;
[0055] FIG. 28 is a top view of the male backup ring of FIG. 27 ;
[0056] FIG. 29A is a sectional side view of the male backup ring of FIG. 27 ;
[0057] FIG. 29B is an enlarged sectional side view of the male backup ring of FIG. 27 ;
[0058] FIGS. 30A and 30B include a sectional view of another embodiment of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
[0059] FIG. 31 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 30A ;
[0060] FIG. 32 is a perspective view of a spacer;
[0061] FIG. 33 is a top view of the spacer of FIG. 32 ;
[0062] FIG. 34A is a sectional side view of the spacer of FIG. 32 ;
[0063] FIG. 34B is an enlarged sectional side view of the spacer of FIG. 32 ;
[0064] FIG. 35 is a perspective view of a female backup ring;
[0065] FIG. 36 is a top view of the female backup ring of FIG. 35 ;
[0066] FIG. 37A is a sectional side view of the female backup ring of FIG. 35 ;
[0067] FIG. 37B is an enlarged sectional side view of the female backup ring of FIG. 35 ;
[0068] FIG. 38 is a perspective view of a seal ring;
[0069] FIG. 39 is a top view of the seal ring of FIG. 38 ;
[0070] FIG. 40A is a sectional side view of the seal ring of FIG. 38 ;
[0071] FIG. 40B is an enlarged sectional side view of the seal ring of FIG. 38 ;
[0072] FIG. 41 is a perspective view of a rope seal;
[0073] FIG. 42 is a top view of the rope seal of FIG. 41 ;
[0074] FIG. 43A is a sectional side view of the rope seal of FIG. 41 ;
[0075] FIG. 43B is an enlarged sectional side view of the rope seal of FIG. 41 ;
[0076] FIG. 44 is a perspective view of a seal ring;
[0077] FIG. 45 is a top view of the seal ring of FIG. 44 ;
[0078] FIG. 46A is a sectional side view of the seal ring of FIG. 44 ;
[0079] FIG. 46B is an enlarged sectional side view of the seal ring of FIG. 44 ;
[0080] FIG. 47 is a perspective view of a seal ring;
[0081] FIG. 48 is a top view of the seal ring of FIG. 47 ;
[0082] FIG. 49A is a sectional side view of the seal ring of FIG. 47 ;
[0083] FIG. 49B is an enlarged sectional side view of the seal ring of FIG. 47 ;
[0084] FIG. 50 is a perspective view of a male backup ring;
[0085] FIG. 51 is a top view of the male backup ring of FIG. 50 ;
[0086] FIG. 52A is a sectional side view of the male backup ring of FIG. 50 ;
[0087] FIG. 52B is an enlarged sectional side view of the male backup ring of FIG. 50 .
DETAILED DESCRIPTION
[0088] Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
[0089] FIGS. 1A and 1B are schematic views showing a top drive rig 1 with one embodiment of a top drive swivel 30 incorporated into drill string 20 . FIG. 1A shows a rig 1 having a top drive unit 10 . Rig 1 comprises supports 16 , 17 ; crown block 2 ; traveling block 4 ; and hook 5 . Draw works 11 uses cable 12 to move up and down traveling block 4 , top drive unit 10 , and drill string 20 . Traveling block 4 supports top drive unit 10 . Top drive unit 10 supports drill string 20 .
[0090] During drilling operations, top drive unit 10 can be used to rotate drill string 20 which enters wellbore 14 . Top drive unit 10 can ride along guide rails 15 as unit 10 is moved up and down. Guide rails 15 prevent top drive unit 10 itself from rotating as top drive unit 10 rotates drill string 20 . During drilling operations drilling fluid can be supplied downhole through drilling fluid line 8 and gooseneck 6 .
[0091] As shown in FIG. 1B , during operations swivel 30 can be connected to rig 1 through clamp 600 and torque arm 630 . Torque are 630 can be pivotally connected to swivel 30 and can resist rotational movement of swivel sleeve 150 relative to rig 1 . Torque arm 630 can be slidably connected to rig 1 to allow a certain amount of longitudinal movement of swivel 30 with drill string 20 .
[0092] At various times top drive operations, beyond drilling fluid, require substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as top drive unit 10 is rotating and/or moving drill or well string 20 up and/or down and bypassing top drive unit 10 so that the substances do not damage/impair top drive unit 10 . Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movements of drill or well string 20 being moved/rotated by top drive unit 10 . This can be accomplished by using top drive swivel 30 .
[0093] Top drive swivel 30 can be installed between top drive unit 10 and drill string 20 . One or more joints of drill pipe 18 can be placed between top drive unit 10 and swivel 30 . Additionally, a valve can be placed between top drive swivel 30 and top drive unit 10 . Pumpable substances can be pumped through hose 31 , swivel 30 , and into the interior of drill string 20 thereby bypassing top drive unit 10 . Top drive swivel 30 is preferably sized to be connected to drill string 20 such as 4½ inch (11.43 centimeter) IF API drill pipe or the size of the drill pipe to which swivel 30 is connected to. However, cross-over subs can also be used between top drive swivel 30 and connections to drill string 20 . Two sizes for swivel 30 will be addressed in this application—a 4½ inch (11.43 centimeter) version and a 6⅝ inch (16.83 centimeter) version.
[0094] FIG. 2 is a perspective view of one embodiment of a swivel 30 . Swivel 30 can be comprised of mandrel 40 and sleeve 150 . Sleeve 150 can be rotatably and sealably connected to mandrel 40 . Accordingly, when mandrel 40 is rotated, sleeve 150 can remain stationary to an observer insofar as rotation is concerned. As will be discussed later inlet 200 of sleeve 150 is and remains fluidly connected to a the central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 .
[0095] FIG. 3 is a sectional view of mandrel 40 which can be incorporated in swivel 30 . Mandrel 40 can be comprised of upper end 50 and lower end 60 . Central longitudinal passage 90 can extend from upper end 50 through lower end 60 . Lower end 60 can include a pin connection 80 or any other conventional connection. Upper end 50 can include box connection 70 or any other conventional connection. Mandrel 40 can in effect become a part of drill string 20 . Sleeve 150 can fit over mandrel 40 and become rotatably and sealably connected to mandrel 40 . Mandrel 40 can include shoulder 100 to support sleeve 150 . Mandrel 40 can include one or more radial inlet ports 140 fluidly connecting central longitudinal passage 90 to recessed area 130 . Recessed area 130 preferably forms a circumferential recess along the perimeter of mandrel 40 and between packing support areas 131 , 132 . In such manner recessed area 130 will remain fluidly connected with radial passage 190 and inlet 200 of sleeve 150 (see FIGS. 6 and 7A ).
[0096] Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 52 and 5/16 inches (132.87 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. NC 50 is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Such tool joint designation is equivalent to and interchangeable with 4½ inch (11.43 centimeter) IF (Internally Flush), 5 inch (12.7 centimeter) XH (Extra Hole) and 5½ inch (13.97 centimeter) DSL (Double Stream Line) connections. Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7G for new rotary shouldered tool joint connections having 6⅝ inch (16.83 centimeters) outer diameter and a 2¾ inch (6.99 centimeter) inner diameter. The Strength and Design Formulas of API 7G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 1,477,000 pounds (6,570 kilo newtons) tensile load at the minimum yield stress; (b) 62,000 foot-pounds (84 kilo newton meters) torsional load at the minimum torsional yield stress; and (c) 37,200 foot-pounds (50.44 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
[0097] In another embodiment, Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 67 and 13/16 inches (172.24 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. 6⅝ inch (16.83 centimeters) FH is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7G for new rotary shouldered tool joint connections having 8½ inch (21.59 centimeter) outer diameter and a 4¼ inch (10.8 centimeter) inner diameter. The Strength and Design Formulas of API 7G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 2,094,661 pounds (9,318 kilo newtons) tensile load at the minimum yield stress; (b) 109,255 foot-pounds (148.1 kilo newton meters) torsion load at the minimum torsional yield stress; and (c) 65,012 foot-pounds (88.14 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
[0098] To reduce friction between mandrel 40 and packing units 305 , 405 and increase the life expectancy of packing units 305 , 405 , packing support areas 131 , 132 can be coated and/or sprayed welded with a materials of various compositions, such as hard chrome, nickel/chrome or nickel/aluminum (95 percent nickel and 5 percent aluminum) A material which can be used for coating by spray welding is the chrome alloy TAFA 95MX Ultrahard Wire (Armacor M) manufactured by TAFA Technologies, Inc., 146 Pembroke Road, Concord N.H. TAFA 95 MX is an alloy of the following composition: Chromium 30 percent; Boron 6 percent; Manganese 3 percent; Silicon 3 percent; and Iron balance. The TAFA 95 MX can be combined with a chrome steel. Another material which can be used for coating by spray welding is TAFA BONDARC WIRE—75B manufactured by TAFA Technologies, Inc. TAFA BONDARC WIRE—75B is an alloy containing the following elements: Nickel 94 percent; Aluminum 4.6 percent; Titanium 0.6 percent; Iron 0.4 percent; Manganese 0.3 percent; Cobalt 0.2 percent; Molybdenum 0.1 percent; Copper 0.1 percent; and Chromium 0.1 percent. Another material which can be used for coating by spray welding is the nickel chrome alloy TAFALOY NICKEL-CHROME-MOLY WIRE-71T manufactured by TAFA Technologies, Inc. TAFALOY NICKEL-CHROME-MOLY WIRE-71T is an alloy containing the following elements: Nickel 61.2 percent; Chromium 22 percent; Iron 3 percent; Molybdenum 9 percent; Tantalum 3 percent; and Cobalt 1 percent. Various combinations of the above alloys can also be used for the coating/spray welding. Packing support areas 131 , 132 can also be coated by a plating method, such as electroplating. The surface of support areas 131 , 132 can be ground/polished/finished to a desired finish to reduce friction and wear between support areas 131 , 132 and packing units 305 , 415 .
[0099] FIG. 4 is a perspective view of a sleeve 150 , clamp 600 , and torque arm 630 which can be incorporated into swivel 30 . FIG. 5 is an exploded view of the components shown in FIG. 4 . FIG. 6 is a cutaway perspective view of swivel 30 . FIG. 7A is a sectional view of swivel 30 taken along the line 7 A- 7 A of FIG. 6 .
[0100] FIG. 6 is an overall perspective view (and partial sectional view) of top drive swivel 30 . Sleeve 150 is shown rotatably connected to mandrel 40 . Bearings 145 , 146 allow sleeve 150 to rotate in relation to mandrel 40 . Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Retaining nut 800 retains sleeve 150 on mandrel 40 . Inlet 200 of sleeve 150 is fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 ; passing through radial passage 190 ; passing through recessed area 130 ; passing through one of the plurality of radial inlet ports 40 ; passing through central longitudinal passage 90 ; and exiting mandrel 40 through central longitudinal passage 90 at lower end 60 and pin connection 80 .
[0101] Sleeve 150 can include central longitudinal passage 180 extending from upper end 160 through lower end 170 . Sleeve 150 can also include radial passage 190 and inlet 200 . Inlet 200 can be attached by welding or any other conventional type method of fastening such as a threaded connection. If welded the connection is preferably heat treated to remove residual stresses created by the welding procedure. Lubrication port 210 (not shown) can be included to provide lubrication for interior bearings. Packing ports 220 , 230 can also be included to provide the option of injecting packing material into the packing units 305 , 405 . A protective cover 240 can be placed around packing port 230 to protect packing injector 235 . Optionally, a second protective cover can be placed around packing port 220 . Sleeve 150 can include a groove 691 for insertion of a key 700 . FIG. 7A illustrates how central longitudinal passage 90 is fluidly connected to inlet 200 through radial passage 190 .
[0102] Sleeve 150 slides over mandrel 40 . Bearings 145 , 146 rotatably connect sleeve 150 to mandrel 40 . Bearings 145 , 146 are preferably thrust bearings although many conventionally available bearing will adequately function, including conical and ball bearings. Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Inlet 200 of sleeve 150 is and remains fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 (arrow 201 ); passing through radial passage 190 (arrow 202 ); passing through recessed area 130 (arrow 202 ); passing through one of the plurality of radial inlet ports 140 (arrow 202 ), passing through central longitudinal passage 90 (arrow 203 ); and exiting mandrel 40 via lower end 60 at pin connection 80 (arrows 204 , 205 ).
[0103] Sleeve 150 is preferably fabricated from 4140 heat treated round mechanical tubing having the following properties: (120,000 psi (827,400 kilo pascal) minimum tensile strength, 100,000 psi (689,500 kilo pascal) minimum yield strength, and 285/311 Brinell Hardness Range). In one embodiment the external diameter of sleeve 150 is preferably about 11 inches (27.94 centimeters). Sleeve 150 preferably resists high internal pressures of fluid passing through inlet 200 . Preferably top drive swivel 30 with sleeve 150 will withstand a hydrostatic pressure test of 12,500 psi (86,200 kilo pascal). At this pressure the stress induced in sleeve 150 is preferably only about 24.8 percent of its material's yield strength. At a preferable working pressure of 7,500 psi (51,700 kilo pascal), there is preferably a 6.7:1 structural safety factor for sleeve 150 .
[0104] To minimize flow restrictions through top drive swivel 30 , large open areas 140 are preferred. Preferably each area of interest throughout top drive swivel 30 is larger than the inlet service port area 200 . Inlet 200 is preferably 3 inches having a flow area of 4.19 square inches (27.03 square centimeters). In one embodiment the flow area of the annular space between sleeve 150 and mandrel 40 is preferably 20.81 square inches (134.22 square centimeters). The flow area through the plurality of radial inlet ports 140 is preferably 7.36 square inches (47.47 square centimeters). The flow area through central longitudinal bore 90 is preferably 5.94 square inches 38.31 square centimeters).
[0105] Retainer nut 800 can be used to maintain sleeve 150 on mandrel 40 . Retainer nut 800 can threadably engage mandrel 40 at threaded area 801 . Set screw 890 can be used to lock in place retainer nut 800 and prevent nut 800 from loosening during operation. A set screw 890 (not shown for clarity) can threadably engages retainer nut 800 through bore 900 (not shown for clarity) and sets in one of a plurality of receiving portions 910 formed in mandrel 40 . Retaining nut 800 can also include grease injection fitting 880 for lubricating bearing 145 . A wiper ring 271 (not shown for clarity) can be set in area 270 protects against dirt and other items from entering between the sleeve 150 and mandrel 40 . A grease ring 291 (not shown for clarity) can be set in area 290 for holding lubricant for bearing 145 .
[0106] Bearing 146 can be lubricated through a grease injection fitting 211 and lubrication port 210 (not shown for clarity).
[0107] FIGS. 4 and 5 best show clamp 600 which can be incorporated into top drive swivel 30 . FIG. 5 is an exploded view of clamp 600 . Clamp 600 can comprises first portion 610 , second portion 620 , and third portion 625 . First, second, and third portions 610 , 620 , 625 can be removably attached by plurality of fasteners 670 , 680 . Key 700 can be inserted in keyway 690 of clamp 600 . A corresponding keyway 691 is included in sleeve 150 of top drive swivel 30 . Keyways 690 , 691 and key 700 prevent clamp 600 from rotating relative to sleeve 150 . A second key 720 can be installed in keyways 710 , 711 . Third, fourth, and additional keys/keyways can be used as desired.
[0108] Shackles can be attached to clamp 600 to facilitate handing top drive swivel 30 when clamp 600 is attached. Torque arm 630 can be pivotally attached to clamp 600 and allow attachment of clamp 600 (and sleeve 150 ) to a stationary part of top drive rig 1 preventing sleeve 150 from rotating while drill string 20 is being rotated by top drive 10 (and top drive swivel 30 is installed in drill string 20 ). Torque arm 630 can be provided with holes for attaching restraining shackles. Restrained torque arm 630 prevents sleeve 150 from rotating while mandrel 40 is being spun. Otherwise, frictional forces between packing units 305 , 405 and packing support areas 131 , 135 of rotating mandrel 40 would tend to also rotate sleeve 150 . Clamp 600 is preferably fabricated from 4140 heat treated steel being machined to fit around sleeve 150 .
[0109] FIG. 8 shows a blown up schematic view of packing unit 305 . FIG. 7B shows a sectional view through packing area 305 . Packing unit 305 can comprise female packing end 330 ; packing ring 340 , packing lubrication ring 350 , packing ring 360 , packing ring 370 , and packing end 380 . Packing unit 305 sealing connects mandrel 40 and sleeve 150 . Packing unit 305 can be encased by packing retainer nut 310 , spacer 320 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 305 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . Packing unit 405 (shown in FIG. 7A ) can be constructed substantially similar to packing unit 305 . The materials for packing unit 305 and packing unit 405 can be similar.
[0110] Spacer 320 can comprise, first end 322 , second end 324 , internal surface 326 , and external surface 328 . Spacer 320 can be sized based on the amount of squeezed to be applied to packing unit 305 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
[0111] Packing end 330 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 330 can comprise tip 332 with concave portion 331 . Concave portion 331 can have an angle of about 130 degrees at its center. Tip 332 can include side 333 , recessed area 334 , peripheral groove 337 and inner diameter 335 . Recessed area 334 and inner diameter 335 can be configured to minimize contact of female packing ring or end 330 with mandrel 40 . Instead, contact will be made between packing ring 340 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 330 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 340 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi (20,700 kilo pascals or 27,600 kilo pascals)). It is also believed that packing rings 370 and/or 360 perform the majority of sealing against lower pressure fluids. Female packing ring 330 can include a plurality of radial ports 336 fluidly connecting peripheral groove 337 with interior groove 338 to allow packing injected to evenly distribute around ring and into the actual sealing rings.
[0112] Packing ring 340 can comprise tip 342 , base 344 , internal surface 346 , and external surface 348 . Tip 342 can have an angle of about 120 degrees to have an non-interference fit with tip 332 of female packing end 330 which is at about 130 degrees Base 344 can have an angle of about 120 degrees. Packing ring 340 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 342 of packing ring 340 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 334 of the female packing ring or end 330 which would cause side 333 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing Base 344 being at about 120 degrees is believed to assist in causing packing ring 340 to bear against mandrel 40 , and not side 333 of female packing ring 330 .
[0113] Packing lubrication ring 350 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 350 is shown after be shaped by packing rings 340 and 360 .
[0114] Packing ring 360 can comprise tip 362 , base 364 , internal surface 366 , and external surface 368 . Tip 362 can have an angle of about 90 degrees. Base 364 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 360 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
[0115] Packing rings 360 , 370 can have substantially the same geometric construction. Packing ring 370 can comprise tip 372 , base 374 , internal surface 376 , and external surface 378 . Tip 372 can have an angle of about 90 degrees. Base 374 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 370 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0116] In an alternative embodiment both packing rings 360 and 370 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
[0117] In another alternative embodiment packing ring 370 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 360 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0118] Male packing end or ring 380 can comprise tip 382 , base 384 , internal surface 386 , and external surface 388 . Tip 382 can have an angle of about 90 degrees. Packing end 380 is preferably an aluminum bronze male packing ring.
[0119] Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
[0120] Using the above packing configuration it has been surprisingly found that packing life in a displacement job at high pressure can be extended from about 45 minutes to about 10 hours, at rotation speeds of about 30, about 40, about 50, and about 60 revolutions per minute.
[0121] In installing packing units 305 , 405 , it has been found that the packing units should first be compressed in a longitudinal direction between sleeve 150 and a dummy cylinder (the dummy cylinder serving as mandrel 40 ) before sleeve 150 is installed on mandrel 40 . This is because a certain amount of longitudinal compression of packing units 305 , 405 will occur when fluid pressure is first exerted on these packing units. This longitudinal compression will be taken up by the respective packing retainer nuts 310 . However, using a dummy cylinder allows the individual packing retainer nuts 310 to cause pre-fluid pressure longitudinal compression on packing units 305 , 405 , but still allow the seals to maintain an internal diameter consistent with the external diameter of mandrel 40 . Such a procedure can avoid the requirement of resetting the individual packing retainer nuts 310 after fluid pressure is applied to the packing units causing longitudinal compression.
[0122] Female packing ring or end 330 can include a packing injection option. Injection fitting 225 can be used to inject additional packing material such as teflon into packing unit 305 . Head 226 for injection fitting 225 can be removed and packing material can then be inserted into fitting 225 . Head 226 can then be screwed back into injection fitting 225 which would push packing material through fitting 225 and into packing port 220 . The material would then be pushed into packing ring or end 330 . Packing ring or end 330 can comprise a plurality of radial ports 336 , outer peripheral groove 337 , and inner peripheral groove 338 . The material would proceed through outer groove 337 , through the plurality of radial ports 336 , and through inner peripheral groove 338 causing a sealing effect. The interaction between injection fitting 235 and packing unit 405 can be substantially similar to the interaction between injection fitting 225 and packing unit 305 . A conventionally available material which can be used for packing injection fittings 225 , 235 is DESCO™ 625 Pak part number 6242-12 in the form of a 1 inch by ⅜ inch (2.54 centimeter by 0.95 centimeter) stick and distributed by Chemola Division of South Coast Products, Inc., Houston, Tex.
[0123] Injection fittings 225 , 235 have a dual purpose: (a) provide an operator a visual indication whether there has been any leakage past either packing units 305 , 405 and (b) allow the operator to easily inject additional packing material and stop seal leakage without removing top drive swivel 30 from drill string 20 .
[0124] FIGS. 30A through 50 show an alternative packing arrangement for packing units 305 , 405 . In this alternative arrangement spacer 420 can include a plurality of radial ports for injecting packing filler material.
[0125] FIG. 31 shows a blown up schematic view of packing unit 405 . FIG. 30B shows a sectional view through packing unit 405 . Packing unit 405 can comprise female packing end 430 ; packing ring 440 , packing lubrication ring 450 , packing ring 460 , packing ring 470 , and packing end 480 . Packing unit 405 sealing connects mandrel 40 and sleeve 150 . Packing unit 405 can be encased by packing retainer nut 310 , spacer 420 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 405 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . An upper packing unit can be constructed substantially similar to packing unit 405 . The materials for packing unit 405 and upper packing unit can be similar.
[0126] Spacer 420 can comprise, first end 421 , second end 422 , internal surface 423 , and external surface 424 . Spacer 420 can be sized based on the amount of squeezed to be applied to packing unit 405 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
[0127] Packing end 430 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 430 can comprise tip 432 with concave portion 431 . Concave portion 431 can have an angle of about 130 degrees at its center. Tip 442 can include side 433 , recessed area 44 , peripheral groove 47 and inner diameter 445 . Recessed area 434 and inner diameter 435 can be configured to minimize contact of female packing ring or end 430 with mandrel 40 . Instead, contact will be made between packing ring 440 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 430 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 440 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi)(20,700 kilo pascals or 27,600 kilo pascals). It is also believed that packing rings 470 and/or 460 perform the majority of sealing against lower pressure fluids.
[0128] Packing ring 440 can comprise tip 442 , base 444 , internal surface 446 , and external surface 448 . Tip 442 can have an angle of about 120 degrees to have an non-interference fit with tip 432 of female packing end 430 which is at about 130 degrees Base 444 can have an angle of about 120 degrees. Packing ring 440 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 442 of packing ring 440 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 434 of the female packing ring or end 430 which would cause side 433 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing Base 444 being at about 120 degrees is believed to assist in causing packing ring 440 to bear against mandrel 40 , and not side 433 of female packing ring 430 .
[0129] Packing lubrication ring 450 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 450 is shown after being shaped by packing rings 440 and 460 .
[0130] Packing ring 460 can comprise tip 462 , base 464 , internal surface 466 , and external surface 468 . Tip 462 can have an angle of about 90 degrees. Base 464 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 460 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
[0131] Packing rings 460 , 470 can have substantially the same geometric construction. Packing ring 470 can comprise tip 472 , base 474 , internal surface 476 , and external surface 478 . Tip 472 can have an angle of about 90 degrees. Base 474 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 470 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0132] In an alternative embodiment both packing rings 460 and 470 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
[0133] In another alternative embodiment packing ring 470 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 460 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
[0134] Male packing end or ring 480 can comprise tip 482 , base 484 , internal surface 486 , and external surface 488 . Tip 482 can have an angle of about 90 degrees. Packing end 480 is preferably an aluminum bronze male packing ring.
[0135] Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
[0136] The following is a list of reference numerals:
[0000]
LIST FOR REFERENCE NUMERALS
(Part No.)
(Description)
Reference Numeral
Description
1
rig
2
crown block
3
cable means
4
travelling block
5
hook
6
gooseneck
7
swivel
8
drilling fluid line
10
top drive unit
11
draw works
12
cable
13
rotary table
14
well bore
15
guide rail
16
support
17
support
18
drill pipe
19
drill string
20
drill string or work string
30
swivel
31
hose
40
swivel mandrel
50
upper end
60
lower end
70
box connection
80
pin connection
90
central longitudinal passage
100
shoulder
110
interior surface
120
external surface (mandrel)
130
recessed area
131
packing support area
132
packing support area
140
radial inlet ports (a plurality)
145
bearing
146
bearing
150
swivel sleeve
155
protruding section
156
shoulder
157
shoulder
158
packing support area
159
packing support area
160
upper end
170
lower end
180
central longitudinal passage
190
radial passage
200
inlet
201
arrow
202
arrow
203
arrow
204
arrow
205
arrow
210
lubrication port
211
grease injection fitting
220
packing port
225
injection fitting
226
head
230
packing port
235
injection fitting
240
cover
250
upper shoulder
260
lower shoulder
270
area for wiper ring
271
wiper ring (preferably Parker part number
959-65)
280
area for wiper ring
281
wiper ring (preferably Parker part number
959-65)
290
area for grease ring
291
grease ring (preferably Parker part number
2501000 Standard Polypak)
300
area for grease ring
301
grease ring (preferably Parker part number
2501000 Standard Polypak)
305
packing unit
310
packing retainer nut
314
bore for set screw
315
set screw for packing retainer nut
316
threaded area
317
set screw for receiving area
320
spacer
322
first end
324
second end
326
internal surface
328
external surface
330
female packing end and packing injection
ring
331
concave portion
332
tip
333
side
334
recessed area
335
inner diameter
336
radial port
337
peripheral groove
338
interior groove
340
packing ring
342
tip
344
base
346
internal surface
348
external surface
350
packing ring
360
packing ring
362
tip
364
base
366
internal surface
368
external surface
370
packing ring
372
tip
374
base
376
internal surface
378
external surface
380
packing end
382
tip
384
base
386
internal surface
388
external surface
405
packing unit
410
packing retainer nut
414
bore for set screw
415
set screw for packing retainer nut
416
threaded area
417
set screw for receiving area
420
spacer and packing injection ring
421
first end
422
second end
423
internal surface
424
external surface
437
radial port
438
peripheral groove
439
interior groove
430
female packing end
431
concave portion
432
tip
433
side
434
recessed area
435
inner diameter
436
external diameter
440
packing ring
442
tip
444
base
446
internal surface
448
external surface
450
packing ring
460
packing ring
462
tip
464
base
466
internal surface
468
external surface
470
packing ring
472
tip
474
base
476
internal surface
478
external surface
480
packing end
482
tip
484
base
486
internal surface
488
external surface
600
clamp
605
groove
610
first portion
620
second portion
625
third portion
630
torque arm
650
shackle
660
shackle
670
plurality of fasteners
680
plurality of fasteners
690
keyway
691
keyway
700
key
710
keyway
711
keyway
720
key
[0137] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
[0138] It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | For use with a top drive power unit supported for connection with a well string in a well bore to selectively impart longitudinal and/or rotational movement to the well string, a feeder for supplying a pumpable substance such as cement and the like from an external supply source to the interior of the well string in the well bore without first discharging it through the top drive power unit including a mandrel extending through a sleeve which is sealably and rotatably supported thereon for relative rotation between the sleeve and mandrel. The mandrel and sleeve have flow passages for communicating the pumpable substance from an external source to discharge through the sleeve and mandrel and into the interior of the well string below the top drive power unit. The unit can include a packing injection system and novel seal configuration. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of U.S. Provisional Application 62/365,178 filed on Jul. 21, 2016, which is herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to bio-based and hydrophilic prepolymers and polyurethane foams. More particularly, the disclosure discusses prepolymers and foams created with feedstocks that are derived from biological sources rather than the traditional petroleum based feedstocks.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure. Accordingly, such statements are not intended to constitute an admission of prior art.
[0004] Biology offers an attractive alternative for industrial manufacturers looking to reduce or replace their reliance on non-renewable petrochemicals and petroleum derived products. The replacement of petrochemicals and petroleum derived products with products and/or feedstocks derived from biological sources (i.e., biobased products) offer many advantages. For example, products and feedstocks from biological sources are typically a renewable resource so there is the inherent advantage of non-depletion of non-renewable natural resources. Also, as the supply of easily extracted petrochemicals continue to be depleted, the economic and political ramifications of petrochemical production will likely force the cost of the petrochemicals and petroleum derived products higher as compared to their biobased analogs. In addition, companies can benefit from the marketing advantages associated with bioderived products from renewable resources in the view of a public becoming more concerned with sustainability and the supply of petrochemicals and other non-renewable resources.
[0005] Traditional or conventional polyether and polyester polyurethane foams are inherently hydrophobic and historically derived entirely from petroleum based resources. Methods and information for those skilled in the art to replace petroleum based raw materials in the polyurethane realm have centered around the use of Natural Oil Polyols (NOPs)—Vegetable based oils like castor, soy, linseed, and the like—as equivalent synthons to their petroleum-based counterparts in the production and commercialization of renewable and biobased polyurethane systems and foams. By their very nature, fatty acid based oils are inherently hydrophobic so there exists a mutual exclusion of polyurethane foam hydrophilicity and natural oil-based content. This invention relates to a new class of hydrophilic polyurethane prepolymers and foams that are based on poly(alkyloxide) polyols originating from plant-based and renewable hydrophilic raw materials, namely high or all-EO based polyether polyols based on fermented sugars. The use of these hydrophilic and renewable polyols allow the production of hydrophilic capped polyurethane prepolymers that are subsequently foamed in the presence of a large amount of water when admixed intimately during the foaming process.
[0006] There is a unique subset of polyurethane foams and technologies that deal with hydrophilic cellular foams, meaning specifically, foams that will readily uptake and reservoir a substantial weight (fluid) to weight (foam) percentage of contact liquid/fluid. Typically a hydrophilic foam is one that will 1) readily accept or wick fluid (>10 seconds) when said fluid is placed in contact with the foam surface and 2) readily absorb said fluid (>5 g fluid/g foam) and 3) adequately retain (>2 g/g) the fluid when the foam is saturated. One such class of hydrophilic foams can be prepared by a “prepolymer” process in which a hydrophilic prepolymer having isocyanate end groups is mixed and reacted with an excess of water. U.S. Pat. Nos. 3,861,993 and 3,889,417 disclose a hydrophilic polyurethane foam which is formed by mixing and reacting with water an isocyanate capped polyoxyethylene glycol prepolymersing a molar ratio of H 2 O to NCO groups in the prepolymer of 6.5 to 390:1.
[0007] Commercial hydrophilic polyurethane foams of this type, known in the art as HYPOL® foams, are prepared by mixing and reacting the prepolymers with water along with other foam modifying additives or fillers. HYPOL® prepolymers are available from The Dow Chemical Company. Similar hydrophilic prepolymers are manufactured and marketed by several other companies, including Rynel Inc., Lendell Manufacturing Inc., Mace Engineering, The Carpenter Company, and the Chemlogics Group.
[0008] All these Hypol and similar Hypol-like hydrophilic prepolymers utilize a polyoxyethylene glycol (PEG) polyol as the main polyether polyol component (>50% total polyol content w/w %) within the entire prepolymer composition and in an aqueous-rich (>15% water) two-stage process of foam production. The prepolymers, and the aqueous two-stage process foams produced therefrom, are disclosed in U.S. Pat. No. 4,365,025.
[0000] It is the hydrogen-bonding of polar molecules along this EO backbone that imparts the inherent hydrophilicity to the resultant foams made from these isocyanate-capped polyether prepolymers. To date all hydrophilic, Hypol-like, PEG-based prepolymers are based on petroleum derived polyol raw materials, namely petroleum derived ethylene oxide (EO) based polyols.
[0009] The present disclosure relates to the use of sugarcane-based derivatives to yield a biobased PEG moiety than can be reacted to produce inherently hydrophilic and bio-based polyurethane prepolymers and foams.
BRIEF SUMMARY OF THE INVENTION
[0010] The biobased polyoxyethylene polyol used as the main reactant in preparing the capped product to be foamed may have a weight average molecular weight of about 200 to about 20,000, and preferably between about 600 to 6,000, with hydroxyl functionality of about 2 or greater, preferably from about 2 to about 8.
[0011] In the present disclosure, the amount of water employed when admixing with the isocyanate capped biobased PEG prepolymer should exceed 6.5 moles H 2 O per mole of NCO groups. The water employed can range up to about 390 moles H 2 O/mole NCO groups. Thus, the available water content in the aqueous reactant is at least 6.5 and can fall within a range from about 6.5 to about 390 moles H 2 O per mole of NCO groups.
[0012] In one embodiment, a method of making a bio-based polyurethane prepolymer and foam comprises: (a) cleaning a bio-based polyoxyalkylene glycol polyol by a method comprising the steps of adding an adsorbent to the biobased polyoxyalkylene glycol polyol to create a mixture in the ratio of 0.5% to 5.0% adsorbent to biobased polyoxyalkylene glycol polyol by weight, stirring the mixture in a gaseous nitrogen environment, replacing the gaseous nitrogen environment with a gaseous carbon dioxide environment, and filtering the mixture to separate impurities from the mixture and create a cleaned bio-based polyoxyalkylene glycol polyol which is suitable for prepolymer preparations; (b) mixing the cleaned bio-based polyoxyalkylene glycol polyol with a polyfunctional isocyanate to create a biobased polyurethane prepolymer; and (c) foaming the biobased polyurethane prepolymer by admixing with an excess of water to make the bio-based hydrophilic polyurethane foam.
[0013] In one embodiment, the isocyanate is chosen from the group consisting essentially of PAPI (a polyaryl polymethylenepolyisocyanate as defined in U.S. Pat. No. 2,683,730), toluene diisocyanate, triphenylmethane-4,4′,4″-triisocyanate, benzene-1,3,5-triisocyanate, toluene-2,4,6-triisocyanate, diphenyl-2,4,4′-triisocyanate, hexamethylene diisocyanate, xylene diisocyanate, chlorophenylene diisocyanate, diphenylmethane-4,4′-diisocyanate, naphthalene-1,5-diisocyanate, xylene-alpha, 3,3′-dimethyl-4,4′-biphenylene diisocyanate, 3,3′-dimethoxy-4,4′-biphenylene diisocyanate, 2,2′,5,5′-tetramethyl-4,4′-biphenylene diisocyanate, 4,4′-methylenebis(phenylisocyanate), 4,4′-sulfonylbis (phenylisocyanate), 4,4′-methylene di-orthotolylisocyanate, ethylene diisocyanate, trimethylenediisocyanate, diicyclohexyl methane-4,4′-diisocyanate, isophorone diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-hexane diisocyanate, and the like or some combination thereof. Whether MDI or TDI is employed, both traditionally rely on a two-stage process for the manufacture of the polyurethane foam. Concerning this two-stage manufacturing process, both MDI and TDI rely upon a “prepolymer” stage. As should be apparent to those skilled in the art, in the first stage, the prepolymer is prepared. In the second stage, the polyurethane foam is produced. Mixtures of any one or more of the above-mentioned organic isocyanates may be used as desired. The aromatic diisocyanates, aliphatic and cycloaliphatic diisocyanates and polyisocyanates or mixtures thereof which are especially suitable are those which are readily commercially available, have a high degree of reactivity and a relatively low production cost.
[0014] In one embodiment, the bio-based polyoxyalkylene glycol polyol is manufactured from feedstock chosen from the group consisting essentially of “bagasse”, which is the fibrous waste that remains after sugar cane stalks are crushed to extract their juice. Such biobased PEG polyols of varying molecular weights are commercially available from Acme-Hardesty and Croda. Typically as produced, these 100% biobased polyols contain residual metals and metal oxides that are detrimental to the preparation of quasi- or pre-polymer polyurethane systems due to the uncontrollable and energetic side reactions enhanced by these chemical residuals leading to too high molecular weight chains forming which ultimately increases the viscosity of the prepolymers into unmanageable and unpumpable levels.
[0015] The adsorbents which may be employed in the practice of this invention are those which will remove the alkaline catalysts. These are the synthetic magnesium and aluminum silicate adsorbents. The synthetic adsorbents may be prepared by the reaction of a magnesium salt or aluminum salt such as magnesium or aluminum sulfate with sodium silicate. The resulting products can have particle sizes ranging from 5 to 500 microns with an average particle size of about 100-200 microns. Such magnesium silicate adsorbents are sold under the trademarks of “BRITE SORB” or “Ambosol” by Philadelphia Quartz Corporation, and “MAGNESOL” by The Dallas Group. Examples of alkali-adsorbents include synthetic magnesium silicate, synthetic aluminum silicate, activated bentonite, acid bentonite and their mixtures.
[0016] In one embodiment, the step of mixing the cleaned polyoxyalkylene glycol polyol with a polyfunctional isocyanate to create a polyurethane prepolymer is performed at a temperature between 20-140 degrees Celsius.
[0017] The scope of the invention is defined by the claims, which are incorporated into this section by reference. A more complete understanding of embodiments on the present disclosure will be afforded to those skilled in the art, as well as the realization of additional advantages thereof, by consideration of the following detailed description of one or more embodiments.
[0018] Reference will be made to the appended sheets of drawings that will first be described briefly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] A clear understanding of the key features of the invention summarized above may be had by reference to the appended drawings, which illustrate the method and system of the invention, although it will be understood that such drawings depict preferred embodiments of the invention and, therefore, are not to be considered as limiting its scope with regard to other embodiments which the invention suggests. Accordingly:
[0020] FIG. 1 shows a method for manufacturing a bio-based polyurethane foam.
[0021] FIG. 2 is a diagram that shows the principles involved in creating and identifying bio-based carbon.
[0022] FIG. 3 depicts a 14-Carbon decay curve.
[0023] FIG. 4 shows the reaction sequence of ethylene oxide and propylene oxide when influenced by potassium hydroxide leading to polyoxyalylene glycol polyols suitable for polyurethane prepolymer formation.
DETAILED DESCRIPTION
[0024] The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention.
[0025] The present disclosure discusses a new class of hydrophilic polyurethane foams that are based on poly(alkyloxide) polyols originating from plant-based and renewable hydrophilic raw materials, namely high or all-EO based polyether polyols. The new class of hydrophilic polyurethane foams overcomes the limitations of the hydrophobic foams that are briefly discussed in the background of this disclosure. The use of these hydrophilic and renewable polyols allow the production of hydrophilic capped polyurethane prepolymers that are subsequently foamed in the presence of a large amount of water admixed intimately during the foaming process to yield a novel class of hydrophilic and biobased polyurethane prepolymers and foams.
[0026] Hydrophilic urethane foams of prior art are described in U.S. Pat. Nos. 4,137,200; 4,339,550; 5,976,847 and others, as well as in Polyurethane's Chemistry and Technology by Saunders and Frisch, Volume XVI Part 2, High Polymer Systems. The primary departure from conventional prior art non-hydrophilic urethane foam is in the polyol component. Utilizing a hydrophilic polyol reacted with isocyanate provides a hydrophilic prepolymer. Mixing said hydrophilic prepolymer with water results in hydrophilic urethane foam. Adding an agent into the water results in hydrophilic foam bearing the agent. If the hydrophilic foam composite including agent is subsequently contacted with an outside water-based effluent, the agent may interact with the effluent for an intended purpose. In this described prior art hydrophilic foam composite technology, the contact between the agent and the effluent, or the expression of agent into effluent, is controlled by the inherent hydrophilicity of the urethane foam carrier.
[0027] Generally stated, the present method includes reacting an isocyanate capped biobased polyoxyethylene polyol by combining with an excess of water forming a cross-linked hydrophilic cellular foam. Cross-linked hydrophilic foam may thus be prepared by capping the purified, biobased polyoxyethylene polyol with a poly- or mono-isocyanate such that the capped product has a reaction functionality equal to or greater than two. The capped product is foamed simply by combining with an aqueous reactant. Optionally, the capped product and/or aqueous reactant may contain a suitable crosslinking agent if desired, in which case the capped biobased polyoxyethylene polyol product may have a functionality approximating 2.
[0028] During capping, it is desirable that polyisocyanate be reacted with the polyol such that the reaction product, i.e., the capped product, is substantially void of reactive hydroxy groups while containing more than two reactive isocyanate sites per average molecule. Another route for achieving this desired result is to react a polyisocyanate having two reactive active isocyanate sites per average molecule, in a reaction system during foaming having a polyfunctional reactive component such as one having from three up to about six or more reactive amine, hydroxy, thiol, or carboxylate sites per average molecule. These latter sites are highly reactive with the two reactive isocyanate sites and thereby form a dimensional product. The novelty as described herein presents the use of bio-derived polyoxyalkylene polyols as the primary hydroxyl moiety of the molecular backbone of the polyurethane prepolymer and resultant foam yielding a biobased cellular matrix that compositionally is greater than 50% by weight based on a truly renewable raw material.
[0029] U.S. Pat. No. 4,137,200, issued Jan. 30, 1979 to Wood et al. discloses a two-step process in which hydrophilic crosslinked polyurethane foams may be prepared by reacting a particular isocyanate-capped petroleum based polyoxyethylene (PEG) polyol with large amounts of an aqueous reactant. The '200 patent further teaches that the prepolymer may be formed from mixtures or blends of various polyols and/or polyisocyanates with this unique family of hydrophilic prepolymers based on PEG and other polyfunctional alcohols. All disclosures and manifestations of this base chemistry utilize polyols and isocyanates that are entirely petroleum derived.
[0030] Biobased polyoxyethylene polyol used as a reactant in preparing the capped product to be foamed may have a weight average molecular weight of about 200 to about 20,000, and preferably between about 600 to about 60,000, with a hydroxyl functionality of about 2 or greater, preferably from about 2 to about 6. Biobased polyoxyethylene polyol is terminated or capped by reaction with a polyisocyanate. The reaction may be carried out in an inert moisture-free atmosphere such as under a nitrogen blanket at atmospheric pressure at a temperature in the range of from about 60 C to about 140 C for a period of time of about hours depending upon the temperature and degree of agitation. This reaction may be effected also under atmospheric conditions provided the product is not exposed to excess moisture. The polyisocyanates used for capping the biobased polyoxyethylene polyol include polyisocyanates and polyisothiocyanates which are PAPPI-1 (a polyaryl polyisocyanate as defined in U.S. Pat. No. 2,683,730), toluene diisocyanate (TDI), triphenylmethane-4,4,4″,-triisocyanate, benzenel,3,5-triisocyanate, toluene-2,4,6-triisocyanate,diphenyl-2,4,4′-triisocyanate, hexamethylene diisocyanate, xylene diisocyanate, chlorophenylene diisocyanate, diphenylmethane-4,4-diisocyanate, naphthalene-1, S-diisocyanate, xylenealpha, alpha′-diisothiocyanate, 3,3-dimethyl-4,4′-biphenylene diisocyanate, 2,2′,5,5-tetramethyl-4, 4-biphenylene diisocyanate, 4,4′-methylenebis (phenylisocyanate), 4,4′-sulfonylbis (phenylisocyanate), 4,4-methylene di-orthotolylisocyanate, ethylene diisocyanate, ethylene diisothiocyanate, trimethylenediisocyanate and the like. Mixtures of any one or more of the above mentioned organic isothiocyanates or isocyanates may be used as desired. The aromatic diisocyanates and polyisocyanates or mixtures thereof which are especially suitable are those which are readily commercially available, have a high degree of reactivity and a relatively low cost but unfortunately there is no known mass produced biobased polyisocyanate. Alternatively, aliphatic di and poly functional isocyanates can be employed to react with the biobased polyethylene glycol polyols to form the capped polyurethane prepolymers with suitable polyisocyanates being 1,4-butylene diisocyanate, 1,6-hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), 2,2,4- and/or 2,4,4-trimethylhexamethylene diisocyanate, the isomeric bis(4,4′-isocyanatocyclohexyl)-methanes or their mixtures of any desired isomer content, 1,4-cyclohexylene diisocyanate, 1,4-phenylene diisocyanate, 2,4- and/or 2,6-tolylene diisocyanate, 1,5-naphthylene diisocyanate, 2,2′- and/or 2,4′- and/or 4,4′-diphenylmethane diisocyanate, 1,3- and/or 1,4-bis(2-isocyanatoprop-2-yl)benzene (TMXDI), 1,3-bis(isocyanatomethyl)benzene (XDI), alkyl 2,6-diisocyanatohexanoate (lysine diisocyanates) with C1-C8 alkyl groups, and also 4-isocyanatomethyl-1,8-octane diisocyanate (nonane triisocyanate) and triphenylmethane 4,4′,4″-triisocyanate.
[0031] Capping of the biobased polyoxyethylene polyol may be effected using stoichiometric amounts of reactants. Desirably, however, a slight excess of isocyanate is used to insure complete capping of the polyol. Thus, the ratio of isocyanate groups to the hydroxyl groups used for capping is between about 1 to about 4 isocyanate to hydroxyl, and preferably about 2 to about 3 isocyanate to hydroxyl molar ratio.
[0032] To obtain the maximum foam strength, resistance to compression set and the like, the isocyanate capped biobased polyoxyethylene polyol reaction products are formulated in such a manner as to give crosslinked, three dimensional network polymers on foaming. In order to achieve such infinite network formation on foaming, the reactive components may be formulated in one of the following by way of example. First, when water slurry is the sole reactant with the isocyanate groups leading to chain growth during the foaming process, the isocyanate capped biobased polyoxyethylene polyol reaction product must have an average isocyanate functionality greater than 2 and up to about 6 or more depending upon the composition of the polyol and capping agent components. Secondly, when the isocyanate capped polyoxyethylene polyol has an isocyanate functionality of only about two, then the water slurry, i.e., aqueous reactant, used may contain a dissolved or dispersed isocyanate-reactive crosslinking agent having an effective functionality greater than two. In this case, the reactive crosslinking agent is reacted with the capped biobased polyoxyethylene polyol when admixed during and after the foaming process has been initiated. Thirdly, when the isocyanate capped biobased polyoxyethylene polyol has an isocyanate functionality of only about two, then a polyisocyanate crosslinking agent having an isocyanate functionality greater than two may be incorporated therein, either preformed or formed in situ, and the resultant mixture may then be reacted with water slurry, i.e., aqueous reactant, optionally containing a dissolved or dispersed reactive isocyanate-reactive crosslinking agent, leading to a crosslinked, infinite network hydrophilic polyurethane foam. It is readily demonstrated that alcohol functional additives can be employed to tailor the physical properties of the desired cellular polyurethane foam. Thus the addition of mono- and polyhydric alcohols and mixtures thereof can be used to improve the properties of the resulting polyurethane foam with examples being mono- or polyhydric alcohols or polyols, such as ethanol, propanol, butanol, decanol, tridecanol, hexadecanol, ethylene glycol, neopentyl glycol, butanediol, hexanediol, decanediol, trimethylolpropane, glycerol, pentaerythritol, monofunctional polyether alcohols and polyester alcohols, polyether diols and polyester diols. If these additives are chosen from available renewable resources, they will be intimately impregnated within the foam matrix and increase the overall biobased content of the foam.
[0033] In order to differentiate bio-based carbon from petroleum-based carbon, ASTM subcommittee D20.96 developed a differentiation methodology into a Standard ASTM D6866. The next few paragraphs discuss the methodology.
[0034] It is known in the art that carbon-14 (C-14), which has a half-life of about 5,700 years, is found in bio-based materials but not in fossil fuels. Thus, “bio-based materials” refer to organic materials in which the carbon comes from non-fossil biological sources. Examples of bio-based materials include, but are not limited to, sugars, starches, corns, natural fibers, sugarcanes, beets, citrus fruits, woody plants, cellulosics, lignocelluosics, hemicelluloses, potatoes, plant oils, other polysaccharides such as pectin, chitin, levan, and pullulan, and any combination thereof. According to a particular embodiment, the at least one bio-based material is selected from corn, sugarcane, beet, potato, starch, citrus fruit, woody plant, cellulosic lignin, plant oil, natural fiber, oily wood feedstock, and a combination thereof.
[0035] The detection of C-14 is indicative of a bio-based material. C-14 levels can be determined by measuring its decay process (disintegrations per minute per gram carbon or dpm/gC) through liquid scintillation counting and this technique has been used for decades by archaeologists to date fossils. Biobased materials may contain 100% biogenic carbon (new carbon) or be mixed (physically, chemically, or biologically) with fossil/petroleum based carbon (old carbon). Therefore, one needs to define biobased content—the amount of biogenic carbon present in the product—to properly and definitively express the biobased content of a particular product or material.
[0036] As shown in FIG. 2, 14C signature forms the basis for identifying and quantifying bio-based content. The CO2 in the atmosphere is in equilibrium with radioactive 14CO2.
[0037] Radioactive carbon is formed in the upper atmosphere through the effect of cosmic ray neutrons on 14N. It is rapidly oxidized to radioactive 14CO2, and enters the Earth's plant and animal lifeways through photosynthesis and the food chain. Plants and animals which utilize carbon in biological food chains take up 14C during their lifetimes. They exist in equilibrium with the 14C concentration of the atmosphere, that is, the numbers of C-14 atoms and non-radioactive carbon atoms stays approximately the same over time. As soon as a plant or animal dies, they cease the metabolic function of carbon uptake; there is no replenishment of radioactive carbon, only decay. Since the half-life of carbon is around 5730 years, the fossil feedstocks formed over millions of years will have no 14C signature. Thus, by using this methodology one can identify and quantify biobased content.
[0038] FIG. 3 depicts a 14 Carbon decay curve.
[0039] In an effort to diminish dependence on petroleum products the United States government enacted the Farm Security and Rural Investment Act of 2002, section 9002 (7 U.S.C. 8102), hereinafter “FRISA”, which requires federal agencies to purchase bio-based products for all items costing over $10,000. In response, the United States Department of Agriculture (“USDA”) has developed Guidelines for Designating Bio-based Products for Federal Procurement (7 C.F.R. §2902) to implement FRISA, including the labeling of bio-based products with a “U.S.D.A. Certified Bio-based Product” label.
[0040] These FRISA methods require the measurement of variations in isotopic abundance between biobased products and petroleum derived products, for example, by liquid scintillation counting, accelerator mass spectrometry, or high precision isotope ratio mass spectrometry. Isotopic ratios of the isotopes of carbon, such as the 13C/12C carbon isotopic ratio or the 14C/12C carbon isotopic ratio, can be determined using analytical methods, such as isotope ratio mass spectrometry, with a high degree of precision. Studies have shown that isotopic fractionation due to physiological processes, such as, for example, CO2 transport within plants during photosynthesis, leads to specific isotopic ratios in natural or bioderived compounds. Petroleum and petroleum derived products have a different 13C/12C carbon isotopic ratio due to different chemical processes and isotopic fractionation during the generation of petroleum. In addition, radioactive decay of the unstable 14C carbon radioisotope leads to different isotope ratios in biobased products compared to petroleum products. Biobased content of a product may be verified by ASTM International Radioisotope Standard Method D 6866. ASTM International Radioisotope Standard Method D 6866 determines biobased content of a material based on the amount of biobased carbon in the material or product as a percent of the weight (mass) of the total organic carbon in the material or product. Both bioderived and biobased products will have a carbon isotope ratio characteristic of a biologically derived composition.
[0041] Polyfunctional hydroxyl compounds, besides the isocyanates, are essential components in the formation of polyurethanes. Smaller chain polyalcohols such as ethylene glycol, glycerine, butanediol, trimethyolpropane, etc. act widely and commercially as chain extenders or cross linkers. Higher molecular weight polyols (with Mw averages up to ˜12000 g/mole) form the basis of the vast polyurethane chemistry and market global profiles.
[0042] In the late 1960s and early 1970s, it became very clear that polyether based polyols were well suited for flexible foam performance requirements and these block and random copolymers of ethyleneoxide and propyleneoxide now dominate the global PU foam market. The alkali-catalyzed addition reaction of expoxides to all kinds of polyol starting materials leads to an infinite array of possible functionalities and molecular weights and distributions.
[0043] FIG. 4 shows the reaction sequence of ethylene oxide and propylene oxide when influenced by potassium hydroxide.
[0044] Common residuals of this commercial process are levels of sodium and potassium salts, metal-oxides, and moisture that remain in the bulk polyols. While existing cleaning methods control and tailor these component concentrations, their typical levels are higher than what is appropriate for the preparation of the described polyurethane prepolymers and foams made therefrom.
[0045] Polyoxyalkylene ether polyols, hereinafter for convenience called polyols, are commonly used in the production of urethane polymers. These polyols are reacted with polyisocyanate and other materials to produce urethane polymers which may be in the form of rubber-like elastomers, flexible or rigid foams and the like. In order that urethane polymers of desired properties and characteristics be produced, it is important that the polyols to be reacted with the polyisocyanate are essentially free of impurities which may function as undesirable catalysts or lead to undesirable side reactions during the desirable urethane polymer reaction.
[0046] The normal concentrations of metal based (sodium or potassium) catalysts range from 1700 to 4000 parts per million during polyol manufacturing. Filtration methods are employed to bring these residual levels into the low tens PPM level when these polyols are subsequently used in the production of conventional or traditional flexible slabstock PU foams. Under the foaming conditions using these traditional secondary polyols, the catalytic effects of these residual metals and metal hydroxides are managed and accommodated during the one-shot foaming process for flexible polyurethane foams where reaction temperatures regularly exceed 150 C. Under these reaction conditions, higher residual levels of these metals are acceptable and well-managed. Currently, all PO or high-PO content copolymers dominate the flexible slabstock foaming markets so production reactivity is mainly governed by the kinetics of the secondary hydroxyl chain ends and their reactivity profiles during the isocyanate reaction during foaming. It is now common for those skilled in the art and industrially to terminate the chain ends of the polyaddit on reaction with EO thus yielding a high concentration of primary hydroxyl termini at the polyol chain ends. Control of this important parameter allows tailoring of the kinetics of the resultant polyurethane reaction so EO containing polyoxyakylene polyols become available and commonplace in the polyurethane marketplace.
[0047] The all EO polyols used in this invention are unique in that they are completely primary hydroxyl-tipped or end-grouped. Primary hydroxyl alcohols have a greater than three-fold reactivity increase over their secondary chain terminated analogs so the reaction with a specific isocyanate is much faster and more energetic for PEG based polyurethane systems and foams over their analogous PO-tipped or secondary dominated alcohol chain ends.
[0048] When making polyurethane prepolymer under the conditions and compositions described in this filing, typical levels of residual metals and other contaminants readily residing within the commercially employed polyether polyol production processes do not work and are not appropriate in the production of biobased hydrophilic polyurethane prepolymers and foams therefrom. Additional cleaning or scrubbing of specific impurities is required to prepare base polyols, Biobased PEG in this case, used in the production of hydrophilic polyurethane prepolymers and foams described herein.
[0049] Not only are residual metal levels critical (Na+ and K+ levels) in the production of hydrophilic polyurethane prepolymers but moisture levels also need to be controlled and minimized. If these levels are kept at typical levels found in conventional polyether polyols used in traditional polyurethane chemistries, one cannot achieve a flowable functioning finished or quasi-prepolymer that can be subsequently foamed when admixing with excess water, as in the case with this patent filing. When combined levels of sodium and potassium exceed 15 ppm within the BioPEG polyol, the reaction with all isocyanates tested and listed herein—even the more slowly reacting aliphatic systems—all lead to an uncontrollable exotherm that invariably yields a gelled, non-flowing, and/or rigid elastomer that can neither be produced or foamed in production. When further processed in this manner to reduce metal, metal oxide, and moisture residual levels, BioPeg1000 was capable of further polymerization into a PU prepolymer to yield biobased hydrophilic prepolymers and foams.
Example #1
[0050] The adsorbents which can be employed in the practice of this invention are synthetic magnesium silicate adsorbents. They may be prepared by the reaction of a magnesium salt such as magnesium sulfate with sodium silicate. The typical resulting products can have particle sizes ranging from 100 to 500 microns with an average particle size of about 325 microns. These adsorbents are sold under trademarks “MAGNESOL” by The Dallas Group or “AMBOSOL” by the PQ Corporation. The amount of adsorbent which was employed depends on the concentration of catalyst present in the polyol. Thus, amounts ranging from about 0.5 percent to about 5 percent by weight based on the weight of the polyol may be employed. Preferably, however, the concentration of adsorbent ranges from about 1.0 percent to about 3.0 percent based on the weight of polyol. More preferably, the concentration of adsorbent ranges from about 1.0 to about 2.0 weight percent based on the weight of the polyol. From an economical point of view it is preferable to use as little as possible of the adsorbent so to 1205 g BioPeg1000 was added 1% (10 g) Magnesol powder in a 1500 mL Erlenmeyer flask blanketed with N2 atmosphere. The mixture was stirred at 80° C. for 30 minutes at which point the N2 atmosphere was replaced with a bubbling addition of gaseous CO2 over the course of 15 minutes. The mixture was then filtered through a pressure filter composed of a horizontal Sparkle filter No. JKS86 with the pressure adjusted to maintain a 45 psi head pressure above the filtering plates. Filtration lasted 30 minutes and yielded 1108 g (92.3% yield) of BioPEG1000 which contained low levels of residual sodium, potassium, moisture, and alkalinity as per the table above.
[0051] TABLE 1 below shows metal cleaning results for polyethylene glycol (PEG) molecules by inductively coupled plasma spectroscopy (ICP).
[0000]
TABLE 1
Potassium
Sodium
Moisture
(ppm)
(ppm)
Level (%)
pH
Peg 1000 Bio. (AH)
112.500
1.042
0.46
6.5
Lot no. 141113A
Before Cleaning
Peg 600 Pet. (Sigma Aldrich Lot.
399.000
2.858
0.57
6.1
BCBM2354V)
Before Cleaning
Peg 1000 Dow
5.110
2.251
0.02
5.1
Sentry Grade Commercial
Peg 1000 Bio. (AH)
1.260
1.252
0.03
4.7
Lot no. 141113A
After Cleaning
Peg 1500 Bio. (AH)
243.000
2.236
0.63
6.1
Lot no. B130203
Before Cleaning
Peg 1500 Pet. (Sigma Aldrich Lot.
−0.001
119.499
0.07
5.7
BCBN3227V)
[0052] Both the biologically sourced and petroleum derived PEG polyols (600, 1000, 1500 g/mole) have a significantly high value of potassium that catalyze the reaction of these PEG molecules with polyfunctional diisocyanate leading to gelling the prepolymer synthesis reaction.
[0053] The filtration process using Magnesol and Ambosol, magnesium silicate adsorbents, adequately sequester residual metals (Na+ and K+) and residual moisture from the PEG polyols.
[0054] The PEG polyols (200-20,000 g/mole, preferably between 600-3000 g/mole and ideally between 800-1500 g/mole) cleaned with adequate adsorbent yield polyols with very low concentration of either metal ion and low moisture levels (<0.5% moisture preferably <0.3% and ideally below 0.1% water). When properly cleaned, these PEG based polyols lead to functional and flowable prepolymers that can be foamed into functional cellular foam products.
Example #2
[0055] A bioprepolymer was prepared by admixing 0.134 molar equivalents of biobased polyethylene glycol having an average molecular weight of 1,000 (PEG—1,000) and 0.046 molar equivalent of Glycerine (GLY). The mixture was slowly added over a period of about one hour to a vessel containing 0.346 molar equivalents of 80/20 toluene diisocyanate (TDI) while stirring the TDI and polyol mixture. The temperature was maintained at 70° C. with stirring for three additional hours. All hydroxyl groups were capped with isocyanate and some chain extension occurred because of crosslinking of the polyols with TDI. The resultant biobased prepolymer has a theoretical NCO % of 7.12% with a titrated (ASTM D3574) NCO % of 7.03. Hydrophilic foams have been prepared from the above prepolymer using large amounts of water as described previously. These foams exhibit good physical properties, and various materials can be incorporated into the aqueous phase when preparing the foams.
Example #3
[0056] A mixture of 304.4 g TDI and 0.34 g of benzoyl chloride was admixed at 70° C. during 3 h with 675.1 g of a biopolyethylene glycol having a molar mass of 1000 g/mole containing 20.5 g Trimethyloyl propane (TMP). To the polyol blend was added 400 ppm BHT with stirring followed by dropwise addition and subsequently stirred for 3 hours. This gave a prepolymer having a theoretical NCO content of 7.08% and a viscosity of 12,000 mPas at 25 C.
Example #4
[0057] A mixture of 105.3 g TDI and 100 ppm benzoyl chloride was admixed at 70° C. during 3 hours with a mixture of 136.0 g of a polyalkylene oxide having a molar mass of 5400 g/mole started on glycerol, an ethylene oxide weight fraction of 72% and a propylene oxide weight fraction of 28% and 258.8 g biobased polyethylene glycol having a molar mass of 1000 g/mol by dropwise addition and subsequently stirred for 3 hours at 70 C. This gave a prepolymer A) having a biobased content of 51.75% and B) a theoretical NCO content of 5.12%, a titrated NCO content of 4.98% and a viscosity of 9,800 cPs at 25 C.
Example #5
[0058] To a reaction vessel containing 145.83 g biobased and cleaned polyethylene glycol having a molar mass of 1000 g/mole and 4.63 g Glycerine along with 300 ppm Irganox 245 antioxidant stirred at 60 C w here added to 99.54 grams of 4,4′MDI stirred at room temperature with 100 ppm isooctylphosphoric acid (IOAP). The reaction exotherm was kept at 70 C. by external cooling with water, while stirring for 4 hours. The actual isocyanate content, determined by titration with standard n-butylamine solution in toluene, remained at the constant level of 5.68% NCO relative to a theoretical content of 5.94% NCO. The resultant pale yellow bioprepolymer has a biocontent of 60.2% and a viscosity of 9750 cPs at 25 C. A foam was prepared by adding to 100 grams of this biobased polyoxyethylene triisocyanate with good stirring (3000 rpm), a mixture of 100 grams water and 1.0 grams of silicone surfactant. After mixing for seconds to achieve an initial cream state, the reaction mixture was poured into a wax-lined cup and allowed to expand and cure to a tack free surface for 4 minutes. The resultant foam was an open-celled, flexible hydrophilic foam with good elongation and tensile strength in both the dry and saturated state.
Example #6
[0059] A mixture of 82.71 g Suprasec 2004 as a modified MDI resin with an equivalent weight of 128.0 and 0.14 g of benzoyl chloride was admixed at 70° C. to which was added with 167.3 g of a biobased and cleaned polyethylene glycol having a molar mass of 1000 g/mole along with 300 ppm Irganox 245 antioxidant. This polyol mixture was dropwise added to the stirred isocyanate mixture followed with stirring for 3 h while the temperature was held at 70 C via an orbital oven. This gave a prepolymer having a theoretical NCO content of 5.23%, a titrated value of 5.18%, and a viscosity of 10,520 cPs at 25 C.
[0060] Table #2 lists the chemical properties of the presented hydrophilic biobased prepolymer formulations and Table #3 lists the physical properties of the resultant foams made from the aforementioned set of prepolymers according to this presented invention.
[0000]
TABLE 2
Theoretical
Isocyanate +
Diol
NCO %,
Viscosity
Prepolymer
(name, NCO
(name, OH
X-Linker
Actual
cPs @25 C.
Composition
eq.)
eq.)
(name, OH eq.)
NCO %
Spindle#4
Example
TDI, 0.3459
BioPEG1000,
Glycerin, 0.0456
7.12, 7.03
11,250
#2
0.1337
Example
TDI, 0.3460
BioPEG1000,
TMP, 0.0457
7.08, 6.99
12,500
#3
0.1337
Trial #7
TDI, 0.3461
BioPEG1000,
TMP, 0.0850
7.13, 7.01
14,750
0.110
Example
TDI, 0.2755
BioPEG1000,
GP5171, 0.0187
5.12, 4.96
9,800
#4
0.1180
Trial #8
TDI, 0.3459
Petroleum
Glycerin, 0.0570
6.00, 5.79
13,100
PEG1000,
0.1420
Example
MDI 4,4′,
BioPEG1000,
Glycerin,
5.94, 5.79
7,500
#5
0.3440
0.126
0.0652
Example
MDI Suprasec
BioPEG1000,
—
5.23, 5.03
6,800
#6
2004, 0.3438
0.1780
Trial #9
MDI Rubinate
BioPEG1000,
Glycerin,
6.17, 6.00
7,700
9433, 0.3523
0.1337
0.0500
Trial #10
TDI, 0.3460
PEG600,
Glycerin, 0.0424
7.04, —
Gelled
0.1337
Trial #11
TDI, 0.2778
BioPEG1000,
Glycerin, 0.0532
7.20, 7.12
9,900
MDI 4,4′,
0.1337
0.0880
Trial #12
IPDI, 0.3422
BioPEG1000,
TMP, 0.0454
6.76, 6.55
10,800
0.1358
+ TDI - 80/20 (2,4-, 2,6-) Toluene diisocyanate, Grade I Suprasec 2004, polymeric MDI, Huntsman Chemical Rubinate 9433, high 2,4 MDI isomer, Huntsman Chemical
~As per ASTM D3574
•Brookfield #4 “ As per ASTM D6866
[0000]
TABLE #3
CFD
Prepolymer
Foam
Tensile
Elongation
@50%
Composition
BioContent %
Properties
(psi)
(%)
(psi)
Example #2
69.4
19
345
0.43
Example #3
67.5
22
320
0.54
Trial #7
61.8
25
250
0.64
Example #4
51.8
27
375
0.55
Trial #8
1.70
23
315
0.55
Example #5
60.2
33
210
0.77
Example #6
66.9
32
230
0.71
Trial #9
59.52
34
245
0.68
Trial #10
—
Gelled
—
—
—
Trial #11
66.3
33
305
0.66
Trial #12
64.0
Long
17
375
0.47
foaming
time
[0061] All patents and publications mentioned in the prior art are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference, to the extent that they do not conflict with this disclosure.
[0062] While the present invention has been described with reference to exemplary embodiments, it will be readily apparent to those skilled in the art that the invention is not limited to the disclosed or illustrated embodiments but, on the contrary, is intended to cover numerous other modifications, substitutions, variations, and broad equivalent arrangements | A bio-based polyurethane foam manufactured by a process that involves cleaning a bio-based polyoxyalkylene glycol polyol by a method comprising the steps of adding an adsorbent to the bio-based polyoxyalkylene glycol polyol to create a mixture in the ratio of 0.5% to 5.0% adsorbent to bio-based polyoxyalkylene glycol polyol by weight, stirring the mixture in a gaseous nitrogen environment, replacing the gaseous nitrogen environment with a gaseous carbon dioxide environment, and filtering the mixture to separate impurities from the mixture and create a cleaned bio-based polyoxyalkylene glycol polyol; then mixing the cleaned bio-based polyoxyalkylene glycol polyol with a polyfunctional isocyanate to create a bio-based polyurethane prepolymer; and then foaming the bio-based polyurethane prepolymer by admixing with an excess of water to make the bio-based polyurethane foam. | 2 |
This application is a continuation of application Ser. No. 08/230,638, filed Apr. 21, 1994 now abandoned.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to a method for closed-loop control of an electric drive of a vehicle utilizing frictional engagement between a wheel and a rail or an underlying surface, to a high degree. Such methods are used in particular in rail vehicles but can also, fundamentally, be used in road vehicles.
There have been efforts for a relatively long time not only to avoid skidding and slipping states with the aid of anti-skid devices but also to permit a travel/braking mode in a stable region just before a maximum frictional engagement. The difficulty of achieving the aimed-at operating region resides in the fact that the frictional engagement which depends on a series of influences, and is also variable during travel mode, cannot be directly measured. That means that the respectively valid characteristic frictional engagement line which specifies the relation between the coefficient of frictional engagement and the slip speed is not known.
Such problems and an explanation of the terms used by a specialist in that connection as well as possible ways of reaching conclusions indirectly as to the respectively achieved operating point, are presented in the publication AET (38)-1983, pp 45 to 56. However, the slip control described therein requires previous precise measurement of the actual speed of the vehicle, and also cannot ensure optimum operation because the maximum torque cannot be transmitted at a constant slip value. The maximum coefficient of frictional engagement, such as for a dry rail, occurs at a different slip speed than for a wet rail.
Published European Application No. 01 95 249 B1 discloses a method which operates without measurement of the vehicle speed, for determining skid states and slip states in vehicles. In that method, an identification signal is superimposed on the set control value for an electric vehicle drive, as a result of which an alternating torque is superimposed on the operating torque produced by an engine. The reaction of the mechanical system to that excitation is detected, for example with a tachometer generator, at a suitable point of the mechanical drive system, for example at the engine shaft or the drive wheel. An alternating voltage from which a measurement signal can be acquired by filtering, is output by the tachometer generator and the measurement signal is compared with the identification signal fed into the drive system, for example with the aid of a correlation calculation. It can be determined whether a skid state or a slip state is present by evaluating the result of the correlation calculation.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method for closed-loop control of an electric drive of a vehicle, which overcomes the hereinafore-mentioned disadvantages of the heretofore-known methods of this general type and which permits good utilization of frictional engagement, which is a better utilization than with known methods.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method for closed-loop control of an electric drive of a vehicle, in particular of a rail vehicle, utilizing frictional engagement or adhesion between a wheel and a rail or an underlying surface, to a high degree, which comprises limiting a set torque value being prescribed operationally as a set traction force or braking force value through logical linkage or connection to a reduction signal, to a set input torque value being fed to an electric drive of a vehicle; and forming the reduction signal in a control device having a control variable being an actual value of a substitute variable being determined by technical measuring means and having a physical relation to a gradient of a characteristic frictional engagement line having been previously determined and being used to form the reduction signal.
The method has the advantage of permitting an operating point which is considered to be an optimum one and lies just in front of the maximum frictional engagement, to be prescribed, and of causing the respective optimum slip speed or the optimum slip, that is to say the relative slip speed related to the vehicle speed, to become established automatically. The method or a configuration operating according to it thus acts as a slip control with an adapted set value.
In accordance with another mode of the invention, there is provided a method which comprises forming a phase shift signal being used as the substitute variable, as follows: superimposing a preferably sinusoidal test signal on the set input torque value; measuring angular speed or angular acceleration at a mechanical output, preferably at an engine shift of the electric drive; filtering out an output-side test signal being contained in a thus obtained measurement signal, from the measurement signal; comparing the input-side and the output-side test signals for determining their phase shift, and using their phase shift as an actual value of the substitute variable; and using a test signal having such a frequency on one side and being known to have an unambiguous relation between phase shift and gradient of the characteristic line.
In accordance with a further mode of the invention, there is provided a method which comprises forming the reduction signal with a control device having integral behavior, especially a PI controller.
In accordance with a concomitant mode of the invention, there is provided a method which comprises raising a set value of the substitute variable with the aid of a modified actual value of the substitute variable, and forming the modified actual value by differentiation of the actual value with subsequent limiting on one side.
The invention is based on the idea that a clear improvement in the drive control is possible by utilizing the frictional engagement to a high degree if information relating to the gradient of the characteristic frictional engagement line is available. However, direct detection of the gradient of the characteristic frictional engagement line by technical measuring means is as impossible as is that of the characteristic line itself.
According to the invention, the system therefore operates with a substitute variable which is formed by evaluating a measured signal and which contains information relating to the gradient of the characteristic frictional engagement line. Thus, the system operates with a substitute variable having a relation to the gradient of the frictional engagement line that is known. Since this relation is known, it is not necessary to convert the substitute variable into a gradient value, that is to say the substitute variable can be used directly to control the drive.
The method which is known from Published European Application No. 01 95 249 B1 and has already been described above can be used advantageously to obtain the substitute variable. The method operates with a test signal which is also designated as an identification signal. By comparing the test signal which is fed in at the input of the electrical drive with a test signal which is detected by technical measuring means at the mechanical output, that is to say at the engine shaft or wheel shaft, a phase shift between these test signals is determined, which phase shift is utilized as a substitute variable. Instead of, or in addition to, the phase change, a change in the size of the signal can also be evaluated.
The method described in Published European Application No. 01 95 249 B1 also utilizes the phase change between input and output test signals in order to evaluate skid states. However, the present invention develops the method substantially further to the extent that the determined phase change is utilized as information relating to the gradient of the characteristic frictional engagement line, and is thus utilized indirectly to determine at what operating point of the characteristic frictional engagement line the system is currently operating. Since, in this way, the current operating point is known, the distance from a prescribed optimum operating point can be determined and a reduction signal can be formed, with the aid of which an operating set value, that is to say one which has been prescribed by a locomotive driver or engineer, can be limited to such an extent that an operating point becomes established in the region of the optimum operating point, that is of the optimum slip.
The method which is described above in abbreviated form is explained in greater detail below with reference to an electric drive of a rail vehicle.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method for closed-loop control of an electric drive of a vehicle, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 includes an upper graph plotting a coefficient of frictional engagement against a slip speed, and a lower graph plotting a gradient against the slip speed;
FIG. 2 is a graph plotting a phase shift against a gradient of a characteristic frictional engagement line; and
FIG. 3 is a schematic and block circuit diagram of a control structure for carrying out the method of the invention; and
FIG. 4 is a schematic view of a rail-borne vehicle with the system of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to the upper part of FIG. 1 thereof, there is seen, by way of example, characteristic frictional engagement lines (coefficient of frictional engagement as a function of slip speed v s ) for a dry and a wet rail state. It can be seen that the maximum of the coefficient of frictional engagement lies at different slip speeds depending on the rail state. The lower part shows the gradient of the characteristic lines shown in the upper part. An advantageous operating point which can be prescribed as an optimum operating point is marked with dashed lines. As is shown by the two vertical dashed lines, this operating point lies just before the maximum point is reached in the rising part of the characteristic frictional engagement line in each case, that is to say both for a dry and a wet rail state. The horizontal dashed line marks the associated gradient value which is, for example, 0.01 or 0.02. It is significant that the same gradient value applies for both characteristic lines so that by selecting one gradient value an optimum operating point for all rail states is selected.
Since the gradient of the characteristic frictional engagement line cannot be detected by technical measuring means, a substitute variable is used having a relation to the gradient of the characteristic frictional engagement line which is known. This is namely preferably a phase shift Φ between a test signal T, which is input into the electric drive on the input side by superimposition with the set torque and an output-side test signal T A which is filtered out of an angular speed measured value w that is tapped off at the mechanical output, for example at the engine shaft. The angular acceleration can also be measured instead of the angular speed.
The relation between the gradient of the characteristic frictional engagement line and this phase shift can be explained as follows. Engine/wheel/rail systems have a non-linear behavior due to the characteristic frictional engagement line for the wheel/rail contact. A linear system with any desired operating point on the characteristic frictional engagement line is obtained by linearizing this non-linear behavior. In this case, the gradient of the characteristic frictional engagement line constitutes a significant operating point parameter. The frequency response of the torque-dependent angular speed can be determined for each gradient. The frequency response of the non-linear engine/wheel/rail system thus constitutes a group of curves of value and phase characteristics as a function of the operating point parameter "gradient of the characteristic frictional engagement line". The characteristic frequency lines in this case show a strong dependence on the phase of the gradient of the characteristic frictional engagement line. In the case of one frequency point of the phase shift curves it is possible to determine a phase shift characteristic gradient line which has an unambiguous relation between the phase shift and the gradient. By way of example, such a characteristic line is illustrated in FIG. 2 for a test signal frequency f=10 Hz. The searched-for relation between the gradient of the characteristic frictional engagement line and the phase shift of the input torque and of the angular speed of the engine shaft of a drive system is thus found for a specific frequency of the characteristic phase shift lines of a non-linear engine/wheel/rail system.
A suitable method for using technical measuring means to determine the phase shift between a test signal which is superimposed on the set torque value and the angular speed of the engine shaft resulting therefrom has already been described above in principle and is described in detail in Published European Application No. 01 95 249 B1.
In relation to the application of the known method for determining the phase shift within the scope of the present method, two modifications are to be noted:
a) The selection of the frequency of the test signal or identification signal preferably takes place according to Published European Application No. 01 95 249 B1 in such a way that it corresponds to a resonance frequency of the mechanical drive. This aspect is insignificant in this case. The frequency which is selected as being suitable is one for which there is an unambiguous relation to the phase change of the gradient of the characteristic frictional engagement line.
b) In the method according to Published European Application No. 01 95 249 B1, preferably the angular acceleration, and in the method according to the invention preferably the angular speed, are measured and evaluated.
The determination of the phase shift signal can be carried out in principle both with a continuous or discrete correlation method, which is to say by using analog technology or by means of software implementation.
A control structure which is suitable for carrying out the method is illustrated by way of example in FIG. 3. A set phase shift value Φ s is prescribed as a substitute value for a gradient value which is to be prescribed.
The set phase shift value Φ s is to correspond to an operating point just before the maximum frictional engagement in the stable region. This is achieved if the set phase shift value Φ s =-1/2π+ε is selected in such a way that the gradient of the characteristic frictional engagement line is, for example, 0.01. The factor ε describes the interval from the start of the instable operating region at Φ=-1/2π. A suitable interval factor can be ε=0.5, for example.
In the configuration according to FIG. 3, the set phase shift value Φ s is fed to a first addition point 1 where a modified actual phase shift value Φ i ,m is subtracted. An actual phase shift value Φ i is subtracted from the resulting value at a second addition point 2. The value resulting therefrom is inverted in an inverter 3 and is subsequently fed to a controller 4. The controller 4 supplies an unlimited reduction factor r* which is limited in a subsequent limiter 5 to values in the range of 0 to 1. A reduction factor r which is formed in this way is logically linked at a multiplication point 6 to a set value M, so that a corrected set input torque value M E is produced which is fed to a drive device 7. The set value M constitutes a superimposition of a set torque value M S which is prescribed, for example, by the locomotive driver or engineer and of an alternating torque which is designated as the test signal T. At the mechanical output of the drive device 7, the angular speed w is detected and fed to an evaluation device 8 which supplies the actual phase shift value Φ i that is fed to the second addition point 2. The actual phase shift value Φ i is additionally fed to a differentiator 9 having an output signal which is limited in a subsequent single-side limiter 10 and fed to the first addition point 1 as the modified actual phase shift value Φ i ,m.
The test signal T is produced in a test signal generator 12 and fed both to a third addition point 11 for logical connection to the set torque value Ms and to the evaluation device 8.
A controller with internal behavior, for example a PI controller, is suitable as the controller 4. However, in principle various controllers which are known from control technology, ranging as far as a fuzzy controller, can be used.
In order to minimize the reaction time which results from the transient condition of the correlation filter of the evaluation device 8, adaptive and/or predictive structures, for example on the basis of heuristic observation (fuzzy logic/fuzzy control) or deterministic methods, can be additionally used. For example, a prediction of the phase shift can be carried out on the basis of past values. The proposed structure can operate in an autarkic fashion or else be integrated into existing anti-skid and anti-slip devices or rpm or torque controls.
Of course, the control must not increase the traction force or braking force prescribed by the operator in the form of the set torque value M S . This is ensured by the limiter 5 which limits the reduction factor r* that is supplied by the controller 4 and is still unlimited to values in the range of 0 to 1.
FIG. 4 illustrates a railcar with wheels connected through an axle shaft. A control device controls a motor, which drives the wheels through a transmission. | A method for open-loop and closed-loop control of an electric drive of a vehicle, in particular of a rail vehicle, utilizes a frictional engagement between a wheel and a rail or an underlying surface, to a high degree. A control is carried out which takes into account a gradient of a characteristic frictional engagement line. The system operates with a substitute variable for the gradient, which can be detected by a technical measurement, and a set torque value which is prescribed by the operator being limited in such a way that a travel/braking mode is achieved at an optimum, prescribed operating point of the characteristic frictional engagement line. | 1 |
This is a division of application Ser. No. 456,769 filed Apr. 1, 1974, now U.S. Pat. No. 3,968,656.
The present invention concerns a method of working under-water and apparatus therefor.
There is a problem in working under-water on the erection and maintenance of sea-bed installations such as oil-well heads. With conventional diving and diving-bell techniques, the personnel are subject to the hydrostatic pressure head corresponding to the water depth and, due to the need to decompress to avoid the bends, their working day is very short. It has been proposed to enclose parts of the sea-bed installation within capsules filled with air or another gas at atmospheric pressure and to bring the personnel down to such capsules within other capsules filled with air at atmospheric pressure; the transfer of personnel involved having mating means on the capsules which formed water-filled conjunction capsules which had to be pumped out or drained into the installation part capsules (which in turn had to be pumped out) and filled with air at atmospheric pressure. This pumping involved the transfer of large volumes of water equal to the volumes of the conjunction capsules against the full hydrostatic pressure head. This pumping out is a heavy duty pumping requirement and involves large amounts of power and is time consuming. It is difficult to make the transit capsule self-sufficient and it is necessary to supply the power from surface support ships. Any parts to be installed must be transported within the transit capsules or so as to be within the conjunction capsules; the alternative is to flood the installation part capsules which then have to be pumped out again. Whenever a pipe or electrical connection has to be made through a wall of an installation part capsule, it is necessary to flood the capsule and subsequently pump it out or use elaborate lock-through arrangements.
Also any leakage of oil tends to collect in the bottoms of the installation part capsules with the result that if the installation part capsules are subsequently flooded the oil smears itself over the installation part. Moreover if a leak occurs when men are inside an installation part capsule the leak takes the form of a high pressure jet of sea-water.
In the subsequent parts of this specification, atmospheric pressure means any pressure accepted by medical opinion as safe for working without the need for lengthy decompression and typically includes up to a pressure corresponding to ten meters less the depth of water in the capsules.
The present invention provides a capsule for enclosing part of a sub-sea installation and enclosing leakage detection means characterised in that the leakage detection means is located within an upper part of the capsule so that if the capsule is filled with water any leakage will float into the upper part and be detected therein.
The capsule according to the present invention is intended for use with the method of U.S. Pat. No. 3,968,656 and will in use be full of water which during manned intervention will be at atmospheric pressure but preferably between interventions is an external sea pressure.
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings.
THE DRAWINGS
FIG. 1 shows part of a sea-bed installation enclosed in a capsule,
FIG. 2 shows a transit module,
FIG. 3 is a schematic circuit diagram showing means for regulating water pressure in various schematically shown capsules,
FIG. 4 is a schematic circuit diagram of a preferred arrangement for providing a breathing supply to personnel working within the installation part capsule,
FIG. 5 shows means for effecting a seal between the transit capsule and the installation part capsule together with means for testing and maintaining the seal,
FIG. 6 shows a removable cover plate in the wall of the installation part capsule,
FIG. 7 shows means for connecting auxiliary equipment through the wall of the installation part capsule and sealing thereto,
FIG. 8 shows an external unit fitted to the installation part capsule, and
FIG. 9 illustrates a simplified second version of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a portion of a sea-bed 11 from which projects the well head casings 12. On the casings is mounted a christmas tree 14 which is enclosed in a sealed installation part capsule 15. Pipes 16 are brought through suitable connectors 17 in the wall of the capsule to connect up to the christmas tree. A hatch 18 is provided on the top of the capsule. The well head casings terminate in known manner in a connector 110 and an adapter 111. The seals between the casings and the adapter may leak. In embodiments of the present invention, these seals are outside the capsule. The adapter is a solid block which penetrates the capsule wall and contains a master valve 112 which can be operated manually or by remote hydraulic means which are arranged not to interfere with each other.
FIG. 2 shows a transit module 20 which can be guided down to the capsule 15 by any of the known means such as guide wires (not shown). At the bottom of this module, there is an entry fairing 21 to receive the hatch 18 and guide a sealing surface 22 around the hatch onto a complementary sealing surface 23 on the module 20.
The module 20 comprises an upper, transit, capsule 24 and a lower chamber which is normally open at its lower end at the fairing 21 but which is sealed by the co-operation of the sealing surfaces to form a third, conjunction, capsule. The chamber will hereinafter be referred to as the capsule 25.
The capsule 24 has double hatches 26 at its lower and upper ends. The upper double hatch is for the entry of personnel and equipment at the sea-surface and the lower double hatch is to give access to the conjunction capsule 25. The double hatches are designed with an outer member 27 to resist external pressure and an inner member 28 to resist pressure within the capsule 24; this allows the capsule to be used normally and as a decompression chamber if the capsule by any mishap becomes pressurised whilst containing personnel as might occur if a leak commenced when personnel were in the capsule 15 and the lower double hatch had to remain open to allow them to re-enter the capsule 24. The personnel could then seal themselves into the capsule at whatever pressure existed and escape to the surface relying on the air in the capsule 24 and possibly external connectors for enabling support vessels to supply further air when on the surface but before it would be safe to leave the capsule because of insufficient decompression. The members of each double hatch pivot about a single pin 101 parallel to the axis of the hatch.
The hatch 18 can be designed to resist major pressure within the capsule 15 only since the capsule is preferably at full hydrostatic pressure except when the pressure across this hatch is balanced at atmospheric pressure.
The christmas tree 14 projects through the capsule 15 being rigidly sealed to the bottom of the capsule and being slidably sealed in a port 31 at the top of the capsule to allow for relative expansion and to allow for connection of wire-line or other auxiliary units 110 (FIG. 8) which would be at the top of the tree. The form of this sliding seal is a rigid collar 32 fast to the port 31 within which collar there is a piston 33 which can be used as a hydrostatic bearing and as a jack to lift elements of the tree of their seatings prior to being removed.
FIG. 3 shows a circuit diagram of means for regulating water pressures. This Figure is rather complex due to the large amount of designed redundancy and it is thought best described by an explanation of how it is used. First it is to assumed that the three capsules 15, 24 and 25 (shown in this Figure in broken lines) are filled, capsule 24 with air at atmospheric pressure and the other two capsules with water at external pressure. A pressure bleed 51 is connected to an expansion tank 52 by means of valves 53. The pressure bleed is provided in or by-passing the lower double hatch 26. The expansion tank is a pressure vessel and initially its pressure rises as sensed by a pressure gauge 54. If there is a leak on the sealing surfaces 22 and 23 the pressure would rise to the external pressure. However normally the pressure rise will be limited indicating the absence of any leak and the expansion tank can be vented to the transit capsule pressure by valves 55. The double hatch can now be opened and access gained to the conjunction capsule 25 to enable flexible connections 56 to be made to the capsule 15 through or by-passing the hatch 18. One of these connections is a pressure bleed and this again is routed by the valves 53 to the expansion tank 52 except that the initial flow is by-passed by valves 57 through a sight glass 58 so that the nature of the flow can be observed and possibly by valves 59 to analytical apparatus 60. If the flow is oil or gas, it is possible to flush any remaining oil or gas from the capsule 15 by pumping water through the other of the flexible connections 56 to an outlet 61 below the expected lowest level of gas or oil by a power driven pump 62 or a hand driven pump 63. This oil or gas would result from a leakage from the well head installation and can be severely limited by means 65 which comprises any one or combination of an oil detector, a gas detector, a differential pressure detector, a pressure relief valve and a frangible diaphragm. This means is disposed in the upper part of the capsule 15 which is so arranged as to provide an oil and gas catchment area around the means. Any detectors used in the means are arranged to prevent further leakage by closing off the well head either by direct mechanical operation or by electrical or hydraulic connections. Preferably the means, or some of it, is disposed to be accessible for closing off purposes from the conjunction capsule. If a pressure relief valve or diaphragm is used, a valve 66 operable from within the capsule 25 is used to isolate the relief valve or diaphragm from the external pressure to allow the pressure relief valve or diaphragm to be serviced. The water which is pumped through the outlet 61 is drawn from a sea connection or possibly from the tank 52 and discharged through another sea connection 68 or a pressure relief valve in the means 65; if oil pollution is to be minimised, it is possible to store the flushed oil in the tank 52 or another tank. In cases where it is impossible to limit the amount of oil leakage, it would be possible to have a diving-bell-like collector to receive any oil coming from the sea connection 68. After all the oil and gas has been flushed out, the pressure in the capsule can be reduced as described in relation to capsule 25 and the hatch opened. Access can then be gained to the well head installation. Since this is still immersed in water which can be fifteen foot deep, it is necessary to have shallow water diving support means, i.e. an air supply system including a compressor 102 (FIG. 4) so that the personnel do not have to suck air against the pressure head of the water in the capsule 15. Each person has a demand valve in his breathing equipment to reduce the air pressure to that required at his working depth. Since even if the capsule 15 becomes pressurised whilst occupied, the pressures in the other capsules will increase by the same amount, the pressure head generated by the compressor does not have to be large. The compressor 102 draws in air from the transit capsule and delivers it to a reservoir 103 controlled by a settable relief valve 104 and thence to a breathing manifold 105 through filters 106 and carbon dioxide absorbing means 107. The pressure in this manifold is controlled by a valve 108. Suitable connecting points 109 for drawing off air are provided on the manifold.
FIG. 3 also illustrates flexible connections 69 which can be used to flush equipment within the capsule 15 if required pressure gauges 70 and external connections 71 to enable the capsule 24 to be used as a decompression chamber or diving bell.
So far it has been assumed that the pressure in the capsule 25 can be reduced. The only reason for the pressure in the capsule 25 not to reduce is a leak on the sealing surfaces 22 and 23. One of these surfaces contains a compressible seal 81 which is arranged to be compressed sufficiently for the surfaces 22 and 23 to limit the amount of leakage if the seal 81 fails. The module 20 has a rotatable collar 82 having projections 83 for gripping in T-shaped slots 84 in a ring 72 containing the surface 22 and removing the ring 72 to the surface along with the module 20. At the surface the sealing surfaces can be rectified possibly by replacing the ring 72 which has compressible seals 85 on its lower surface. When the ring 72 has been rectified or replaced it can be brought down on the module 20 and the lower surface sealed. The seals on the lower surface are rendered permanent by sealants and/or inhibitors injected through ducts 86 (which can in turn be sealed by plugs) and this time the ring 72 should give a good seal so that the capsule 25 can be reduced in pressure.
Various functions can be performed from maintenance up to the erection of the christmas tree and making external connections. When the capsule is initially installed using divers or diving bells, it may consist of the bare shell which is attached by the divers to the well head casings, the christmas tree not yet being installed. The holes in the shell such as the port 31 and ports 90 (FIG. 6) for the entry of the pipelines are blanked off from the outside by removable cover plates 91 whose securing means 92 are access accessible from the inside of the shell. These cover plates are arranged so that even in the absence of the securing means the external pressure will cause the cover plates to make a seal with the rest of the shell. Thus the shell immediately after installation can be used to provide a safe working environment for personnel to erect the christmas tree. When a new part of the christmas tree is to brought within the shell, it is possible to bring down the new part within the transit capsule as in the prior art. However because of the low depressurisation time required, it is possible for personnel from the transit capsule to release the securing means of a plate over a port 90, buoy the cover plate by means of a hawser 93 and an eyebolt 94 and attach a haul-down hawser 95 to an eyebolt 96. They can then return to, and seal themselves inside the transit capsule and repressurise the capsule 15 so that the cover plate is expelled from its seating and can be recovered by a support ship. A new part and the cover plate or, for example a pipe 97 (FIG. 7) can then be arranged on the hawser 95 and the hawser drawn in by a winch in the capsule 25 operated from within the capsule 24 so that the cover plate or pipe flange is drawn tight back on its seating with the new part within the capsule 15. The personnel can then reduce the pressure in the capsule 15 to regain access thereto and secure the pipe flange or to resecure the cover plate and fit the new part.
Some parts of the well head installation may be connected by flexible leads to the christmas tree and be removably secured within the capsule 15 so that they can be drawn up into the transit capsule for maintenance in a dry environment. Such a part is a control panel 119 (FIG. 1).
After the maintenance or installation function is completed the personnel return to the transit capsule sealing the hatches behind them and repressurising the equipment part and conjunction capsules. The transit capsule then returns to the sea-surface.
In this Specification and the apended claims, a capsule means a shell capable of resisting pressure exerted by the external seal water when the pressure inside the shell or capsule is reduced to atmospheric. | A capsule for enclosing a sub-sea installation part is intended to be left water-filled and thus means for sensing oil or gas leaks from the part is disposed in the upper part of the capsule to where such leakage will float. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to large gun systems.
Conventional indirect fire gun systems fire "dumb bullets" where the bullets follow a trajectory based on gun muzzle velocity and the direction the gun barrel is pointed. As with all conventional gun systems shooting dumb bullets, it's systems effectiveness, defined by its range and accuracy and rate of fire, are to a great extent limited to what the gun barrel and gun pointing system can provide. Since bullets of these larger gun systems can weigh 70 lb. and more, are over 4 inches in diameter, and often stand more that 4 feet tall, conventional gun systems also require complicated loading systems that expose people to the dangers associated with loading and handling these munitions. An additional problem of these larger gun systems is that all of the bullets need to be fired out of a single barrel, thereby creating a single point failure possibility of the entire gun systems. Even when the gun system is properly operating, simple physics involved with gun barrel heating and the related loss of mechanical strength of the material at too high of a temperature, often is the limiting factor in gun system rate of fire, one of the critical performance parameters of the gun.
Currently there are gun launched guided munitions, so called "smart bullets" being developed that, much like missiles that have been used for years, once they are launched from the gun they are actively guided to a preprogrammed target. Many are also being fitted with rocket motors that light off at a preset time interval once leaving the gun, thereby further increasing the range of these munitions. Properly designed, these rocket motors require less muzzle velocity, and less internal gun pressure, to achieve the desired range. These smart bullets achieve their longest range when fired at or near vertical position of the gun barrel. A big problem that has been identified by the gun community is that these guided projectiles have a limited shelf life once they leave the environmental protection of their shipping container. In the container the shelf life of the guided rounds can approach 10+ years however out of the container the shelf life is estimated at about 1 year.
Current military battle threats are defeated one of two ways: missiles or indirect fire guns lobbing in munitions at a target. Missiles are typically very expensive, $500,000 and up per missile is not unrealistic, and have ranges of up to hundreds of miles. These missiles are typically used on far out targets, and when guided are very accurate. Indirect fire guns usually have ranges limited to 20 miles or less and usually cost a couple of thousand dollars per round. They are also typically not very accurate and thus required a large amount of rounds to defeat the target. For threats that are at 20 to 100 miles the only current option is to fire a very expensive missile. It is desirable to be able to defeat a target 20 to 100 miles out with something less expensive than missiles. It is also desirable to be more accurate at hitting targets in the gun range thus requiring less munitions, and thus less overall cost, to defeat the close target. It is also more desirable to reduce manpower requirements of the gun and loading system while increasing the overall reliability.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a gun system that has limited moving parts and that can be operated autonomously.
It is another object of the invention to provide a gun system, where the projectiles are less expensive than a conventional missile.
The invention provides a matrix gun system that uses guided projectiles stored in a disposable barrel, which houses the guided projectile, a propelling charge, and a recoil system.
This invention addresses the design of a smart bullet gun launching system that overcomes the well understood problems and issues associated with conventional gun launching systems shooting these bullets, while at the same time addressing the need for a low cost, low manning, high reliability gun system. This invention also allows for autonomous and/or remote operation of the gun system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut away perspective view of a single cell of preferred embodiment of the invention.
FIG. 2 is a perspective view of a plurality of cells forming the preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a cut away perspective view of a single cell 10 of a matrix gun. The cell comprises a barrel 12, a projectile 13, a propelling charge 14, a recoil system 15, and a frangible closure 16.
In the preferred embodiment, the barrel 12 is a steel lined composite overwrap pressure vessel, which is designed to contain the launching pressures required for the ordnance design, and has a bore of 5 inch (12.7 cm) and a length of 310 inches (7.9 m). The barrel 12 is in the form of a cylinder with a first end and a second end, with the first end being a closed end. The projectile 13 is a guided projectile, which can be launched in a vertical direction, and then be turned towards an intended target. The guided projectile 13 has an internal propulsion system, which is able to change the direction of the guided projectile 13 towards a target. Such guided projectiles 13 can be radio controlled, or can have an on board computer which is programmed with the location of the target, or the projectile may be able to detect and seek a target, or have other means for controlling the internal propulsion system to direct the projectile towards a target.
Below the projectile 13 between the projectile 13 and the first end of the barrel 12 is the propelling charge 14. As shown, the propelling charge 14 is outside of (or external to) the projectile 13. In the preferred embodiment, the propelling charge 14 has a propellant volume of 1150 cubic inches (11,845 cm 3 ). A recoil system 15 is placed around the first end of the barrel 12. In the preferred embodiment the recoil system 15 is a collapsible foam which is not reusable. The recoil system 15 is in a cylindrical shape, with a diameter approximately equal to the outer diameter of the barrel 12 and with a length of 20 inches (50.8 cm). A frangible closure 16, such as a plastic sheet is placed across the opening at the second end of the barrel 12, to seal the barrel 12 and protect the projectile 13 and propelling charge 14 from the elements. An ignition system 18, which utilizes one of a multitude of available ignition methods such as electrical, percussion, or laser ignition is placed adjacent to the propelling charge 14. An electrical wire 19 is placed between the ignition system 18 and a control system 20.
The assembly begins at an ordnance depot with a one time use, recoil system 15 being attached to the barrel 12. The propelling charge 14 is then inserted into the barrel 12. The guided projectile 13 is then inserted into the barrel 12. Once inside, the interior of the barrel 12 is filled with a preservative gas to ensure longest shelf life, typically dry air. The air tight, frangible closure 16 is then placed into the open end of the barrel 12 and sealed to the barrel 12. The frangible closure 16 creates an air tight seal, so that the barrel 12 becomes an air tight environment for storage and transportation of the guided projectile 13. The ignition system 18 is then inserted into the barrel 12. This completes the assembly of a single cell 10.
FIG. 2 shows a plurality of cells 10 in a preferred embodiment of a matrix configuration 21. In the preferred embodiment the cells 10 are placed in a box shaped container 22 that has a length 23 of 80 inches 203 cm), a width 24 of 80 inches (203 cm) and a height 25 of 240 inches (610 cm). 24 cells 10 may be packed in the container 22.
In operation, the matrix configuration 21 is placed on board of a ship or placed on land. Electrical wires 19 (FIG. 1) pass from the ignition systems 18 of the individual cells 10 to a single control system 20, which also provides power electronics. The control system 20 is the control center of the entire matrix. The control system 20 can receive firing commands from a remote site and sends signals through the electrical wires 19 to the ignition systems 18 of individual cells 10, to cause the propelling charge 14 to ignite, firing the projectiles 13. The projectiles 13 may be either fired sequentially or more than one at a time. The recoil from the propellant 14 accelerating the projectile 13 is absorbed by the recoil system 15, where in this embodiment the foam is inelastically compressed. The projectile 13 breaks the seal of the frangible closure 16 and exits the barrel 12, which to this point in the procedure has been used as a shipping and storage tube for the projectile 13. The guidance system of the projectile 13 causes an internal propulsion system to turn the projectile 13 towards the target. The barrels 12 and recoil systems 15 of the cells 10 where the single projectile has been fired are removed and either disposed of or refurbished and replaced
In another method of using the single cell 10, the single cell 10 is shipped to the field where it is used to replace a fired single cell 10 in an already fielded matrix configuration 10. Once again, the barrel 12 is both the shipping container and the launching tube thus ensuring maximum shelf life, and thus maximum ordnance effectiveness of the projectile 13.
In either method outlined above, once the projectile 13 is fired from the barrel 12, the barrel 12 can be discarded or sent back to the ordnance depot for overhaul and reuse.
In another embodiment, the matrix uses a smaller container to house fewer cells, like 10 cells. The matrix is placed on the ground, which supports the matrix in a vertical position or in a position angled from the vertical.
In another embodiment, electromagnetic waves carried through space and receivers connected to the ignition systems 18 replace electrical signals carried through wires 19 as another means for electrically connecting the control system 20 to ignition systems 18.
The advantages of this invention include a virtual unlimited firing rate since no loading mechanism is used. Another major advantage is that the shelf life of the guided rounds can be held to their maximum shelf life, since the only time the container seal is broken is when the munitions is fired. Another subtle yet very important advantage the matrix gun has over conventional guns is the ability for continuous system readiness testing of the individual guided munitions. In a conventional gun with a moving munitions handling system, continuous readiness testing of the guided munitions is virtually impossible, or at the very best a complicated and often manpower intensive operation. The matrix gun system with disposable barrels and recoil systems eliminates complex loading systems and human contact with ordinance, typical of large gun systems. This allows for in a reduction of down time caused by failures in the loading system, human error, or problems with single point of failure gun barrels and recoil systems. The reduction of human contact also increases safety.
While preferred embodiments of the present invention have been shown and described herein, it will be appreciated that various changes and modifications may be made therein without departing from the spirit of the invention as defined by the scope of the appended claims. | The invention provides a method and apparatus for firing a guided projectile. The invention provides a matrix of one time shot gun systems. Each one time shot gun system has a one time shot barrel, a one time shot recoil system, a propelling charge, breakable seal, and a guided projectile which is stored in and from the barrel. The one time shot system provides an inexpensive firing system, which eliminates single points of failure that exist in conventional gun systems. | 5 |
The present application is a divisional application of co-pending application Ser. No. 381,528, filed on May 24, 1982, U.S. Pat. No. 4,443,608.
BACKGROUND OF THE INVENTION
The preparation of β-glucuronides has been carried out by a number of different techniques. Chemical synthesis typically involves condensation of a suitably protected aglycon with an alkyl (2,3,4-tri-O-acetyl-β-D-glucopyranosyl halide) glucuronate followed by deprotection of the glucuronide and aglycon (Ando, K., Suzuki, S., and Arita, M. [1970] J. Antibiotics 23, 408; Sarett, L. H., Strachan, R. G., and Hirschmass, R. F. [1966] U.S. Pat. No. 3,240,777). A second approach involves feeding large amounts of the aglycon to animals, collecting their urine and isolating the glucuronide (Hornke, I., Fehlhaber, H. W., Uihlein, M. [1979] U.S. Pat. No. 4,153,697). Alternatively, the animal can be sacrificed and the bile isolated from its gall bladder from which the glucuronide is purified (DeLuca, H. F., Schnoes, H. K., and LeVan, L. W. [1981] U.S. Pat. No. 4,292,250). This in vivo synthesis is catalyzed by the class of enzymes known as uridine diphosphoglucuronyl transferases. In vitro use of this enzyme to produce various β-glucuronides has been reported; for example, a phenolic compound has been glucuronidated (Johnson, D. B., Swanson, M. J., Barker, C. W., Fanska, C. B., and Murrill, E. E. [1979] Prep. Biochem. 9, 391).
BRIEF SUMMARY OF THE INVENTION
Upon incubating liver microsomes in the presence of a suitable buffer to maintain the pH at about 7 to about 8.5, (+,-)-tropicamide, and uridine 5'-diphosphoglucuronic acid (UDPGA), for a sufficient time, there is obtained a preparation of (+),(-)-tropicamide O-β-D-glucuronide. This ammonium salt mixture can be isolated in its essentially pure form by reversed phase chromatography. The diastereomers can be completely resolved to their essentially pure forms by a high pressure liquid chromatographic (HPLC) system disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
The enzymatic method for the synthesis of β-glucuronides, described herein, has several advantages over prior art chemical synthesis or animal feeding methods. Chemical synthesis requires a minimum of four steps: (1) protection of all the nucleophilic groups in the aglycon except the one involved in the glycosidic linkage, (2) preparation of a suitably protected reactive derivative of D-glucuronic acid, e.g., methyl (2,3,4-tri-O-acetyl-β-D-glucopyranosyl halide) glucuronate, (3) condensation, and (4) deprotection. Complications arise if the aglycon contains functional groups sensitive to the conditions of deprotection. For example, aglycons containing esters or other alkali sensitive linkages can be hydrolyzed during the saponification of the methyl and acetyl protecting groups. In contrast, the enzymatic method described herein involves a single step condensation between a readily available cofactor and the aglycon.
The animal feeding approach to making β-glucuronides also has several disadvantages as compared to the subject enzymatic method. The most significant disadvantage is that stringent purification is required. Other disadvantages are the inconvenience of maintaining animals, and other metabolic pathways including hydroxylation, alkylation, and sulfation can compete with glucuronidation, thus resulting in low yields of the desired product.
The subject enzymatic process for the glucuronidation of (+,-)-tropicamide was unexpectedly successful in view of the fact that attempts to glucuronidate another primary alcohol, i.e., (-)scopolamine, were unsuccessful. Also, there is no known prior art which discloses the preparation of essentially pure (+),(-)-tropicamide O-β-D-glucuronide and the two diastereomers (+)-tropicamide O-β-D-glucuronide and (-)-tropicamide O-β-D-glucuronide. The subject process is particularly advantageous because the reaction yields a single pair of stereospecific products, as disclosed above.
The enzymatic reaction, described herein, can be carried out over a pH range of about 7 to about 8.5 with different buffer strengths and with various buffers, for example, sodium N-2-hydroxyethyl piperazine-N'-2-ethanesulfonic acid, tris hydrochloride, and the like. Quantitative glucuronidation can be obtained by increasing the amount of UDP glucuronic acid in the reaction.
The chromatographic methods described herein are based on reversed phase liquid chromatography on C-18 silica supports. This technique is well suited for the purification of enzymatically-produced glucuronides of hydrophobic compounds. Unreacted aglycon is much more hydrophobic than the corresponding glucuronide and thus will be well resolved on reversed phase systems. The cofactor, UDP glucuronic acid, and the byproduct, UDP, are both very hydrophilic and will be much less retained than the glucuronide of a hydrophobic compound. Finally, all the solvent systems described are based on NH 4 OAc, a volatile buffer. Modifications to this system may be necessary in order to purify glucuronides of very hydrophilic compounds. Other reversed phase stationary supports, for example, phenyl silica, C-8 silica, and the like, can be used. The resolution of the two diastereomers is enhanced when the pH is lowered from 7.0 to 3.7, which would increase the fraction of the molecules in the zwitterionic form necessary for an intramolecular ionic interaction. In addition, increasing the ionic strength from 0.1% NH 4 OAc to 1% NH 4 OAc diminishes the resolution as would be expected if an intramolecular "salt bridge" were present.
Liver microsomes which can be used in the subject invention can be obtained from animal sources, for example, rabbit, bovine, and the like.
The temperature of incubation in the enzymatic step can be from about 20° to about 45° C.
The compounds of the invention, i.e., (+),(-)-tropicamide O-β-D-glucuronide, (+)-tropicamide O-β-D-glucuronide, and (-)-tropicamide O-β-D-glucuronide are useful because of their absorption of ultraviolet light. These compounds can be incorporated in standard vehicles suitable for application to the human skin to produce compositions useful to prevent sunburn. For example, a one percent solution in corn oil applied to the skin absorbs ultraviolet light, and, thus, protects the skin. The invention compounds also can be used as ultraviolet absorbents in technical and industrial areas as follows:
(a) Textile materials: such textile materials may consist of natural materials of animal origin, such as wool or silk, or of vegetable origin, such as cellulosic materials of cotton, hemp, flax, or linen, and also semi-synthetic materials, such as regenerated cellulose, for example, artificial silk viscoses, including staple fibers of regenerated cellulose.
(b) Fibrous materials of other kinds (that is to say not textile materials) which may be of animal origin, such as feathers, hair, straw, wood, wood pulp or fibrous materials consisting of compacted fibers, such as paper, cardboard or compressed wood, and also materials made from the latter; and also paper masses, for example, hollander masses, used for making paper.
(c) Coating or dressing agent for textiles or paper.
(d) Lacquers or films of various compositions.
(e) Natural or synthetic resins.
(f) Hydrophobic oily, fatty or wax-like substances.
(g) Natural rubber-like materials.
(h) Cosmetic preparations.
(i) Filter layers for photographic purposes, especially for color photography.
Depending on the nature of the material to be treated, the requirements with regard to the degree of activity and durability, and other factors, the proportion of the light-screening agent to be incorporated in the material may vary within fairly wide limits, for example, from about 0.01 to 10%, and advantageously 0.1% to 2%, of the weight of the material which is to be directly protected against the action of ultraviolet rays.
The following examples are illustrative of the process and products of the invention, but are not to be construed as limiting. All percentages are by weight and all solvent mixture proportions are by volume unless otherwise noted.
EXAMPLE 1
Enzymatic preparation of (+,-)-tropicamide O-β-D-glucuronide
Four grams of a rabbit liver or bovine liver microsomal fraction (Sigma Chemical Co., St. Louis, Mo.) are suspended in 100 ml of a 75 mM tris hydrochloride buffer (pH=7.5-8.0). The microsomes are suspended by repeatedly drawing the mixture through a pipette tip. The microsomes are then pelleted by centrifugation at 100,000 g for 30 minutes. The supernatant is discarded, and the pellet is resuspended to 100 ml with a 150 mM tris hydrochloride (pH=7.5-8.0) solution, containing 200 mg (+,-)-tropicamide (Hoffman-LaRoche, Nutley, N.J., also disclosed in U.S. Pat. No. 2,726,245) and 1 gram of sodium uridine 5'-diphosphoglucuronic acid (Sigma Chemical Co.). After a 20 hr. incubation at 37° C., the reaction is terminated by heating to about 70° C., and centrifuging the reaction mixture. The desired product is in the supernatant. The yield of desired product is determined by high pressure liquid chromatography (HPLC) to be ˜75%.
The HPLC conditions are as follows: a 0.47×25 cm C-18 μBondapak column (Waters Associates, Milford, Mass.) is eluted at 2 ml/min. with 0.1% NH 4 OAc (pH=5.75). After injection of the sample, a linear gradient to 60% methanol is applied to the column over a 20 minute period. The column eluant is monitored with an ultraviolet detector set at 254 nm. Under these conditions the reaction product elutes as a partially resolved doublet. On the basis of the chemical and spectral data presented below the two peaks are assigned as (+)-tropicamide O-β-D-glucuronide and (-)-tropicamide O-β-D-glucuronide.
EXAMPLE 2
Isolation of essentially pure (+),(-)-tropicamide O-β-D-glucuronide
The pH of the reaction mixture, obtained in Example 1, is adjusted to 5.75 with 1.26 ml of 10% NH 4 OAc (pH=5.75); 25 ml of methanol is added to the reaction, and the suspension is centrifuged at 44,000 g for 60 minutes. The supernatant is collected and loaded onto a 15 mm by 250 cm column of octadecyl derivatized silica (50-100μ particles) (Waters Associates) which had been equilibrated with an 80/20 solution of 0.1% NH 4 OAc (pH=5.75)/methanol. The column is washed at 3 ml/min. until the absorbance of the eluant at 254 nm is less than 0.05. Essentially pure (+),(-)-tropicamide O-β-D-glucuronide is then eluted with a 55/45 solution of 0.1% NH 4 OAc (pH=5.75)/methanol. Unreacted (+,-)-tropicamide is eluted from the column with a 40/60 solution of 0.1% NH 4 OAc (pH=5.75)/methanol. The desired product contains less than 1% of (+,-)-tropicamide contamination.
EXAMPLE3
Separation of (+)- and (-)-tropicamide O-β-D-glucuronide
The two isomers are isolated from the mixture obtained in Example 2 as follows:
The two isomers are isolated by HPLC on a 0.39×30 cm column of C-18 μBondapak (Waters Associates). The column is equilibrated with 0.013 M NH 4 OAc (pH=3.7) containing 10% methanol at a flow rate of 2 ml/min. One minute after injection of the sample, the percentage of methanol in the eluant is raised to 22% in one minute. The two diastereomers elute at about eleven and thirteen minutes respectively. Retention times vary with column condition and the optimal concentration of methanol is normally determined with analytical injections. The two diastereomers are obtained in their essentially pure form.
Characterization of (+)- and (-)-tropicamide O-β-D-glucuronide
The two reaction products (50 μg in 150 μl of 50 mM sodium phosphate, pH=6.8) are individually treated with ten Fishman units of E. coli β-glucuronidase (EC 3.2.1.31) at 37° C. for 1 hour. Both compounds are quantitatively hydrolyzed by the glucuronidase to products which were indistinguishable by HPLC from the starting material, (+,-)-tropicamide, in the 0.1% NH 4 OAc (pH=5.75)/methanol solvent system described above. The products are also indistinguishable from (+,-)-tropicamide when chromatographed on C-18 in a second solvent system consisting of 1% triethylammonium acetate (pH=7.0) eluted with a linear gradient to 50% acetonitrile in 25 minutes. These data show that both products contain an intact tropicamide moiety. The known specificity of this enzyme shows the presence of a glucuronic acid moiety and shows that the glycosidic linkage has the β configuration. The tropicamides released by glucuronidase treatment are individually converted back to the corresponding glucuronides using the conditions described above. These reactions produced single products, i.e., the tropicamide derived from glucuronidase treatment of component 1 yields only component 1, and the tropicamide derived from component 2 yields only component 2. Thus the two products are diastereomers which differ only in the configuration of the optically active carbon in the tropicamide moiety.
The products of β-glucuronidase hydrolysis are further characterized by their rotation of 589 nm plane polarized light. These measurements show that the component which elutes earlier in the HPLC assay is dextrorotatory and the later eluting compound is levorotatory. Experiments with lesser amounts of E. coli glucuronidase show that the hydrolysis rate of (+)-tropicamide O-β-D-glucuronide is approximately twice as rapid as (-)-tropicamide O-β-D-glucuronide.
The ultraviolet spectra of (+),(-)-tropicamide, (+)-tropicamide O-β-D-glucuronide, and (-)-tropicamide O-β-D-glucuronide are recorded in a 0.05% NH 4 OAc (pH=7.0) solution. All three samples have identical spectra with maxima at 257 nm (Emax=2140) and shoulders at 252 nm and 263 nm characteristic of a para substituted pyridone moiety.
The molecular weights of the two diastereomers are determined by direct chemical ionization (DCI) mass spectrometry and fast atom bombardment (FAB) mass spectrometry. The ammonia DCI spectrum of each isomer gives a quasi molecular ion at m/z=461 (M+H)+, confirming the molecular weight as 460. Similarly the zenon FAB spectrum of both isomers contains a series of ions at m/z=461 (M+H)+, m/z=483 (M+Na)+, and m/z=499 (M+K)+ clearly showing a molecular weight of 460.
The infrared spectra in KBr pellets of the two tropicamide glucuronides both exhibit strong absorption bands centered at 3150 cm -1 and 1400 cm -1 confirming that the ammonium salt had been formed as expected. Both compounds also exhibit a broad band at 1600 cm -1 which is consistent with the presence of both a carboxylate and a tertiary amide carbonyl. In addition, a shoulder at 3350 cm -1 is consistent with the hydroxyl groups in the glucuronides.
The ammonium and other base salts of the compounds are useful in the same manner as the free acid form. If desired the ammonium salt can be converted to the free acid by means well known in the art, for example, by adjusting the pH of the ammonium salt solution with weak acid so as not to cause hydrolysis of the diastereomer. Salts with both inorganic and organic bases can be formed with the free acid. For example, in addition to ammonium salt, there also can be formed the sodium, potassium, calcium, and the like, by neutralizing an aqueous solution of the free acid.
(+),(-)-Tropicamide O-β-D-glucuronic acid has the following formula: | An in vitro enzymatic process which efficiently converts (+,-)-tropicamide to essentially pure (+), (-)-tropicamide O-β-D-glucuronide. This product is then separated, advantageously, into the novel compounds (+)-tropicamide O-β-D-glucuronide and (-)-tropicamide O-β-D-glucuronide. The products disclosed herein absorb ultraviolet light, and, thus, can be incorporated into suitable plastic films which are then useful for screening out harmful ultraviolet radiation for the protection of packaged goods. Also, the products can be used to protect the skin against burning by sunlight. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of Korean Patent Application Nos. 2012-0137345, 2012-0138316 and 2013-0147836, filed Nov. 29, 2012, Nov. 30, 2012 and Nov. 29, 2013, respectively, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present application relates to a coating method capable of inhibiting reduction of a water transmission rate by performing a non-contact coating method on a barrier layer when protective coating is performed to protect a barrier layer of a barrier film.
[0004] 2. Discussion of Related Art
[0005] A gas barrier film, that is, a barrier film, has a gas barrier property because a barrier layer having a thickness of about tens or 100 nm is stacked. Examples of a method of forming the barrier layer include atomic layer deposition (ALD). This method is used to form a metal barrier layer in a semiconductor device, a wear resistant film, or a corrosion resistant film because it has good thickness uniformity, film density, and conformality. In the field of semiconductors, atomic layer deposition (ALD) is generally performed on a deposition substrate made of inorganic materials such as a silicon wafer. Water molecules are adsorbed onto the surfaces of these inorganic materials to naturally form hydroxyl groups, and then the hydroxyl groups react with organometals, and thus a homogeneous oxide film with good adhesion may be stacked by atomic layer deposition (ALD). For example, an Al 2 O 3 deposition process may be represented by the following Reaction 1. As known in Reaction 1(a), when a density of a hydroxyl group is increased on the surface of a substrate, adhesion between a deposition layer and the substrate is increased, durability of a composite stacking body is improved, and thus a denser barrier layer is formed on the surface:
[0000] Reaction 1
[0000] substrate-OH+Al(CH 3 ) 3 →substrate-O—Al(CH 3 ) 2 +CH 4 (a):
[0000] substrate-O—Al(CH 3 ) 2 +2H 2 O→substrate-O—Al(OH) 2 +2CH 4 (b):
[0006] However, when the film is damaged because a thickness of the barrier layer is very small, a gas barrier property is decreased significantly. Accordingly, the barrier layer should be protected by a coating layer to suppress reduction of a gas barrier property.
SUMMARY OF THE INVENTION
[0007] The present application is directed to a barrier film capable of protecting products which are likely to be deteriorated by water during general use, such as display devices or photovoltaic elements; a method of preparing a barrier film in which, when a protective layer protecting a thin inorganic layer, that is, a barrier layer, formed on a substrate by atomic layer deposition (ALD) is formed, the protective layer is formed in such a way that contact with the barrier layer is minimized using a non-contact coating method, and thus damage of the barrier layer and reduction of a gas barrier property are prevented; and a barrier film forming apparatus.
[0008] According to an aspect of the present application, there is provided a method of preparing a barrier film including forming a barrier layer and a protective layer on a substrate layer. An exemplary method of preparing the barrier film may include forming the barrier layer on a substrate layer by atomic layer deposition (ALD) and coating the barrier layer with a coating composition by a non-contact coating method to form the protective layer.
[0009] Hereinafter, the present application will be described in detail.
[0010] The barrier film of the present application is formed by forming a thin barrier layer on a substrate layer by atomic layer deposition (ALD), and forming a protective layer using a non-contact coating method which minimizes contact with the barrier layer when the protective layer protecting the barrier layer is formed. Thus damage of the barrier layer is prevented, and reduction of a gas barrier property is suppressed.
[0011] The barrier layer of the barrier film of the present application may be formed above or below the substrate layer, and may be used by attaching two sheets of composite films.
[0012] Examples of the substrate layer may include a metal oxide substrate, a semiconductor substrate, a glass substrate, a plastic substrate, and the like.
[0013] The substrate layer may be a monolayer, or a multilayer of two or more layers of the same or different kinds.
[0014] Also, the surface of the substrate layer may be subjected to corona treatment, normal pressure plasma treatment, or adhesive primer treatment to enable adhesion.
[0015] According to the present application, an intermediate layer may be further formed on the substrate layer.
[0016] The intermediate layer flattens the surface of the substrate layer having a surface roughness of tens to hundreds of nanometers. The intermediate layer uniformly distributes a functional group which is easily reacted with organometals on the surface of the substrate layer so that organometals to be used for atomic layer deposition (ALD) may be uniformly adsorbed onto the surface of the substrate layer. Accordingly, the intermediate layer may have, for example, a thickness of 0.1 nm to 10 nm or 0.3 μm to 2 μm. As the intermediate layer has the aforementioned thickness range, the rough surface of a commercially available substrate layer is covered by the intermediate layer and flattened, thus preventing locally concentrated stress. Accordingly, cracks may minimally occur in bending, heat shrinking or expansion, and then improve durability of a composite film.
[0017] The intermediate layer may be optionally disposed on either or both surfaces of a primerized substrate. The intermediate layer may be one of an organic material and mixture of organic and inorganic materials.
[0018] The intermediate layer is conventionally formed of a coating composition including (i) a photoinitiator; (ii) a low molecular reactive diluent (for example, monomer acrylate); (iii) an unsaturated oligomer (for example, acrylate, urethane acrylate, polyether acrylate, epoxy acrylate, or polyester acrylate); and (iv) a solvent. Such a coating composition is cured by a free radical reaction which is initiated according to a photodegradable route. A blend of respective components may be changed depending on desired final features. In one embodiment, a coating composition forming the intermediate layer includes a UV-curable mixture of a monomer and an oligomer acrylate (preferably including methyl methacrylate and ethyl acrylate) in a solvent (for example, methyl ethyl ketone), in which the coating composition conventionally includes an acrylate in a solid content of 20 to 30 wt % based on the total weight of the composition, and further includes a small amount (for example, about 1 wt % of solid content) of a photoinitiator (for example, Irgacure™ 2959, manufactured by Ciba).
[0019] The term “lower molecular weight” described herein refers to a polymerizable monomer species. The term “reactive” refers to polymerizability of monomer species.
[0020] An coating composition includes a crosslinkable organic polymer (for example, polyethylene imine (PEI), polyester, polyvinyl alcohol (PVOH), polyamide, polythiol, or polyacrylic acid) and a crosslinking agent (for example, Cymel™ 385 or those described herein) in a solvent (a general aqueous solvent). The coating composition preferably includes PEI (preferably, with a molecular weight (Mw) in a range of 600,000 to 900,000).
[0021] Other examples of the intermediate layer are disclosed in U.S. Pat. No. 4,198,465, U.S. Pat. No. 3,708,225, U.S. Pat. No. 4,177,315, U.S. Pat. No. 4,309,319, U.S. Pat. No. 4,436,851, U.S. Pat. No. 4,455,205, U.S. Pat. No. 0,142,362, WO2003/087247 and EP1418197.
[0022] A coating composition of the intermediate layer may be applied continuously or using coating methods including a dip coating process. Coating is generally applied to have a thickness after drying of about 1 to 20 μm, preferably 2 to 10 μm, more preferably 3 to 10 μm. A coating composition may be applied in an “off-line” mode that is a different process from a film preparation process or an “in-line” mode in which a film preparation process is continuously performed. Coating is preferably performed in the in-line mode. The thermosetting coating composition after applied on a substrate layer may be cured at about 20 to 200° C., and preferably about 20 to 150° C. Whereas the coating composition may be cured for several days at room temperature of 20° C., or may be cured for several seconds at a heating temperature of 150° C.
[0023] The barrier layer is deposited on the intermediate layer. Thus, when the intermediate layer is not flattened, defects may occur during deposition of the barrier layer so that a gas barrier property is decreased. When flatness of the surface is decreased, a gas barrier property is increased. Accordingly, flatness of the intermediate layer may have Ra of less than 0.7 nm, preferably less than 0.6 nm, more preferably less than 0.5 nm, even more preferably less than 0.4 nm, even more preferably less than 0.3 nm, and ideally less than 0.25 nm, and/or Rq of less than 0.9 nm, preferably less than 0.8 nm, more preferably less than 0.75 nm, even more preferably less than 0.65 nm, even more preferably less than 0.6 nm, even more preferably less than 0.50 nm, even more preferably less than 0.45 nm, even more preferably less than 0.35 nm, and ideally less than 0.3 nm.
[0024] The surface of the intermediate layer may be subjected to plasma pretreatment before deposition of the barrier layer. Plasma pretreatment may be generally performed under argon/nitrogen or argon/oxygen atmosphere for about 2 to 8 minutes, preferably about 5 minutes. Specifically, plasma pretreatment is microwave-activated. In other words, plasma pretreatment is performed using microwave plasma generation source without another plasma generation source.
[0025] A gas barrier layer is formed on the intermediate layer by chemical bonds with functional groups, and therefore a peeling problem which is likely to occur in a multilayer composite film may be solved.
[0026] In order to prepare a barrier film of the present application, the barrier layer is formed on the surface of the substrate layer.
[0027] The barrier layer provides a sufficient barrier property to obtain water vapor and/or oxygen transmittance, and specifically, a water vapor transmittance rate is less than 10 −3 g/m 2 /day and an oxygen transmittance rate is less than 10 −3 g/m 2 /day. Specifically, the water vapor transmittance rate is less than 10 −4 g/m 2 /day, preferably less than 10 −5 g/m 2 /day, and more preferably less than 10 −6 g/m 2 /day. Oxygen transmittance rate is less than 10 −4 g/m 2 /day or less than 10 −5 g/m 2 /day.
[0028] The barrier layer is formed by atomic layer deposition (ALD). The ALD is self-limiting sequential surface chemistry which allows a conformal thin film of materials to be deposited on a substrate in an atomic level. A film generated by ALD is formed layer-wise, and an atomic layer of a generated superfine film is controlled to about 0.1 A per monolayer. The total thickness of the deposited film is typically about 1 to 500 nm. Coating may be performed by ALD at a uniform thickness inside a deep trench, inside a porous medium, and around of particles. An ALD-growth film is chemically bonded to a substrate layer. Description of an ALD process is described in detail in “Atomic Layer Epitaxy” by Tuomo Suntola in Thin Solid Films, vol. 216 (1992) pp. 84-89. While precursor materials are maintained separately during coating process and reaction, ALD is chemically similar to chemical vapor deposition (CVD) except that a CVD reaction is split into two half reactions in ALD. During the process, precursor vapor is absorbed into a substrate layer in a vacuum chamber. Subsequently, the vapor is pumped from the chamber, and a thin layer (barrier layer) formed of the absorbed precursor is deposited on the substrate layer. Subsequently, reactants are introduced into the chamber under a thermal condition which accelerates a reaction with the absorbed precursor such that a layer of target materials is formed. Reaction byproducts are pumped from the chamber. The substrate may be exposed again to precursor vapor and the deposition processes may be performed repeatedly to form a subsequent layer of the material. ALD is different from conventional CVD and physical vapor deposition (PVD) which is performed after growth is initiated on a limited number of nuclear forming portions on the surface of the substrate layer. CVD and PVD technologies may derive column growth having a granular fine structure, showing a boundary in which a gas easily permeates between columns. An ALD process includes a non-directional growth mechanism to obtain a fine structure having no characterization part. Suitable materials for a barrier layer which is formed by ALD in the present application are inorganic materials and include oxides, nitrides, and sulfides of groups IVB, VB, VIB, IIIA, IIB, IVA, VA and VIA of the periodic table, and combinations thereof. Specifically, oxides, nitrides, or mixtures of oxides and nitrides are preferable. Oxides show good optical transparency to electronic displays and photovoltaic cells, such that visible rays are discharged from the element or enter the element, and nitrides of Si and Al are transparent in the visible spectrum. For example, SiO 2 , Al 2 O 3 , ZnO, ZnS, HfO 2 , HfON, MN, Si 3 N 4 , SiON, SnO 2 , and the like can be used.
[0029] Precursors which are used for the ALD process to form such barrier materials are known widely (for example, see M. Leskela and M. Ritala, “ALD precursor chemistry: Evolution and future challenges,” Journal de Physique IV, vol. 9, pp 837-852 (1999) and references cited therein). A temperature of a substrate layer preferable for synthesis of a barrier coating by ALD is 50 to 250° C. Since dimensional changes of the substrate layer cause chemical decomposition or collapse of ALD coating, it is not preferable for the temperature to exceed 250° C.
[0030] A thickness of the barrier layer may be 2 to 100 nm, 2 to 50 nm, or 2 to 20 nm. When a thickness of the layer is decreased, the film may endure bending without generation of cracks.
[0031] The protective layer in the present application may be formed on the aforementioned barrier layer by a non-contact coating method.
[0032] Examples of the non-contact coating method include inkjet coating, capillary coating, slot die coating, plasma polymerization coating, sputtering coating, evaporation coating, CVD coating, iCVD coating, and the like.
[0033] The protective layer is formed by coating the barrier layer with a coating composition, in which the coating composition contains nanoparticles and a binder, and an amount of the nanoparticles is 40 to 70 wt % based on the total weight of the nanoparticles and the binder.
[0034] The nanoparticles may be spherical nanoparticles having an average diameter of 1 to 100 nm, 1 to 90 nm, 1 to 80 nm, 1 to 70 nm, 1 to 60 nm, 1 to 50 nm, or 5 to 50 nm. The nanoparticles include low conductive materials or insulation materials. Examples of the nanoparticles include silica particles, alumina particles, and the like.
[0035] An amount of the nanoparticles may be 40 to 70 wt % based on the total weight of the nanoparticles and the binder. Specifically, an amount of the nanoparticles having an average diameter of 10 to 20 nm may be 45 to 55 wt %.
[0036] The binder may include at least one selected from the group consisting of a radical curable compound and a cationic curable compound.
[0037] The radical curable compound may be classified as a radical polymerizable monofunctional group monomer, a radical polymerizable polyfunctional group monomer, or a radical polymerizable oligomer.
[0038] Examples of the radical polymerizable monofunctional group monomer include acrylic acid, methyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, tetrahydrofurfuryl acrylate, phenoxyethyl acrylate, trioxyethyl acrylate, nonylphenoxyethyl acrylate, tetrahydrofurfuryloxyethyl acrylate, phenoxy diethyleneglycol acrylate, benzyl acrylate, butoxyethyl acrylate, cyclohexyl acrylate, dicyclopentanyl acrylate, dicyclopentenyl acrylate, glycidyl acrylate, carbitol acrylate, isobornyl acrylate, and the like.
[0039] Examples of the radical polymerizable polyfunctional group monomer include 1,6-hexanediol diacrylate, neopentyl glycol diacrylate, diethylene glycol diacrylate, tripropylene glycol diacrylate, dicyclopentanyl diacrylate, butylene glycol diacrylate, pentaerythritol diacrylate, trimethylolpropane triacrylate, propionoxide modified trimethylolpropane triacrylate, pentaerythritol triacrylate, ditrimethylolpropane tetraacrylate, dipentaerythritol hexaacrylate, caprolactone modified dipentaerythritol hexaacrylate, tetramethylolmethane tetraacrylate, and the like.
[0040] Examples of the radical polymerizable oligomer include polyester acrylate, polyether acrylate, urethane acrylate, epoxy acrylate, polyol acrylate, and the like.
[0041] Examples of the cationic curable compound include a cationic polymerizable epoxy compound, a vinyl ether compound, an oxetane compound, an oxolane compound, a cyclic acetal compound, a cyclic lactone compound, a thiirane compound, a thiovinylether compound, a spirortho ester compound, an ethylenic unsaturated compound, a cyclic ether compound, a cyclic thioether compound, and the like, and preferably, a cationic polymerizable epoxy compound, an oxetane compound, and the like.
[0042] Examples of the cationic polymerizable epoxy compound include a cresol novolac type epoxy resin, a phenol novolac type epoxy resin, and the like, and preferably a phenol novolac type epoxy resin.
[0043] Examples of the cationic polymerizable epoxy compound include an alicyclic epoxy compound, an aromatic epoxy compound, an aliphatic epoxy compound, and the like, and at least one selected from the aforementioned compounds may be used.
[0044] The term “alicyclic epoxy compound” herein means a compound including at least one alicyclic epoxy group. The term “alicyclic epoxy group” in the specification means a functional group including an epoxy group formed by two carbon atoms in an aliphatic saturated hydrocarbon ring.
[0045] Examples of the alicyclic epoxy compound include an epoxycyclohexylmethyl epoxycyclohexanecarboxylate-based compound, an epoxycyclohexane carboxylate-based compound of an alkanediol, an epoxy cyclohexylmethyl ester-based compound of a dicarboxylic acid, an epoxycyclohexylmethyl ether-based compound of polyethylene glycol, an epoxycyclohexylmethyl ether-based compound of an alkanediol, a diepoxytrispiro-based compound, a diepoxymonospiro-based compound, a vinylcyclohexene diepoxide compound, an epoxycyclopentyl ether compound, a diepoxy tricyclo decane compound, and the like.
[0046] Examples of the alicyclic epoxy compound include a difunctional epoxy compound, that is, a compound having two epoxy groups, and preferably a compound in which two epoxy groups are alicyclic epoxy groups, but are not limited thereto.
[0047] Examples of the aliphatic epoxy compound include an epoxy compound which has an aliphatic epoxy group without an alicyclic epoxy group. Examples of the alicyclic epoxy compound include a polyglycidyl ether of an aliphatic polyvalent alcohol; a polyglycidyl ether of an alkylene oxide adduct of an aliphatic polyvalent alcohol; a polyglycidyl ether of a polyester polyol of an aliphatic polyvalent alcohol and an aliphatic polyvalent carboxylic acid; a polyglycidyl ether of an aliphatic polyvalent carboxylic acid; a polyglycidylether of a polyester polycarboxylic acid of an aliphatic polyvalent alcohol and an aliphatic polyvalent carboxylic acid; a dimer, an oligomer, or a polymer obtained by vinyl polymerization of glycidyl acrylate or glycidyl methacrylate; or an oligomer or polymer obtained by vinyl polymerization of a vinyl-based monomer different from glycidyl acrylate or glycidyl methacrylate, and the like, preferably a polyglycidyl ether of an aliphatic polyvalent alcohol or an alkylene oxide adduct thereof, but are not limited thereto.
[0048] Examples of the aliphatic polyvalent alcohol include aliphatic polyvalent alcohols having 2 to 20 carbon atoms, 2 to 16 carbon atoms, 2 to 12 carbon atoms, 2 to 8 carbon atoms or 2 to 4 carbon atoms, for example, an aliphatic diol such as ethylene glycol, 1,2-propanediol, 1,3-propanediol, 2-methyl-1,3-propanediol, 2-butyl-2-ethyl-1,3-propanediol, 1,4-butanediol, neopentyl glycol, 3-methyl-2,4-pentanediol, 2,4-pentanediol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, 2-methyl-2,4-pentanediol, 2,4-diethyl-1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 3,5-heptanediol, 1,8-octanediol, 2-methyl-1,8-octanediol, 1,9-nonanediol, or 1,10-decanediol; an alicyclic diol such as cyclohexane dimethanol, cyclohexanediol, hydrogenated bisphenol A, or hydrogenated bisphenol F; trimethylolethane; trimethylolpropane; hexytols; pentitols; glycerin; polyglycerin; pentaerythritol; dipentaerythritol; tetramethylolpropane; and the like.
[0049] Also, examples of the alkylene oxide include alkylene oxides having 1 to 20 carbon atoms, 1 to 16 carbon atoms, 1 to 12 carbon atoms, 1 to 8 carbon atoms or 1 to 4 carbon atoms, for example, ethylene oxide, propylene oxide, butylene oxide, and the like.
[0050] Also, examples of the aliphatic polyvalent carboxylic acid include, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, dodecanedioic acid, 2-methylsuccinic acid, 2-methyladipic acid, 3-methyladipic acid, 3-methylpentanedioic acid, 2-methyloctanedioic acid, 3,8-dimethyldecanedioic acid, 3,7-dimethyldecanedioic acid, 1,20-eicosamethylene dicarboxylic acid, 1,2-cyclopentanedicarboxylic acid, 1,3-cyclopentanedicarboxylic acid, 1,2-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, 1,4-dicarboxylmethylenecyclohexane, 1,2,3-propanetricarboxylic acid, 1,2,3,4-butanetetracarboxylic acid, 1,2,3,4-cyclobutanetetracarboxylic acid, and the like, but are not limited thereto.
[0051] The aliphatic epoxy compound includes a compound having at least three epoxy groups, preferably three epoxy groups, without an alicyclic epoxy group, which is preferable in terms of a curing property, weather resistance, and a refractive index, but is not limited thereto.
[0052] The aromatic epoxy compound is an epoxy compound including an aromatic group in one molecule, and for example, includes a bisphenol type epoxy resin such as a bisphenol A-based epoxy, a bisphenol F-based epoxy, a bisphenol S epoxy, and a brominated bisphenol-based epoxy; a novolac type epoxy resin such as a phenolnovolac type epoxy resin and a cresolnovolac type epoxy resin; a cresol epoxy, a resorcinol glycidyl ether, and the like.
[0053] Examples of the cationic polymerizable oxetane compound include 3-ethyl-3-hydroxymethyl oxetane, 1,4-bis [(3-ethyl-3-oxetanyl)methoxymethyl]benzene, 3-ethyl-3-(phenoxymethyl)oxetane, di[(3-ethyl-3-oxetanyl)methyl]ether, 3-ethyl-3-(2-ethylhexyloxymethyl)oxetane, phenolnovolac oxetane, and the like. Examples of the oxetane compound include “ARONE oxetane OXT-101,” “ARONE oxetane OXT-121,” “ARONE oxetane OXT-211,” “ARONE oxetane OXT-221,” “ARONE oxetane OXT-212,” and the like (manufactured by TOAGOSEI Co., Ltd.).
[0054] Examples of the cationic polymerizable compound include an epoxy compound, preferably an epoxy resin such as a cresol novolac type epoxy resin and a phenol novolac type epoxy resin.
[0055] The protective layer further includes a radical initiator or a cationic initiator as a component to initiate a curing reaction.
[0056] Examples of the radical initiator include a radical photoinitiator or a radical thermal initiator. Examples of the radical photoinitiator include initiators such as benzoine-based initiators, a hydroxyketone compound, an aminoketone compound or phosphine oxide compound, and preferably a phosphine oxide compound. Specific examples of the photoinitiator include benzoine, benzoine methylether, benzoine ethylether, benzoine isopropylether, benzoine n-butylether, benzoine isobutylether, acetophenone, dimethylamino acetophenone, 2,2-dimethoxy-2-phenylacetophenone, 2,2-diethoxy-2-phenylacetophenone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexylphenylketone, 2-methyl-1-[4-(methylthio)phenyl]-2-morpholino-propan-1-one, 4-(2-hydroxyethoxy)phenyl-2-(hydroxy-2-propyl)ketone, benzophenone, p-phenylbenzophenone, 4,4′-diethylaminobenzophenone, dichlorobenzophenone, 2-methylanthraquinone, 2-ethylanthraquinone, 2-t-butylanthraquinone, 2-aminoanthraquinone, 2-methylthioxanthone, 2-ethylthioxanthone, 2-chlorothioxanthone, 2,4-dimethylthioxanthone, 2,4-diethylthioxanthone, benzyldimethylketal, acetophenone dimethylketal, p-dimethylamino benzoic acid ester, oligo[2-hydroxy-2-methyl-1-[4-(1-methylvinyl)phenyl]propanone], bis(2,4,6-trimethylbenzoyl)-phenyl-phosphine oxide, 2,4,6-trimethylbenzoyl-diphenyl-phosphine oxide, and the like, but are not limited thereto.
[0057] Examples of the cationic initiator include cationic photoinitiators which discharge components capable of initiating cationic polymerization by radiation of activation energy rays or application of heat, that is, cationic photoinitiators or cationic thermal initiators.
[0058] Examples of the cationic photoinitiator include ionized cationic initiators such as onium salt or organometallic salt series; or non-ionized cationic photoinitiators such as organic silane or latent sulfonic acid series or other non-ionized compounds. Examples of the initiators of onium salt series include diaryliodonium salts, triarylsulfonium salts or aryldiazonium salts. Examples of the initiators of oganometallic salt series include iron arenes, or the like. Examples of the initiators of organic silane series include o-nitrobenzyl triaryl silyl ethers, triaryl silyl peroxides, acyl silanes, and the like. Examples of the initiators of latent sulfonic acid series include α-sulfonyloxy ketones, α-hydroxymethylbenzoine sulfonates, and the like, but are not limited thereto. Also, the cationic initiator includes a mixture of the initiator of an iodine series and a photosensitizer.
[0059] Examples of the cationic initiator include an ionized cationic photoinitiator, preferably an ionized cationic photoinitiator of an onium series, and more preferably an ionized cationic photoinitiator of a triarylsulfonium salt series, but are not limited thereto.
[0060] A thickness of the protective layer is suitably determined depending on use materials, a light transmittance rate required for a barrier film, and required durability. When a thickness of a protective layer formed on a barrier layer is very small, the protective layer does not satisfactorily protect the barrier layer. Meanwhile, when a thickness of the protective layer is increased, transparency of the film is decreased. Specifically, when insulation materials are used, such a problem becomes serious. When a thickness of the protective layer is increased, a thickness of a barrier film also increases. Accordingly, a thickness of the protective layer is preferably 0.5 nm to 100 nm, and more preferably 0.5 to 50 nm.
[0061] The aforementioned barrier film of the present application may have a water transmittance rate of 0.00085 to 0.00200 g/m 2 /day.
[0062] FIG. 1 is a cross-sectional schematic diagram of a barrier film according to one example of the present application. Referring to FIG. 1 , a gas barrier film 10 according to one example of the present application sequentially includes a substrate layer 14 , an intermediate layer 13 , and a barrier layer 12 . Also, a protective layer 11 is attached to the barrier layer 12 to further improve durability and a gas barrier property.
[0063] FIG. 2 is a cross-sectional schematic diagram of a barrier film according to another example of the present application. Referring to FIG. 2 , a gas barrier film 20 according to another example of the present application sequentially includes a substrate layer 24 , an intermediate layer 23 , and a barrier layer 22 . Also, the intermediate layer 23 and the barrier layer 22 are attached to each other and a protective layer 21 is attached to the barrier layer 22 .
[0064] According to another aspect of the present invention, there is provided an barrier film forming apparatus, including a transferring unit including an unwinding roll provided to introduce a substrate layer into a processing region, one or more guide rolls provided to transfer the substrate layer, and a winding roll provided to recover the substrate layer; a treating region including a deposition device provided to form a barrier layer on the surface of the substrate layer by atomic layer deposition (ALD), and a protective layer forming device including a non-contact coating unit for forming a protective layer on the barrier layer formed on the substrate layer,
[0065] in which the transferring unit is provided such that the substrate layer introduced into the treating region by the unwinding roll is subsequently transferred through the deposition device and the protective layer forming device, and is recovered by the winding roll.
[0066] The barrier film forming apparatus of the present application includes a transferring unit and a processing region, in which the treating region includes a deposition device and a protective layer forming device. When the transferring unit is used, the substrate layer introduced into a treating region by the unwinding roll is subsequently transferred through the deposition device and the protective layer forming device, and is recovered by the winding roll. In the processing region, a precursor gas is deposited on the substrate layer by ALD in the deposition device to form a barrier layer, and a protective layer may be formed by a non-contact coating method on the barrier layer of the substrate layer in the protective layer forming device.
[0067] The treating region of the present application may further include an intermediate forming device provided to form an intermediate layer on the substrate layer. In this case, when the transferring unit is used, the transferring unit is provided such that the substrate layer introduced into the treating region by the unwinding roll is subsequently transferred through the intermediate layer forming device, the deposition device and the protective layer forming device, and recovered by the winding roll.
[0068] FIG. 3 is a cross-sectional diagram of a barrier film forming apparatus according to one example of the present application. As shown in FIG. 3 , the barrier film forming apparatus includes the transferring unit and the treating region, the transferring unit includes an unwinding roll 120 , a guide roll 110 and a winding roll 130 , and the treating region includes an intermediate layer forming device 160 , a deposition device 140 , and a protective layer forming device 150 .
[0069] An exemplary intermediate forming device may form an intermediate layer on the substrate layer using methods known in the art. According to formation of the intermediate layer, an intermediate layer coating composition may be applied continuously and by using coating methods including a dip coating process. The coating composition of an intermediate layer may use the aforementioned composition.
[0070] An exemplary treating region includes at least two regions (hereinafter referred to as first and second regions) and one or more flow-limiting paths may be formed in the first and second regions. The term “flow-limiting path” herein means a path through which a substrate may be transferred and through which a precursor gas which may be in respective regions does not move. Examples of a method of forming these paths will be described below. The respective regions are provided such that the precursor gas may be deposited on the surface of the substrate introduced through the flow-limiting path to form a barrier layer.
[0071] At least one of the guide rolls serving as a transferring unit is present in each of the first and second regions. The flow-limiting path is provided as a path formed such that the substrate is transferred at least one time through the first and second regions by the guide roll. The barrier film forming apparatus may include a precursor gas supplying unit to supply the precursor gas to the first and second regions. For example, a first precursor gas is supplied to the first region so that a first monolayer is formed on the substrate layer, a second precursor gas is supplied to the second region so that a second monolayer is formed on the substrate layer or the monolayer, and thereby a desirable barrier layer may be formed on the substrate layer. The first and second precursor gases are the same as or different from each other, and if necessary, processes of forming the first and second monolayers may be performed multiple times in consideration of a desired thickness. As will be described below, a third region in which a third monolayer is formed by a third precursor gas or purging is performed by an inert gas may be included in the apparatus.
[0072] An exemplary protective layer forming device may use a non-contact coating method when a protective layer is formed on the surface of the barrier layer formed on the substrate layer. The method minimizes contact with a processing layer (barrier layer), and thereby damage of the processing layer is prevented, and reduction of gas barrier property is suppressed.
[0073] Examples of the non-contact coating method include inkjet coating, capillary coating, slot die coating, plasma polymerization coating, sputtering coating, evaporation coating, CVD coating, iCVD coating, and the like.
[0074] Hereinafter, a deposition device, that is, a deposition device using atomic layer deposition (ALD) according to one example of the present application will be described.
[0075] An exemplary deposition device is separated into first and second regions. The first and second regions are separated by a wall such that precursor gases present in respective regions are not dispersed into each other. A flow-limiting path may be formed in the wall and the substrate layer may be transferred through the path. A discharging unit may be present in each region and a precursor gas may be discharged by the discharging unit.
[0076] The substrate layer introduced into the deposition device by the transferring unit is transferred sequentially and processed through the regions, transferred to the protective layer forming device and then recovered by the winding roll.
[0077] An exemplary deposition device may be provided such that the first and second regions are disposed sequentially, and the substrate layer is transferred through the upside of the region by the guide roll. In such a structure, a precursor gas may be discharged at the side of each region. A third region may be further present between these regions so long as the apparatus is formed such that the substrate layer is transferred sequentially through the first and second regions.
[0078] The deposition device may include the third region. The third region is, for example, a region into which an inert gas is introduced during a purging process of atomic layer deposition (ALD) or a region into which a precursor gas which is the same as or different from a gas introduced into the first and/or second regions is introduced. When the third region is present, the third region is connected to the first and/or second regions by the flow-limiting path, and the transferring unit may be provided such that the substrate is transferred to the second region through the third region from the first region (that is, an order of “first region→third region→second region”).
[0079] Separate rolls are not present in the third region, but if necessary the guide roll may be present in the region. The plurality of third regions may be present. In other words, the plurality of third regions may be present between the first region and the second region, and the plurality of third regions may be separated by a wall in which a flow-limiting path is present. The substrate layer may be introduced into the second region through flow-limiting paths in the plurality of third regions from the first region.
[0080] When the third region is present, the transferring unit, for example, a guide roll, is provided such that the substrate is transferred through the first and second regions multiple times while it is transferred through the substrate in the third region every time.
[0081] In one example, the transferring unit may include the plurality of first guide rolls in the first region and a plurality of second guide rolls in the second region. At least one of the first guide rolls is provided to change a path of the substrate layer to the second region and at least one of the second guide rolls is provided to change a path of the substrate layer to the first region.
[0082] In the aforementioned apparatus, the substrate is transferred through respective regions by the transferring unit, and the precursor gas is deposited to form a monolayer or purging is performed in the region. The precursor gas may be supplied by a separate precursor gas supplying unit. The supplying unit includes a precursor gas generation source provided at the inside or outside of each region and further includes a pipe, a pump, a valve, a tank, and other known units to supply the precursor gas to a region. For example, when other regions such as the third region are present in addition to the first region and the second region, the precursor gas or the inert gas is introduced into the region by the supplying unit.
[0083] Each region may be a chamber to control internal pressure through gas discharge by the discharging unit or introduction pressure of the precursor gas or the inert gas. The chamber may be interfaced with other processing modules or devices for process control.
[0084] In the barrier film forming apparatus, in order to prevent a non-ALD reaction which may result from mixing a non-adsorbed precursor gas to the substrate present in each reaction with gases of other regions, a precursor gas of the region should be suppressed from moving to other regions. Thus, respective regions may be connected by the flow-limiting path or internal pressures may be controlled. Methods of constituting the flow-limiting path (hereinafter, simply referred to as a path) are not specifically limited and examples thereof include known methods. For example, each of the paths may be a slit which is thicker and wider than a substrate passing through the path. When a substrate passes through the path, the path allows very small space such that the substrate passes through the path smoothly. For example, the space may be specified in a range of several microns to several millimeters. The path may have a small, long tunnel shape such that a substrate may pass through, and if necessary may include a wiper to limit flow of gas passing through the path. The path may be a series of long, small paths, and the inert gas introduced into the third region may be directly injected into the path in the middle of the first and second regions, which helps to prevent mixing and moving of precursor gases.
[0085] There may be pressure differences between respective regions in order to prevent mixing of precursor gases. When a third region is present between the first region and the second region, an inert gas or a precursor gas is injected into the third region under higher pressure than each of the other regions, and thus mixing of gases may be prevented. For example, discharge flow of a gas is throttled or discharged manually to control internal pressure. In other examples, a region is pumped using a pump or other absorption source to produce a pressure difference. For example, pumps are connected to all regions, and the pressure of each region is controlled to produce a pressure difference. Moving of the precursor gas is prevented by controlling a relative flow rate of a gas and a pumping rate using a flow control valve or another flow control device. Also, a control device responding to a pressure sensor is used to control gas injection and discharge flow rates, which helps to maintain a desirable pressure difference.
[0086] According to still another aspect of the present invention, there is provided a method of preparing a barrier film using the aforementioned barrier film forming apparatus.
[0087] In the preparing method, a substrate layer is introduced into a deposition device in a treating region using an unwinding roll to form a barrier layer by atomic layer deposition (ALD), and the substrate layer on which the barrier layer has been formed is introduced into a protective layer forming device to form a protective layer on the barrier layer by a non-contact coating method, and then recovered by a winding roll.
[0088] The method further includes forming an intermediate layer on a substrate layer before introducing a substrate layer into a deposition device in a processing region.
[0089] According to still another aspect of the present application, there is provided a display device or a photovoltaic element including the barrier film in which durability and a gas barrier property are improved.
[0090] The barrier film of the present application may be used to protect products likely to be deteriorated by water, for example, display devices such as a liquid crystal display (LCD) or an organic light emitting diode (OLED) or photovoltaic elements such as solar cell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0091] The above and other objects, features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail exemplary embodiments thereof with reference to the accompanying drawings, in which:
[0092] FIG. 1 is a diagram showing a barrier film according to one example of the present application;
[0093] FIG. 2 is a diagram showing a structure of a barrier film according to another example of the application; and
[0094] FIG. 3 is a diagram showing a cross-section of a barrier film forming apparatus according to one example of the present application.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0095] Hereinafter, the present application will be described in detail through Examples which follow the present application and Comparative Examples which do not follow the present application, but scope of the present application is not limited to the following Examples.
Example 1
[0096] A PET film having a thickness of 125 μm and a water vapor transmission rate (WVTR) of about 3 to 4 g/m 2 /day was used as a substrate layer. 50 g of tetraethoxy orthosilicate and 50 g of 3-glycidoxypropyltrimethoxysilane were diluted with 150 g of ethanol, 56.4 g of water and 1.6 g of 0.1 N HCl were added thereto, and then the mixture was reacted for one day at room temperature to form a coating composition solution in a sol state. The coating composition solution was coated on the substrate layer by bar coating, and thermally cured for 10 minutes at 120° C. to form an intermediate layer having a thickness of about 0.6 μm. Subsequently, a TiO 2 layer (barrier layer) was formed to have a thickness of about 15 nm on the intermediate layer by atomic layer deposition (ALD) using TiCl 4 and H 2 O as precursor gas. Specifically, TiCl 4 and H 2 O were each deposited and reacted in a pulse shape for 5 seconds on the intermediate layer to form a film, followed by purging with argon gas to remove un-reacted H 2 O or byproducts. Such processes were set to one cycle, and the cycle was performed 40 times to form a barrier layer. Subsequently, a composition including condensate of pentaerythritol triacrylate and tetraethoxysilane was used as a coating composition to form a protective layer, and the coating composition was applied on the barrier layer in an inkjet method and cured to form a protective layer having a thickness of about 200 nm.
Example 2
[0097] A barrier film was prepared in the same manner as in Example 1 except that a coating composition was coated by a capillary coating method.
Example 3
[0098] A barrier film was prepared in the same manner as in Example 1 except that a coating composition was coated by a slot die coating method.
Example 4
[0099] A barrier film was prepared in the same manner as in Example 1 except that a barrier layer having a thickness of about 12 nm was formed.
Comparative Example 1
[0100] A barrier film was prepared in the same manner as in Example 1 except that a protective layer was formed by a bar coating method.
Experiment 1
[0101] WVTR was measured for 100 hours at room temperature and 100% of relative humidity using Aquatran manufactured by Mocon, and results thereof for the barrier films prepared in Examples 1 to 4 and Comparative Examples 1 to 3 are described in Table 1.
[0000]
TABLE 1
Exam-
Exam-
Exam-
Exam-
Comparative
ple 1
ple 2
ple 3
ple 4
Example 1
WVTR (unit:
0.0016
0.0016
0.0016
0.0016
0.0145
g/m 2 /day)
[0102] According to the present application, there is an effect in that a barrier film is provided in which a protective layer is formed on a barrier layer formed on a substrate by atomic layer deposition (ALD) according to a non-contact coating method, and thus contact with the barrier layer is minimized and damage of the barrier layer is prevented, and a gas barrier property is suppressed from reducing, thus improving durability and a gas barrier property.
[0103] Accordingly, the barrier film of the present application is used for products likely to be deteriorated by water, for example, display devices such as an LCD or an OLED, or photovoltaic elements such as a solar cell.
[0104] It will be apparent to those skilled in the art that various modifications can be made to the above-described exemplary embodiments of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers all such modifications provided they come within the scope of the appended claims and their equivalents.
DESCRIPTION OF REFERENCE NUMERALS
[0000]
10 , 20 : Barrier film structure
11 , 21 : Protective layer
12 , 22 : Barrier layer
13 , 23 : Intermediate layer
14 , 24 : Substrate layer | A coating method which reduces damage of a barrier layer is provided. The barrier film has a gas barrier property improved by suppressing reduction of a water vapor transmittance rate through a non-contact coating method on a barrier layer when a protective coating is performed to protect a barrier layer of the barrier film. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a thermal food container and particularly to a food container, such as a salad bowl, sandwich tray or a food platter, with a portable device for cooling the food.
OBJECTS AND SUMMARY OF THE INVENTION
[0002] It is an object of the present invention to provide a thermal food container with a portable thermal source, such as an ice pack, that can be accessed from outside the container, thereby avoiding the opening of the container and allowing ambient air in when it is needed to replace the thermal source.
[0003] It is still another object of the present invention to provide a thermal food container with a portable thermal source, such as an ice pack, disposed outside the container such that risk of contamination from condensate or ice melt with the food is minimized.
[0004] It is another object of the present invention to provide a thermal food container in the form of a salad bowl, sandwich tray, deviled egg tray or a vegetable/fruit platter made from inexpensive and highly insulating styrofoam and including a thermal source, such as an ice pack, easily accessible from the outside the container.
[0005] In summary, the present invention provides a thermal food container, comprising a receptacle having an upwardly disposed opening and a bottom and side walls; and a lid coextensive with the opening. The bottom wall includes a first pocket with a first cover operable outside the receptacle, the first pocket being adapted to receive a first thermal storage device. The lid includes a second pocket with a second cover operable outside the receptacle when the lid is secured to the receptacle, the second pocket being adapted to receive a second thermal storage device.
[0006] These and other objects of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0007] [0007]FIG. 1 is a cross-sectional view of a thermal food container made in accordance with present invention.
[0008] [0008]FIG. 2 is a top view of FIG. 1.
[0009] [0009]FIG. 3 is a cross-sectional view of another embodiment of a thermal food container made in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] A thermal food container 2 made in accordance with the present invention is disclosed in FIG. 1. The container 2 comprises a receptacle 4 with an upwardly disposed opening 6 , a side wall 8 and a bottom wall 10 . A lid 12 provides a closure to the opening 6 and is co-extensive with the opening. A peripheral groove 14 receives the outer edge 16 of the receptacle to provide a positive closure.
[0011] A pocket 18 is preferably provided in the bottom wall 10 for receiving a thermal storage device 20 , such as an ice pack or gel pack. A cover 22 is preferably connected to the receptacle 4 with hinge 23 for closing the opening to the pocket 18 . The hinge 23 is preferably made of plastic material. The cover 22 is advantageously operable from outside the receptacle to provide access to the pocket 18 and the thermal storage device 20 while keeping the lid 12 closed. In this manner, the container need not be emptied or the contents otherwise disturbed to gain access to the pocket if it were accessible from the inside. Further, the pocket is blocked off and does not communicate, such as by holes or slots, with the interior of the container to minimize any risk of contaminating the contents of the receptacle 4 from ice melt or condensate forming on the thermal storage device surface. The pocket 18 is preferably molded or built in into the receptacle 4 .
[0012] A pocket 24 is disposed in the lid 12 for receiving another thermal storage device 26 . A cover 28 is preferably connected to the lid 12 with hinge 27 to provide closure to the opening of the pocket. The hinge 27 is preferably made of the same plastic material as the cover 28 . The cover 28 is advantageously operable from outside the receptacle when the lid 12 is secured to the receptacle 4 to provide access to the pocket 24 without opening the lid 12 . Advantageously, the lid need not be removed from the receptacle 4 to gain access to the pocket 24 , which would be the case if it were located on the bottom surface of the lid. In this manner, the cold air within the container will remain inside. The pocket 24 is configured such that an air space between the bottom surface of the cover 28 and the top surface of the thermal storage device 26 is provided for insulation. The pocket 24 is preferably molded or built-in into the lid 12 . The pocket 24 is advantageously blocked off from the interior of the container to minimize any risk of contaminating the contents of the receptacle 4 from the any condensate or ice melt formed from the thermal storage device 26 .
[0013] The pockets 18 and 24 may be made separately and then integrated or built-in into the receptacle 4 and the lid 12 , respectively. The pockets may also be molded with the respective receptacle and lid.
[0014] Although the container 4 is disclosed as a salad bowl, with the receptacle being a truncated sphere and the lid 12 being circular, other shapes may be made, depending on the application. The receptacle 4 and lid 12 are preferably made of styrofoam, which is a relatively inexpensive material and possesses good insulating characteristics.
[0015] The bottom wall 10 of the pocket 18 is preferably made of a rigid plastic material that allows heat transfer between the contents and the heat storage device 20 . The bottom 29 of the pocket 24 is also made of a thin rigid plastic material that allows heat transfer between the thermal storage device 26 and the interior fo the container.
[0016] The receptacle 4 and the lid 12 may also be made in different shapes, such rectangular. When the pockets 18 and 24 are molded into the respective receptacle 4 and lid 12 , any suitable material may be used that provides heat transfer between the thermal storage devices 20 and 26 the contents of the receptacle 4 , while at the same maintaining a suitable insulation from the ambient temperature. The lid 12 may be secured to the receptacle 4 in a sealing, airtight manner, as commonly found in standard airtight food containers, such as those available from Tupperware.
[0017] A finger clasp 30 is provided for the covers 22 and 28 for convenient opening and closing of the respective covers.
[0018] Another embodiment of a thermal food container 32 is disclosed in FIG. 3. The container 32 may be a sandwich tray, a deviled egg tray or a vegetable/fruit platter, which can be of any shape, such as rectangular. The thermal food container 32 includes a receptacle 34 with a side wall 36 and a bottom wall 38 . A lid 40 provides closure to the opening 42 of the receptacle 34 . The lid 40 is preferably provided with a peripheral groove 44 with inwardly projecting lip 46 that cooperates with an outwardly projecting lip 48 along the outer edge of the opening 42 of the receptacle 34 .
[0019] The bottom wall of the receptacle 34 is provided with a plurality of pockets 50 for receiving a respective thermal storage device 52 , such as an ice pack. A cover 54 is provided for each pocket 50 . The covers 54 are advantageously operable from outside the receptacle 34 to provide access to the respective pockets without emptying the contents of the receptacle which would be the case if the covers were operable from within. The covers 54 are preferably provided with hinges 56 secured to the receptacle 34 .
[0020] The lid 40 is also provided with a pocket 58 for receiving a thermal storage device 60 , such as an ice pack or a cooling gel pack. A cover 62 provides closure to the opening of the pocket. The cover 62 is preferably connected to the lid 40 with a hinge 64 . Depending on the size of the receptacle 34 , multiple pockets may be provided in the lid 40 , although only one is shown. The cover 62 is advantageously operable from outside the receptacle 34 when the lid 40 is secured to the receptacle. In this manner, access to the pocket 60 is provided, for example, for replacing the thermal storage device 52 , without lifting the lid 40 off the receptacle 34 , thereby maintaining the temperature within the receptacle.
[0021] The receptacle 34 and the lid 40 may be made of any suitable material, such as styrofoam, which is relatively inexpensive and has good insulating properties. The pockets 50 and 58 may be made with rigid plastic material that permits heat transfer between the thermal storage devices 52 and 60 and the contents of the receptacle 34 . In addition, the peripheral portion of the cover 40 may be made with a flexible material, such as plastic, to provide the lip 46 to flex and grasp the lip 48 of the receptacle. The engagement of the cover 40 with the receptacle 34 may be in a sealing, airtight manner, as commonly found in standard airtight food containers, such as those available from Tupperware.
[0022] The pockets disclosed in the embodiments above are preferably molded or built-in with the respective container components.
[0023] While this invention has been described as having preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims. | A thermal food container comprises a receptacle having an upwardly disposed opening and a bottom and side walls; and a lid coextensive with the opening. The bottom wall includes a first pocket with a first cover operable outside the receptacle, the first pocket being adapted to receive a first thermal storage device. The lid includes a second pocket with a second cover operable outside the receptacle when the lid is secured to the receptacle, the second pocket being adapted to receive a second thermal storage device. | 5 |
[0001] This application claims priority from U.S. patent application Ser. No. 11/346,952, filed on Feb. 3, 2006 which claims priority from U.S. patent application Ser. No. 11/035,319, filed Jan. 13, 2005, which claims priority from U.S. Provisional Patent Application 60/536,452 filed on Jan. 14, 2004.
BACKGROUND
[0002] The instant invention relates to polymers that resist dissolution in organic solvents, are vasodilators, and are tunable explosives. These polymers also form solvent resistant coatings and solvent resistant fibers as well as bonding materials.
[0003] Polymers that resist dissolution in organic solvents have important applications such as solvent resistant coatings for objects. Fluorinated polymers (such as TEFLON® and KYNAR® brand polymers) are resistant to organic solvents but tend to have a number of undesirable properties such as relatively poor adhesion to surfaces such as glass surfaces.
SUMMARY OF THE INVENTION
[0004] In one embodiment, the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein R 1 and R 2 are aromatic organic groups and X is selected from the group consisting of SO 2 , CO, N═N, O, and CR 7 R 8 , wherein R 7 is selected from the group consisting of H and an organic group and wherein R 8 is independently selected from the group consisting of H and an organic group and wherein R 3 is selected from the group consisting of NO 2 , N 2 O 2 , O and H, wherein R 4 is selected from the group consisting of a sulfonate group, H, NO 2 and NH 2 , wherein R 5 is selected from the group consisting of NO 2 and NH 2 , wherein R 6 is selected from the group consisting of NO 2 and NH 2 and wherein n is greater than about twenty. These materials are useful, for example, in forming solvent resistant coatings and solvent resistant fibers as well as for bonding materials.
[0005] In another embodiment, the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein R 1 is selected from the group consisting of cyclic and acyclic organic groups, wherein R 2 is independently a cyclic or acyclic organic group, wherein R 3 is selected from the group consisting of NO 2 , N 2 O 2 , O and H, wherein R 4 is selected from the group consisting of an alkyl group, a sulfonate group, H, NO 2 and NH 2 , wherein R 5 is selected from the group consisting of NO 2 and NH 2 , wherein R 6 is NO 2 or NH 2 and where n is greater than about twenty.
[0006] These materials are useful, for example, in forming solvent resistant coatings and solvent resistant fibers as well as for bonding materials.
[0007] In yet another embodiment, the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein R 2 is independently selected from the group consisting of cyclic and acyclic organic groups, wherein R 3 is selected from the group consisting of NO 2 , N 2 O 2 , O and H, wherein R 4 is selected from the group consisting of an alkyl group, a sulfonate group, H, NO 2 and NH 2 , wherein R 5 is selected from the group consisting of NO 2 and NH 2 , wherein R 6 is selected from the group consisting of NO 2 and NH 2 and wherein n is greater than about twenty.
[0008] A specific example of a polymer of the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein x is in the range of from 2 to 12 and wherein n is greater than about twenty.
[0009] Another specific example of a polymer of the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein R 3 is N 2 O 2 − M + and x is in the range of from 2 to 12 and wherein n is greater than about twenty. These materials also have vasodilatation effects and can be used as vasodilatators. It is believed that the polymers slowly release NO to give the desired effect. Certain of these polymers are explosives given the requisite amount of shock. For example, polymers such as those having five nitro groups, three on the ring and two on the nitrogen atoms. The explosives materials are “tunable” in the sense that polymers having longer aliphatic alkyl chains are less dangerous while those have shorter aliphatic alkyl chains, for example, two methylene units, are more potent.
DETAILED DESCRIPTION OF THE INVENTION
[0010] In one embodiment, the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein R 1 and R 2 are aromatic organic groups and X is selected from the group consisting of SO 2 , CO, N═N, O, and CR 7 R 8 , wherein R 7 is selected from the group consisting of H and an organic group and wherein R 8 is independently selected from the group consisting of H and an organic group, wherein R 3 is selected from the group consisting of NO 2 , N 2 O 2 , O and H, wherein R 4 is selected from the group consisting of a sulfonate group, H, NO 2 and NH 2 , wherein R 5 is selected from the group consisting of NO 2 and NH 2 , wherein R 6 is selected from the group consisting of NO 2 and NH 2 and wherein n is greater than about twenty. These materials are also useful, for example, in forming solvent resistant coatings and solvent resistant fibers as well as for bonding materials.
[0011] In another embodiment, the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein R 1 is a selected from the group consisting of cyclic and acyclic organic group, where R 2 is independently a cyclic or acyclic organic groups, wherein R 3 is selected from the group consisting of NO 2 , N 2 O 2 , O and H, wherein R 4 is selected from the group consisting of a sulfonate group, H, NO 2 and NH 2 , wherein R 5 is selected from the group consisting of NO 2 and NH 2 , wherein R 6 is selected from the group consisting of NO 2 and NH 2 and wherein n is greater than about twenty.
[0012] In yet another embodiment, the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein R 2 is independently selected from cyclic and acyclic organic groups, wherein R 3 is selected from the group consisting of NO 2 , N 2 O 2 , O and H, wherein R 4 is selected from the group consisting of a sulfonate group, H, NO 2 and NH 2 , wherein R 5 is selected from the group consisting of NO 2 and NH 2 , wherein R 6 is selected from the group consisting of NO 2 and NH 2 and wherein n is greater than about twenty.
[0013] A specific example of a polymer of the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein x is in the range of from 2 to 12 and wherein n is greater than about twenty. This embodiment of the instant invention can be made by the following synthesis scheme.
[0000]
[0000] Preferably, the maximum temperature of the synthesis reaction is from about one hundred degrees Celsius to two hundred and fifty degrees Celsius with a time at such maximum temperature of from fifteen to thirty minutes. A gradual linear temperature rise to such maximum temperature from room temperature is preferably employed over a period of time of from two and one half to four hours.
[0014] This invention also deals with polymeric amines corresponding to the general formula:
[0000]
[0000] wherein R is selected from a group consisting of (i) a methylene group wherein m has a value ranging from 2 to 20, (ii) a cyclic group, (iii) a polycyclic group, and (iv) a branched aliphatic group, and n has a value of greater than twenty.
[0015] Still further, this invention deals with per-nitrated polymeric amines having the general formula:
[0000]
[0000] wherein R is selected from a group consisting of (i) a methylene group wherein m has a value ranging from 2 to 20, (ii) a cyclic group, (iii) a polycyclic group, and (iv) a branched aliphatic group and n has a value greater than twenty.
[0016] This invention also deals with nitrosolated polymeric amines having the general formula:
[0000]
[0000] wherein R is selected from the group consisting of (i) a methylene group wherein m has a value of from 2 to 20, (ii) a cyclic group, (iii) a polycyclic group, and (iv) a branched aliphatic group, M is selected from the group consisting of sodium and potassium and n has a value of greater than twenty.
[0017] This invention also deals with nitrated polymeric amines having the general formula:
[0000]
[0000] wherein R is a methylene group, m has a value of from 2 to 20 and n has a value of greater than twenty.
[0018] The following examples illustrate the preferred synthesis scheme for various values of x.
[0000]
x
Max Temp (° C.)
Solvent
% Yield
2
230/190
diphenyl sulfone/NMP
70.0%
3
135/190
diphenyl sulfone/NMP
88.6%
4
220/190
diphenyl sulfone/NMP
87.2%
5
205
NMP
87.4%
6
210/200
diphenyl sulfone/NMP
85.6%
7
210/200
diphenyl sulfone/NMP
79.9%
8
210/200
diphenyl sulfone/NMP
81.5%
9
190/200
diphenyl sulfone/NMP
74.5%
10
210/200
diphenyl sulfone/NMP
82.1%
11
215/200
diphenyl sulfone/NMP
88.8%
12
220/200
diphenyl sulfone/NMP
92.5%
[0019] The polymers made by the above synthesis scheme have the following thermal decomposition characteristics.
[0000] TABLE 4 Thermogravimetric analysis data ofl (a-k) Number of methylene unit per repeating Percent Isotherma unit Residue at 1 loss # 1 x 850° C. (%) a 2 22.77 1.62 b 3 29.37 4.44 c 4 29.84 3.53 (1 5 52.25 9.56 e 6 53.17 9.19 f 7 44.65 9.13 8 8 40.12 9.40 h 9 36.46 8.92 i 10 32.84 8.74 .1 11 32.10 8.02 k 12 26.86 7.07
TGA Heating rate: 10 “/mm, N2
# 240° C., lh, N2
[0020] The polymers made by the above synthesis scheme have the following melting points and intrinsic viscosity in aqueous concentrated sulfuric acid at twenty-five degrees Celsius.
[0000]
x
Tm
Viscosity [n]
2
n/a
0.083
3
n/a
0.114
4
n/a
0.171
5
149.54
0.394
6
148.03
0.347
7
133.31
0.770
8
99.76; 152.22*
0.406
9
12036; 149.47*
0.394
10
110.87
0.431
11
93.96; 110.87*
0.348
12
104.43
1.351
[0021] The polymers made by the above synthesis scheme have the following specific solvent resistant characteristics.
[0000]
x
THF
CH 2 Cl 2
CHCl 3
DMAC
NMP
conc H 2 SO 4
2
I
I
I
SS*
I
S
3
I
I
I
SS*
I
S
4
I
I
I
SS*
I
S
5
1
S*
I
SS*
S*
S
6
S*
S*
S*
S*
S*
S
7
S*
S*
S*
S*
S*
S
8
S*
S*
S*
S*
S*
S
9
S*
S*
S*
S*
S*
S
10
S*
S*
S*
S*
S*
S
11
S*
S*
S*
S*
S*
S
12
S*
S*
S*
S*
S*
S
S: soluble at room temp.
S*: soluble upon heating
SS*: slightly soluble upon heating
I: insoluble
[0022] Another specific example of a polymer of the instant invention is a polymer corresponding to the formula:
[0000]
[0000] wherein x is in the range of from 2 to 12 and wherein n is greater than about twenty, also useful, for example, in forming solvent resistant coatings and solvent resistant fibers as well as for bonding materials wherein x is in the range of from 2 to 12 and wherein n is greater than twenty. The compounds of this embodiment of the instant invention can be made by nitrating the dinitro analog of the polymer to the tetra-nitro polymer as will be described below in greater detail.
Example 1
[0023] A steel object was coated with powdered polymer of the instant invention wherein x in the formula, just infra, is 7 .
[0000]
[0000] The steel object was heated to melt the polymer so that it evenly coated the steel object. The steel object was cooled to produce a steel object coated with a durable coating.
Example 2
[0024] A copper plate was coated with a powdered polymer of the instant invention, wherein x in the formula, just infra was 8.
[0000]
[0000] The copper object was heated to melt the polymer so that it evenly coated the copper object. The copper object was cooled to produce a copper object coated with a water resistant durable coating.
Example 3
[0025] A powdered sample of the instant invention, wherein X in the formula
[0000]
[0000] was 9 was placed between two glass plates. Sturdy steel clips held the glass plates together. The prepared sample was heated to melt the polymer and then cooled. The two glass plates were strongly bonded together by the polymer of the instant invention. The bond remains strong even when the assembly was exposed to water and even after extensive exposure to water.
Example 4
[0026] A saturated solution of a polymer of the instant invention in concentrated sulfuric acid, wherein x in the formula
[0000]
[0000] was 10, was spun into water to form solvent resistant fibers of the polymer of the instant invention.
Example 5
[0027] The solvent resistant fibers of Example 4 were used to make a filter element for filtering suspended solids from tetrahydrofuran.
Example 6
[0028] A saturated solution of a polymer of the instant invention in concentrated sulfuric acid, wherein x in the formula
[0000]
[0000] was 10, was spun into water to form solvent resistant fibers of the polymer of the instant invention.
Example 7
[0029] The solvent resistant fibers of Example 9 are used to make a filter element for filtering suspended solids from tetrahydrofuran.
Example 8
[0030] A 100 mL, three-necked flask was fitted with a nitrogen inlet, a magnetic stir bar and a Dean-Stark trap fitted with a condenser. The flask was charged with aniline (0.93 g, 0.005 mole), 1,5-difluoro-2,4-dinitrobenzene (1.02 g, 0.005 mole), 20 mL of N,N-dimethylacetamide, 15 mL of toluene, and anhydrous potassium carbonate (1.5 g, excess). The reaction vessel was heated with an external temperature-controlled oil bath. The reaction temperature was gradually raised to 135° C., and water, the by-product of the reaction, was removed by azeotropic distillation with toluene. After the removal of water, toluene was gradually removed and the temperature of the reaction mixture was raised to 150° C. The reaction was allowed to continue with stirring at this temperature for 18 h. The heating bath was removed and the temperature of the reaction mixture was allowed to cool to room temperature and then poured into rapidly stirring, acidified (glacial acetic acid) water (150 mL). Saturated aqueous sodium chloride solution (20 mL) was then added and the solid, which slowly precipitates out, was collected by filtration. The crude residue was allowed to dry overnight, dissolved in dichloromethane, washed repeatedly with water, and the organic layer was dried over anhydrous magnesium sulfate and filtered. The filtrate was evaporated at reduced pressure to yield deep brown residue. The residue was dissolved in dichloromethane and eluted on an alumina column using a mobile phase of dichloromethane to yield the following model compound 3.
[0000]
Example 9
[0031] The following model compound 1
[0000]
[0000] was prepared by controlled nitration of the corresponding secondary amine. The starting material, the secondary amine (100 mg) was placed in a one necked-100 mL, round-bottomed flask, fitted with a magnetic stir bar. The flask was cooled to −30° C., by using a dry-ice-acetone bath. A 25 mL, measuring cylinder was cooled by an external ice-water bath, and aqueous concentrated sulfuric acid (9 mL), and aqueous concentrated nitric acid (9 mL) are added to the cylinder and mixed using a disposable pipette. The mixture was allowed to stand in the ice bath for 30 minutes, to equilibrate to the cylinder temperature. The acid solution was added very slowly to the solid starting material in the round-bottomed flask, over a period of 30 minutes. The temperature of the reaction vessel was maintained between −30° C. and −20° C., during the addition process. The reaction was allowed to continue with stirring for an additional 2 hr. The color of the reaction mixture turned aqua blue. At the completion of the reaction, the entire reaction mixture was poured over crushed ice. The ice-water mixture was stirred and allowed to warm up to room temperature. The solid, that precipitated out was filtered, and washed repeatedly with water to remove residual acid. The solid was allowed to dry overnight at room temperature and then was dissolved in dichloromethane washed with water twice, and then with a saturated solution of sodium bicarbonate, and finally with water, a saturated solution of sodium chloride, and then with water again. The organic layer was removed, dried over anhydrous magnesium sulfate, filtered, and the filtrate was evaporated at reduced pressure to yield a pale yellow, very pure crystalline solid. Further purifications were not necessary.
Example 10
[0032] The following polymer 4 was prepared in this example:
[0000]
[0033] The reaction vessel consists of a 100 mL, four-necked, round bottomed flask, fitted with a nitrogen inlet, a thermometer, a Dean-Stark apparatus, fitted with a condenser, and an over-head stirrer. The diamine, trans-1,4-cyclohexanediamine (1.142 g, 0.01 mole), 1,5-difluoro-2,4-dinitrobenzene (2.041 g, 0.01 mole), anhydrous potassium carbonate (2.201 g, excess), diphenyl sulfone, the solvent, (20.0 g), and toluene (20 mL) are added to the reaction vessel. The reaction vessel was heated by an external oil bath. The temperature of the reaction mixture was gradually raised to 130° C., and water, the by-product of the reaction mixture was removed by azeotropic distillation. After the removal of water, the temperature of the reaction mixture was gradually raised to 220° C., over a period of 2 h. The reaction was allowed to continue at this temperature for 10 minutes, and the hot reaction mixture was poured into rapidly stirring acetone (acidified with glacial acetic acid). The solid, which precipitates out, was collected by filtration and then extracted with acetone, water, and acetone, in that order by using a Sohxlet apparatus. The yellow colored powdery polymer was dried in a vacuum oven at 50° C., overnight.
Example 11
[0034] The following polymer 6 was prepared in this example:
[0000]
[0035] The reaction vessel consists of a 100 mL, four-necked, round bottomed flask, fitted with a nitrogen inlet, a thermometer, a Dean-Stark apparatus, fitted with a condenser, and an over-head stirrer. The diamine, 4,4′-diaminodiphenylsulfone (1.24 g, 0.005 mole), 1,5-difluoro-2,4-dinitrobenzene (1.02 g, 0.005 mole), anhydrous potassium carbonate (1.50 g, excess), N,N-dimethylacetamide, the solvent, (20 mL), and toluene (16 mL) are added to the reaction vessel. The reaction vessel was heated by an external oil bath. The temperature of the reaction mixture was gradually raised to 135° C., and water, the by-product of the reaction mixture was removed by azeotropic distillation. After the removal of water, the temperature of the reaction mixture was gradually raised to 150° C., over a period of 2 h. The reaction was allowed to continue at this temperature for 4 hours, and the hot reaction mixture was poured into rapidly stirring acetone (acidified with glacial acetic acid). The solid, which precipitates out, was collected by filtration and was extremely powdery in nature, which was believed to be indicative of a relatively low molecular weight.
Example 12
[0036] The following model compound 5 was prepared in this example:
[0000]
[0037] The starting material, containing the aromatic nitro group (0.254 g, 0.001 mole) was dissolved in ethanol (2.5 mL) in a 16 oz screw-cap vial. Hydrazine (0.1 ml, 0.003 mole) was added to the yellow colored solution, followed by the addition of 10 drops of 50% aqueous Raney nickel suspension. Vigorous, exothermic reaction ensues with copious evolution of gases. The reaction was allowed to continue with stirring until the temperature of the reaction mixture equilibrates to room temperature, over a period of 20 minutes, and the gas evolution ceases. The reaction mixture was then diluted with 10 mL of dichloromethane, filtered through celite to remove residual solid particles, and the filtrate was evaporated using a rotary evaporator. The desired product was a colorless oil. | What is disclosed relates to polymers that resist dissolution in organic solvents, are vasodilators, and are tunable explosives. These polymers also form solvent resistant coatings and solvent resistant fibers as well as bonding materials. | 2 |
BACKGROUND
[0001] This disclosure relates generally to blade knives used for hunting, fishing and sporting applications. More particularly, this disclosure relates to blade knives having a blade which is positionable in a protective case.
SUMMARY
[0002] Briefly stated, a sliding blade knife comprises an elongated frame-like handle. A blade is longitudinally positionable relative to the handle. The handle comprises a structure which defines an extended and a retracted position disposed between the ends of a guide slot. A spring loaded assembly comprises a button having an operating pin engageable with the slot to allow the button to be depressed and the blade to be retracted to a stable, retracted position fully retracted within the handle and longitudinally projected to a stable, extended position wherein the blade projects outwardly of the handle for usage.
[0003] The handle preferably has a concave finger grip. A spring biases the button to a stable position. The handle comprises transversely opposed pairs of a forward bolster member, a back bolster member and elongated strips which form generally transversely opposed sides defining a pair of spaced, generally parallel planes. The frame, at one side, provides a protective sheath which fully receives a blade in the retracted position. The handle preferably has a central plate-like support frame which defines a longitudinal channel for the blade. Closed plate members are mounted to opposed sides of the support frame in a laminar construction. The concave finger grip is preferably disposed adjacent a forward end of the handle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a first side view of a sliding blade knife in a retracted blade position;
[0005] FIG. 2 is an inverse opposite side view of the sliding blade knife in the retracted position of FIG. 1 ;
[0006] FIG. 3 is a first side view of the sliding blade knife of FIG. 1 in the extended position;
[0007] FIG. 4 is an inverse opposite side view of the extended blade knife in the position of FIG. 3 ;
[0008] FIG. 5 is a first side diagrammatic view of the sliding blade knife in the extended position of FIG. 3 ; and
[0009] FIG. 6 is an exploded perspective view of the sliding blade knife of FIG. 1 .
DETAILED DESCRIPTION
[0010] With reference to the drawings wherein like numerals represent like parts throughout the figures, a sliding blade knife is generally designated by the numeral 10 . The sliding blade knife 10 is linearly transformable between a retracted protective position ( FIGS. 1 and 2 ) and an extended usage position ( FIGS. 3 and 4 ). In the retracted position, the knife blade is enclosed within a rugged, durable protective frame-like case 20 . The protective case 20 also functions as a handle. In the extended and the retracted positions, the blade is maintained in a highly stable, positively locked position.
[0011] The knife 10 may be employed for hunting, fishing, sporting and other tactical-type applications. In one preferred embodiment, knife 10 has a longitudinally extended dimension of approximately 218 cm and a nominal height of approximately 46 cm, as designated in FIG. 5 . The knife includes a blade 12 with a sharpened peripheral edge 14 . The blade 12 has a shank 16 with a medial opening 18 ( FIG. 6 ). The blade 12 is preferably a rugged steel member which has a plating composition of nitrides, carbide and/or carbonitrides of titanium and/or chromium.
[0012] The handle case 20 has a rugged multi-component elongated construction of laminar form with a contoured exterior surface. The principal central component is an elongated medial support frame 22 having a quasi-U-shaped configuration. The frame 22 defines a longitudinal channel 24 dimensioned to fully receive blade 12 . The frame has a peripheral recessed portion 28 .
[0013] A plate 30 engages against an underside (opposing side) of the frame 22 . The plate 30 includes an elongated longitudinal guide slot 32 which terminates in a pair of opposed enlarged circular openings 34 and 36 . The plate 30 also includes a frontal recessed portion 38 .
[0014] A second plate 40 engages the other side (first side) of the frame 22 and includes an enlarged longitudinal slot 42 which is closed, but otherwise generally commensurate with the U-shaped channel 24 of the frame 22 . The plate 40 also includes a recessed peripheral portion 48 generally commensurate with the corresponding recessed peripheral portions 28 , 38 of the frame 22 and the plate 30 , respectively.
[0015] A pair of aluminum back bolster members 31 and 41 each have a corresponding recess portion and is respectively mounted to the rear or heel of frame 22 . Plastic spaced medial handle strips 33 , 35 and 43 , 45 are mounted to opposed intermediate sides of the respective plates 30 and 40 by screws or other fasteners. A pair of aluminum forward bolster members 37 and 47 is mounted to opposed forward sides of respective plates 30 and 40 . Bolster members 37 and 47 respectively, have recessed peripheral portions 39 and 49 congruent with portions 38 and 28 to form a well-defined concave finger grip 48 . The leading and trailing edges of the handle medial strips engage against opposing bolsters 31 , 41 and 37 , 47 so that the forward, medial and back exterior sides of the handle case 20 have a generally integrated construction upon assembly.
[0016] The extreme exterior sides of back bolster member 31 , strips 33 , 35 and bolster member 37 generally define a plane which is spaced from the central plane of the blade 12 . The extreme exterior sides of back bolster member 41 , handle strips 43 , 45 and forward bolster member 47 also define a plane which is spaced from the central plane of the blade. The planes are spaced a significant transverse distance so that the formed handle case has an integrated construction which is rugged and is also spaced transversely outwardly from the blade to provide a highly protective and functional handle.
[0017] A button 60 carries a projecting pin 62 with a recessed circumferential portion of reduced diameter which is dimensioned so that it will enter and slide along the longitudinal guide slot 32 of the plate 30 . The pin 62 extends through opening 18 . The opposing end of the pin 62 is secured by a rivet or connector head 64 .
[0018] A spring 66 encircles the pin 62 and biases the button 60 to an extended lock position wherein the enlarged portion of the pin 62 is captured in either of the openings 34 or 36 of the plate member. These openings 34 and 36 define the stable, longitudinally spaced, extended and retracted locked positions for the sliding knife blade. The spring 66 has a significant pre-load force to ensure positional stability at the extended and retracted positions. When the button 60 is depressed, the pin recessed portion aligns with the guide slot 32 and is longitudinally displaceable along the slot for displacement either to or from the end openings 34 and 36 . When the button 60 is in the normal (undepressed) state and the pin 62 is received in the opening 34 or 36 , the pin 62 functions as a lock stop to thereby prevent longitudinal movement of the blade.
[0019] The longitudinal position of the pin 62 functions to determine the position of the blade 12 . The sliding blade knife 10 is transformable between a compact retracted position wherein the blade 12 is fully retracted within the handle case and an extended position for usage.
[0020] While the foregoing has been set forth to describe a preferred embodiment of the invention, the foregoing should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention. | A sliding blade knife has an elongated frame-like handle. A blade is longitudinally positionable relative to the handle and is transformable between a stable extended and a stable retracted position relative to the handle. An exteriorly accessible button is depressible to allow the blade to be transformed between the retracted positions and the stable extended position. In the extended position, the blade projects outwardly of the handle for usage. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to packaging and manufacturing of integrated circuits and the like, and more particularly to a solder ball attachment system.
BACKGROUND INFORMATION
[0002] Integrated circuits in an electronic device are typically electrically connected to multiple other integrated circuits or components of the electronic device. For example, a processor chip in a computer will be connected to one or more sources of power, to memory devices or modules, input/output interfaces and the like. This can require that hundreds of electrical connections be made to the processor chip or integrated circuit (IC) chip. The IC chip will typically be mounted to a printed circuit board (PCB) and the multiple different electrical connections will need to be made between the IC chip and the PCB. One technology for making these multiple electrical connections is ball grid array (BGA) technology. In BGA technology, sometimes hundreds of extremely small solder balls, on the order of a micron in diameter, must be precisely placed according to a predetermined pattern to make electrical contact between conductive pins or pads on the IC chip and conductive pads on the substrate of the PCB. A misplacement of few microns or less can result in a defective product.
[0003] The predetermined pattern in which the solder balls are placed will vary from one particular IC chip design to another. When a new IC chip is under development, the process for attaching or placing the solder balls must be confirmed or certified as being accurate and reliable before being implemented in a high volume manufacturing operation. A manual ball attachment jig is typically used in the development stage but this arrangement and process is time consuming and costly to load and place the balls and can delay the certification or acceptance of a new product and the process for manufacturing the product.
[0004] Accordingly, for the reason stated above, and for other reasons that will become apparent upon reading and understanding the present specification, there is a need for a semiautomatic solder ball attachment system that is efficient to shorten the lead time of development activities and reduce costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a perspective view of a solder ball attachment system in accordance with the present invention.
[0006] [0006]FIG. 2 is a detailed perspective view of a flux station for the ball attachment system of FIG. 1.
[0007] [0007]FIG. 3 is a detailed perspective view of a tray portion of a ball placement station for the ball attachment system of FIG. 1.
[0008] [0008]FIG. 4 is a detailed side elevation view of a pivotable carriage assembly of a ball placement station in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
[0010] [0010]FIG. 1 shows a perspective view of a solder ball attachment system 100 in accordance with the present invention. The solder ball attachment system 100 includes a flux station 102 to apply flux to a substrate 104 and a solder ball placement station 106 to place solder balls onto the substrate 104 . The flux station 102 and the solder ball placement station 106 are mounted on a platform 108 adjacent one another. A conveyor assembly 110 is also mounted on the platform 108 and moves the substrate 104 between the flux station 102 and the solder ball placement station 106 . The conveyor assembly 110 includes a belt or pair of conveyor belts 112 . The belts 112 is driven by a motor 114 and a hand crank 116 may be provided to operate the conveyor belts 112 manually. A substrate holder or support 118 rests on or is attachable to the conveyor belts 112 to hold the substrate 104 during processing.
[0011] The solder ball attachment system 100 further includes an alignment arrangement 119 for proper alignment of the substrate 104 during processing in the flux station 102 and the solder ball placement station 106 . As part of the alignment arrangement 119 , the substrate support 118 may include a plurality guide pins 120 mounted thereon for proper alignment of the substrate 104 during processing in the flux station 102 and solder ball placement station 106 .
[0012] To begin a solder ball placement process, the substrate 104 is placed onto the substrate support 118 on the conveyor belt or belts 112 and the substrate 104 is moved into proper position at the flux station 102 . Referring also to FIG. 2 which is a detailed perspective view of the flux station 102 , the flux station 102 includes a flux screen 122 . The flux screen 122 is lowered over the substrate 104 . The flux screen 122 has at least two guide holes 124 formed therein through which the guide pins 120 of the substrate support 118 are inserted for alignment of the flux screen 122 with the substrate 104 . The flux screen 122 has a plurality of openings 126 formed therein in a predetermined pattern through which flux is applied or printed onto the substrate 104 according to the predetermined pattern. The predetermined pattern of the openings 126 may vary according to the design of the particular IC chip and the required placement of the solder balls on the substrate 104 to make electrical connections between the particular IC chip and conductive pads 128 (FIG. 1) formed on the substrate 104 .
[0013] The alignment arrangement 119 may also include a plurality of adjustment screws 130 selectively positioned around a perimeter or sides 132 of the flux station 102 to precisely adjust the placement of the openings 126 in the flux screen 122 relative to the conductive pads 128 formed on the substrate 104 for proper alignment between the opens 126 and the conductive pads 128 . After alignment, the flux screen 122 may then be clamped in place by clamp screws 134 to prevent the flux screen 122 from moving relative to the substrate 104 during application of the flux.
[0014] The flux station 102 also includes a flux applicator assembly 136 . The flux applicator assembly 136 includes a first upright support member 138 attached to one side 140 of the flux station 102 and a second upright member 142 attached to another side 144 of the flux station 102 opposite to the one side 140 . A horizontal support member 146 is suspended between the first and second upright support members 138 and 140 at a predetermined distance above the flux screen 122 . The horizontal support member 146 is preferably hinged to the first upright member 138 by a hinge arrangement 148 and the horizontal support member 146 may be attached to the second upright support member 142 by a removable pin 150 or the like. This horizontal support member 146 can then be swung open to remove or replace the flux screen 122 . The horizontal support member 146 has a longitudinal slot 152 formed therein through which a handle 154 is attached to a squeeze blade 156 . The squeeze blade 156 may be made from a resilient material such a flexible plastic or rubber type material with one end 158 in sliding contact with the upper or exposed surface of the flux screen 122 . The handle 154 is slidable within the slot 152 to move the squeeze blade 156 back and forth across the flux screen 122 to push or force flux uniformly through the openings 126 and onto the substrate 104 . The flux will then be applied or printed evenly or uniformly on the substrate 104 in the predetermined pattern.
[0015] After flux is applied to the substrate 104 , the flux screen 122 is removed from the substrate 104 and the conveyor belts 112 may be activated to move the substrate 104 to the solder ball placement station 106 . A conveyor belt operation switch 160 (FIG. 1) is mounted to the platform 108 and is electrically connected to the motor 114 to control the operation of the motor 114 to move the conveyor belts 112 in a forward direction or a reverse direction. In one position the conveyor switch 160 causes the motor 112 to move the substrate holder 118 from the flux station 102 to the ball placement station 106 and in another switch position, the conveyor operation switch 160 causes the substrate holder 118 to move in an opposite direction.
[0016] Referring also to FIG. 3 which is a detailed perspective view of a tray portion 162 of the solder ball placement station 106 , the tray portion 162 includes a first section or ball placement section 164 and a second section or ball bin 166 . A ball placement mask 168 is mounted in the first section 164 and the second section or ball bin 166 is where the solder balls 169 are stored. The ball placement mask 168 is mounted to an underside of the first section 164 by an attachment mechanism 170 . The attachment mechanism 170 may be a latch-arrangement or magnetic holders. The ball placement mask 168 is properly aligned to the first section 164 by guide holes 171 formed in the ball placement mask 168 which are received on guide pins 172 formed on the underside of the first section 164 .
[0017] Each section 164 and 166 has a respective ramp 173 and 174 that slopes away from a center segment 175 of the tray portion 162 . Accordingly, the solder balls 169 will be retained in the ball bin 166 when the tray portion 162 is level in a non-ball placement or non-operational position.
[0018] Referring also to FIG. 4 which is a detailed view of a portion of a pivotable carriage assembly 176 of the solder ball placement station 106 . The pivotable carriage assembly 176 includes a lower portion or substrate support holder 177 and an upper portion or tray portion support 178 . As the conveyor belts 112 move the substrate support 118 into the solder ball placement station 106 , side edges 179 of the substrate support 118 will be received into recesses 180 formed in the substrate support holder 177 of the pivotable carriage assembly 176 . When the substrate support 118 is in proper position at the solder ball placement station 106 , an “UP” illuminated pushbutton 181 (FIG. 1) will turn on. The “UP” pushbutton 181 may then be pushed to operate a pair of actuators 182 to raise the substrate support holder 177 and substrate 104 to position the substrate 104 under the ball placement mask 168 . The actuators 182 are each respectively mounted proximate to opposite ends of the tray portion holder 178 of the pivotable carriage assembly 176 , as best shown in FIG. 1. Each of the actuators 182 may be an air cylinder or similar device to raise the substrate support holder 177 into position and to lower the substrate support holder 177 and substrate 104 after a ball placement operation.
[0019] The tray portion 162 is mounted to the tray portion holder 178 . The tray portion holder 178 has a plurality of guide posts 183 formed on an underside 184 thereof. As the substrate support holder 177 is raised, the guide posts 183 will be received into respective guide holes 185 formed in the substrate support holder 177 to properly align the substrate support 118 and substrate 104 with the ball placement mask 168 . Additionally, a pair of stability shafts 186 are mounted to the substrate support holder 177 at each end thereof proximate to each actuator 182 , as best shown in FIG. 1. The stability shafts 186 each extend through openings 187 formed in the tray portion holder 178 and guide movement of the substrate support holder 177 into proper position with the tray portion holder 178 and the substrate 104 into proper alignment with the ball placement mask 168 for a ball placement operation.
[0020] Referring also back to FIG. 1, the tray portion 162 of the solder ball placement station 106 is mounted in the tray portion holder 178 of the pivotable carriage assembly 176 . The pivotable carriage assembly 176 is pivotably mounted at two opposite ends thereof to a pair of respective stanchion members 189 . The stanchion members 189 are mounted on the platform 108 and support the pivotable carriage assembly 176 over the conveyor assembly 110 at the solder ball placement station 106 . The pivotable carriage assembly 176 is retained in a level position while the substrate support 118 is raised to a location under the tray portion 162 . After alignment of the substrate support 118 with the tray portion 162 , the pivotable carriage assembly 176 is released and may be pivoted to a position to cause the solder balls 169 (FIG. 3) to roll from the ball bin section 166 into the first section 164 of the tray portion 162 containing the ball placement mask 168 (FIG. 3). The ball placement mask 168 has a plurality of holes 190 formed therein in a selected pattern to place the solder balls 169 on the substrate 104 according to the selected pattern. The selected pattern of holes 190 may be substantially the same as or coordinate with the predetermined pattern of openings 126 (FIG. 2) formed in the flux screen 122 for applying the flux. When the solder balls 169 roll over the ball placement mask 168 , the solder balls 169 will drop by gravity into any unfilled holes 190 in the mask 168 and are placed or attached to the substrate 104 according to the selected pattern of holes 190 . The pivotable carriage assembly 176 may be tilted back and forth until all of the holes 190 have been filled with a solder ball 169 . The carriage assembly 176 is then tilted or pivoted to a position to cause all remaining or unused solder balls 169 to roll back into the ball bin 166 where the balls 169 are retained until the next substrate 104 is received for processing. The carriage assembly 176 may be tilted or pivoted by a wheel 191 attached to an axle (not shown) of the carriage assembly 176 through a hub of the stanchion 189 .
[0021] After placement of the solder balls 169 on the substrate 104 , the carriage assembly 176 is returned and retained in a level or horizontal position. A “DOWN” illuminated pushbutton 192 is turned on. The “DOWN” pushbutton 192 is pushed to operate the actuators 182 to lower the substrate support 118 back onto the conveyor belts 112 . The conveyor belt operation switch 160 may then be operated in the reverse direction to move the substrate support 118 from the solder ball placement station 106 . The completed substrate 104 may be removed from the substrate support 118 and another unfinished substrate may be placed on the support 118 for solder ball placement.
[0022] The solder ball attachment system 100 also preferably includes a power ON/OFF switch 194 mounted on the platform 108 to control the overall application of power to the solder ball attachment system 100 . The solder ball attachment system 100 may also include actuator covers 196 to cover the actuators 182 and protect them from damage.
[0023] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof. | A solder ball attachment system for manufacturing an integrated circuit or the like is disclosed. The solder ball attachment system includes a flux station adapted to apply flux onto a substrate and a solder ball placement station adapted to place solder balls onto the flux. A conveyor assembly is included to move the substrate between the flux station and the solder ball placement station. | 1 |
PRIORITY CLAIM
[0001] The present application is a National Phase entry of PCT Application No. PCT/EP2009/067354, filed Dec. 16, 2009, which claims priority from German Application No 102008062658.9, filed Dec. 17, 2008, the disclosures of which are hereby incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to an ophthalmological laser system with a laser, the radiation of which is focusable in an examination region via an illumination beam path, which exhibits a scanner unit; particularly with an immobilization device for an eye positioned in the examination region. Furthermore, the invention relates to an operating method for an ophthalmological laser system.
BACKGROUND
[0003] In ophthalmology it has been established, in case of defective vision, to form the cornea of the human eye with its approximate thickness of 500 μm through ablation of tissue in order to correct myopia, hypermetropia, and astigmatism. This is called refractive surgery. In addition, the transplant of pieces of the cornea from a donor eye into a recipient's eye has been established in order to replace diseased or damaged corneal tissue and therefore retain or restore vision. Both methods are collectively termed keratoplasty and can be executed by means of lasers. In the so-called lamellar keratoplasty, a single disc from a donor cornea is transplanted in or onto a recipient's cornea.
[0004] Anatomically, the human cornea consists of five different tissue layers. From anterior to posterior they are: Epithelium, Bowman's membrane, stroma, Descemet's membrane, and endothelium. Thereby, the stroma takes up the largest volume.
[0005] During laser-supported intrastromal keratomileusis (LASIK), a flap with an approximate thickness of typically 80 μm or more is detached from the cornea and folded up. For example, it is known from US 2006/0155265 A1 (Intralase Corp.) to cut the flap by means of a femtosecond laser system (Femto-LASIK). Such devices are also called laser microkeratomes. Thereby, a photodisruption is produced in the focus, which leads to a minimal formation of bubbles in the stromal tissue. If focal spot is set next to focal spot by means of a scanner system, incisions (perforations) can be made in the cornea.
[0006] The ablation of the stromal tissue, necessary for a refractive correction, is subsequently executed conservatively by means of an excimer laser. After treatment, the flap is folded back. Disadvantageously, said method requires two laser systems.
[0007] In WO 2008/064771 A1 (Carl Zeiss Meditec AG), a femtosecond laser system is described which can also prepare the flap but is additionally capable of separating the ablation of stromal tissue, necessary for a refractive correction, through multiple incisions for the preparation of a lenticle. This can be called femtosecond lenticle extraction. Subsequently, the lenticle can be removed after opening the flap, e.g., with a pair of pincers. Then the flap is folded back again. For said method, only one laser system is required, the use of an excimer laser can be forgone. Such a laser system also allows for the execution of incisions during the transplant of corneal tissue. Thereby, the femtosecond laser system can be used for incisions on the donor eye as well as for incisions in the recipient's eye.
[0008] During keratoplasty (refractive correction, transplant), the shape of the cornea of the human eye is problematic. For example, the refractive power of the cornea depends on its shape. The anterior corneal surface is in a first approximation a toric surface and is generally described through two radii of a certain axial position perpendicular to one another. The thickness of the cornea also increases towards its periphery. In addition, further irregularities of the corneal thickness can occur with certain pathologies.
[0009] According to prior art, for the planning of a laser-supported keratoplasty, the shape of the cornea is specially measured (pachymetry), e.g., contactless by means of a Scheimpflug camera or an optical coherence tomography system (OCT) for the anterior eye segment. The contacting measurement by means of ultrasound is also known. However, during the actual surgery, the cornea is held on the femtosecond laser through the application of a contact glass and suctioning of the eye, whereby, as a rule, the shape of the cornea is altered (applanation).
[0010] As a result, the parameters of the shape of the cornea, obtained outside of the actual surgery, are now, among others, only meaningful within limits. Therefore, the accuracy of the laser treatment, as far as it is based on the measured shape, is limited. As a result, the transplant can deviate from its planned shape and not be implanted optimally in the recipient's eye. This can lead to complications, e.g., the detachment of the transplant or glaucoma due to a shift of the transplant.
[0011] Regardless of the shape of the cornea, there is also the problem that in some cases optically opaque bubbles (opaque bubble layer—OBL) may appear during the perforation of corneal tissue by means of femtosecond laser radiation with lamellar incisions. This refers to an area in the immediate surroundings of the actual laser incision, whereby the forming of the laser-induced micro-gas bubbles not only occurs in the plane of the incision. Depending on position and characteristic of an OBL field, the perforation of the tissue in this area is not ideal. In comparison to the surrounding area, the result is a more difficult manual detachment of the tissue components to be separated, which leads to tissue stress and/or to a prolonged duration of surgery. Therefore, prior art attempts to avoid the formation of OBL. For example, this is accomplished through optimization of treatment parameters, such as pulse energy and spot distance and/or track distance. The modification of the incision geometry towards deeper incisions, e.g., greater flap thickness or the creation of a low-lying gas pocket, e.g., at a depth of 250 μm, can contribute to a decrease of the frequency of OBL. However, experience has shown that even under said conditions, OBL occurs in some eyes. Furthermore, modifications of the incision geometry and gas pockets are disadvantageous with regard to the preservation of as much residual stromal thickness as possible.
SUMMARY OF THE INVENTION
[0012] The invention is based on the task of improving an ophthalmological laser system and a corresponding operating method of the initially mentioned type in such a way that a laser-supported surgical procedure within the course of a keratoplasty is made possible with greater accuracy, whereby improved chances for success and a decreased treatment risk are to be achieved and/or that an easier manual detachment of perforated tissue components is made possible.
[0013] According to a first aspect of the invention, a detection beam path with a confocal aperture diaphragm and a detector for mapping of detection light from the focused part of the examination region is provided in an ophthalmological laser system. Furthermore, a control unit for irradiating the cornea by means of the laser and recording of detection light by means of the detector is provided, whereby it scans the cornea three-dimensionally through irradiating said cornea at illumination laser power by means of the scanner unit at several spots and simultaneously mapping detection light from said spots. By means of the detection light, the control unit determines position and/or form of a posterior boundary layer of the cornea. Said information can subsequently be displayed or immediately processed further and/or stored for later utilization.
[0014] The posterior boundary layer is the transition from the endothelium, the posterior border of the cornea, to the aqueous humor of the eye. At said media border, a refractive index jump and an increased reflection occur which can be measured with great accuracy with a confocal detector. Measuring devices, such as a Scheimpflug camera or an OCT system are not required thereto. For example, the detection beam path can be part of a confocal laser scanning microscope (LSM) which is provided in addition to the treatment laser.
[0015] Through the measuring of the posterior boundary layer, said layer can, advantageously, be used as a reference plane for keratoplastic incisions.
[0016] Particularly with an immobilization device with a contact glass, whose boundary layer on the side facing the eye exhibits a radius of curvature which differs from the eye, the positional change/deformation of the cornea, resulting from the applanation, and particularly its posterior boundary layer, is taken into consideration during the measurement.
[0017] Through the knowledge of the form and/or position of the posterior boundary layer and information about form and/or position of the anterior boundary layer presupposedly known or to be measured, the actual shape of the cornea is known with great accuracy for a subsequent laser surgical treatment. This also applies particularly for the shape in applanated condition insofar as an appropriate contact glass is used. This way, a thickness distribution of the cornea in terms of a pachymetric mapping (pachy-map) can be determined and utilized in the irradiation planning. Particularly, the anterior and posterior radii of the cornea can be determined, which are relevant for the determination of the refractive index ratios. With conventional methods, it was possible to obtain said parameters only outside of the actual keratoplastic surgery. A possible applanation could not be taken into account. However, the invention not only allows for a more accurate determination of the geometric parameters for surgery but also for the measurement during or at least immediately before surgery in the treatment condition of the patient. As a result, inaccuracies which result from undocking and redocking of the eye, are avoided. Due to the now possible, highly accurate reference to the posterior boundary layer, a keratoplasty can be performed with great accuracy, resulting in improved chances for success and a decreased treatment risk.
[0018] The posterior boundary layer can be, e.g., analytically depicted through adaptation of a model function, particularly with Zernike polynomials, by means of an adjustment calculation at the measuring points. Since it is a curved surface, the detection light must be mapped from at least four points of the posterior boundary layer. With a low number of sampling points, additional facts about the deformation of the cornea under applanation are required a priori for an analytical depiction. Such requirement is not applicable with a large number of sampling points.
[0019] In order to determine the position and/or form of the anterior boundary layer, the principle for measuring the boundary layer of the contact glass which faces the eye, as described, e.g., in WO 2008/040436 A1, can be applied. The measurement of the anterior boundary layer can be performed before or after the measurement of the posterior boundary layer, but preferably in a narrow temporal connection with said measurement, particularly during or immediately before a keratoplastic surgery.
[0020] Advantageously, the control unit, after determining form and/or position of the posterior boundary layer of the cornea, can determine irradiation control data for a laser surgical treatment, while taking into consideration the determined position and/or form of the posterior boundary layer, and irradiate the cornea by means of the laser at surgical therapy laser power in accordance with the determined irradiation control data. As a result, a keratoplasty with great accuracy is possible since the actual current position of the posterior boundary layer allows for the highly accurate placement of incisions relative to said boundary. Since the measurement of the posterior boundary layer can be performed during the treatment condition of the patient, the likelihood of a substantial change of position and/or form is slim.
[0021] In an example embodiment, the control unit is designed in such a way that it can cut a lamella parallel to the posterior boundary layer, i.e., parallel to the endothelium, based on the determined position and/or form of the posterior boundary layer. Particularly, the lamella can be cut exclusively from the endothelium. Of course, it is also possible to cut a lamella from the endothelium and the stroma. In order to cut an anterior or posterior lamella parallel to the cornea surface in the back, the radii of the boundary layers in the back are, according to the invention, determined beforehand. With the laser system and the operating method, according to the invention, said parameters can be determined with great accuracy and in the quasi-absolute coordinate system of the laser. Therefore, the invention allows particularly for endothelial keratoplasty with great accuracy and little effort.
[0022] Expediently, an immobilization device for the cornea and/or the eye is provided, whereby the control unit immobilizes the cornea and/or the eye through activation of the immobilization device prior to the (first) detection cycle. This can lead to the applanation of the cornea if a contact glass is used. The control unit releases the immobilization after termination of the irradiation. Due to the immobilization, a change in position or form of the cornea between detection/determination of the posterior boundary layer and treatment is avoided. In future embodiments without immobilization of the eye, or at least the cornea, the movement of the cornea and/or the entire eye can be traced contactless with optical means in order to immediately determine a change in position of the cornea and adjust the beam guidance accordingly. However, even with such embodiments, the posterior boundary layer must first be measured in order to achieve great accuracy of a keratoplasty.
[0023] A measurement of the posterior radii, once suctioned intraoperatively directly before the laser incision with the femtosecond laser, gathers the required parameters for the definition of the individual front and back surface of the retina through the contact glass on the eye, also particularly in cases where the eye is applanated. This allows for the cutting of a thin lamella in predetermined form relative (e.g., parallel) to the posterior surface of the cornea within the course of a lamellar keratoplasty with great accuracy.
[0024] The invention is also suited for the measurement of the thickness distribution of the cornea in other keratoplastic procedures. Such a procedure is known, e.g., from WO 2006/051364 A1 (20/10 Perfect Vision Optische Geraete GmbH). In said procedure, incisions in the stromal tissue are made with a femtosecond laser in order to create a coherent cavity, particularly with a cylindrical shape, without ablation of tissue. When the cavity collapses due to the intraocular pressure, the cornea relaxes and takes on a new form with altered curvature. This way, defective vision is to be improved. The certainty of said procedure can be improved, according to the invention, whereby at first the thickness distribution of the cornea is determined and, based on said determination, safety distances from the adjacent membranes are monitored.
[0025] Said measurement can be performed particularly intraoperatively without temporary undocking of the eye.
[0026] Advantageously, a beam splitter for decoupling of the detection beam path is arranged in the illumination beam path. This way, the illumination beam path and the detection beam path can be aligned to one another with great accuracy. As a result, the same optical elements (focusing optics, etc.) can be utilized twice. Thereby, embodiments are preferred which, in addition to the illumination laser power, can be adjusted to a surgical therapy laser power. As a result, the same laser can be utilized for the illumination during the determination of form and/or position of the posterior boundary layer of the cornea as well as for the subsequent treatment with great positioning accuracy. Thereby, the use of the same laser for measurement and treatment allows for great accuracy for the positioning of the treatment focus since the measurement of the posterior boundary layer can be performed in the quasi-absolute reference system of the treatment laser.
[0027] In an advantageous embodiment, the beam splitter is a polarization beam splitter, which decouples the detection light on the detector in such a way that it exhibits a polarization direction different from the emitted illumination light. A large portion of the light, which impinges on the beam splitter from the examination region, originates from reflections on the optical components of the beam path, e.g., the surfaces of the focusing optics; therefore, it exhibits the same polarization direction as the illumination light. Since the beam splitter only directs light as detection light to the detector with a different polarization direction, such stray light is suppressed. However, light backscattered in the cornea exhibits an altered polarization direction. Therefore, the detection of the light backscattered in the cornea is possible with greater accuracy.
[0028] Moreover, due to the polarization properties of the cornea, varying polarization properties of the introduced diagnostic radiation are advantageous for the image generation within varying areas of the cornea.
[0029] Said properties can be produced through one or several polarizing optical elements in the illumination beam path.
[0030] Advantageously, a polarization filter is positioned in the detection beam path between the beam splitter and the detector, which is fixed in terms of rotation or rotatable with regard to its polarization direction. With regard to its effect, a polarization filter, which is fixed in terms of rotation, corresponds to the aforementioned polarization beam splitter. Due to the polarization properties of the cornea, a selection of the polarization direction backscattered to the confocal detector through a twist of the polarization filter assigned to the detector is advantageous for the efficient diagnosis of particular areas of the cornea. Hence, a complete detection of an overall image with high contrast is accomplished through multiple scanning at various settings of the polarization filter to a respective individual image and appropriate superimposition of the individual images to the overall image. Instead of a separate polarization filter, a polarization beam splitter can also be designed rotatable in order to selectively detect stray light of varying polarization directions. However, the determination of position and/or form of the posterior boundary layer is also possible with a polarization filter/polarization beam splitter, which is fixed in terms of rotation, or entirely without polarization filtering, particularly by means of a single scan cycle. A single scan cycle can be executed in a short period of time.
[0031] It is possible to achieve an even greater signal strength, whereby an optical phase retardation system in the illumination beam path between the focusing optics and the examination region is arranged in such a way that the passing illumination light obtains a polarization direction corresponding to the decoupled detection light. As a result, the stray light exhibits the same polarization direction as the radiation from the laser, while the illumination light, which reaches the cornea and is modified in the phase retardation system, obtains a defined, different polarization direction. Through the selection of the light of said polarization direction as detection light by means of the polarization beam splitter, only such light, which was backscattered in the cornea, is detected almost exclusively. Stray light, which originates from reflections on optical components, is even more effectively kept away from the detector.
[0032] In order to improve the image contrast, a lock-in amplifier, coupled with the laser, can be provided for the detector. This allows for the mapping of the detector light with great sensitivity so that a possible treatment can be executed with great accuracy.
[0033] For the three-dimensional scanning of the cornea, the radiation exposure can be reduced in such a way that two consecutive scan points differ from each other in all three spatial coordinates. Through this type of scanning, representative data about form and/or position of the posterior boundary layer of the cornea can be obtained in a short period of time. Alternatively, during scanning for either one or several series of scan points respectively, it is possible to maintain one or two spatial coordinates constant and to only vary the two coordinates and/or the one remaining spatial coordinate. As a result, several series of scan points can be illuminated and detected in a plane curve at a constant z-coordinate, respectively. Alternatively, one series of scan points can be mapped with a constant x- and y-coordinate while varying the z-coordinate, e.g., beginning at the contact glass. For the latter approach, the curve in z-direction must inevitably pierce through the posterior boundary layer. Once this has been identified through a significant increase of the intensity of the detection light, the z-scan can be terminated at said x/y coordinates and restarted at a different x/y point.
[0034] Preferred are embodiments, in which one or two mirrors of the scanner unit oscillate during scanning, particularly, oscillate harmonically. A control of the scanners in the form of harmonic oscillations, such as sine functions, is technically particularly advantageous. Controlling the x-y-scanners in such a way that one of the scanners is controlled with exactly double the frequency than that of the other scanner results in a Lissajous figure, which resembles the FIG. 8 . Simultaneously to the x-y-scan, e.g., a monotone or a strictly monotone variation of the focus distance, i.e., a z-scan, takes place. This results in a continuous space curve. In the case of the above frequency ratio of 2:1, it exhibits the form of several offset figure eights, layered by depth.
[0035] This particular form and generally all frequency ratios of 2N:1 (N=1,2,3, . . . ) are advantageous since two key incisions and the optical axis are available for the determination of sampling points for the posterior boundary layer, which allows for great accuracy for the determination of form and/or position of the posterior boundary layer.
[0036] Preferably, a pulse frequency of the laser light, depending on the motion speed of a focal point of the laser beam, is set or reversed relative to the cornea. As a result, the radiation exposure of the cornea and the eye overall can be decreased during the detection of the posterior boundary layer. For example, for a slow motion speed of the focal point, which, e.g., occurs during the motion reversal of oscillating scanners, a low pulse frequency is used. For a high motion speed, a high pulse frequency is used in order to obtain a high spatial resolution.
[0037] The invention also comprises advantageous embodiments, wherein a treatment cycle is followed by a repeated detection cycle with determination of the posterior boundary layer, followed by another treatment cycle. As a result, the accuracy of the treatment can be increased, e.g., through an iterative approach to an optimal treatment outcome. Even during the first treatment, changes in form and/or position of the cornea and therefore also its posterior boundary layer can occur due to swellings. Through a remeasuring between two treatment cycles, such and other changes can be taken into consideration.
[0038] Expediently, a darkfield value is subtracted from the mapped detection light. This can either be a mutual darkfield value for all scan points or several point-specific darkfield values. This embodiment allows for a greater accuracy of the imaging of the light backscattered in the cornea.
[0039] In addition to the ophthalmological laser system and an operating method, the invention also comprises a computer program for said method as well as a control unit, which is designed for the execution of the operating method, according to the invention.
[0040] Advantageously, the step of irradiating and scanning the cornea can be executed several times along a scan curve, whereby the scan curve is utilized during each scan cycle in a varyingly offset and/or varyingly rotated position. Since a depth scan and a side scan through the confocal detection system only results in a sectional image of the cornea, an almost complete three-dimensional analysis is possible, for example, through repetition with a rotated scan curve in increments of 1°, 5°, 10°, . . . 90° centrally symmetrical to the first scanning cycle.
[0041] In addition to the ophthalmological laser system and an operating method for said system, the invention in accordance with its first aspect also comprises a computer program as well as a control unit, which are designed for the execution of an operating method or keratoplasty method, according to the invention. Furthermore, it comprises a general surgical method for the execution of the keratoplasty, whereby a position and/or form of the posterior boundary layer of a cornea is determined through confocal detection, and an endothelial lamella parallel to the posterior boundary layer is cut by means of the determined position and/or form of the posterior boundary layer.
[0042] According to a second aspect of the invention, a light source for the illumination of the eye, a detector for mapping detection light from the examination region, and a control unit are provided in an ophthalmological laser system. The control unit determines irradiation control data for a laser surgical treatment, activates the immobilization device, irradiates the cornea by means of the laser at a surgical therapy laser power in accordance with the determined irradiation control data, illuminates the cornea by means of the light source, and identifies an area of the cornea in which opaque bubbles are present by means of the detection light mapped by the detector, irradiates at least the identified area of the cornea again by means of the laser at a surgical therapy laser power, and deactivates the immobilization device, whereby it leaves the immobilization device permanently activated between the first irradiation and the last repeated irradiation.
[0043] Expediently, a consent of an operator can be prompted prior to the repeated irradiation. Said aspect of the invention also comprises a general method for the execution of a keratoplasty on a cornea of an eye, whereby the eye is immobilized by an immobilization device, whereby the cornea is irradiated by a laser at a surgical therapy laser power, and whereby the immobilization is released at the end of the irradiation. After the irradiation of the cornea and prior to the release of the immobilization, an area of the cornea is identified, according to the invention, which contains opaque bubbles. Then, also prior to the release of the immobilization, at least the identified area of the cornea is irradiated again by the laser at surgical therapy laser power.
[0044] Through the identification of OBL, particularly automated by a control unit, and repeated irradiation at least in the area affected by OBL, a significantly easier and therefore improved manual detachability of tissue components is achieved in the affected area. Due to the continuous immobilization of the patient's eye, the repeated irradiation can be executed with great positioning accuracy, particularly relative to the positions in the already determined irradiation control data. The repeated irradiation with continuous immobilization can be termed as intraoperative “recutting.”
[0045] Advantageously, the repeated irradiation can be performed in accordance with the determined irradiation control data or in accordance with a subset thereof, particularly through the control unit. This equals an at least partial repetition of the planned laser incision, hence no new irradiation control data have to be determined. As a result, the repeated irradiation can be executed in as short a time as possible, minimizing the risk of a change of position of the eye. Due to the continuous immobilization, initial incisions are reproducible with great accuracy.
[0046] Alternatively to the at least partial repetition of an initial incision, one or several laser incisions can be performed, the irradiation control data of which differ from the initial incision(s). Particularly, the irradiation energy, the spot and/or track distance as well as the scan direction can be varied in order to achieve a better treatment outcome.
[0047] According to the invention, the operating method for an ophthalmological laser system, the laser of which is switchable between an illumination laser power and a therapy laser power, and the laser light of which is focusable three-dimensionally variable in a cornea, can also be executed without the automatic execution of the steps “illumination,” “detection,” “identification of OBL,” and “triggering recutting.” Thereto, the following steps are provided:
Determination of irradiation control data for a laser surgical treatment; Activation of the immobilization device; Irradiation of the cornea by means of the laser at a surgical therapy laser power in accordance with the determined irradiation control data; Identification of an area of the cornea, which contains opaque bubbles, by means of images of the cornea, e.g., manually through a microscope or by means of a camera and an image display; Repeated irradiation of at least the identified area of the cornea by means of the laser at a surgical therapy laser power;
[0053] and
Deactivation of the immobilization device,
whereby the immobilization device remains permanently activated between the first irradiation and the last repeated irradiation. The identification, e.g., is performed visually through an operator, and the triggering of the repeated irradiation is performed manually also by the operator.
[0055] Preferably, the irradiation control data utilized for the repeated irradiation of the cornea are stored in a treatment database. For example, the treatment database can be managed in the control unit or an external control computer. Advantageously, the stored irradiation control data can be used during later irradiation cycles for the optimization of irradiation control data.
[0056] In addition to the ophthalmological laser system and an operating method for said system, the invention in accordance with its second aspect also comprises a computer program as well as a control unit, which are designed for the execution of an operating method or keratoplasty method, according to the invention. Advantageously, they can be designed for the provision of a control element for triggering a repeated irradiation of the cornea, whereby said provision is executed prior to a deactivation of an immobilization device.
[0057] The initial determination of irradiation control data can be executed in all aspects of the invention before or after an activation of the immobilization device for the eye, particularly temporally beforehand in preparation of the actual operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] In the following, the invention shall be further explained by means of embodiment examples.
[0059] It is shown in:
[0060] FIG. 1 is an ophthalmological laser system for the analysis of the cornea;
[0061] FIG. 2 depicts the measurement of the cornea up to the posterior boundary layer;
[0062] FIG. 3 is an ophthalmological laser system for the analysis and treatment of the cornea;
[0063] FIG. 4 is a flow diagram of an operating method; and
[0064] FIG. 5 depicts a space curve for the scanning of the cornea.
[0065] In all drawings, all corresponding parts bear the same legend.
DETAILED DESCRIPTION
[0066] FIG. 1 shows an exemplary ophthalmological laser system 1 for identification and localization of the posterior boundary layer of a cornea 2 of an eye 3 with regard to form and position of the boundary layer. The laser system 1 comprises a laser 4 , a polarization beam splitter 5 , scan optics 6 , a scanner unit 7 , focusing optics 8 , and an optical phase retardation system 9 , which together form an illumination beam path B; as well as a deflection mirror 10 , a confocal aperture diaphragm 11 , and a detector 12 , which form a decoupled detection beam path D. In addition, the laser system 1 comprises an amplifier 13 and a control unit 14 . Between the laser system 1 and the eye 3 , an immobilization device 17 with a contact glass for the eye 3 is positioned, behind which lies the examination region. On the side facing the eye 3 , the contact glass can exhibit a spherical, planar, eye-curved, or any other surface rotationally symmetric around the optical axis. This example shows a spheric curvature, whereby the cornea 2 is applanated in an immobilized (e.g., suctioned) condition.
[0067] Other embodiments for the realization of the solution, according to the invention, are possible (not depicted). For example, the beam splitter 5 can be designed non-polarizing. In this case, the phase retardation system 9 can be omitted. In further embodiments (not depicted), the immobilization device 17 can immobilize the eye 3 instead of the cornea 2 , whereby no contact glass is used. Hereby, the cornea 2 can be surrounded, e.g., with a liquid or an inert gas. Particularly, in such a case, the movement of the cornea 2 can be tracked with optical means in order to trace the movement with the laser beam for detection and/or treatment.
[0068] For example, the laser 4 is designed as a pulsed TiSa infrared laser with a pulse length between 100 fs and 1000 fs. It emits laser radiation at an eye-safe illumination laser power in the range of 100 mW. The scanner unit 7 comprises, for example, a number of galvanometric mirrors for the deflection of the laser radiation in the x- and y-directions via the cornea 2 . The focusing of the laser radiation in z-direction along the optical axis is effected, e.g., through a movable lens or lens group within the scan optics 6 or the focusing optics 8 , or alternatively through a movable tube lens (not depicted). The optical phase retardation system 9 , for example, is designed as a λ/4 plate, which forms a border of the laser system 1 . The detector 12 , e.g., is designed as a photomultiplier (PMT) or as an avalanche photo diode (APD) since the light intensities to be mapped are low.
[0069] The amplifier 13 is designed as a lock-in amplifier and connected to the detector 12 as well as the laser 4 .
[0070] The pulsed IR laser radiation emerges from the laser 4 and initially passes unchanged through the polarization beam splitter 5 . Then it is focused via scan optics 6 , scanner unit 7 , and focusing optics 8 as illumination light on a scan point P in the cornea 2 . Said scan point P can be shifted in the cornea 2 by means of the scanner unit 7 and a movable lens or lens group within the scan optics 6 or the focusing optics 8 in x-, y-, and z-direction. Thereby, the optical phase retardation system 9 effects a defined change of the polarization direction of the illumination light passing through.
[0071] At the boundary layers 2 . 1 , 2 . 2 and inside the cornea 2 , a scattering/reflection of the IR radiation occurs, whereby the radiation is partially depolarized. Backscattered/reflected light also impinges on the illumination beam path B and there returns all the way back to the polarization beam splitter 5 . The radiation components with unchanged polarization status pass through the polarization beam splitter 5 onto the laser 4 . This refers particularly to reflections which originate from the scan optics 6 or the focusing optics 8 . Such radiation components, which, after passing through the phase retardation system 9 and/or through depolarization in the eye 3 , exhibit a changed polarization status in the cornea 2 , are deflected by the polarization beam splitter 5 as detection light into the detection beam path D to the detector 12 . The detection light passes via a deflection mirror 10 through the confocal aperture diaphragm 11 onto the detector 12 . In an alternative embodiment (not depicted), the deflection mirror 10 can be omitted or replaced by other beam guidance units. The confocal aperture 11 acts as discriminator in the z-direction, therefore, spatially resolved, only backscattered light is detected from a low focus volume. The control unit 14 , through the deflection of the illumination light in x- and y-direction by means of the scanner unit 7 and change of the focusing in z-direction by means of the focusing optics 8 , can irradiate random scan points P inside of the cornea 2 with illumination light and determine the strength of the backscatter at said points P via the intensity of the corresponding detection light.
[0072] In the depicted embodiment, the optical phase retardation system 9 between the eye 3 and focusing optics 8 effects a defined rotation of the polarization direction of the passing illumination light, while stray light, previously reflected at the optical components, maintains the original polarization direction. As a result, the relative intensity of the detection light is increased since the polarization beam splitter 5 separates only light with deviating polarization direction as detection light. In alternative embodiments (not depicted), the optical phase retardation system 9 can be omitted. Alternatively or additionally, additional polarizers (not depicted) can be positioned in the illumination and/or detection beam path in order to improve the signal quality. In another embodiment, the phase retardation system can be realized as depolarizer so that the extent of the phase retardation varies via the beam profile.
[0073] Since the signals registered at the detector 12 exhibit a very low intensity, the electronic amplifier is adjusted to an optimized signal-to-noise ratio. A particularly advantageous embodiment is the lock-in amplifier, which is temporally synchronized with the pulse generation and/or the repetition frequency of the laser 2 . Other embodiments, for example, utilize so-called boxcar techniques or scanning techniques (sampling) with adding up or averaging for noise suppression. Advantageously, the entire amplifier system of the detector signal exhibits a nonlinear characteristic. However, a peak detector and/or a sample-and-hold circuit can also be used to achieve signal improvement.
[0074] In an alternative embodiment (not depicted), the detection beam path D can be arranged separate from the illumination beam path, whereby it is provided with its own objective. Hereby, a separate laser can be provided for the illumination during one or several detection cycles.
[0075] In such an embodiment, the laser 4 of the treatment system 1 can be operated, e.g., permanently at therapy laser power without an attenuator.
[0076] In order to determine information about form and position of the posterior boundary layers 2 . 2 of the cornea 2 with great accuracy in a short period of time, a suitable spatial distribution of points P is scanned confocally, regardless of the embodiment. For example, as depicted in FIG. 2 , several series (for reasons of simplification, only three in partial FIG. 2A ) of scan points P can be scanned along an appropriate number of different paths R with constant x- and y- coordinates. Expediently, one of the paths R lies on the optical axis of the laser system 1 and the remaining paths, e.g., in equidistant angular steps on a concentric circle around the optical axis. Partial FIG. 2B depicts the frontal view of the eye 3 . Only one of the scan points P of each path series is depicted. Altogether, seven paths R are scanned along the z-direction, respectively.
[0077] For example, the scan can start along an individual path R within the contact glass 17 , the measurements of which are known, or on its surface which faces the eye and continue in equidistant z-steps up to a distance of e.g., 1.5 mm from the contact glass. For the purpose of acceleration, it is also conceivable to start the scan at a distance of 100 μm to 300 μm from the surface of the contact glass 17 which faces the eye. Also, the scan cannot be executed to a fixed depth but, e.g., only until the second significant increase of the detection light intensity as characteristic for the posterior boundary layer 2 . 2 . Four or six different paths R with an appropriate number of scan point series are expedient. From the thereby obtained values for the intensity of the backscatter, the form and position of the posterior boundary layer 2 . 2 can be reconstructed since the backscatter at the boundary layers (anterior, posterior) 2 . 1 , 2 . 2 is, in comparison with the stroma and the inner layers, intensified. For example, by means of said parameters, a thickness distribution of the cornea 2 in applanated condition can be determined. If the contact glass radius is known, it is also possible to deduce the posterior radii of curvature of the cornea 2 in applanated condition from the form and/or position of the posterior boundary layer 2 . 2 .
[0078] For example, with such data, the irradiation pattern for the laser 4 can be computed for the calculation of an endothelial lamella L parallel to the posterior boundary layer 2 . 2 . As a result, the invention allows for an endothelial keratoplasty with great accuracy. If only a few sampling points were determined, accuracy can be improved through the utilization of known mathematical models for the calculation of the deformation of an applanated cornea.
[0079] The positioning accuracy of the positions of the measurements is relatively noncritical since the thickness changes of the cornea in the area to be measured are usually smaller than 100 μm. A positioning accuracy (x-y) of +/−100 μm is sufficient. The accuracy of the thickness measurement is more important. An accuracy of +/−5 μm is expedient.
[0080] FIG. 3 shows an exemplary ophthalmological laser system 1 for the highly accurate execution of a keratoplasty. It corresponds to a large extent to the laser system 1 in accordance with FIG. 1 but is additionally equipped with an attenuator 15 , which can be tilted into the illumination beam path B, and a modulator 16 , e.g., an acousto-optical modulator. The attenuator 15 is used for switching between an illumination laser power and therapy laser power. Illumination laser power is obtained through the attenuator 15 , tilted into the illumination beam path B, and therapy laser power is obtained without the attenuator 15 . The optical components, particularly optics 6 and 8 , are optimized, corrected, and synchronized towards the goal of a best possible focus miniaturization. For example, its optical aberrations are minimized to a high degree, requiring only a low energy input for a photodisruption.
[0081] The control unit 14 executes the operating method as shown in FIG. 4 , whereby for a pure determination of position and/or form (without therapeutic treatment) of the posterior boundary layer 2 . 2 of the cornea 2 only the solidly outlined steps S 1 , S 2 , S 3 , and S 6 are executed. For treatment, all steps are executed. Thereby, the same laser 4 is utilized not only for illumination during the confocal detection phase but also for the treatment of the cornea 2 during the immediately following treatment phase.
[0082] At first, the eye 3 of the patient is immobilized, for example, sucked towards a contact glass device by means of a vacuum (step S 1 ). In addition, the head of the patient can also be immobilized. Through a suitable target, the eye position of the patient can be kept as constant as possible. Thereby, an adjustable compensation of the angle between geometric and optical axis of the eye 3 is possible.
[0083] The illumination light at illumination laser power is guided across the cornea 2 along one or several adjustable, three-dimensional scan curves or scan structures, and detection light is mapped (step S 2 ). Thereby, the pulse frequency, in dependence of the speed of the scan movement, is adjusted in such a way that a lower pulse frequency results from a slow scan movement than from a fast scan movement. The backscattered detection light is assigned sectionally or pointwise to individual points P of the scan curve. With a consistent scan curve, consecutive scan points differ with regard to all spatial coordinates. From the detected signal values, respective darkfield values are advantageously subtracted, which are determined in a separate calibration phase.
[0084] From the intensities assigned to the scan points P, the posterior boundary layer 2 . 2 is identified and its form and position reconstructed (step S 3 ) in order to determine a thickness distribution of the cornea 2 . Thereto, for example, scan points, the intensity of which exceeds an intensity threshold, which is predetermined or specified by the surgeon, are determined as sampling points of the boundary layer 2 . 2 . With an adjustment calculation, e.g., a model of the boundary layer 2 . 2 is adjusted to the three-dimensional coordinates of the determined sampling points in order to make available all coordinates of the posterior boundary layer 2 . 2 as a basis for the surgical treatment. Said information is used to adjust the incisions to be performed, e.g., predefined by the surgeon beforehand, to the actual individual condition of the cornea 2 before the irradiation control data are determined (step S 4 ).
[0085] The irradiation control data comprise, e.g., control signals for the axes of the scanner unit 7 and/or the internal z-focusing, and for the laser beam source 4 and the power modulator 16 .
[0086] Immediately thereafter, by means of the irradiation control data, the surgical treatment is executed at therapy laser power (step S 5 ). Advantageously, pulse energies from 10 nJ to 3 μJ, particularly 50 nJ to 1 μJ are utilized. Thereby, for example, one or several series of photodisruptions are produced through the laser radiation at a pulse frequency from 100 kHz to 10 MHz and with a pulse length of less than 1 ps, particularly from 100 fs to 800 fs. Lastly, the immobilization of the eye 3 is released (step S 6 ).
[0087] Due to the identical beam path for analysis and treatment, the system 1 is self-calibrating. Since the irradiation control data are determined by means of the information about form and/or position of the posterior boundary layer 2 . 2 , obtained with the identical beam path, the treatment always allows for great accuracy.
[0088] Through the use of adjusted scan curves (scan patterns), for example, in the form of Lissajous figures, the combined procedure can also be executed in a short period of time, for example, within a maximum of 30 seconds, which reduces inaccuracies due to movement and leads to better acceptance by the patient. FIG. 5 shows an exemplary scan curve in the form of spatially offset FIGS. 8 , which can be realized as a Lissajous figure by means of the scanner unit 6 .
[0089] Other exemplary forms of scanning and/or rastering can be (not depicted): two crossed rectangles in space; two cylindrical surfaces; a cylindrical body with a profile in the form of a FIG. 8 or 4 ; several scans along one-dimensional lines. It is also possible to raster the volume of a cylinder or a cube. The volumes and/or surfaces can be scanned continuously or only partially, i.e., with gaps between the individual scan points. As a result, greater distances can occur between individual lines.
[0090] For example, the invention in accordance with its first aspect can be used in all types of laser-supported cornea surgery, e.g., LASIK, in order to determine the actual (residual) thickness distribution of the cornea 2 , for example, in treatment condition prior to or during surgery, particularly in applanated condition. Said thickness distribution can particularly be used to define and monitor safety distances from the boundary layers 2 . 1 , 2 . 2 .
[0091] In an ophthalmological laser system 1 in accordance with FIG. 3 , the invention can also be realized according to its second aspect. Thereby, the control unit 14 can, after the above described first irradiation cycle and before the release of the immobilization device, activate the laser 4 with the attenuator 15 , tilted into the illumination beam path B, for the illumination of the cornea 2 and produce a two-dimensional image of the cornea 2 by the detector 12 . For example, with a still active immobilization of the eye 3 , it can identify and localize OBL fields by means of digital image processing. Compared to the surroundings, the OBL fields are characterized through a detection signal with altered intensity and are easily localized, e.g., through a gray-scale value discriminator. Alternatively to the separate image acquisition, the control unit 14 can already map the two-dimensional image during the first irradiation cycle, whereby the illumination through the treatment light at surgical therapy laser power is utilized for the image acquisition. Thereto, the attenuator 15 is not required. Such embodiment has the advantage of not requiring additional time for an image acquisition. In a further embodiment (not depicted), the detection can be executed by means of a 2D camera or by means of an optical coherence tomography (OCT).
[0092] If the identified OBL field lies outside the accessible treatment diameter or if it is too small to have significant impact on the detachment behavior, the control unit 14 , e.g., will not take it into consideration. If a significant OBL field is detected by the control unit 14 , it is possible to execute a second complete laser incision, i.e., a repeated irradiation with the use of all previously utilized irradiation control data.
[0093] Alternatively, the repeated laser incision is only repeated in the area(s) affected by the OBL and is therefore a partial second laser incision.
[0094] The second laser incision can either be executed fully automated subsequent to the first laser incision or the user can be prompted to confirm said second laser incision. Said confirmation can take place on an image display in combination with the visualization of the automatically detected OBL fields and correspondingly planned laser incision zones. FIG. 6 shows an exemplary process in the form of a flow chart. In FIG. 7 , an image display 18 with the image of a first-time irradiated cornea 2 with an area Q with OBL is indicated. Also indicated is an exemplary area X for an automatically suggested recut. By means of push buttons 19 , which are implemented in software, the user can, e.g., choose between “partially” (partial laser incision of the OBL area), “completely” (a complete second laser incision in case of an insufficient automatic detection), and “no recutting” (the device does not execute a second laser incision and continues with the normal process, typically the release of the immobilization of the eye 3 ).
[0095] The described automation of the OBL detection via suitable detection methods is not necessarily required but adds additional convenience for the operator and can significantly reduce the additional radiation exposure through the option of the partial laser incision.
[0096] Further possible realizations:
[0097] a) Manual repetition of an identical laser incision
The user monitors the course of treatment through a suitable observation device (screen, operating microscope, etc.). As a rule, the OBL fields occur immediately at the beginning of the treatment. If the user observes incidences of OBL fields, he/she can meanwhile trigger the automatic repetition of the laser incision through an appropriate input option at the laser system 1 , particularly on the control unit 14 .
[0099] b) Manual repetition of a non-identical laser incision
After manual selection of the second laser incision (recut), said incision can differ from the first incision with regard to its parameters. Particularly, the energy, the spot and track distance as well as the scan direction can be varied in order to achieve a better treatment outcome.
[0101] c) Manual localization of the OBL fields with selective repetition of the laser incision
During or shortly after the treatment, the user can, through an appropriate input option (pointer, touch on the camera image of the observation device) manually mark those areas in which the laser incision is subsequently repeated automatically.
Legend
[0000]
1 Ophthalmological laser system
2 Cornea
2 . 1 Anterior boundary layer
2 . 2 Posterior boundary layer
3 Eye
4 Laser
5 Beam splitter
6 Scan optics
7 Scanner unit
8 Focusing optics
9 Optical phase retardation system
10 Deflection mirror
11 Confocal aperture diaphragm
12 Detector
13 Amplifier
14 Control unit
15 Attenuator
16 Modulator
17 Immobilization device
18 Image display
19 Push button
B Illumination beam path
D Detection beam path
P Scan point
L Planned lamella
Q Area with OBL
X Suggested area for repeated irradiation | An ophthalmological laser system and operating method wherein laser-supported operative interventions can be achieved with higher accuracy. The cornea is irradiated with an ophthalmological laser and a detection light confocally recorded, the cornea being scanned in three-dimensions by irradiation with an illuminating laser power using a scanner unit along several directions at several points. Using the simultaneously recorded detection light the position and/or shape of a posterior boundary surface of the cornea is determined. A lamella parallel to the posterior boundary surface can then be cut. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 61/775,875 filed on Mar. 11, 2013.
BACKGROUND
Commercial aircraft typically utilize a gas turbofan engine mounted under wing or in a tail structure. The gas turbine engine typically includes a fan section, and a core section including a compressor section, a combustor section and a turbine section all rotating about a common axis. Air entering the compressor section is compressed and delivered into the combustion section where it is mixed with fuel and ignited to generate a high-speed exhaust gas flow. The high-speed exhaust gas flow expands through the turbine section to drive the compressor and the fan section.
The fan section drives air through a bypass passage to develop a majority of thrust produced by the engine. Larger fan diameters increase engine efficiencies. Increased diameters require correspondingly large cases and nacelle structures that are currently mounted under an aircraft wing. Accommodations such as longer landing gear, cantilevered engine mounting structures and/or complex wing structures required due to the larger fan sections increase weight and counteract the engine efficiency gains.
Accordingly, engine and aircraft manufactures continue to seek further improvements to aircraft design to take advantage of advances in engine performance including improvements to thermal, transfer and propulsive efficiencies.
SUMMARY
A turbofan engine according to an exemplary embodiment of this disclosure, among other possible things includes a core engine section including a compressor section feeding air to a combustor to generate high speed exhaust gases that drive a turbine section all disposed about an engine axis, a geartrain driven by the core engine section, a fan section driven by the geartrain about a fan axis spaced apart from the engine axis, and an accessory gearbox driven by the geartrain and mounted apart from the core engine section and the fan section.
In a further embodiment of the foregoing turbofan engine, includes an input shaft driven by the core engine section and a first output shaft driven by the geartrain for driving the fan section. The input shaft and first output shaft rotate about different axes.
In a further embodiment of any of the foregoing turbofan engines, the input shaft extends axially forward of the core engine section.
In a further embodiment of any of the foregoing turbofan engines, includes a second output shaft driven by the geartrain driving the accessory gearbox.
In a further embodiment of any of the foregoing turbofan engines, the fan axis is spaced horizontally apart from the engine axis.
In a further embodiment of any of the foregoing turbofan engines, the fan axis and the engine axis are substantially parallel.
In a further embodiment of any of the foregoing turbofan engines, the fan section includes a bypass ratio greater than about 10.
An aircraft propulsion system according to an exemplary embodiment of this disclosure, among other possible things includes a core engine section mounted within an aft portion of an aircraft fuselage. The core engine section includes a compressor section feeding air to a combustor to generate high speed exhaust gases that drive a turbine section all disposed about an engine axis. A geartrain is mounted within the aircraft fuselage and driven by the core engine section. A fan section is externally mounted to the aircraft fuselage and driven by the geartrain about a fan axis spaced apart from the engine axis. An accessory gearbox is supported within the aircraft fuselage and driven by the geartrain and mounted apart from the core engine section and the fan section.
In a further embodiment of the foregoing aircraft propulsion system, includes an inlet for supplying air to the core engine section mounted to the aircraft fuselage.
In a further embodiment of any of the foregoing aircraft propulsion systems, includes a fan case surrounding the fan section. The fan case includes a first thrust reverser movable to a position directing thrust from the fan section in a direction to slow the aircraft.
In a further embodiment of any of the foregoing aircraft propulsion systems, includes an exhaust nozzle disposed about the engine axis. The exhaust nozzle includes a second thrust reverser for directing exhaust gases from the core engine section in a direction to slow the aircraft.
In a further embodiment of any of the foregoing aircraft propulsion systems, includes an input shaft driven by the core engine section for driving the geartrain, a first output shaft from the geartrain driving the fan section, and a second output shaft from the geartrain driving the accessory gearbox.
In a further embodiment of any of the foregoing aircraft propulsion systems, the fan axis is parallel to the engine axis.
In a further embodiment of any of the foregoing aircraft propulsion systems, the core engine section includes a first core engine section and a second core engine section mounted side-by-side within the aft portion of the aircraft fuselage and the fan section includes first and second fan sections driven by a corresponding one of the first and second core engine sections.
In a further embodiment of any of the foregoing aircraft propulsion systems, geartrain includes first and second geartrains and the accessory gearbox includes first and second accessory gearboxes driven by a corresponding one of the first and second geartrains.
An aircraft system according to an exemplary embodiment of this disclosure, among other possible things includes an elongated fuselage. A wing structure extends from opposing sides of the fuselage. A vertical stabilizer includes a horizontal stabilizer surface mounted to an upper portion of the vertical stabilizer. A core engine section is mounted within an aft portion of an aircraft fuselage. The core section includes a compressor section feeding air to a combustor to generate high speed exhaust gases that drive a turbine section all disposed about an engine axis. A geartrain is mounted within the aircraft fuselage and driven by the core section. A fan section is externally mounted to the aircraft fuselage and driven by the geartrain about a fan axis spaced apart from the engine axis. An accessory gearbox is supported within the aircraft fuselage and driven by the geartrain and mounted apart from the core section and the fan section.
In a further embodiment of the foregoing aircraft system, the core section includes first and second core sections and the fan section includes first and second fan sections driven by corresponding ones of the first and second core engine sections.
In a further embodiment of any of the foregoing aircraft systems, includes an air inlet supplying air to each of the first and second core engine sections.
In a further embodiment of any of the foregoing aircraft systems, the fan section is mounted above the wing structure.
In a further embodiment of any of the foregoing aircraft systems, the fan section includes a bypass ratio greater than about 10.
Although the different examples have the specific components shown in the illustrations, embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.
These and other features disclosed herein can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an example aircraft including ultra-high bypass turbofan engines.
FIG. 2 is an aft perspective view of the example aircraft and propulsion system.
FIG. 3 is an enlarged view of a portion of the example propulsion system.
FIG. 4 is a side view of the aft portion of the aircraft including the example propulsion system.
FIG. 5 is an aft view of the example propulsion system.
FIG. 6 is another perspective view of the example propulsion system.
FIG. 7 is an example view of a thrust reverser of the example propulsion system.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , an example aircraft 10 is shown that includes wings 14 that extend from a fuselage 12 . The aircraft 10 includes landing gear 16 are provided on each of the wings 14 and at a front of the fuselage 12 . The example aircraft 10 includes a T-tail 18 . The T-tail 18 includes a vertical stabilizer 20 and a horizontal stabilizer 22 disposed at an upper end of the vertical stabilizer 20 .
The fuselage 12 includes an aft portion 24 that supports a propulsion system 25 . The example propulsion system 25 includes core engine sections 26 a , 26 b that drive corresponding fan sections 28 a and 28 b . The core engine sections 26 a and 26 b are disposed about respective axes A that are spaced apart from respective axes B of the fan sections 28 a and 28 b . An inlet 30 defined within the fuselage 12 provides airflow to feed the core engine sections 26 a and 26 b.
Referring to FIGS. 2 and 3 with continued reference to FIG. 1 , the example propulsion system 25 includes two core engine sections 26 a and 26 b that are mounted side-by-side at the aft portion 24 of the fuselage 12 . Each of the core engine sections 26 a , 26 b include a compressor section 48 , a combustor section 50 and a turbine section 52 disposed about respective axes A. An auxiliary power unit 34 is also mounted in the aft portion 14 of the fuselage 12 .
As appreciated each of the core engine sections 26 a and 26 b include similar structure for powering respective fan sections 28 a and 28 b . One of the example core engine sections 26 a is described with the understanding that identical structure (not shown) is duplicated for the core engine section 26 b.
The core engine section 26 a drives an input shaft 42 that in turn drives a geartrain 38 . The geartrain 38 includes a first output shaft 44 that drives the corresponding fan section 28 a . The fan section 28 a includes a plurality of fan blades disposed within corresponding fan cases 32 a that rotate about the axis B. The axis B is spaced apart and parallel to the axis A of the core engine section 26 a.
The geartrain 38 also includes a second output shaft 46 that drives an accessory gearbox 36 . The accessory gearbox 36 drives systems required to support operation of the corresponding core engine 26 a along with systems utilized for aircraft operation. Moreover, although the disclosed embodiment includes an accessory gearbox 36 for each core engine 26 a , 26 b , it is within the contemplation of this disclosure that a single accessory gearbox 36 could be utilized for both core engine sections 26 a , 26 b.
Referring to FIGS. 4, 5 and 6 , the example fan sections 28 a and 28 b are mounted to a side of the fuselage 12 and above the wings 14 . Gas turbine engines that are mounted below the wing 14 are limited as to the size of the fan due to restrictions and minimum clearance requirements for the aircraft 10 . Large fan sections that are mounted under the wing 14 require longer aircraft landing gear 16 that in turn add weight that can eliminate or reduce the effectiveness and efficiencies provided by the larger fan sections 28 a and 28 b.
In this example, the aircraft 10 includes the fan sections 28 a and 28 b that are mounted to the aft portion 24 of the fuselage 12 in a position above the wing 14 and therefore can provide ultra-high bypass ratios greater than about 10. Moreover, by separating the core engine sections 26 a , 26 b from the fan sections 28 a , 28 b , the mounting structures supporting the fan sections 28 a and 28 b can be lighter to further increase engine efficiency.
The T-tail section 18 includes the vertical stabilizer 20 and the horizontal stabilizer 22 . The horizontal stabilizer 22 is mounted substantially on an upper tip of the vertical stabilizer 20 such that airflow over the control surfaces of the horizontal stabilizer 22 is not detrimentally affected by airflow output from the fan sections 28 a and 28 b.
Referring to FIG. 7 , the example propulsion system 25 includes thrust reversing features. In this example, both the fan sections 28 a and 28 b include a thrust reverser 56 a , 56 b along with thrust reverser 58 mounted to the core engine sections 26 a and 26 b . In operation, the fan sections 28 a and 28 b both include the corresponding thrust reversers 56 a , 56 b that include doors that open radially outward to direct thrust outwardly to slow the aircraft 10 .
The propulsion system 25 also includes thrust reversing doors on a nozzle 40 corresponding to the core engines 26 a and 26 b . The thrust reversing portion 58 includes doors that close along a center line of each of the core engines 26 a and 26 b . Thrust generated by the core engines 26 a and 26 b is thereby directed in a manner to slow the aircraft once it has landed.
The aft fuselage mounting of the core engine sections 26 a and 26 b eliminates requirements for heavier and more robust engine mounting structures that would be required for traditional wing and fuselage mounted turbofan engines. Moreover, the coupling of the core engine sections 26 a and 26 b from the corresponding fan sections 28 a and 28 b allows for a more efficient and smaller fan support structures. Furthermore, a fuselage mounting of the fan sections 28 a and 28 b along with the core engine sections 26 a and 26 b does not require extending or raising the aircraft 10 by providing longer landing gear structures.
Accordingly, the example aircraft and propulsion system disclosed for the example aircraft provides for the use of an ultra-high bypass fan section in commercial aircraft without limit to the fan diameter or without the requirement for heavy mounting structures to support core engine and fan components.
Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the scope and content of this disclosure. | A turbofan engine includes a core engine section including a compressor section feeding air to a combustor to generate high speed exhaust gases that drive a turbine section all disposed about an engine axis, a geartrain driven by the core engine section, a fan section driven by the geartrain about a fan axis spaced apart from the engine axis, and an accessory gearbox driven by the geartrain and mounted apart from the core engine section and the fan section. | 5 |
BACKGROUND OF THE INVENTION
This invention relates generally to hot tub or spa water treatment, and more particularly to time related control of such treatment.
Prior spa controls operate to circulate water, to heat water and to filter the water. A spa user manually activates the spa control or controls, turning it on for use and then turning it off.
Spas typically operate thermostatically, in the sense that the temperature is “set” and the spa operates to maintain that temperature. The spa user can “set” a filter cycle i.e. pre-programmed times or times when the spa will operate in order to filter the water. This allows the water to be circulated and run through the equipment's filtration apparatus, so that the water is filtered or “turned over”, meaning that all water is run through the filter. This helps to keep the water clean, prevents algae formation and circulates whatever sanitizer is being employed, to kill bacteria in the tub.
At the present time, all three of these functions operate independently of each other. The spa runs to maintain temperature, the spa owner can use the spa as he pleases, and the filter cycles turn on automatically at their pre-programmed or pre-set times. If the spa or tub should run for 1 hour a day to keep the water clean, the filter cycles are set for one hour per day in order to keep the water clean and clear. Dependent on the outside ambient temperature, the spa could satisfactorily operate for no time in the hot summer, or for 24 hours a day in the winter, to maintain temperature. The filter operates during such heating cycles, because the filter is connected to the main pump and heater.
There is need to provide for more efficient spa or tub operation, for example to reduce consumption of power needed to operate pumps, and without compromising efficient water filtering or sanitizing, or water heating.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide apparatus and methods of operation which will meet the above, as well as other needs, as will appear. Basically, the invention concerns a novel combination of steps of operation, employing timed control of spa water pumping, water filtering and/or water sanitizing.
The invention recognizes and concerns, for example, the following type situation:
If the spa only needs to run for 1 hour to keep the water clean and filtered, any operation over the 1 hour is not necessary to keep the water clean. If a tub runs for 2 hours to maintain the water set temperature, certain pre-set or pre-programmed filter cycles are not necessary, and are a waste of energy. The present invention enables a comparison of the total run time of the spa in between filter cycles with a selected parameter such as a desired filter cycle. If, in a 12 hour period between filter cycles, the tub does not run for a heat call, the filter cycle will run as it should. If the tub runs in order to maintain heat, the amount of time the tub has run is compared to the desired filter cycle, and a portion of the filter cycle is eliminated if sufficient filtering has occurred during heating. Accordingly, the tub operation will not waste energy to filter and clean the water, if the spa already has run for enough time to keep the water clean. These concepts are applicable to an enclosed body of water that is filtered and either heated, sanitized, run for therapy or display, with the filtration equipment connected to the pump being run. Examples are spas, hot tubs, pools, ponds, fountains, etc.
The program that determines the required filtration time of the tub varies with the size of the tub, usage, number of jets, size of filter, sanitizer being used, etc. and can be set or selected as by trial and error or calculated by comparison methods, knowing the desired objectives. Additionally, whether the filter cycle is completely turned off or calculated to the actual difference in time between the programmed filter time and the actual amount of time the tub ran (i.e. 60 minutes desired filter cycle−45 minutes heating=15 minutes left) is of lesser consequence. The concepts of comparing and contrasting these operations or actions in order to increase energy efficiency, reduce unnecessary wear on equipment, extend the life of the filter and seal, and numerous other benefits are of importance to the invention.
Accordingly, it is a major object of the invention to provide a method of controlling the operation of a spa water treating system, where such treating is selected from the group:
i) water filtration
ii) water sanitizing
iii) water heating
and that includes the steps
a) determining a desired water treating time interval as a function of timing of spa water prior treating interval, or usage,
b) and treating the spa water for that determined time interval.
Such treating may comprise water filtration, sanitizing, or heating, or combinations of these. Also, the timing of spa water prior treating interval is the time duration of such treating.
Yet another object is to provide a method of reducing pump water energy requirement, in a spa water circulation system, wherein the water pump is programmed to operate during timewise spaced cyclic intervals A 1 and A 2 to effect water filtration by a filter during such intervals, and wherein a water heater is operable for a time interval B to heat the water being circulated and filtered and in response to a drop in spa water temperature, the steps that include
a) determining said intervals A 1 , A 2 , and B 1 and
b) reducing or eliminating said cyclic interval A 2 as a function of duration of said time interval B.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a schematic diagram showing a spa water control system;
FIG. 1 a is a control system diagram;
FIG. 2 is a circuit diagram;
FIG. 3 is a circuit diagram;
FIG. 4 a is a time cycle example description;
FIG. 4 b is a view of the lower portion of the apparatus, and
FIG. 5 is a timing sheet summary.
DETAILED DESCRIPTION
FIG. 1 schematically shows a hot tub or spa 10 containing water 11 to be treated. Treatment may typically include heating (as by a heater 11 ′); filtering (as by filter 12 through which water flows); and sanitizing (as by use of dispenser 13 for sanitizing chemicals, as for example chlorine to be added to the water flowing to or from the spa 10 . A motor driven water pump 14 operates to withdraw water at 14 a from the spa, and return it to the spa at 14 b . A control unit 15 is operatively connected at 15 a , 15 b and 15 c , to the pump water 14 a to turn the water ON and OFF and thereby control circulation, to the heater 11 to turn the heater ON and OFF in accordance with changes in sensed temperature of the water flowing to the pump; and to the chemical dispenser 13 to control a sanitizer (i.e. to dispense sanitizer at 13 a into the water flow, periodically). See also FIG. 1 a , showing a water temperature sensor 16 providing a heating control signal at 16 a to controller 15 .
Definition of water and controllable components are as follows:
A chemical sanitizer is defined as a chemical that has the ability to destroy or control the formation of contaminants. Typical of these are chlorine, bromine, biguanide, ozone, hydrogen peroxide and iodine.
A filter is defined as a device used to remove particulate from water by several means, including but not limited to pressure, vacuum, evaporation, or osmosis. Typical of these are fine mesh of varying materials and construction, sand particles, plastic particles, chemical particles, charcoal particles, reefing systems, coagulants, skimmers or vacuums.
A filtration system is defined as a device that incorporates a filter.
Additional water treating components that can be used are defined as follows:
An ozonator is a sanitizing system that creates ozone. Typical of these are an Ultra-Violet (UV) bulb, microchip or corona discharge (CD) chamber that produces varying amounts of ozone.
An ionizer is a sanitizing system that adds, either electrically or chemically, ions or halogens to the water via chemical or electrical reactions. Typical of these are electrolytic plates, copper and silver plates, stainless steel balls or plates and charcoal grids.
A predetermined or initially computed time for the cyclic operation of a filtration or sanitation system as at predetermined intervals is input at 17 into the control. The control then stores this information for reference and use. The system as at 17 a is initially activated when power is introduced to the system. A default setting, input by the manufacturer, will be the operational condition unless superceded by manual input or internal computation.
There are several means by which a filtration or sanitation system will operate during time periods when the spa, hot tub or pool is not being used. During such timewise spaced periods of operation, the filtration or sanitation system is operating, not as or for it's primary purpose, but as a secondary operation, concurrent to another programmed, automatic or required function. Typical of these are thermostatic controls, solar powered operation, circulation systems, automated vacuums, automatic leveling devices or spa covering devices.
Upon completion of a predetermined time period, the control compares the total run time of all systems that either directly or indirectly control or operate the filtration or sanitation system. The aforementioned predetermined time limit of cyclic filtering is initially input by the manufacturer, unless superceded by manual input or internal computation.
If the time limit of filtering (during pump operation as for example two fifteen minute periods of filtering over a 24 hour period), is met or exceeded, (as for example by additional filtering during operation of water heating equipment) the next set filtration or sanitation cycle is bypassed for that next time period, and a new comparison interval is initiated.
If the time limit is not met, the system will either operate for the entire pre-set time period, or for the remaining time difference between the two, or for a computed percentage of the original value. This is based on the application, usage, versatility of the control being employed or a number of other factors or constraints.
The control system can be utilized on newly designed or pre-existing apparatus. Various methods for sensing or measuring operation of the filtration or sanitation system can be employed. Likewise, the methods of connection to and means of controlling such systems can vary upon design and material construction and usage. However, none of the aforementioned connections, or sensing or operating constraints limit the scope of the described system or its accompanying design, description or applicable logical control.
EXAMPLE
Referring to FIG. 5, it shows timewise spaced cyclic intervals A 1 , A 2 , A 3 -A n of water filtration, during which the spa water pump 14 is operating to circulate water in or through the hot tub or spa 10 . Such intervals are typically set. Typically, the circulating water passes in heating relation with the water heater 11 ; and, when the heater is ON, the flowing water is heated. The water is turned ON or OFF by control circuitry 15 which responds to the spa water temperature sensor 16 , as in thermostatic relation, to keep the water in the spa within acceptable temperature limits. A water filter 12 also operates to filter the water as it circulates (see path 14 a in FIG. 1 ).
The water pump is typically programmed to operate during timewise spaced or set cyclic intervals, shown for example at A 1 , A 2 -A n , which are equally spaced apart in time. The time spacing of such intervals is indicated by t 1 , which may for example be 12 hours. Thus, filtration occurs during equal time intervals A 1 , A 2 -A n . which may be between 5 and 30 minutes long, for example.
The circulating water heater 11 is or may for example, be operable during time intervals B to heat the water being circulated and filtered, and in response to a drop in water temperature, as referred to above, heating ending when sensed water temperature has increased to threshold level. B may occur timewise simultaneously, in whole or in part, with one or more of A 1 , A 2 -A n , and may have different time durations, dependent upon water heating requirements, as determined by weather, tub usage, etc.
The invention contemplates that if B occurs at a time t 2 , as indicated, it means that the pool water is being circulated at that time, which in turn means that water filtration is also occurring at that time. If the duration t 3 of B is greater than the duration t 4 of a subsequent set filtering cycle, say A 2 , then this means that the water has already been filtered, during B, by an amount in excess of filtration that would occur in A 2 , so that when the time arrives for A 2 to start, there is no need for A 2 . This then contemplates the steps:
a) determining said intervals A, A 2 and B, and
b) reducing or eliminating said cyclic interval A 2 , as a function of duration of said time interval B.
Therefore, the circuitry in software control 15 provides for A 1 , B, and controls the pump to eliminate A 2 (i.e. not operate to circulate water) if B is sufficiently long in duration (i.e. t 3 >t 4 ) or, if B is less than A 2 in duration, (i.e. t 3 <t 4 ) the duration of A 2 is controllably reduced (i.e. the pump motor is deactivated) by or for the time duration of B, for example, i.e. the pump operates during the shortened interval (t 4 −t 3 ) Therefore, since the pump motor operation is reduced, electrical energy is saved.
The same mode of operation occurs for water treatment such as sanitizing, such treatment typically occurs cyclically, during filtration cycles as at A 1 , A 2 -A n . Therefore, need for sanitizing is reduced as A 2 is reduced, as a function of heater operation B.
FIG. 2 shows a comparator 40 for comparing t 3 and t 4 where t 3 is determined by needed water heating as determined by water temperature sensing at 16 .
FIG. 3 is an overall control circuit 40 a having input and output, as shown. | A method of controlling the operation of a spa water treating system, where such treating is selected from the group:
iv) water filtration
v) water sanitizing
vi) water heating
and that includes the steps:
a) determining a desired water treating time interval as a function of timing of spa water prior treating interval, or usage,
b) and treating the spa water as a function of said determined time interval. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to a slide hammer used with a tire spoon. More particularly, the present invention relates to a slide hammer capable of being altered by the addition of additional weights where the slide hammer may also be used on a tire spoon.
BACKGROUND OF THE INVENTION
[0002] Slide hammers are tools that include a weight that is attached to a shaft and can be slid up and down the shaft. Usually at at least one location along the shaft, there is a stop that the slide hammer is rammed against to stop the slide hammer and thereby exert a force on the tool.
[0003] For various applications it may be desirable to use various levels or degrees of force with the slide hammer. Changing the level of force exerted by the slide hammer can be done by increasing or decreasing the velocity at which the slide hammer hits the stop. However, in some applications it may be desirable to equip a slide hammer to be able to impart a much larger force against the stop that can normally be done with conventional slide hammers. Slide hammers are sometimes limited in the force that can exert against a stop by several factors. These factors may include the length the shaft in which the slide hammer is able to slide and the weight of the slide hammer.
[0004] Furthermore, in some instances, it may be desirable to have a slide hammer that can exert force in two directions. This may be accomplished by a tool that has two stops so that the slide hammer can be slid in one direction and then encounter to stop. The slid hammer can also be slid in the other direction along the shaft where it encounters a second stop and thereby allowing the slide hammer to exert forces on tools at either end of the tool depending upon which stop the slide hammer rams into.
[0005] In situations where slide hammers are able to exert forces in multiple directions the tools often need to be manufactured with the slide hammer in place before the stops are located on the tools. Otherwise, if the stops are placed on the shaft before the slide hammer has been mounted and placed, there is no way the slide hammer may be mounted on the tool using conventional slide hammer technology.
[0006] Accordingly, it is desirable to provide a method and apparatus that may allow a slide hammer to be altered so that it can impart different levels of force and activate it. Further, it may also be desirable to provide a slide hammer that may be constructed in such a manner, that the slide hammer may be mounted on the shaft of the tool after stops or other tool features have been manufactured on tool.
SUMMARY OF THE INVENTION
[0007] The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus is provided that in some embodiments permits the slide hammer to be modified so that the slide hammer may impart various levels of force when activated.
[0008] In some embodiments of the invention, the slide hammer may be constructed in such a manner that the hammer portion may be mounted on the shaft after other shaft features such as a stop or other features have been manufactured into the tool containing the shaft.
[0009] In accordance with one embodiment of the present invention, a slide hammer may be provided. The slide hammer may include: a body defining a through hole and a first attaching surface; an auxiliary weight having a second attaching surface configured to attach to the body at the first attaching surface, the auxiliary weight having a through hole located to align with the through hole in the body when the auxiliary weight is attached to the body; and a shaft located in the through holes in the body and auxiliary weight.
[0010] In accordance with another embodiment of the present invention, a method of constructing a slide hammer is provided. The method may include: forming a body having a through hole and a first attaching surface; providing an auxiliary weight having a second attaching surface configured to attach to the body at the first attaching surface, the auxiliary weight having a through hole located to align with the through hole in the body when the auxiliary weight is attached to the body; and inserting a shaft in the through holes in the body and auxiliary weight.
[0011] In accordance with yet another embodiment of the present invention a slide hammer may be provided. The slide hammer may include: means for hammering defining a through hole and a first attaching surface; an auxiliary weight having a second attaching surface configured to attach to the means for hammering at the first attaching surface, the auxiliary weight having a through hole located to align with the through hole in the body when the auxiliary weight is attached to the means for hammering; and a shaft located in the through holes in the means for hammering and auxiliary weight.
[0012] There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
[0013] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
[0014] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an exploded, perspective view of a side hammer in accordance with an embodiment of the invention.
[0016] FIG. 2 is a perspective view of a tire spoon having a slide hammer mounted on it in accordance with an embodiment of the invention.
[0017] FIG. 3 is a partial cross-sectional view of the slide hammer in accordance with an embodiment of the invention.
[0018] FIG. 4 is an exploded, respective view of the slide hammer in accordance with an embodiment of the invention.
[0019] FIG. 5 is a cross-sectional view of a slide hammer in accordance with an embodiment of the invention.
[0020] FIG. 6 is a cross-sectional view of a slide hammer in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0021] The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides a slide hammer that is fit upon a tire spoon. An embodiment in accordance with the invention is shown as an exploded, perspective view in FIG. 1 .
[0022] FIG. 1 shows a slide hammer assembly 10 . The slide hammer assembly 10 includes a hammer body 12 . The hammer body 12 may be comprised of two halves 14 and 16 that fit together in a clam shell type manner. The hammer body 12 may be made of steel or other suitable substance for use as a slide hammer. The two halves 14 and 16 define a through hole 18 that extends through the hammer body 12 .
[0023] As shown in FIG. 1 , some embodiments may include a chamfered edge 20 located at the through hole 18 . The chamfered edge 20 may be present at both ends of the body 12 . The hammer body 12 may be equipped with exterior threads 22 . Exterior threads 22 are configured to secure additional or auxiliary weights 24 to the hammer body 12 . The exterior threads 22 are located on both halves 14 and 16 . The additional weight 24 has a through hole 26 that aligns with the through hole 18 and the hammer body 12 when the additional weight 24 is attached with its interior threads 28 to the exterior threads 22 of the hammer body 12 .
[0024] In some embodiments of the invention, the internal weights 24 may provide several functions. For example, the additional weights 24 may be used to keep the two halves 14 and 16 of the clam shell body 12 together. When the extra weights 24 are secured to the hammer body 12 , the halves 14 and 16 are connected and unable to separate. The auxiliary weights 24 also provide the advantage of adding additional weight to the body 12 of the slide hammer. Adding or not adding the additional weight allows a user to modify and select a weight of the slide hammer.
[0025] In some embodiments of the invention, at least one additional weight 24 is needed to secure the two halves 14 and 16 over hammer body together at 12 . However, additional weights 24 can be added to make the mass of hammer body 12 greater in order to increase the force that the slide hammer 12 can impart on to a stop 34 (see FIG. 2 ) when the slide hammer 12 is activated. Not all embodiments in accordance of the invention require that the hammer body 12 be in two halves 14 and 16 . In some embodiments, the hammer body 12 may be a solid piece with a through hole 18 . In such embodiments, the exterior weights 24 primarily provide the function of adding weight to hammer body 12 .
[0026] In some embodiments of the invention, various different weights 24 can be used in order to bring the hammer body 12 to a desired weight in order to impart a desired force when side hammer 12 is activated. In some embodiments of the invention, the exterior weights 24 can be steel or may be made of other substances. Not all embodiments require that the exterior weights 24 be of the same material as the hammer body 12 .
[0027] Turning to FIG. 2 , a slide hammer assembly 10 is shown mounted onto a tire spoon 30 . The tire spoon 30 includes a shaft 32 upon which the slide hammer assembly 10 may slide between stops 34 . The stops 34 are robust and connected to the tire spoon 30 so that the slide hammer assembly 10 can strike the stops 34 without dislodging stops 34 thereby causing force of the blow of the hammer assembly 10 to be transferred to the tire spoon 30 . In embodiments of the invention where the hammer body 12 is made up of two halves 14 and 16 as shown in FIG. 1 , advantages may be achieved in that the slide hammer assembly 10 can be mounted to the shaft 32 after the tool of which the shaft 32 is a part of may be manufactured. For example, in the case of tire spoon 30 as shown in FIG. 2 , the tire spoon 30 may have the spoons 36 and the stops 34 manufactured on the tire spoon 30 without having the slide hammer assembly 10 being required to be placed on the shaft before the spoons 36 and stops 34 are formed. The two halves 14 and 16 may be mounted to the shaft 32 after the stops 34 and spoons 36 are formed.
[0028] In some embodiments of the invention (with reference to FIGS. 1 and 2 ), the through holes 26 on the additional weights 24 may be sized large enough to fit over the features the tool such as the tire spoon 36 and/or stops 34 . Therefore the tire spoon 30 may be manufactured with the stop 34 and the tire spoon 36 without the additional weights 24 located on the shaft 32 . The additional weights 24 may be mounted to hammer body 12 later. The through hole 26 of the additional weight 24 is sized and dimensioned so the additional weight 24 will fit over the tire spoon 36 , the stop 34 and be secured to the hammer body 12 via the exterior threads 22 interacting with the interior threads 28 . If it is a desired to use additional weights 24 of additional size or weight, they may be added or removed as required and fit over the stop 34 and tire spoon 36 . As such, additional weights 24 may be available as an after market items and may or may not be manufactured or sold with the tire spoon 30 .
[0029] In some embodiments of the invention, the slide hammer assembly 10 may include a lock mechanism 38 . The lock mechanism 38 may be activated in several different ways, for example, as shown in FIG. 2 , the lock mechanism 38 may include a detent button 40 .
[0030] FIG. 3 is a partial cross-sectional of a slide hammer assembly 10 where the lock mechanism 38 includes a detent button 40 . The detent button 40 is mounted to a rocking lever 42 which pivots over a pivot point 44 . The rocking lever 42 is biased by a spring 36 which biases a engaging member 48 against the shaft 32 . The force of the spring 36 is selected such that the engaging member 48 generates sufficient friction against the shaft 32 that the slide hammer assembly 10 does not move with respect to the shaft 32 unless the detent 40 is depressed. In other embodiments, the engaging member 48 may more positively lock with the shaft 32 for example, by fitting into a detent in the shaft 32 .
[0031] Depressing the detent button 40 pivots the locking lever 42 , compresses the spring 46 and causes the engaging member 48 to disengage from the shaft 32 , thereby allowing a user to operate the slide hammer assembly 10 . When it is no longer desired to operate the slide hammer assembly 10 , the user releases the detent button 40 , thereby locking the slide hammer assembly 10 in place on the shaft 32 . Such a feature may be useful when it is not desired for the slide hammer assembly 10 to move about the shaft 34 when the tool such as a tire spoon 30 is being manipulated and the use of the slide hammer assembly 10 is not desired.
[0032] Another locking mechanism 38 is illustrated in FIGS. 4-6 . In FIGS. 4-6 a slide hammer assembly 10 is shown with a locking mechanism 38 that is activated by twisting the hammer body 12 . In the embodiment shown in FIG. 4 , the hammer body 12 is made up a fore 50 and aft 52 half. The fore 50 and aft half 52 may attach to each other by exterior threads 54 mating with interior threads 56 as shown. Other attaching methods may also be used in accordance with the invention. Attaching the fore 50 and aft 52 halves together traps a lock collet 58 between them. The lock collet 58 is generally C-shaped. The lock collet 58 is a unclosed ring as shown in FIG. 4 and may include locking member 60 which have a greater thickness in axial length than the remainder of the lock collet 58 as shown.
[0033] FIG. 5 is a cross-sectional view of a hammer body 12 including the locking mechanism 38 and a lock collet 58 . The lock collet 58 is located in an off center trench 62 . The off center trench 62 may be circular as shown but is located off center from the through hole 18 in a hammer body 12 . Locating the trench 62 off center results in the trench forming a shallow side 64 and a deeper side 66 with respect to the through hole 18 .
[0034] In FIG. 5 , the shaft 32 is shown extending through the lock collet 58 . The thick part 68 of the lock collet 58 (also referred to as the locking member 60 ) is located in the deep part 66 of the off center trench 62 . The thin part 70 of the lock collet 58 is located in the shallow side 64 of the off center trench 62 . This results in minimal friction or interference between the lock collet 58 and the shaft 32 . When it is desired to lock the hammer body 12 onto the shaft 32 , the user rotates the hammer body 12 to a locking position as shown in FIG. 6 .
[0035] In FIG. 6 , the hammer body 12 has been rotated on the shaft 32 . This rotation has caused the thick part of 68 (one side of the thick part 68 is now compressed and identified in FIG. 6 as reference character 72 ) of the lock collet 58 to move to a more narrow or shallow side 64 of the trench 62 . Moving the lock collet 58 in this manner has caused the lock collet 58 to compress between the shaft 32 and hammer body 12 . In some embodiments the lock collet 58 may be made of nylon or any other suitable substance.
[0036] The amount of compression that the thick part 72 of the lock collet 58 or the locking member 60 is the reduction of the diameter of the off center trench 62 . As shown in FIG. 6 , part of the lock collet 58 is a compressed portion 72 . The difference between the compressed portion 72 and the thick part 68 illustrates the reduction in a diameter of the off center trench 62 with respect to the shaft 32 . The compression of the lock collet 58 results in friction and/or interference between the lock collet 58 and the shaft 32 thereby locking the hammer body 12 onto the shaft 32 . When it is desired to unlock the hammer body 12 with respect to the shaft 32 , the user may twist the hammer body 12 back to the position shown in FIG. 5 which allows the locking member 60 or thick part 68 of the lock collet 70 to reside in the deep part 66 of the off center trench 62 and the thin part 70 of the lock collet 58 to reside in the shallow side 64 of the off center trench 62 as shown in FIG. 5 .
[0037] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A slide hammer may be provided. The slide hammer may include: a body defining a through hole and a first attaching surface; an auxiliary weight having a second attaching surface configured to attach to the body at the first attaching surface, the auxiliary weight having a through hole located to align with the through hole in the body when the auxiliary weight is attached to the body; and a shaft located in the through holes in the body and auxiliary weight. A method of constructing a slide hammer is provided. | 1 |
BACKGROUND OF THE INVENTION
Electronic information services, such as for example what are called online information services, interactive video services, etc., are rapidly increasing in importance. The users of services of this sort have an interest in the observance of their rights of data protection, in particular their anonymity in relation to the operators of such information services. The protection of these user interests is very important, particularly in the area of electronic information services, since here there is an increased risk of abuse of user data due to particular technological possibilities.
To simplify the presentation of the present invention, the following discussion is mostly limited to interactive video services in broadband networks, although it is known without further teachings to one skilled in the art that the present invention can be used analogously in connection with arbitrary electronic information services and arbitrary communication networks.
Access to interactive video services is enabled for a subscriber by means of what is called a set-top box (STB), i.e. a communication terminal apparatus, arranged between the network terminal and the television apparatus. The set-top box (STB) (generally, the communication terminal apparatus) creates a connection to storage units for video information (what is known as a video server, generally, information server) via a broadband data transmission network (generally, a communication network), and controls the selection and reproduction thereof, dependent on inputs from the subscriber (user).
The retrieval of video and multimedia information from the video servers is subject to a fee in most cases, whereby a broad offering of private operators of such apparatus becomes possible. For this reason, these costs to the user of the services must be taken into account. The importance of the protection of data and of personal rights is also to be taken into account.
In the existing testing grounds for interactive video services, as well as in the previously available software for video servers, the identity of a user is checked at the video server. For this purpose the following data must be known to the video server: name, address or bank affiliation, secret number or password. By this means the operator of the video service can in principle associate the name of the user with his consumption behavior (e.g., films requested or film categories; frequency of use). Protection against the abuse of such information, e.g. for advertising purposes, can ensue exclusively via contractual regulations, but not through technological means.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for guaranteeing the anonymity of users of electronic information services.
In general terms the present invention is a method for using electronic information services with guarantee of anonymity of users in relation to the operators of such services. A connection is produced between a communication terminal apparatus of the user and an information server via a communication network. A connection is produced between a communication terminal apparatus of the user and an authorization server via a communication network. Identification information is transmitted to the authorization server by the communication terminal apparatus of the user. User authorization information is transmitted to a communication server, which information contains no information concerning the identity of the user. This use authorization information is transmitted to the information server by a communication terminal apparatus of the user, whereupon this server checks the validity of the user authorization information and, if the result of the check is positive, permits the user to use the information service.
Advantageous developments of the present invention are as follows.
The use authorization information consists of a transaction data word or a sequence o f transaction data words. These transaction data words can be used respectively only once for proof of the use authorization, and lose their validity after this unique use. A transaction data word corresponds to a determined monetary value or to a determinate use time unit.
A transaction data word gives authorization for the use of a particular offering.
The connection between the communication terminal apparatus of the user and the information server is formed such that the identity of the user remains concealed from the information server.
The validity of the use authorization information is limited in time.
The information server transmits billing information concerning used use authorization information to the authorization server, whereby such billing information contain no information concerning the type of use.
In this method, connections are created between at least one communication terminal apparatus of the user, an information server and an authorization server (AR) via a communication network (CN). Identification information is transmitted to the authorization server (AR) by a communication terminal apparatus of the user. Use authorization information is thereupon transmitted to a communication terminal apparatus of the user by the authorization server, which information contains no information concerning the identity of the user. This use authorization information is transmitted to the information server by a communication terminal apparatus of the user, whereupon this server checks the validity of the use authorization information, and, if the result of the check is positive, allows the use of the information service.
The present invention makes it possible to keep the identity of the user secret from the operator of the video service, but nonetheless allows a billing of fees in accordance with consumption. For this purpose, an authorization server is used that knows the identity of the customer, but has no information concerning the consumption behavior in the video service.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several Figures of which like reference numerals identify like elements, and in which:
FIG. 1 schematically shows a basic configuration of a communication terminal apparatus, an authorization server and an information server, such as forms the basis of a preferred embodiment of the invention;
FIG. 2 schematically shows the arrangement between communication terminal apparatus and servers of the basic configuration and its operators, as well as the contractual relations between these;
FIG. 3 schematically shows the sequence of the communication between the communication terminal apparatus and servers according to a preferred exemplary embodiment of the present invention;
FIG. 4 schematically shows the sequence of communication between authorization server and information server before a use of a service by the subscriber, and during the arrangement of use authorization information (e.g. transaction data words) between authorization server and information server; and
FIG. 5 schematically shows the sequence of the communication between authorization server and information server during an authorization callback during a use of a service.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the basic configuration. The user is connected with the overall system via the set-top box (STB). The set-top box (generally, the communication terminal apparatus) communicates both with the authorization server (AR) and with the information server via a data network (generally, a communication network). The manner in which these communication connections are set up is not pertinent for the present invention. However, a flexible connection setup, e.g. via switched connections, is desirable. In order to ensure the reliability of the authorization, an exchange of information between the information server and the authorization server is also necessary. As is explained more precisely below, for this purpose a one-sided flow of information from the information server to the authorization server is however sufficient. This takes place before the calling up of the actual video service and thus cannot contain any information concerning the use.
FIG. 2 shows the contractual relations that exist between the operators of the different network components. The STB is operated in this sense by the service user (end customer), the information server by a service provider (e.g. for video on demand) and the authorization server by a neutral switching and billing company, e.g. the network operator or a credit card organization.
The service user is known by name to the authorization server. For identification, the authorization server assigns a secret number (or uses comparable mechanisms known to one skilled in the art). In the following, an identification via a secret number (PIN=personal identification number) is assumed. However, the invention is not limited to this exemplary embodiment. No direct contractual relations exist between the service user and the service provider. The billing for the use of the service ensues only via the authorization server. The fees incurred for the service are reimbursed to the service provider by the operator of the authorization server. Likewise, a form of the identification is used between the authorization server and the service provider that is anonymous, i.e. allows no connection back to the name of the service user. In the following it is assumed that arbitrarily selected passwords are used for this anonymous identification.
FIG. 3 shows the course of communication between the components at the time at which the service is used, when e.g. a film is requested. Before the set-top box (STB) can connect itself with the information server, a selection process must have taken place among the accessible servers, e.g. by means of a computer specifically for service switching (sometimes called a "broker").
Before the information server can be addressed, a connection to the authorization server must first be set up (cAR). The service user identifies himself (uid) with his name and with the PIN agreed upon with the broker. A valid transaction data word (e.g. from a current table), or also several transaction data words, is thereupon transmitted to the set-top box (STB) (aut1). Transaction data words are standard in e.g. the German Datex-J telecom system (transaction numbers), e.g. for home banking applications. There, they can only be used once and incorrect input is limited to a few attempts. In connection with the present invention, one skilled in the art (with the help of the relevant literature, if warranted) can easily use other forms of a use authorization information without himself having to display inventive performance.
Subsequently, the connection to the information server can be set up (cVS), whereby the connection terminal number can remain hidden from the set-top box (STB) (CLIR=calling line identification restriction, supported in ISDN and B-ISDN). Before the execution of the actual service (sc), the authorization of the user is ensured in that the set-top box (STB) transmits the transaction data word (previously received from the authorization server) to the information server (aut2). The information server must now check the validity of the transaction data word and, dependent thereon, permit the user to use the service.
Of course, the above-depicted sequence depends on the knowledge of the allowable transaction data words by the information server. In the present invention, this is ensured in that the transaction data words are arbitrarily determined either by the information server or by the authorization server, and are matched via a communication between the information server and the authorization server. FIG. 4 shows a possible solution by means of an interaction that precedes the actual service use by a time interval, and can also be valid for several service uses. The video server thereby determines a basis for authorization (e.g. a table of arbitrarily chosen transaction data words) and communicates it to the authorization server (saut). Analogously, the initiative for the production of the transaction data words and the connection setup can also proceed from the authorization server. The solution shown in FIG. 4 is particularly secure against abuse, since the information server can still have no information about the future service use at the time when it establishes contact with the authorization server.
A further solution is indicated in FIG. 5. It is also possible that the video server does not establish contact with the authorization server until the need arises (i.e. given a service use/film request). In this case, the authorization server can arbitrarily select the transaction data word given to the set-top box (STB), and the communication between the video server and the authorization server is a pure callback (conf).
Different further variants of the method used above are also possible, including among others the following.
The billing for the service in accordance with consumption can be ensured in various ways. The anonymity of the user is most effectively protected when the assigned transaction data words are conceived as "vouchers" for a determined quantity of services. Alternatively, the video server can communicate to the authorization server the total sum of the consumed services for a transaction data word (without reference to details of use such as time of use, film category, etc.).
The function of an authorization server can be combined with the ensuring of a regulated access to interactive multimedia services, as required in some circumstances by the legal framework (e.g. "level 1 gateway" in the USA). For this purpose, the network operator may allow only service providers who operate according to the method described above, and must operate the authorization server himself. For this purpose, it is particularly advantageous to combine the authorization server with the selection function for a video server ("broker").
Transaction data words can be made valid only for a limited time by means of the indication of "expiration data," in order to further limit the possibility of misuse.
The invention enables the use of interactive video services with the guarantee of the anonymity of the service user in relation to the service provider. This enables the maintenance of data protection conditions (only usage-related, no personal data at the service provider). In addition, the invention can represent an important distinguishing feature in market competition between service providers, since the service users can be offered maximally extensive protection against problems due to abuse of data.
Finally, in a network with regulated access to interactive video services, the present invention enables the use of simple and standardized methods for connection setup (e.g. automatic calling), without harmful effect on the control of the network operator.
The invention is not limited to the particular details of the method depicted and other modifications and applications are contemplated. Certain other changes may be made in the above described method without departing from the true spirit and scope of the invention herein involved. It is intended, therefore, that the subject matter in the above depiction shall be interpreted as illustrative and not in a limiting sense. | Given a use-oriented billing of interactive video services, the method enables the guaranteeing of the anonymity of the service user in relation to the service operator. For this purpose, an authorization server is used that knows the identity of the customer but has no information concerning the consumption behavior in the video service. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to composite particles having high fluidity and liquid carrying properties, and keeping compactibility and fluidity of the particles even after retention of the liquid to prevent tableting problems.
BACKGROUND ART
[0002] Conventionally, in the fields of pharmaceuticals, foods, and other chemical industries, cellulose powder is widely used as an excipient for molding when a molded article containing an active ingredient is prepared. In addition, in the case where the active ingredient is a liquid ingredient, the liquid ingredient is carried by a single inorganic compound to obtain a powder. The obtained powder is molded into a molded article by using a cellulose powder as an excipient.
[0003] Unfortunately, the single inorganic compound has an excessively large apparent specific volume, which limits the amount of the active ingredient to be powdered at one time. There is also a handling problem such that the inorganic compound scatters, or the like. For this reason, use of cellulose-inorganic compound porous composite particles as the excipient has been examined.
[0004] Patent Literature 1 describes an invention of fine particles produced by co-processing a microcrystalline cellulose particle and calcium carbonate having a particle size less than 30 μm in a specific mass ratio in order to reduce cost of a pharmaceutical excipient.
[0005] Patent Literature 2 describes an invention of an excipient composition composed of a fine particle agglomerates including a microcrystalline cellulose and silicon dioxide as a pharmaceutical excipient having improved compressibility.
[0006] Patent Literature 3 describes an invention of cellulose inorganic compound porous composite particles which are an aggregate of a specific cellulose dispersed particle and a water-insoluble inorganic compound particle, and having an intraparticle pore volume of 0.260 cm 3 /g or more. According to Patent Literature 3, the cellulose and the inorganic compound are formed into composite particles to obtain a particle having a large intraparticle pore volume, and high compactibility, disintegration properties, and fluidity.
[0007] Patent Literature 4 describes an invention of a solid formulation which is not a composite product but a physical mixture of an inorganic compound and a microcrystalline cellulose, and comprises a drug, calcium silicate, and starch and/or microcrystalline cellulose, in which 10 to 45% by weight of calcium silicate is blended based on the drug, and 40 to 250% by weight of starch and/or microcrystalline cellulose is blended based on calcium silicate. According to the description, even if a drug having poor compactibility such as phenacetin and acetaminophen is directly tableted, 70 to 90 parts by weight of the drug can be blended without capping.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: U.S. Pat. No. 4,744,987
Patent Literature 2: JP 10-500426 A
Patent Literature 3: JP 2005-232260 A
Patent Literature 4: JP 3-52823 A
SUMMARY OF INVENTION
Technical Problem
[0012] Usually, a tablet is produced by tableting by filling a powder into a die and compressing the powder with a punch. In the case where the drug easily adheres to the punch, it causes a phenomenon called sticking such that the surface of the molded article is peeled off. Usually, a single inorganic compound is used as an excipient, but the single inorganic compound cannot always prevent the sticking. Moreover, because the single inorganic compound has a large apparent specific volume, flushing properties of the powder are increased in tableting to reduce filling properties into the die, leading to problems such as variation in the weight of the molded article and a phenomenon called capping: part of the molded article is peeled off. For this reason, a large amount of the inorganic compound cannot be added.
[0013] Cellulose powder is an excipient having high compactibility. Once the cellulose powder gets wet, however, the compactibility is reduced, the function as the excipient is no longer demonstrated. Moreover, compared to the inorganic compound, the cellulose powder has lower liquid retention. Moreover, the composite products of cellulose and an inorganic compound known in the related art have a low liquid retention rate, and low fluidity of the particle after retention of the liquid. In addition, problems such as sticking and capping cannot be sufficiently eliminated.
[0014] An object of the present invention is to provide composite particles having a high liquid retention rate and having high fluidity of the particles even after retention of a liquid. In addition, another object of the present invention is to provide composite particles that can be tableted with gravity feeder in a direct tableting method, hardly cause tableting problems, and have high compactibility. Further another object of the present invention is to provide a molded article in which the weight of the molded article and the content of an active ingredient are uniform, hardness is high, and friability is low when the composite particles and the active ingredient are formed into the molded article.
Solution to Problem
[0015] In order to solve the problems above, the present inventors have found out that if cellulose and an inorganic compound are formed into a composite product, the apparent specific volume, the pore volume, and the liquid retention rate can be increased, and compactibility and fluidity of the particles even after retention of a liquid can be increased. Thus, the present invention has been made.
[0016] Namely, the present invention is as follows.
[0000] (1) Composite particles comprising a cellulose and an inorganic compound, and having an apparent specific volume of 7 to 13 cm 3 /g.
(2) The composite particles according to (1), wherein the cellulose has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm.
(3) The composite particles according to (1) or (2), comprising 10 to 60 parts by mass of the cellulose and 40 to 90 parts by mass of the inorganic compound.
(4) The composite particles according to any one of (1) to (3), wherein the inorganic compound is at least one selected from the group consisting of silicon dioxide hydrate, light anhydrous silicic acid, synthetic aluminum silicate, magnesium hydroxide-aluminum hydroxide co-precipitate, magnesium aluminometasilicate, magnesium aluminosilicate, calcium silicate, non-crystalline silicon oxide hydrate, magnesium silicate, and magnesium silicate hydrate.
(5) The composite particles according to any one of (1) to (4), wherein the inorganic compound is calcium silicate.
(6) The composite particles according to any one of (1) to (5), wherein a pore size is 0.003 to 1 μm, and a pore volume is 1.9 to 3.9 cm 3 /g.
(7) The composite particles according to any one of (1) to (6), wherein a retention rate of tocopherol acetate is 500 to 1000%.
(8) The composite particles according to any one of (1) to (7), wherein a weight average particle size is 30 to 250 μm.
(9) The composite particles according to any one of (1) to (8), further comprising starch.
(10) A molded article comprising the composite particles according to any one of (1) to (9) and an active ingredient.
(11) The molded article according to (10), wherein the active ingredient is an ingredient for a medicament or an ingredient for health food.
(12) A molded article comprising composite particles comprising a cellulose and an inorganic compound, and an active ingredient, wherein the active ingredient is a liquid having a viscosity at 25° C. of 3 to 10000 mPa·s, and the molded article contains 105 to 250 mg of the active ingredient per 500 mg of one molded article.
(13) The molded article according to (12), wherein the liquid ingredient is tocopherol acetate.
Advantageous Effects of Invention
[0017] The composite particles according to the present invention have a large apparent specific volume and pore volume, and a high retention rate of tocopherol acetate as an index of the liquid retention rate. Scattering properties are reduced by forming a composite product, providing good operability. Thereby, the composite particles of the present invention can be used as an adsorption carrier of the liquid ingredient. By forming a composite product, high fluidity after retention of the liquid can be provided, a uniformity in weight of the molded article and content of the active ingredient can be provided among molded articles, and a large content of the liquid ingredient can be contained in the molded article. In addition, the molded article according to the present invention has sufficient hardness, can prevent sticking and capping, and provide a molded article having low friability.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles B according to Example 2.
[0019] FIG. 2 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles D according to Example 4.
[0020] FIG. 3 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles G according to Example 7.
[0021] FIG. 4 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles I according to Example 9.
[0022] FIG. 5 is an enlarged SEM photograph at a magnification of 200 times of a dried product of a cellulose WET cake.
[0023] FIG. 6 is an enlarged SEM photograph at a magnification of 500 times of calcium silicate according to Reference Example 2.
[0024] FIG. 7 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles K according to Example 11.
[0025] FIG. 8 is an enlarged SEM photograph at a magnification of 500 times of Composite Particles M according to Example 13.
[0026] FIG. 9 is an enlarged SEM photograph at a magnification of 200 times of Composite Particles H according to Example 8.
[0027] FIG. 10 is an enlarged SEM photograph at a magnification of 100 times of a mixture of cellulose and calcium silicate.
DESCRIPTION OF EMBODIMENTS
[0028] Hereinafter, an embodiment for implementing the present invention (hereinafter, simply referred to as “the present embodiment”) is described in detail with reference to the drawings when necessary. The present embodiment below is only an example for describing the present invention, and is not intended to limit the present invention to the contents below. Moreover, the attached drawings show an example of the embodiment, and the present embodiment should not be construed to be limited to the drawings. The present invention can be properly modified without departing from the gist, and implemented.
[0029] The composite particles according to the present embodiment comprise a cellulose and an inorganic compound formed into a composite product and having a specific apparent specific volume.
[0030] In the present embodiment, the cellulose refers to fibrous materials containing a natural polymer obtained from natural products. In the present embodiment, the cellulose preferably has a crystal structure of a cellulose type I. Preferably, the cellulose has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm. If the average width and average thickness of the cellulose are within the ranges above, preferably, the pore within the particle can be sufficiently developed by forming a composite product. More preferably, the cellulose has an average width of 2 to 25 μm and an average thickness of 1 to 5 μm.
[0031] The cellulose in the present invention includes microcrystalline cellulose. The microcrystalline cellulose used in the present invention is a white crystalline powder obtained by partially depolymerizing α-cellulose obtained as pulp obtained from a fibrous plant with mineral acid, and purifying the partially depolymerized product. The microcrystalline cellulose has various grades. In the present invention, the microcrystalline cellulose having a polymerization degree of 100 to 450 is preferable. As a commercially available product, “Ceolus” PH grade, “Ceolus” KG grade, and “Ceolus” UF grade (all made by Asahi Kasei Chemicals Corporation) can be used. The UF grade is most preferable.
[0032] Preferably, the cellulose has a volume average particle size of 10 to 100 μm. The volume average particle size is preferably 10 to 50 μm, and more preferably 10 to 40 μm.
[0033] The cellulose preferably has an average polymerization degree of 10 to 450. The average polymerization degree is more preferably 150 to 450.
[0034] In the present embodiment, the inorganic compound is not particularly limited as long as the inorganic compound is insoluble in water and has an apparent specific volume of 10 to 50 cm 3 /g. For example, silicon dioxide hydrate, light anhydrous silicic acid, synthetic aluminum silicate, magnesium hydroxide-aluminum hydroxide co-precipitate, magnesium aluminometasilicate, magnesium aluminosilicate, calcium silicate, non-crystalline silicon oxide hydrate, magnesium silicate, and magnesium silicate hydrate are preferable. Preferably, the inorganic compound has a volume average particle size of 10 to 50 μm because the concentration of the dispersion liquid of the cellulose and the inorganic compound can be increased. Particularly preferably, the inorganic compound is calcium silicate. Calcium silicate is composed of CaO, SiO 2 , and H 2 O. Those represented by the formula 2CaO.3SiO 2 .mSiO 2 .nH 2 O (1<m<2, 2<n<3) are preferable. As a commercially available product, a product name Florite R (made by Tokuyama Corporation), a product name Florite RE (CaO 2 is 50% or more, CaO is 22% or more, available from Eisai Food & Chemical Co., Ltd.), and the like are available. Calcium silicate is a white powder, and water-insoluble. Calcium silicate is a substance having a high liquid absorbing ability and good compactibility. The volume average particle size is preferably 10 to 40 μm, and more preferably 20 to 30 μm.
[0035] From the viewpoint of prevention of sticking, it is thought that when the inorganic compound has a larger apparent specific volume and specific surface area, higher properties can be demonstrated. Light anhydrous silicic acid has higher physical properties described above than those of calcium silicate. As a result of extensive research of an inorganic compound used with the cellulose as the composite particles in the present invention, however, it was found that the highest sticking-preventing effect is demonstrated in the case where calcium silicate is used.
[0036] The present inventors found out that the inorganic compound and the cellulose are formed into a composite product to make the apparent specific volume as large as possible; thereby, a retention rate of tocopherol acetate as an index of the liquid retention rate can be maximized.
[0037] Single calcium silicate has a retention rate of tocopherol acetate of 800 to 900%, and has a high retention rate among the inorganic compounds. The retention rate of tocopherol acetate by the cellulose is 200 to 250%. For this reason, it is thought that a mixture having a retention rate of more than 800% cannot be obtained even if calcium silicate is simply mixed with the cellulose. It was found, however, that the pore within the particle is sufficiently developed by forming a composite product to provide a retention rate higher than a simple arithmetic average value.
[0038] As an example, the retention rate of tocopherol acetate is compared between a mixture of cellulose and calcium silicate, in which the amount of calcium silicate to be blended is approximately 50%, and the composite particles. In the case of the mixture, the logical value of the retention rate of tocopherol acetate is approximately 550%. Meanwhile, the composite particles having the same blending amount of calcium silicate has an extremely high retention rate of approximately 740%.
[0039] In other words, by forming the cellulose and calcium silicate into a composite product, the liquid retention rate is improved, and further, the properties of the cellulose are successfully given to the composite particles. Thereby, the composite particles having a high liquid retention rate and given compactibility and fluidity that the cellulose has can be provided.
[0040] Preferably, the composite particles according to the present embodiment contain 10 to 60 parts by mass of the cellulose and 40 to 90 parts by mass of the inorganic compound. More preferably, the composite particles according to the present embodiment contain 15 to 45 parts by mass of the cellulose and 55 to 85 parts by mass of the inorganic compound. If the inorganic compound is 40 parts by mass or more, a large intraparticle pore volume can be given to the obtained composite particles including the cellulose and the inorganic compound to provide sufficient liquid retention. Moreover, compression compactibility after retention of the liquid is improved. If the inorganic compound is 90 parts by mass or less, flushing properties can be suppressed, and variation in the weight of the molded article and the content of the active ingredient and reduction in compactibility can be suppressed.
[0041] In the present embodiment, the composite particles are not simply a mixture of the cellulose and the inorganic compound. The composite particles need to contain a single aggregate larger than a single particle, the aggregate being composed of several particles of the cellulose and several particles of the inorganic compound. When the surfaces of the composite particles according to the present embodiment are observed using an SEM (magnification of 200 to 500 times), particles of the cellulose and particles of the inorganic compound are observed individually. It can be found that several particles of the cellulose and several particles of the inorganic compound collect to form the aggregate (see FIG. 9 ). For comparison, a simple mixture is shown in FIG. 10 . The aggregate is larger than a single particle of the cellulose and a single particle of the inorganic compound. Meanwhile, in the simple mixture of the cellulose powder and the inorganic compound powder, primary particles of the cellulose and primary particles of the inorganic compound individually exist, and no aggregate is formed. For this reason, in the case of the simple mixture, high compactibility and fluidity as demonstrated by the composite particles according to the present embodiment are not obtained. Formation of the composite particles can be determined by observation with an SEM, or the weight proportion of the particles remaining on a sieve when the particles are sieved with the sieve having an opening of 75 μm. If the proportion of the particles remaining on the 75 μm sieve is 5 to 70% by weight, and preferably 10 to 70% by weight, it is determined that the composite particles are formed. The composite particles can have pores formed within the particle. Thereby, the composite particles can carry the amount of the liquid ingredient more than the amount of the liquid ingredient that can be carried by individual particles of the cellulose and individual particles of the inorganic compound. As formation of the composite product is progressed, the amount of the pores within the particles is increased, leading to a higher ability to carry the liquid ingredient. For example, the degree of formation of the composite product can be measured by comparing the retention rate of tocopherol acetate. In the simple physical mixture of the cellulose and the inorganic compound, the retention rate of tocopherol acetate is only an arithmetic average value based on the composition ratio of the cellulose and the inorganic compound. Meanwhile, as formation of the composite product is progressed, the amount of the pores within the particles is increased. For this reason, the composite particles have a higher retention rate of tocopherol acetate.
[0042] The composite particles according to the present embodiment need to have an apparent specific volume of 7 to 13 cm 3 /g. At an apparent specific volume of 7 cm 3 /g or more, the liquid retention rate is improved. At an apparent specific volume of 13 cm 3 /g or less, increase in flushing properties can be suppressed, and variation in the content of the active ingredient and reduction in compactibility can be suppressed. More preferably, the apparent specific volume is 8 to 12 cm 3 /g.
[0043] The composite particles according to the present embodiment preferably have a pore size of 0.003 to 1 μm. Here, the pore size means the size of the pore on the surface of the composite particle. More preferably, the pore size is 0.05 to 0.5 μm.
[0044] The composite particles according to the present embodiment preferably have a pore volume of 1.9 to 3.9 cm 3 /g. Here, the pore volume means the volume of fine pores that the composite particles have. A pore volume of 1.9 cm 3 /g or more improves the liquid retention rate. At a pore volume of 3.9 cm 3 /g or less, increase in flushing properties can be suppressed, and variation in the content of the active ingredient and reduction in compactibility can be suppressed. More preferably, the pore volume is 2 to 3.5 cm 3 /g.
[0045] The pore volume contributes to the compression compactibility of the composite particles and the liquid retention of the molded article. At a large pore volume, the composite particles are likely to be crushed during compression, leading to improved plastic deformability and enhanced hardness of the molded article. Moreover, a large pore volume promotes penetration of the liquid into the composite particles, leading to improved liquid retention.
[0046] Preferably, the composite particles according to the present embodiment have a porosity of 15 to 50%. Here, the porosity means a proportion of the pore volume to the volume of the composite particles. A porosity of 15% or more provides a high liquid retention rate, thus it is preferable. A porosity of 50% or less can suppress increase in flushing properties and reduction in compactibility, thus it is preferable. More preferably, the porosity is 20 to 40%.
[0047] The composite particles according to the present embodiment preferably have a weight average particle size of 30 to 250 μm. From the viewpoint of fluidity, the weight average particle size is preferably 30 μm or more. From the viewpoint of suppression in separation and segregation, the weight average particle size is preferably 250 μm or less. More preferably, the weight average particle size is 40 to 100 μm. Here, separation and segregation mean that the active ingredient is not uniformly mixed with the composite particles, and that a uniformly mixed state is not kept.
[0048] The composite particles according to the present embodiment preferably have a retention rate of tocopherol acetate of 500 to 1000%. At a high retention rate of tocopherol acetate, namely, a high liquid retention rate, the content of the active ingredient in the molded article can be increased. At a retention rate of tocopherol acetate less than 500%, the amount of the liquid to be carried is small. From the viewpoint of liquid retention, the retention rate of tocopherol acetate is preferably as high as possible, but approximately 1000% at best. The retention rate of tocopherol acetate is more preferably 600 to 1000%, and particularly preferably 700 to 1000%.
[0049] From the viewpoint of fluidity, the composite particles according to the present embodiment preferably have a repose angle of 45° or less. The repose angle is preferably as small as possible, and the lower limit is not particularly limited. From the viewpoint of suppression in separation and segregation of the active ingredient during continuous compression at a high speed, the repose angle is preferably 25°. More preferably, the repose angle is 25 to 40°. Similarly, from the viewpoint of fluidity, preferably, the composite particles after retention of the liquid have a repose angle of 45° or less, and preferably 25 to 40°.
[0050] The composite particles according to the present embodiment preferably have a hardness of 200 to 340 N. Here, the hardness is a value obtained by measurement of a cylindrical molded article obtained by compressing 0.5 g of the composite particles at a pressure of 10 MPa with a punch having a circular flat surface having a diameter of 1.1 cm by a Schleuniger hardness tester.
[0051] Preferably, the composite particles according to the present embodiment further include starch. Starch has binding properties, thus contributes to keeping a composite state of the cellulose and the inorganic compound. Thereby, a granulation state is fixed. Accordingly, addition of starch is preferable. As starch, for example, dextrin, soluble starch, corn starch, potato starch, partly pregelatinized starch, pregelatinized starch, and the like can be used. Those having binding properties are preferable. As starch contributing to improvement in disintegration properties, a “SWELSTAR (trademark) WB-1 (made by Asahi Kasei Chemicals Corporation)” is particularly preferable because the outer shell is a glue ingredient having binding properties and the inner shell is a disintegrable particle. 5 parts by mass to 15 parts by mass of starch is preferably contained based on 100 parts by mass of the composite particles including starch. At this time, 85 to 95 parts by mass of the microcrystalline cellulose and the inorganic compound in total are preferably contained.
[0052] The composite particles according to the present embodiment have a large apparent specific volume, a high liquid retention rate, and high fluidity. Further, the composite particles according to the present embodiment can be suitably used for a direct tableting method and a wet tableting method. The composite particles according to the present embodiment also have reduced scattering properties and high operability to prevent tableting problems such as sticking and capping.
[0053] The composite particles according to the present embodiment are particularly suitable for an active ingredient having low fluidity and difficulties to provide hardness of the tablet. Specific examples thereof include essence powders of over-the-counter drugs such as cold medicines and Kampo medicines, and drugs easy to be deactivated by a compression force or friction with an excipient such as enzymes and proteins.
[0054] The composite particles according to the present embodiment are also suitable for tablets easy to have tableting problems such as breakage or chips of the surface of the tablet, peel off from the inside, and cracks. Specific examples of the tablets include small tablets, non-circular deformed tablets having a portion such as a constriction of an edge to which a compression force is difficult to be uniformly applied, tablets containing a large amount of various drugs, and tablets containing coating granules.
[0055] Hereinafter, a method for producing the composite particles according to the present embodiment is described.
[0056] The composite particles according to the present embodiment are obtained by dispersing the cellulose and the inorganic compound in a medium, and drying the obtained dispersion liquid. Alternatively, the composite particles according to the present embodiment can also be obtained by strongly stirring the cellulose and the inorganic compound by a wet method (i.e., formation of a composite product, co-processing).
[0057] A raw material for the cellulose is natural products containing a cellulose. Examples of the raw material for the cellulose include wood materials, bamboo, wheat straw, rice straw, cotton, ramie, bagasse, kenaf, beet, hoya, and bacterial cellulose. The raw material may be of plant or animal origin, and two or more thereof may be mixed. Alternatively, the raw material may be hydrolyzed. Particularly in the case of hydrolysis, examples thereof include acid hydrolysis, alkali oxidative decomposition, hydrothermal decomposition, and steam explosion. These may be used in combination.
[0058] In the hydrolysis, a medium for dispersing the solid content containing the cellulose is not particularly limited as long as the medium is industrially used. As such medium, water or an organic solvent can be used. Examples of the organic solvent include alcohols such as methanol, ethanol, isopropyl alcohol, butyl alcohol, 2-methyl butyl alcohol, and benzyl alcohol; hydrocarbons such as pentane, hexane, heptane, and cyclohexane; and ketones such as acetone and ethyl methyl ketone. Particularly, the organic solvent is preferably those used for pharmaceuticals. Examples of the organic solvent include those classified as solvents in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited). The medium is preferably water. Water and the organic solvents may be used in combination. Alternatively, the cellulose and the inorganic compound may be dispersed in one medium once, and the medium may be removed; then, the cellulose and the inorganic compound may be dispersed in a different medium.
[0059] The cellulose in the present invention preferably has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm. The method is not particularly limited as long as it is a method for tearing the cellulose mainly in the longitudinal length. The average width and average thickness of the cellulose can be controlled within specific ranges by treating wood pulp with a high-pressure homogenizer, and when necessary, performing a mechanical treatment such as grinding and sorting, or combining these two properly. Alternatively, for example, a pulp whose cellulose has an average width of 2 to 30 μm and an average thickness of 0.5 to 5 μm may be selected and used. The volume average particle size of a water-dispersed cellulose is preferably 10 to 100 μm. The volume average particle size is preferably 10 to 50 μm, and more preferably 10 to 40 μm. Patent Literature 3 describes a cellulose for composing in which the cellulose dispersed in water has an L/D of 2.0 or more in a 10 to 100 μm fraction. As shown in Examples in Patent Literature 3, the cellulose cannot attain a high apparent specific volume as in the present application. Further, the cellulose of Patent Literature 3 is inferior to the composite product according to the present invention with respect to the pore volume and the retention rate of tocopherol acetate. The cellulose having a specific average width and average thickness is preferable for increasing the amount of the pores within the particles.
[0060] Examples of a method for obtaining a cellulose having a volume average particle size of 10 to 100 μm in the state of the cellulose dispersed in water include:
[0000] i) a method of shearing, grinding, crushing, and pulverizing a cellulose to adjust a particle size,
ii) a method of performing a high pressure treatment such as explosion on a cellulose to separate the cellulose particles in the direction along their long axis, and when necessary, applying a shear force to adjust a particle size, and
iii) a method of performing a chemical treatment on a cellulose to adjust a particle size.
[0061] Any of the methods described above may be used, and two or more methods described above may be used in combination. The methods i) and ii) may be performed by a wet method or a dry method. These wet and dry methods may be used in combination.
[0062] Examples of the methods i) and ii) include shearing methods using a stirring blade of a one-direction rotation type, a multi-axis rotation type, a reciprocal inversion type, a vertical movement type, a rotation+vertical movement type, or a piping type such as a portable mixer, a three-dimensional mixer, and a side-wall mixer; a jet type stirring/shearing method such as a line mixer; a treatment method using a high-shear homogenizer, a high-pressure homogenizer, and an ultrasonic homogenizer; and an axial rotation extrusion type shearing method such as a kneader.
[0063] Particularly, examples of a pulverizing method include a screen type pulverizing method such as a screen mill and a hammer mill, a blade rotation shearing screen type pulverizing method such as a flush mill, an air stream type pulverizing method such as a jet mill, a ball type pulverizing method such as a ball mill and a vibratory ball mill, and a blade stirring type pulverizing method. Two or more methods among them may be used in combination.
[0064] The volume average particle size of the cellulose can also be controlled within a desired range by adjusting a condition on a step of hydrolyzing or dispersing the cellulose, particularly, adjusting a stirring force applied to the solution containing the cellulose. Generally, if the concentrations of an acid and an alkali in the hydrolysis solution are increased or the reaction temperature is increased, the polymerization degree of the cellulose is likely to be reduced to provide a smaller volume average particle size of the cellulose in the dispersion liquid. If the stirring force applied to the solution is stronger, the cellulose particle is likely to have a smaller volume average particle size.
[0065] Next, a method for producing a dispersion liquid containing the cellulose and the inorganic compound is described. The dispersion liquid can be produced by dispersing the cellulose and the inorganic compound in a medium. Specifically, examples of the method include:
[0000] i) a method of adding a mixture of the cellulose and the inorganic compound in a medium to prepare a dispersion liquid,
ii) a method of adding the inorganic compound to a cellulose dispersion liquid to prepare a dispersion liquid,
iii) a method of adding the inorganic compound to a dispersion liquid prepared by mixing a third ingredient such as starch with cellulose particles to prepare a dispersion liquid,
iv) a method of adding the inorganic compound to a mixture of a third ingredient such as starch and a cellulose dispersion liquid to prepare a dispersion liquid, and
v) a method of adding the cellulose to a dispersion liquid having the inorganic compound added to prepare a dispersion liquid.
[0066] A method for adding the respective ingredients is not particularly limited as long as it is a method usually performed. Specifically, examples of the addition method include those using a small size suction transport apparatus, an air transport apparatus, a bucket conveyor, a pneumatic transport apparatus, a vacuum conveyer, a vibration type quantitative metering feeder, a spray, a funnel, or the like. The respective ingredients may be continuously added, or added in batch.
[0067] A mixing method is not particularly limited as long as it is a method usually performed. Specifically, a vessel rotation type mixer such as V-type, W-type, double cone type, and container tack type mixers, a stirring type mixer such as high speed stirring type, universal stirring type, ribbon type, pug type, and Nauta-type mixers, a high speed fluid type mixer, a drum type mixer, and a fluidized bed type mixer may be used. Alternatively, dispersing methods using vessel shaking type mixer such as a shaker, and a stirring blade of a one-direction rotation type, a multi-axis rotation type, a reciprocal inversion type, a vertical movement type, a rotation+vertical movement type, or a piping type such as a portable mixer, a three-dimensional mixer, a side-wall mixer, a jet type stirring/dispersing method such as a line mixer, a treatment method using a high-shear homogenizer, a high-pressure homogenizer, or an ultrasonic homogenizer, and an axial rotation extrusion type shearing method such as a kneader may be used, for example. Two or more methods among them may be used in combination.
[0068] The concentration of the cellulose, inorganic compound, and starch in the dispersion liquid obtained by the above-described operation is preferably 5 to 40% by mass. From the viewpoint of fluidity of the composite particles obtained by drying the dispersion liquid, the concentration is preferably 5% by mass or more. From the viewpoint of compression compactibility, the concentration is preferably 40% by mass or less. The concentration is more preferably 5 to 30% by mass, and still more preferably 5 to 20% by mass.
[0069] The dispersion liquid obtained by the above-described operation is dried to obtain the composite particles according to the present embodiment. A drying method is not particularly limited. Examples thereof include lyophilization, spray drying, drum drying, shelf drying, air stream drying, and vacuum drying. Two or more methods among them may be used in combination. A spraying method during spray drying may be any spray drying method such as a disc type drying method, a pressure nozzle type drying method, a compressed two-fluid nozzle type drying method, and a compressed four-fluid nozzle type drying method. Two or more methods among them may be used in combination.
[0070] During the spray drying, a slight amount of a water-soluble polymer and a surfactant may be added in order to reduce the surface tension of the dispersion liquid. In order to accelerate the vaporization rate of the medium, a foaming agent or a substance to generate a gas may be added, or a gas may be added to the dispersion liquid. Specific examples of the water-soluble polymer, the surfactant, the foaming agent, the substance to generate a gas, and the gas are shown below, respectively. The water-soluble polymer, the surfactant, and the substance to generate a gas may be added before drying, and the order of addition is not particularly limited. Two or more of water-soluble polymers, surfactants and the substances to generate a gas respectively may be used in combination.
[0071] Examples of the water-soluble polymer include water-soluble polymers described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyacrylic acid, carboxovinyl polymers, polyethylene glycol, polyvinyl alcohol, polyvinylpyrrolidone, methylcellulose, acacia, and starch paste.
[0072] Examples of the surfactant include those classified as a surfactant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as phosphoruslipid, glycerin fatty acid ester, polyethylene glycol fatty acid ester, sorbitan fatty acid ester, polyoxyethylene hardened castor oil, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether, polyoxyethylene polyoxypropylene glycol, polyoxyethylene sorbitansan monolaurate, polysorbate, sorbitan monooleate, glyceride monostearate, monooxyethylene sorbitan monopalmitate, monooxyethylene sorbitan monostearate, polyoxyethylene sorbitan monooleate, sorbitan monopalmitate, and sodium lauryl sulfate.
[0073] Examples of the foaming agent include foaming agents described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as tartaric acid, sodium hydrogencarbonate, potato starch, anhydrous citric acid, medical soap, sodium lauryl sulfate, lauric acid diethanolamide, and Lauromacrogol.
[0074] Examples of the substance to generate a gas include bicarbonates that generate a gas by pyrolysis such as sodium hydrogen carbonate and ammonium hydrogen carbonate; and carbonates that react with an acid to generate a gas such as sodium carbonate and ammonium carbonate. In use of the carbonates, the carbonates are preferably used with an acid. Examples of the acid include organic acids such as citric acid, acetic acid, ascorbic acid, and adipic acid; proton acids such as hydrochloric acid, sulfuric acid, phosphoric acid, and nitric acid; and Lewis acids such as boron fluoride. Particularly, those used in pharmaceuticals and foods are preferable.
[0075] As the gas, gases such as nitrogen, carbon dioxide, liquefied petroleum gas, and dimethyl ether may be impregnated into the dispersion liquid.
[0076] The composite particles according to the present embodiment are formed by simultaneously drying the cellulose and the inorganic compound in the state where the inorganic compound exists in the dispersion liquid containing the cellulose. It is thought that if the medium is vaporized in the state where the cellulose and the inorganic compound are uniformly associated, capillary condensation acts to aggregate the cellulose and the inorganic compound densely. Even if only the cellulose is dried and the inorganic compound is added to and mixed with the dried cellulose, or only the inorganic compound is dried and the cellulose is added to and mixed with the dried inorganic compound, a composite product is not formed, thus the aggregate structure cannot be obtained. In the case where the cellulose in the dispersion liquid has a specific average width and average thickness, the cellulose has a large suppressing effect on excessive aggregation of particles caused by capillary condensation during drying, and can provide a large pore volume within the composite particles. When the composite particles according to the present embodiment are produced, cellulose particles and inorganic compound particles also remain in the dried powders. These cellulose particles and inorganic compound particles may be used as they are without separation.
[0077] The molded article according to the present embodiment is obtained by molding the composite particles according to the present embodiment and an active ingredient. Hereinafter, the molded article according to the present embodiment is described.
[0078] In the molded article, the proportion of the active ingredient to be used is in the range of 0.001 to 99%, and the proportion of the composite particles to be used is in the range of 1 to 99.999%. From the viewpoint of ensuring an amount effective in treatment, the proportion of the active ingredient is preferably 0.001% or more. From the viewpoint of practical hardness, friability, and disintegration properties, the proportion of the active ingredient is preferably 99% or less. More preferably, the molded article contains 1 to 90% of the composite particles. In the case where the active ingredient is a liquid, tableting problems such as sticking and capping occur. For this reason, the content of the active ingredient in the molded article is limited.
[0079] The composite product according to the present invention has high liquid retention and compactibility, and can be blended with more than 20% of a liquid ingredient. The proportion of the liquid ingredient is preferably 21 to 50%, and particularly preferably 21 to 30%. The largest content of tocopherol acetate in the commercially available molded articles at present is 100 mg/500 mg of the total amount of the tablet. No commercially available molded articles contain more than 20% of tocopherol acetate. By use of the composite product according to the present invention, at a blending amount of the liquid ingredient of 21 to 50%, the molded article can be downsized in the range of 250 to 480 mg. Moreover, at a weight of a tablet of 500 mg, the amount of the liquid ingredient can be increased in the range of 105 to 250 mmg. The amount of the liquid ingredient is preferably 120 to 200 mg, and more preferably 120 to 150 mg.
[0080] The molded article according to the present embodiment can be processed by a known method such as granulation, sizing, and tableting. Particularly, the composite particles according to the present embodiment are suitable for molding by tableting. If the composite particles according to the present embodiment and the active ingredient are contained in the ranges as described above, a molded article having sufficient hardness can be produced by the direct tableting method. In addition to the direct tableting method, the composite particles according to the present embodiment are also suitable for a dry granule compression method, a wet granule compression method, a compression method with extragranular addition of an excipient, a method of producing a multicore tablet using a tablet which is compressed in advance as an inner core, and a method of layering a plurality of molded articles compressed in advance and compressing the layered molded articles again to produce a multilayer tablet.
[0081] In the present embodiment, examples of the active ingredient include ingredients for a medicament, ingredients for health food, pesticide ingredients, fertilizer ingredients, livestock food ingredients, food ingredients, cosmetic ingredients, dyes, flavoring agents, metals, ceramics, catalysts, and surfactants. Ingredients for a medicament and ingredients for health food are suitable active ingredients.
[0082] The ingredients for a medicament are used in substances orally administered such as antipyretic analgesic anti-inflammatory, sedative hypnotic, drowsiness preventing, dizziness suppressing, children's analgesic, stomachic, antacid, digestive, cardiotonic, antiarrhythmic, hypotensive, vasodilator, diuretic, antiulcer, intestinal function-controlling, bone-building, antitussive expectorant, antiasthmatic, antimicrobial, pollakiuria-improving, analeptic drugs, and vitamins. Active pharmaceutical ingredients may be used alone, or two or more of ingredients may be used in combination. Specifically, examples of the medicinal ingredients can include ingredients for a medicament described in “Japanese Pharmacopeia,” “Japanese Pharmaceutical Codex (JPC),” “USP,” “NF,” and “EP” such as aspirin, aspirin aluminium, acetaminophen, ethenzamide, sasapyrine, salicylamide, lactyiphenetidin, isotibenzyl hydrochloride, diphenylpyraline hydrochloride, diphenhydramine hydrochloride, difeterol hydrochloride, triprolidine hydrochloride, tripelenamine hydrochloride, thonzylamine hydrochloride, fenethazine hydrochloride, methdilazine hydrochloride, diphenhydramine salicylate, carbinoxamine diphenyldisulfonate, alimemazine tartrate, diphenhydramine tannate, diphenylpyraline teoclate, mebhydrolin napadisylate, promethazine methylenedisalicylate, carbinoxamine maleate, chlorpheniramine dl-maleate, chlorpheniramine d-maleate, difeterol phosphate, alloclamide hydrochloride, cloperastine hydrochloride, pentoxyverine citrate (carbetapentane citrate), tipepidine citrate, dibunate sodium, dextromethorphan hydrobromide, dextromethorphan-phenolphthalic acid, tipepidine hibenzate, chloperastine fendizoate, codeine phosphate, dihydrocodeine phosphate, noscapine hydrochloride, noscapine, dl-methylephedrine hydrochloride, dl-methylephedrine saccharin salt, potassium guaiacolsulfonate, guaifenesin, caffeine and sodium benzoate, caffeine, anhydrous caffeine, vitamin B1 and its derivatives and their salts, vitamin B2 and its derivatives and their salts, vitamin C and its derivatives and their salts, hesperidin and its derivatives and their salts, vitamin B6 and its derivatives and their salts, nicotinic acid amide, calcium pantothenate, aminoacetic acid, magnesium silicate, synthetic aluminum silicate, synthetic hydrotalcite, magnesia oxide, dihydroxyaluminum-aminoacetate (aluminum glycinate), aluminium hydroxide gel (as dried aluminium hydroxide gel), dried aluminium hydroxide gel, aluminium hydroxide-magnesium carbonate mixed dried gel, aluminium hydroxide-sodium hydrogen carbonate coprecipitation products, aluminium hydroxide-calcium carbonate-magnesium carbonate coprecipitation products, magnesium hydroxide-potassium aluminum sulfate coprecipitation products, magnesium carbonate, magnesium aluminometasilicate, ranitidine hydrochloride, cimetidine, famotidine, naproxen, diclofenac sodium, piroxicam, azulene, indometacin, ketoprofen, ibuprofen, difenidol hydrochloride, diphenylpyraline hydrochloride, diphenhydramine hydrochloride, promethazine hydrochloride, meclizine hydrochloride, dimenhydrinate, diphenhydramine tannate, fenethazine tannate, diphenylpyraline teoclate, diphenhydramine fumarate, prometthazine methylenedisalicylate, spocolamine hydrobromide, oxyphencyclimine hydrochloride, dicyclomine hydrochloride, methixene hydrochloride, atropine methylbromide, anisotropine methylbromide, spocolamine methylbromide, methyl-1-hyoscyamine bromide, methylbenactyzium bromide, belladonna extract, isopropamide iodide, diphenylpiperidinomethyldioxolan iodide, papaverine hydrochloride, aminobenzoic acid, cesium oxalate, ethyl piperidinoacetylaminobenzoate, aminophyllin, diprophylline, theophylline, sodium hydrogen carbonate, fursultiamine, isosorbide nitrate, ephedrine, cefalexin, ampicillin, sulfixazole, sucralfate, allyl isopropylacetyl urea, bromovalerylurea and the like, ephedra herb, Nandina fruit, yellow bark, polygala root, licorice, platycodon root, plantago seed, plantago herb, senega root, fritillaria bulb, fennel, phellodendron bark, coptis rhizome, zedoary, matricaria, cassia bark, gentian, oriental bezoar, beast gall (containing bear bile), adenophorae radix, ginger, atractylodes lancea rhizome, clove, citrus unshiu peel, atractylodes rhizome, earthworm, panax rhizome, ginseng, japanese valerian, moutan bark, zanthoxylum fruit and extracts thereof, insulin, vasopressin, interferon, urokinase, serratio peptidase, and somatostatin. One selected from the above may be used alone, or two or more ingredients selected from the above may be used in combination.
[0083] The ingredients for health food are not limited as long as these are an ingredient blended for the purpose of augmenting. Examples thereof include powdered green juice, aglycone, agaricus, ashwagandha, astaxanthin, acerola, amino acids (valine, leucine, isoleucine, lysine, methionine, phenylalanine, threonine, tryptophan, histidine, cystine, tyrosine, arginine, alanine, aspartic acid, powdered seaweed, glutamine, glutamic acid, glycin, proline, serine, etc.), alginic acid, ginkgo biloba extract, sardine peptides, turmeric, uronic acid, echinacea , Siberian ginseng, oligosaccharides, oleic acid, nucleoproteins, dried skipjack peptides, catechin, potassium, calcium, carotenoid, garcinia cambogia , L-carnitine, chitosan, conjugated linoleic acid, Aloe arborescens, Gymnema sylvestre extract, citric acid, Orthosiphon stamineus , glycerides, glycenol, glucagon, curcumin, glucosamine, L-glutamine, chlorella , cranberry extract, Uncaria tomentosa , germanium, enzymes, Korean ginseng extract, coenzyme Q10, collagen, collagen peptides, coleus blumei, chondroitin, powdered psyllium husks, Crataegi fructus extract, saponin, lipids, L-cystine, Japanese basil extract, citrimax, fatty acids, phytosterol, seed extract, spirulina , squalene, Salix alba , ceramide, selenium, St. John's wort extract, soy isoflavone, soy saponin, soy peptides, soy lecithin, monosaccharides, proteins, chaste tree extract, iron, copper, docosahexaenoic acid, tocotrienol, nattokinase, Bacillus natto culture extract, sodium niacin, nicotine acid, disaccharides, lactic acid bacterium, garlic, saw palmetto, sprouted rice, pearl barley extract, herb extract, valerian extract, pantothenic acid, hyaluronic acid, biotin, chromium picolinate, vitamin A and A2, vitamin B1, B2 and B6, vitamin B12, vitamin C, vitamin D, vitamin E, vitamin K, hydroxytyrosol, bifidobacterium , beer yeast, fructo oligosaccharides, flavonoid, Butcher's broom extract, black cohosh, blueberry, prune concentrate, proanthocyanidin, proteins, propolis, bromelain, probiotics, phosphatidylcholine, phosphatidylserine, β-carotene, peptides, safflower extract, Grifola frondosa extract, maca extract, magnesium, milk thistle, manganese, mitochondria, mineral, mucopolysaccharides, melatonin, Fomes yucatensis , powdered melilot extract, molybdenum, vegetable powder, folic acid, lactose, lycopene, linolic acid, lipoic acid, phosphorus, lutein, lecithin, rosmarinic acid, royal jelly, DHA, and EPA
[0084] The active ingredient may be any form of powdery, crystalline, liquid, and semi-solid forms. A liquid active ingredient is suitable. The active ingredient may be coated or encapsulated for control of elution, reduction in bitterness, or the like. In use of the active ingredient, the active ingredient may be dissolved, suspended, or emulsified in a medium. A plurality of active ingredients may be used in combination.
[0085] Examples of the liquid active ingredient include ingredients for a medicament described in “Japanese Pharmacopeia,” “JPC,” “USP,” “NF,” and “EP” such as teprenone, indomethacin-farnesyl, menatetrenone, phytonadione, vitamin A oil, fenipentol, vitamins such as vitamin D and vitamin E, higher unsaturated fatty acids such as DHA (docosahexaenoic acid), EPA (eicosapentaenoic acid), and liver oil, coenzyme Qs, and oil-soluble flavorings such as orange, lemon, and peppermint oils. Moreover, vitamin E has various homologues and derivatives thereof. Examples thereof can include dl-α-tocopherol, dl-α-tocopherol acetate, tocopherol acetate, and d-α-tocopherol acetate. The homologues and derivatives of vitamin E are not particularly limited as long as these are a liquid at 25° C. These having a viscosity in the range of 3 to 10000 mPa·s are preferable. If a homologue or derivative of vitamin E has a proper viscosity, it preferably provides a good balance between compactibility and fluidity of the composite particles after the liquid ingredient is carried by the composite product. Tocopherol acetate is particularly preferable.
[0086] Examples of the semi-solid active ingredient can include, Kampo medicines or crude drug extracts such as earthworm, licorice, cassia bark, peony root, moutan bark, japanese valerian, zanthoxylum fruit, ginger, citrus unshiu peel, ephedra herb, nandina fruit, yellow bark, polygala root, platycodon root, plantago seed, plantago herb, shorttube lycoris, senega root, fritillaria bulb, fennel, phellodendron bark, coptis rhizome, zedoary, matricaria , gentian, oriental bezoar, beast gall, adenophorae radix, ginger, atractylodes lancea rhizome, clove, citrus unshiu peel, atractylodes rhizome, panax rhizome, ginseng, kakkonto, keishito, kousosan, saiko-keishito, shosaikoto, shoseiryuto, bakumondoto, hangekobokuto, and maoto, an oyster meat essence, propolis or an extract thereof, and coenzyme Qs.
[0087] The crystal of the active ingredient after molding may have the same shape as that before molding, or may have a shape different from that before molding. Preferably, the shape of the crystal after molding is the same as that before molding from the viewpoint of stability.
[0088] In addition to the active ingredient and the composite particles, the molded article according to the present embodiment freely contains excipients such as an excipient, a disintegrant, a binder, a fluidizing agent, a lubricant, a corrigent, a flavoring agent, a coloring agent, and a sweetener when necessary. Two or more excipients among them may be used in combination.
[0089] Examples of the excipient include those classified as an excipient in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as acrylated starch, L-asparagic acid, aminoethyl sulfonic acid, aminoacetate, wheat gluten (powder), acacia, powdered acacia, alginic acid, sodium alginate, pregelatinized starch, inositol, ethyl cellulose, ethylene-vinyl acetate copolymer, sodium chloride, olive oil, kaolin, cacao butter, casein, fructose, light gravel granule, carmellose, carmellose sodium, silicon dioxide hydrate, dry yeast, dried aluminum hydroxide gel, dried sodium sulfate, dried magnesium sulfate, agar, agar powder, xylitol, citric acid, sodium citrate, disodium citrate, glycerin, calcium glycerophosphate, sodium gluconate, L-glutamine, clay, clay grain, croscarmellose sodium, crospovidone, magnesium aluminosilicate, calcium silicate, magnesium silicate, light anhydrous silicic acid, light liquid paraffin, cinnamon powder, microcrystalline cellulose, microcrystalline cellulose-carmellose sodium, microcrystalline cellulose (grain), brown rice malt, synthetic aluminum silicate, synthetic hydrotalcite, sesame oil, wheat flour, wheat starch, wheat germ powder, rice powder, rice starch, potassium acetate, calcium acetate, cellulose acetate phthalate, safflower oil, white beeswax, zinc oxide, titanium oxide, magnesium oxide, β-cyclodextrin, dihydroxyaluminum aminoacetate, 2,6-dibutyl-4-methylphenol, dimethylpolysiloxane, tartaric acid, potassium hydrogen tartrate, plaster, sucrose fatty acid ester, magnesium hydroxide-aluminum hydroxide co-precipitate, aluminum hydroxide gel, aluminum hydroxide/sodium hydrogen carbonate coprecipitate, magnesium hydroxide, squalane, stearyl alcohol, stearic acid, calcium stearate, polyoxyl stearate, magnesium stearate, purified gelatine, purified shellac, purified sucrose, purified sucrose spherical granulated powder, cetostearyl alcohol, polyethylene glycol 1000 monocetyl ether, gelatine, sorbitan fatty acid ester, D-sorbitol, tricalcium phosphate, soybean oil, unsaponified soy bean, soy bean lecithin, powdered skim milk, talc, ammonium carbonate, calcium carbonate, magnesium carbonate, neutral anhydrous sodium sulfate, low substitution degree hydroxypropylcellulose, dextran, dextrin, natural aluminum silicate, corn starch, powdered tragacanth, silicon dioxide, NEWKALGEN 204, calcium lactate, lactose, par filler 101, white shellac, white vaseline, white clay, sucrose, sucrose/starch spherical granulated powder, naked barley green leaf extract powder, dried powder of bud and leaf juice of naked barley, honey, paraffin, potato starch, semi-digested starch, human serum albumin, hydroxypropyl starch, hydroxypropylcellulose, hydroxypropylcellulose, hydroxypropyl methylcellulose phthalate, phytic acid, glucose, glucose hydrate, partially pregelatinized starch, pullulan, propylene glycol, starch syrup of reduced malt sugar powder, powdered cellulose, pectin, bentonite, sodium polyacrylate, polyoxyethylene alkyl ethers, polyoxyethylene hydrogenated castor oil, polyoxyethylene (105) polyoxypropylene (5) glycol, polyoxyethylene (160) polyoxypropylene (30) glycol, sodium polystyrene sulfonate, polysorbate, polyvinylacetal diethylamino acetate, polyvinylpyrrolidone, polyethylene glycol (molecular weight of 1500 to 6000), maltitol, maltose, D-mannitol, water candy, isopropyl myristate, anhydrous lactose, anhydrous dibasic calcium phosphate, anhydrous dibasic calcium phosphate granulated substance, magnesium aluminometasilicate, methyl cellulose, cottonseed powder, cotton oil, haze wax, aluminum monostearate, glyceryl monostearate, sorbitan monostearate, pharmaceutical carbon, peanut oil, aluminum sulfate, calcium sulfate, granular corn starch, liquid paraffin, dl-malic acid, calcium monohydrogen phosphate, calcium hydrogenphosphate, calcium hydrogenphosphate granulated substance, sodium hydrogenphosphate, potassium dihydrogen phosphate, calcium dihydrogen phosphate, and sodium dihydrogen phosphate.
[0090] Examples of the disintegrant include those classified as a disintegrant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as croscarmellose sodium, carmellose, carmellose calcium, carmellose sodium, celluloses such as low substitution degree hydroxypropylcellulose, starches such as sodium carboxymethyl starch, hydroxypropyl starch, rice starch, wheat starch, corn starch, potato starch, and partly pregelatinized starch, and synthetic polymers such as crospovidone and crospovidone copolymer.
[0091] Examples of the binder include those classified as a binder in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) sugars such as sucrose, glucose, lactose and fructose, sugar alcohols such as mannitol, xylitol, maltitol, erythritol, and sorbitol, water-soluble polysaccharides such as gelatine, pullulan, carrageenan, locust bean gum, agar, glucomannan, xanthan gum, tamarind gum, pectin, sodium alginate, and acacia, celluloses such as microcrystalline cellulose, powdered cellulose, hydroxypropylcellulose and methyl cellulose, starches such as cornstarch, potato starch, pregelatinized starch and starch paste, synthetic polymers such as polyvinylpyrrolidone, carboxyvinyl polymer and polyvinyl alcohol, and inorganic compounds such as calcium hydrogenphosphate, calcium carbonate, synthetic hydrotalcite, and magnesium aluminosilicate.
[0092] Examples of the fluidizing agent include those classified as a fluidizing agent in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as silicon compounds such as silicon dioxide hydrate and light anhydrous silicic acid, wet silicas such as sodium silicates, calcium silicate, and sodium stearyl fumarate (trade name “PRUV” made by JRS).
[0093] Examples of the lubricant include those classified as a lubricant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as magnesium stearate, calcium stearate, stearic acid, sucrose fatty acid ester, talc, Fujicalin, and sodium stearyl fumarate (trade name “PRUV” made by JRS).
[0094] Examples of the corrigent include those classified as a corrigent in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as glutamic acid, fumaric acid, succinic acid, citric acid, sodium citrate, tartaric acid, malic acid, ascorbic acid, sodium chloride, and 1-menthol.
[0095] Examples of the flavoring agent include those classified as aromatics and flavoring agents in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as orange, vanilla, strawberry, yogurt, menthol, oils such as fennel oil, cinnamon bark oil, orange peel oil, and peppermint oil, and green tea powder.
[0096] Examples of the colorant include those classified as a colorant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as edible dyes such as edible red 3, edible yellow 5, and edible blue 1, sodium copper chlorophyllin, titanium oxide, and riboflavin.
[0097] Examples of the sweetener include those classified as a sweetener in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as aspartame, saccharin, dipotassium glycyrrhizinate, stevia, maltose, maltitol, starch syrup, and powdered sweet hydrangea leaf.
[0098] Examples of a form of the molded article include solid preparations such as tablets, powders, subtle granules, granules, and pills when the molded article is used for pharmaceuticals.
[0099] Hereinafter, a tablet is described as a suitable specific example of the molded article according to the present embodiment.
[0100] The tablet refers to a molded article containing the composite particles according to the present embodiment, the active ingredient, and when necessary other excipients, and obtained by tableting. The composite particles according to the present embodiment have high compression compactibility. Accordingly, a tablet for practical use can be obtained at a relatively low compression force. The composite particles according to the present embodiment can be molded and tableted at a low compression force. For this reason, the tablet can keep gaps (water introducing pipes) inside thereof. Such a tablet is suitable for an orally disintegrating tablet rapidly disintegrated in an oral cavity. In addition, the composite particles according to the present embodiment are suitable for multilayer tablets and core tablets obtained by compressing ingredients in several compositions at one stage or at multi stages. The composite particles according to the present embodiment have high effects of imparting high hardness to the molded article, and suppressing tableting problems, peel off between interlayers, and cracks. Further, the composite particles according to the present embodiment themselves have high dividing properties, thus a tablet formed of the composite particles according to the present embodiment is easy to be divided uniformly. Accordingly, the composite particles according to the present embodiment are also suitable for a scored tablet and the like.
[0101] The composite particles according to the present embodiment have a porous structure, and the composite particles themselves have high retention of the liquid ingredient such as fine particle drugs, suspended drugs, and liquid ingredients. For this reason, the molded article of the composite particles according to the present embodiment also has high retention of the liquid ingredient. For this reason, when a suspended or liquid ingredient is layered and coated on the tablet, the tablet also has a preventive effect on peel off of an outer layer such as a coating layer. Accordingly, the composite particles according to the present embodiment are also suitable for a layered tablet and a tablet having a coating layer (such as sugar-coated tablets, and tablets having a layered ingredient such as calcium carbonate).
[0102] Hereinafter, a method of producing a molded article containing the active ingredient and the composite particles according to the present embodiment is described. This is only an example, and the present invention is not limited to the description below.
[0103] Examples of a method for molding a molded article include a method of mixing the active ingredient with the composite particles according to the present embodiment, and compressing the mixture. At this time, the excipients other than the above-described active ingredient may be blended when necessary. The order of addition is not particularly limited. Examples of the method include:
[0000] 1) a method in which the active ingredient is mixed with the composite particles according to the present embodiment and, when necessary, an excipient in batch, and the mixture is compressed;
2) a method in which the active ingredient is mixed with an excipient such as a fluidizing agent or a lubricant, and then mixed with the composite particles according to the present invention and, when necessary, an additional excipient, and the mixture is compressed; and
3) a method in which a lubricant is further mixed with the mixed powder for compression obtained by 1) or 2), and the obtained mixture is compressed.
[0104] A method for adding ingredients is not particularly limited as long as the method is a method usually performed. The ingredients may be added continuously or in batch using a small size suction transport apparatus, an air transport apparatus, a bucket conveyor, a pneumatic transport apparatus, a vacuum conveyer, a vibration type quantitative metering feeder, a spray, a funnel, or the like.
[0105] A mixing method is not particularly limited as long as the method is a method usually performed. A vessel rotation type mixer such as V-type, W-type, double cone type, and container tack type mixers, or a stirring type mixer such as high speed stirring type, universal stirring type, ribbon type, pug type, and Nauta-type mixers, a high speed fluid type mixer, a drum type mixer, or a fluidized bed type mixer may be used. Alternatively, a vessel shaking type mixer such as a shaker can be used.
[0106] A compression method is not particularly limited as long as the method is a method usually performed. The method may be a method of compressing ingredients into a desired shape using a die and a punch, or a method of compressing ingredients into a sheet form in advance and cutting the sheet into a desired shape. A usable compression machine is, for example, a compressor such as a hydrostatic press, a roller type press such as a briquetting roller type press or a smoothing roller type press, a single-punch tableting machine, or a rotary tableting machine.
[0107] In the case where an active ingredient poorly-soluble in water is used, generally, examples of the compression method include:
[0000] A) a method in which the active ingredient is pulverized, and mixed with the composite particles according to the present embodiment and, when necessary, other ingredient; and the obtained mixture is compressed; and
B) a method in which the active ingredient is dissolved or dispersed in water, an organic solvent, or a solubilizing agent, and mixed with the composite particles according to the present embodiment and, when necessary, other excipients; when necessary, water or the organic solvent is removed; and the obtained mixture is compressed.
[0108] The composite particles according to the present embodiment are suitable for the above-described method B). In the method B), the active ingredient poorly-soluble or insoluble in water is once dissolved or dispersed. For this reason, the active ingredient can be carried by the composite particles securely. Thereby, separation or elution of the active ingredient during compression can be prevented to suppress sticking. The composite particles according to the present embodiment have high compression compactibility and fluidity. For this reason, in the case of the method B), the composite particles according to the present embodiment can be formed into a tablet at little variation in the weight by the compression.
[0109] The method B) is more suitable in the case where the active ingredient in the drug is used for pharmaceuticals and a liquid medium such as polyethylene glycol is used in combination as a dispersion medium. Polyethylene glycol or the like is used in order to keep the efficacy of the active ingredient which is easily metabolizable in the liver by coating the active ingredient with polyethylene glycol in the blood when the active ingredient is absorbed in a human body.
[0110] In the method B), in order to assist dissolution, it is effective to use a water-soluble polymer or a surfactant as a solubilizing agent in combination to disperse the active ingredient in a medium.
[0111] The organic solvent is not particularly limited as long as it is used for pharmaceuticals. Examples of the organic solvent include those classified as a solvent in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as alcohols such as methanol and ethanol, and ketones such as acetone. Two or more organic solvents among them are freely used in combination.
[0112] Examples of the water-soluble polymer as the solubilizing agent in the method B) include water-soluble polymers described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as hydroxypropyl cellulose, hydroxypropyl methylcellulose, polyacrylic acid, carboxyvinyl polymer, polyethylene glycol, polyvinyl alcohol, polyvinylpyrrolidone, methylcellulose, ethylcellulose, acacia, and starch paste. Two or more water-soluble polymers among them are freely used in combination.
[0113] Examples of oils and fats as the solubilizing agent include oils and fats described in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as monoglyceride stearate, triglyceride stearate, sucrose stearic acid ester, paraffins such as liquid paraffin, carnauba wax, hydrogenated oils such as hydrogenated castor oil, castor oil, stearic acid, stearyl alcohol, and polyethylene glycol. Two or more oils and fats among them are freely used in combination.
[0114] Examples of the surfactant in the solubilizing agent include those classified as a surfactant in “Japanese Pharmaceutical Excipients Directory” (issued by Yakuji Nippo Limited) such as phospholipid, glycerin fatty acid ester, polyethylene glycol fatty acid ester, sorbitan fatty acid ester, polyoxyethylene hardened castor oil, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether, polyoxyethylene nonylphenyl ether, polyoxyethylene polyoxypropylene glycol, polyoxyethylene sorbitansan monolaurate, polysorbate, sorbitan monooleate, glyceride monostearate, monooxyethylene sorbitansan monopalmitate, monooxyethylene sorbitan monostearate, polyoxyethylene sorbitan monooleate, sorbitan monopalmitate, and sodium lauryl sulfate. Two or more surfactants among them are freely used in combination.
[0115] In the method B), a dissolving or dispersing method is not particularly limited as long as it is a dissolving or dispersing method usually performed. A stirring/mixing method using a stirring blade of a one-direction rotation type, a multi-axis rotation type, a reciprocal inversion type, a vertical movement type, a rotation+vertical movement type, or a piping type such as a portable mixer, a three-dimensional mixer, and a side-wall mixer; a jet type stirring/mixing method such as a line mixer; a gas-blowing stirring/mixing method; a mixing method using a high-shear homogenizer, a high-pressure homogenizer, or an ultrasonic homogenizer; or a vessel shaking type mixing method using a shaker, or the like may be used.
[0116] The composite particles according to the present embodiment have a porous structure, and the composite particles themselves have high retention of the drug. For this reason, the particles carrying the drug within pores may be used as they are as fine granules, may be granulated as used for granules, or may be compressed.
[0117] A method for carrying a drug is not particularly limited as long as it is a known method. Examples of the method include:
[0000] i) a method in which the composite particles according to the present embodiment are mixed with a fine particle drug to be carried within pores;
ii) a method in which the composite particles according to the present embodiment are mixed with a powdery drug at a high speed to be forcibly carried within pores;
iii) a method in which the composite particles according to the present embodiment are once mixed with a drug prepared as a solution or a dispersion liquid, the drug is carried within pores, and the obtained one is dried if necessary;
iv) a method in which the composite particles according to the present embodiment are mixed with a sublimation drug, and the mixture is heated and/or the pressure is reduced, thereby, the drug is sublimated and adsorbed within pores; and
v) a method in which the composite particles according to the present embodiment are mixed with a drug before or during heating, and molten.
[0118] Two or more methods as described above may be used in combination.
[0119] Besides use as the tablet thus compressed, the composite particles according to the present embodiment may be used as granules or powders particularly in order to improve fluidity, blocking resistance, and aggregation resistance because the composite particles according to the present embodiment also have high retention of a solid or liquid ingredient. The above-described fine granules and the granules may be further coated.
[0120] As a method for producing granules and powders, the same effect is obtained even if any of dry granulation, wet granulation, heating granulation, spray drying, and microencapsulation is used, for example.
[0121] Moreover, the composite particles according to the present embodiment have proper moisture retention and oil retention. Accordingly, other than the excipient, the composite particles according to the present embodiment can be used as a core particle for layering and coating, and have a suppressing effect on aggregation of particles in a layering or coating step. The layering and coating may be a dry method or a wet method.
[0122] The composite particles according to the present embodiment are also used for foods such as confectionery, health foods, texture-improving agents, and dietary fiber-reinforcing agent, cake makeups, bath agents, animal drugs, diagnostic reagents, agricultural chemicals, fertilizers, and ceramic catalysts, and the like.
Examples
[0123] The present invention is described based on Examples. Embodiments of the present invention are not limited to the description of these Examples. In Examples and Comparative Examples, methods for measuring physical properties are as follows.
(1) Average Width of Cellulose (μm)
[0124] Cellulose primary particles formed of a natural cellulose were dried when necessary, and placed on a sample stage to which a carbon tape was attached. Platinum palladium was vacuum deposited (the membrane thickness of the deposited membrane at this time was 20 nm or less). Using a JSM-5510LV (trade name) made by JASCO Corporation, the cellulose primary particles were observed at an accelerating voltage of 6 kV and at a magnification of 250 times. A short diameter in the vicinity of the center of a long diameter of a cellulose particle was considered as a representative width, and the width was measured. The widths of three representative cellulose primary particles were measured, and the average was defined as the average width of the cellulose.
(2) Average Thickness of Cellulose (μm)
[0125] Cellulose primary particles formed of a natural cellulose were dried when necessary, and placed on a sample stage to which a carbon tape was attached. Gold was vacuum deposited. Then, using a focused ion beam processing apparatus (made by Hitachi, Ltd., FB-2100 (trade name)), a cross section of the cellulose primary particles was cut out with a Ga ion beam, and observed at an accelerating voltage of 6 kV and a magnification of 1500 times. A shorter diameter in the cross section of the cellulose particles was measured, and the obtained value was defined as the thickness (the cross section was cut out such that a longer diameter corresponded to the short diameter of the cellulose particle). The thicknesses of three representative cellulose primary particles were measured, and the average value thereof was defined as the thickness of the cellulose.
(3) Volume Average Particle Size of Cellulose or Inorganic Compound (μm)
[0126] The cellulose or the inorganic compound was dispersed in water to prepare a dispersion liquid. The volume average particle size of the cellulose or inorganic compound was defined as a 50% cumulative volume of particles in the dispersion liquid measured using a laser diffraction particle size distribution analyzer (made by HORIBA, Ltd., LA-910 (trade name)) wherein a measurement mode at 4 stirrings and 5 circulations was selected and the measurement condition was the transmittance of around 85%, an ultrasonic treatment for 1 minute, and the refractive index of 1.20. The measurement value as obtained above does not always correlate with the particle size distribution of dried particles obtained by the following Ro-Tap type apparatus because the measurement principles are totally different from each other. The volume average particle size measured by laser diffraction is measured from volume frequencies depending on the long diameter of fibrous particles while the weight average particle size obtained by the Ro-Tap type apparatus depends on the short diameter of fibrous particles because the obtained powder is shaken on a sieve and fractionated. Thus, there is a case that the value measured by the laser diffraction type apparatus depending on the long diameter of fibrous particles is larger than that measured by the Ro-Tap type apparatus depending on the short diameter of fibrous particles.
(4) Weight Average Particle Size of Composite Particles (μm)
[0127] 10 g of a powder sample (dried composite particles) was sieved for 10 minutes using a Ro-Tap type sieve shaker (made by Taira Kosakusho Ltd., trade name “Sieve Shaker type A”) with a JIS standard sieve (Z8801-1987) to measure particle size distribution, and the weight average particle size of the powder sample was defined as a 50% cumulative weight particle size. The particle size distribution was determined using a 300 μm sieve, a 212 μm sieve, a 177 μm sieve, a 150 μm sieve, a 106 μm sieve, a 75 μm sieve, and a 38 μm sieve.
[0000] (5) Pore Size (μm), Intraparticle Pore Volume (cm 3 /g), Porosity (%)
[0128] Pore distribution was determined using a trade name “Autopore type 9520” made by SHIMADZU Corporation according to mercury porosimetry. Approximately 0.03 g to 0.05 g of each of sample powders used in the measurement was placed in a standard cell, and the pore distribution was measured twice on the condition of an initial pressure of 7 kPa (corresponding to approximately 1 psia, pore diameter of approximately 18 μm). From the obtained pore distribution, a volume at a pore size in the specific range of 0.003 to 1.0 μm was calculated as the pore volume. The porosity is the proportion of the pore volume to the volume of the sample when mercury is pressed into pores having a diameter of approximately 180 μm at an initial atmospheric pressure.
(6) Repose Angle (°)
[0129] Using a Sugihara-type repose angle measuring instrument (slit size depth 10×width 50×height 140 mm, a protractor was set at a position of 50 mm in width), a sample was continuously deposited in a measurement part little by little (3 g/min as a guideline) with an electromagnetic feeder (MF-1 type/TSUTSUI SCIENTIFIC INSTRUMENTS CO., LTD.). Thus, an inclined surface was formed. Immediately when an excessive sample started falling and the inclined surface became substantially linear, the feeder was turned off. The angle of the inclined surface was measured with the set protractor, and defined as the repose angle.
(7) Method for Compressing Sample
[0130] 0.5 g of a sample was weighed, and placed in a die (Kikusui Seisakusho Ltd., a material used was SUS2,3). The sample was compressed with a punch having a circular flat surface having a diameter of 1.1 cm (made by Kikusui Seisakusho Ltd., a material of SUS2,3 was used) until the pressure reached 10 MPa (made by AIKOH ENGINEERING CO., LTD., a trade name “PCM-1A”, compression rate of 1 cm/min), and kept at a target pressure for 10 seconds to produce a cylindrical molded article.
(8) Hardness of Tablet (N)
[0131] Using a Schleuniger hardness tester (made by Freund Corporation, trade name “8M type”), a load was applied to a cylindrical molded article or a tablet in the diameter direction of the cylindrical molded article or tablet, and the load when the cylindrical molded article or tablet was broken was measured. The hardness of the tablet was defined as the average value obtained from ten samples.
[0000] (9) Apparent Specific Volume (cm 3 /g)
[0132] A 25 cm 3 container was set in a Scott Volumeter (made by VWR SCIENTIFIC, 564985 type). Next, using an electromagnetic feeder (MF-1 type/TSUTSUI SCIENTIFIC INSTRUMENTS CO., LTD.), a sample was put into the container at a rate of 10 to 20 g/min. When the sample overflowed from the set container, the container was taken out. An excessive amount of the sample was leveled off, and the mass of the sample was measured. The apparent specific volume was defined as a value (cm 3 /g) obtained by dividing the volume of the container (25 cm 3 ) by the mass of the sample. The sample was measured twice, and the average value was used.
(10) Retention Rate of Tocopherol Acetate (%)
[0133] 2 g of a sample was weighed. While the sample was kneaded, tocopherol acetate (viscosity at 25° C.: 3300 mPa·s) was dropped on the sample little by little. The end point was defined as the amount of the liquid when the liquid eluted on the surface of the sample. The retention rate of tocopherol acetate is represented by the following expression: retention rate of tocopherol acetate (%)=amount of dropped liquid g/2 g of sample×100 The measurement value was defined as the average value of measurement values obtained from two samples.
(11) The Number of Capping to be Occurred
[0134] 50 tablets after tableting were arbitrarily sampled, and the number of the tablets cracked or partially peeled was counted.
(12) Sticking Occurrence Rate (%)
[0135] 50 tablets were examined visually, and the number of the tablets having peel-off or damages on the surface was counted. The sticking occurrence rate (%) was defined as the proportion of the number of tablets having sticking.
(13) Weight CV Value
[0136] 10 tablets after tableting were arbitrarily sampled, and the weights of the samples were measured. From the average value and standard deviation of the measured values, the weight CV value was defined as weight CV value=(standard deviation/average value)×100[%]. A larger weight CV value causes larger variation in the weight, leading to increase in variation in the content of the drug and reduced yield of products. At a weight CV value of more than 1.0%, practical problems arise.
(14) Scanning Electron Microscope Photograph (Hereinafter, Abbreviated to SEM)
[0137] Measurement was performed using an electron microscope (made by JEOL, Ltd., JSM-551OLV type). A sample was mounted on a sample moving stage. According to a gold deposition method (AUTO FINE COATER, made by JEOL, Ltd., JFC-1600 type), the surface of the sample is thinly and uniformly coated with metal particles. Then, the sample moving stage was installed within a sample chamber. The inside of the sample chamber was made to be vacuum. The sample position was irradiated with an electron beam, and an enlarged image of the portion to be observed was output.
(15) Average Polymerization Degree
[0138] The average polymerization degree was defined as the value measured by a copper ethylenediamine solution viscosity method described in the Identification Test for Microcrystalline Cellulose (3) of The Japanese Pharmacopoeia, Fourteenth Edition.
(16) L/D of Cellulose Particles Dispersed in Water
[0139] The average L/D of cellulose particles dispersed in water was measured as follows. Using a JIS standard sieve (Z8801-1987), an aqueous dispersion liquid of the cellulose was passed through a 75 μm sieve. In the particles remaining on a 38 μm sieve, an optical microscope image of the remaining particles was subjected to an image analysis processing (made by Inter Quest Co., Ltd., apparatus: Hyper700, software: Imagehyper). The L/D of a particle was defined as the ratio of a longer side to a shorter side (longer side/shorter side) of the rectangle having the smallest area among rectangles circumscribed about the particle. The average L/D of the particle was obtained using the average value of L/D obtained from at least 100 particles.
Example 1
[0140] A broad leaf tree was subjected to known pulping and bleaching treatments to obtain a pulp (the average width of the cellulose primary particle was approximately 19 μm, and the average thickness of the cellulose primary particle was approximately 3 μm). 4.5 kg of the chipped pulp and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 124° C. for 1 hour to obtain an acid insoluble residue (hereinafter, referred to as a Wet cake). The volume average particle size of the cellulose particle was measured by a laser diffraction/scattering particle size distribution analyzer (made by HORIBA, Ltd., trade name “LA-910”) at a refractive index of 1.20. The obtained volume average particle size was 25 μm.
[0141] Pure water was introduced into a plastic bucket. While pure water was stirred by a 3-1 motor, the Wet cake was added and mixed. Next, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) was added and mixed. The mass ratio was cellulose/calcium silicate=28.6/71.4 (based on the solid content), and the concentration of the total solid content was approximately 8.5% by mass. The obtained mixture was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 70 to 95° C., number of rotation of an atomizer of 15000 rpm) to obtain Composite Particles A. The physical properties of Composite Particles A are shown in Table 1.
Examples 2 and 3
[0142] A broad leaf tree was subjected to known pulping treatment and bleaching treatments to obtain a pulp (the average width of the cellulose primary particle was approximately 19 μm, and the average thickness of the cellulose primary particle was approximately 3 μm). 4.5 kg of the chipped pulp and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 124° C. for 1 hour to obtain an acid insoluble residue (hereinafter, referred to as a Wet cake). The volume average particle size of the cellulose particle was measured by a laser diffraction/scattering particle size distribution analyzer (made by HORIBA, Ltd., trade name “LA-910”) at a refractive index of 1.20. The obtained volume average particle size was 25 μm.
[0143] Pure water was introduced into a plastic bucket. While pure water was stirred by a 3-1 motor, starch (made by Asahi Kasei Chemicals Corporation, trade name “SWELSTAR” WB-1) was added and mixed. Next, the Wet cake was added and mixed. Next, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) was added and mixed. The mass ratio was starch/cellulose/calcium silicate=10/20/1970 (based on the solid content), and the concentration of the total solid content was approximately 8.5% by mass (pH was 10.2). The obtained mixture was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 70 to 95° C., number of rotation of an atomizer of 15000 rpm, 30000 rpm). Thus, Composite Particles B (number of rotation of an atomizer of 15000 rpm) and Composite Particles C (number of rotation of an atomizer of 30000 rpm) were obtained. The physical properties of Composite Particles B and C are shown in Table 1.
Examples 4 and 5
[0144] A broad leaf tree was subjected to known pulping and bleaching treatments to obtain a pulp (the average width of the cellulose primary particle was approximately 19 μm, and the average thickness of the cellulose primary particle was approximately 3 μm). 4.5 kg of the chipped pulp and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 124° C. for 1 hour to obtain an acid insoluble residue (hereinafter, referred to as a Wet cake). The volume average particle size of the cellulose particle was measured by a laser diffraction/scattering particle size distribution analyzer (made by HORIBA, Ltd., trade name “LA-910”) at a refractive index of 1.20. The obtained volume average particle size was 25 μm.
[0145] Pure water was introduced into a plastic bucket. While pure water was stirred by a 3-1 motor, the Wet cake was added and mixed. Next, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) was added and mixed. The mass ratio was cellulose/calcium silicate=20/80 (based on the solid content), and the concentration of the total solid content was approximately 8.5% by mass. The mixture was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 70 to 95° C., number of rotation of an atomizer of 15000 rpm and 30000 rpm). Thus, Composite Particles D (number of rotation of an atomizer of 15000 rpm), and Composite Particles E (number of rotation of an atomizer of 30000 rpm) were obtained. The physical properties of Composite Particles D and E are shown in Table 1.
Examples 6 and 7
[0146] Composite particles F (number of rotation of an atomizer of 15000 rpm) and Composite Particles G (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 2 and 3 except that the mass ratio was starch/cellulose/calcium silicate=5/40/55 (based on the solid content). The physical properties of Composite Particles F and G are shown in Table 1.
Examples 8 and 9
[0147] Composite Particles H (number of rotation of an atomizer of 15000 rpm) and Composite Particles I (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 2 and 3 except that the mass ratio was starch/cellulose/calcium silicate=7/43/50 (based on the solid content), and the concentration of the total solid content was 9.3% by mass. The physical properties of Composite Particles H and I are shown in Table 1.
Examples 10 and 11
[0148] Composite particles J (number of rotation of an atomizer of 15000 rpm) and Composite Particles K (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 4 and 5 except that the mass ratio was cellulose/calcium silicate=60/40 (based on the solid content), and the concentration of the total solid content was 11.7% by mass. The physical properties of Composite Particles J and K are shown in Table 1.
Examples 12 and 13
[0149] Composite particles L (number of rotation of an atomizer of 8000 rpm) and Composite Particles M (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Examples 2 and 3 except that the mass ratio was starch/cellulose/calcium silicate=3/60/37 (based on the solid content), the concentration of the total solid content was 11.7% by mass, and the number of rotation of an atomizer was 8000 rpm and 30000 rpm. The physical properties of Composite Particles L and M are shown in Table 1.
Example 14
[0150] Composite particles N (number of rotation of an atomizer of 15000 rpm) were obtained in the same manner as in Example 2 except that the mass ratio was starch/cellulose/calcium silicate=2.5/72.5/25 (based on the solid content), and the concentration of the total solid content was 11.7% by mass. The physical properties of Composite Particles N are shown in Table 1.
Example 15
[0151] Composite particles O (number of rotation of an atomizer of 30000 rpm) were obtained in the same manner as in Example 5 except that the mass ratio was cellulose/light anhydrous silicic acid=50/50 (based on the solid content), and the concentration of the total solid content was 4% by mass. The physical properties of Composite Particles O are shown in Table 1.
Example 16
[0152] Composite particles P (number of rotation of an atomizer of 15000 rpm) were obtained in the same manner as in Example 4 except that the mass ratio was cellulose/magnesium aluminometasilicate=30/70 (based on the solid content), and the concentration of the total solid content was 5% by mass. The physical properties of Composite Particles P are shown in Table 1.
Example 17
[0153] Composite particles Q (number of rotation of an atomizer of 15000 rpm) were obtained in the same manner as in Example 4 except that the mass ratio was cellulose/magnesium silicate hydrate=50/50 (based on the solid content), and the concentration of the total solid content was 5% by mass. The physical properties of Composite Particles Q are shown in Table 1.
[0000]
TABLE 1
Inorganic
Cellulose
compound
volume
volume
Cellulose
Cellulose
average
average
Inorganic
Starch
average
average
particle
particle
Cellulose
compound
Kind of
parts
width
thickness
size
size
parts by
parts by
inorganic
by
Table 1
[μm]
[μm]
[μm]
[μm]
mass
mass
compound
mass
Example 1
A
19
3
35
25
28.6
71.4
Calcium silicate Ca
—
Example 2
B
19
3
25
25
20
70
Calcium silicate Ca
10
Example 3
C
19
3
25
25
20
70
Calcium silicate Ca
10
Example 4
D
19
3
25
25
20
80
Calcium silicate ca
—
Example 5
E
19
3
25
25
20
80
Calcium silicate Ca
—
Example 6
F
19
3
25
25
40
55
Calcium silicate Ca
5
Example 7
G
19
3
25
25
40
55
Calcium silicate Ca
5
Example 8
H
19
3
25
25
43
50
Calcium silicate Ca
7
Example 9
I
19
3
25
25
43
50
Calcium silicate Ca
7
Example 10
J
19
3
25
25
60
40
Calcium silicate Ca
—
Example 11
K
19
3
25
25
60
40
Calcium silicate Ca
—
Example 12
L
19
3
25
25
60
37
Calcium silicate Ca
3
Example 13
M
19
3
25
25
60
37
Calcium silicate Ca
3
Example 14
N
19
3
25
25
72.5
25
Calcium silicate Ca
2.5
Example 15
O
19
3
20
0.016
50
50
Light anhydrous
—
silicic acid
Example 16
P
19
3
25
12
30
70
Magnesium
—
aluminometasilicate
Example 17
Q
19
3
50
0.07
50
50
Magnesium silicate
—
hydrate Mg
Weight
Retention
Apparent
average
rate of
Hardness
specific
Repose
Pore
particle
tocopherol
of
volume
angle
Volume
Porosity
size
acetate
tablet
Table 1
[cm 3 /g]
[°]
[cm 3 /g]
[%]
[μm]
[%]
[N]
Example 1
A
10.8
35
2.71
33.1
48
860
240
Example 2
B
10.4
34.5
2.70
32.4
38
830
233
Example 3
C
10.7
37.5
2.81
33.1
55
860
244
Example 4
D
11.5
35
3.15
35.5
31
915
325
Example 5
E
11.6
36.5
3.15
35.5
32
875
312
Example 6
F
8.7
32
1.97
27.4
80
703
243
Example 7
G
8.8
34
2.09
28.2
60
738
261
Example 8
H
9.4
30
2.32
29.8
90
725
264
Example 9
I
8.7
33
2.05
28.0
70
760
240
Example 10
J
8.2
35
1.84
26.5
65
575
239
Example 11
K
7.7
39
1.63
25.0
50
520
220
Example 12
L
7.1
35
1.43
23.8
210
590
190
Example 13
M
7.2
35.5
1.48
24.1
61
530
200
Example 14
N
7.1
38.5
1.44
23.9
49
485
236
Example 15
O
12.5
41
1.50
25.1
29
500
150
Example 16
P
10.5
37
1.55
24.9
40
510
170
Example 17
Q
11.6
38
1.21
20.2
38
450
148
Reference Example 1
[0154] 100 g of pure water was introduced into a stainless steel jug. While pure water was stirred by a 3-1 motor, calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 to 30 μm) was added little by little with a dispensing spoon and stirred. When the amount of calcium silicate added reached 10.7 g, stirring became impossible.
Reference Example 2
[0155] Pure water was introduced into a stainless steel jug. While pure water was stirred by a 3-1 motor, the Wet cake obtained in Example 1 was added and mixed. Next, while SiO 2 (trade name: Aerosil 200, made by Nippon Aerosil Co., Ltd., volume average particle size of 0.016 μm) was added little by little with a dispensing spoon, the materials were stirred and mixed. The mass ratio was cellulose/light anhydrous silicic acid=29.3/70.7 (based on the solid content), and the concentration of the total solid content was 8.5% by mass (pH was 10.2). The obtained product was gluey, and could not be spray dried.
Reference Example 3
[0156] Pure water was introduced into a stainless steel jug. While pure water was stirred by a 3-1 motor, the Wet cake obtained in Example 1 was added and mixed. Next, magnesium aluminometasilicate (trade name: Neusilin, made by Fuji Chemical Industry Co., Ltd.) was mixed. The mass ratio was cellulose/magnesium aluminometasilicate=31.0/69.0 (based on the solid content), and the concentration of the total solid content was 11.7% by mass (pH was 10.2). The obtained product was creamy, and could not be spray dried.
Comparative Example 1
[0157] The physical properties of calcium silicate (made by Tokuyama Corporation, product name: Florite R, volume average particle size of 25 μm) are shown in Table 2.
Comparative Example 2
[0158] Composite particles R were obtained in the same manner as in Example 4 except that the mass ratio was starch/cellulose/calcium silicate=2.5/72.5/25 (based on the solid content), and the concentration of the total solid content was 11.7% by mass. The physical properties of Composite Particles R are shown in Table 2.
Comparative Example 3
[0159] 2 kg of a chipped commercially available dissolved pulp (acicular tree pulp, average width of the cellulose primary particle was approximately 39 μm, average thickness of the cellulose primary particle was approximately 8 μm) and 30 L of a 0.4% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 116° C. for 1 hour to obtain an acid insoluble residue (the volume average particle size of the cellulose dispersed particle was 51 and L/D was 3.4). The obtained acid insoluble residue and silicon dioxide (made by Tokuyama Corporation, trade name, FINESEAL, volume average particle size of 5 μm) as a water insoluble inorganic compound were introduced into a 90 L plastic bucket at an amount ratio of 30/70 (based on the solid content). Pure water was added such that the concentration of the total solid content became 20% by weight. While the materials were stirred by a 3-1 motor, the materials were neutralized with aqueous ammonia (pH after neutralization was 7.5 to 8.0). The obtained product was spray dried (dispersion liquid feed rate of 6 kg/hr, inlet temperature of 180 to 220° C., outlet temperature of 50 to 70° C., number of rotation of an atomizer of 30000 rpm) to obtain Composite Particles S (corresponding to Example 2 in Patent Literature 3). The physical properties of Composite Particles S are shown in Table 2.
Comparative Example 4
[0160] 2 kg of a chipped commercially available pulp (acicular tree pulp, average width of the cellulose primary particle was approximately 39 μm, average thickness of the cellulose primary particle was approximately 8 μm) and 30 L of a 0.2% hydrochloric acid aqueous solution were put into a low speed stirrer (made by Ikebukuro Horo Kogyo Co., Ltd., trade name, 30LGL reactor). While the chipped pulp and the aqueous solution were stirred, hydrolysis was performed at 116° C. for 1 hour to obtain an acid insoluble residue (the volume average particle size of the cellulose dispersed particle was 72 μm, and L/D was 4.0). And talc (made by Wako Pure Chemical Industries, Ltd., prepared so as to have a volume average particle size of 5 μm) were introduced into a 90 L plastic bucket at an amount ratio of 98/2 (based on the solid content). Pure water was added such that the concentration of the total solid content became 10% by weight. While the materials were stirred by a 3-1 motor, the materials were neutralized with aqueous ammonia (pH after neutralization was 7.5 to 8.0). The obtained product was spray dried in the same manner as that in Comparative Example 3 to obtain Composite Particles T (corresponding to Example 6 in Patent Literature 3). The physical properties of Composite Particles T are shown in Table 2.
Comparative Example 5
[0161] Ceolus PH-101 (made by Asahi Kasei Chemicals Corporation) was used as a microcrystalline cellulose. The cellulose and calcium silicate at a mass ratio of cellulose/calcium silicate=28.6/71.4 were sufficiently mixed in a plastic bag for 3 minutes to obtain Mixture U of cellulose/calcium silicate (the mixture having the largest amount of silicic acid to be blended which is described in Patent Literature 4). The physical properties of Mixture U are shown in Table 2.
Comparative Example 6
[0162] Ceolus PH-101 (made by Asahi Kasei Chemicals Corporation) was used as a microcrystalline cellulose. The cellulose and calcium silicate at a mass ratio of cellulose/calcium silicate=71.4/28.6 were sufficiently mixed in a plastic bag for 3 minutes to obtain Mixture V of cellulose/calcium silicate (the mixture having the smallest amount of silicic acid to be blended which is described in Patent Literature 4). The physical properties of Mixture V are shown in Table 2.
[0000]
TABLE 2
Inorganic
Cellulose
Cellulose
compound
Inorganic
average
average
Cellulose
particle
Cellulose
compound
Starch
width
thickness
particle size
size
parts by
parts by
Kind of inorganic
parts by
[μm]
[μm]
[μm]
[μm]
mass
mass
compound
mass
Comparative
—
—
—
—
25
—
100
Calcium silicate Ca
—
Example 1
Comparative
R
19
3
22-27
25
72.5
25
Calcium silicate Ca
2.5
Example 2
Comparative
S
39
8
51
≦0.1
30
70
Silicon dioxide
—
Example 3
Comparative
T
39
8
72
5
98
2
Talc
—
Example 4
Comparative
U
39
8
38
25
28.6
71.4
Calcium silicate Ca
—
Example 5
Comparative
V
39
8
38
25
71.4
28.6
Calcium silicate Ca
—
Example 6
Retention
Apparent
Average
rate of
specific
Repose
Pore
particle
tocopherol
Hardness
volume
angle
volume
Porosity
size
acetate
of tablet
[cm 3 /g]
[°]
[cm 3 /g]
[%]
[μm]
[%]
[N]
Comparative
—
13.7
40
3.95
41.0
56
885
348
Example 1
Comparative
R
6.9
40.5
1.37
23.3
50
440
215
Example 2
Comparative
S
5.1
32
1.25
22.1
52
400
45
Example 3
Comparative
T
6
45
0.29
17.2
45
204
110
Example 4
Comparative
U
11
42
1.88
27.1
29
687
265
Example 5
Comparative
V
7.4
38
1.00
20.4
39
390
145
Example 6
<SEM Photograph>
[0163] Using a “JSM-5510LV type” electron microscope made by JEOL, Ltd., Composite Particles B, D, G, I, K, and M were observed by SEM.
[0164] It is found that the particle has relatively few irregularities on the surface, and has a shape close to a sphere in Composite Particles B in Example 2 (see FIG. 1 ), Composite Particles D in Example 4 (see FIG. 2 ), Composite Particles G in Example 7 (see FIG. 3 ), and Composite Particles I in Example 9 (see FIG. 4 ). It is also found that the cellulose WET cake (see FIG. 5 ) and calcium silicate in Reference Example 2 (see FIG. 6 ) are formed into a composite product which has gaps. The gaps can provide a molded article having high liquid retention rate and hardness.
[0165] Meanwhile, the particle has irregularities on the surface in Composite Particles K in Example 11 ( FIG. 7 ) and Composite Particles M in Example 13 (see FIG. 8 ).
<Evaluation of Prevention of Sticking>
[0166] Ibuprofen is a representative example of a drug easy to stick. Using ibuprofen, comparison was made about the sticking-preventing effect. Granulated granules having ibuprofen blended were produced by the following method.
[0167] In the total amount of ingredients of 1000 g, 45% of ibuprofen (made by API Corporation), 38% of lactose hydrate (trade name: lactose 200M, made by DMV International), and 17% of corn starch (GRDE: ST-C, made by NIPPON STARCH CHEMICAL CO., LTD.) were weighed and mixed in a polyethylene bag for 3 minutes. Then, the mixture was placed in a vertical granulator (made by Powrex Corporation, FM-VG-10P type) and mixed (blade at 200 rpm, chopper at 2100 rpm). 200 g of a hydroxypropyl cellulose (trade name: HPC-L, made by NIPPON SODA CO., LTD.) 6% solution was poured over 30 seconds. Further, the ingredients were mixed (granulated) for 3 minutes, and taken out from the granulator. Next, the mixture was dried using a MULTIPLEX (made by Powrex Corporation, MP-01 type). The drying was completed when the temperature of exhaust air reached 40° C. Then, a granulated product was extracted. The granulated product was sieved with a sieve having an opening of 710 and used as a test sample (hereinafter, referred to as granulated granules).
Example 18
[0168] 88% by mass of the granulated granules, 2% by mass of croscarmellose sodium (made by NICHIRIN CHEMICAL INDUSTRIES, LTD.), “KICCOLATE” ND-2HS), and 10% by mass of Composite Particles C of Example 3 were mixed in a polyethylene bag for 3 minutes. Next, based on the total weight of the mixed powder, 0.5% by mass of magnesium stearate (made by TAIHEI CHEMICAL INDUSTRIAL CO., LTD.) was added, and mixed slowly for 30 seconds. Using a rotary tableting machine (made by Kikusui Seisakusho Ltd., CLEANPRESS CORRECT 12HUK), the mixed powder was tableted with a punch having a diameter of 0.8 cm and 12R on the condition of the number of rotation of the turn table of 54 rpm, a compression force of 5 to 15 kN, and open feed. Thus, a tablet having a weight of 180 mg was produced. The physical properties of the tablet are shown in Table 3.
Example 19
[0169] The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Composite Particles H of Example 8. The physical properties of the tablet are shown in Table 3.
Comparative Example 7
[0170] The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by light anhydrous silicic acid (made by Nippon Aerosil Co., Ltd., Aerosil 200). The physical properties of the tablet are shown in Table 3.
Comparative Example 8
[0171] The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Composite Particles S of Comparative Example 3. The physical properties of the tablet are shown in Table 3.
Comparative Example 9
[0172] The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Composite Particles T of Comparative Example 4. The physical properties of the tablet are shown in Table 3.
Comparative Example 10
[0173] The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Mixture U of Comparative Example 5. The physical properties of the tablet are shown in Table 3.
Comparative Example 11
[0174] The operation was performed in the same manner as that in Example 18 except that Composite Particles C used in Example 18 were replaced by Mixture V of Comparative Example 6. The physical properties of the tablet are shown in Table 3.
[0000]
TABLE 3
Sticking occurrence
Number of
Items
Hardness [N]
Mass CV [%]
Friability [%]
rate [%]
cappings occurred
Compression force [kN]
5
10
15
5
10
15
5
10
15
15
15
Example 18
Composite particles C
59
85
102
0.5
0.6
0.5
0.45
0.15
0.11
0
None
Example 19
Composite particles H
70
90
79
0.9
0.5
0.9
0.16
0.08
0.17
0
None
Comparative
Light anhydrous silicic
30
53
38
2.2
2.1
1.6
0.39
0.43
2.85
0
2
Example 7
acid
Comparative
Composite particles S
20
35
40
1.9
2.3
1.5
2.50
1.90
1.20
5
25
Example 8
Comparative
Composite particles T
20
48
60
2.8
1.8
3.4
2.40
1.00
0.80
20
5
Example 9
Comparative
Mixture U
26
40
30
1.5
1.4
1.9
1.00
0.90
0.80
10
25
Example 10
Comparative
Mixture V
20
37
43
1.8
1.6
2.1
1.8
1.20
0.70
50
40
Example 11
[0175] In Examples 18 and 19, tablets having a practical hardness of 50 N or more, the weight CV value of 1.0% or less, and no tableting problems (sticking, capping) were obtained. Meanwhile, in Comparative Example 7, tableting problems (no sticking, but two cappings) were occurred. The weight CV value was more than 1.0%. Accordingly, the tablet in Comparative Example 7 is not suitable for practical use. In Comparative Examples 8 to 11, the weight CV value was more than 1.0%, and tableting problems (sticking, capping) were remarkable. Accordingly, the tablets in Comparative Examples 8 to 11 are not suitable for practical use.
[0176] In Comparative Example 9, a practical hardness of 50 N or more was obtained at the compression force of 15 kN while the friability was 0.8% and did not satisfy the practical level of 0.5% or less.
[0177] The disintegrating time of the tablet was measured in the respective tablets, but no remarkable difference was found among the tablets.
<Method for Producing Emulsion Solution>
[0178] 360 g of Riken tocopherol acetate (Riken Vitamin Co., Ltd.) as an liquid active ingredient, Tween 80 (Wako Pure Chemical Industries, Ltd.), and 1000 g of pure water were weighed, and stirred and mixed with a TK homomixer (PRIMIX Corporation, MARK2 2.5 type) at 10000 rpm for 15 minutes to produce an emulsified solution.
Example 20
[0179] 360 g of Composite Particles C of Example 3 was put into a vertical granulator (made by Powrex Corporation, FM-VG-10P). While Composite Particles C were mixed on the condition of a blade at 200 rpm and a chopper at 2100 rpm, 360 g of the emulsified solution produced above was poured in 30 seconds. The obtained mixture was granulated for 6 minutes, and discharged. Next, the granulated product was dried with an oven (made by Tabai Espec Corp., ESPEC Oven PV-211), and passed through a sieve having an opening of 710 μm (made by Iida Seisakusho K.K., sieve for a test) to obtain a dried product. The dried product was used as a test sample (hereinafter, referred to as VE granules). The repose angle of the VE granules was 35° and good.
[0180] 35% by mass of the VE granules, 45% by mass of a microcrystalline cellulose (made by Asahi Kasei Chemicals Corporation, UF-711), 18% by mass of anhydrous dibasic calcium phosphate (made by Fuji Chemical Industry Co., Ltd., Fujicalin), and 2% by mass of croscarmellose sodium (made by NICHIRIN CHEMICAL INDUSTRIES, LTD, “KICCOLATE” ND-2HS) were mixed in a polyethylene bag for 3 minutes. Next, based on the total weight of the mixed powder, 2.0% by mass of magnesium stearate (made by TAIHEI CHEMICAL INDUSTRIAL CO., LTD.) was added, and further mixed slowly for 30 seconds. Using a rotary tableting machine (made by Kikusui Seisakusho Ltd., LIBRA2), the mixed powder was tableted using a punch having a diameter of 0.8 cm and 12R on the condition of the number of rotation of the turn table of 30 rpm, the compression force of 2 to 7 kN, and open feed to produce a tablet having a weight of 200 mg. The physical properties of the tablet are shown in Table 4.
Comparative Example 12
[0181] The operation was performed in the same manner as in Example 20 except that Composite Particles C were replaced by calcium silicate (made by Tokuyama Corporation, product name: Florite Grade(R), volume average particle size (which was measured at the state of aggregated particles) of 25 to 30 μm). The physical properties of the tablet are shown in Table 4. The repose angle of the VE granules was 41°. Fluidity was inferior to that in the case where Composite Particles C were used.
Comparative Example 13
[0182] The operation was performed in the same manner as in Example 20 except that Composite Particles C were replaced by Composite Particles S. The physical properties of the tablet are shown in Table 4.
Comparative Example 14
[0183] The operation was performed in the same manner as in Example 20 except that Composite Particles C were replaced by Mixture U. The physical properties of the tablet are shown in Table 4.
[0000]
TABLE 4
Items
Sticking occurrence rate [%]
Compression force [kN]
2
3
4
5
6
7
Example 20
Composite particles C
0
0
0
Comparative
Calcium silicate
31.0
11.3
75.0
Example 12
Comparative
Composite particles S
Powder cannot be obtained
Example 13
Comparative
Mixture U
Powder cannot be obtained
Example 14
[0184] In Example 20, a tablet having a practical hardness of 50 N or more, a weight CV value of 1.0% or less, and no tableting problems (sticking, capping) were obtained. Meanwhile, in Comparative Example 12, the sticking occurrence rate was not 0 at all of the compression forces. Accordingly, the tablet is not suitable for practical use. In Comparative Examples 13 and 14, the retention rate of tocopherol acetate was low, and powder could not be obtained.
INDUSTRIAL APPLICABILITY
[0185] The composite particles according to the present invention have extremely high compactibility and fluidity. For this reason, the composite particles according to the present invention have high uniformity of mixing with the active ingredients when the composite particles according to the present invention are used as an excipient mainly in the pharmaceutical field in production of a molded article containing a variety of active ingredients. Moreover, the composite particles according to the present invention can keep the compactibility and fluidity of the particles even after retention of the liquid to prevent tableting problems. In addition, the weight of the molded article according to the present invention is hardly fluctuated. The molded article according to the present invention has high uniformity of the active ingredients contained, high sufficient hardness, and low friability. | Provided are composite particles which exhibit excellent fluidity and high liquid retentivity and which exhibit high fluidity even in a liquid-holding sate. Also provided are composite particles which permit direct compressing in an open feed manner and which suffer from little compressing trouble and exhibit high shapability. When shaped together with an active ingredient, the composite particles provide shaped bodies which have uniform weight, uniform active ingredient content, and high hardness and which suffer from less galling. | 8 |
The invention concerns a clocking system, used for clocking digital circuits, in which the periodic collapse and expansion of a sinusoidal standing wave is used as a clock signal.
BACKGROUND OF THE INVENTION
One factor which limits the speed of operation of computers is the requirement of delivering synchronous clock signals to modules which are physically separated. For example, it is often required that two modules M1 and M2 in FIG. 1 receive synchronous clock signals 3 from a clock CL. Clock CL delivers the clock signals 3 to a branched transmission line 6, and they travel in the direction of arrow 8.
One way to make the clock signals synchronous is to assure that they arrive at M1 and M2 simultaneously, by locating modules M1 and M2 equidistant from clock CL. (FIG. 1 does not show this.) However, in the general case, equal distances cannot be attained, for practical reasons.
When the distances are not equal, the situation shown in FIG. 1 can occur. When clock pulse P1 reaches module M2, a later pulse P4 reaches module M1. This represents non-synchronous operation, because, at any given time, the modules respond to different clock pulses. Module M1 operates four clock cycles ahead of module M2.
To attain synchronous operation, the modules can be positioned as shown in FIG. 2, wherein their pick-off points 10 are 1/2 wavelength apart, or less. With this positioning, the situation will never arise wherein one pulse, such as P1, triggers module M2 while a later pulse, such as P2, triggers module M1.
In actual practice, the modules are frequently spaced closer, at 1/10 wavelength. The physical distance which this 1/10 wavelength spacing represents will now be estimated. As a rough estimate, signal travel on both printed circuit boards (PCBs) and integrated circuits (ICs) is in the range of one-half the speed of light. A rule-of-thumb for the speed of light is one foot per nano-second, so that a clock pulse, in a PCB or IC, takes about two nano-seconds to travel one foot.
If the wavelength of the clock pulse is one foot, then one wavelength occurs every 2 nano-seconds. The frequency is then 1/(2×10 -9 ), or 5×10 8 Hz, which is 0.5 Giga-Hertz, GHz. One-tenth of this one-foot wavelength is 1.2 inches.
Thus, under the 1/10 wavelength limitation, the maximum separation between modules M1 and M2 allowed by a clock running at 0.5 GHz would be 1.2 inches. For other clock frequencies and other signal velocities, the limits on separation are computed in the same way. In general, as clock frequencies increase, the separation between modules receiving the same clock signals must be reduced. This reduction creates problems in the design of digital circuitry, because, in general, designers wish to avoid constraints on the positioning of modules such as M1 and M2.
OBJECTS OF THE INVENTION
An object of the invention is to provide high-speed synchronous clocks to multiple digital devices.
SUMMARY OF THE INVENTION
In one form of the invention, a standing wave is used to clock digital circuitry located at various positions along the wave.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates two modules being clocked by different clock pulses.
FIG. 2 illustrates positioning the modules of FIG. 1 sufficiently closely to assure that they are clocked by the same clock pulse.
FIG. 3 illustrates one cycle 30 of a wave approaching a perfect conductor 33.
FIG. 4 illustrates one cycle 36 of a wave reflected from the perfect conductor.
FIGS. 5-13 illustrate various stages of two oppositely traveling waves crossing each other, together with their SUM at each stage.
FIG. 14 illustrates one form of the invention.
FIG. 15 illustrates detectors D1-D3 used with the apparatus of FIG. 14. FIGS. 16A, 16B, and 16C illustrate another form of the invention. FIG. 17 illustrates another form of the invention.
FIG. 18 illustrates two mathematical expressions, used to provide an analytical description of the standing wave at any location.
FIG. 19 illustrates one form of the invention. The PLLs contain automatic gain-control circuitry.
FIG. 20 illustrates a specific embodiment of the form of the invention shown in FIG. 19.
DETAILED DESCRIPTION OF THE INVENTION
This discussion will first explain how certain types of standing waves are created, and then explain how a generalized standing wave can be used as a clock signal.
First, expression (4), below, will be justified. Expression (4) is a classical equation for an electromagnetic wave reflected from a perfect conductor. The reader may wish to jump to expression (4) directly, because the justification to be given is known in the art, and is available in many textbooks.
FIG. 3 shows one cycle 30 of an electromagnetic wave approaching a perfect conductor 33. The electric field (not shown) of wave 30 is represented in phasor form as E + e -jkz , wherein:
"k" is the propagation constant,
"z" represents distance from the point z=0,
"j" is the imaginary operator, and
the "+"superscript of "E" means that the wave travels to the right.
FIG. 4 shows one cycle of reflected wave 36, which travels away from the perfect conductor 33. The electric field of that wave is represented as E 31 e +jkz , wherein the "-" superscript of "E" indicates that the wave travels to the left.
Assume that the distance to the left of the perfect conductor 33 is infinitely long, so that no additional reflections of the reflected wave 36 occur. That is, the only waves present are waves 30 and 36.
At the reflection point on the perfect conductor 33, the total electric field must be zero. Thus, at the point z=0, the incoming and reflected waves must sum to zero, as the following expression indicates:
.sup.+ e.sup.-jk0 +E-e.sup.+jk0 =0. (1)
Since the zeroes in the exponents cause the exponential terms to both equal unity, this expression indicates that E - =-E + .
To the left of the perfect conductor, the total electric field is the sum of the approaching wave and the reflected wave:
E.sub.tot =E.sup.+ e.sup.-jkz +E.sup.- e.sup.+jkz. (2)
Using the fact, just shown, that E - =-E + , this expression can be re-written as:
E.sub.tot =E.sup.+ e.sup.jkz -E.sup.+ e.sup.+jkz =E.sup.+ (e.sup.-jkz -e.sup.+jkz)=-2jE.sup.+ sin kz. (3)
This expression is the sinusoidal, steady-state, phasor representation of the electric field to the left of the perfect conductor. To obtain the instantaneous time-domain representation, that expression is multiplied by e jwt , wherein w is angular frequency and t is time, and then the real part is taken, to produce the expression (4), as promised above:
E.sub.tot (z,t)=Re[(-2jE.sup.+ sin kz)e.sup.jwt.sub.]= 2E.sup.+ (sin kz)(sin wt). (4)
While the preceding derivation was made in the context of an electromagnetic wave, it also applies to reflections on a transmission line. This derivation can be found in many textbooks on electromagnetic wave propagation or transmission line theory. One example of the former is Fields and Waves in Communication Electronics, 3d ed., Ramo, Whinnery & Van Duzer (John Wiley, 1994) ISBN 0 471 58551 3, which is hereby incorporated by reference.
FIGS. 5-13 illustrate the time-behavior of the standing wave in graphical format, and were generated by the software package MATHEMATICA, available from Wolfram Research, Inc., Champaign, Ill. In each Figure, a wave labeled RIGHT is traveling to the right, a wave labeled LEFT is traveling to the left, and a wave labeled SUM is the algebraic sum of the LEFT and RIGHT wave.
The sequence of the SUMs in the Figures illustrates the standing wave. The standing wave SUM is at its maximum value in FIG. 5. It is collapsing in FIGS. 6-8. It is zero in FIG. 9. In FIGS. 10-12, it is growing, but now as the negative of the waves in FIGS. 6-8. In FIG. 13 it reaches its negative maximum. Then, the sequence reverses: the standing wave SUM assumes the plots shown in FIG. 12, FIG. 11, . . . FIG. 5. Then, the sequence repeats again, beginning with FIG. 5 through FIG. 13, and then from FIG. 13 through FIG. 5.
Three significant features of the standing wave are the following.
1. One is that the zero-points, or nodes, N in FIG. 5, remain fixed in space. The standing wave has a value of zero at these nodes N, at all times.
2. A second is that, between the nodes, the standing wave fluctuates between two extreme values, shown in FIGS. 5 and 13.
3. A third is that, as in FIG. 9, the standing wave periodically assumes a value of zero at all locations.
In one form of the invention, the standing wave is used as a clock. A detector is placed between nodes N in FIG. 5, such as at point P10. The detector can take the form of a level detector, indicated by the digital comparator COMP. The comparator COMP is fed two signals. One is a fixed voltage reference, Vref, whose value is indicated by the dashed line labeled "Vref" in the SUM plot. The other is the standing wave picked off at point P10.
Whenever the standing wave SUM exceeds Vref, a clock pulse occurs. Thus, the comparator COMP produces the pulse train 50. This pulse train 50 is of the same frequency as the waves LEFT and RIGHT, as will be demonstrated later.
Another form of detector (not shown) can be a zero-crossing detector. Zero-crossing detectors are known in the art, and respond either a positive-to-negative zero crossing of the SUM signal, or a negative-to-positive zero crossing, as determined by their design.
FIG. 14 is a schematic of hardware which can implement one form of the invention. A sine wave generator 55 is connected to a loop 60 of coaxial cable, or other transmission line. The sine wave generator 55 creates two oppositely traveling sine waves, indicated by arrows 65 and 70.
Resistor R1 represents the source impedance of the sine wave generator 55, and resistor R2 is an external resistor, which is grounded. The values of the resistors R1 and R2 are chosen so that, after sine waves 65 and 70 traverse the loop 60 once, and return to point 75, no reflections occur. Under these conditions, only two oppositely traveling sine waves exist in the loop 60.
Of course, in some situations, a complex impedance may be required to suppress reflections. Thus, resistors R1 and R2 should be interpreted as generalized impedances.
Various detectors, such as D1, D2, and D3 in FIG. 15 are connected to the loop 60. They can be of the types described above. Each detector issues a clock signal, analogous to signal 50 in FIG. 5. The clock signal is used to trigger digital equipment (not shown).
FIG. 16 illustrates a particular embodiment, which can be implemented in an integrated circuit, or a printed circuit board. FIG. 16A is an exploded view, showing a conductive trace 90, a dielectric 85, and a ground plane 80.
FIG. 16B shows the components in assembled form, with a sine wave generator 100 added. The sine wave generator 40 launches two sine waves, indicated by arrows 105 and 110. These are oppositely traveling, as in the case of loop 60 in FIG. 15, and create a standing wave (not shown).
FIG. 16C shows an IC PIN 120. This pin 120 leads to an input of an integrated circuit (not shown) which contains a detector, such as one of the types identified above. The pin 120 does not contact the ground plane 80, but does contact the conductive trace 90. The pin 120 acts as a pick-off for the clock signal.
FIG. 17 illustrates another form of the invention, wherein the trace 90A is terminated by a TERMINATION 130. A single sine wave Al is launched into the trace, and is reflected at the TERMINATION 130, as indicated by arrow A3. Preferably, the TERMINATION 130 acts as a short circuit, providing a standing wave as described by equation (4) above. TERMINATION 130 can also be an open circuit.
ALTERNATE EMBODIMENT
It is not necessary that a standing wave actually be generated. In fact, when a standing wave is used in some situations, the nodes N in FIG. 5 can shift in position, causing difficulty in picking off a clock signal. As a specific example, under some conditions, when an attempt is made to generate a standing wave, the result is a standing wave over which is superimposed a traveling wave, which causes shifts in the nodes N.
To solve this problem, two waves can be generated on two transmission lines. The wave on each transmission line is sampled, and then normalized to, in effect, cause the magnitude of the underlying sine waves to become identical. For example, assume both sine waves are 2.0 volts peak-to-peak when leaving their respective generators. However, the waves may travel different distances, so that one wave may be 1/2 the peak-to-peak voltage of the other, at the sampling locations. In this example, the normalization amplifies the former wave by 2, and leaves the larger wave alone. After normalization, the waves are added.
FIG. 19 illustrates an apparatus for accomplishing this process, wherein a sinusoidal signal generator S1 produces a sine wave traveling in the direction of arrow A1 on transmission line L1. Another sinusoidal signal generator S2 produces a sine wave traveling in the direction of arrow A2 on transmission line L2. Terminations R1 and R2 are impedance-matched with the lines L1 and L2 to suppress reflections. Thus, the only wave on line L1 is that traveling in the direction of arrow A1, and the only wave on line L2 is that traveling in the direction of arrow A2.
Analog Phase-Locked-Loops (PLLs) 100 and 102 pick off signals from the lines L1 and L2. Each PLL produces a sine wave which is in-phase (or in-phase within a known amount of error) with the sine wave sampled. Further, the sine waves produced by the PLLs are of the same magnitude, regardless of the magnitude of the sampled sine waves. Such PLLs are known in the art, and can use automatic gain control circuits to establish this equality in magnitude. An example will illustrate the significance of this feature.
Assume that signal generators S1 and S2 both produce signals of identical magnitude. The signal, from signal generator S1, reaching point P20 will be different in magnitude from that reaching point P21 from signal generator S2. The reason is that the points lie at different distances from their respective signal generators, and thus the signals will experience different attenuations over those different distances.
However, since the PLLs produce output signals, on lines 106 and 109, which are of identical magnitude (in the phasor sense) to each other, the difference in signal magnitude at points P20 and P21 does not matter. From another point of view, the PLLs merely extract phase information from the signals on lines L1 and L2. The PLLs ignore the magnitude information, and fabricate sine waves of identical magnitude, based on the phase information extracted.
The outputs of the PLLs are added in summer SUM. The output 115 of the summer SUM is, in effect, a standing wave, as if detected at a single point on a single transmission line. A significant feature is that the distances of sampling locations P22 and P23 from their respective signal sources S1 and S2 are not important, nor is the distance between P22 and P23. For example, P22 can be located many wavelengths from source S1, P23 can be located many wavelengths from source S2, and P22 and P23 can be separated from each other by many wavelengths.
(However, each pick-off point P22 and P23 contains two taps, which are not shown. Regarding point P22, one tap is connected to the "signal" line of transmission line L1, and one is connected to the "ground" line. Preferably, the two individual taps should be the same distance from the signal source S1.)
To implement this embodiment on an integrated circuit or printed circuit board, the apparatus of FIG. 20 can be used. A sinusoidal signal source S produces a signal which is split by a signal splitter SP, and delivered to transmission lines T1 and T2. Resistors RA and RB represent the source resistance of source S, seen by lines T1 and T2. Terminations TERM1 and TERM2 suppress reflections at the ends of the lines.
With this arrangement, only a single wave exists on line T1, traveling in direction A1, and only a single wave exists on line T2, traveling in direction A2. Phase-Locked-Loops PLL sample the waves, as described in connection with FIG. 19.
It should be observed that, in the case of FIG. 14, two oppositely traveling sine waves are generated on a single transmission line. However, in FIG. 19, the concept of opposite travel is not defined. That is, source S2 and resistor R2 can be switched as to position. In such a case, the wave on line L2 would travel in the "same" direction as that on line L1.
ADDITIONAL CONSIDERATIONS
1. Ordinary clock signals, such as a 100 MHz clock used in a computer, produce significant amounts of Electro-Magnetic Interference, EMI. One reason is that the clock signals are square waves. Square waves are composed, in theory, of an infinite Fourier Series of sinusoids, at integral multiples, or overtones, of the clock frequency. All of these overtones radiate energy.
In addition, the clock signals are relatively large in voltage, at one to five volts, approximately. These large voltages cause large current surges in the conductors carrying the clock signals. These currents cause radiation.
In contrast, the invention utilizes a single-frequency sinusoid, produced by sine wave generator 100 in FIG. 16. Overtones comparable to the square-wave clock signals are absent.
Further, the invention's sinusoid can be very small in magnitude. By analogy, a television signal, received by an ordinary television receiver, lies in the range of a few micro-volts. (One microvolt equals one-millionth of a volt.) These signals are easily detected, using known approaches.
The invention can use a similarly small sinusoid, to further reduce radiating currents. Specifically, selected values of the peak-to-peak voltage of the sine wave produced by sine wave generator 100 are
1-10 microvolts,
11-100 microvolts,
101-1,000 microvolts,
1-10 millivolt,
11-100 millivolt,
101-1,000 millivolts, or
1-10 volts.
2. The peaks PK in FIG. 6 rise and fall simultaneously. That is, once the standing wave SUM is established, all peaks PK rise and fall together, irrespective of their distances from the sine wave generator. This simultaneity allows very close synchronism of the detectors D in FIG. 15 to be attained.
In an experiment, a standing wave was generated in a loop of common coaxial cable, about 10 feet long, in the manner of FIG. 15. Twelve detectors were applied to the cable. The sine wave frequency was 150 MHz. It was found that the detectors were triggered simultaneously by the standing wave, within a few hundred pico-seconds, and certainly less than 1.0 nano-second, of each other.
To place these results in context, propagation velocity of signals in coaxial cables is about one foot of travel in 1.5 or 2.0 nano-seconds, as explained in the Background of the Invention. Assume a speed of one foot in 1.5 nano-seconds, and a clock connected to one end of a five-foot linear coaxial cable. (A length of five feet is chosen because that is the longest possible distance between a detector and the sine wave generator in a ten-foot loop, as used in the experiment.)
A detector located at the other end of the cable will receive a clock signal 6 nano-seconds later than a detector located one foot from the clock generator, because of the four-foot difference in travel by the clock signal. (4.0 ft×1.5 nS/ft.=6.0 nS.) In contrast, the experiment indicates that, with the standing wave, the time difference for detectors similarly spaced is 1.0 nano-second, or less, which is a significantly smaller time than 6 nanoseconds.
3. Expanding upon the previous point, the invention allows higher clock frequencies to be transmitted over distances not previously possible. For example, in 1997, the largest practical separation of modules M1 and M2 in FIG. 1 is about four feet, for a clock of 100 MHz. However, as the experiment above showed, the invention allowed use of a 10-foot loop at 150 MHz.
4. The time-frequency of the standing wave SUM in FIGS. 5-13 equals that of the underlying traveling sine waves, provided the traveling sine waves are of identical frequency. To illustrate this frequency, the instantaneous values of one wave reaching detector D2 in FIG. 18 is given by the expression SIN(wt+f 1 ). For the other wave, the expression is SIN(wt+f 2 ). The terms f 1 and f 2 are phase delays. The total time for one wave to traverse the loop 60 is (f 1 +f 2 ), which is a constant.
The following trigonometric identity will be used:
SIN x+SIN y=2[SIN 1/2(x+y)][COS 1/2(x-y)].
Substituting the expressions of FIG. 18 into this identity produces:
SIN(wt+f.sub.1) +SIN(wt +f.sub.2)=2[SIN 1/2(wt+f.sub.1 +wt+f.sub.2)][COS 1/2(wt+f.sub.1 -wt-f.sub.2)]=2[SIN 1/2(wt+f.sub.1 +wt+f.sub.2)][COS 1/2(f.sub.1 -f.sub.2)]
The frequency of the last expression is w, the frequency of the individual sine waves.
5. The invention should not be confused with a square pulse traveling on a transmission line. A square pulse, as explained above, contains a base sinusoid and a series of harmonics. These frequencies will probably be reflected at various points in the transmission line. Thus, oppositely traveling waves will probably exist in the transmission line, which produce standing waves.
However, so many waves are involved, at so many different frequencies, that no useful standing wave of the type SUM in FIGS. 5-13 will exist. That is, because numerous standing waves will exist, at different frequencies, the node points N will be scattered everywhere, and the overall "standing wave" will be badly distorted.
The invention differs from the situation just described in several respects. One is that only a single sinusoid frequency is used, and is the same in both traveling waves. Another is that, if any harmonics are present, they are intentionally suppressed to be less than 10 percent of the magnitude of the basic sinusoids. This suppression can be taken, for example, by installing a filter F between the sine wave generator 55 and the loop 60 in FIG. 15.
6. The invention provides clock signals at two points, from a common source, with a delay between them which is less than the time required for a signal to travel along a transmission medium connecting the two points. The clock signals produced by the invention are absolutely synchronous, or substantially so. "Absolutely synchronous" means that no delay between corresponding clock signals exceeds 500 pico-seconds.
7. The tapping point P10 in FIG. 5 should not be close to a node N, because the swing in signal magnitude at N is too small. Preferably, point P10 is more than 20, 30, 45, or 60 degrees away, as desired, from the nearest node N, and should be at the 90-degree position, where the envelope of the standing wave is largest.
8. A unit of distance may be defined, analogous to a certain unit used in astronomy, namely, the "light year," which is the distance traveled by light, in vacuum, in one year. By analogy, Applicant defines a "light nanosecond" to be the distance traveled by light, in vacuum, in one nanosecond. Since light travels 982,080,000 feet in one second, a light-nanosecond equals 982,080,000/10 9 , or 0.982 feet, or approximately one foot.
Under Einstein's theory of relativity, no signal can travel faster than the speed of light. Thus, if the taps for the two modules M1 and M2 in FIGS. 1 and 2 are separated by one light-nanosecond, the clock signals which they receive will not be simultaneous, and will lack simultaneity by at lease one nano-second.
However, if detectors D1 and D2 in FIG. 15 are separated by one light-nanosecond, or more, nevertheless, the clock signals which they receive will be simultaneous within 500 pico-seconds, which is one-half of one nano-second. Further, as the experiment described above showed, even with a separation of five feet, the clock signals are simultaneous within 500 pico-seconds. That is, a clock signal traveling at the speed of light would experience a delay of about 5 nano-seconds in traveling between the two detectors. But the invention allows clocking with a simultaneity of 500 pico-seconds. Numerous substitutions and modifications can be undertaken without departing from the true spirit and scope of the invention. What is desired to be secured by Letters Patent is the invention as defined in the following claims. | A clock for digital devices. Ordinarily, when multiple digital devices are clocked by a common clock, the clock signals frequently arrive at the digital devices at different times, due to propagation delays. The devices are thus not clocked synchronously. Under the invention, the multiple devices are connected to a common transmission line. A standing wave is generated on the transmission line, and the periodic collapse of the standing wave is used to clock the devices. Synchronous clocking to within about 1.0 nano-seconds has been attained, in a transmission line about ten feet long, wherein a clock signal ordinarily takes about 15 nanoseconds to travel from one end to the other. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved method of, and apparatus for, generating increased energy in an electromagnetic fuze system of a low-acceleration projectile, meaning not only low-acceleration projectiles as such but also, for instance, rockets or missiles.
In its more particular aspects, the present invention relates specifically to an improved method of, and apparatus for, generating increased energy in an electromagnetic fuze system of a low-acceleration projectile, as such term is hereinbefore defined, and in such electromagnetic fuze system a detonator or ignition generator is provided with a reaction member which is mechanically disarmed in its inactive or rest position and which is displaceable relative to an associated stator under the action of the firing acceleration. The thus generated electrical energy is stored in a capacitor and is made available for the detonation of an electric primer capsule.
There are already known fuze systems for projectiles and such fuze systems comprise a generator. During acceleration a reaction member is displaced through a coil, the inductive effect of which is increased by an iron core, in order to provide the required detonation energy by means of a capacitor. In an arrangement as known, for example, from Swiss Pat. No. 356,045 a permanent magnet is displaceably arranged within a coil surrounded by a magnet. The magnet is mounted in its inactive or rest position in a recess or cut-out of an insulator by means of a contact pin. During firing of the associated projectile the pin is released due to the acceleration, the magnet moves through the magnetic field of the coil and charges a capacitor which stores the detonation energy until impact of the projectile at the target.
Such systems operate in a satisfactory manner at high firing accelerations which enable an unlocking or arming operation to be accomplished for the projectile, however, such systems fail at relatively low accelerations.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved method of, and apparatus for, generating increased energy in an electromagnetic fuze system of a low-acceleration projectile and by means of which sufficiently high detonation energy is provided.
Another and more specific object of the present invention is directed to the provision of a new and improved method of, and apparatus for, generating increased energy in an electromagnetic fuze system of a low-acceleration projectile and by means of which a fuze system is provided which insures a high degree of safety during handling as well as during firing of the projectile.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method of the present development is manifested by the features that the detonation generator is held in a first position at its front side in a bore by means of an elastic force at the moment of firing. After the onset of the firing acceleration the detonator generator is coaxially displaced into a second position due to its inertial forces, whereby the detonator generator impacts at an impact body or anvil which is provided with a central bore and located within a rear portion of a housing. In this second position a mechanical safety or disarming device of a reaction member of the detonator generator is rendered ineffective and the reaction member is accelerated, whereby electrical energy is produced. The detonator generator is returned into its first position by means of the elastic force and in this first position the electrical energy is provided and transmitted to a mechanically and/or electrically disarmed fuze system.
It is one of the advantages of the inventive method that after the onset of the firing acceleration the energy which is required for detonating the electric detonator is directly generated during firing, namely by the detonator generator itself. This detonator generator is accelerated along a predetermined travel path for a predetermined time interval and thrust against the impact body or anvil which is provided with a bore. During the impact at the impact body or anvil the reaction member of the detonator generator produces a voltage pulse by means of which a capacitor is charged and which is present within the detonator generator. At the end of the acceleration phase the detonator generator is thrust back into its original position by means of the elastic force and transmits its energy, in cooperation with further safety elements, at the correct moment of time for detonation.
Advantageously, the detonator generator is displaced conjointly with a fuze element which is in a mechanically and/or electrically disarmed or safety condition, within the housing of the electromagnetic fuze system by means of inertial forces and is displaced in the reverse direction by means of the force of a compression spring. The advantage of this further development resides in the fact that the mass which moves relative to the housing is substantially increased, so that a greater energy affecting the movable members is available.
Preferably, the detonator generator is axially guided in a bore and during its movements between the first and second positions is guided along a predetermined limited travel path for a predetermined time interval.
Advantageously, the detonator generator is held by means of an elastic force in the first position which is located at the side of the target and the associated compression spring generating this elastic force is selected such that the detonator generator is brought into its second position within at least 3 milliseconds by means of a firing acceleration in the range of about 100 to about 300 g.
As alluded to above, the invention is not only concerned with the aforementioned method aspects, but also relates to a novel construction of apparatus for the performance thereof. Generally speaking, the inventive apparatus comprises a detonator or ignition generator provided with a reaction member which is mechanically disarmed in its inactive or rest position and which is displaceable relative to an associated stator under the action of the firing acceleration. The resulting electrical energy is stored in a capacitor and made available for detonating an electric primer capsule.
To achieve the aforementioned measures, the inventive apparatus for generating increased energy in an electromagnetic fuze system of a low-acceleration projectile, in its more specific aspects, comprises:
a compression spring located in a housing and mounting the detonator generator in a first position;
a contact pin provided in the detonator generator and telescopingly displaceable in a contact sleeve;
a rotor which is located in a housing and supports the electric primer capsule and which can be rotated from a disarmed or safety position into an active or armed position; and
the detonator generator, in the first position thereof, being electrically connected to the rotor when the latter assumes the armed position.
Such apparatus is particularly favorable in terms of safety aspects. The apparatus prevents premature detonation during firing of the projectile because the electrical connection leading to the support of the electric primer capsule is interrupted by "lifting off" the contact pin already at low-firing acceleration.
Advantageously, the detonator generator is longitudinally displaceably arranged in a threaded first or lower housing member or housing and the disarmed fuze element is fixedly mounted in a second or upper housing member or housing.
According to another modification of the inventive apparatus the detonator generator is mounted within insulating sleeves conjointly with the disarmed fuze element, and these insulating sleeves are longitudinally slideably mounted in a housing, preferably constituted by a one-piece housing. This variant represents a constructional simplification. The movable mass intended to initiate the detonation in this particular apparatus is greater as concerns the technically required components.
Preferably, peripheral recesses are provided in the cylindrical bore of the first or lower housing member. Such peripheral recesses serve to reduce the friction of the detonator generator at the wall of the lower housing member during its acceleration and prevent jamming of the detonator generator in the bore of such lower housing member.
According to a preferred embodiment of the inventive apparatus the recesses are symmetrically arranged. Four symmetrically arranged recesses have proven particularly favorable. The detonator generator is able to slide at the remaining surfaces of the bore practically free of friction. The air which is present in the bore can be displaced without any difficulties.
Advantageously, an impact body is mounted in the rear portion of the housing, for instance the lower portion of the first or lower housing member and serves as an anvil. This impact body or anvil is made of an aluminum alloy.
Advantageously, the impact body is wedged or flanged over a compressible body with which it snugly engages. Particularly suitable are compressible bodies made of lead, aluminum, zinc and other appropriate compressible materials.
Preferably, a central bore is provided in the impact body and serves to provide contactless accommodation of a tip or tip portion of the reaction member. The central bore comprises a conical opening which permits reliable penetration of the tip of the reaction member even with larger tolerances for the axial guidance of the reaction member.
Preferably, the housing or its component housing parts, as the case may be, are manufactured of an aluminum alloy. Such aluminum alloys possess low density and can be economically processed to yield a threadable fuze housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures of the drawings there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 is a longitudinal section through a first embodiment of the inventive apparatus showing the electromagnetic fuze system in the disarmed or safety condition;
FIG. 2 is a top plan view of the opening of a lower housing member of the two-part housing of the apparatus shown in FIG. 1;
FIG. 3 is an enlarged section through a detonator generator of the apparatus shown in FIG. 1;
FIG. 4 is a graph which plots the characteristic acceleration as a function of time of a projectile accelerated by propulsion engines;
FIG. 5 is a longitudinal section through a second embodiment of the apparatus according to the invention in the disarmed or safety condition; and
FIG. 6 is a longitudinal section through the apparatus shown in FIG. 5 during firing of the projectile.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that only enough of the construction of the apparatus has been shown as needed for those skilled in the art to readily understand the underlying principles and concepts of the present development, while simplifying the showing of the drawings. Turning attention now specifically to FIG. 1, there has been illustrated in longitudinal section a first exemplary embodiment of the inventive apparatus for generating increased energy in an electromagnetic fuze system of a low-acceleration projectile. The electromagnetic fuze system is generally designated by reference numeral 1 in FIG. 1. A first or lower housing member 3 is threadably connected to a second or upper housing member 2, with the housing members 2 and 3 defining a two-part housing structure or housing. This second or upper housing member 2 is provided with at least one mounting member 2'. The first or lower housing member 3 has a smaller diameter than the second or upper housing member 2. This second or upper housing member 2 of the electromagnetic fuze system 1 carries a threaded ring 4 and a cylindrical pin 5.
In the interior of the second or upper housing member 2 a rotor 7 is installed in an insulating sleeve 6 of a fuze element 8. The rotor 7 comprises a bore 7' and contains an electric primer capsule 9 which is provided with a pole pin 9'. In the disarmed or safety condition the electric primer capsule 9 is transversely positioned with respect to the detonating or ignition chain. Two barriers or blocking devices prevent the rotor 7 from premature rotation and completion of the detonating or ignition chain and since they are of conventional design such blocking devices therefore have not been particularly illustrated. A threaded bore 10 is provided for accommodating a booster-detonator.
A further bore 11 is provided in the fuze element 8 and serves for centering a telescoping contact pin 12 which is arranged in a contact sleeve 13 of a detonator generator 14. A conductive contacting surface 15 is provided between the detonator generator 14 and the insulating sleeve 6. By means of the front elevation shown in FIG. 1 there is depicted a reaction member 16 of the detonator generator 14 and this reaction member 16 constitutes the lower one of two pole pieces or pole shoes. A disk or plate 17 is held by means of a compression spring 18 which is fixed by means of a retainer 17'. The compression spring 18 is wedged into a recess or cut-out 19 formed between a compressible body 20 and the cylindrical wall of the first or lower housing member 3. The compressible body 20 comprises a void or empty space 20' and is made of lead. This compressible body 20 serves for mounting an impact body or anvil 21 which comprises a wedge-shaped central bore 22.
FIG. 2 is a top plan view and shows the bore 23 of the first or lower housing member 3. The outer margin of the bore 23 is formed by a thread 24. Peripheral recesses 3' are provided at the inner surface of the bore 23. FIG. 2 shows four such peripheral recesses 3'.
FIG. 3 shows the detonator generator 14 in an enlarged scale, and with reference thereto there will now be described the components thereof which are essential for the inventive apparatus. In its top portion the detonator generator 14 contains a dielectric 25 which, for example, is made of a cured epoxy resin (Araldite available from the well known company Ciba Geigy Limited, Switzerland). A capacitor 26 and a diode 27 are imbedded in the dielectric 25. In the base portion of the detonator generator 14 there is located a coil 28, defining a stator, and which surrounds a magnet core 29 between the reaction member 16 which constitutes a lower pole piece or pole shoe and a member 30 which constitutes an upper pole piece or pole shoe. The top portion and the base portion of the detonator generator 14 are separated from each other by means of a blocking spring 31. The detonator generator 14 is enclosed in a casing 32 from which there protrudes the contact pin 12.
FIG. 4 shows a characteristic course of an acceleration curve for a projectile. Therein the variation of the acceleration b is shown as a function of time t. At a moment of time t 0 prior to projectile firing, the detonator generator 14 of the inventive electromagnetic fuze system is in its first inactive or rest position. After the onset of the firing acceleration b and at the moment of time t 1 the detonator generator 14 of the electromagnetic fuze system is displaced into its second position. During such displacement the tip portion or end of the reaction member 16 enters the central bore 22 of the impact body 21 located at the rear end of the first or lower housing member 3 and impacts against such impact body or anvil 21. During such displacement the detonator generator 14 is accelerated and slides along the edges of the recesses 3' with a minimum of friction. The air present in the first or lower housing member 3 is not compressed since such air can escape sufficiently rapidly through the passages formed by the recesses 3'. During the retardation phase the detonator generator 14 is returned into its first position by means of the compression spring 18 and arrives at this first position at the moment of time t 2 . At the moment of time t 3 the acceleration b is constant, at the moment of time t 4 the fuze is activated or armed and the detonation occurs at the moment of time t 5 . The detonation occurs when the target is hit, whereby the double cap or dome of the projectile is crushed and thus closes the electric detonation circuit.
An exemplary second embodiment of the apparatus according to the invention is illustrated by FIGS. 5 and 6 in a longitudinally sectional view. The apparatus shown in FIG. 5 is in the disarmed or safety condition and FIG. 6 shows the state of the apparatus during projectile firing. In this second embodiment of the inventive apparatus an integrally formed or one-piece housing 33 is provided with a cover 34. This cover 34 comprises an opening 35. The fuze element 8 is provided with a first insulating disk or plate 36 comprising an opening 37. An O-ring 38 is located below the fuze element 8. This O-ring 38 spaces the fuze element 8 from the detonator or ignition generator 14. A disk or plate 39 provided with an opening 40 is arranged below the detonator generator 14. This disk or plate 39 serves as an upper or top support for the compression spring 18 and corresponds to the disk or plate 17 in the first embodiment of the inventive apparatus shown in FIG. 1. The upper position of the compression spring 18 is insured by means of an annularly shaped retainer 41.
An electric primer capsule 9 containing a pole pin 9' is arranged in a rotor 7 mounted in the fuze element 8. The pole pin 9' is located witin a bore 7' of the rotor 7. A blocking pin 42 extends into the region of the rotor 7. On its lower or bottom side the fuze element 8 is provided with a second insulating disk or plate 43.
The integrally formed or one-piece housing 33 comprises a mounting flange 44. The detonator generator 14 is placed in a second or lower insulating sleeve 45 which is fixedly connected to a first or upper insulating sleeve 6' such that the fuze element 8 and the detonator generator 14 form an integral unit. As already described with reference to the first exemplary embodiment, an impact body or anvil 21 which is mounted at a compressible body 20, is also contained in the second exemplary embodiment of the inventive apparatus.
The mode of operation of the apparatus illustrated by FIGS. 5 and 6 is the same as in the first exemplary embodiment described hereinbefore with reference to FIGS. 1 to 4. The difference between the two embodiments essentially is that in the second exemplary embodiment the fuze element 8 and the detonator generator 14 are interconnected by means of the first and second or upper and lower insulating sleeves 6 and 45. These components thus form an integral unit and are conjointly displaceable within the integrally formed, one-piece housing 33. As already pointed out hereinbefore, there is thus obtained a greater moveable mass which additionally increases the functional reliability of the inventive apparatus.
The inventive apparatus containing the electromagnetic fuze system described hereinbefore is specifically designed for low accelerations such as occur in rocket-propelled projectiles.
In case the electrical detonation circuit remains interrupted for one reason or another, the capacitor 26 of the detonator generator 14 is discharged during a time interval of about 10 minutes. There thus results a disarmed or de-energized dud projectile.
The inventive construction permits the provision of autonomous detonating systems which are functional independently of secondary or external power supplies such as batteries and so forth. The generated electrical energy is sufficient for supplying power to electrical safety devices, timers and proximity sensors in addition to reliably detonating so-called thin-layer electric primer capsules.
In comparison to hitherto known detonating methods and detonating apparatus used in rocket-propelled projectiles, the inventive method and apparatus further permit extensive simplifications in testing and servicing such weapons. The safety of the maintenance and operating personnel is thereby increased to a high degree because due to the inventive system maintenance and/or testing operations can be performed at any time and independent of the current supply to the remaining system, i.e. to the electronic control and other components.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. | In the method of increasing the detonation energy in an electromagnetic fuze system of a low-acceleration projectile a detonator generator which is held in an inactive or rest position by an elastic force, is accelerated along a predetermined travel path in the rear portion of a housing at the onset of the firing acceleration. The detonator generator is accelerated such that the detonator generator impacts upon an impact body which is provided with a central bore. As a result, a reaction member of the detonator generator inactivates its mechanical safety device and is accelerated, thus providing the detonation energy. In the retarding phase the detonator generator is returned into its original position by means of the elastic force and thus is ready for detonation. In comparison to known methods and apparatus there can thus be dispensed with an external power supply, whereby safety is increased with respect to maintenance, tests and firing. | 5 |
TECHNICAL FIELD
[0001] The embodiments described below relate generally to electronic circuits, and more particularly, to power distribution in a multi-power-source, multi-domain, integrated circuit.
BACKGROUND
[0002] Logic control signals generated by the power-up reset signals of various power supplies are commonly used to determine the power-up sequence logic in an integrated circuit device. However, during power-up of an integrated circuit device that has multi-power domains, there is no sequencing control by the integrated circuit device over the external power supplies, and the traditional methods cannot control the sequencing of power supplies within functional blocks where specific power-up sequences are required.
[0003] The transitional instability of the power level of different power supplies during the power-up process is an important issue during the power-up process. Conventional level shifters can be used to transfer logic signals among various power levels when power supplies are stable; however, during power-up mode, not all power supplies are stable. In most cases, during power-up process, some power supplies become stable while others either continue to ramp up or remain inactivated. Specially designed level shifting circuits are needed to handle the power-up processes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 illustrates an example of a power-up sequence control circuit, in accordance with an embodiment of the invention.
[0005] FIG. 2 illustrates a power-switch, which is an element of the power-up sequence control circuit of FIG. 1 , in accordance with an embodiment of the invention.
[0006] FIG. 3 illustrates a power-switch controller, which is an element of the power-up sequence control circuit of FIG. 1 , in accordance with another embodiment of the invention.
[0007] FIG. 4 illustrates a power-switch controller, in accordance with yet another embodiment of the invention.
[0008] FIG. 5 illustrates a power-switch controller, in accordance with yet another embodiment of the invention.
DETAILED DESCRIPTION
[0009] Various embodiments of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail, so as to avoid unnecessarily obscuring the relevant description of the various embodiments.
[0010] The terminology used in the description presented below is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.
[0011] The described embodiments illustrate the use of self-controlled power switches to control the power supplied by different power supplies to various functional blocks of an integrated circuit device. The required power-up sequence within a functional block is controlled by a set of power switches. When the power levels (voltages) of different power supplies are not the same, it is often required for a signal from a lower power supply level to control the power switches that control the higher power levels.
[0012] Another issue concerning the power-up process is the potential instability of the power being supplied during the power-up transition period of a power supply. When power supplies are stable, conventional level shifters may be used to transfer logic signals among various power levels; however, during power-up mode, not all power supplies are stable. In fact in most cases some power supplies become stable while others either continue to ramp up or remain inactivated. Therefore, especially designed level shifting circuits are needed to handle the power-up processes.
[0013] In circumstances where a power-up sequence is required, since not all power supplies may be stable or activated, the power switches must be controlled by the power-up sequence, rather than by a fixed logic that is only suitable for stable power levels. In these cases the controls to the power switches are designed to be self-timed and self-adjusted to satisfy the required power-up sequences.
[0014] FIG. 1 illustrates an example of a power-up sequence control circuit 100 , in accordance with an embodiment of the invention. In this example, there are three power supplies for the integrated circuit device, and the power levels of these power supplies are different. Power 1 , Power 2 , and Power 3 represent these three power supplies.
[0015] Power 3 has the highest power level (voltage), Power 2 has a power level lower than Power 3 but higher than Power 1 , and Power 1 has the lowest power level. During the power-up stage, Power 3 is the first to be stable, while Power 2 and Power 1 will be ramping up to stable levels. It is also required that Power 2 goes to the corresponding functional blocks after Power 1 is stable, regardless of the order in which they become stable. By controlling the power switch 110 located between Power 2 and the functional blocks supplied by Power 2 , the switch controller 112 regulates the required sequencing of Power 1 and Power 2 .
[0016] FIG. 2 is a schematic diagram of the power switch 110 , which consists of a PMOS transistor 210 whose body is connected to Power 2 , and whose gate is controlled by the switch controller 112 . There is also an NMOS transistor 212 serving as a leakage device when the power switch is not turned on. This leakage device discharges the Internal Power 2 Supply when the switch M 1 is turned off, so that the Internal Power 2 Supply is not in a floating state.
[0017] FIG. 3 is a schematic diagram of the power switch controller 112 . The power switch controller 112 has three parts:
1—Power 1 detection circuit (M 2 , M 7 , M 1 , M 5 , M 6 ) 2—Power 1 detection trigger circuit (M 3 , M 8 ) 3—Power 1 signal to Power 3 signal level shifting circuit (M 3 , M 8 , INV 1 , INV 2 )
[0021] Transistors M 1 , M 5 , M 6 generate a bias voltage for M 7 to limit its current. The gate of transistor M 2 is tied to ground (GND) so that it becomes conducting as soon as Power 1 is above V t (the device threshold turn-on voltage). M 3 is a weak PMOS device and M 8 is turned on only if Power 1 is high enough to offset the biased current sink by M 7 .
[0022] When Power 3 is on and Power 1 is off, the output of the circuit (Switch_en_b) is high (Power 3 level) because M 3 is on and M 8 is fully off.
[0023] When Power 1 starts to ramp up, M 2 starts conducting. When the voltage level at point A reaches V t of M 8 , M 8 starts conducting, and the Voltage level at point B starts to drop. In this situation the output Switch_en_b changes from high to low.
[0024] FIG. 4 is a schematic diagram of another power switch controller 112 , where:
M 4 is the feedback for the switch on lock-up (because M 3 is a weak pull-up device, it is sensitive to noise. M 4 reduces the noise sensitivity by providing a latch-like structure, especially when the Power 1 is not ready.); D 1 is the diode for preset state (D 1 provides a discharge path for the gate of M 8 to turn off M 8 when Power 1 is off so that the control circuit can return back to the preset state.); and C 1 is to reduce noise (in an integrated device, there are noise generated by other circuits. C 1 reduces the M 8 gate sensitivity to such noise.).
[0028] FIG. 5 is a schematic diagram of an alternative power switch controller 112 , where M 9 and M 10 are feedbacks for turning off bias and detection circuit static currents. M 9 and M 10 are for power management. When Power 1 is off, M 9 and M 10 are turned on so that the control circuit is ready to operate. After Power is up and stable, M 9 and M 10 are turned off so that the DC current I 1 and I 2 are eliminated, thus reducing the power consumption of the control circuit.
CONCLUSION
[0029] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof.
[0030] Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.
[0031] The above detailed description of embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.
[0032] The teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.
[0033] Changes can be made to the invention in light of the above Detailed Description. While the above description describes certain embodiments of the invention, and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Details of the compensation system described above may vary considerably in its implementation details, while still being encompassed by the invention disclosed herein.
[0034] As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the invention under the claims.
[0035] While certain aspects of the invention are presented below in certain claim forms, the inventors contemplate the various aspects of the invention in any number of claim forms. Accordingly, the inventors reserve the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention | Methods and apparatus are disclosed for controlling power distribution during transitory power-up period of multi-domain electronic circuits that are supplied by multiple power supplies. The power distribution is controlled by self-regulating power control circuits that operate based on power-up sequencing requirements. Described embodiments of the invention illustrate examples of power-switch and power-switch controller circuits used as elements of the power control circuitry. | 6 |
BACKGROUND
[0001] Package-on-package (POP) structures are designed for products with package area imitations but with few vertical size limitations. Devices, such as mobile phones, digital cameras, and other portable devices that have horizontal size limitations, can include POP structures. POP structures can save horizontal space in a device by vertically stacking packages on top of one another rather than placing packages horizontally adjacent to one another.
[0002] A POP configuration can include two or more ball grid arrays (BGA) stacked on top of one another. In a two-piece assembly, the bottom package can include a logic device, and the top package can include a memory device.
[0003] In order to affix the top package to the bottom package, a mold compound can be used. The mold compound can be applied to a center portion of the bottom package and can cover the die of the bottom package.
[0004] A problem associated with POP structures includes heat and warping. Heat can cause warping by causing one portion of the POP structure to expand faster and larger than other portions of the POP structure. For example, mismatches in thermal expansion of the die, the molding compound, and/or the substrate can cause warping. Bottom substrates of bottom packages can be especially prone to warping, for example, because the molding compound on the die has a different coefficient of thermal expansion compared to the die of the bottom package. For this reason, die sizes are often limited to reduce warping effects on the dies, especially the dies located on the bottom package.
SUMMARY OF EMBODIMENTS
[0005] According to one embodiment, a device may include a package-on-package structure including a top package and a bottom package; and a heatsink interposer located between the top package and the bottom package, where the heatsink interposer includes: a heatsink; an interposer substrate; and interposer solder balls.
[0006] According to another embodiment, a package-on-package structure may include a top package; a heatsink interposer, where the heatsink interposer is under the top package and the heatsink interposer, including: an interposer substrate; a top heatsink between the top package and the interposer substrate; a bottom heatsink between the bottom package and the interposer substrate; and interposer solder balls between the bottom package and the interposer substrate; and a bottom package under the heatsink interposer.
[0007] According to still another embodiment, a package-on-package heatsink interposer for use between a top package and a bottom package of a package-on-package device, may include a top heatsink below the top package; an interposer substrate below the top heatsink; a bottom heatsink below the interposer substrate; a first interposer substrate metal layer between the interposer substrate and the top heatsink; a second interposer substrate metal layer between the interposer substrate and the bottom heatsink; and interposer solder balls between the second interposer substrate metal layer and the bottom package.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments described herein and, together with the description, explain these embodiments. In the drawings:
[0009] FIG. 1A is a diagram of an example package-on-package structure according to an embodiment described herein;
[0010] FIG. 1B is a diagram of an example package-on-package structure according to an embodiment described herein;
[0011] FIG. 2 is a diagram of an example heatsink interposer according to an embodiment described herein;
[0012] FIG. 3A is a diagram of an example package-on-package structure with capillary underfill;
[0013] FIG. 3B is a diagram of an example package-on-package structure with capillary underfill and a heatsink interposer according to an embodiment described herein;
[0014] FIG. 4A is a diagram of an example package-on-package structure with mold underfill;
[0015] FIG. 4B is a diagram of an example package-on-package structure with mold underfill and a heatsink interposer according to an embodiment described herein;
[0016] FIG. 5A is a diagram of an example package-on-package structure with capillary underfill;
[0017] FIG. 5B is a diagram of an example package-on-package structure with capillary underfill and an increased die size;
[0018] FIG. 5C is a diagram of an example package-on-package structure with capillary underfill, an increased die size, and a heatsink interposer according to an embodiment described herein;
[0019] FIG. 6A is a diagram of an example package-on-package structure with capillary underfill;
[0020] FIG. 6B is a diagram of an example side-by-side structure with capillary and a heatsink; and
[0021] FIG. 6C is a diagram of an example package-on-package structure with capillary underfill, an increased die size, increased thermal dissipation requirement, and a heatsink interposer according to an embodiment described herein.
DETAILED DESCRIPTION
[0022] The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements.
Overview
[0023] Systems and/or methods described herein may utilize a heatsink interposer to provide temperature regulation, accommodation of die sizes for varying sized top and bottom packages, and provide increased stiffness. Systems and/or methods described herein may also utilize a heatsink interposer to enable higher power and larger dies in a POP structure with smaller footprints.
Example Arrangement
[0024] FIG. 1A is a diagram of an example POP structure 100 according to an embodiment described herein. As shown, POP structure 100 may include a top package 110 , a bottom package 120 , and a heatsink interposer 130 .
[0025] Top package 110 may include any mechanically mating device. In one implementation, top package 110 can include a memory device that can work with a logic device bottom package 120 . Top package 110 can be any size capable of fitting on heatsink interposer 110 . In one implementation, top package 110 , bottom package 120 , and heatsink interposer 130 can be approximately the same length and width. For example, top package 110 , bottom package 120 , and heatsink interposer 130 can be 10-17 mm in length and width, (e.g., top package 110 , bottom package 120 , and heatsink interposer 130 can be 12 mm×12 mm).
[0026] In one implementation, top package 110 , bottom package 120 , and heatsink interposer 130 can be approximately the same height. For example, top package 110 , bottom package 120 , and heatsink interposer 130 can have a height of 500-1500 microns (e.g., 1000 microns). In another implementation, the height of the heatsink interposer 130 can be different from the top package 110 and/or the bottom package 120 . For example, top package 110 can have a height of 1000 microns, bottom package 120 can have a height of 800 microns, and heatsink interposer 130 can have a height of 500 microns.
[0027] Bottom package 120 may include any mechanically mating device. In one implementation, bottom package 120 can include a logic device with a die on a top portion of the bottom package 120 . In one implementation, the die can be any size smaller than bottom package 120 . For example, the die can be 5-15 mm in length and width, and 150-250 microns in height (e.g., bottom package 120 can be 15 mm×15 mm×1000 microns and the die can be 10 mm×10 mm×200 microns).
[0028] Heatsink interposer 130 may include a structure that can provide heat dispersal, heat dissipation, and structural support for POP structure 100 . In one implementation, heatsink interposer 130 can include a bottom ball footprint to accommodate a die size of bottom package 120 , while having the space on a top portion of heatsink interposer 130 to accommodate the ball footprint of top package 110 . For example, heatsink interposer 130 can include a bottom ball footprint that includes a space of 10 mm×10 mm to accommodate a die of 8 mm×8 mm, and can include space around a top portion of heatsink interposer 130 to accommodate solder balls on top package 110 .
[0029] In another implementation, as illustrated in FIG. 1B , POP structure 100 can be provided with a bottom package 120 that is larger than a top package 110 and heatsink interposer 130 between bottom package 120 and top package 110 . Bottom package 120 may be larger than top package 110 for any number of reasons. For example, bottom package 120 may be larger than top package 110 to accommodate a larger die size, a smaller top package 110 may be desirable for cost reasons, etc.
[0030] As illustrated in FIG. 1B , heatsink interposer 130 can be manufactured to accommodate the size of die 125 and bottom package 120 and also accommodate top package solder balls 115 and top package 110 . For example, heatsink interposer 130 can include solder balls on a bottom surface with an area between interposer solder balls 135 that can accommodate the die 125 in bottom package 120 and a top surface with an area to accommodate solder balls 115 of top package 110 . As further illustrated in FIG. 1B , die 125 can be larger than an area 140 between solder balls 115 and die 125 can be smaller than an area 150 between solder balls 135 on a bottom surface of heatsink interposer 130 .
[0031] In another implementation, higher power than a standard power for POP structure 100 can be used on the bottom package while the heat produced by the higher power can be dissipated using heatsink interposer 130 .
[0032] In another implementation, heatsink interposer 130 can be used as a stiffener to reduce warpage of bottom package 120 and help on the mounting of bottom package 120 to POP structure 100 .
[0033] Although FIGS. 1A and 1B show example components of POP structure 100 , in other embodiments, POP structure 100 may include fewer components, different components, differently arranged components, or additional components than depicted in FIGS. 1A and 1B .
[0034] For example, although FIGS. 1A and 1B show POP structure 100 as a two-stacked structure with heatsink interposer 130 , in other embodiments, POP structure 100 may be implemented to include more stacks in the POP structure 100 .
[0035] FIG. 2 is a diagram of example components of a heatsink interposer 130 that may be included in POP structure 100 . Heatsink interposer 130 may include a top heatsink 210 , an interposer substrate 220 with interposer substrate vias 230 , interposer substrate metal layers 240 , interposer solder balls 135 , and a bottom heatsink 260 . In one implementation, heatsink interposer 130 may range from 10-17 mm in length and width, and may have a thickness of 500-1000 microns. For example, a heatsink interposer 130 can be 12 mm×12 mm with a thickness of 500 microns.
[0036] Top heatsink 210 and bottom heatsink 260 may be provided in heatsink interposer 130 to provide thermal conduction between heatsink interposer 130 and top package 110 and bottom package 120 , as well as to provide thermal dissipation and structural integrity. In one embodiment top heatsink 210 may or may not be in thermal communication with top package 110 and bottom heatsink 220 can be in thermal communication with bottom package 120 .
[0037] Top heatsink 210 , material filling interposer substrate vias 230 , interposer substrate metal layers 240 , and bottom heatsink 260 may include any conductive material, such as a metal (e.g., copper, aluminum, metal alloy) or a non-metal (e.g., diamond, copper-tungsten pseudoalloy, AlSiC (silicon carbide in aluminum matrix)) material. In one implementation, top heatsink 210 , material filling interposer substrate vias 230 , interposer substrate metal layers 240 , and bottom heatsink 260 may be the same or different materials. For example, top heatsink 210 , material filling interposer substrate vias 230 , interposer substrate metal layers 240 , and bottom heatsink 260 may be formed of copper.
[0038] Top heatsink 210 and bottom heatsink 260 may be any size in width, length, or height. In one implementation, top heatsink 210 and bottom heatsink 260 and can be 10-17 mm in length and width, top heatsink 210 can be 100-300 microns, and bottom heatsink can be 50-150 microns. For example, top heatsink 210 and bottom heatsink 260 can be 12 mm×12 mm×200 microns. Additionally, or alternatively, as illustrated in FIG. 2 , top heatsink 210 can be different in height, width, and/or length from bottom heatsink 260 . For example, top heatsink 210 can be 12 mm×12 mm×200 microns and bottom heatsink 260 can be 10 mm×10 mm×100 microns.
[0039] Additionally, or alternatively, top heatsink 210 can be customized in size to accommodate solder balls from top package 110 . For example, top heatsink 210 can be 10 mm×10 mm for a 15 mm×15 mm top package 110 with an area between solder balls of 11 mm×11 mm, so that top heatsink 210 can fit within the area between the solder balls of top package 110 .
[0040] Additionally, or alternatively, bottom heatsink 260 can be customized in size and shape to accommodate any portion of bottom package 110 , including a die 125 . In one implementation, bottom heatsink 260 can be sized larger than a die 125 from bottom package 110 . For example, for a bottom package with a die 125 of 10 mm×10 mm×100 microns, bottom heatsink 260 can be 12 mm×12 mm×200 microns.
[0041] Interposer substrate 220 can provide insulating and stiffening properties to interposer heatsink 130 . Interposer substrate 220 may include any insulating material including a rigid material such as glass-reinforced epoxy laminate sheets (e.g., FR-4), Bismaleimide-Triazine (BT-Epoxy), Ajinomoto Build-Up Film (ABF), or any available industry substrate dielectric material. In one implementation, interposer substrate 220 may be 400-750 micron in height and may be the same length and width as heatsink interposer 130 . For example, interposer substrate 220 may be 12 mm×12 mm×500 microns.
[0042] Interposer substrate vias 230 can be found in interposer substrate 220 to provide heat dissipation and/or electrical connection ability between top and bottom interposer substrate metal layers 240 and the heatsink interposer 130 . In one implementation, interposer substrate vias 230 may be cylindrical or rectangular in shape and can be through holes in interposer substrate 220 . Interposer substrate vias 230 can range in diameter or width from 200-400 microns. For example, interposer substrate vias 230 can be 300 microns in diameter.
[0043] Material can be used to completely or partially fill interposer substrate vias 230 to improve thermal conduction. In one implementation, interposer substrate vias 230 can be filled with the same material as the top heatsink 210 , interposer substrate metal layers 240 , and bottom heatsink 260 , as mentioned above. For example, interposer substrate vias 230 may be filled with copper.
[0044] Additionally, or alternatively, material can be used to completely fill interposer substrate vias 230 . For example, interposer substrate vias 230 can be at least partially filled by a conductive material to disperse heat from bottom heatsink 260 .
[0045] Interposer substrate metal layers 240 may be located between top heatsink 210 and interposer substrate 220 and may be located between bottom heatsink 260 and interposer substrate 220 . Interposer substrate metal layers 240 may also be located between interposer substrate 220 and interposer solder balls 135 . In one implementation, interposer metal layers 240 may be 25-75 microns. For example, interposer metal layers may be 50 microns. Interposer substrate metal layers 240 can be patterned to provide electrical connections between top and bottom interposer substrate metal layers 240 and to accommodate the electrical connections to top package 110 and bottom package 120 .
[0046] Interposer solder balls 135 may include any number of solder balls in any size that assists in heat transfer from the bottom package 120 to the heatsink interposer 130 . Interposer solder balls 135 may also provide electrical connections between the bottom package 120 and the heatsink interposer 130 . Interposer solder balls 135 can be customized in size and pattern to accommodate any portion of bottom package 110 , including a die 125 . In one implementation, interposer solder balls 135 can have a diameter of 200-400 microns and can be sized to be the same or different in material and diameter compared to solder balls of top package 110 and bottom package 120 . For example, interposer solder balls can be 300 microns. Interposer solder balls 135 may be made of any soldering material, such as SAC305 (Sn, Ag, Cu, such as 96.5% Sn, 3% Ag, 0.5% Cu).
[0047] As illustrated in FIGS. 3A and 3B , heat interposer 130 can be used with a POP structure including capillary underfill (CUF).
[0048] As illustrated in FIG. 3A , POP structure 300 can include a top package 110 , a bottom package 120 , die 125 placed on top of bottom package 120 , CUF 320 to package interconnections 330 , and top package solder balls 115 to separate and electrically connect top package 110 and bottom package 120 .
[0049] As illustrated in FIG. 3B , heatsink interposer 130 can be used with POP structure 350 including CUF. Heatsink interposer 130 can be placed between top package 110 and bottom package 120 and on top of die 125 . Interposer solder balls 135 can be placed between heatsink interposer 130 and bottom package 120 . Top package solder balls 115 can be placed between top package 110 and heatsink interposer 130 .
[0050] In one implementation, heatsink interposer 130 can have a bottom heatsink 260 with a larger horizontal area than die 125 to provide uniform heat transfer from die 125 to heatsink interposer 130 . In one implementation, CUF 320 can cover any portion of die 125 and interposer solder balls 135 can be placed on heatsink interposer 130 with sufficient space for CUF 320 to not contact with interposer solder balls 135 .
[0051] As illustrated in FIGS. 4A and 4B , heat interposer 130 can be used with a POP structure including mold underfill (MUF).
[0052] As illustrated 4 A, POP structure 400 can include a top package 110 , a bottom package 120 , die 125 can be placed below top package 110 , MUF 420 can cover package interconnections 430 , and top package solder balls 115 can separate and electrically connect top package 110 and bottom package 120 .
[0053] As illustrated in FIG. 4B , heatsink interposer 130 can be used with POP structure 450 including MUF. In FIG. 4B , heatsink interposer 130 can be placed on top of die 125 , interposer solder balls 135 can be placed between heatsink interposer 130 and bottom package 120 , and top package solder balls 115 can be placed between top package 110 and heatsink interposer 130 . In one implementation, heatsink interposer 130 can have a bottom heatsink 260 with a larger horizontal area 460 (outlined) than die 125 to provide heat transfer from die 410 to heatsink interposer 130 .
[0054] Additionally, or alternatively, MUF 420 can be in contact with bottom heatsink 260 and interposer solder balls 135 . In one implementation, as illustrated in FIG. 4B , MUF 420 can cover die 125 and package interconnections 430 , and be in contact with bottom heatsink 260 and interposer solder balls 135 . Additionally, or alternatively, MUF 420 can partially or completely package interposer solder balls 135 . For example, can be provided for packaging die 125 and package interconnections 430 after interposer solder balls 135 are placed on bottom package 120 .
[0055] As illustrated in FIGS. 5A-5C , increasing die size from a smaller die 125 in FIG. 5A to a larger die 520 in FIG. 5B could conventionally lead to a larger package size 530 , as illustrated in FIG. 5B , compared to the original package size 500 in FIG. 5A . However, using heatsink interposer 130 , as illustrated in FIG. 5C , increasing the die size to larger die 520 can be done without changing the width or length of the original package 500 by providing an interposer structure to accommodate the larger die 520 in FIG. 5B and the area between top solder balls 115 .
[0056] In one implementation, as illustrated in FIG. 5C , interposer solder balls 135 can be placed on heatsink interposer 120 to accommodate a larger die 520 by moving interposer solder balls 135 to create an area for larger die 520 to fit. For example, interposer solder balls 135 can be placed to provide a larger area 150 between interposer solder balls 135 than an area 140 between top package solder balls 115 , and larger die 520 can be accommodated by area 150 but not area 140 .
[0057] Additionally, or alternatively, the size and shape of top heatsink 210 can be customized to allow for top package solder balls 115 to remain the same or be changed. In one implementation, top package solder balls 115 can be positioned in their same locations with the same area 140 between top package solder balls 115 . For example, as illustrated in FIGS. 5A and 5C , area 140 can be the same width and length even though die 125 is increased in width and length to larger die 520 .
[0058] By allowing the size of original package 500 to be maintained, the size of top package 110 can also be maintained. By maintaining the size of top package 110 , new and/or different top packages 110 do not have to be provided in order to compensate for the larger die 520 size if a larger die is used.
[0059] As illustrated in FIGS. 6A-6C , increasing die size from a smaller die 610 in FIG. 6A to a larger die 620 in FIG. 6B and/or increasing power from the power used for the original POP structure in 6 A can increase the heat in bottom package 120 . In order to dissipate the increased heat, heatsink 630 , as illustrated in FIG. 6B can be provided. The addition of heatsink 630 to a structure has conventionally led to a side-by-side structure 600 , as illustrated in FIG. 6B . Side-by-side structures can be less than ideal because they tend to have larger horizontal footprints than vertically-stacked POP structures.
[0060] As illustrated in FIG. 6C , heat sink interposer 130 can be provided to dissipate heat similar to heatsink 630 , and allow for POP structure 600 to be vertically-stacked.
[0061] In one implementation, POP structure 640 can be provided with substantially identically sized top package 110 , bottom package 120 , and heatsink interposer 130 . For example, each of the top package 110 , bottom package 120 , and heatsink interposer 130 can be 15 mm×15 mm×1000 microns. In another implementation, POP structure 100 can be provided with three different sized top package 110 , bottom package 120 , and heatsink interposer 130 . For example, each of the top package 110 can be a 10 mm×10 mm×800 microns, bottom package 120 can be a 12 mm×12 mm×500 microns, and heatsink interposer 130 can be a 12 mm×12 mm×1000 microns.
[0062] Systems and/or methods described herein may utilize a heatsink interposer in a POP structure to provide temperature regulation, accommodation of die sizes for varying sized top and bottom packages, and provide increased stiffness. The heatsink interposer may be used with POP structures that utilize CUF or MUF. The heatsink interposer may be used to accommodate larger die sizes and/or increased power, while maintaining package size overall, as well as top package size. The heatsink interposer can also be used as a stiffener to reduce warpage of the bottom package and help with the mounting of the top package to the POP structure. The heatsink interposer can also be used to lower the temperature of the POP structure, especially the bottom package when higher power is used on the bottom package.
[0063] The foregoing description of embodiments provides illustration and description, but is not intended to be exhaustive or to limit the claims to the precise form disclosed. Modifications and variations are possible in light of the above disclosure or may be acquired from practice of implementations described herein.
[0064] Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of the possible implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification. Although each dependent claim listed below may directly depend on only one other claim, the disclosure of the possible implementations includes each dependent claim in combination with every other claim in the claim set.
[0065] No element used in the present application should be construed as critical or essential to an implementation unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. | According an embodiment, a package-on-package heatsink interposer for use between a top package and a bottom package of a package-on-package device, may include a top heatsink below the top package; an interposer substrate below the top heatsink; a bottom heatsink below the interposer substrate; a first interposer substrate metal layer between the interposer substrate and the top heatsink; a second interposer substrate metal layer between the interposer substrate and the bottom heatsink; and interposer solder balls between the second interposer substrate metal layer and the bottom package. | 7 |
TECHNICAL FIELD
[0001] The disclosure relates generally to a machine and, more particularly, to a machine with at least one articulating conveyor.
BACKGROUND
[0002] Many machines are mobile machines configured to perform one or more tasks while traveling along a ground surface, such as a road surface. A cold planer is an example of such a mobile machine. The cold planer includes a grinding mechanism that grinds a top layer of the road surface. The cold planer includes a conveyor, connected to a frame of the machine, which receives the material that was removed from the road surface. The conveyor conveys the material to another vehicle, such as a dump truck, traveling next to the cold planer. The conveyor may be rotated relative to the machine frame, such that the conveyor is positioned to deposit the material into the dump truck, for example.
[0003] In some instances it may be desirable to allow a conveyor to pivot in order to adjust the position of the conveyor. One of the problems associated with moving or pivoting a conveyor is the prospect of material falling off of the conveyor or otherwise losing material through gaps between the conveyor and structure with respect to which the conveyor has been pivoted. US patent publication number 2006/0061204 describes a conveyor that can be pivoted using a four bar mechanism. However, the conveyor in this publication swings to the right or left but does not pivot to adjust the elevation of the conveyor.
SUMMARY
[0004] In one embodiment, a machine is provided. The machine includes a first conveyor and a second conveyor that is pivotable, with respect to the first conveyor, about two different axes that intersect and define a plane.
[0005] In another embodiment, machine capable of performing a method for operating a set of conveyors is provided. The method includes pivoting a second conveyor with respect to a first conveyor about two different axes that intersect and define a plane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a side view pictorial illustration of a machine having an exemplary disclosed pivotal connection between a frame and a conveyor.
[0007] FIG. 2 illustrates a side view of an exemplary machine having a pivotal conveyor, according to one embodiment of the present disclosure.
[0008] FIG. 3 is an isometric view of two conveyors with a transition zone therebetween.
[0009] FIG. 4 is a side view of the transition zone.
[0010] FIG. 5 is an isometric view of the transition zone with the flashing removed.
DETAILED DESCRIPTION
[0011] The disclosure will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present disclosure provides a machine, such as, a cold planer that has two conveyors that are pivotal with respect to each other about at least 2 different pivot axes.
[0012] FIG. 1 illustrates an embodiment of a machine 10 in accordance with the present disclosure. Machine 10 is a mobile machine operable to move along a ground surface 12 . The ground surface 12 may be a man-made surface, such as a road, parking lot, concrete cement, or other paved surface.
[0013] The machine 10 is configured to perform various functions when traveling over the ground surface 12 . In the embodiment shown in FIG. 1 , the machine 10 is a cold planer. In such an embodiment, the machine 10 is configured to cut or grind a top layer of concrete, asphalt, or similar material, to a depth that is typically between 1″ to 14″ below the ground surface 12 .
[0014] The machine 10 includes a frame 14 . The frame 14 serves to tie together and support other components and systems of the machine 10 . In addition to the frame 14 , the machine 10 has various other components and systems that serve various purposes. In the embodiment where the machine 10 is a cold planer, a frame 14 supports a material removal mechanism such as a cutting drum 15 that is configured to cut or grind the top layer of ground surface 12 . In the embodiment shown in FIG. 1 , the cutting drum 15 is a grinding mechanism that includes a rotor with a plurality of teeth configured to grind the ground surface 12 . However, the cutting drum 15 is not limited to such an arrangement. Although FIG. 1 shows a cutting drum 15 housed in a rear , lower portion of the machine 10 , the cutting drum 15 may be disposed in various places on the machine 10 . Alternatively or additionally, the machine 10 may include one or more supplementary grinding mechanisms that are located in rear and/or forward positions in the machine 10 .
[0015] The frame 14 supports a lower conveyor 16 that is located adjacent the cutting drum 15 and configured to receive the material removed from the ground surface 12 by the cutting drum 15 . The frame 14 also supports an upper conveyor 18 configured to receive the material from the lower conveyor 16 and to further convey the material to a location off of the machine 10 , such as to a receiver (e.g., another truck separate from machine 10 ). For example, the truck may be a dump truck that includes a bed. The dump truck may drive next to the machine 10 during grinding of the ground surface 12 , at approximately the same speed as the machine 10 , so that the material is conveyed by the upper conveyor 18 and dropped into the bed.
[0016] The machine 10 may also include one or more power sources (not shown) for powering the cutting drum 15 , the upper conveyor 18 , and/or various other components and systems of machine 10 . For example, the machine 10 may include one or more internal combustion engines, batteries, fuel cells, or the like for providing power. The machine 10 may also include various provisions for transmitting power from such power sources to the cutting drum 15 and/or various other components of the machine 10 . For example, where the machine 10 includes an internal combustion engine as a power source, the machine 10 may include one or more mechanical or electrical power-transmission devices, such as, mechanical transmissions, hydraulic pumps and motors, and/or electric generators and motors, for transmitting power from the engine to the cutting drum 15 and upper conveyor 18 .
[0017] The machine 10 includes a support system 20 and a steering system 22 to support the machine 10 from the ground surface 12 and steer the machine 10 while moving along the ground surface 12 . The support system 20 includes one or more front ground-engaging components 24 and one or more rear ground-engaging components 26 configured to move along ground surface 12 . The ground-engaging components 24 , 26 are connected to struts 30 , 40 via under carriage brackets 28 , 38 . FIG. 1 shows a front ground-engaging component 24 on a right side of machine 10 , as well as a rear ground-engaging component 26 on the right side of machine 10 . The machine 10 includes similar front and rear ground-engaging components 24 , 26 on a left side. Each ground-engaging component 24 , 26 includes any device or devices configured to move across ground surface 12 , including but not limited to track units, wheels, and skids.
[0018] Another example machine is shown in FIG. 2 . An exemplary machine 10 in which disclosed embodiments may be implemented is schematically illustrated in FIG. 2 . In the accompanied drawings, the machine 10 is illustrated as a cold planer machine. The machine 10 may be used in the art of construction.
[0019] The machine 10 includes a plurality of ground-engaging components or drive tracks 24 , 26 configured for propelling the machine 10 along a ground surface 12 . The machine 10 also includes a cutting drum 15 , supported on the frame 14 . The cutting drum 15 mills the road surface. A cutting plane of the machine 10 may be tangent to the bottom of the cutting drum 15 and parallel to the direction of travel of the machine 10 . The drive tracks 24 , 26 of the machine 10 are connected to a frame 14 of the machine 10 by hydraulic legs or struts 30 , 40 . The hydraulic legs or struts 30 , 40 are configured to raise and lower the cutting drum 15 relative to the drive tracks 24 , 26 so as to control a depth of cut for the cutting drum 15 .
[0020] The machine 10 is further equipped with a lower 16 and upper conveyor 18 configured to transport excavated asphalt from the cutting drum 15 to a discharge location such as the bed of a dump truck.
[0021] FIG. 3 is an isometric view of the lower conveyor 16 and the upper conveyor 18 . FIG. 4 is a partial side view of the lower conveyor 16 and the upper conveyor 18 . As shown in both FIGS. 3 and 4 ,
[0022] The lower conveyor 16 is attached to the frame 14 and an anti-slab structure through a linkage and sliding mechanism (not shown). The upper conveyor 18 is attached to the frame 14 through a pivotal structure 50 . The mechanism of the lower conveyor connection controls the discharge location of the lower conveyor 16 through the various working depths of the machine 10 . The lower conveyor 16 includes a discharge end 61 . The discharge end 61 of the lower conveyor 16 is located at the transition zone 62 . The transition zone 62 is the area between the lower conveyor 16 and the upper conveyor 18 . Generally, material passing from the discharge end 61 of the lower conveyor 16 to intake end 69 the upper conveyor 18 does so at the transition zone 62 .
[0023] In some embodiments of the disclosure, the transition zone 62 has flashing 64 . The flashing 64 aides in guiding material moving from the lower conveyor 16 to the upper conveyor 18 and helps reduce the likelihood of material falling off the conveyors 16 , 18 . An intake hopper 65 acts as a transition guide on the upper conveyor 18 . The intake hopper 65 is often a steel component. The intake hopper 65 is, as shown in FIGS. 3-5 be primarily mounted to the upper conveyor 18 . Other portions of the flashing 64 may be attached to the lower conveyor 16 .
[0024] The upper conveyor 18 includes an upper conveyor belt 66 that rides on the upper head pulleys 68 . The upper head pulleys 68 ride on upper head pulley axles 70 which are attached to the upper conveyor frame 72 . In some embodiments of the disclosure and as shown in FIG. 3 , the upper conveyor 18 has an upper conveyor frame housing 74 which provides a housing for the upper conveyor frame 72 . Some of the upper conveyor frame housing 74 is not shown in FIG. 3 in order to better illustrate the upper conveyor frame 72 . It will be understood by those of ordinary skill in the art that some embodiments can include upper conveyor frame housing 74 and other embodiments may not. The upper conveyor frame 72 is mounted to the frame 14 through an upper frame superstructure 75 which is equipped with actuators 77 and other devices in order to allow the upper conveyor 18 to pivot about the axis B-B shown in FIG. 3 .
[0025] The operation and structure of conveyors generally is well known as well as the ability of the conveyors to pivot whether vertically (about axis B-B) or pivot along the slew axis (A-A). In addition to the specific structure shown in the FIGS. one of ordinary skill in the art after reading this disclosure will appreciate that other types of conveyors and mechanisms for pivoting the upper conveyor 18 with respect to the lower conveyor 16 may be used and fall within the scope of this disclosure.
[0026] FIG. 3 illustrates the discharge end 78 of the upper conveyor 18 . In many embodiments, the discharge end 78 of the upper conveyor 18 is oriented proximate to a dump truck in order for material moving along the upper conveyor 18 to be deposited into the dump truck. FIG. 3 also illustrates that material moving along the lower conveyor 16 across the transition zone 62 and along the upper conveyor 18 moves in the same general direction of travel as illustrated by dashed line C-C. In other embodiments in accordance with the disclosure, the upper conveyor 18 may be rotated on the pivotal connection 50 about axis A-A so the lower conveyor 16 and the upper conveyor 18 are not in alignment to cause material to move along a general direction of travel C-C.
[0027] FIG. 4 is a partial side view of the lower conveyor 16 and upper conveyor 18 . In the view shown in FIG. 4 , the pivot axis B-B is illustrated as a pivot point 80 . The upper conveyor 18 pivot from side to side along one the slew axis A-A with respect to the lower conveyor 16 . This permits the upper conveyor 18 to move material either along the direction defined by the longitudinal direction of lower conveyor 16 or the material may turn when the material enters the upper conveyor 18 and move in a direction out of alignment with the longitudinal direction of lower conveyor 16 depending upon the pivotal direction of the upper conveyor 18 as that pivots about axis A-A. The upper conveyor 18 can also pivot with respect to pivot point 80 as shown in FIG. 4 or in other words about axis B-B as shown in FIGS. 3 and 5 . This elevation pivoting allows the discharge and 78 of the upper conveyor 18 to be raised or lowered as needed. As illustrated in FIGS. 4 through 5 , the axes A-A and B-B intersect at the upper conveyor 18 near the transition zone 62 . Because these two axes A-A and B-B intersect each other they define a plane.
[0028] FIG. 5 is a partial isometric view of a transition zone 62 of part of a machine 10 . The front ground engaging components or drive tracks 24 are seen. The lower conveyor 16 and associated lower conveyor belt 52 are shown. The pivotal connection 50 between the upper conveyor 18 and the machine 10 is also illustrated. The slew axis A-A extends through the pivotal connection 50 and is the axis about which the upper conveyor 18 pivots on the pivotal connection 50 .
[0029] Some of the flashing 64 at the transition zone 62 has been removed in order to better illustrate the transition zone 62 . The intake hopper 65 is illustrated in FIG. 5 . A material hard stop 82 is mounted to the machine frame 14 . In many embodiments in accordance with this disclosure, the material hard stop 82 is contained within the flashing 64 and is therefore not shown in FIGS. 3 and 4 due to concealment by the flashing 64 .
[0030] The material hard stop 82 is designed to work with the mounting mechanism and working speed range of the lower conveyor belt 52 , to maintain a transition intake point aligned with axis A on the upper conveyor. When the lower conveyor 16 is being run at a relatively low speed, the material coming off the lower conveyor 16 may have unimpeded travel into the intake hopper 65 . The alignment of the material transition intake to the intersection of axis A-A and axis B-B in the working elevation of the secondary conveyor reduces material spillage and improves conveyor belt tracking The hard stop 82 reduces the momentum of the material along axis C-C. The primary material momentum is transferred to the upper conveyor 18 in a vertical direction.
[0031] As mentioned above, the upper conveyor 18 also pivots about the elevation axis B-B in order to raise and lower the discharge and 78 (best seen in FIG. 3 ) to a desired height. The desired height may be controlled by the height of a wall associated with a dump truck into which the upper conveyor 18 is depositing material. It should be appreciated that the elevation axis B-B is not necessarily the axis of the upper head pulley axle 70 . In some embodiments the axis associated with the upper head pulley axles 70 and the elevation axis B-B may be the same however, in other embodiments as shown in FIGS. 3 through 5 , the elevation axis B-B is not the same axis as the axis associated with the axle 70 of the upper head pulley 68 .
[0032] Axis C-C illustrates a general direction of travel of material moving along the lower conveyor 16 and the upper conveyor 18 . In some embodiments in accordance with the disclosure, the lower conveyor 16 is aligned with the upper conveyor 18 so that material moving along the lower conveyor 16 across the transition zone 62 and along the upper conveyor 18 moves along a substantially similar general direction of travel. In some embodiments, the material hard stop 82 is also aligned along the axis C-C. In other embodiments in accordance with the disclosure, the upper conveyor 18 is pivoted along the pivotal connection 50 about the axis A-A so that the upper conveyor 18 is not aligned with the lower conveyor 16 to cause material moving along the lower conveyor 16 across the transition zone 62 and along the upper conveyor 18 episodes potentially same direction of travel.
INDUSTRIAL APPLICABILITY
[0033] Conveyors are often used to move material in a variety of settings. One example setting, but by no means, is a limiting example, is the use of a conveyor to move asphalt or other roadbed material from a cold planer machine to another vehicle. The second vehicle is often used to haul away the material moved by the conveyor. Due to the variety of settings and equipment that may be used in a milling operation, it may be desirable to provide a wide range of locations for the output of the material carried by the conveyor. One way to provide a multiple of locations for the output of the material is to provide a system of multiple conveyors. When multiple conveyors are used, they may be able to move by pivoting with respect to each other in order to adjust the final output of material. For example, by pivoting with respect to a slew axis (in other words, left or right with respect to a first conveyor), the output of the material may be moved to the left or to the right. By allowing the second conveyor to also pivot with respect to an elevation axis, the output of material can be raised or lowered as desired.
[0034] One of the problems associated with pivoting conveyors with respect to each other is at the transitional zone between the two conveyors provides an opportunity for material to be spilled or lost between the conveyors at the transition zone between the conveyors. When a conveyors run at a constant speed the location of the material being output from the conveyor may be predicted. In such a case, an operator may desire to place the input of a second conveyor at a location where it is predicted the output of the first conveyor will be in order to reduce the likelihood of material being spilled or lost during the transition of one conveyor to the other. However, the problem of material being lost or spilled between the conveyors is exacerbated when the speed of the two conveyors is adjusted. As the speed of a conveyor changes the location of the material being discharged can also change. For example, a conveyor run at a faster speed will “throw” material farther than the same conveyor moving the same material at lower speed. As a result, the area of where the material may end up when it comes off the conveyor is enlarged.
[0035] When the area of where the material may end up is enlarged, is more difficult to determine where the best place to put the input of the second conveyor. Further, the larger this area, the more flashing and guiding material is required to guide the material to the input of a second conveyor. Therefore it is desirable to consider ways to shrink or reduce the area of where material may end up when it is coming off a conveyor.
[0036] Another factor that can result in enlarging the transition area and therefore requiring more flashing in guiding material is the more axes the second conveyor pivots about potentially can enlarge the area where the input to the second conveyor may move. For example, if the input end of the second conveyor is in a desired location with respect to the output of the first conveyor, but the output end of the second conveyor needs to be adjusted, pivoting the second conveyor to a position where the output and is at a desired location may result in moving the input end of the second conveyor out of the desired position. This situation can result in enlarging the transition area between the two conveyors. Additional factors such as changing the working depth of the cutting drum and other movement of the first conveyor can also result in enlarging the transition area between conveyors.
[0037] An additional problem is that if the second conveyor is aligned at a significantly different angle with respect to the first conveyor, material from the first conveyor will enter the second conveyer moving in a different direction then the first conveyor. This may impart a force on the belt of the first conveyer that may tend to cause the belt of the first conveyer to move off its pulleys or come off track.
[0038] In some embodiments, these concerns are addressed by configuring and aligning the second conveyor so that the slew axis and the elevation axis about which the second conveyor pivots intersect each other and define a plane. In some embodiments, the slew axis and the elevation axis intersect proximal to an input and of the second conveyor. In some embodiments, configuring the conveyor system so that the slew axis and the elevation axis intersect and define a plane resulting in limiting the amount of travel the input end of the second conveyor does thereby reducing the size of the transitional area.
[0039] In some embodiments, the likelihood of spilling or losing material at the transitional area is reduced by aligning the first conveyor with the second conveyor to result in the material being moved along a direction of travel, and to both conveyors. Furthermore, in some embodiments, aligning the material hard stop with the common direction of travel can aid in reducing the likelihood of material being spilled or lost at the transitional area or the material entering the second conveyor to impart a force on the belt of the second conveyer to cause the belt of the second conveyer to come off of its pulleys.
[0040] The many features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the disclosure which fall within the true spirit and scope of the disclosure. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure. | A machine is provided. The machine includes a first conveyor and a second conveyor that is pivotable, with respect to the first conveyor, about two different axes that intersect and define a plane. A machine capable of performing a method for operating a set of conveyors is also provided. The method includes pivoting a second conveyor with respect to a first conveyor about two different axes that intersect and define a plane. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of co-pending applications Ser. No. 573,953, filed May 2, 1975, and Ser. No. 632,502, filed of even date herewith, which is in turn a continuation-in-part of Ser. No. 573,953.
BACKGROUND OF THE INVENTION
The present invention relates to metal panels having a system of internal tubular passageways disposed between spaced apart portions of the thickness of the panel. Said panels possess utility in heat exchange applications wherein a heat exchange medium is circulated through said passageways. A particular application of said panels resides in devices utilizing solar energy, and specifically, solar energy absorbing devices for elevating fluid temperature.
It is well known that the radiation of the sun can be collected as a source of energy for heating or cooling or for direct conversion to electricity. Heating and cooling depend upon collection of rays of solar energy in a fluid heating transfer system. The heated fluid is pumped or allowed to flow to a place of utilization for the thermal energy it has acquired.
In certain areas of the world, solar energy is the most abundant form of available energy if it could be harnessed economically. Even in more developed areas of the world, the economic harnessing of solar energy would provide an attractive alternative to the use of fossil fuels for energy generation.
One of the problems attending the development of an efficient system for the conversion of solar energy resides with the structure and design of the solar energy absorbing device, or solar collector. This solar collector generally comprises a rectangular plate-like structure possessing channels or passageways for the circulation of the energy absorbing fluid medium. Conventionally, these panels have comprised a pair of opposed expanded passageways, known as headers, which are placed at opposite ends of the panel, and are connected by a plurality of tubular passageways which are often in parallel relation with respect to each other. These passageways, as well as the headers themselves, have generally been disposed at right angles with respect to each other and in parallel relation with respect to the horizontal and vertical dimensions, respectively, of the panel.
The aforementioned configuration suffers from certain deficiencies, in that fluid flow tends to encounter pockets of stagnation which cut down on the efficient circulation of solar energy. Further, various entrained gases tend to collect in the passageways, with the result that air locks which greatly inhibit flow and reduce the maximum fluid circulation capacity of the panel are often formed.
In our co-pending application Ser. No. 573,953, the disclosure of which is incorporated herein by reference, it was determined that improved flow was obtainable by a modification of the disposition of the headers wherein the headers define an angle of at least 91° with respect to the direction of flow of the heat exchange medium. Though this modification alleviates the aforenoted problems to an extent, it was felt that further improvement in flow was desirable in certain of the panel configurations. To this end the improvements embodied in the present invention were developed.
SUMMARY OF THE INVENTION
In accordance with the present invention, a heat exchange panel is provided which possesses significantly improved fluid distribution and efficiency, and specific utility in solar energy applications.
The panel of the present invention comprises a planar structure possessing a system of tubular passageways for a heat exchange medium defining opposed headers connected by connecting portions of said passageways extending therebetween, said passageways having entry and exit portions extending from opposite ends of said headers to provide ingress and egress openings for said heat exchange medium, said headers defining an angle of at least 91° with respect to the direction of flow of said heat exchange medium wherein said headers are triangular shaped and are in substantially planar alignment at one of the boundary sides thereof with the longitudinal dimensions of said respective entry and exit portions. Said headers possess a plurality of parallel fluid channels communicating with said connecting portions, running in a direction substantially transverse thereto, and adapted to direct heat exchange fluid between said connecting portions and said respective entry and exit portions.
In the preferred embodiment, the panel of the present invention employs a uniquely shaped header provided with a plurality of parallel-directed, elongated bonded portions defining channels for directing fluid between said entry and exit portions and said connecting portions. The header employed in the present invention is so situated as to allow the greatest degree of capacity and depth in the area of greatest turbulence of fluid flow, while providing an ordered system of dispersing channels designed to apportion fluid flow to the respective connecting portions.
In addition to the above advantages, the headers employed in the panels of the present invention exhibit improved fluid flow control and directionality as well as increased header strength.
As indicated above, the preferred embodiment of the present invention utilizes a metal panel having a system of internal fluid passageways, conventionally painted black, as will be described in more detail hereinbelow. The concepts of the present invention may, however, also be advantageously utilized in heat exchangers generally, such as, for example, using extrusions. Since the concepts of the present invention are particularly advantageous in metal panels having a system of internal fluid passageways, the present invention will be specifically described hereinbelow utilizing this type of system.
Accordingly, it is a principal object of the present invention to provide a metal panel for use in heat exchange applications which enables the efficient and economical transfer of heat energy.
It is a further object of the present invention to provide a metal panel aforesaid which is particularly suited for use in a solar energy collector system.
It is yet a further object of the present invention to provide a metal panel as aforesaid which is efficiently designed to allow maximum utilization of internal passageway systems in a solar energy collector.
Further objects and advantages will become apparent to those skilled in the art as a detailed description proceeds with reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing schematically the manner in which the panels of the present invention can be employed;
FIG. 2 is a perspective view of a sheet of metal having a pattern of weld-inhibiting material applied to a surface thereof;
FIG. 3 is a perspective view of a composite metal blank wherein a second sheet of metal is superimposed on the sheet of metal shown in FIG. 2 with the pattern of weld-inhibiting material sandwiched therebetween;
FIG. 4 is a schematic perspective view showing the sheets of FIG. 3 being welded together while passing through a pair of mill rolls;
FIG. 5 is a top view showing the panel of the present invention having internal tubular passageways diposed between spaced apart portions of the thickness of the panel in the areas of the weld-inhibiting material;
FIG. 6 is a sectional view taken along lines 6--6 of FIG. 5;
FIG. 7 is an alternate view showing a variation in the tube configuration similar to the view of FIG. 6;
FIG. 8 is a top view showing an alternate embodiment of the present invention; and
FIG. 9 shows the panel of FIG. 8 rotated 90° about an axis perpendicular to the plane of the panel.
DETAILED DESCRIPTION
The panels of the present invention are preferably utilized in a solar heating system as shown in FIG. 1 wherein a plurality of panels of the present invention 10 are mounted on roof 11 of building 12 with conduits 13 and 14 connected in any convenient fashion to the equipment in the building, with the connections not shown. Thus, for example, cold water may go into conduit 13 from the building 12 by means of a conventional pump or the like. The water flows along common manifold 13a and is distributed into panels 10. The water flows through panels 10 is heated by means of solar energy, is collected in common manifold 14a, and flows into conduit 14. The heated water is then stored or utilized in a heat exchange system inside the building in a known manner. Naturally, if desired, the water flow may be reversed with the cold water entering via conduit 14 and collected via conduit 13. Alternatively, the solar heating unit of the present invention may be used or placed in any suitable environment, such as on the ground with suitable fasteners to prevent displacement by wind or gravity. The solar heating unit of the present invention may be used for residential heating purposes, such as in providing hot water in a residential environment. For example, three panels of the present invention having dimensions of 8 feet × 4 feet would efficiently supply an average household of four with hot water for home use. Alternatively, the solar panels of the present invention may be conveniently used for heating water for swimming pools or for preheating water for domestic gas or oil fired domestic hot water heaters. The fluid is preferably retained in a closed system with the water in the system heated in the solar unit and delivered into an insulated cistern or container so that the heated fluid may be stored up during sunshine for use on cool, cloudy days or at night when the heating of the fluid in the panel will not be of sufficient degree to provide the desired heat at the point of use.
A thermostat, not shown, is desirably installed at the top of the solar heater and this termostat may be set to turn on a circulating pump whenever the temperature reaches a predetermined reading. The pump will then pump the water through the system as generally outlined above.
As indicated above, the present invention contemplates a particularly preferred panel design for optimum efficiency in a solar heating system as described above. The metal panel or plate of the present invention is desirably fabricated by the ROLL-BOND® process as shown in U.S. Pat. No. 2,690,002. FIG. 2 illustrates a single sheet of metal 20 as aluminum or copper or alloys thereof, having applied to a clean surface 21 thereof a pattern of weld-inhibiting material 22 corresponding to the ultimate desired passageway system. FIG. 3 shows the sheet 20 having superimposed thereon a second sheet 23 with a pattern of weld-inhibiting material 22 sandwiched between the units. The units 20 and 23 are tacked together as by support welds 24 to prevent relative movement between the sheets as they are subsequently welded together as shown in FIG. 4 by passing through a pair of mill rolls 25 to form welded blank 26. It is normally necessary that the sheets 20 and 23 be heated prior to passing through the mill rolls to assure that they weld to each other in keeping with techniques well known in the rolling art.
The resultant blank 26 is characterized by the sheets 20 and 23 being welded together except at the area of the weld-inhibiting material 22. The blank 26 with the unjoined inner portion corresponding to the pattern of weld-inhibiting material 22 may then be softened in any appropriate manner as by annealing, and thereafter the blank may be cold rolled to provide a more even thickness and again annealed. The portions of the panel adjacent the weld-inhibiting material 22 are then inflated by the introduction of fluid distending pressure, such as with air or water, in a manner known in the art to form a system of internal tubular passageways 30 corresponding to the pattern of weld-inhibiting material as shown in FIG. 5. The passageways 30 extend internally within panel 10 and are disposed between spaced apart portions of the thickness of said panel. Thus, panel 10 comprises a hollow sheet metal panel or plate having a system of fluid passageways 30 for a heat exchange medium extending internally therein. If the passageways are inflated by the introduction of fluid distending pressure between flat die platens, the resultant passageways have a flat topped configuration 31 as shown in FIG. 6. If, on the other hand, passageways 30 are formed without the presence of superimposed platens the resultant passageway configuration has a semicircular shape 32 as shown in FIG. 7.
As shown in FIG. 5, the passageways 30 include opposed headers 33 connected by connecting portions 34 of said passageways extending substantially longitudinally in panel 10 between headers 33 and interconnecting same, with the opposed headers 33 extending in a direction substantially transverse to said longitudinal passageways. Preferably, opposed headers 33 are connected by a plurality of spaced, parallel individual connecting portions 34 of said passageways extending between the headers.
In accordance with the present invention, headers 33 are provided which are triangular in shape and are provided with boundary sides 35 which define a part of the outer perimeter of the passageways 30, as well as two of the three borders of the header structure.
Sides 35 are continuous with the fluid ports of the panel comprising entry portion 36 and exit portion 37, whereby the longitudinal dimension of at least one of respective sides 35 resides in substantially the same longitudinal plane as that containing the longitudinal dimension of the respective port. In the illustration of FIG. 5, the respective longitudinal dimensions of the sides and the entry and exit portions lie in the same longitudinal plane.
The advantage conferred by this arrangement is the availability of the greatest depth or capacity of header 33 is placed closest to the area of greatest turbulence and flow, that being the locus of entry and exit or heat exchange fluid. Thus, for example, fluid entering entry portion 36 in FIG. 5 encounters the greatest depth of header 33 as defined by vertically extending side 35 as illustrated therein. As panel 10 is generally employed in the upright position wherein the top edge or apex of the perimeter defined by sides 35 comprises the location of entry portion 36, the primary direction of flow is naturally dictated by gravity to be vertically downward by the most direct route. Thus, fluid entering at portion 36 tends to travel directly down through vertically adjacent connecting portions 34, and, as said connecting portions become filled, tends to spill over to laterally displaced parallel connecting portions.
Accordingly respecting the above, a further primary feature of the present invention resides in the provision of bonded portions 38 which are elongated in shape and which are aligned to define parallel-directed fluid channels 39 integral with said connecting portions and running substantially transverse thereto, which serve to assist in the lateral displacement of heat exchange fluid to respective connecting portions 34. Though the invention has been illustrated with bonded portions 38 comprising oblong or substantially rectangular shapes, it is to be understood that the invention is not limited thereto, as a wide variety of shapes may be employed which would provide the parallel channels 39 desired and employed herein.
The foregoing design can be seen to provide increased flow efficiency over designs providing the inlet and outlet structures at the regions of least depth of the headers. In the instance where flow is directed to the outlet portion, for example, the provision of the outlet at a shallow area of the header further serves to constrict and thereby impede the flow of heat exchange fluid. With the present invention, however, the area leading to outlet 37 is widened as the approach to said outlet is made, so as a greater quantity of fluid may be rapidly brought to said outlet.
Though the above discussion has proceeded with reference to solar panel structures employing connecting portions 34 running parallel to the longitudinal dimension of said panel, it can be seen that the invention is equally applicable to the instance where said connecting portions define angles of at least 1° with respect to said longitudinal dimension as determined by a longitudinal edge of the panel, such as disclosed in our co-pending application Ser. No. 632,502 commonly assigned and filed, the disclosure of which is incorporated herein by reference. As disclosed therein, the connecting portions define angles of at least 1° with respect to fluid flow, said fluid flow indicated in FIG. 8 by phantom line 40 as passing in the direction of a longitudinal edge of panel 10'. Thus, the angle β defined by line 40 and connecting portions 34', generally ranges from 20° to 10° and preferably from 21/2° to 71/2°. The foregoing angles may also be measured with respect to the central axis of the entry portion 36' which can be visualized as an extended straight line running through entry portion 36' in the direction of connecting portions 34'.
Referring further to FIG. 8, an angle α is described by phantom line 40 which is taken within the plane of panel 10', and boundary side 35' lying adjacent entry portion 36' which corresponds to at least 91° with respect to said direction of flow as defined by the central axis of said entry portion 36' and said exit portion 37', in accordance with parent application Ser. No. 573,953 noted earlier. In this embodiment, header 33' is provided with aligned, elongated bonded portions 38' which define parallel-directed passageways 39' in the manner discussed earlier. Also as indicated earlier, headers 33' are associated with respective portions 36' and 37' whereby the greatest depth of header 33' is provided adjacent the respective entry and exit portion. Likewise, the longitudinal dimensions of said exit and entry portions are in substantial planar alignment with the boundary sides 35' of respective headers 33'. In this embodiment, said alignment is not direct, as both boundary sides 35' are disposed at angles corresponding to those angles defined by connecting portions 34' and header 33', as defined with respect to the direction of fluid flow. Thus, the respective planes of said longitudinal dimensions will vary by an angle from 1° to 10°, said angle corresponding to the respective angles α and β discussed above. In the illustration of FIG. 8 herein, entry portion and exit portion 36' and 37', respectively, are aligned with the longitudinal dimension of panel 10' defined by phantom line 40, the angle of variation between the respective planes will comprise the angle β defined by connecting portions 34' and phantom line 40.
If, however, said entry and exit portions are displaced 90° away from the directions of entry portion 36' and exit portion 37' as illustrated in phantom in FIG. 8 and in solid line form in FIG. 9, the angle of variation between the respective planes will nonetheless remain within the aforenoted range of values, as said angle is always determined in relation to a boundary side most closely corresponding in direction to that of the respective port. Thus, referring now to FIG. 9, entry portion 36" and exit portion 37" are shown in 90° removal from the plane of respective portions 36' and 37' in FIG. 8. Accordingly, the direction of flow is likewise displaced and is now represented by phantom line 41, and the angle defined by the divergence by the plane of line 41 and that of most closely aligned boundary side 35" ranges from 1° to 10°, and is depicted as the angle γ in FIG. 9. In all of the above instances where angles have been defined with respect to lines representing the longitudinal definition of the respective panel, it is to be understood that said angles may be determined with respect to the convergence of the boundary side of the header with the central axis extrapolated through the entry or exit portion.
As in the illustration of FIG. 8, fluid flow is directed to the deepest portion of header 33" immediately upon entry through portion 36". Flow is assisted through connector portions 34" by the degree of inclination of said portions 34' denoted by the angle β. Fluid issuing from connector portions 34' is collected in header 33" situated in integral relation with exit portion 37". It is thus apparent from the foregoing illustrations that the provision of both angled headers and angled connecting portions facilitates the preparation and employment of the panels of the present invention which are suitable for mounting of the longitudinal dimension of the panel in either the horizontal or the vertical direction.
Referring back to FIGS. 8 and 9, an additional feature comprising the essence of our co-pending application Ser. No. 632,645, now U.S. Pat. No. 4,021,901 also commonly assigned and filed herewith, the disclosure of which is incorporated herein by reference, is discussed therein which comprises the provision of a nib-like marker structure 42 comprising in the present illustrations a distension of one of the respective connecting portions 34' and 34". Marker 42 enables the alignment of the inflated panel with a cutting means to either trim or sever said panel to the final dimensions thereof desired. Marker 42 is provided by the appropriate configuration of the pattern of weld-inhibiting material prior to the welding process.
Naturally, several alternative designs may be envisioned by one skilled in the art in accordance with the concepts described above.
This invention may be embodied in other forms or carried out in other ways without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes which come within the meaning and range of equivalency are intended to be embraced therein. | A heat exchange panel possessing a system of internal tubular passageways connecting opposed headers, said headers defining an angle of at least 91° with respect to the direction of flow of heat exchange medium passing therethrough, wherein said headers are triangular in shape and wherein fluid entry and exit portions extending from said headers are provided with their longitudinal dimensions lying in substantially the same plane as one of the sides defining the outer boundaries of said headers. Said headers are further provided with a plurality of bonded portions placed in alignment so as to define discrete, parallel-directed fluid channels assisting in the distribution of heat exchange fluid. The configuration of the headers provides improved and efficient drainage of fluid from the panel. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The application is a continuing application of U.S. patent application Ser. No. 10/688,632 (filed Oct. 17, 2003) entitled “Instrumentation and Methods for Use in Implanting a Cervical Disc Replacement Device” (“the '632 application”), which is a continuation in part of U.S. patent application Ser. No. 10/382,702 (filed Mar. 6, 2003) entitled “Cervical Disc Replacement” (“the '702 application”), which '632 and '702 applications are hereby incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
[0002] This invention relates generally to systems and methods for use in spine arthroplasty, and more specifically to instruments for inserting and removing cervical disc replacement trials, and inserting and securing cervical disc replacement devices, and methods of use thereof.
BACKGROUND OF THE INVENTION
[0003] The structure of the intervertebral disc disposed between the cervical bones in the human spine comprises a peripheral fibrous shroud (the annulus) which circumscribes a spheroid of flexibly deformable material (the nucleus). The nucleus comprises a hydrophilic, elastomeric cartilaginous substance that cushions and supports the separation between the bones while also permitting articulation of the two vertebral bones relative to one another to the extent such articulation is allowed by the other soft tissue and bony structures surrounding the disc. The additional bony structures that define pathways of motion in various modes include the posterior joints (the facets) and the lateral intervertebral joints (the unco-vertebral joints). Soft tissue components, such as ligaments and tendons, constrain the overall segmental motion as well.
[0004] Traumatic, genetic, and long term wearing phenomena contribute to the degeneration of the nucleus in the human spine. This degeneration of this critical disc material, from the hydrated, elastomeric material that supports the separation and flexibility of the vertebral bones, to a flattened and inflexible state, has profound effects on the mobility (instability and limited ranges of appropriate motion) of the segment, and can cause significant pain to the individual suffering from the condition. Although the specific causes of pain in patients suffering from degenerative disc disease of the cervical spine have not been definitively established, it has been recognized that pain may be the result of neurological implications (nerve fibers being compressed) and/or the subsequent degeneration of the surrounding tissues (the arthritic degeneration of the facet joints) as a result of their being overloaded.
[0005] Traditionally, the treatment of choice for physicians caring for patients who suffer from significant degeneration of the cervical intervertebral disc is to remove some, or all, of the damaged disc. In instances in which a sufficient portion of the intervertebral disc material is removed, or in which much of the necessary spacing between the vertebrae has been lost (significant subsidence), restoration of the intervertebral separation is required.
[0006] Unfortunately, until the advent of spine arthroplasty devices, the only methods known to surgeons to maintain the necessary disc height necessitated the immobilization of the segment. Immobilization is generally achieved by attaching metal plates to the anterior or posterior elements of the cervical spine, and the insertion of some osteoconductive material (autograft, allograft, or other porous material) between the adjacent vertebrae of the segment. This immobilization and insertion of osteoconductive material has been utilized in pursuit of a fusion of the bones, which is a procedure carried out on tens of thousands of pain suffering patients per year.
[0007] This sacrifice of mobility at the immobilized, or fused, segment, however, is not without consequences. It was traditionally held that the patient's surrounding joint segments would accommodate any additional articulation demanded of them during normal motion by virtue of the fused segment's immobility. While this is true over the short-term (provided only one, or at most two, segments have been fused), the effects of this increased range of articulation demanded of these adjacent segments has recently become a concern. Specifically, an increase in the frequency of returning patients who suffer from degeneration at adjacent levels has been reported.
[0008] Whether this increase in adjacent level deterioration is truly associated with rigid fusion, or if it is simply a matter of the individual patient's predisposition to degeneration is unknown. Either way, however, it is clear that a progressive fusion of a long sequence of vertebrae is undesirable from the perspective of the patient's quality of life as well as from the perspective of pushing a patient to undergo multiple operative procedures.
[0009] While spine arthroplasty has been developing in theory over the past several decades, and has even seen a number of early attempts in the lumbar spine show promising results, it is only recently that arthoplasty of the spine has become a truly realizable promise. The field of spine arthroplasty has several classes of devices. The most popular among these are: (a) the nucleus replacements, which are characterized by a flexible container filled with an elastomeric material that can mimic the healthy nucleus; and (b) the total disc replacements, which are designed with rigid endplates which house a mechanical articulating structure that attempts to mimic and promote the healthy segmental motion.
[0010] Among these solutions, the total disc replacements have begun to be regarded as the most probable long-term treatments for patients having moderate to severe lumbar disc degeneration. In the cervical spine, it is likely that these mechanical solutions will also become the treatment of choice.
[0011] It is an object of the invention to provide instrumentation and methods that enable surgeons to more accurately, easily, and efficiently implant fusion or non-fusion cervical disc replacement devices. Other objects of the invention not explicitly stated will be set forth and will be more clearly understood in conjunction with the descriptions of the preferred embodiments disclosed hereafter.
SUMMARY OF THE INVENTION
[0012] The preceding objects are achieved by the invention, which includes cervical disc replacement trials, cervical disc replacement devices, cervical disc replacement device insertion instrumentation (including, e.g., an insertion plate with mounting screws, an insertion handle, and an insertion pusher), and cervical disc replacement device fixation instrumentation (including, e.g., drill guides, drill bits, screwdrivers, bone screws, and retaining clips).
[0013] More particularly, the devices, instrumentation, and methods disclosed herein are intended for use in spine arthroplasty procedures, and specifically for use with the devices, instrumentation, and methods described herein in conjunction with the devices, instrumentation, and methods described herein and in the '702 application. However, it should be understood that the devices, instrumentation, and methods described herein are also suitable for use with other intervertebral disc replacement devices, instrumentation, and methods without departing from the scope of the invention.
[0014] For example, while the trials described herein are primarily intended for use in distracting an intervertebral space and/or determining the appropriate size of cervical disc replacement devices (e.g., described herein and in the '702 application) to be implanted (or whether a particular size can be implanted) into the distracted intervertebral space, they can also be used for determining the appropriate size of any other suitably configured orthopedic implant or trial to be implanted (or whether a particular size can be implanted) into the distracted intervertebral space. And, for example, while the insertion instrumentation described herein is primarily intended for use in holding, inserting, and otherwise manipulating cervical disc replacement devices (e.g., described herein and, in suitably configured embodiments, in the '702 application), it can also be used for manipulating any other suitably configured orthopedic implant or trial. And, for example, while the fixation instrumentation described herein is primarily intended for use in securing within the intervertebral space the cervical disc replacement devices (e.g., described herein and, in suitably configured embodiments, in the '702 application), it can also be used with any other suitably configured orthopedic implant or trial.
[0015] While the instrumentation described herein (e.g., the trials, insertion instrumentation, and fixation instrumentation) will be discussed for use with the cervical disc replacement device of FIGS. 1 a - 3 f herein, such discussions are merely by way of example and not intended to be limiting of their uses. Thus, it should be understood that the tools can be used with suitably configured embodiments of the cervical disc replacement devices disclosed in the '702 application, or any other artificial intervertebral disc having (or being modifiable or modified to have) suitable features therefor. Moreover, it is anticipated that the features of the cervical disc replacement device (e.g., the flanges, bone screw holes, and mounting holes) that are used by the tools discussed herein to hold and/or manipulate these devices (some of such features, it should be noted, were first shown and disclosed in the '702 application) can be applied, individually or collectively or in various combinations, to other trials, spacers, artificial intervertebral discs, or other orthopedic devices as stand-alone innovative features for enabling such trials, spacers, artificial intervertebral discs, or other orthopedic devices to be more efficiently and more effectively held and/or manipulated by the tools described herein or by other tools having suitable features. In addition, it should be understood that the invention encompasses artificial intervertebral discs, spacers, trials, and/or other orthopedic devices, that have one or more of the features disclosed herein, in any combination, and that the invention is therefore not limited to artificial intervertebral discs, spacers, trials, and/or other orthopedic devices having all of the features simultaneously.
[0016] The cervical disc replacement device of FIGS. 1 a - 3 f is an alternate embodiment of the cervical disc replacement device of the '702 application. The illustrated alternate embodiment of the cervical disc replacement device is identical in structure to the cervical disc replacement device in the '702 application, with the exception that the vertebral bone attachment flanges are configured differently, such that they are suitable for engagement by the instrumentation described herein.
[0017] More particularly, in this alternate embodiment, the flange of the upper element extends upwardly from the anterior edge of the upper element, and has a lateral curvature that approximates the curvature of the anterior periphery of the upper vertebral body against which it is to be secured. The attachment flange is provided with a flat recess, centered on the midline, that accommodates a clip of the present invention. The attachment flange is further provided with two bone screw holes symmetrically disposed on either side of the midline. The holes have longitudinal axes directed along preferred bone screw driving lines. Centrally between the bone screw holes, a mounting screw hole is provided for attaching the upper element to an insertion plate of the present invention for implantation. The lower element is similarly configured with a similar oppositely extending flange.
[0018] Once the surgeon has prepared the intervertebral space, the surgeon may use one or more cervical disc replacement trials of the present invention to distract the intervertebral space and determine the appropriate size of a cervical disc replacement device to be implanted (or whether a particular size of the cervical disc replacement device can be implanted) into the distracted cervical intervertebral space. Preferably, for each cervical disc replacement device to be implanted, a plurality of sizes of the cervical disc replacement device would be available. Accordingly, preferably, each of the plurality of trials for use with a particular plurality of differently sized cervical disc replacement devices would have a respective oval footprint and depth dimension set corresponding to the footprint and depth dimension set of a respective one of the plurality of differently sized cervical disc replacement devices.
[0019] Each of the cervical disc replacement trials includes a distal end configured to approximate relevant dimensions of an available cervical disc replacement device. The distal end has a head with an oval footprint. The upper surface of the head is convex, similar to the configuration of the vertebral body contact surface of the upper element of the cervical disc replacement device (but without the teeth). The lower surface of the head is flat, similar to the configuration of the vertebral body contact surface of the lower element of the cervical disc replacement device (but without the teeth). The cervical disc replacement trial, not having the teeth, can be inserted and removed from the intervertebral space without compromising the endplate surfaces. The cervical disc replacement trial further has a vertebral body stop disposed at the anterior edge of the head, to engage the anterior surface of the upper vertebral body before the trial is inserted too far into the intervertebral space.
[0020] Accordingly, the surgeon can insert and remove at least one of the trials (or more, as necessary) from the prepared intervertebral space. As noted above, the trials are useful for distracting the prepared intervertebral space. For example, starting with the largest distractor that can be wedged in between the vertebral bones, the surgeon will insert the trial head and then lever the trial handle up and down to loosen the annulus and surrounding ligaments to urge the bone farther apart. The surgeon then removes the trial head from the intervertebral space, and replaces it with the next largest (in terms of height) trial head. The surgeon then levers the trial handle up and down to further loosen the annulus and ligaments. The surgeon then proceeds to remove and replace the trial head with the next largest (in terms of height) trial head, and continues in this manner with larger and larger trials until the intervertebral space is distracted to the appropriate height.
[0021] Regardless of the distraction method used, the cervical disc replacement trials are useful for finding the cervical disc replacement device size that is most appropriate for the prepared intervertebral space, because each of the trial heads approximates the relevant dimensions of an available cervical disc replacement device. Once the intervertebral space is distracted, the surgeon can insert and remove one or more of the trial heads to determine the appropriate size of cervical disc replacement device to use. Once the appropriate size is determined, the surgeon proceeds to implant the selected cervical disc replacement device.
[0022] An insertion plate of the present invention is mounted to the cervical disc replacement device to facilitate a preferred simultaneous implantation of the upper and lower elements of the replacement device. The upper and lower elements are held by the insertion plate in an aligned configuration preferable for implantation. A ledge on the plate maintains a separation between the anterior portions of the inwardly facing surfaces of the elements to help establish and maintain this preferred relationship. The flanges of the elements each have a mounting screw hole and the insertion plate has two corresponding mounting holes. Mounting screws are secured through the colinear mounting screw hole pairs, such that the elements are immovable with respect to the insertion plate and with respect to one another. In this configuration, the upper element, lower element, and insertion plate construct is manipulatable as a single unit.
[0023] An insertion handle of the present invention is provided primarily for engaging an anteriorly extending stem of the insertion plate so that the cervical disc replacement device and insertion plate construct can be manipulated into and within the treatment site. The insertion handle has a shaft with a longitudinal bore at a distal end and a flange at a proximal end. Longitudinally aligning the insertion handle shaft with the stem, and thereafter pushing the hollow distal end of the insertion handle shaft toward the insertion plate, causes the hollow distal end to friction-lock to the outer surface of the stem. Once the insertion handle is engaged with the insertion plate, manipulation of the insertion handle shaft effects manipulation of the cervical disc replacement device and insertion plate construct. The surgeon can therefore insert the construct into the treatment area. More particularly, after the surgeon properly prepares the intervertebral space, the surgeon inserts the cervical disc replacement device into the intervertebral space from an anterior approach, such that the upper and lower elements are inserted between the adjacent vertebral bones with the element footprints fitting within the perimeter of the intervertebral space and with the teeth of the elements' vertebral body contact surfaces engaging the vertebral endplates, and with the flanges of the upper and lower elements flush against the anterior faces of the upper and lower vertebral bones, respectively.
[0024] Once the construct is properly positioned in the treatment area, the surgeon uses an insertion pusher of the present invention to disengage the insertion handle shaft from the stem of the insertion plate. The insertion pusher has a longitudinal shaft with a blunt distal end and a proximal end with a flange. The shaft of the insertion pusher can be inserted into and translated within the longitudinal bore of the insertion handle shaft. Because the shaft of the insertion pusher is as long as the longitudinal bore of the insertion handle shaft, the flange of the insertion handle and the flange of the insertion pusher are separated by a distance when the pusher shaft is inserted all the way into the longitudinal bore until the blunt distal end of the shaft contacts the proximal face of the insertion plate stem. Accordingly, a bringing together of the flanges (e.g., by the surgeon squeezing the flanges toward one another) will overcome the friction lock between the distal end of the insertion handle shaft and the stem of the insertion plate.
[0025] Once the insertion handle has been removed, the surgeon uses a drill guide of the present invention to guide the surgeon's drilling of bone screws through the bone screw holes of the upper and lower elements' flanges and into the vertebral bones. The drill guide has a longitudinal shaft with a distal end configured with a central bore that accommodates the stem so that the drill guide can be placed on and aligned with the stem. The distal end is further configured to have two guide bores that have respective longitudinal axes at preferred bone screw drilling paths relative to one another. When the central bore is disposed on the stem of the insertion plate, the drill guide shaft can be rotated on the stem into either of two preferred positions in which the guide bores are aligned with the bone screw holes on one of the flanges, or with the bone screw holes on the other flange.
[0026] To secure the upper element flange to the upper vertebral body, the surgeon places the drill guide shaft onto the stem of the insertion plate, and rotates the drill guide into the first preferred position. Using a suitable bone drill and cooperating drill bit, the surgeon drills upper tap holes for the upper bone screws. The surgeon then rotates the drill guide shaft on the stem of the insertion plate until the guide bores no longer cover the upper bone screw holes. The surgeon can then screw the upper bone screws into the upper tap holes using a suitable surgical bone screw driver. To then secure the lower element flange to the lower vertebral body, the surgeon further rotates the drill guide shaft on the stem of the insertion plate until the drill guide is in the second preferred position, and proceeds to drill the lower bone screw tap holes and screw the lower bone screws into them in the same manner.
[0027] Once the upper and lower elements are secured to the adjacent vertebral bones, the surgeon removes the drill guide from the stem of the insertion plate and from the treatment area. Using a suitable surgical screw driver, the surgeon then removes the mounting screws that hold the insertion plate against the elements' flanges and removes the insertion plate and the mounting screws from the treatment area.
[0028] Once the mounting screws and the insertion plate are removed, the surgeon uses a clip applicator of the present invention to mount retaining clips on the flanges to assist in retaining the bone screws. Each of the clips has a central attachment bore and, extending therefrom, a pair of oppositely directed laterally extending flanges and an upwardly (or downwardly) extending hooked flange. The clips can be snapped onto the element flanges (one clip onto each flange). Each of the laterally extending flanges of the clip is sized to cover at least a portion of a respective one of the bone screw heads when the clip is attached in this manner to the flange so that the clips help prevent the bone screws from backing out.
[0029] Also disclosed is an alternate dual cervical disc replacement device configuration suitable, for example, for implantation into two adjacent cervical intervertebral spaces. The configuration includes an alternate, upper, cervical disc replacement device (including an upper element and an alternate lower element), for implantation into an upper cervical intervertebral space, and further includes an alternate, lower, cervical disc replacement device (including an alternate upper element and a lower element), for implantation into an adjacent, lower, cervical intervertebral space. The illustrated alternate, upper, embodiment is identical in structure to the cervical disc replacement device of FIGS. 1 a - 3 f , with the exception that the flange of the lower element is configured differently and without bone screw holes. The illustrated alternate, lower, embodiment is identical in structure to the cervical disc replacement device of FIGS. 1 a - 3 f , with the exception that the flange of the upper element is configured differently and without bone screw holes.
[0030] More particularly, in the alternate, upper, cervical disc replacement device of this alternate configuration, the flange of the alternate lower element does not have bone screw holes, but does have a mounting screw hole for attaching the alternate lower element to an alternate, upper, insertion plate. Similarly, in the alternate, lower, cervical disc replacement device of this alternate configuration, the flange of the alternate upper element does not have bone screw holes, but does have a mounting screw hole for attaching the alternate upper element to an alternate, lower, insertion plate. The extent of the flange of the alternate lower element is laterally offset to the right (in an anterior view) from the midline, and the extent of the flange of the alternate upper element is laterally offset to the left (in an anterior view) from the midline, so that the flanges avoid one another when the alternate lower element of the alternate, upper, cervical disc replacement device, and the alternate upper element of the alternate, lower, cervical disc replacement device, are implanted in this alternate configuration.
[0031] The alternate, upper, insertion plate is identical in structure to the insertion plate described above, with the exception that the lower flange is offset from the midline (to the right in an anterior view) to align its mounting screw hole with the offset mounting screw hole of the alternate lower element. Similarly, the alternate, lower, insertion plate is identical in structure to the insertion plate described above, with the exception that the upper flange is offset from the midline (to the left in an anterior view) to align its mounting screw hole with the offset mounting screw hole of the alternate upper element.
[0032] Accordingly, the upper and lower elements of the alternate, upper, cervical disc replacement device, being held by the alternate upper insertion plate, as well as the upper and lower elements of the alternate, lower, cervical disc replacement device, being held by the alternate lower insertion plate, can be implanted using the insertion handle, insertion pusher, drill guide, clips (one on the uppermost element flange, and one on the lowermost element flange, because only the uppermost element and the lowermost element are secured by bone screws), and clip applicator, in the manner described above with respect to the implantation of the cervical disc replacement device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] [0033]FIGS. 1 a - c show anterior (FIG. 1 a ), lateral (FIG. 1 b ), and bottom (FIG. 1 c ) views of a top element of a cervical disc replacement device of the invention.
[0034] [0034]FIGS. 2 a - c show anterior (FIG. 2 a ), lateral (FIG. 2 b ), and top (FIG. 2 c ) views of a bottom element of the cervical disc replacement device.
[0035] [0035]FIG. 3 a - f show top (FIG. 3 a ), lateral (FIG. 3 b ), anterior (FIG. 3 c ), posterior (FIG. 3 d ), antero-lateral perspective (FIG. 3 e ), and postero-lateral perspective (FIG. 3 f ) views of the cervical disc replacement device, assembled with the top and bottom elements of FIGS. 1 a - c and 2 a - c.
[0036] [0036]FIGS. 4 a - g show top (FIG. 4 a ), lateral (FIG. 4 b ), anterior (FIG. 4 c ), posterior (FIG. 4 d ), antero-lateral perspective (head only) (FIG. 4 e ), and postero-lateral perspective (head only) (FIG. 4 f ) views of a cervical disc replacement trial of the present invention.
[0037] [0037]FIGS. 5 a - d show top (FIG. 5 a ), lateral (FIG. 5 b ), anterior (FIG. 5 c ), and posterior (FIG. 5 d ) views of an insertion plate of the insertion instrumentation of the present invention. FIGS. 5 e and 5 f show anterior (FIG. 5 e ) and antero-lateral perspective (FIG. 5 f ) views of the insertion plate mounted to the cervical disc replacement device.
[0038] [0038]FIGS. 6 a - d show top (FIG. 6 a ), lateral (FIG. 6 b ), anterior (FIG. 6 c ), and postero-lateral (FIG. 6 d ) views of an insertion handle of the insertion instrumentation of the present invention. FIG. 6 e shows an antero-lateral perspective view of the insertion handle attached to the insertion plate. FIG. 6 f shows a magnified view of the distal end of FIG. 6 e.
[0039] [0039]FIGS. 7 a - c show top (FIG. 7 a ), lateral (FIG. 7 b ), and anterior (FIG. 7 c ) views of an insertion pusher of the insertion instrumentation of the present invention. FIG. 7 d shows an antero-lateral perspective view of the insertion pusher inserted into the insertion handle. FIG. 7 e shows a magnified view of the proximal end of FIG. 7 d.
[0040] [0040]FIGS. 8 a - c show top (FIG. 8 a ), lateral (FIG. 8 b ), and anterior (FIG. 8 c ) views of a drill guide of the insertion instrumentation of the present invention. FIG. 8 d shows an antero-lateral perspective view of the drill guide inserted onto the insertion plate. FIG. 8 e shows a magnified view of the distal end of FIG. 8 d.
[0041] [0041]FIG. 9 a shows an antero-lateral perspective view of the cervical disc replacement device implantation after bone screws have been applied and before the insertion plate has been removed. FIG. 9 b shows an antero-lateral perspective view of the cervical disc replacement device after bone screws have been applied and after the insertion plate has been removed.
[0042] [0042]FIGS. 10 a - f show top (FIG. 10 a ), lateral (FIG. 10 b ), posterior (FIG. 10 c ), anterior (FIG. 10 d ), postero-lateral (FIG. 10 e ), and antero-lateral (FIG. 10 f ) views of a retaining clip of the present invention.
[0043] [0043]FIGS. 11 a - c show top (FIG. 11 a ), lateral (FIG. 11 b ), and anterior (FIG. 11 c ) views of a clip applicator of the insertion instrumentation of the present invention. FIG. 11 d shows a postero-lateral perspective view of the clip applicator holding two retaining clips. FIG. 11 e shows an antero-lateral perspective view of FIG. 11 d.
[0044] [0044]FIG. 12 a shows the clip applicator applying the retaining clips to the cervical disc replacement device. FIGS. 12 b - h show anterior (FIG. 12 b ), posterior (FIG. 12 c ), top (FIG. 12 d ), bottom (FIG. 12 e ), lateral (FIG. 12 f ), antero-lateral perspective (FIG. 12 g ), and postero-lateral perspective (FIG. 12 h ) views of the cervical disc replacement device after the retaining clips have been applied.
[0045] [0045]FIGS. 13 a - b show a prior art one level cervical fusion plate in anterior (FIG. 13 a ) and lateral (FIG. 13 b ) views. FIGS. 13 c - d show a prior art two level cervical fusion plate in anterior (FIG. 13 c ) and lateral (FIG. 13 d ) views.
[0046] [0046]FIGS. 14 a - e show an alternate, dual cervical disc replacement device configuration and alternate insertion plates for use therewith, in exploded perspective (FIG. 14 a ), anterior (FIG. 14 b ), posterior (FIG. 14 c ), lateral (FIG. 14 d ), and collapsed perspective (FIG. 14 e ) views.
[0047] [0047]FIGS. 15 a - c show an alternate upper element of the configuration of FIGS. 14 a - e , in posterior (FIG. 15 a ), anterior (FIG. 15 b ), and antero-lateral (FIG. 15 c ) views.
[0048] [0048]FIGS. 16 a - c show an alternate lower element of the configuration of FIGS. 14 a - e , in posterior (FIG. 16 a ), anterior (FIG. 16 b ), and antero-lateral (FIG. 16 c ) views.
[0049] [0049]FIGS. 17 a - c show an alternate, upper, insertion plate of the configuration of FIGS. 14 a - e in anterior (FIG. 17 a ), posterior (FIG. 17 b ), and antero-lateral (FIG. 17 c ) views.
[0050] [0050]FIGS. 18 a - c show an alternate, lower, insertion plate of the configuration of FIGS. 14 a - e in anterior (FIG. 18 a ), posterior (FIG. 18 b ), and antero-lateral (FIG. 18 c ) views.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] While the invention will be described more fully hereinafter with reference to the accompanying drawings, it is to be understood at the outset that persons skilled in the art may modify the invention herein described while achieving the functions and results of the invention. Accordingly, the descriptions that follow are to be understood as illustrative and exemplary of specific structures, aspects and features within the broad scope of the invention and not as limiting of such broad scope. Like numbers refer to similar features of like elements throughout.
[0052] A preferred embodiment of a cervical disc replacement device of the present invention, for use with the instrumentation of the present invention, will now be described.
[0053] Referring now to FIGS. 1 a - 3 f , a top element 500 of the cervical disc replacement device 400 is shown in anterior (FIG. 1 a ), lateral (FIG. 1 b ), and bottom (FIG. 1 c ) views; a bottom element 600 of the cervical disc replacement device 400 is shown in anterior (FIG. 2 a ), lateral (FIG. 2 b ), and top (FIG. 2 c ) views; and an assembly 400 of the top and bottom elements 500 , 600 is shown in top (FIG. 3 a ), lateral (FIG. 3 b ), anterior (FIG. 3 c ), posterior (FIG. 3 d ), antero-lateral perspective (FIG. 3 e ), and postero-lateral perspective (FIG. 3 f ) views.
[0054] The cervical disc replacement device 400 is an alternate embodiment of the cervical disc replacement device of the '702 application. The illustrated alternate embodiment of the cervical disc replacement device is identical in structure to the cervical disc replacement device 100 in the '702 application (and thus like components are like numbered, but in the 400s rather than the 100s, in the 500s rather than the 200s, and in the 600s rather than the 300s), with the exception that the vertebral bone attachment flanges are configured differently, such that they are suitable for engagement by the instrumentation described herein. (It should be noted that, while the '702 application illustrated and described the cervical disc replacement device 100 as having an upper element flange 506 with two bone screw holes 508 a , 508 b , and a lower element flange 606 with one bone screw hole 608 , the '702 application explained that the number of holes and the configuration of the flanges could be modified without departing from the scope of the invention as described in the '702 application.)
[0055] More particularly, in this alternate embodiment, the upper element 500 of the cervical disc replacement device 400 has a vertebral body attachment structure (e.g., a flange) 506 that preferably extends upwardly from the anterior edge of the upper element 500 , and preferably has a lateral curvature that approximates the curvature of the anterior periphery of the upper vertebral body against which it is to be secured. The attachment flange 506 is preferably provided with a flat recess 507 , centered on the midline, that accommodates a clip 1150 a (described below) of the present invention. The attachment flange 506 is further provided with at least one (e.g., two) bone screw holes 508 a , 508 b , preferably symmetrically disposed on either side of the midline. Preferably, the holes 508 a , 508 b have longitudinal axes directed along preferred bone screw driving lines. For example, in this alternate embodiment, the preferred bone screw driving lines are angled upwardly at 5 degrees and inwardly (toward one another) at 7 degrees (a total of 14 degrees of convergence), to facilitate a toenailing of the bone screws (described below and shown in FIGS. 12 a - h ). Centrally between the bone screw holes 508 a , 508 b , at least one mounting feature (e.g., a mounting screw hole) 509 is provided for attaching the upper element 500 to an insertion plate 700 (described below) for implantation.
[0056] Similarly, in this alternate embodiment, the lower element 600 of the cervical disc replacement device 400 also has a vertebral body attachment structure (e.g., an oppositely directed and similarly configured vertebral body attachment flange) 606 that preferably extends downwardly from the anterior edge of the lower element 600 , and preferably has a lateral curvature that approximates the curvature of the anterior periphery of the lower vertebral body against which it is to be secured. The attachment flange 606 is preferably provided with a flat recess 607 , centered on the midline, that accommodates a clip 1150 b (described below) of the present invention. The attachment flange 606 is further provided with at least one (e.g., two) bone screw holes 608 a , 608 b , preferably symmetrically disposed on either side of the midline. Preferably, the holes 608 a , 608 b have longitudinal axes directed along preferred bone screw driving lines. For example, in this alternate embodiment, the preferred bone screw driving lines are angled downwardly at 5 degrees and inwardly (toward one another) at 7 degrees (a total of 14 degrees of convergence), to facilitate a toenailing of the bone screws (described below and shown in FIGS. 12 a - h ). Centrally between the bone screw holes 608 a , 608 b , at least one mounting feature (e.g., a mounting screw hole) 609 is provided for attaching the lower element 600 to the insertion plate 700 (described below) for implantation.
[0057] Prior to implantation of the cervical disc replacement device, the surgeon will prepare the intervertebral space. Typically, this will involve establishing access to the treatment site, removing the damaged natural intervertebral disc, preparing the surfaces of the endplates of the vertebral bones adjacent the intervertebral space, and distracting the intervertebral space. (It should be noted that the cervical disc replacement device of the present invention, and the instrumentation and implantation methods described herein, require minimal if any endplate preparation.) More particularly, after establishing access to the treatment site, the surgeon will remove the natural disc material, preferably leaving as much as possible of the annulus intact. Then, the surgeon will remove the anterior osteophyte that overhangs the mouth of the cervical intervertebral space, and any lateral osteophytes that may interfere with the placement of the cervical disc replacement device or the movement of the joint. Using a burr tool, the surgeon will then ensure that the natural lateral curvature of the anterior faces of the vertebral bodies is uniform, by removing any surface anomalies that deviate from the curvature. Also using the burr tool, the surgeon will ensure that the natural curvature of the endplate surface of the upper vertebral body, and the natural flatness of the endplate surface of the lower vertebral body, are uniform, by removing any surface anomalies that deviate from the curvature or the flatness. Thereafter, the surgeon will distract the intervertebral space to the appropriate height for receiving the cervical disc replacement device. Any distraction tool or method known in the art, e.g., a Caspar Distractor, can be used to effect the distraction and/or hold open the intervertebral space. Additionally or alternatively, the cervical disc replacement trials of the present invention can be used to distract the intervertebral space (as described below).
[0058] Referring now to FIGS. 4 a - f , a cervical disc replacement trial 1200 of the present invention is shown in top (FIG. 4 a ), lateral (FIG. 4 b ), lateral (head only) (FIG. 4 c ), posterior (FIG. 4 d ), anterior (FIG. 4 e ), antero-lateral perspective (head only) (FIG. 4 f ), and postero-lateral perspective (head only) (FIG. 4 g ) views.
[0059] Preferably, a plurality of cervical disc replacement trials are provided primarily for use in determining the appropriate size of a cervical disc replacement device to be implanted (or whether a particular size of the cervical disc replacement device can be implanted) into the distracted cervical intervertebral space (e.g., the cervical disc replacement device 400 of FIGS. 1 a - 3 f ). Preferably, for each cervical disc replacement device to be implanted, a plurality of sizes of the cervical disc replacement device would be available. That is, preferably, a plurality of the same type of cervical disc replacement device would be available, each of the plurality having a respective footprint and depth dimension combination that allows it to fit within a correspondingly dimensioned intervertebral space. For example, the plurality of cervical disc replacement devices could include cervical disc replacement devices having oval footprints being 12 mm by 14 mm, 14 mm by 16 mm, or 16 mm by 18 mm, and depths ranging from 6 mm to 14 mm in 1 mm increments, for a total of 27 devices. Accordingly, preferably, each of the plurality of trials for use with a particular plurality of differently sized cervical disc replacement devices would have a respective oval footprint and depth dimension set corresponding to the footprint and depth dimension set of a respective one of the plurality of differently sized cervical disc replacement devices. For example, the plurality of trials for use with the set of cervical disc replacement devices described, for example, could include trials having oval footprints being 12 mm by 14 mm, 14 mm by 16 mm, or 16 mm by 18 mm, and depths ranging from 6 mm to 14 mm in 1 mm increments, for a total of 27 static trials. It should be understood that the cervical disc replacement devices and/or the trials can be offered in a variety of dimensions without departing from the scope of the invention, and that the dimensions specifically identified and quantified herein are merely exemplary. Moreover, it should be understood that the set of trials need not include the same number of trials for each cervical disc replacement device in the set of cervical disc replacement devices, but rather, none, one, or more than one trial can be included in the trial set for any particular cervical disc replacement device in the set.
[0060] Each of the cervical disc replacement trials (the cervical disc replacement trial 1200 shown in FIGS. 4 a - g is exemplary for all of the trials in the plurality of trials; preferably the trials in the plurality of trials differ from one another only with regard to certain dimensions as described above) includes a shaft 1202 having a configured distal end 1204 and a proximal end having a handle 1206 . Preferably, the proximal end is provided with a manipulation features (e.g., a hole 1216 ) to, e.g., decrease the weight of the trial 1200 , facilitate manipulation of the trial 1200 , and provide a feature for engagement by an instrument tray protrusion. The distal end is configured to approximate relevant dimensions of the cervical disc replacement device. More particularly in the illustrated embodiment (for example), the distal end 1204 has a trial configuration (e.g., a head 1208 having an oval footprint dimensioned at 12 mm by 14 mm, and a thickness of 6 mm). The upper surface 1210 of the head 1208 is convex, similar to the configuration of the vertebral body contact surface of the upper element 500 of the cervical disc replacement device 400 (but without the teeth). The lower surface 1212 of the head 1208 is flat, similar to the configuration of the vertebral body contact surface of the lower element 600 of the cervical disc replacement device 400 (but without the teeth). The illustrated embodiment, therefore, with these dimensions, approximates the size of a cervical disc replacement device having the same height and footprint dimensions. The cervical disc replacement trial, not having the teeth, can be inserted and removed from the intervertebral space without compromising the endplate surfaces. The cervical disc replacement trial 1200 further has an over-insertion prevention features (e.g., a vertebral body stop 1214 ) preferably disposed at the anterior edge of the head 1208 , to engage the anterior surface of the upper vertebral body before the trial 1200 is inserted too far into the intervertebral space. The body of the trial 1200 preferably has one or more structural support features (e.g., a rib 1216 extending anteriorly from the head 1208 below the shaft 1202 ) that provides stability, e.g., to the shaft 1202 for upward and downward movement, e.g., if the head 1208 must be urged into the intervertebral space by moving the shaft 1202 in this manner. Further, preferably as shown, the head 1208 is provided with an insertion facilitation features (e.g., a taper, decreasing posteriorly) to facilitate insertion of the head 1208 into the intervertebral space by, e.g., acting as a wedge to urge the vertebral endplates apart. Preferably, as shown, the upper surface 1210 is fully tapered at approximately 5 degrees, and the distal half of the lower surface 1212 is tapered at approximately 4 degrees.
[0061] Accordingly, the surgeon can insert and remove at least one of the trials (or more, as necessary) from the prepared intervertebral space. As noted above, the trials are useful for distracting the prepared intervertebral space. For example, starting with the largest distractor that can be wedged in between the vertebral bones, the surgeon will insert the trial head 1208 (the tapering of the trial head 1208 facilitates this insertion by acting as a wedge to urge the vertebral endplates apart), and then lever the trial handle 1206 up and down to loosen the annulus and surrounding ligaments to urge the bone farther apart. Once the annulus and ligaments have been loosened, the surgeon removes the trial head 1208 from the intervertebral space, and replaces it with the next largest (in terms of height) trial head 1208 . The surgeon then levers the trial handle 1206 up and down to further loosen the annulus and ligaments. The surgeon then proceeds to remove and replace the trial head 1208 with the next largest (in terms of height) trial head 1208 , and continues in this manner with larger and larger trials until the intervertebral space is distracted to the appropriate height. This gradual distraction method causes the distracted intervertebral space to remain at the distracted height with minimal subsidence before the cervical disc replacement device is implanted. The appropriate height is one that maximizes the height of the intervertebral space while preserving the annulus and ligaments.
[0062] Regardless of the distraction method used, the cervical disc replacement trials are useful for finding the cervical disc replacement device size that is most appropriate for the prepared intervertebral space, because each of the trial heads approximates the relevant dimensions of an available cervical disc replacement device. Once the intervertebral space is distracted, the surgeon can insert and remove one or more of the trial heads to determine the appropriate size of cervical disc replacement device to use. Once the appropriate size is determined, the surgeon proceeds to implant the selected cervical disc replacement device.
[0063] A preferred method of, and instruments for use in, implanting the cervical disc replacement device will now be described.
[0064] Referring now to FIGS. 5 a - f , an insertion plate 700 of the insertion instrumentation of the present invention is shown in top (FIG. 5 a ), lateral (FIG. 5 b ), anterior (FIG. 5 c ), and posterior (FIG. 5 d ) views. FIGS. 5 e and 5 f show anterior (FIG. 5 e ) and antero-lateral perspective (FIG. 5 f ) views of the insertion plate 700 mounted to the cervical disc replacement device 400 .
[0065] The insertion plate 700 has a base 702 with a first mounting area 704 a (preferably an upwardly extending flange) and a second mounting area 704 b (preferably a downwardly extending flange), and a primary attachment feature (e.g., an anteriorly extending central stem) 706 . The connection of the stem 706 to the base 702 preferably includes an axial rotation prevention feature, e.g., two oppositely and laterally extending key flanges 708 a , 708 b . The stem 706 preferably has a proximal portion 710 that is tapered to have a decreasing diameter away from the base 702 . That is, the tapered proximal portion 710 has an initial smaller diameter that increases toward the base 702 gradually to a final larger diameter. The base 702 preferably has a posteriorly extending ledge 716 that has a flat upper surface and a curved lower surface.
[0066] The insertion plate 700 is mounted to the cervical disc replacement device 400 to facilitate the preferred simultaneous implantation of the upper and lower elements 500 , 600 . The upper and lower elements 500 , 600 are held by the insertion plate 700 in a preferred relationship to one another that is suitable for implantation. More particularly, as shown in FIGS. 3 a - f , 5 e , and 5 f , the elements 500 , 600 are preferably axially rotationally aligned with one another, with the element perimeters and flanges 506 , 606 axially aligned with one another, and held with the bearing surfaces 512 , 612 in contact. The ledge 716 maintains a separation between the anterior portions of the inwardly facing surfaces of the elements 500 , 600 to help establish and maintain this preferred relationship, with the flat upper surface of the ledge 716 in contact with the flat anterior portion of the inwardly facing surface of the upper element 500 , and the curved lower surface of the ledge 716 in contact with the curved anterior portion of the inwardly facing surface of the lower element 600 .
[0067] While any suitable method or mechanism can be used to mount the elements 500 , 600 to the insertion plate 700 , a preferred arrangement is described. That is, it is preferred, as shown and as noted above, that the flanges 506 , 606 of the elements 500 , 600 (in addition to having the bone screw holes 508 a , 508 b , 608 a , 608 b described above) each have at least one mounting feature (e.g., mounting screw hole 509 , 609 ), and the insertion plate 700 has two (at least two, each one alignable with a respective mounting screw hole 509 , 609 ) corresponding mounting features (e.g., mounting screw holes 712 a , 712 b ), spaced to match the spacing of (and each be colinear with a respective one of) the mounting screw holes 509 , 609 on the flanges 506 , 606 of the elements 500 , 600 of the cervical disc replacement device 400 when those elements 500 , 600 are disposed in the preferred relationship for implantation. Accordingly, mounting screws 714 a , 714 b or other suitable fixation devices are secured through the colinear mounting screw hole pairs 509 , 712 a and 609 , 712 b (one screw through each pair), such that the elements 500 , 600 are immovable with respect to the insertion plate 700 and with respect to one another. Thus, in this configuration, the upper element 500 , lower element 600 , and insertion plate 700 construct is manipulatable as a single unit.
[0068] Preferably, for each size of cervical disc replacement device, the described configuration is established (and rendered sterile in a blister pack through methods known in the art) prior to delivery to the surgeon. That is, as described below, the surgeon will simply need to open the blister pack and apply the additional implantation tools to the construct in order to implant the cervical disc replacement device. Preferably, the configuration or dimensions of the insertion plate can be modified (either by providing multiple different insertion plates, or providing a single dynamically modifiable insertion plate) to accommodate cervical disc replacement devices of varying heights. For example, the positions of the mounting screw holes 712 a , 712 b on the flanges 704 a , 704 b can be adjusted (e.g., farther apart for replacement devices of greater height, and close together for replacement devices of lesser height), and the size of the flanges 704 a , 70 b can be adjusted to provide structural stability for the new hole positions. Preferably, in other respects, the insertion plate configuration and dimensions need not be modified, to facilitate ease of manufacturing and lower manufacturing costs.
[0069] It should be noted that the described configuration of the construct presents the cervical disc replacement device to the surgeon in a familiar manner. That is,, by way of explanation, current cervical fusion surgery involves placing a fusion device (e.g., bone or a porous cage) in between the cervical intervertebral bones, and attaching a cervical fusion plate to the anterior aspects of the bones. Widely used cervical fusion devices (an example single level fusion plate 1300 is shown in anterior view in FIG. 13 a and in lateral view in FIG. 13 b ) are configured with a pair of laterally spaced bone screw holes 1302 a , 1302 b on an upper end 1304 of the plate 1300 , and a pair of laterally spaced bone screw holes 1306 a , 1306 b on a lower end 1308 of the plate 1300 . To attach the plate 1300 to the bones, two bone screws are disposed through the upper end's bone screw holes 1302 a , 1302 b and into the upper bone, and two bone screws are disposed through the lower end's bone screw holes 1306 a , 1306 b and into the lower bone. This prevents the bones from moving relative to one another, and allows the bones to fuse to one another with the aid of the fusion device.
[0070] Accordingly, as can be seen in FIG. 5 e , when the upper and lower elements 500 , 600 of the cervical disc replacement device 400 are held in the preferred spatial relationship, the flanges 506 , 606 of the elements 500 , 600 , and their bone screw holes 508 a , 508 b , present to the surgeon a cervical hardware and bone screw hole configuration similar to a familiar cervical fusion plate configuration. The mounting of the elements 500 , 600 to the insertion plate 700 allows the elements 500 , 600 to be manipulated as a single unit for implantation (by manipulating the insertion plate 700 ), similar to the way a cervical fusion plate is manipulatable as a single unit for attachment to the bones. This aspect of the present invention simplifies and streamlines the cervical disc replacement device implantation procedure.
[0071] As noted above, the cervical disc replacement device 400 and insertion plate 700 construct is preferably provided sterile (e.g., in a blister pack) to the surgeon in an implant tray (the tray preferably being filled with constructs for each size of cervical disc replacement device). The construct is preferably situated in the implant tray with the stem 706 of the insertion plate 700 facing upwards for ready acceptance of the insertion handle 800 (described below).
[0072] Referring now to FIGS. 6 a - e , an insertion handle 800 of the insertion instrumentation of the present invention is shown in top (FIG. 6 a ), lateral (FIG. 6 b ), anterior (FIG. 6 c ), and postero-lateral (distal end only) (FIG. 6 d ) views. FIG. 6 e shows an antero-lateral perspective view of the insertion handle 800 attached to the stem 706 of the insertion plate 700 . FIG. 6 f shows a magnified view of the distal end of FIG. 6 e.
[0073] The insertion handle 800 is provided primarily for engaging the stem 706 of the insertion plate 700 so that the cervical disc replacement device 400 and insertion plate 700 construct can be manipulated into and within the treatment site. The insertion handle 800 has a shaft 802 with an attachment feature (e.g., a longitudinal bore) 804 at a distal end 806 and a manipulation feature (e.g., a flange) 810 at a proximal end 808 . Preferably, the longitudinal bore 804 has an inner taper at the distal end 806 such that the inner diameter of the distal end 806 decreases toward the distal end 806 , from an initial larger inner diameter at a proximal portion of the distal end 806 to a final smaller inner diameter at the distal edge of the distal end 806 . The distal end 806 also preferably has an axial rotation prevention feature, e.g., two (at least one) key slots 814 a , 814 b extending proximally from the distal end 806 . Each slot 814 a , 814 b is shaped to accommodate the key flanges 708 a , 708 b at the connection of the base 702 to the stem 706 when the distal end 806 is engaged with the stem 706 . The material from which the insertion handle 800 is formed (preferably, e.g., Ultem™), and also the presence of the key slots 814 a , 814 b , permits the diameter of the hollow distal end 806 to expand as needed to engage the tapered stem 706 of the insertion plate 700 . More particularly, the resting diameter (prior to any expansion) of the hollow distal end 806 of the insertion handle 800 is incrementally larger than the initial diameter of the tapered proximal portion 710 of the stem 706 of the insertion plate 700 , and incrementally smaller than the final diameter of the tapered proximal portion 710 of the stem 706 of the insertion plate 700 . Accordingly, longitudinally aligning the insertion handle shaft 802 with the stem 706 , and thereafter pushing the hollow distal end 806 of the insertion handle shaft 802 toward the insertion plate 700 , causes the hollow distal end 806 to initially readily encompass the tapered proximal portion 710 of the stem 706 (because the initial diameter of the tapered proximal portion 710 is smaller than the resting diameter of the hollow tapered distal end 806 ). With continued movement of the insertion handle shaft 802 toward the insertion plate base 702 , the hollow distal end 806 is confronted by the increasing diameter of the tapered proximal portion 710 . Accordingly, the diameter of the hollow distal end 806 expands (by permission of the shaft 802 body material and the key slots 814 a , 814 b as the slots narrow) under the confrontation to accept the increasing diameter. Eventually, with continued movement under force, the inner surface of the hollow distal end 806 is friction-locked to the outer surface of the tapered proximal portion 710 . Each of the key slots 814 a , 814 b straddles a respective one of the key flanges 708 a , 708 b at the connection of the base 702 to the stem 706 . This enhances the ability of the insertion handle 800 to prevent rotation of the insertion handle shaft 802 relative to the insertion plate 700 (about the longitudinal axis of the insertion handle shaft 802 ). It should be understood that other methods or mechanisms of establishing engagement of the stem 706 by the insertion handle 800 can be used without departing from the scope of the invention.
[0074] Once the insertion handle 800 is engaged with the insertion plate 700 , manipulation of the insertion handle shaft 802 effects manipulation of the cervical disc replacement device 400 and insertion plate 700 construct. The surgeon can therefore remove the construct from the implant tray, and insert the construct into the treatment area. More particularly, according to the implantation procedure of the invention, after the surgeon properly prepares the intervertebral space (removes the damaged natural disc, modifies the bone surfaces that define the intervertebral space, and distracts the intervertebral space to the appropriate height), the surgeon inserts the cervical disc replacement device 400 into the intervertebral space from an anterior approach, such that the upper and lower elements 500 , 600 are inserted between the adjacent vertebral bones with the element footprints fitting within the perimeter of the intervertebral space and with the teeth of the elements' vertebral body contact surfaces 502 , 602 engaging the vertebral endplates, and with the flanges 506 , 606 of the upper and lower elements 500 , 600 flush against the anterior faces of the upper and lower vertebral bones, respectively. (As discussed above, the flanges 506 , 606 preferably have a lateral curvature that approximates the lateral curvature of the anterior faces of the vertebral bones.)
[0075] Referring now to FIGS. 7 a - e , an insertion pusher 900 of the insertion instrumentation of the present invention is shown in top (FIG. 7 a ), lateral (FIG. 7 b ), and anterior (FIG. 7 c ) views. FIG. 7 d shows an antero-lateral perspective view of the insertion pusher 900 inserted into the insertion handle 800 . FIG. 7 e shows a magnified view of the proximal end of FIG. 7 d.
[0076] Once the construct is properly positioned in the treatment area, the surgeon uses the insertion pusher 900 to disengage the insertion handle shaft 802 from the stem 706 of the insertion plate 700 . More particularly, the insertion pusher 900 has a longitudinal shaft 902 having a preferably blunt distal end 904 and a proximal end 906 preferably having a flange 908 . The shaft 902 of the insertion pusher 900 has a diameter smaller than the inner diameter of the insertion handle shaft 802 , such that the shaft 902 of the insertion pusher 900 can be inserted into and translated within the longitudinal bore 804 of the insertion handle shaft 802 . (The longitudinal bore 804 preferably, for the purpose of accommodating the insertion pusher 900 and other purposes, extends the length of the insertion handle shaft 802 .) The shaft 902 of the insertion pusher 900 is preferably as long as (or, e.g., at least as long as) the longitudinal bore 804 . Accordingly, to remove the insertion handle shaft 802 from the insertion plate 700 , the shaft 902 of the insertion pusher 900 is inserted into the longitudinal bore 804 of the insertion handle shaft 802 and translated therein until the blunt distal end 904 of the pusher shaft 802 is against the proximal end of the tapered stem 706 of the insertion plate 700 . Because the shaft 902 of the insertion pusher 900 is as long as the longitudinal bore 804 of the insertion handle shaft 802 , the flange 810 of the insertion handle 800 and the flange 908 of the insertion pusher 900 are separated by a distance (see FIGS. 7 d and 7 e ) that is equivalent to the length of that portion of the stem 706 that is locked in the distal end 806 of the insertion handle shaft 802 . Accordingly, a bringing together of the flanges 810 , 908 (e.g., by the surgeon squeezing the flanges 810 , 908 toward one another) will overcome the friction lock between the distal end 806 of the insertion handle shaft 802 and the stem 706 of the insertion plate 700 , disengaging the insertion handle shaft 802 from the insertion plate 700 without disturbing the disposition of the cervical disc replacement device 400 and insertion plate 700 construct in the treatment area.
[0077] Referring now to FIGS. 8 a - e , a drill guide 1000 of the insertion instrumentation of the present invention is shown in top (FIG. 8 a ), lateral (FIG. 8 b ), and anterior (FIG. 8 c ) views. FIG. 8 d shows an antero-lateral perspective view of the drill guide 1000 inserted onto the stem 706 of the insertion plate 700 . FIG. 8 e shows a magnified view of the distal end of FIG. 8 d.
[0078] Once the insertion handle 800 has been removed, the surgeon uses the drill guide 1000 to guide the surgeon's drilling of the bone screws (described below) through the bone screw holes 508 a , 508 b and 608 a , 608 b of the upper 500 and lower 600 elements' flanges 506 , 606 and into the vertebral bones. More particularly, the drill guide 1000 has a longitudinal shaft 1002 having a configured distal end 1004 and a proximal end 1006 with a manipulation feature (e.g., lateral extensions 1008 a , 1008 b ). The lateral extensions 1008 a , 1008 b are useful for manipulating the shaft 1002 . The distal end 1004 is configured to have a shaft guiding feature (e.g., a central bore 1010 ) suitable for guiding the shaft 1002 in relation to the stem 706 of the insertion plate 700 therethrough. For example, the central bore 1010 accommodates the stem 706 so that the drill guide 1000 can be placed on and aligned with the stem 706 . The longitudinal axis of the bore 1010 is preferably offset from the longitudinal axis of the drill guide shaft 1002 . The distal end 1004 is further configured to have two guide bores 1012 a , 1012 b that have respective longitudinal axes at preferred bone screw drilling paths relative to one another. More particularly, the central bore 1010 , drill guide shaft 1002 , and guide bores 1012 a , 1012 b , are configured on the distal end 1004 of the drill guide 1000 such that when the central bore 1010 is disposed on the stem 706 of the insertion plate 700 (see FIGS. 8 d and 8 e ), the drill guide shaft 1002 can be rotated on the stem 706 into either of two preferred positions in which the guide bores 1012 a , 1012 b are aligned with the bone screw holes 508 a , 508 b or 608 a , 608 b on either of the flanges 506 or 606 . Stated alternatively, in a first preferred position (see FIGS. 8 d and 8 e ), the drill guide 1000 can be used to guide bone screws through the bone screw holes 508 a , 508 b in the flange 506 of the upper element 500 , and in a second preferred position (in which the drill guide is rotated 180 degrees, about the longitudinal axis of the stem 706 , from the first preferred position), the same drill guide 1000 can be used to guide bone screws through the bone screw holes 608 a , 608 b in the flange 606 of the lower element 600 . When the drill guide 1000 is disposed in either of the preferred positions, the longitudinal axes of the guide bores 1012 a , 1012 b are aligned with the bone screw holes 508 a , 508 b or 608 a , 608 b on the flanges 506 or 606 , and are directed along preferred bone screw drilling paths through the bone screw holes.
[0079] Accordingly, to secure the upper element flange 506 to the upper vertebral body, the surgeon places the drill guide shaft 1002 onto the stem 706 of the insertion plate 700 , and rotates the drill guide 1000 into the first preferred position. Preferably, the surgeon then applies an upward pressure to the drill guide 1000 , urging the upper element 500 tightly against the endplate of the upper vertebral body. Using a suitable bone drill and cooperating drill bit, the surgeon drills upper tap holes for the upper bone screws. Once the upper tap holes are drilled, the surgeon rotates the drill guide shaft 1002 on the stem 706 of the insertion plate 700 until the guide bores 1012 a , 1012 b no longer cover the upper bone screw holes 508 a , 508 b . The surgeon can then screw the upper bone screws into the upper tap holes using a suitable surgical bone screw driver.
[0080] Additionally, to secure the lower element flange 606 to the lower vertebral body, the surgeon further rotates the drill guide shaft 1002 on the stem 706 of the insertion plate 700 until the drill guide 1000 is in the second preferred position. Preferably, the surgeon then applies a downward pressure to the drill guide 1000 , urging the lower element 600 tightly against the endplate of the lower vertebral body. Using the suitable bone drill and cooperating drill bit, the surgeon drills lower tap holes for the lower bone screws. Once the lower tap holes are drilled, the surgeon rotates the drill guide shaft 1002 on the stem 706 of the insertion plate 700 until the guide bores 1012 a , 1012 b no longer cover the lower bone screw holes 608 a , 608 b . The surgeon can then screw the lower bone screws into the lower tap holes using the suitable surgical bone screw driver.
[0081] It should be noted that the bone screws (or other elements of the invention) may include features or mechanisms that assist in prevent screw backup. Such features may include, but not be limited to, one or more of the following: titanium plasma spray coating, bead blasted coating, hydroxylapetite coating, and grooves on the threads.
[0082] Once the elements 500 , 600 are secured to the adjacent vertebral bones, the surgeon removes the drill guide 1000 from the stem 706 of the insertion plate 700 and from the treatment area (see FIG. 9 a ). Using a suitable surgical screw driver, the surgeon then removes the mounting screws 714 a , 714 b that hold the insertion plate 700 against the elements' flanges 506 , 606 , and removes the insertion plate 700 and the mounting screws 714 a , 714 b from the treatment area (see FIG. 9 b ).
[0083] Referring now to FIGS. 10 a - f , a retaining clip 1150 a of the present invention is shown in top (FIG. 10 a ), lateral (FIG. 10 b ), posterior (FIG. 10 c ), anterior (FIG. 10 d ), postero-lateral perspective (FIG. 10 e ), and antero-lateral perspective (FIG. 10 f ) views. (The features of retaining clip 1150 a are exemplary of the features of the like-numbered features of retaining clip 1150 b , which are referenced by b's rather than a's.) Referring now to FIGS. 11 a - e , a clip applicator 1100 of the insertion instrumentation of the present invention is shown in top (FIG. 11 a ), lateral (FIG. 11 b ), and anterior (FIG. 11 c ) views. FIG. 11 d shows a postero-lateral perspective view of the clip applicator 1100 holding two retaining clips 1150 a , 1150 b of the present invention. FIG. 11 e shows an antero-lateral perspective view of FIG. 11 d . Referring now to FIGS. 12 a - h , the clip applicator 1100 is shown applying the retaining clips 1150 a , 1150 b to the cervical disc replacement device 400 . FIGS. 12 b - h show anterior (FIG. 12 b ), posterior (FIG. 12 c ), top (FIG. 12 d ), bottom (FIG. 12 e ), lateral (FIG. 12 f ), antero-lateral perspective (FIG. 12 g ), and postero-lateral perspective (FIG. 12 h ) views of the cervical disc replacement device 400 after the retaining clips 1150 a , 1150 b have been applied.
[0084] Once the mounting screws 714 a , 714 b and the insertion plate 700 are removed, the surgeon uses the clip applicator 1100 to mount the retaining clips 1150 a , 1150 b on the flanges 506 , 606 to assist in retaining the bone screws. As shown in FIGS. 10 a - f , each of the clips 1150 a , 1150 b preferably has an applicator attachment feature (e.g., a central attachment bore 1152 a , 1152 b ) and, extending therefrom, a pair of bone screw retaining features (e.g., oppositely directed laterally extending flanges 1156 a , 1156 b and 1158 a , 1158 b ) and a flange attachment feature (e.g., an upwardly (or downwardly) extending hooked flange 1160 a , 1160 b ). The extent of the hook flange 1160 a , 1160 b is preferably formed to bend in toward the base of the hook flange 1160 a , 1160 b , such that the enclosure width of the formation is wider than the mouth width of the formation, and such that the extent is spring biased by its material composition toward the base. The enclosure width of the formation accommodates the width of the body of a flange 506 , 606 of the cervical disc replacement device 400 , but the mouth width of the formation is smaller than the width of the flange 506 , 606 . Accordingly, and referring now to FIGS. 12 b - h , each clip 1150 a , 1150 b can be applied to an element flange 506 , 606 such that the hook flange 1160 a , 1160 b grips the element flange 506 , 606 , by pressing the hook's mouth against the edge of the element flange 506 , 606 with enough force to overcome the bias of the hook flange's extent toward the base, until the flange 506 , 606 is seated in the hook's enclosure. The attachment bore 1152 a , 1152 b of the clip 1150 a , 1150 b is positioned on the clip 1150 a , 1150 b such that when the clip 1150 a , 1150 b is properly applied to the flange 506 , 606 , the attachment bore 1152 a , 1152 b is aligned with the mounting screw hole 509 , 609 on the flange 506 , 606 (see FIGS. 12 b - h ). Further, the posterior opening of the attachment bore 1152 a , 1152 b is preferably surrounded by a clip retaining features (e.g., a raised wall 1162 a , 1162 b ), the outer diameter of which is dimensioned such that the raised wall 1162 a , 1162 b fits into the mounting screw hole 509 , 609 on the element flange 506 , 606 . Thus, when the clip 1150 a , 1150 b is so applied to the element flange 506 , 606 , the element flange 506 , 606 will be received into the hook's enclosure against the spring bias of the hook's extent, until the attachment bore 1152 a , 1152 b is aligned with the mounting screw hole 509 , 609 , at which time the raised wall 1162 a , 1162 b will snap into the mounting screw hole 509 , 609 under the force of the hook's extent's spring bias. This fitting prevents the clip 1150 a , 1150 b from slipping off the flange 506 , 606 under stresses in situ. Each of the laterally extending flanges 1156 a , 1156 b and 1158 a , 1158 b of the clip 1150 a , 1150 b is sized to cover at least a portion of a respective one of the bone screw heads when the clip 1150 a , 1150 b is attached in this manner to the flange 506 , 606 (see FIGS. 12 b - h ), so that, e.g., the clips 1150 a , 1150 b help prevent the bone screws from backing out.
[0085] Referring again to FIGS. 11 a - e , the clip applicator 1100 has a pair of tongs 1102 a , 1102 b hinged at a proximal end 1104 of the clip applicator 1100 . Each tong 1102 a , 1102 b has an attachment feature (e.g., a nub 1108 a , 1108 b ) at a distal end 1106 a , 1106 b . Each nub 1108 a , 1108 b is dimensioned such that it can be manually friction locked into either of the attachment bores 1152 a , 1152 b of the retaining clips 1150 a , 1150 b . Thus, both clips 1150 a , 1150 b can be attached to the clip applicator 1100 , one to each tong 1102 a , 1102 b (see FIGS. 11 d and 11 e ). Preferably, as shown in FIGS. 11 d and 11 e , the clips 1150 a , 1150 b are attached so that their hook flanges 1154 a , 1154 b are directed toward one another, so that they are optimally situated for attachment to the element flanges 506 , 606 of the cervical disc replacement device 400 (see FIG. 12 a ).
[0086] Preferably, the clips 1150 a , 1150 b are attached to the clip applicator 1100 as described above prior to delivery to the surgeon. The assembly is preferably provided sterile to the surgeon in a blister pack. Accordingly, when the surgeon is ready to mount the clips 1150 a , 1150 b to the element flanges 506 , 606 of the cervical disc replacement device 400 , the surgeon opens the blister pack and inserts the tongs 1102 a , 1102 b of the clip applicator 1100 (with the clips 1150 a , 1150 b attached) into the treatment area.
[0087] Accordingly, and referring again to FIGS. 12 a - h , the clips 1150 a , 1150 b can be simultaneously clipped to the upper 500 and lower 600 elements' flanges 506 , 606 (one to each flange 506 , 606 ) using the clip applicator 1100 . More particularly, the mouths of the clips 1150 a , 1150 b can be brought to bear each on a respective one of the flanges 506 , 606 by manually squeezing the tongs 1102 a , 1102 b (having the clips 1150 a , 1150 b attached each to a set of the distal ends of the tongs 1102 a , 1102 b ) toward one another when the mouths of the clips 1150 a , 1150 b are suitably aligned with the flanges 506 , 606 (see FIG. 12 a ). Once the clips 1150 a , 1150 b have been attached to the flanges 506 , 660 with the raised walls 1162 a , 1162 b fitting into the mounting screw holes 509 , 609 of the flanges 506 , 606 , the clip applicator 1100 can be removed from the clips 1150 a , 1150 b by manually pulling the nubs 1108 a , 1108 b out of the attachment bores 1152 a , 1152 b , and the clip applicator 1100 can be removed from the treatment area.
[0088] After implanting the cervical disc replacement device 400 as described, the surgeon follows accepted procedure for closing the treatment area.
[0089] Referring now to FIGS. 14 a - e , an alternate dual cervical disc replacement device configuration and alternate insertion plates for use therewith, suitable, for example, for implantation in two adjacent cervical intervertebral spaces, are illustrated in exploded perspective (FIG. 14 a ), anterior (FIG. 14 b ), posterior (FIG. 14 c ), lateral (FIG. 14 d ), and collapsed perspective (FIG. 14 e ) views. Referring now also to FIGS. 15 a - c , an alternate upper element of the configuration is shown in posterior (FIG. 15 a ), anterior (FIG. 15 b ), and antero-lateral (FIG. 15 c ) views. Referring now also to FIGS. 16 a - c , an alternate lower element of the configuration is shown in posterior (FIG. 16 a ), anterior (FIG. 16 b ), and antero-lateral (FIG. 16 c ) views. Referring now also to FIGS. 17 a - c , an alternate, upper, insertion plate of the configuration is shown in anterior (FIG. 17 a ), posterior (FIG. 17 b ), and antero-lateral (FIG. 17 c ) views. Referring now also to FIGS. 18 a - c , an alternate, lower, insertion plate of the configuration is shown in anterior (FIG. 18 a ), posterior (FIG. 18 b ), and antero-lateral (FIG. 18 c ) views.
[0090] More particularly, the alternate dual cervical disc replacement device configuration 1350 is suitable, for example, for implantation into two adjacent cervical intervertebral spaces. The configuration preferably, as shown, includes an alternate, upper, cervical disc replacement device 1400 (including an upper element 1500 and an alternate, lower, element 1600 ), for implantation into an upper cervical intervertebral space, and further includes an alternate, lower, cervical disc replacement device 2400 (including an alternate, upper, element 2500 and a lower element 2600 ), for implantation into an adjacent, lower, cervical intervertebral space. The illustrated alternate, upper, embodiment of the cervical disc replacement device is identical in structure to the cervical disc replacement device 400 described above (and thus like components are like numbered, but in the 1400s rather than the 400s, in the 1500s rather than the 500s, and in the 1600s rather than the 600s), with the exception that the flange 1606 of the lower element 1600 is configured differently and without bone screw holes. The illustrated alternate, lower, embodiment of the cervical disc replacement device is identical in structure to the cervical disc replacement device 400 described above (and thus like components are like numbered, but in the 2400s rather than the 400s, in the 2500s rather than the 500s, and in the 2600s rather than the 600s), with the exception that the flange 2506 of the upper element 2500 is configured differently and without bone screw holes.
[0091] More particularly, in the alternate, upper, cervical disc replacement device 1400 of this alternate configuration, the flange 1606 of the lower element 1600 does not have bone screw holes, but has at least one mounting feature (e.g., a mounting screw hole) 1609 for attaching the lower element 1600 to the alternate, upper, insertion plate 1700 (described below). Similarly, and more particularly, in the alternate, lower, cervical disc replacement device 2400 of this alternate configuration, the flange 2506 of the upper element 2500 does not have bone screw holes, but has at least one mounting feature (e.g., a mounting screw hole) 2509 for attaching the upper element 2500 to the alternate, lower, insertion plate 2700 (described below). As can be seen particularly in FIGS. 14 a - c , 15 b , 16 b , 17 a , and 18 a , the extent of the flange 1606 is laterally offset to the right (in an anterior view) from the midline (and preferably limited to support only the mounting screw hole 1609 ), and the extent of the flange 2506 is laterally offset to the left (in an anterior view) from the midline (and preferably limited to support only the mounting screw hole 2509 ), so that the flanges 1606 , 2506 avoid one another when the alternate lower element 1600 of the alternate, upper, cervical disc replacement device 1400 , and the alternate upper element 2500 of the alternate, lower, cervical disc replacement device 2400 , are implanted in this alternate configuration (FIGS. 14 a - e ).
[0092] It should be noted that the alternate, upper, cervical disc replacement device 1400 does not require both elements 1500 , 1600 to be secured to a vertebral body. Only one need be secured to a vertebral body, because due to natural compression in the spine pressing the elements' bearing surfaces together, and the curvatures of the saddle-shaped bearing surfaces preventing lateral, anterior, or posterior movement relative to one another when they are compressed against one another, if one element (e.g., the upper element 1500 ) is secured to a vertebral body (e.g., to the upper vertebral body by bone screws through the bone screw holes 1508 a , 1508 b of the element flange 1506 ), the other element (e.g., the alternate, lower, element 1600 ) cannot slip out of the intervertebral space, even if that other element is not secured to a vertebral body (e.g., to the middle vertebral body). Similarly, the alternate, lower, cervical disc replacement device 2400 does not require both elements 2500 , 2600 to be secured to a vertebral body. Only one need be secured to a vertebral body, because due to natural compression in the spine pressing the elements' bearing surfaces together, and the curvatures of the saddle-shaped bearing surfaces preventing lateral, anterior, or posterior movement relative to one another when they are compressed against one another, if one element (e.g., the lower element 2600 ) is secured to a vertebral body (e.g., to the lower vertebral body by bone screws through the bone screw holes 2608 a , 2608 b of the element flange 2606 ), the other element (e.g., the alternate, upper, element 2500 ) cannot slip out of the intervertebral space, even if that other element is not secured to a vertebral body (e.g., to the middle vertebral body).
[0093] Accordingly, the alternate, upper, insertion plate 1700 is provided to facilitate a preferred simultaneous implantation of the upper and lower elements 1500 , 1600 of the alternate, upper, cervical disc replacement device 1400 into the upper intervertebral space. Similarly, the alternate, lower, insertion plate 2700 is provided to facilitate a preferred simultaneous implantation of the upper and lower elements 2500 , 2600 of the alternate, lower, cervical disc replacement device 2400 into the lower intervertebral space. The upper and lower elements 1500 , 1600 are held by the insertion plate 1700 (preferably using mounting screws 1714 a , 1714 b ) in a preferred relationship to one another that is suitable for implantation, identical to the preferred relationship in which the upper and lower elements 500 , 600 are held by the insertion plate 700 as described above. Similarly, the upper and lower elements 2500 , 2600 are held by the insertion plate 2700 (preferably using mounting screws 2714 a , 2714 b ) in a preferred relationship to one another that is suitable for implantation, identical to the preferred relationship in which the upper and lower elements 500 , 600 are held by the insertion plate 700 as described above.
[0094] The illustrated alternate, upper, insertion plate 1700 is identical in structure to the insertion plate 700 described above (and thus like components are like numbered, but in the 1700s rather than the 700s), with the exception that the lower flange 1704 b is offset from the midline (to the right in an anterior view) to align its mounting screw hole 1712 b with the offset mounting screw hole 1609 of the alternate lower element 1600 of the alternate, upper, cervical disc replacement device 1400 . Similarly, the illustrated alternate, lower, insertion plate 2700 is identical in structure to the insertion plate 700 described above (and thus like components are like numbered, but in the 2700s rather than the 700s), with the exception that the upper flange 2704 a is offset from the midline (to the left in an anterior view) to align its mounting screw hole 2712 a with the offset mounting screw hole 2509 of the alternate upper element 2500 of the alternate, lower, cervical disc replacement device 2400 .
[0095] Accordingly, the upper and lower elements 1500 , 1600 , being held by the insertion plate 1700 , as well as the upper and lower elements 2500 , 2600 , being held by the insertion plate 2700 , can be implanted using the insertion handle 800 , insertion pusher 900 , drill guide 1000 , clips 1150 a , 1150 b (one on the upper element flange 1506 , and one on the lower element flange 2606 , because only the upper element 1500 and the lower element 2600 are secured by bone screws), and clip applicator 1100 , in the manner described above with respect to the implantation of the cervical disc replacement device 400 .
[0096] It should be noted that the described alternate configuration (that includes two cervical disc replacement devices) presents the cervical disc replacement devices to the surgeon in a familiar manner. That is, by way of explanation, current cervical fusion surgery involves placing a fusion device (e.g., bone or a porous cage) in between the upper and middle cervical intervertebral bones, and in between the middle and lower vertebral bones, and attaching an elongated two-level cervical fusion plate to the anterior aspects of the bones. Widely used two-level cervical fusion devices (an example two level fusion plate 1350 is shown in anterior view in FIG. 13 c and in lateral view in FIG. 13 d ) are configured with a pair of laterally spaced bone screw holes 1352 a , 1352 b on an upper end 1354 of the plate 1350 , a pair of laterally spaced bone screw holes 1356 a , 1356 b on a lower end 1358 of the plate 1350 , and a pair of laterally spaced bone screw holes 1360 a , 1360 b midway between the upper and lower ends 1354 , 1358 . To attach the plate 1350 to the bones, bone screws are disposed through the bone screw holes and into the corresponding bones. This prevents the bones from moving relative to one another, and allows the bones to fuse to one another with the aid of the fusion device.
[0097] Accordingly, as can be seen in FIG. 14 b , when the upper and lower elements 1500 , 1600 of the cervical disc replacement device 1400 , and the upper and lower elements 2500 , 2600 of the cervical disc replacement device 2400 , are held in the preferred spatial relationship and aligned for implantation, the upper element flange 1506 and lower element flange 2606 , and their bone screw holes 1508 a , 1508 b and 2608 a , 2608 b , present to the surgeon a cervical hardware and bone screw hole configuration similar to a familiar two level cervical fusion plate configuration (as described above, a middle pair of bone screws holes is not needed; however, middle bone screw holes are contemplated by the present invention for some embodiments, if necessary or desirable). The mounting of the elements 1500 , 1600 to the insertion plate 1700 allows the elements 1500 , 1600 to be manipulated as a single unit for implantation (by manipulating the insertion plate 1700 ), similar to the way a cervical fusion plate is manipulatable as a single unit for attachment to the bones. Similarly, the mounting of the elements 2500 , 2600 to the insertion plate 2700 allows the elements 2500 , 2600 to be manipulated as a single unit for implantation (by manipulating the insertion plate 2700 ), similar to the way a cervical fusion plate is manipulatable as a single unit for attachment to the bones. This aspect of the present invention simplifies and streamlines the cervical disc replacement device implantation procedure.
[0098] While there has been described and illustrated specific embodiments of cervical disc replacement devices and insertion instrumentation, it will be apparent to those skilled in the art that variations and modifications are possible without deviating from the broad spirit and principle of the invention. The invention, therefore, shall not be limited to the specific embodiments discussed herein. | A method of securing a retaining clip for an intervertebral disc replacement device comprising the steps of removingly engaging the retaining clip to a first end of a first applicator arm of an applicator having said first applicator arm and a second applicator arm, inserting the applicator into a patient treatment area having the intervertebral disc replacement device installed therein, placing the hook flange of the body member of the retaining clip over the at least one flange of the intervertebral disc replacement device, applying a closing force to the first and second applicator arms such that the hook flange securingly engages the at least one flange of the intervertebral disc replacement device and a portion of the at least one lateral flange extends over a portion of the bone screw, disengaging the first applicator arm from the retaining clip and removing the applicator from the patient treatment area. | 0 |
RELATED APPLICATION
This application is a continuation of application Ser. No. 07/014,310 filed Feb. 13, 1987, now abandoned, which is a division of application Ser. No. 06/730,453 filed May 6, 1985, entitled Apparatus for Gasifying Waste oil, now U.S. Pat. No. 4,673,413.
BACKGROUND OF THE INVENTION
In view of the increasing awareness of improving the ecology, it has been observed that the disposing of used or waste oil and other types of carbonaceous material presents a considerable ecological problem. Waste oil, e.g. oil that has been used in a manufacturing process and which has been contaminated with water, machine filings and other matter generally does not render such waste oil suitable for recycling. Heretofore, such used or waste oil was simply discarded. Invariably, such discarded waste oil would eventually find its way to some land fill or dump, only to pollute the surrounding area, seeping into the underground water source and the like. Frequently, even reclaimable oil is simply discarded.
In addition to the ecological problems presented by the abundance of waste oil and/or other types of carbonaceous materials, there exists a related energy crisis, viz. the progressive deterioration of the available oil and/or natural gas reserves, as more and more oil and gas is used.
As a result, many efforts have been made to supplement the natural oil and gas reserves by producing a gas substitute from coal. A number of coal gasification processes are known, e.g. as disclosed in U.S. Pat. Nos. 3,124,435 and 4,101,295. The teaching of these patents are primarily directed to a method and apparatus for effecting the gasification of coal to produce a gas substitute.
Efforts have also been made to reform hydrocarbons into gaseous products as evidenced in U.S. Pat. Nos. 3,945,805 and 3,945,806.
OBJECTS
An object of this invention is to provide a method for treating used or waste oil in an ecologically acceptable manner and for producing a high BTU content gas substitute.
Another object is to provide a method for effecting the gasification of waste oil to produce a high BTU gas substitute; which when burned is environmentally clean.
Another object is to provide a non-catalytic process for effecting the gasification of waste oil and other types of carbonaceous materials containing toxic materials.
Another object is to provide low pressure, pyrolytic process for effecting the gasification of carbonaceous materials that is environmentally clean with respect to its emissions from its feed stock.
Another object is to provide a method for reforming organic carbonaceous material to produce a usable gas.
SUMMARY OF THE INVENTION
The foregoing objects and other features and advantages are attained by a method for treating organic carbonaceous material, e.g. waste oil to produce therefrom a high BTU content gas substitute in a low pressure pyrolytic manner. This is attained in a furnace which is suitably fired to effect the separate preheating of the carbonaceous material and the generation of steam. The carbonaceous material is mixed with water and this mixture is initially pre-heated to a temperature of 200° to 600° F. and thereafter mixed with steam. The preheated material and steam mixture in one embodiment is directed to a primary dynamic mixing chamber disposed within the furnace for heating the mixture to a range of 1600° to 1800° F. The mixture may then be passed through one or more secondary mixing chambers wherein supplementary steam is added to the mixture just prior to entering the respective secondary chambers wherein the mixture is further heated to a temperature of 1800° to 2200° F.
The gases generated from the carbonaceous material in passing through the mixing chamber exit to a washing station wherein the solid residues are precipitated out. Upon washing of the generated gases, the washed gases flow through a condensor wherein the gases are cooled and the moisture carried along therewith is condensed. The cooled gases are then collected and stored for subsequent use, a portion of which may be used to fire the furnace. In accordance with this invention, the respective primary and secondary chambers are uniquely construed so as to enhance the mixing action as the temperature of the waste oil and associated steam mixed therewith are heated to the temperature sufficient to effect the gasification.
In another embodiment, the initial preheated carbonaceous material and steam are introduced into a premixing chamber wherein the carbonaceous material and steam are intimately mixed and preheated to a temperature ranging between 1500°-1700° F. From the premixing chamber, the mixture is directed to serially connected primary and secondary heating chambers where the carbonaceous material is finally heated and gasified to a temperature of 1800°-2200° F.
FEATURES
A feature of this invention resides in a method for effecting the gasification of carbonaceous material, e.g. waste oil.
Another feature resides on a pyrolytic, non-catalytic generator for processing organic carbonaceous material in an ecological manner.
Another feature resides in a method for effecting the gasification of an organic carbonaceous material, e.g. waste oil to produce a high BTU gas.
Another feature resides in the provision of a generator for treating waste oil having a mixing chamber constructed so as to enhance the mixing of the gases flowing through the generator.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages will become readily apparent when considered in view of the drawings and specifications in which:
FIG. 1 is a schematic view of an apparatus embodying the invention.
FIG. 2 is an alternate construction of a secondary mixing chamber.
FIG. 3 is a sectional view taken on line 3--3 on FIG. 2.
FIG. 4 is a schematic side view of a modified embodiment.
DETAILED DESCRIPTION
Referring to the drawings, there is shown in FIG. 1, a diagrammatic representation of an apparatus to effect the handling and/or pyrolytic gasification of organic carbonaceous material. It will be understood that such carbonaceous material may comprise coal, oil, either reclaimable and/or waste oil, methane, propane, and such other material which may contain PCB or other toxic materials. For purposes of description only, reference will be made to used or waste oil. Oil used in machine shops to facilitate machining operations is a typical kind of waste oil. Such oil is often contaminated with a relatively large proportion of water and/or metal filings and/or chips. Such other waste oil may comprise oil drained from vehicles or the like.
The apparatus for handling such waste oil in accordance with this invention, comprises a furnace 10 which may be suitably fired by one or more burners 11, e.g. gas burners or the like. The upper end of the furnace 10 connects to a flue or stack portion 12, which connects to a chimney to which the combustion gases are exhausted to atmosphere. Disposed in the flue or stack portion 12 of the furnace are one or more banks of steam generating tubes 13. Also disposed within the flue or stack portion of the furnace 10 is a coil 14, through which the waste oil is directed. One end 14A of coil 14 connects to the waste oil supply 15. The other end 14B of coil 14 is in communication with a steam nozzle 16 at the end of steam tubes 13. The waste oil is pumped from its supply 15 through coil 14 past a spray nozzle 16 which is steam driven. The steam nozzle 16 is connected adjacent the end 14B of the supply coil 14 in communication with a primary mixing chamber 17 which is disposed within the furnace 10. The nozzle 16 is fed by steam generated in coil 51, which is arranged to atomize the oil in coil 14 as it enters chamber 17.
in the illustrated embodiment, the primary dynamic heating and mixing chamber 17 comprises an outer shell 18 which is closed at opposite ends, except for an inlet 18A and outlet 18B. The inlet 18A comprises a tubular conduit member 19 that extends into shell 18 and which is open at its lower end. Disposed between the outer shell 18 and conduit member 19 is an intermediate shell 20, which has a closed lower end 20A spaced from the outlet end of tubular member 19. The intermediate portion 20B is provided with an enlarged portion to accommodate a baffle 21 which circumscribes the tubular member 19. Thus, as noted by the arrows, the mixture of waste oil and steam upon entering the inlet 18A is directed down the tubular member 19 to make a series of passes within the primary mixing chamber. The tortuous path thus defined by the tubular member 19, the intermediate shell 20 and outer shell 18 enables the oil and steam to throroughly mix while being heated to a temperature ranging between 1600° to 1800° F. as it flows therethrough forming an initially or partially gasified effluent. If desired, a booster steam coil 52 is provided for generating steam used to boost the oil through coil 14. The booster steam is introduced into the oil coil 14 through a spray nozzle N.
The outlet end 18B of the outer shell 18 connects in communication with the inlet 22 of a secondary dynamic heating and mixing chamber 23. The secondary chamber 23 comprises an outer shell 23A and an inner shell 23B spaced therefrom, the latter being spaced from the extended portion 22A of the inlet 22.
The outer shell 23A is provided with an outlet 23C which connects to a conduit 24 which connects to a second, secondary heating and mixing chamber 25.
A second steam coil 26 is disposed in the furnace to be heated by the combustion gases, and it is coiled about the conduit 18C interconnecting the outlet 18B of the primary chamber 18 to the inlet of the secondary chamber 23. The steam generated in coil 26 is introduced into the inlet of the secondary chamber at 22B to mix with the waste oil and steam mixture i.e. the initial gasified effluent leaving the primary chamber 17. Connected in series with secondary chamber 23 is a second secondary chamber 25 which is constructed like the first described secondary chamber 23. A third steam coil 27 is disposed in the furnace to be heated by the combustion gases therein, and it is coiled about the conduit 24 leading to the second secondary chamber 25. Steam coil 27 is arranged to add supplemental steam to the mixture entering the inlet of the second secondary chamber 25. The described apparatus may be provided with a third secondary chamber 28, which is serially connected to the second secondary chamber 25 by an interconnecting conduit 29, and a fourth steam coil 30 is provided for adding additional steam to the mixture entering the third secondary chamber 28.
It is to be noted that the respective secondary chambers 23, 25 and 28 are serially connected and each is provided with a steam coil for adding steam to the medium flowing from the preceding mixing chamber. In the illustrated embodiment, the fourth steam coil 30 is coiled about the conduit 31, which is connected to the outlet end of the mixing chamber 28, or last secondary mixing chamber.
Mixing chambers 23, 25 and 28 are similarly constructed and each is arranged to effect a mixing of the medium flowing therethrough and which cumulatively provides the requisite residence time within the furnace, necessary for the waste oil to be gasified into its gaseous constituents wherein the material to be gasified is heated to a final temperature ranging between 1800° to 2200° F.
Upon exiting from the last mixing chamber 28, conduit 31 directs the gaseous products to a washing station 32. The washing station 32 is shown as a container 33 for holding a supply or body of water 34 having a water level 34A. The container 33 is provided with a gas inlet 35 and a gas outlet 36. It will be noted that the gas inlet extends into the washing station so that its outlet is located below the water level 34A. Thus, as the gaseous products enter the washer, the discharged gases are washed by the water, causing any solid residue within the gaseious medium to be precipitated out. The gaseous products relieved of their solid particles or residue flow through the outlet and to a condensing station 37 by way of conduit 37A. If desired, the gases generated can be precooled prior to entering the washing station 32 by providing a series of water spray nozzles 31A in communication with conduit 31 upstreamwise from the washer as shown in FIG. 1. It will be understood that nozzles 31A are connected to a suitable source of water supply.
The condensing station 37 comprises a vessel 38 having spaced apart headers 38A and 38B interconnected by a series of tubes 39 which interconnect an upper header chamber 40 to a lower header chamber 41. Between the headers 38A and 38B and surrounding the tubes 39 is a cooling medium, e.g. water. Thus, as the washed gases pass through tubes 39, they are cooled by the surrounding water or cooling medium, thereby causing any moisture content within the generated gases to condense, the condensate being collected in the lower header chamber 41 from which the water or condensate is removed through a suitable drain 42.
The gas thus cooled exits the lower header chamber 41 and are directed to a collecting tank 43 through conduit 44. Disposed between the outlet 44A of the lower header and the collecting tank 43 is a meter 45 to measure the amount of gases generated.
The collecting tank 43 comprises an outer tank 43A containing a water level 46 and an inverted open end inner tank 43B, which is rendered movable relative to the outer tank 43A. The top of the inner tank 43B is provided with an inlet 48 and an outlet 49. The arrangement is such that as the gases generated enter into the upper end of the inner tank 43B, above the water level 46, the inner tank 43B defines an expandible chamber 43C for storing the generated gas until used. It will be understood that a portion of the generated gases may be used to fire the gas burners 11 for generating the products of combustion necessary to effect the gasification of the waste oil.
FIGS. 2 and 3 illustrate a modified embodiment of a secondary mixing chamber 50, which may be utilized in the apparatus described in lieu of secondary chambers 23, 25 and 28 herein described.
As shown, the modified construction of secondary chamber 50 comprises an outer tubular shell 51, which has closed ends 51A and 51B, except for opposed inlets which connect with conduits 52 and 53, which branch off in opposite directions from the connecting conduit 54, for connecting the secondary chamber 50 to the primary mixing chamber or to preceding secondary chamber as herein described. A steam coil 26 is located contiguous to conduit 54 for directing supplemental steam to the generated gases products flowing through conduit 54 prior to entering the secondary chamber 50.
Disposed within the secondary mixing chamber 50 is a tubular inner shell 55 disposed in spaced relationship to the outer shell 51 to define open end passes within the chamber. As shown, the inlet of conduits 52 and 53 are directed toward one another whereby the gases discharging therefrom are caused to impinge on one another to provide a thorough mixing action, and whereby the gases are directed through the passages defined between the inner and outer shells, 51 and 55 respectively, as the gases flow to the outlet 57, which directs the gases to the next succeeding secondary mixing chamber as herein described or to the washer 32 as the case may be.
It will be understood that the system described can be constructed with either type of secondary mixing chamber 23 or 50, disposed in series, as herein described, so as to provide for the necessary residence time to effect the gasification of the waste oil passing through the heating chamber of the furnace. By providing a primary chamber 17 and a plurality of secondary mixing chambers in a series and utilizing the construction herein described further enables the size of the furnace to an optimum minimum.
FIG. 4 illustrates a modified furnace arrangement for use in the system shown in FIG. 1. The modified furnace arrangement 60 of FIG. 4 comprises the furnace walls 61 to define the furnace primary heating furnace chamber 62 and the secondary heating portion 63, leading to the stack.
As hereinbefore described, the furnace chamber 62 is fired by one or more burners 64, preferably gas burners. In this form of the invention, the organic carbonaceous material to be gasified, e.g. oil, coal or the like, is delivered to the furnace through a supply conduit 65 which connects to a source of supply as hereinbefore described; and therefore not shown in FIG. 4.
The supply conduit 65 extends in a coil or undulating manner into the secondary heating chamber 63 of the furnace 60 to be preheated therein. In this form of the invention, the coils of the supply conduit 65 are jacketed by a complementary steam jacket 66 and which jacket is supplied with steam generated in a steam coil 67.
The supply conduit 65 and its steam jacket 66 are axially connected to the top of a mixing pre-heat chamber 66. A steam nozzle 69 connected to a steam coil 70 is disposed adjacent to outlet 65A of the supply conduit to supply supplemental steam to the material to be gasified. One or more steam nozzles 71 are tangentially disposed about the pre-mixing chamber for introducing steam generated in coils 72 tangentially about the pre-mixing chamber 68. For the foregoing, it will be noted that the axially introduced mixture through conduit 65A is impinged upon by a plurality of tangential steam nozzles 71 to provide for intimate mixing and a pre-heating of the medium to be gasified. The arrangement is such that the medium to be gasified, e.g. oil, is heated to a temperature of 1500°-1700° F.
From the pre-mixing chamber 68 the heated medium or partially gasified effluent is directed from the chamber's outlet 68A to the primary heating chamber 17 which is similar to that described with respect to FIG. 1. In all other respects, the apparatus to be utilized with the furnace 60 of FIG. 4 is similar to that described with respect to FIG. 1, and need not be further described.
The embodiments herein disclosed operate at relatively low pressures, e.g. 5 to 35 psi; and they are extremely safe in that the system will not explode even if a tube rupture occurs. In the event of a tube rupture, the generated gases will merely burn and not explode.
From the foregoing, it will be noted that the described apparatus enables the effecting of an efficient pyrolytic process for the treating of organic carbonaceous material so as to effect the gasification thereof in an ecological manner. While the apparatus has been particularly described with respect to effecting the gasification of oil, the same apparatus and method herein set forth can be utilized to effect the gasification of coal or any other organic type carbonaceous material, either separately and/or in combination. Thus, the apparatus is capable of generating a usable gas substitute from any organic hydrocarbon material.
A chemical analysis of one oil gasified by the foregoing described apparatus and method defined disclosed the following chemical components an concentration by volume.
______________________________________ ConcentrationChemical Component Percent by Volume______________________________________Methane 33Water 0.9Ethylene 16Ethane 3.5Propene 3.8Butadiene 1.4Cyclopentadiene 3.5Benzene 14Toluene 0.7Carbon Dioxide 23Others 0.2 100.0______________________________________
The test conducted did not reveal the presences of any chlorine or sulfur containing components that could result in hydrogen chloride or sulfur dioxide formation on combustion.
While the invention has been described with respect to several embodiments thereof, it will be understood and appreciated that variations and modifications may be made without departing from the spirit or scope of the invention. | A method for treating carbonaceous material, e.g. waste oil containing PCB toxic materials, by effecting the pyrolytic gasification thereof to produce a relatively high BTU content gas that is substantially free of the toxic materials to supplement or substitute for natural gas. This is attained by a furnace in which the products of combustion are utilized to separately generate steam and to preheat a supply of carbonaceous material which may be mixed with water. The generated steam is mixed with the preheated carbonaceous material and passed through a premixing and/or a primary dynamic mixer wherein the preheated carbonaceous material and steam mixture is further heated to a temperature ranging between 1600°-1800° F. to effect a partial gasification of the carbonaceous material. The partially gasified material is thereafter directed through one or more secondary dynamic mixing chambers to be further heated in the presence of additional steam to complete the gasification thereof. The generated gases are thereafter scrubbed and washed to remove any solid residue and thereafter passed through a condensor to effect the removal of any residual water; and from which the condensed gases are collected and/or stored for future use. | 2 |
TECHNICAL FIELD
The present invention relates to an apparatus for use in a liquid circulation system, said system comprising a primary and a secondary liquid circulation circuit defining a primary forward flow, a primary return flow, a secondary forward flow and a secondary return flow.
BACKGROUND ART
In such systems, a need can arise to be able to operate with different pressures in the primary and secondary liquid circulation circuits, respectively, this normally being achieved by leading the primary liquid circulation circuit through a heat exchanger, and leading the secondary liquid circulation circuit through the heat exchanger separate from the primary circulation circuit by means of a pump. In addition to the possibility of operating with different pressures in the primary and secondary circuits, this arrangement also provides protection against liquid from the primary circulation circuit flowing out uncontrollably caused by a possible leak in the secondary circulatory circuit; this may be called for e.g. in district heating systems in order to protect against water damage. The heat exchanger will, however, introduce an undesired loss of heat, and will normally make it necessary to circulate the liquid in the secondary circulatory circuit by means of a circulation pump.
DISCLOSURE OF THE INVENTION
It is the object of the present invention to provide an apparatus, with which the disadvantages of the known separating systems based upon the use of heat exchangers described above are avoided, while at the same time making it possible to maintain different pressures in the primary and secondary liquid circulation circuits, respectively.
This object is achieved with an apparatus of the kind set forth mentioned above, according to the present invention exhibiting the arrangements of two positively interconnected displacement machines, one of which receives the primary forward flow and which delivers the secondary forward flow and the other of which receives the secondary return flow and delivers the primary return flow together with a flow equalization means whereby the volumetric effects of the displacement machines are attuned to each other in a manner to ensure that the volume flows in the primary forward flow, the secondary forward flow, the secondary return flow and the primary return flow are substantially equal.
By arranging the apparatus as set forth in claim 1 it is possible to have the same liquid circulate from primary forward flow to secondary forward flow, to secondary return flow and to primary return flow, without the pressure conditions in these flows necessarily being equal, because a pressure difference between these two liquid circulation circuits is exploited to supply power to one of the displacement machines, this machine then driving the other machine to pump the circulated liquid from the second to the first of these liquid circulation circuits whilst maintaining substantially equal flow volumes to and from the two circuits (primary and secondary, respectively) and without using a separate circulation pump for the secondary circulatory circuit, because the pressure difference between the primary forward flow and the primary return flow is utilized to create a pressure difference between the secondary forward flow and the secondary return flow.
The arrangement where the displacement machines act as a pump and a motor with the pump having a greater volumetric effect which is reduced by a pressure-controlled bypass means. This provides for an active balancing of the volume flows in the apparatus simultaneously with a control of the pressure on one side of the pump (delivery/inlet).
In especially preferred embodiments of the apparatus, in which the displacement machines are in the form of piston-cylinder units. By arranging these piston-cylinder units as two cylinders placed in a coaxial extension of each other the advantage is achieved that the seal between each piston and the associated cylinder solely has to withstand the prevailing differential pressure between a primary forward flow and return flow or a secondary forward flow and return flow, respectively, i.e. not the potentially substantially greater pressure difference between the primary and secondary circulatory circuit, in this arrangement being separated by means of the valve system or the central member, respectively.
One embodiment employs the utilization of the difference in volumetric effect for the inner and outer piston-cylinder pair, respectively, being "built-in" with this arrangement, so as to achieve the difference used of the volumetric effect for pressure control or attunement of the apparatus. A preferred dimensioning of the axial length of the pistons to match a stroke in the cylinders is made with a view to ensuring that the circulating forward-flow liquid does not exchange heat with the circulating return-flow liquid via the wall of the cylinder.
In specify preferred embodiments, the volumetric effects can be adjusted with high accuracy by means of the diameter on a piston-rod extension reducing the volumetric effect of the outer piston-cylinder unit.
In specify a preferred embodiment, the quantitative effect of the pump is greater than that of the motor, and in which the corresponding surplus amount is balanced out by means of a pressure-controlled return flow or by-pass flow.
In the preferred embodiments, the quantitative effect of the pump is less than that of the motor, and in which the corresponding surplus of liquid in the secondary circuit is drained via a pressure-controlled overflow or a pressure-controlled valve, respectively, or pumped back to the primary return flow by means of an auxiliary cylinder-piston unit, the control of the pumping-back operation possibly occurring via an expansion tank with a float-controlled valve.
Other embodiments specify various arrangements of the apparatus with which an adjustable volumetric effect is achieved.
Still other embodiment specify preferred arrangements of the seal between the pistons and the cylinders in the apparatus in the form of a rolling diaphragm, making it possible to achieve complete sealing, and which the hollow, toroid-shaped rolling diaphragm can provide a safe thermal insulation between the liquid on the forward-flow side and the liquid on the return-flow side.
Also specified are preferred methods for using the apparatus according to the invention, in which the use of displacement machines in the apparatus is exploited for measuring the volume flow in the system or for calorimetric measurements, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following detailed portion of the present description, the invention will be explained in more detail with reference to the exemplary embodiments of the apparatus according to the invention shown in the drawings, in which
FIG. 1 is an overall diagrammatic sketch showing the apparatus according to the invention,
FIG. 2 shows in detail a first embodiment of the apparatus according to the invention,
FIG. 3 shows a second embodiment,
FIG. 4 shows a variant of the embodiments shown in FIGS. 2 and 3,
FIGS. 5-10 show various applications of the apparatus according to the invention,
FIG. 11 is a sketch showing a variant of the apparatus according to the invention,
FIGS. 12-15 show various pressure-control means for use in connection with the apparatus according to the invention,
FIGS. 16 and 17 show various arrangements of the apparatus according to the invention with which an adjustable volumetric effect is achieved,
FIG. 18 shows yet another possible arrangement of pressure-control means,
FIGS. 19 and 20 show additional possible ways of providing an adjustable volumetric effect,
FIG. 21 shows the use of an auxiliary cylinder for pumping surplus liquid back from the secondary circuit to the primary circuit, and
FIGS. 22-24 show a rolling seal for sealing and insulation between piston and cylinder in the apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus according to the invention shown diagrammatically in FIG. 1 is connected through pipes to a primary forward flow P.F. with a pressure P 1 and a primary return flow P.R. with a pressure P 2 , as well as to a secondary forward flow S.F. with a pressure P 3 and a secondary return flow S.R. with a pressure P 4 , respectively. The pressures P 1 and P 2 in the primary forward flow and the primary return flow, respectively, are maintained with P 1 greater than P 2 by means of a circulation pump (not shown) in the primary circulatory circuit. The apparatus comprises a displacement machine A connected to receive the primary forward flow P.F. and deliver the secondary forward flow S.F., as well as a displacement machine B connected to receive the secondary return flow S.R. and deliver the primary return flow P.R. The volumetric effects of the displacement machines A and B are mutually attuned in such a manner that the volume flows in the four pipes are substantially equal. A prerequisite for the displacement machines to be active is that P 1 -P 3 +P 4 -P 2 is greater than the pressure drop (P t ) arising in the displacement machines because of friction and losses in them. This may be re-written to read (P 1 -P 2 )-P t >(P 3 -P 4 ), meaning that the pressure difference between primary forward flow and primary return flow is transferred to the secondary circulatory circuit to a pressure difference between the secondary forward flow and the secondary return flow by means of the interconnected displacement machines A and B shown.
If the apparatus is used in a district heating system, heating water will usually be circulated in the primary circulatory circuit with a primary forward-flow pressure P 1 of e.g. 5 bars and a primary return-flow pressure P 2 of e.g. 4 bars. Now, it is desirable to reduce these pressures in the secondary circulatory circuit to e.g. a secondary forward-flow pressure P 3 of 1 bar and a secondary return-flow pressure P 4 of 0.5 bar, thus reducing substantially the probability of leakage in the secondary circulatory circuit. In this situation, the displacement machine A functions as a motor and the displacement machine B as a pump, and if the displacement machine B has a greater volumetric effect that the displacement machine A, the displacement machine B will attempt to pump more liquid out of the secondary circulatory circuit than is being supplied via the displacement machine A, and this greater volumetric effect may then be compensated by means of a pressure-controlled by-pass T from the primary return flow to the secondary return flow, adapted to open when the pressure P 4 in the secondary return flow falls below e.g. 0.5 bar.
Additional control of the apparatus according to the present invention may be achieved by introducing a pressure-controlled or pressure-difference-controlled valve in the primary forward-flow line, e.g. adapted to be controlled by the pressure difference P 3 -P 4 , thus opening for primary forward flow when this pressure difference falls below an adjustable level.
In another application, the secondary circulatory circuit may e.g. comprise the supply of district heating to a high-level position (e.g. the uppermost floors in a tall building or a house situated at a level higher than the district-heating centre), and in this case, P 1 will be less than P 3 and P 4 be greater than P 2 . In this situation, the displacement machine B functions as a motor and the displacement machine A as a pump. Then, the by-pass mentioned above must be placed between the secondary forward flow and the primary forward flow and adapted to open when the pressure P 3 in the secondary forward flow is greater than the forward-flow pressure required for circulating the liquid in the secondary circulatory circuit.
The attention should now be directed to FIG. 2, showing a preferred embodiment of the invention, in which the displacement machines consist of two co-axially aligned cylinders 2, 3, 2', 3', each being subdivided into two parts by a piston 1 and 1', respectively, said pistons being mutually connected through a piston rod 4 extending in a fluid-tight manner through a stationary central wall 5 separating the two cylinders 2, 3 and 2', 3', respectively. The piston-cylinder pairs situated internally of the pistons 1, 1' constitute a displacement motor, the operation of which is controlled by valves 6, 7 situated in the central wall 5 and having their valving functions controlled by the movements of the pistons 1, 1' in the cylinders 2, 3, 2', 3'. The apparatus is connected to a primary forward flow 9 and a primary return flow 36 as well as a secondary forward flow 31 and a secondary return flow 33, in this Figure being imagined as a district-heating system with radiators for domestic heating purposes in the secondary circulatory circuit. In the embodiment shown in FIG. 2, the supply pressure to the displacement motor is controlled by a valve 10 adapted to open when the pressure difference between the inlet to the displacement motor and the primary return flow falls below a predetermined level, said level being set by means of an adjustment screw 13 and a spring 12 and controlled by a diaphragm 11. In this system, the displacement pump is constituted by the piston-cylinder units situated outside of the pistons 1, 1'. The operation of the pump is controlled by non-return valves 32, 34, 32', 34'. In the position of the valves 6, 7 shown in FIG. 2, the circulating liquid flows from the primary forward flow 9 via the valve 10 and the valve 6 to the rear side of the piston 1', the latter moving towards the right and thus causing circulating liquid to flow through the valve 7 to the secondary forward flow 31. Secondary-return-flow liquid from the line 33 flows via the non-return valve 32 to the external side of the piston 1, which moves to the right, and liquid on the external side of the piston 1' flows via the non-return valve 34' to the line 35' and via the pressure-difference regulator to the primary return flow 36. Due to the piston rod 4, the volumetric effect of the displacement motor constituted by the piston-cylinder units situated internally of the pistons 1, 1' is less than the volumetric effect of the displacement pump constituted by the piston-cylinder unit situated outside of the pistons 1, 1'. This greater volumetric effect is compensated by means of valves 20, 20', in the embodiment shown in FIG. 2 controlled by the difference in pressure between the piston-cylinder unit of the pump and the atmosphere, because when the pressure outside of the piston 1 falls below atmospheric, the diaphragm 22 opens the valve 20 and allows return flow of circulating liquid from the primary return flow in the line 35 via the line 21. When the pistons 1, 1' have reached their extreme right-hand position, the valves 6, 7 are switched by means of a mechanism not shown in detail, said mechanism being adapted to switch the valves substantially instantaneously, so that subsequently, the inflow of circulating liquid from the primary forward flow occurs internally of the piston 1, and the outflow of circulating liquid to the secondary forward flow occurs from internally of the piston 1', causing the pistons 1, 1' to move toward the left. This will also cause switching of the displacement pump externally of the pistons 1, 1', as the non-return valve 32 closes and the non-return valve 32' opens, and correspondingly the non-return valve 34 opens and the non-return valve 34' closes, and the pressure control previously carried out by the diaphragm 22 and the valve 20 is now transferred to the diaphragm 22' and the valve 20'. A corresponding switching occurs in the opposite extreme position of the pistons 1, 1'. The diaphragms 22, 22' can, of course, be provided with suitable springs and adjustment devices in order to adjust the pressure, at which the return flow from the primary return line is opened for.
The embodiment of the apparatus shown in FIG. 3 is substantially identical to the one shown in FIG. 2 with the exception of the arrangement of a pressure-difference sensor 14. This pressure-difference sensor controls the opening of the primary-forward-flow valve 15 on the basis of the difference in pressure between the secondary return flow 33 and the secondary forward 31, each acting upon a respective side of the diaphragm situated in the housing of the pressure-difference sensor 14, this diaphragm again controlling the opening of the valve 15. Further, the diaphragm is acted upon by a spring, the effect of which may be adjusted by means of an adjustment screw.
Otherwise, the embodiment shown in FIG. 3 operates in the same manner as the one described above with reference to FIG. 2.
FIG. 4 shows an embodiment in which the bypass valves of FIGS. 2 and 3 have been moved so as to allow bypass flow directly from the primary return flow to the secondary return flow bypassing the non-return valves 32, 32', so that it is sufficient to use a single bypass valve T as distinct from the two bypass valves 20, 20', 22, 22' as in the FIGS. 2 and 3.
FIGS. 5-10 show a series of examples of the use of the apparatus according to the invention, all to be explained in more detail below.
FIG. 5 shows the apparatus in operation in connection with a district-heating system, in which the pressure in the secondary return flow is regulated by means of the bypass valve T, e.g. to be sub-atmospheric, so that a possible leak in the secondary circulatory circuit will not cause water to flow out, but rather air to be aspirated into the secondary circulatory circuit. In the example shown in FIG. 5, the primary forward flow and the secondary forward flow are connected to the displacement motor and the secondary return flow and the primary return flow are connected to the displacement pump, all corresponding to FIGS. 2 and 3.
FIG. 6 shows the apparatus according to the invention being used to reduce the pressure in the water being circulated in a heat exchanger C with a view to ensuring that the liquid circulating in the secondary circulatory circuit does not penetrate into the liquid circulating on the other side of the heat exchanger C, such as water for domestic use that should not be contaminated with the liquid circulating in the primary and secondary circulatory circuits. In the arrangement shown in FIG. 6, the pressures in the secondary circulatory circuit are maintained lower than the pressure in the domestic-water circuit on the other side of the heat exchanger C, the bypass T ensuring that the pressure in the secondary return flow is held at a suitably low level. In this arrangement, there is no need for a pressure regulator, as long as the pressure difference between the primary forward flow and the primary return flow is lower than the pressure in the domestic water on the other side of the heat exchanger C.
In the application shown in FIG. 7, the arrangement according to FIG. 5 has been supplemented with a pressure-regulating valve P ensuring that the pressure in the secondary forward flow downstream of this valve does not exceed a preset pressure, such as could occur with the embodiment according to FIG. 5, if minor leaks are present in connection with valves and pistons in the apparatus according to the invention, and there is no movement, i.e. when there is no flow through the apparatus.
FIG. 8 shows another arrangement of the pressure control in the secondary forward flow, in which the inflow to the displacement motor is controlled by a valve adapted to open for the inflow when the pressure in the secondary forward flow falls below a predetermined level, e.g. atmospheric pressure.
In FIGS. 5-8, the apparatus according to the invention is shown diagrammatically, showing the primary forward flow to be supplied to the displacement motor delivering the secondary forward flow, and the secondary return flow flows into the displacement pump delivering the primary return flow.
In the application shown in FIG. 9, the primary forward flow is supplied to the displacement pump delivering the secondary forward flow, while the secondary return flow is supplied to the displacement motor delivering the primary return flow. In this embodiment, the apparatus according to the invention is used to increase the pressure in the secondary circulatory circuit, so that the latter is able to circulate the liquid to an elevated level as indicated by the house on the hilltop. In this situation, the bypass valve T is placed so as to allow circulating liquid to flow back from the secondary forward flow to the primary forward flow when the pressure in the secondary forward flow increases beyond a predetermined level, the latter being adjusted by means of the bypass valve and corresponding to the pressure head desired (the head H as measured to the house on the hilltop).
If the apparatus is constructed in the manner shown in FIG. 2 with the exception of the pressure-difference-controlled valve 10 etc., it will be seen that the valve mechanism of the displacement motor is placed in the cold return line and only the simple non-return valves are placed on the hot side, this being advantageous with this application.
FIG. 10 shows an application fully corresponding to that of FIG. 5, but in which the displacement machines constructed substantially in the manner shown in FIG. 2 are used additionally to deliver impulses to a calorie counter for each cycle of the displacement machines, thus delivering impulses to the calorie counter in a number proportional to the volume of the circulated liquid. Further, the calorie counter receives signals from a set of temperature sensors placed in the primary forward flow and the primary return flow, respectively, but the associated temperature sensors may, of course, be placed internally in the apparatus (the displacement machines).
Because the circulating liquid is usually water, in the radiator system R being cooled from e.g. 80° C. to 40° C., an increase in the specific weight of the liquid will occur. In order to compensate for this increase in specific weight, the volumetric effect of the pump pumping liquid from the return line in the secondary circulatory system to the return line in the primary circulatory system must be reduced corresponding to this increase in specific weight. In FIG. 11, this reduction is provided by means of a piston-rod extension 17 co-operating with an auxiliary cylinder 18, the latter being sealed relative to the piston-cylinder unit 1, 3 by means of a lip seal 19. The diameter d 1 of the piston-rod extension 17 is greater than the diameter d 2 of the piston rod 4, so that the volumetric effect of the piston-cylinder unit 1, 3 acting as a pump is less than that of the piston-cylinder unit 1, 2 acting as a motor. In the embodiment shown in FIG. 11, the auxiliary cylinder 18 is connected to the corresponding auxiliary cylinder 18' in connection with the piston 1' via a bore in the piston rod 17, 4, 17' connecting the two cylinders 18, 18'. In this manner, the pressure between the cylinders 18 and 18' is equalized, so that these cylinders are "idling". By suitably dimensioning the diameters d 1 and d 2 as well as the diameter d 3 of the main cylinders 2, 2' 3, 3', it is possible, when cooling the circulating liquid in a known manner from a temperature t 2 to a temperature t 1 , to achieve a well-defined balance between the quantity of liquid being supplied to the secondary circulatory system via the secondary circulatory forward flow and the quantity of liquid being removed from the secondary circulatory system via the secondary circulatory return flow.
If the quantity of liquid being pumped to the secondary circulatory system is greater than the quantity of liquid being pumped from the secondary circulatory system, there will be a need for controlling the maximum pressure in the secondary circulatory system that can be provided, as shown in FIG. 12, in which an overflow B with a certain rise head h [m] ensures that the surplus quantity is allowed to drip out at B. Alternatively, an excess-pressure valve A may correspondingly allow the surplus quantity to drip away at A, the pressure possibly being adjustable by means of a spring in the excess-pressure valve A.
If the seals between the pistons 1, 1' and the associated cylinders 2, 2', 3, 3' are so constructed that they cannot withstand a too high pressure, the pressure difference between P 3 and P 4 may be limited by means of a safety valve C as shown in FIG. 12.
FIG. 13 shows an alternative arrangement of the overflow system in connection with a multi-storey radiator system R1, R2 and R3. This overflow system comprises an expansion tank EK, in the embodiment shown placed in the secondary forward-flow line and provided with a signaller M, which in case of leaks in the radiator system R1, R2 and R3 detects a fall in the level of liquid in the expansion tank EK and controlled by this fall closes a valve 55 in the forward-flow line, so that liquid is no longer supplied to the radiator system R1, R2 and R3. Additionally, the radiator system may possibly be emptied of liquid via a further valve 56, through which the liquid is drained from the radiator system R1, R2 and R3 to an outlet. This arrangement prevents water damage in case of leaks in the radiator system R1, R2, R3.
The system shown in FIG. 13 is especially suitable for multi-storey buildings, in which the radiators R1, R2, R3 are situated in different storeys and thus subjected to different pressures corresponding to the pressure heads h 1 , h 2 and h 3 as shown.
As an alternative to the level sensing by the signaller M, the detection of the falling liquid level in the expansion tank EK may be provided by means of a pressure gauge P in the return-flow line of the secondary circulatory system.
FIG. 14 shows diagrammatically a system corresponding to that of FIG. 12, but with a number of houses being supplied from a common displacement-machine unit and provided with a single overflow only. In the case of a breakage in the system causing the liquid pressure in the secondary circulatory system to fall, the valve Vi will interrupt the supply of liquid to the radiator system.
FIG. 15 shows an alternative system for controlling the pressure in the radiator system R. The secondary forward-flow pressure P 3 is controlled by means of the pressure-difference-control valve DR to be identical to atmospheric pressure. As the displacement machines are constructed to supply more liquid to the secondary circulatory system than is removed from this system, this surplus quantity will drip out from the system via the valve 24 and a floor drain. Because the dripping-off occurs at floor level, the pressure in the return flow of the secondary circulatory system is maintained identical to the pressure at this floor drain, so that the pressure in the radiators R lies below atmospheric pressure. Thus, a possible leak in a radiator R will cause air to be drawn into the radiator and the corresponding quantity of liquid to drip out via the floor drain. In order to prevent a possible rise in the pressure P 3 , the forward flow of the secondary circulatory system is provided with an overflow B at a suitable level. With a view to making it possible to bleed air from the radiators R a set of valves 23, 24 are provided, and when bleeding is to be carried out, the valve 24 is closed and the valve 23 is opened to allow the pressure of the primary return flow to reach the radiators enabling them to be bled by means of this pressure, the maximum pressure, however, being limited by the overflow B, and after the bleeding operation, the valve 23 is closed and the valve 24 opened for normal operation as described above.
FIG. 16 shows an alternative embodiment of the displacement machines shown in FIG. 11 in which it is possible to adjust the volumetric effect for the externally situated piston-cylinder units 1, 1', 3, 3'. The adjustability is provided by supplementing the effect of the externally situated piston-cylinder unit with the effect of the auxiliary piston-cylinder units 17, 18, 17', 18' along a certain length of the path of movement of the pistons. The length of the movement, in which the volumetric effect is supplemented with that of the auxiliary piston-cylinder units, is adjusted by means of a sleeve 28 adapted to close transverse bores into each of the central bores in the piston rod along a certain length of the movement of the piston rod, so that the auxiliary piston-cylinder units 17, 17', 18, 18' will pump liquid past the lip seals 19, 19' when these transverse bores are closed and the associated cylinder 18 or 18' is under compression. The liquid is supplied to the auxiliary piston-cylinder unit 17, 17', 18, 18' from the secondary return flow 33 via a tube to the central wall 5, in which the sleeve 28 is situated. The sleeve 28 has a V-shaped cut-out, so that rotation of the sleeve will provide a greater or lesser coverage of the transverse bores in the piston rod 4. The piston rod is held against rotation in order to ensure a constant position of these transverse bores by means of a guide pin 26 that is secured to the end wall and co-operates with a bore in the piston 1.
FIG. 17 shows an alternative embodiment of such an arrangement with adjustable volumetric effect, in which only one auxiliary piston-cylinder unit 17, 18 is used to supplement the volumetric effect of the pump unit. In this arrangement, secondary return-flow liquid is pumped from the line 33 via a transverse hole in the piston rod 4, which hole during part of its movement is covered by the sleeve 28, the latter again having a V-shaped cut-out and being rotatable by means of an adjusting screw 27. Thus, liquid is supplied to the auxiliary piston-cylinder unit 17, 18 via the transverse bore in the piston rod 4 and the central bore in the latter, a non-return valve 29 ensuring that the liquid only flows to wards the cylinder 18. During the compression stroke in the auxiliary cylinder 18, liquid will be forced past the lip seal 19 and to the primary return flow via the main cylinder and the non-return valve 34. The other auxiliary piston-cylinder unit 17', 18' may be used for return pumping of surplus liquid, to be explained below.
FIG. 18 shows an alternative embodiment of a bypass flow in association with a displacement machine, in which more liquid is pumped away from the secondary circulatory system than is supplied to it. This bypass flow comprises a float-control bypass valve SV allowing liquid from the primary return flow to flow to an expansion tank EK, in which is placed a float S for controlling the float valve SV. When the liquid level in the expansion tank EK falls, the flow valve SV will open for bypass flow of liquid from the primary return flow to the expansion tank, from which the liquid is pumped via the secondary return flow and the pump part of the displacement machine. In FIG. 18 the expansion tank EK is shown placed at a level lower than the radiator R, so that the pressure in the radiator R will be below atmospheric. Alternatively, the expansion tank EK may be placed at a higher level, e.g. in connection with multi-storey buildings, in which it is necessary to prevent the pressure in the radiators from being too low, in order to avoid the formation of steam in them. In FIG. 18 the secondary forward-flow pressure P 3 is controlled by a pressure-difference-control valve DR. In the case of a leak in the radiator R in FIG. 18 air will be aspirated via the leak, and the radiator R will be emptied into the expansion tank EK, from which the liquid will be pumped back to the primary circulatory system by means of the displacement machine.
A possible overflow from the expansion tank EK may be conducted to an outlet or a drain.
FIG. 19 shows an alternative possibility for adjusting the volumetric effect of the pump section. Primarily, the volumetric effect is set slightly higher than desired by means of the diameters d 1 , d 2 and d 3 corresponding to what is shown in FIG. 11. The volumetric effect of the piston-cylinder unit 1, 3 is reduced by means of an auxiliary piston 30 moving together with the piston 1 through the final part of the latter's movement while liquid is being pumped out to the primary return flow, as well as through the initial part of this piston movement while liquid is being pumped in from the secondary return flow. The auxiliary piston 30 has a diameter d 4 and reduces the volumetric effect of the piston 1 in the cylinder 3 with the corresponding area through the movements of the piston 30, this movement being adjusted by means of an adjusting screw 38 with associated locking nut 39, so that the extent to which the piston 30 penetrates into the cylinder 3 is adjustable, and the piston 30 moves to the left by the action of the piston 1 and moves to the right by means of a spring 37, all as shown in FIG. 19.
FIG. 20 shows yet another alternative arrangement to adjust the volumetric effect of the piston-cylinder unit 1, 3. In the embodiment shown in FIG. 20, the auxiliary piston-cylinder unit 17, 18 is utilized during part of the movement of the piston 17 to pump liquid from the cylinder 18 to the cylinder 3. The part of the movement, during which liquid is pumped from the cylinder 18 to the cylinder 3, and correspondingly pumped back from the cylinder 3 to the cylinder 18, is adjusted by means of an axially movable valve-actuating rod 43, that during the movement through the desired path of movement 1 keeps a valve member 40 in the open position against the force of a spring 42 urging the member 40 towards the closing position in abutment against a seal 41. During the movement along this path of movement 1, the volumetric effect of the piston 1 in the cylinder 3 is supplemented by the auxiliary piston-cylinder unit 17, 18, the latter pumping liquid both into and out of the cylinder 3 during the movement towards the left and right, respectively, as shown in FIG. 20. Since equal amounts of liquid are being pumped into and out of the cylinder 18, the piston 1 can be provided with a diaphragm 44 ensuring that the liquid being pumped back and forth between the cylinder 18 and the cylinder 3 in the space 45 limited by the diaphragm 44 is always the same liquid, so that it is not contaminated by the liquid being circulated. The axial position of the valve-actuating rod 43 is adjusted by means of an adjusting screw 38 in engagement with a thread 48, and the position of the adjusting screw 38 can possibly be read by means of a scale on the screw co-operating with a pointer 47.
In connection with the embodiments, in which more liquid is pumped into the secondary circulatory system than away from it, e.g. a shown in FIGS. 12, 13, 14 and 15, the arrangement shown in FIG. 21 can be used. With this arrangement, the auxiliary piston-cylinder unit 17, 18 is used for pumping surplus liquid back from an expansion tank EK via a float valve SV and a non-return valve 49 conducting the liquid to the cylinder 18 and, via the lip seal 19 and the cylinder 3, to the primary return flow. Surplus liquid dripping from the various overflows shown in the above-mentioned Figures or the like is conducted to the expansion tank EK via a filter F, the latter provided to prevent contamination of the valves SV and 49, and the auxiliary piston-cylinder unit 17, 18 aspirates liquid from the expansion tank EK as long as the float S keeps the valve SV open, and the non-return valve 49 ensures that the higher pressure in the auxiliary piston-cylinder unit 17, 18 forces the liquid past the lip seal 19 into the cylinder 3. The auxiliary piston-cylinder unit 17, 18 could possibly be provided with an automatic escape tube 50, not shown in detail, so that steam and air can escape from the cylinder 18.
In order to ensure an effective seal between the pistons 1, 1' and the associated cylinders, 2, 3, 2', 3', a rolling seal 51 of a kind known per se can be placed between them, normally having a cross-sectional shape as shown in FIG. 24. The piston-cylinder units according to the present invention are, however, intended to circulate liquid in the separate cylinders 2, 2' and 3, 3', respectively having different temperatures, as no heat exchange between the liquids separated by the pistons 1, 1' is desired. To minimize the heat exchange between the liquids in the chambers separated by the pistons 1, 1', the rolling diaphragm 51 can be in the form of a double rolling diaphragm as shown in FIGS. 22 and 23, respectively. To provide additional protection against heat exchange between the liquids via the piston 1, the rolling diaphragm can have the form shown in FIG. 22, so that its substantially toroid-shaped internal space is filled with an insulating material 52. As shown in FIG. 22, in the extreme position shown in the middle part of FIG. 22, the rolling diaphragm and the insulating material cover completely the side of the piston 1 facing the wall of the cylinder. In the opposite extreme position shown below in FIG. 22, the insulating material 52 in the rolling diaphragm 51 covers half of the side wall of the piston 1 facing the cylinder 3. In this manner it is ensured that this side wall of the piston 1 does not contribute to heat exchange between the liquids in the two chambers separated by the piston 1. In addition to this, a shield 54 may be placed on the side of the piston 1 facing the chamber defined by the piston 1 and the cylinder 2, 3, so that the liquid present in this chamber is also prevented from exchanging heat with the piston 1 on the latter's rear side. In this manner, the piston 1 is thermally insulated from the liquid in the chamber defined by the piston 1 and the cylinder 2. A cavity between the shield 54 and the piston 1 may be filled with air or liquid, and in the latter case, the shield 54 is preferably made of insulating material.
The insulating material 52 can be a liquid material or alternatively, as shown in FIG. 23, consist of a ring of an insulating plastic material embedded in the substantially toroid-shaped rolling diaphragm 51. In order to equalize the pressure in the toroid-shaped rolling diaphragm 51, the latter can be provided with a small opening 53 communicating the inner space of the rolling diaphragm with the chamber defined by the piston 1 and the cylinder 2. | The invention relates to an apparatus for use in a liquid circulation system of the kind comprising a primary circulatory circuit provided with a circulation pump and having a primary forward flow and a primary return flow, as well as a secondary circulatory circuit with a secondary forward flow and a secondary return flow, said primary and secondary forward and return flow being connected to the apparatus, and the liquid circulating in the primary and secondary circulatory circuits being of substantially the same composition. The apparatus comprises two positively interconnected displacement machines (A, B), of which one (A) receives the primary forward flow (P.F.) and delivers the secondary forward flow (S.F.), whilst the other (B) receives the secondary return flow (S.R.) and delivers the primary return flow (P.R.), the volumetric effects for the displacement machines (A, B) being mutually attuned so as to ensure that the volume flows in the primary forward flow, the secondary forward flow, the secondary return flow and the primary return flow are substantially equal. This makes it possible to operate with different pressures in the primary and the secondary circulatory circuits, respectively, without the necessity of using a heat exchanger between them. The invention also comprises control facilities for protecting against loss of liquid from the primary circuit to the secondary circuit in the case of leakage in the latter. | 5 |
The invention was made in the course of or under U.S. Department of Energy Contract No. W-7405-ENG-48 with the University of California.
This is a division of application Ser. No. 77,811, filed Sept. 21, 1979, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a new method for synthesizing alpha amino acids in which novel intermediates are utilized. More particularly, the principal distinguishing reaction is that of a cyanohydrin with thionyl chloride.
Alpha amino acids have been synthesized for a number of years. A major use of alpha amino acids is in vitamin supplements. Another use is in nuclear medicine wherein a synthesized alpha amino acid is labeled with a 11 C atom in the carboxyl group.
In U.S. Pat. No. 2,520,312 a method is disclosed for synthesizing amino acids. In particular, a cyanohydrin is converted to a corresponding amino nitrile by the action of ammonia at high temperature and pressure, an endothermic step. Of course, a synthesis of shorter duration and avoiding reacting under high pressure would be desirable.
It is another object of this invention to provide a new method for synthesizing alpha amino acids having both higher yields and lower pressure requirements than the prior art.
Another object of the invention is a synthesis which proceeds more rapidly than those of the prior art.
Yet another object is an alpha amino acid synthesis in which each step is exothermic so that the overall process is relatively fast.
SUMMARY OF THE INVENTION
In the present invention, a novel process for synthesizing alpha amino acids employs as a reactant, thionyl chloride (SOCl 2 ), and proceeds through novel intermediates. The process generally includes the steps of reacting an aldehyde or ketone with cyanide to generate a cyanohydrin, reacting the cyanohydrin with thionyl chloride at room temperature to generate a novel 2-chlorosulfinyl nitrile, reacting the novel 2-chlorosulfinyl nitrile with liquid ammonia to generate an alpha amino nitrile and hydrolyzing the alpha amino nitrile to produce an alpha amino acid.
The novel intermediates are of the formula:
R.sub.1 R.sub.2 C(OSOCl)CN, R.sub.1 R.sub.2 C(Cl)CN, and [R.sub.1 R.sub.2 C(CN)O].sub.2 SO,
wherein R 1 and R 2 are each selected from hydrogen and monovalent substituted and unsubstituted hydrocarbon radicals of 1 to 12 carbon atoms as defined in more detail hereinafter and preferably methyl, ethyl, propyl, butyl or isobutyl. The last-mentioned sulfite intermediate above is a bis compound which can be symmetrical or asymmetrical.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The general reaction scheme, scheme A, for the alpha amino acid synthesis of this invention is as follows: ##STR1##
Among the monovalent substituted and unsubstituted hydrocarbon radicals, which R 1 and R 2 can be, are alkyl radicals (e.g., methyl, ethyl, propyl, butyl, isobutyl, decyl); aryl radicals (e.g., phenyl, naphthyl, biphenyl); alkaryl radical (e.g., tolyl, xylyl, ethylphenyl); aralkyl radicals (e.g., benzyl, phenylethyl), and alkenyl radicals (e.g., vinyl, methallyl), and p-hydroxybenzyl. The R 1 R 2 C(OSOCl)CN compounds are novel.
It is preferred that hydrocarbon radicals contains from 1-5 carbon atoms. It is further preferred that one of R 1 and R 2 be hydrogen.
Alternatively, but less preferred, the conditions of the thionyl chloride reaction can be modified so that the reaction proceeds through another intermediate which is also novel. This alternative reaction scheme, scheme B, is ##STR2##
In addition, yet another alternative exists and follows the thionyl chloride step of scheme A. This alternative which may prove advantageous involves an additional intermediate step which yields a novel intermediate. This further step, scheme C, is ##STR3##
In more detail, the synthesis of the invention according to scheme A begins with reacting an aldehyde or ketone, both commonly available, with a metal cyanide, such as potassium or sodium cyanide, to yield a cyanohydrin. This reaction can be carried out at room temperature and pressure by suspending the metal cyanide in anhydrous ether, dissolving the aldehyde or ketone in glacial acetic acid, and then adding the dissolved aldehyde or ketone to the suspended metal cyanide dropwise. The reaction mixture is cooled with an ice bath. An almost quantitative conversion to the cyanohydrin occurs. The carrying out of this reaction in the absence of water is believed to be novel.
No special precautions are needed to exclude traces of water during the cyanohydrin generation. Water appears to be involved in the reaction, but only trace amounts appear necessary to drive it forward. Potassium cyanide typically contains some moisture leading to the reaction:
CN.sup.- +H.sub.2 O=HCN+OH.sup.-
OH.sup.- +CH.sub.3 COOH=CH.sub.3 COO.sup.- +H.sub.2 O
To separate the cyanohydrin product, filtration and distillation can be utilized. By-product acetate ion precipitates as metal acetate, i.e., potassium acetate. The presence of increased amounts of water, although not adversely affecting the yield, results in precipitated potassium acetate which is heavy and pasty and, hence, makes mixing difficult. A large volume of ether facilitates mixing and isolation of the product.
The precipitated potassium acetate can be removed by filtration from the solution. The filter cake should be washed several times with small portions of anhydrous ether which is added to the solution. The ether in the solution can be evaporated at room temperature and reduced pressure to leave the cyanohydrin product.
The next step in the synthesis yields a novel 2-chlorosulfinyl nitrile. Cyanohydrin is added slowly to a preferably stoichiometric equivalent amount of thionyl chloride over a period of time. The mixture is stirred and preferably kept at room temperature or below by means of a water bath. Higher temperatures favor the product of scheme B. If a stoichiometric excess of thionyl chloride is used, the mixture is preferably anhydrous. The reaction is rapid and smooth and a 90% of theory conversion of the cyanohydrin to the chlorosulfinyl nitrile product can be obtained. The product can be separated by means of fractional distillation. The product is removed as one of the overhead products.
Also formed by the reaction of thionyl chloride and a cyanohydrin are two other novel compounds. The residue of the distillation consists almost entirely of the sulfite corresponding to the chlorosulfinyl nitrile. This sulfite can also be prepared by treating the chlorosulfinyl nitrile with an excess of formamide, HCONH 2 (scheme C). The sulfite residue can be converted to the chlorosulfinyl nitrile by refluxing with SOCl 2 for 5 to 10 minutes or can be reacted with liquid ammonia at room temperature and normal pressure to bypass the chlorosulfinyl nitrile and yield the amino nitrile corresponding to the chlorosulfinyl nitrile, the next intermediate in the synthesis.
Another compound formed by the reaction of thionyl chloride with a cyanohydrin is the 2-chloronitrile (scheme C) corresponding to the chlorosulfinyl nitrile. This chloronitrile can be formed quantitatively by refluxing the reaction mixture of the cyanohydrin and thionyl chloride for 4 to 5 hours. After removal of excess SOCl 2 , the product oil (chloronitrile) can be distilled at atmospheric pressure. This chloronitrile can be reacted with liquid ammonia at room temperature and normal pressure to yield the corresponding 2-amino nitrile, the next intermediate in the synthesis.
As indicated in preceding paragraphs, the next step is to convert the chlorosulfinyl nitrile to the corresponding amino nitrile. This reaction is highly exothermic and therefor the chlorosulfinyl nitrile is preferably added dropwise to anhydrous ammonia cooled with a dry ice-acetone bath. A vigorous reaction occurs. Upon completion, the excess ammonia is preferably removed by evaporation by allowing the mixture to warm to yield the amino nitrile.
This amino nitrile, in turn, is converted to the amino acid corresponding to this amino nitrile by refluxing the amino nitrile with sodium hydroxide. Alternatively, a mineral acid such as hydrochloric acid can be used for this hydrolysis, but base is preferred for most amino acids because there is no apparent tar formation and a chromatographically pure sample is obtained.
Below is a table of some common amino acids which can be synthesized with the process of this invention.
__________________________________________________________________________TABLE OF ILLUSTRATIVE ALPHA AMINO ACIDSAldehyde Chlorosulfinyl (Common Name)or Ketone nitrile Amino Acid__________________________________________________________________________ (Valine)(CH.sub.3).sub.2 CHCHO (CH.sub.3).sub.2 CHCH(OSOCl)CN (CH.sub.3).sub.2 CHCH(NH.sub.2)COOH (Alanine)CH.sub.3 CHO CH.sub.3 CH(OSOCl)CN CH.sub.3 CH(NH.sub.2)COOH (Tyrosine)C.sub.6 H.sub.4 OHCHO C.sub.6 H.sub.4 OHCH(OSOCl)CN C.sub.6 H.sub.4 OHCH(NH.sub.2)COOH (Alanine -α Amino Butyric Acid)CH.sub.3 CH.sub.2 CHO CH.sub.3 CH.sub.2 CH(OSOCl)CN CH.sub.3 CH.sub.2 CH.sub.2 (NH.sub.2)COOH (Norvaline)CH.sub.3 CH.sub.2 CH.sub.2 CHO CH.sub.3 CH.sub.2 CH.sub.2 CH(OSOCl)CN CH.sub.3 CH.sub.2 CH.sub.2 CH.sub.2 (NH.sub.2)COOH__________________________________________________________________________
EXPERIMENTAL PREPARATION OF VALINE
Isobutyraldehyde was purified by distillation just before use. A purified grade of thionyl chloride was further purified by distillation from about 10% of its weight of boiled linseed oil. The ammonia was dried by distillation from a small quantity of clean sodium. All other materials were reagent grade. All boiling points are uncorrected. The infrared spectra were determined on a Perkin Elmer 1R421 (liquid film between KBr plates).
2-Hydroxyisobutyronitrile ##STR4##
A well stirred suspension of 50 g of potassium cyanide in 800 ml of anhydrous ether was cooled in an icewater bath and 36.5 g of isobutyraldehyde in 45 ml of glacial acetic acid was added dropwise within 1 hour. A light voluminous precipitate of potassium acetate began to form immediately. After stirring for another hour the acetate was removed by filtration and the filter cake washed several times with small portions of anhydrous ether. The ether was removed from the combined filtrate and washings using a rotary evaporator at room temperature and reduced pressure. The remaining oil, 2-hydroxyisobutyronitrile, weighed approximately 50 g. It distilled without decomposition at 66°-67° C. and 0.1 mm pressure.
Anal. % Calcd. for C 5 H 9 ON: C, 60.60; H, 9.09; N, 14.14. Found: C, 60.62; H, 9.04; N, 14.12.
2-Chlorosulfinylisobutyronitrile ##STR5##
The cyanohydrin product (50 g) from the above preparation was added to 118 g of thionyl chloride over a period of 30 minutes while the mixture was stirred and kept at room temperature by means of a water bath. When the evolution of HCl had ceased, the excess thionyl chloride was removed under reduced pressure and the residue fractionated to yield an almost colorless oil, 2-chlorosulfinylisobutyronitrile, bp 40°-41° C. and 0.1 mm pressure as one of the cuts.
Anal. % Calcd. for C 5 H 8 O 2 NSCl: C, 33.06; H, 4.40, S, 17.63; Cl, 19.53; N, 7.71. Found: C, 33.36; H, 4.48, S, 17.56; Cl, 19.51; N, 7.70.
The yield for a number of runs varied between 80 and 86 grams. The residue which remained was distilled and consisted almost entirely of the sulfite corresponding to the chlorosulfinyl nitrile, bp 97°-98° C. at 0.1 mm pressure.
Anal. % Calcd. for C 10 H 16 O 3 N 2 S: C, 49.18; H, 6.56; N, 11.47; S, 13.11. Found: C, 49.52; H, 6.63; N, 11.61; S, 12.86.
2-Chloroisobutyronitrile ##STR6##
Alternatively, the chlorosulfinyl nitrile (50 g) as prepared above was refluxed with 60 g of thionyl chloride for five hours after which the excess thionyl chloride was removed at atmospheric pressure. The residue was distilled at 149°-150° C. at atmospheric pressure to yield a colorless oil, 2 chloroisobutyronitrile, weighing 30 g.
Anal. % Calcd. for C 5 H 8 NCl: C, 51.08; H, 6.81; N, 11.91; Cl, 30.18. Found: C, 51.31; H, 6.85; N, 12.15; Cl, 29.86.
Isobutyronitrile sulfite ##STR7##
Also alternatively, the chlorosulfinyl nitrile (30 g) was added to 30 ml of formamide and the mixture shaken for several minutes until the resulting exothermic reaction was complete. The mixture was poured into water (100 ml) and the oil extracted with either. The ether solution was washed twice with two 20 ml portions of water and dried over anhydrous sodium sulfate. Upon removal of ether and distillation of the residue there was obtained 18 g of a colorless oil, isobutyronitrile sulfite, bp 97°-98° C. at 0.1 mm.
Anal. % Calcd. for C 10 H 16 O 3 N 2 S: C, 49.18; H, 6.56; N, 11.47; S, 13.11. Found: C, 49.09, H, 6.62; N, 11.59; S, 13.15.
Valine ##STR8##
To approximately 35 ml of anhydrous ammonia cooled with a dry ice-acetone bath was added dropwise 18 g of the 2-chlorosulfinylisobutyronitrile. A vigorous reaction occurs and when complete, the cooling bath was removed and the ammonia allowed to evaporate. To the resulting residue was added 75 ml of absolute ethyl alcohol and the mixture heated to reflux. On cooling, 20 g of NaOH in 100 ml of water was added and the temperature increased to above 90° C. allowing the alcohol to distill off. The mixture was refluxed for 24 hr. After cooling, 100 ml of 6N HCl was added and the mixture taken to dryness under reduced pressure. A few ml of water was added to the residue and it was again taken to dryness. The residue was extracted several times with a total of 200 ml of hot absolute ethyl alcohol. The alcoholic solution was concentrated to approximately 50 ml, filtered and treated with 15 ml of pyridine. After standing in the refrigerator overnight the crystals were collected, washed with alcohol and air dried. The yield for several runs was from 8 to 9 g of very pure almost colorless valine. Paper chromatography showed the sample to be homogeneous having the same Rf value as a standard sample of valine (n-butanol; acetic acid; water; pyridine; 10, 2, 2, 1).
Anal. % Calcd. for C 5 H 11 O 2 N: C, 51.28; H, 9.4; N, 11.96. Found C, 50.90; H, 8.96; N, 11.99. | A method for synthesizing alpha amino acids proceding through novel intermediates of the formulas:
R.sub.1 R.sub.2 C(OSOCl)CN, R.sub.1 R.sub.2 C(Cl)CN and [R.sub.1 R.sub.2
C(CN)O] 2 SO
wherein R 1 and R 2 are each selected from hydrogen monovalent substituted and unsubstituted hydrocarbon radicals of 1 to 10 carbon atoms. The use of these intermediates allows the synthesis steps to be exothermic and results in an overall synthesis method which is faster than the snythesis methods of the prior art. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national phase application of PCT International Application No. PCT/AU97/00075, filed Feb. 12, 1997, which is entitled to priority to Australian patent application PN 8012, filed Feb. 12, 1996.
FIELD OF THE INVENTION
This invention relates to stabilised growth hormone (GH) formulations and in particular to liquid formulations of human growth hormone (hGH) which are stabilized by the incorporation of stabilizing excipients. These liquid formulations of hGH have improved chemical and physical stability. The present invention relates particularly to a method for the preparation of these stabilized GH formulations.
BACKGROUND OF THE INVENTION
The growth hormones of humans and animals are proteins containing approximately 191 amino acids which are found in the anterior pituitary. A major biological action of GH is to promote somatogenesis in young humans and animals and to maintain tissues in older creatures. Organs affected by GH include the skeleton, muscles, connective tissue and the viscera. Growth hormone acts by interacting with specific receptors on the target cell membranes.
Human growth hormone (hGH) is a key hormone involved in the regulation of normal human somatic growth and also affects a variety of physiological and metabolic functions, including linear bone growth, lactation and cellular energy use, among others. Deficiency of hGH in young children leads to short stature, and this condition has been treated by exogenous administration of hGH.
In the past, attention has been focused on determining the molecular functions of the growth hormones of various species. Commercial interest has been strong from both medical and veterinary circles, and the hGH gene has been cloned. Both hGH and a derivative thereof, methionyl-hGH (met-hGH), are now being biosynthetically produced in mammalian and bacterial cell culture systems.
In order for hGH to be available commercially as a therapeutic pharmaceutical preparation, stable formulations must be prepared. Such formulations must be capable of maintaining activity for appropriate storage times, they must be readily formulated and be acceptable for administration by patients.
Human GH has been formulated in a variety of ways. By way of example, U.S. Pat. No. 5,096,885 discloses a stable pharmaceutically acceptable formulation of hGH comprising, in addition to the hGH, glycine, mannitol, a buffer and optionally a non-ionic surfactant, the molar ratio of hGH:glycine being 1:50-200. International Patent Publication No. WO 93/19776 discloses injectable formulations of GH comprising citrate as buffer substance and optionally growth factors such as insulin-like growth factors or epidermal growth factor, amino acids such as glycine or alanine, mannitol or other sugar alcohols, glycerol and/or a preservative such as benzyl alcohol. International Patent Publication No. WO 94101398 discloses a GH formulation containing hGH, a buffer, a non-ionic surfactant and, optionally, mannitol, a neutral salt and/or a preservative.
In European Patent Publication No. 0131864 (and corresponding Australian Patent No. 579016) there is disclosed an aqueous solution of proteins with molecular weight above 8500 daltons, which have been protected from adsorption at interfaces, against denaturing and against precipitation of the protein by addition of a linear polyoxyalkylene chain-containing surface-active substance as a stabilizing agent.
European Patent Publication No. 0211601 discloses a growth promoting formulation comprising an aqueous mixture of growth promoting hormone and a block copolymer containing polyoxyethylene-polyoxypropylene units and having an average molecular weight of about 1,100 to about 40,000 which maintains the fluidity of the growth promoting hormone and its biological activity upon administration. Subsequent European Patent Publication No. 0303746 discloses various other stabilizers for growth promoting hormone in aqueous environments including certain polyols, amino acids, polymers of amino acids having a charged side group at physiological pH and choline salts.
Pharmaceutical preparations of hGH tend to be unstable, particularly in solution. Chemically degraded species such as deamidated or sulfoxylated forms of hGH occur, and dimeric or higher molecular weight aggregated species may result from physical instability (Becker et al (1988) Biotechnol Applied Biochem 10, 326; Pearlman and Nguyen (1989), In D. Marshak and D. Liu (eds), Therapeutic Peptides and Proteins, Formulations, Delivery and Targeting, Current Communications in Molecular Biology , Cold-Spring Harbour Laboratory, Cold Spring Harbour, N.Y., pp 23-30; Becker et al (1987) Biotechnol Applied Biochem 9, 478).
As a consequence of the instability of hGH in solution, pharmaceutical formulations of hGH tend to be presented in lyophilised form, which must then be reconstituted prior to use. Lyophilisation is often used to maintain bioactivity and biochemical integrity of polypeptides under a range of storage conditions where stability in solution is not adequate, however it would be advantageous to avoid lyophilisation as this is a costly and time-consuming production step. Lyophilised formulations of hGH are reconstituted before use, usually by the addition of a pharmaceutically acceptable diluent such as sterile water for injection, sterile physiological saline or an appropriate sterile physiologically acceptable diluent. Reconstituted solutions of hGH are preferably stored at 4° C. to minimize chemical and physical degradation reactions, however some degradation will occur during such storage which can be for a period of up to 14 days.
A pharmaceutical formulation of hGH provided in a liquid form, particularly one that maintained stability of hGH over a prolonged period of time, would be particularly advantageous. As described above, current liquid formulations are limited in storage time by the products of chemical and physical degradation reactions that occur during processing and storage. The problems associated with dimer formation have been reported in Becker, et al. (1987), supra., and previous attempts to avoid hGH dimer formation have not succeeded.
It is an object of the present invention to provide stable liquid formulations of hGH that do not result in the formation of undesirable aggregated species or cause chemical changes that reduce biological activity or alter receptor recognition. Another object is to provide a formulation that may be delivered via the needleless injector for subcutaneous injection, or aerosolised for pulmonary use.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method for the preparation of a stable, liquid formulation of growth hormone comprising growth hormone, a buffer and a stabilizing effective amount of at least one stabilizing agent selected from the group consisting of:
(i)
polyoxyethylene-polyoxypropylene block copolymer non-ionic
surfactants,
(ii)
taurocholic acid or salts or derivatives thereof, and
(iii)
methylcellulose derivatives,
wherein the method comprises admixing the growth hormone with the buffer and the stabilizing agent(s) under conditions such that the growth hormone is not exposed to concentrations of the buffer or stabilizing agent(s) which are greater than 2× the final concentrations of the buffer or stabilizing agent(s) in the formulation.
The present invention also extends to a stable, liquid formulation of growth hormone, prepared by the method as broadly described above.
In yet another aspect, the invention also extends to a stable, liquid formulation of growth hormone, comprising growth hormone, a buffer and a stabilizing effective amount of at least one stabilizing agent selected from taurocholic acid or salts or derivatives thereof, and methyl cellulose derivatives.
Throughout this specification, unless the context requires otherwise, the word “comprise”, or variations such as “comprises” or “comprising”, 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.
In a particularly preferred embodiment, this invention provides a method for the preparation of a stabilized, pharmaceutically acceptable liquid formulation of human growth hormone comprising:
(a)
a pharmaceutically effective amount of hGH,
(b)
0.01-5.0% w/v of at least one stabilizing agent selected from the
group broadly defined above, and
(c)
a pharmacologically acceptable buffer.
Preferably, this formulation comprises 0.05-2.0% w/v, more preferably 0.08-1.0% w/v, of the stabilizing agent(s).
Particularly preferred stabilizing agents are Pluronic polyols, taurocholic acid and its salts, and hydroxypropylmethyl cellulose.
The stabilized, liquid formulation of growth hormone preferably also contains a pharmacologically acceptable buffer such as a phosphate or citrate buffer, at a concentration of 2.5-50 mM, most preferably 10-20 mM.
The pH of the formulation is preferably from 5.0 to 7.5, more preferably from 5.0 to 6.8, even more preferably from 5.2 to 6.5, and most preferably from 5.4 to 5.8.
In the preparation of the stabilized, liquid formulation of growth hormone, the growth hormone is admixed with the buffer under conditions such that the growth hormone is not exposed to buffer concentrations greater than 2× the final concentration of buffer in the formulation, and subsequently the stabilizing agent(s) is added to the admixture under corresponding conditions.
In a particularly preferred method of preparation of the stabilized, liquid formulation of growth hormone, exposure of growth hormone is restricted to concentrations of phosphate or citrate buffer and Pluronic polyols not greater than 2× the final concentration of each component.
The present invention also extends to a method for treatment of a human or animal patient in need of growth hormone, which comprises administration to said patient of a pharmaceutically effective amount of a stable, liquid formulation of growth hormone as broadly described above.
The GH liquid formulation may be administered by bolus injection, with an aerosol device or needleless injector gun or by continuous IV infusion.
In the present context, references to “growth hormone” are intended to include all species of GH including human, bovine, porcine, ovine and salmon, among others, particularly hGH, as well as biologically active derivatives of GH. Derivatives of GH are intended to include GH of human or animal species with variations in amino acid sequence, such as small deletions of amino acids or replacement of amino acids by other amino acid residues. Also included are truncated forms of GH and derivatives thereof, as well as GH with amino acid additions to the amino- or carboxyl-terminal end of the protein, such as methionyl-hGH. Another type of hGH modification is that formed through the covalent addition of polyethylene glycol to reactive hGH amino acids (Davis et al., U.S. Pat. No. 4,179.,337).
DETAILED DESCRIPTION OF THE INVENTION
The method of preparation of liquid formulations of GH and stabilizing agents provided by the present invention results in a stable liquid GH formulation suitable for prolonged storage at temperatures below freezing and above freezing, and for, therapeutic administration. Therapeutic formulations containing these stabilizing agents are stable, while still allowing therapeutic administration of the formulation.
According to a preferred embodiment of the present invention the GH is hGH.
(1) Human Growth Hormone Compositions
The terms “human growth hormone” or “hGH” denote human growth hormone produced, for example, by extraction and purification of hGH from natural sources, or by recombinant cell culture systems. The sequence of hGH and its characteristics are described, for example, in Hormone Drugs, Gueriguigan et al, USP Convention, Rockville, Md. (1982). As described above, the terms also cover biologically active human growth hormone equivalents that differ in one or more amino acids in the overall sequence of hGH, including in particular met-hGH. The terms are also intended to cover substitution, deletion and insertion amino acid variants of hGH or post translational modifications. The hGH used in the formulations of the present invention is generally produced by recombinant means as previously discussed.
A “pharmaceutically effective amount” of GH, particularly hGH, refers to that amount which provides therapeutic effect in various administration regimens. The compositions of the present invention may be prepared containing amounts of GH at least about 0.1 mg/ml up to about 20 mg/ml or more, preferably from about 1 mg/ml to about 10 mg/ml, more particularly from about 1 mg/ml to about 5 mg/ml.
(2) Buffer and pH
The buffer may be any pharmaceutically acceptable buffering agent such as phosphate, tris-HCI, citrate and the like. The preferred buffer is a phosphate or citrate buffer. A buffer concentration greater than or equal to 2 mM and less than 50 mM is preferred, most advantageously 10-20 mM. Suitable pH ranges, adjusted with buffer, for the preparation of the formulations hereof are from about 5 to about 7.5, most advantageously about 5.6. The formulation pH should be less than 7.5 to reduce deamidation of GH.
(3) Stabilizing Agents
In accordance with the present invention, the formulation contains one or more stabilizing agents for enhanced GH stability. The stabilizing agent may be a polyoxyethylene-polyoxypropylene block copolymer non-ionic surfactant such as a Pluronic polyol, for example, Pluronics F127, F68, L64, PE6800 and PE6400, a bile salt such as a taurocholic acid salt or derivative thereof, or a methylcellulose derivative such as hydroxypropylmethylcellulose (HPMC). The formulation may contain a single stabilizing agent or a combination of two or more thereof.
The concentration of stabilizing agent(s) added will be determined by the selection of buffer and pH, but advantageously would be in the range of 0.01% to 5.0%, more preferably 0.05 to 2.0% and even more preferably 0.08 to 1.0%, on a weight to volume basis. The use of stabilizing agents improves formulation stability when subjected to prolonged storage over a range of temperatures, including below freezing and above freezing, or when the formulation is subjected to interfacial stress.
The stabilizing agent(s) improve formulation stability to interfacial stress with increasing concentration. However, increased stabilizing agent(s) concentration reduces chemical stability. In accordance with the present invention, the concentration of stabilizing agent(s) is optimised to achieve high stability to interfacial stress with minimum additional chemical instability.
(4) Preferred Formulation of Stabilizing Agents and hGH
In the preparation of a formulation in accordance with the present invention, one or more stabilizing agents are added to a hGH liquid formulation. As described above, during formulation, the growth hormone is exposed to buffer concentrations no greater than 2× the final concentration of buffer, and preferably the stabilizing agent(s) are added to the formulation immediately prior to final volume adjustment. The resulting formulations have enhanced stability to denaturation and are not susceptible to undesirable reactions that may be met during processing and storage. As used herein, the term processing includes filtration, filling of hGH solutions into vials and other manipulations involved in production of the formulations.
Liquid formulations of hGH for therapeutic administration may be prepared by combining hGH and stabilizing agents having the desired degree of purity with physiologically acceptable excipients, buffers or preservatives ( Remington's Pharmaceutical Sciences , 16th Edition, Osol, A. Ed (1980). Acceptable excipients are those which are nontoxic to the patient at the concentrations and dosages employed, and include buffers, preservatives, antioxidants, pH and tonicity modifiers.
The liquid formulation of growth hormone may also include one or more other stabilizing excipients if desired. Additional stabilizing excipients may include, for example, amino acids such as glycine or alanine, mannitol or other sugar alcohols, or glycerol. In addition, the liquid formulation may include other growth factors such as insulin-like growth factors or epidermal growth factor.
The preferred embodiment of the invention provides a means for effectively stabilizing hGH. The preferred formulation contains one or more stabilizing agents selected from Pluronic polyols, taurocholic acid or salts or derivatives thereof, and methylcellulose derivatives. The formulation preferably contains substantially pure hGH free of contaminating peptides or proteins or infectious agents found in humans. Formulations of this preferred embodiment may additionally contain pharmaceutically acceptable additives. These include, for example, buffers, isotonicity and pH modifiers, chelating agents, preservatives, antioxidants, cosolvents and the like, specific examples of these could include citrate salts, phosphate salts and the like. A preservative may be added where the anticipated use of the formulation may compromise sterility, and in such a case a pharmaceutically acceptable preservative such as benzyl alcohol or phenol may be used.
The increased stability of hGH provided by the formulation prepared in accordance with the present invention permits a wider use of hGH formulations that may be more concentrated than those commonly in use in the absence of stabilizing agents. For example, stabilized hGH liquid formulations also reduce the incidence of surface induced denaturation of hGH that occurs during aerosolisation or needleless injection of an hGH formulation. Further optimal dispensing of the hGH formulations may be made wherein the hGH formulations of the present invention are dispensed into vials at 1-50 mg/vial, preferably 2-25 mg/vial, and more preferably 3-10 mg/vial. The increased stability of hGH formulations permits long term storage at an appropriate temperature, such as below freezing (most preferably at −20° C.), or above freezing, preferably at 2-8° C., most preferably at 4° C.
Formulations of hGH to be used for in vivo administration must be sterile. This is readily accomplished by filtration through sterile filtration membranes.
Therapeutic hGH liquid formulations generally are placed into a container having a sterile access port, for example, an intravenous solution bag or vial having a stopper which can be pierced by a hypodermic injection needle.
The route of administration of the hGH liquid formulations in accordance with the present invention is in accord with known practice, e.g. injection or infusion by intravenous, intraperitoneal, intracerebral, intramuscular, intraocular, intraarterial, or intralesional routes, or by continuous IV infusion.
Further features of the present invention will be apparent from the following Examples, and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the chemical stability of hGH (1.5 mg/ml) in 5 mM phosphate buffer, pH 6.0-7.5.
FIG. 2 shows the dependence of aggregation of hGH (2 mg/ml in 10 mM acetate buffer, pH 4.1-4.5 or 5 mM phosphate buffer, pH 6.0-7.5) induced through interfacial stress (vortex agitation) on solution pH.
FIG. 3 summarizes graphically the ability of various stabilizing agents to reduce the precipitation of aggregated hGH induced through interfacial stress (vortex agitation).
FIG. 4 shows stability of two hGH (5 mg/ml) formulations which differ only in the method of introducing the hGH to the excipients, and a third hGH formulation to which 0.005% w/v EDTA has been added.
EXAMPLES
Example 1
Methods for Screening Stabilizing Agents
The ability of stabilizing agents to reduce or prevent GH and in particular hGH aggregation in response to interfacial stress has been evaluated using a rapid aggregation method and analyzed by size exclusion chromatography (SEC). Chromatography of hGH was conducted using two TSK G3000SW columns (7.8 mm i.d.×300 mm, Toyo Sodo, Japan) in series. The mobile phase consisted of 0.1 M phosphate, pH 7.0 buffer and was pumped at a flow rate of 0.9 ml/min. Elution of hGH was detected by UV absorbance at 214 nm using a sample volume of 20 μl.
The rapid aggregation method involved the introduction of a high air/water interface by vortex agitation of hGH solutions at constant speed for 15-60s in capped polypropylene tubes (11 mm i.d.×74 mm). Samples were equilibrated for 30 min at room temperature to allow precipitation to proceed, then were filtered through 0.2 μm cellulose acetate microcentrifuge filters and the filtrate was analyzed by SEC. Control solutions of each sample that did not receive treatment were included in SEC analysis.
The amount of total soluble hGH remaining (peak area of monomeric and higher molecular weight species) was expressed as a percentage of the total peak area (due to hGH) of the appropriate untreated control solution.
Table 1 shows the effect of various stabilizing agents on the extent of aggregation of hGH induced by interfacial stress at pH 7.0.
Table 2 shows the effect of various stabilizing agents on the extent of aggregation of hGH induced by interfacial stress at pH 6.0.
Table 3 shows the effect of various stabilizing agents on the extent of aggregation of hGH induced by interfacial stress at pH 5.6.
Table 4 shows the effect of isotonicity adjustment on the extent of aggregation of hGH (1.5 mg/ml) in various buffers at pH 5.6.
Table 5 shows the effect of various stabilizing agents on the extent of aggregation of hGH induced by freeze-thawing at pH 5.6.
As shown in the accompanying tables, a number of excipients were very effective at reducing or preventing aggregation of hGH induced by interfacial stress. Pluronic polyols provided near quantitative protection at concentrations above 0.05% w/v with monomeric hGH only remaining. Taurocholate, provided near quantitative protection at concentrations above 0.02% w/v with monomeric hGH only remaining. Taurodeoxycholate was not suitable as a stabilizer at a pH of 5.6 as it caused dimerisation of hGH in the absence of interfacial stress.
TABLE 1
Aggregation of hGH (1.5 mg/ml) in the presence of excipients
at pH 7.0 induced by interfacial stress.
% Total Soluble hGH
Concentration
Remaining
Species of hGH
Excipient
(mM
(% w/v)
(n = 2, SEC analysis)
Remaining
buffer
control
7.0 ± 1.15
(mean ± sd, n = 5)
Pluronic Polyols:
Pluronic F-127
1.4
1.75
100, 99.8
monomer only in
3.2
4.0
100, 100
all samples
Taurocholic Acid
Derivatives:
Taurocholate
1.3
0.07
75.3, 68.5
monomer only in
5
0.27
100, 100
all samples
75
4.0
100, 100
Taurodeoxycholate
0.4
0.02
13.7, 15.0
monomer only in
2
0.11
100, 100
all samples
30
1.6
100, 100
Methyl cellulose
derivatives:
Hydroxypropylmethyl-
0.01
0.1
44.1, 47.1
monomer only in
cellulose (HPMC)
0.05
0.5
98.9, 99.4
all samples
TABLE 2
Aggregation of hGH (1.5 mg/ml) in the presence of excipients
at pH 6.0 induced by interfacial stress.
% Total Soluble hGH
Concentration
Remaining
Species of hGH
Excipient
(mM
(% w/v)
(n = 2, SEC analysis)
Remaining
buffer
control
2.4 ± 2.05
(mean ± sd, n = 6)
Pluronic Polyols:
Pluronic F-127
0.01
0.01
3.34, 1.12
monomer only in all
0.04
0.05
93.7, 91.9
samples
0.08
0.1
100, 100
0.4
0.5
100, 99.6
1.6
2.0
98.5, 97.7
Pluronic F-68
0.01
0.01
1.2, 2.1
monomer only in all
0.06
0.05
86.4, 97.5
samples
0.12
0.1
98.6, 100
0.6
0.5
100, 99.7
Pluronic L-64
0.03
0.01
1.1, 1.4
monomer only in all
0.17
0.05
93.7, 79.4
samples
0.35
0.1
100, 100
1.7
0.5
100, 98.4
Pluronic PE-6800
0.12
0.1
98.7, 99.2
monomer only in all
0.6
0.5
99.6, 99.6
samples
2.4
2.0
100, 99.0
Pluronic PE-6400
0.35
0.1
100, 100
monomer only in all
1.7
0.5
100, 100
samples
Taurocholic Acid
Derivatives:
Taurocholate
1.3
0.07
16.8, 11.9
monomer only in all
6
0.34
98.5, 100
samples
15
0.84
97.8, 99.3
25
1.4
98.7, 99.1
Taurodeoxycholate
0.4
0.02
9.2, 4.9
2
0.10
22.6, 22.0
approximately 0.5%
6
0.31
87.2, 88.3
dimer
12
0.63
99.5, 100
approximately 4%
dimer
Methyl Cellulose
Derivatives:
HPMC
0.01
0.1
28.6, 24.0
monomer only in all
0.03
0.25
58.6, 63.4
samples
0.04
0.4
91.9, 93.6
TABLE 3
Aggregation of hGH (1.5 mg/ml) in the presence of excipients
at pH 5.6 induced by interfacial stress.
% Total Soluble hGH
Concentration
Remaining
Species of hGH
Excipient
(mM
(% w/v)
(n = 2, SEC analysis)
Remaining
buffer
control
0.79, 1.16
(mean ± sd, n = 2)
Pluronic Polyols:
0.04
0.05
69.6, 53.8
2% dimer present
0.08
0.1
99.5, 99.7
0.7% dimer
Pluronic F-127
0.4
0.5
99.5, 98.8
present monomer
only
Pluronic F-68
0.06
0.05
69.9, 66.8
monomer only in
0.12
0.01
99.3, 98.1
all samples
0.6
0.5
99.8, 100
Taurocholic Acid
Derivatives:
Taurocholate
5
0.27
99.7, 99.2
monomer only in
10
0.54
100, 100
all samples
25
1.4
99.4, 100
Taurodeoxycholate
2
0.10
95.7, 91.8*
6
0.32
92.1, 87.8*
7% dimer present
12
0.63
91.6, 84.4*
27% dimer
present
34% dimer
present
Methyl Cellulose
Derivatives:
HPMC
0.01
0.1
5.8, 2.1
monomer only in
0.03
0.25
34.8, 36.7
all samples
0.04
0.4
88.8, 88.4
*in the presence of taurodeoxycholate, dimerisation occurred in the absence of interfacial stress
Aggregation characteristics of hGH (1.5 mg/ml, pH 5.6) in citrate or phosphate (5 or 20 mM) buffers with or without added sodium chloride (to isotonicity) were investigated as aggregation has been reported to be dependent on phosphate concentration (Pearlman and Nguyen, 1992 , J. Pharm. Pharmacol . 44: 178-185).
The experimental method as described previously was followed with modification of treatment time (15 sec).
TABLE 4
Aggregation of hGH (1-5 mg/ml) in various buffer systems at pH 5.6.
% Total Soluble hGH Remaining a
Species of
Buffer system
no added NaCl
added NaCl
hGH present
5 mM phosphate
— b
44.5, 30.3
monomer only
5 mM citrate
18.9, 21.2
44.3, 46.4
monomer only
20 mM phosphate
28.5, 33.1
43.1, 38.7
monomer only
20 mM citrate
24.6, 33.2
55.5, 50.0
monomer only
a monomer plus higher molecular weight species
b insufficient hGH solubility.
Aggregation of hGH was not found to be dependent on the nature of the buffer or buffer concentration. Aggregation of hGH was inversely related to ionic strength (when adjusted with NaCl).
Aggregation of hGH (1.5 mg/ml in 20 mM isotonic citrate buffer, pH 5.6) in the presence of excipients induced by freeze-thawing was investigated. Samples of hGH (100 μl) in the presence of various excipients were frozen at −20° C. for 24 hr then thawed at room temperature and equilibrated for 30 min to allow precipitation to proceed. Analysis of filtered samples was conducted by SEC as described previously.
TABLE 5
Aggregation of hGH (1.5 mg/ml) in the presence of excipients
at pH 5.6 induced by freeze-thawing.
% Total Soluble hGH
Concentration
Remaining
Species of hGH
Excipient
(mM
(% w/v)
(n = 2, SEC analysis)
Remaining
buffer
control
98.8, 95.5
monomer only
Pluronic Polyols:
Pluronic F-127
0.08
0.1
95.9, 97.5
monomer only
Pluronic F-68
0.12
0.1
100, 100
monomer only
Taurocholic Acid
Derivatives:
Taurocholate
5
0.27
97.9, 100
monomer only
Taurodeoxycholate
2
0.1
95.7, 91.8
contains 24% dimer
MethylCellulose
Derivatives:
HPMC
0.03
0.25
97.2, 97.3
monomer only
Aggregation of hGH after freeze-thawing was not extensive but was not increased by the addition of excipients.
Example 2
FIG. 1 is a representative profile of the chemical stability of hGH (1.5 mg/ml) in 5 mM phosphate buffer, pH 6.0-7.5 (stored at 40° C.). Degraded samples were analyzed by reversed-phase high performance liquid chromatography (RP-HPLC) according to the method described in the United States Pharmacopoeia (USP 1990) using a Vydac C4 column. Degradation products were identified according to the method described in U.S. Pharmacopeial Previews, November-December, 1990, as desamido-hGH or oxidised hGH. The amount of native hGH (Panel A), desamido-hGH (Panel B) and oxidised-hGH (Panel C) present in a degraded sample was expressed as a percentage of peak area (for native hGH or degraded species) relative to the total peak area (due to hGH) for pH 6.0 (◯), pH 6.5 (), pH 7.0 (∇) and pH 7.5 (▾).
Loss of native hGH was found to follow first order kinetics in the pH range 6.0-7.5 and Arrhenius behaviour in the temperature range of 8-40° C. The first order rate constants at 40° C. were found to range from 2.4×10 −2 day −1 at pH 6.0 to 7.4×10 −2 day −1 at pH 7.5 Deamidation and oxidation were the major routes of degradation of hGH consistent with published reports (Pearlman and Nguyen, 1989, supra). Desamido-hGH formed at a faster rate than oxidised hGH. Chemical stability was enhanced at a pH value of 6.0 or below.
FIG. 2 shows aggregation and precipitation of hGH (2 mg/ml) in 10 mM acetate buffer (pH 4.14.5) or 5 mM phosphate buffer (pH 6.6-7.5) induced through interfacial stress using methods as described in Example 1. The amount of monomeric hGH (peak area due to monomer) or total soluble hGH (peak area due to monomer plus higher order aggregated species) remaining was expressed as a percentage relative to the peak area of the appropriate untreated control solution. The data represent the amount of soluble monomeric hGH (Panel A) or total soluble hGH (Panel B) remaining after vortexing for 30 s (◯) or 60 s ().
Aggregation and subsequent precipitation of hGH was maximal in the region of pH 5 to 6. Only monomeric hGH remained in solution after interfacial stress in the pH range of 4.16.0. Soluble aggregated species (dimer and higher order aggregates) were present mainly in the pH range of 7.0-7.5.
FIG. 3 shows the effect of excipients (% w/v) on aggregation of hGH (1.5 mg/ml in 5 mM phosphate buffer, pH 5.6) induced through interfacial stress by vortexing at constant speed for 60 s as described in FIG. 2 . The data represent the percentage of total soluble hGH (monomer plus higher order aggregated species) remaining after treatment expressed as a percentage relative to the peak area due to hGH from SEC analysis in the appropriate control solution in the presence of Pluronic F-68 (◯), Pluronic F-127 (), sodium taurocholate (∇) or HPMC (▾).
In the absence of excipients, less than 1% hGH remained in solution. Addition of Pluronic polyols, taurocholate or HPMC resulted in a substantial increase in soluble hGH remaining. Pluronics F-68 and F-127 and taurocholate, in particular, provided near quantitative protection of hGH against aggregation.
Example 3
FIG. 4 shows effect of method of formulation on stability of hGH formulations. Formulation 1 was prepared by concentrating purified hGH solution to 7-7.5 mg/mL and adding a two-fold concentrate of a solution containing all the excipients adjusted to a pH which produces a liquid formulation of pH 5.6 without further adjustment, and a final adjustment with water to achieve a final hGH concentration of 5 mg/ml.
Formulation 2 was prepared by buffer exchange, and purified hGH solution was concentrated to the desired concentration by exchange into a buffer which contained all the excipients (except Pluronic F-68) at the required concentration. Sufficient solid Pluronic F-68 was then added to give the required concentration. The pH was then checked and adjusted if necessary.
Formulations 1 and 2 have the same specifications:
hGH (Somatropin)
5
mg
citric acid monohydrate
2.04
mg/mL
trisodium citrate dihydrate
2.85
mg/mL
sodium chloride
6.23
mg/mL
sodium hydroxide
0.388
mg/mL
benzyl alcohol
0.9%
Pluronic F-68
0.08%
pH
5.6
Formulation 3 was prepared as for formulation 2 to the same specifications as formulations 1 and 2, with the addition of 0.005% w/v EDTA.
Formulations 1 to 3 were stored at 40° C. and tested for hGH content by size exclusion HPLC at intervals over 40 days. As shown in FIG. 4, formulation 2 and 3 showed superior stability, particularly in comparison with formulation 1, in this accelerated stability test at 40° C. | A method for the preparation of a stable, liquid formulation of growth hormone, comprising growth hormone, a buffer and a stabilizing effective amount of at least one stabilizing agent selected from the group consisting of: (i) polyethylene-polypropylene glycol non-ionic surfactants, (ii) taurocholic acid or salts or derivatives thereof, and (iii) methyl cellulose derivatives, wherein the method comprises admixing the growth hormone with the buffer and the stabilizing agent(s) under conditions such that the growth hormone is not exposed to concentrations of the buffer or stabilizing agent(s) which are greater than 2× the final concentrations of the buffer or stabilizing agent(s) in the formulation. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to a tire for vehicle wheels comprising an improved elastomeric component, wherein the elastomeric component preferably comprises a metal reinforcing element covered with an elastomeric composition comprising a tiodicarboxylic acid as an adhesion promoter.
BACKGROUND OF THE ART
[0002] It is well known in the art to reinforce rubber articles or products with metal elements such as steel cords. It is, of course, of the utmost importance to have a strong bond between the rubber and the metal element which should be maintained over a long period of time, even under severe aging or using conditions. One of the most important phenomena which causes a reduction of rubber-metal bonding is the oxidation of the metal surface, especially in the case of steel cords. These corrosion problems have generally been reduced by coating the steel wire with brass or other alloys.
[0003] Further improvement in the adhesion of rubber to coated wire, particularly brass plated steel wire, has been proposed.
[0004] For example, U.S. Pat. No. 4,075,159 to Koyama et al. discloses the addition of benzoic acid or monohydroxybenzoic acid to rubber to improve the adhesion of rubber to brass plated reinforcing elements.
[0005] U.S. Pat. No. 4,182,639 to Pignocco et al. discloses a method for improving the adhesion of brass-coated steel cord to rubber by coating the cord with specific combination of sulfur-containing rubber vulcanization accelerating agents and organic or inorganic phosphate corrosion inhibitors.
[0006] U.S. Pat. No. 4,513,123 discloses a sulfur-curable rubber skim stock which upon curing exhibits improved adhesion to brass-plated steel under high humidity, heat aging conditions. The sulfur-curable rubber skim stock comprises natural rubber or a blend of natural rubber and synthetic rubber, carbon black, an organo-cobalt compound, sulfur and a small amount of dithiodipropionic acid.
[0007] U.S. Pat. No. 4,532,080 to Delseth et al. discloses a method to increase the bond strength between a sulphur-vulcanizable rubber and a metal, especially brass, by using in the sulphur-vulcanizable rubber, as bonding promoter, an organic substance containing one or more groups of the formula —S—SO 2 R where R represents (a) a radical —OM where M is a monovalent metal, the equivalent of a multivalent metal, a monovalent ion derived by the addition of a proton to a nitrogenous base or the equivalent of a multivalent ion derived by the addition of two or more protons to a nitrogenous base, or (b) an organic radical.
[0008] U.S. Pat. No. 4,851,469 to Saitoh discloses the use of a combination of silica, a resorcin donor, a methylene donor and an organic sulfur-containing compound to improve the adhesion of sulfur-vulcanizable rubber to brass.
[0009] U.S. Pat. No. 5,085,905 to Beck discloses an elastomeric composition having improved adhesion to metal reinforcement, the elastomeric composition comprising an elastomer containing an adhesion promoting amount of a polysulfide.
[0010] U.S. Pat. No. 5,394,919 to Sandstrom et al. discloses a laminate of rubber and steel cord, which may be brass coated steel, where the rubber comprises an elastomer, carbon black, optionally silica, dithiodipropionic acid and methylene donor material. The combination of dithiodipropionic acid, carbon black, optionally silica, and the methylene donor is described to enhance the rubber adhesion to cord.
[0011] The Applicant has faced the technical problem of improving adhesion of crosslinked elastomeric materials to metals, particularly to metal reinforcing elements embedded in the elastomeric material.
[0012] Moreover, the Applicant has also faced the problem of improving adhesion between tyre components including crosslinked elastomeric materials. A small adhesion may occur when the tyre components include different elastomeric materials, but may also occur when the elastomeric materials are the same, such as in case of multilayer carcass structures or belt structures. The poor adhesion of different components comprising the same crosslinked elastomeric material can cause, for example, detachment of belt edges or carcass ply edges, in particular under heavy load and stressed conditions.
[0013] The Applicant has now found that the addition of a tiodicarboxylic acid to a crosslinkable elastomeric composition improves the adhesion of the resulting crosslinked elastomeric material to a metal reinforcing element embedded therein.
[0014] The Applicant has also found that the addition of said tiodicarboxylic acid allows to obtain crosslinked elastomeric materials which show improved adhesion to adjacent components present in the tire, the abovementioned detachments problems being so avoided.
[0015] Said improvements are obtained without having a negative impact on the remaining properties of said elastomeric compositions, in particular, mechanical properties (both static and dynamic), hysteresis, and hardness.
[0016] According to a first aspect, the present invention relates to a tire for vehicle wheels, comprising at least one elastomeric component comprising a crosslinked elastomeric material obtained by crosslinking an elastomeric composition comprising:
at least one diene elastomeric polymer; at least one sulfur-based vulcanizing agent, and at least one adhesion promoting agent having formula
[0000] HOOC—R—S—R′—COOH
[0000] wherein each of R and R′, equal or different from each other, is a divalent organic group.
[0020] In a preferred embodiment of the first aspect of the present invention, said elastomeric component comprises a metal reinforcing agent embedded therein.
[0021] According to a second aspect, the present invention relates to an elastomeric article comprising a crosslinkable elastomeric composition, said crosslinkable elastomeric composition comprising:
at least one diene elastomeric polymer; at least one sulfur-based vulcanizing agent, and at least one adhesion promoting agent having formula
[0000] HOOC—R—S—R′—COOH
[0000] wherein each of R and R′, equal or different from each other, is a divalent organic group.
[0025] In a preferred embodiment of the second aspect of the present invention, said elastomeric article comprises a metal reinforcing agent embedded therein.
[0026] According to a further aspect, the present invention relates to a crosslinkable elastomeric composition comprising:
at least one diene elastomeric polymer; at least one sulfur-based vulcanizing agent, and at least one compound having formula
[0000] HOOC—R—S—R′—COOH
[0000] wherein each of R and R′, equal or different from each other, is a divalent organic group.
[0030] When the term “group” is used in this invention to describe a chemical compound or substituent, the described chemical material includes the basic group and that group with conventional substitution. For example, “alkyl group” includes not only the unsubstituted alkyl as methyl, ethyl, octyl, tearyl, etc., but also the alkyl bearing substituents groups such as halogen, cyano, hydroxy, nitro, amino, carboxylate, and the like.
[0031] According to one preferred embodiment, each of R and R′ is a divalent organic group having an aliphatic structure or an aromatic structure.
[0032] Preferably, aliphatic groups represented by R and R′ may comprise from 1 to 12 carbon atoms and may include a linear, branched, or cyclic structure. Further preferably, aromatic groups represented by R and R′ may comprise from 6 to 14 carbon atoms.
[0033] Divalent organic groups having a linear or branched alkylene structure include, for example, methylene, ethylene, propane-1,1-diyl, propane-1,2-diyl, propane-1,3-diyl, butane-1,1-diyl, butane-1,2-diyl, butane-1,3-diyl, butane-1,4-diyl, pentane-1,1-diyl, pentane-1,2-diyl, pentane-1,3-diyl, pentane-1,4-diyl, pentane-1,5-diyl, hexane-1,1-diyl, hexane-1,2-diyl, hexane-1,3-diyl, hexane-1,4-diyl, hexane-1,5-diyl, hexane-1,6-diyl, octane-1,8-diyl, dodecane-1,12-diyl, and the like.
[0034] Divalent organic groups having a cyclic alkylene structure include, for example, cyclopropane-1,1-diyl, cyclopropane-1,2-diyl, cyclobutane-1,1-diyl, cyclobutane-1,2-diyl, cyclobutane-1,3-diyl, cyclopentane-1,1-diyl, cyclopentane-1,2-diyl, cyclopentane-1,3-diyl, cyclohexane-1,1-diyl, cyclohexane-1,2-diyl, cyclohexane-1,3-diyl, cyclohexane-1,4-diyl, and the like.
[0035] Divalent organic groups having an aromatic structure include, for example, phenylene, naphthylene, biphenylene, and polyphenylene.
[0036] These divalent organic groups may include a group having an element other than a carbon atom and a hydrogen atom, such as, for example, oxygen, nitrogen, sulfur and the like. Examples of such groups include hydroxide group (—OH), ether group (—O—), mercapto group (—SH), thio group (—S—), sulfinyl group (—SO—), sulfonyl group (—SO 2 —), sulfo group (—SO 3 H), carboxy group (—COOH), carbonyl group (—CO—), oxycarbonyl group (—O—CO—), nitro group (—NO 2 ), amino group (—NH 2 ), imino group (—NH—), imido group, (═NH), amido group (—CONH 2 ), halogen atoms (Br—, Cl—, I—, F—), and the like.
[0037] According to a more preferred embodiment, R and R′ are selected from the group comprising methylene, propylene, cyclohexylene, and phenylene.
[0038] Useful adhesion promoting agents include the following exemplified, but not limitative compounds:
[0000]
[0039] The adhesion promoters defined above are very effective in promoting bonding between the crosslinked elastomeric material and other tyre components comprising similar or different crosslinked elastomeric material as well as between the crosslinked elastomeric material and metal reinforcing elements embedded therein.
[0040] Said adhesion promoter is present in the crosslinkable elastomeric composition of the present invention in an amount generally of from 0.1 phr to 10 phr, preferably from 0.2 phr to 5 phr.
[0041] The metal reinforcing elements used in the practice of this invention can have a wide variety of structural configurations, but will generally be a metal elongated element such as, for example, a cord, a strand, or a wire. For example, a wire cord used in the practice of this invention can be composed of 1 to 50 or even more filaments of metal wire which are twisted together to form a metal cord. Therefore, such a cord can be monofilament in nature, or can be composed of multiple filaments, or multiple strands or a combination of filaments and strands. For example, the cords used in automobile tires generally are composed of three to six twisted filaments, the cords used in truck tires normally contain 10 to 30 twisted filaments, and the cords used in giant earth mover tires generally contain 40 to 50 twisted filaments.
[0042] The metal generally used in the reinforcing elements of this invention is steel. The term “steel” as used in the present specification and claims refers to what is commonly known as carbon steel, which is also called high-carbon steel, ordinary steel, straight carbon steel, and plain carbon steel. An example of such a steel is American Iron and Steel Institute Grade 1070-high-carbon steel (AISI 1070). Such steel owes its properties chiefly to the presence of carbon without substantial amounts of other alloying elements. It is generally preferred for steel reinforcements to be individually coated or plated with transition or post-transition metals or alloy thereof. Some representative examples of suitable metals include: zirconium, cerium, lanthanum, manganese, molybdenum, nickel, cobalt, tin, titanium, zinc, and copper. Some representative examples of suitable alloys thereof include brass and bronze. Brass is an alloy of copper and zinc which can contain other metals in varying lesser amounts and bronze is an alloy of copper and tin which sometimes contains traces of other metals. The metal reinforcements which are generally most preferred for use in the practice of this invention are brass plated carbon steels. The brass typically has a copper content of from 60 to 70% by weight, more especially from 63 to 68% by weight, with the optimum percentage depending on the particular conditions under which the bond is formed. The brass coating on brass-coated steel can have a thickness of, for example, from 0.05 to 1 micrometer, preferably from 0.07 to 0.7 micrometer, for example from 0.15 to 0.4 micrometer.
[0043] According to one preferred embodiment, the diene elastomeric polymer which may be used in the present invention may be selected from those commonly used in sulfur-crosslinkable elastomeric compositions, that are particularly suitable for producing tires, that is to say from elastomeric polymers or copolymers with an unsaturated chain having a glass transition temperature (Tg) generally below 20° C., preferably in the range of from 0° C. to −110° C. These polymers or copolymers may be of natural origin or may be obtained by solution polymerization, emulsion polymerization or gas-phase polymerization of one or more conjugated diolefins, optionally blended with at least one comonomer selected from monovinylarenes and/or polar comonomers in an amount of not more than 60% by weight.
[0044] The conjugated diolefins generally contain from 4 to 12, preferably from 4 to 8 carbon atoms, and may be selected, for example, from the group comprising: 1,3-butadiene, isoprene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene, 1,3-hexadiene, 3-butyl-1,3-octadiene, 2 phenyl-1,3-butadiene, or mixtures thereof.
[0045] Monovnylarenes which may optionally be used as co-monomers generally contain from 8 to 20, preferably from 8 to 12 carbon atoms, and may be selected, for example, from: styrene; 1-vinylnaphthalene; 2-vinylnaphthalene; various alkyl, cycloalkyl, aryl, alkylaryl or arylalkyl derivatives of styrene such as, for example, α-methylstyrene, 3-methylstyrene, 4-propylstyrene, 4-cyclohexylstyrene, 4-dodecylstyrene, 2-ethyl-4-benzylstyrene, 4-p-tolylstyrene, 4-(4-phenylbutyl)styrene, or mixtures thereof. Polar comonomers which may optionally be used may be selected, for example, from: vinylpyridine, vinylquinoline, acrylic acid and alkylacrylic acid esters, nitriles, or mixtures thereof, such as, for example, methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate, acrylonitrile, or mixtures thereof.
[0046] Preferably, the diene elastomeric polymer or copolymer may be selected, for example, from: cis-1,4-polyisoprene (natural or synthetic, preferably natural rubber), 3,4-polyisoprene, polybutadiene (in particular polybutadiene with a high 1,4-cis content), optionally halogenated isoprene/isobutene copolymers, 1,3-butadiene/acrylonitrile copolymers, styrene/1,3-butadiene copolymers, styrene/isoprene/1,3-butadiene copolymers, styrene/1,3-butadiene/acrylonitrile copolymers, or mixtures thereof.
[0047] The crosslinkable elastomeric composition according to the present invention may optionally comprises at least one elastomeric polymer of one or more monoolefins with an olefinic comonomer or derivatives thereof, which have been already disclosed above. Among these, the following are particularly preferred: ethylene/propylene copolymers (EPR) or ethylene/propylene/diene copolymers (EPDM); polyisobutene; butyl rubbers; halobutyl rubbers, in particular chlorobutyl or bromobutyl rubbers; or mixtures thereof.
[0048] A diene elastomeric polymer or copolymer or an elastomeric polymer selected from those above disclosed which has been functionalized by reaction with at least one suitable terminating agent or coupling agent may also be used. In particular, the diene elastomeric polymers or copolymers obtained by anionic polymerization in the presence of an organometallic initiator (in particular an organolithium initiator) may be functionalized by reacting the residual organometallic groups derived from the initiator with at least one suitable terminating agent or coupling agent selected, for example, from: imines, carbodiimides, alkyltin halides, substituted benzophenones, alkoxysilanes or aryloxysilanes (see, for example, European Patent EP 451,604, or Patents U.S. Pat. No. 4,742,124 and U.S. Pat. No. 4,550,142).
[0049] For the purposes of the present description and of the claims, the term “phr” means the parts by weight of a given component of the crosslinkable elastomeric composition per 100 parts by weight of the diene elastomeric polymer.
[0050] According to one preferred embodiment, the sulfur-based vulcanizing agent may be selected from sulfur or derivatives thereof such as, for example:
soluble sulfur (crystalline sulfur); insoluble sulfur (polymeric sulfur); sulfur dispersed in oil (for example a dispersion of 33% sulfur in oil known under the trade name Crystex® OT33 from Flexsys); sulfur donors such as, for example, tetramethylthiuram disulfide (TMTD), tetrabenzylthiuram disulfide (TBzTD), tetraethylthiuram disulfide (TETD); tetrabutylthiuram disulfide (TBTD), dimethyldiphenyl-thiuram disulfide (MPTD), pentamethylenethiuram tetra-sulfide or hexasulfide (DPTT), morpholinobenzothiazole disulfide (MBSS), N-oxydiethylenedithiocarbamyl-N′-oxydiethylene-sulphenamide (OTOS), dithiodimorpholine (DTM or DTDM), caprolactam disulfide (CLD).
[0055] Said sulfur-based vulcanizing agent is present in the crosslinkable elastomeric composition of the present invention in an amount generally of from 0.5 phr to 5 phr, preferably from 1 phr to 3 phr.
[0056] At least one reinforcing filler may be advantageously added to the crosslinkable elastomeric composition of the present invention, in an amount generally of from 0.1 phr to 120 phr, preferably from 20 phr to 90 phr. The reinforcing filler may be selected from those commonly used for crosslinked manufactured products, in particular for tires, such as, for example, carbon black, silica, alumina, aluminosilicates, calcium carbonate, kaolin, or mixtures thereof.
[0057] The types of carbon black which may be used in the present invention may be selected from those conventionally used in the production of tires, generally having a surface area of not less than 20 m 2 /g (determined by CTAB absorption as described in Standard ISO 6810:1995).
[0058] The silica which may be used in the present invention may be, generally, a pyrogenic silica or, preferably, a precipitated silica, with a BET surface area (measured according to Standard ISO standard 5794-1:1994) of from 50 m 2 /g to 500 m 2 /g, preferably from 70 m 2 /g to 200 m 2 /g.
[0059] The crosslinkable elastomeric composition of the present invention may be vulcanized according to known techniques. To this end, in the composition, after a first stage of thermal-mechanical processing, a sulfur-based vulcanizing agent is incorporated together with vulcanization accelerators and activators. In this second processing stage, the temperature is generally kept below 120° C. and preferably below 100° C., so as to avoid any unwanted pre-crosslinking phenomena.
[0060] Activators that are particularly effective are zinc compounds, and in particular ZnO, ZnCO 3 , zinc salts of saturated or unsaturated fatty acids containing from 8 to 18 carbon atoms, such as, for example, zinc stearate, which are preferably formed in situ in the elastomeric composition from ZnO and fatty acid, and also BiO, PbO, Pb 3 O 4 , PbO 2 , or mixtures thereof. Accelerators that are commonly used may be selected from: dithiocarbamates, guanidine, thiourea, thiazoles, sulfenamides, thiurams, amines, xanthates, or mixtures thereof.
[0061] The crosslinkable elastomeric composition according to the present invention may comprise other commonly used additives selected on the basis of the specific application for which the composition is intended. For example, the following may be added to said composition: antioxidants, anti-aging agents, plasticizers, adhesives, anti-ozone agents, modifying resins, fibers (for example Kevlar® pulp), or mixtures thereof.
[0062] In particular, for the purpose of further improving the processability, a plasticizer generally selected from mineral oils, vegetable oils, synthetic oils, or mixtures thereof, such as, for example, aromatic oil, naphthenic oil, phthalates, soybean oil, or mixtures thereof, may be added to the crosslinkable elastomeric composition according to the present invention. The amount of plasticizer generally ranges from 2 phr to 100 phr, preferably from 5 phr to 50 phr.
[0063] The crosslinkable elastomeric composition according to the present invention may be prepared by mixing together the elastomeric polymeric materials, the sulfur-based vulcanizing agent, and the adhesion promoting agent with the other additives according to techniques known in the art. The mixing may be carried out, for example, using an open mixer of open-mill type, or an internal mixer of the type with tangential rotors (Banbury) or with interlocking rotors (Intermix), or in continuous mixers of Ko-Kneader type (Buss) or of co-rotating or counter-rotating twin-screw type.
BRIEF DESCRIPTION OF THE DRAWING
[0064] The present invention will now be illustrated in further detail by means of an illustrative embodiment, with reference to the attached FIG. 1 , which is a view in cross section of a portion of a tire made according to the invention.
[0065] “a” indicates an axial direction and “r” indicates a radial direction. For simplicity, FIG. 1 shows only a portion of the tire, the remaining portion not represented being identical and symmetrically arranged with respect to the radial direction “r”.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] The tire ( 100 ) comprises at least one carcass ply ( 101 ) shaped in a substantially toroidal configuration, the opposite lateral edges of which are associated with respective Bead wires ( 102 ). The association between the carcass ply ( 101 ) and the bead wires ( 102 ) is achieved here by folding back the opposite lateral edges of the carcass ply ( 101 ) around the bead wires ( 102 ) so as to form the so-called carcass back-folds ( 101 a ) as shown in FIG. 1 .
[0067] Alternatively, the bead wires ( 102 ) can be replaced with a pair of annular inserts formed from elongate components comprising a metal reinforcing element and a crosslinkable elastomeric composition according to the present invention arranged in concentric coils (not represented in FIG. 1 ) (see, for example, European Patent Applications EP 928,680 and EP 928,702). In this case, the carcass ply ( 101 ) is not back-folded around said annular inserts, the coupling being provided by a second carcass ply (not represented in FIG. 1 ) applied externally over the first.
[0068] The carcass ply ( 101 ) generally consists of a plurality of reinforcing elements arranged parallel to each other and at least partially coated with a layer of elastomeric compound according to the present invention. These reinforcing elements are often made of steel wires stranded together, coated with a metal alloy (for example copper/zinc, zinc/manganese, zinc/molybdenum/cobalt alloys, and the like).
[0069] The carcass ply ( 101 ) is usually of radial type, i.e. it incorporates elastomeric articles according to the present invention arranged in a substantially perpendicular direction relative to a circumferential direction. Each bead wire ( 102 ) is enclosed in a bead ( 103 ), defined along an inner circumferential edge of the tire ( 100 ), with which the tire engages on a rim (not represented in FIG. 1 ) forming part of a vehicle wheel. The space defined by each carcass back-fold ( 101 a ) contains a bead filler ( 104 ) wherein the bead wires ( 102 ) are embedded. An antiabrasive strip ( 105 ) is usually placed in an axially external position relative to the carcass back-fold ( 101 a ).
[0070] A belt structure ( 106 ) is applied along the circumference of the carcass ply ( 101 ). In the particular embodiment in FIG. 1 , the belt structure ( 106 ) comprises two belt strips ( 106 a, 106 b ) which incorporate a plurality of elastomeric articles according to the present invention, typically comprising a metal cord and a crosslinkable elastomeric component, which are parallel to each other in each strip and intersecting with respect to the adjacent strip, oriented so as to form a predetermined angle relative to a circumferential direction. On the radially outermost belt strip ( 106 b ) may optionally be applied at least one zero-degree reinforcing layer ( 106 c ), commonly known as a “0° belt”, which generally incorporates a plurality of reinforcing cords, typically textile cords, arranged at an angle of a few degrees relative to a circumferential direction, and coated and welded together by means of an elastomeric material.
[0071] A side wall ( 108 ) is also applied externally onto the carcass ply ( 101 ), this side wall extending, in an axially external position, from the bead ( 103 ) to the end of the belt structure ( 106 ).
[0072] A tread band ( 109 ), whose lateral edges are connected to the side walls ( 108 ), is applied circumferentially in a position radially external to the belt structure ( 106 ). Externally, the tread band ( 109 ) has a rolling surface ( 109 a ) designed to come into contact with the ground. Circumferential grooves which are connected by transverse notches (not represented in FIG. 1 ) so as to define a plurality of blocks of various shapes and sizes distributed over the rolling surface ( 109 a ) are generally made in this surface ( 109 a ), which is represented for simplicity in FIG. 1 as being smooth.
[0073] A strip made of elastomeric material ( 110 ), commonly known as a “mini-side wall”, may optionally be present in the connecting zone between the side walls ( 108 ) and the tread band ( 109 ), this mini-side wall generally being obtained by co-extrusion with the tread band and allowing an improvement in the mechanical interaction between the tread band ( 109 ) and the side walls ( 108 ). Alternatively, the end portion of the side wall ( 108 ) directly covers the lateral edge of the tread band ( 109 ).
[0074] A layer of elastomeric material ( 111 ) which serves as an “attachment sheet”, i.e. a sheet capable of providing the connection between the tread band ( 109 ) and the belt structure ( 106 ), may be placed between the tread band ( 109 ) and the belt structure ( 106 ).
[0075] In the case of tubeless tires, a rubber layer ( 112 ) generally known as a “liner”, which provides the necessary impermeability to the inflation air of the tire, may also be provided in a radially internal position relative to the carcass ply ( 101 ).
[0076] The process for producing the tire according to the present invention may be carried out according to techniques and using apparatus that are known in the art, as described, for example, in European Patent EP 199,064 and in Patents U.S. Pat. No. 4,872,822, U.S. Pat. No. 4,768,937, said process including at least one stage of manufacturing the green tire and at least one stage of vulcanizing this tire. Alternative processes for producing a tire or parts of a tire without using semi-finished products are disclosed, for example, in the above mentioned Patent Applications EP 928,680 and EP 928,702.
[0077] Although the present invention has been illustrated specifically in relation to a tire, other crosslinked elastomeric manufactured products that may be produced according to the invention may be, for example, belts such as, conveyor belts, power belts or driving belts; flooring and footpaths which may be used for recreational area, for industrial area, for sport or safety surfaces; flooring tiles; mats such as, antistatic computer mats, automotive floor mats; mounting pads; shock absorbers sheetings; sound barriers; membrane protections; shoe soles; carpet underlay; automotive bumpers; wheel arch liner; seals such as, automotive door or window seals; o-rings; gaskets; watering systems; pipes or hoses materials; flower pots; building blocks; roofing materials; geomembranes; and the like.
[0078] The present invention will be further illustrated below by means of a number of preparation examples, which are given for purely indicative purposes and without any limitation of this invention.
EXAMPLE 1
Adhesion of the Vulcanized Elastomeric Material
[0079] The adhesion of the vulcanized elastomeric material to steel cords was measured on test pieces of vulcanized mixture on a brass coated steel cord made of 3 wires having a diameter of 0.28 mm), using the method described in “Kautschk and Gummi Kunststoffe”, 5, 228-232, (1969), which measures the force required to remove a cord from a cylinder of vulcanized rubber.
[0080] The “pull-out force” was measured in Newtons using an electronic dynamometer. The values were measured both on freshly prepared vulcanized test pieces and on test pieces after age-hardening for sixteen days at a temperature of 65° C. and at 90% relative humidity (R.H.). The measure was repeated on ten different test pieces and the results were averaged.
[0081] The composition of the mixture which formed the vulcanized rubber was, in parts % by weight, as described in the following Table 1:
[0000]
TABLE 1
Sample
1
2
3
4
5
(Ref.)
(Inv.)
(Inv.)
(Comp.)
(Inv.)
Natural rubber
100.00
100.00
100.00
100.00
100.00
Carbon black
60.00
60.00
60.00
60.00
60.00
ZnO
10.00
10.00
10.00
10.00
10.00
Cobalt salt
1.00
1.00
1.00
1.00
1.00
6-PPD
1.00
1.00
1.00
1.00
1.00
DCBS
1.50
1.50
1.50
1.50
1.50
PVI
0.20
0.20
0.20
0.20
0.20
Sulphur
5.00
5.00
5.00
5.00
5.00
Thiodipropionic acid
—
0.50
2.50
—
—
Dithiodipropionic acid
—
—
—
0.50
—
Tiodibenzoic acid
—
—
—
—
0.50
Ref.: Reference
Comp.: Comparison (as suggested in U.S. Pat. No. 5,394,919)
Inv.: Invention
6-PPD (antioxidant): N-(1,3-dimethylbutyl)-N′-phenyl-p-phenylenediamine;
PVI (retardant): N-cyclohexylthiophthalimide (San-togard ® PVI - Flexys);
DCBS (accelerator): benzothiazyl-2-dicyclohexyl-sulfenamide (Vulkacit ® DZ/EGC - Lanxess).
[0082] The results are shown in Tables 2 for fresh samples and on Table 3 for aged samples.
[0000]
TABLE 2
Average
Fresh
Pull-out
Sample
Force
Coverage
1
264
100%
2
288
100%
3
288
100%
4
276
100%
5
283
100%
[0000]
TABLE 3
Average
Aged
Pull-out
Sample
Force
Coverage
1
204
90%
2
233
100%
3
246
100%
4
241
90%
5
243
95%
EXAMPLE 2
[0083] The static mechanical properties according to Standard ISO 37:1994 as well as hardness in IRHD degrees at 23° C. according to ISO standard 48:1994, were measured on samples of the above mentioned elastomeric compositions vulcanized at 170° C. for 10 min. The results are given in Table 4.
[0084] The crosslinkable elastomeric compositions were also subjected to MDR rheometric analysis using a Monsanto MDR rheometer, the tests being carried out at 170° C. for 20 minutes at an oscillation frequency of 1.66 Hz (100 oscillations per minute) and an oscillation amplitude of ±0.5°°, measuring the minimum and maximum torque (ML and MH) and the time required to reach 30%, 60%, and 90% of the final torque value (T30, T60, and T90). The results are given in Table 4.
[0085] Table 4 also shows the dynamic mechanical properties, measured using an Instron dynamic device in the traction-compression mode according to the following methods. A test piece of the crosslinked elastomeric composition obtained as disclosed above (vulcanized at 170° C. for 10 min) having a cylindrical form (length=25 mm; diameter=14 mm), compression-preloaded up to a 25% longitudinal deformation with respect to the initial length, and kept at the prefixed temperature (23° C. or 70° C.) for the whole duration of the test, was submitted to a dynamic sinusoidal strain having an amplitude of ±3.5% with respect to the length under preload, with a 100 Hz frequency. The dynamic mechanical properties are expressed in terms of dynamic elastic modulus (E′) and Tan delta (loss factor) values. The Tan delta value is calculated as a ratio between viscous modulus (E″) and elastic modulus (E′).
[0086] Furthermore, the crosslinkable elastomeric compositions obtained as disclosed above were subjected to adhesion (peeling) tests.
[0087] Using the elastomeric compositions obtained as described above, two-layer test pieces were prepared for measuring the peel force, by superimposing two layers of the same non-crosslinked elastomeric composition, followed by crosslinking (at 170° C., for 10 minutes). In detail, the test pieces were prepared as follows. Each elastomeric composition was calendered so as to obtain a sheet with a thickness equal to 3 mm±0.2 mm. From the sheet thus produced were obtained plates with dimensions equal to 220 mm (±1.0 mm)×220 mm (±1.0 mm)×3 mm (±0.2 mm), marking the direction of the calendering. One side of each plate was protected with a polyethylene sheet, while a reinforcing fabric made of rubberized polyamide with a thickness of 0.88 mm±0.05 mm was applied to the opposite side, orienting the strands in the direction of calendering and rolling the composite thus assembled so as to achieve good adhesion between the fabric and the non-crosslinked elastomeric composition. After cooling, sheets were produced from the composite thus obtained, by punching, these sheets having dimensions equal to 110 mm (±1.0 mm)×25 mm (±1.0 mm)×3.88 mm (±0.05 mm), taking care to ensure that the major axis of each sheet was oriented in the direction of the strands of the fabric.
[0088] A first sheet made of the crosslinkable elastomeric composition obtained as disclosed above constituting the first layer was placed in a mould, the polyethylene film was removed, two Mylar® strips acting as lateral separators (thickness=0.2 mm) were applied laterally and a third strip again made of Mylar® (thickness=0.045 mm) was applied to one extremity of the sheet in order to create a short free section not adhering to the second layer. A second sheet made of the same crosslinkable elastomeric composition above disclosed, from which the polyethylene film was previously removed, was then applied to the first sheet thus prepared, constituting the second layer (the first layer and the second layer being made of the same crosslinkable elastomeric composition), thus obtaining a test piece which was then crosslinked by heating at 170° C., for 10 min, in a press.
[0089] Subsequently, the test pieces crosslinked as described above were conditioned at room temperature (23° C.±2° C.) for at least 16 hours and were then subjected to the peel test using a Zwick 2005 dynamometer, the clamps of which were applied to the free section of each layer. A traction speed equal to 260 mm/min±20 mm/min was then applied and the peel force values thus measured, expressed in Newtons (N), are given in Table 4 and are each the average value calculated for 4 test pieces. The same tests were carried out on the test pieces crosslinked as described above and conditioned at 100° C. for at least 16 hours: the obtained results were given on Table 4 and are each the average value calculated for 4 test pieces.
[0000]
TABLE 4
SAMPLE
1 (Ref.)
2 (Inv.)
4 (Comp.)
5 (Inv.)
100% Modulus
5.041
5.167
5.383
4.973
(CA1) (MPa)
Stress at break
16.130
15.306
16.306
15.713
(MPa)
Elongation at
271.75
276.94
285.57
294.14
break (%)
ML (dN m)
2.760
2.270
2.120
2.140
MH (dN m)
33.430
33.080
33.680
31.070
T30 (min)
1.390
1.460
1.430
1.140
T60 (min)
1.910
2.010
2.030
1.570
T90 (min)
3.220
3.360
3.500
2.700
E′ (23° C.)
10.899
10.795
10.994
10.211
E′ (70° C.)
9.031
8.939
9.118
8.456
Tan delta (23° C.)
0.179
0.203
0.199
0.196
Tan delta (70° C.)
0.105
0.118
0.117
0.112
Peeling (23° C.)
210.0
198.0
156.1
218.1
Peeling (100° C.)
124.7
132.7
101.5
141.3 | A tire for vehicle wheel includes at least one elastomeric component including a crosslinked elastomeric material obtained by crosslinking an elastomeric composition including at least one diene elastomeric polymer; at least one sulfur-based vulcanizing agent, and at least one adhesion promoting agent having formula HOOC—R—S—R′—COOH wherein each of R and R′, equal or different from each other, is a divalent organic group. In a preferred embodiment of the first aspect of the present invention, the elastomeric component includes a metal reinforcing agent embedded therein. | 8 |
PRIORITY CLAIM
[0001] The present application is a non-provisional utility patent application, claiming the benefit of priority of U.S. Provisional Patent Application No. 60/1715,370, filed Sep. 7, 2005, titled, “ELECTRO-OPTIC IMAGING FOURIER TRANSFORM SPECTROMETER (EOIFTS) FOR HYPERSPECTRAL IMAGING.”
GOVERNMENT RIGHTS
[0002] The invention described herein was made in the performance of work under a NASA contract, and is subject to the provisions of Public Law 96-517 (35 USC 202) in which the Contractor has elected to retain title.
BACKGROUND OF THE INVENTION
[0003] (1) Field of Invention
[0004] The present invention relates to a Spectrometer and more particularly to an electro-optic imaging Fourier transform spectrometer comprising a single optical path in which the intensity of light that exits the spectrometer after the light traverses an input polarizer, a series of adjustable birefringent phase retarders. and an output polarizer is simply related by the total optical phase delay to a portion of the frequency spectrum of the light.
[0005] (2) Description of Related Art
[0006] Fourier transform spectrometers (FTS) have long been known in the art. FTSs require large changes in total optical path length traversed by a beam of electromagnetic radiation. This has typically been accomplished by scanning Michelson interferometers in which one mirror of the interferometer is physically moved to change its length. Such an interferometer design has the advantage that a large, continuous band of frequencies can be resolved by scanning large distances with the great precision usually enjoyed by modem mechanical devices. However, because of the necessity to move large distances, such interferometers tend to be very large, heavy, slow, have many moving parts, require ultra-precise alignment, and consume relatively large amounts of power to operate.
[0007] The motivation for the present invention was partially born from a need to take a FTS into orbit around Earth and every problem mentioned in the above paragraph becomes exacerbated in the context of space missions: being large and heavy significantly increases the cost of launching the FTS into orbit; as the satellites typically orbit through the atmosphere at speeds upwards of 17,000 miles per hour, they can pass through relevant samples very quickly, requiring faster-than-normal operational scanning speeds; many moving parts makes mechanical failure more likely during the violent launch period; once launched, the satellites must function on their own without human intervention, making any alignment tolerances problematic as they cannot ever be realigned; and lastly, large power consumption means that, for a given mission lifetime, either more fuel must be taken along with the satellite or larger solar panels must be used in orbit, both of which drastically increase the cost of a space mission.
[0008] In addition to the shortcomings of modem FTSs with regard to space missions, the same shortcomings of commercial FTSs and wave-meters, namely that they are expensive, large, and slow, are notable in the modem-day research laboratory.
[0009] Thus, a continuing need exists for an improved FTS that is more compact, lighter-weight, faster, has fewer moving parts, is less sensitive to alignment, and consumes less power than the FTSs that are currently available.
SUMMARY OF INVENTION
[0010] The present invention relates to a spectrometer. The spectrometer comprises an input polarizer. The input polarizer includes an input polarizer center point, an input polarizer axis through the input polarizer center point, and an input polarizer azimuth vector originating on the input polarizer center point. The input polarizer azimuth vector points substantially perpendicular to the input polarizer axis. The spectrometer also comprises an output polarizer. The output polarizer includes an output polarizer center point, an output polarizer axis through the output polarizer center point, and an output polarizer azimuth vector, which originates on the output polarizer center point and points substantially perpendicular to the output polarizer axis. The output polarizer output polarizer axis is substantially collinear with the input polarizer axis, thus defining a long axis with an input end proximate the input polarizer and an output end proximate the output polarizer. The long axis projects through the input polarizer center point and the output polarizer center point. The long axis further defines an input polarizer orientation between the input polarizer azimuth vector and the long axis and an output polarizer orientation between the output polarizer azimuth vector and the long axis.
[0011] The spectrometer also comprises a plurality of birefringent phase elements residing between the input polarizer and the output polarizer. The birefringent phase elements include a birefringent phase element center point and a birefringent phase element azimuth vector originating on the birefringent phase element center point. The birefringent phase element azimuth vector point substantially perpendicular to the long axis, thus defining a birefringent phase element orientation between the birefringent phase element azimuth vector and the long axis. At least one orientation is selected from the group consisting of the input polarizer orientation, the output polarizer orientation, and any of the birefringent phase element orientations, allowing the user to substantially reproduce Fourier components of frequency spectra of light passing fully through spectrometer substantially parallel to the long axis.
[0012] In another aspect, the spectrometer further comprises a controller. The controller is operably connected with at least one element selected from the group consisting of the input polarizer, the output polarizer, and any of the birefringent phase elements. The controller can change the orientation of any element to which it is operably connected.
[0013] In yet another aspect, each birefringent phase element comprises an achromatic switch and a birefringent phase retarder. The birefringent phase retarder is substantially adjacent to the achromatic switch. The birefringent phase element is oriented such that the achromatic switch is nearer the output end of the long axis than the birefringent phase retarder.
[0014] In yet another aspect, the birefringent phase element adjacent to the input polarizer has an achromatic switch with phase retardance of substantially 90 degrees and all other birefringent phase elements have achromatic switches with phase retardances of substantially 180 degrees.
[0015] In yet another aspect, there are an integer N of birefringent phase elements, and for every integer, j, from 0 to N, there is exactly one birefringent phase element with an achromatic switch with phase retardance of substantially 180 degrees and a birefringent phase retarder with phase retardance of substantially 2 j times 360 degrees. Thus the orientations of the N birefringent phase elements can be changed to create a substantially binary set of phase delay values.
[0016] Finally, as can be appreciated by one in the art, the present invention also comprises a method for forming and using the spectrometer described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The objects, features and advantages of the present invention will be apparent from the following detailed descriptions of the various aspects of the invention in conjunction with reference to the following drawings, where:
[0018] The objects, features and advantages of the present invention will be apparent from the following detailed descriptions of the various aspects of the invention in conjunction with reference to the following drawings, where:
[0019] FIG. 1 is a block diagram, illustrating an Electro-optic Imaging Fourier Transform Spectrometer with three birefringent phase elements and a controller. FIG. I also contains an exploded view of one of the birefringent phase elements, showing that the birefringent phase element comprises a birefringent phase retarder and an achromatic switch.
DETAILED DESCRIPTION
[0020] The present invention relates to spectrometer and more particularly to an electro-optic imaging Fourier transform spectrometer for hyperspectral imaging. The following description is presented to enable one of ordinary skill in the art to make and use the invention and to incorporate it in the context of particular applications. Various modifications, as well as a variety of uses in different applications will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to a wide range of embodiments. Thus, the present invention is not intended to be limited to the embodiments presented, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
[0021] In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced without necessarily being limited to these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present invention.
[0022] The reader's attention is directed to all papers and documents which are filed concurrently with this specification and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All the features disclosed in this specification, (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0023] Furthermore, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of” or “act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.
[0024] Please note, if used, the labels left, right, front, back, top, bottom, forward, reverse, clockwise and counter clockwise have been used for convenience purposes only and are not intended to imply any particular fixed direction.
[0025] Instead, they are used to reflect relative locations and/or directions between various portions of an object.
[0026] Before describing the invention in detail, first a glossary of terms used in the description and claims is provided. Next, a description of various principal aspects of the present invention is provided. Subsequently, an introduction provides the reader with a general understanding of the present invention. Finally, details of the present invention are provided to give an understanding of the specific aspects.
[0027] (1) Glossary
[0028] The following glossary is intended to provide the reader with a general understanding of the intended meaning of the terms, but is not intended to convey the entire scope of each term. Rather, the glossary is intended to supplement the rest of the specification in order to more accurately explain the terms used.
[0029] Achromatic switch—The term “achromatic switch” as used with respect to this invention refers to a series of optical components with two special orientations that transform the polarization of light propagating through the material in some set of special directions, the degree of polarization transformation being substantially independent of the wavelength of light over a range determined by the user and the material parameters. As it is most commonly used by those in the art of the present invention, the achromatic switch comprises at least 2 passive birefringent films or crystals on either side of a twisted nematic or ferroelectric liquid crystal.
[0030] Birefringent—The term “birefringent” as used with respect to this invention refers to a material whose index of refraction depends on polarization. In particular, the index of refraction is different for two, independent, linear polarizations orthogonal to the propagation direction.
[0031] Birefringent phase retarder—The term “birefringent phase retarder” as used with respect to this invention refers to a birefringent material so oriented that light propagating through the material in some set of special directions and orientations has the phases of its orthogonal polarization components changed with respect to one another by some desired amount.
[0032] Frequency Spectra—The term “frequency spectrum” or “frequency spectra” (plural) as used with respect to this invention refers to the function that describes the relative energy density per unit frequency or per unit wavelength in a beam of light.
[0033] Polarizer—The term “polarizer” as used with respect to this invention refers to a material that attenuates orthogonal linear polarizations of light by dramatically different amounts, so that light that interacts with the material becomes substantially polarized in some desired direction after the interaction.
[0034] (2) Description
[0035] As shown in FIG. 1 , the spectrometer 100 comprises an input polarizer 102 , including an input polarizer center point 104 , an input polarizer axis 106 through the input polarizer center point 104 , and an input polarizer azimuth vector 108 originating on the input polarizer center point 104 and pointing substantially perpendicular to the input polarizer axis 106 . The spectrometer 100 also includes an output polarizer 110 , including an output polarizer center point 112 , an output polarizer axis 114 through the output polarizer center point 112 , and an output polarizer azimuth 116 vector originating on the output polarizer center point 112 and pointing substantially perpendicular to the output polarizer axis 114 . The output polarizer axis 114 is substantially collinear with the input polarizer axis 106 , thus defining a long axis 118 with an input end 120 proximate the input polarizer 102 and an output end 122 proximate the output polarizer 110 . The long axis 118 projects through the input polarizer center point 104 and the output polarizer center point 112 . The long axis 118 further defines an input polarizer orientation 124 between the input polarizer azimuth vector 108 and the long axis 118 and an output polarizer orientation 126 between the output polarizer azimuth vector 116 and the long axis 118 . The spectrometer 100 further comprises a plurality of birefringent phase elements 128 residing between the input polarizer 102 and the output polarizer 110 . Each of the birefringement phase elements 128 include a birefringent phase element center point 130 and a birefringent phase element azimuth vector 132 originating on the birefringent phase element center point 130 and pointing substantially perpendicular to the long axis 118 , thus defining a birefringent phase element orientation 134 between the birefringent phase element azimuth vector 132 and the long axis 118 . The spectrometer 100 is capable of changing a variety of orientations, non-limiting examples of which include the input polarizer orientation 124 , the output polarizer orientation 126 , and any of the birefringent phase element orientations 134 to substantially reproduce Fourier components of frequency spectra of light passing fully through the spectrometer 100 substantially parallel to the long axis 118 .
[0036] FIG. 1 also shows a controller 136 operably connected with at least one element selected from the group consisting of the input polarizer 102 , the output polarizer 110 , and any of the birefringent phase elements 128 . The controller 136 can change the orientation of any element to which it is operably connected.
[0037] FIG. 1 also shows, in an exploded view demarcated by the dashed box, that, in a particular mode, the birefringent phase elements 128 comprise a birefringent phase retarder 140 and an achromatic switch 138 . The birefringent phase retarder 140 substantially adjacent to the achromatic switch 138 . Additionally, the birefringent phase element 128 is oriented such that the achromatic switch 138 is nearer the output end 122 of the long axis 118 than the birefringent phase retarder 140 .
[0038] National Aeronautics and Space Administration's (NASA's) Jet Propulsion Laboratory is developing an innovative, compact, low mass, Electro-Optic Imaging Fourier Spectrometer (EOIFTS) for hyperspectral imaging applications. NASA headquarters are located at 300 East Street, Southwest, Washington, D.C. The spectral region of this spectrometer will be 1000 to 4000 wave-numbers to allow high-resolution, high-speed hyperspectral imaging applications. Due to the use of a combination of birefringent phase retarders and multiple achromatic phase switches to achieve phase delay, this spectrometer is capable of hyperspectral measurements similar to that of the conventional Fourier transform spectrometer but without any moving parts. Major NASA applications are the remote sensing of the measurement of a large number of different atmospheric gases simultaneously in the same airmass.
[0039] The reported new technology will result in the development of a high-resolution spectrometer without any moving parts that will provide a substantial improvement in reliability, mission duration, and performance to the next-generation Earth orbiting Fourier transform spectrometers that have been extensively deployed in orbit for atmospheric monitoring. It also promises to be much smaller in size and mass.
[0040] Traditional Fourier transform spectrometers possess two major advantages over grating, prism, and circular variable filter (CVF) spectrometers. One is the time-multiplexing effect. The Michelson interferometer's single detector views all the wavelengths (within the instrument passband) simultaneously throughout the entire measurement. This effectively lets the detector collect data on each wavelength for the entire measurement time, measuring more photons and therefore, results in higher signal-to-noise ratios, this type of operations being best for situations where the source is stable. The other is the throughput advantages, since the FTS does not need spatial filters (e.g. a slit) in the optical light path.
[0041] However, traditional Fourier transform spectrometers, used in space flight missions, obtain their optical delay by physically translating one or more optical components. The so-called translation mechanism usually dominates the risk, cost, power consumption, and performance of such instruments because: 1) over the course of a 5-year-period, tens of millions of strokes will be required, making wear or fatigue a serious risk; 2) the moving optical element(s) cannot be rigidly held, making it sensitive to vibration and requiring that it be “caged” during launch to prevent damage, adding risk (failure of the caging mechanism to open); and 3) accelerating and decelerating the optical elements that can torque the spacecraft, making it difficult to maintain accurate pointing.
[0042] The solution to the above problems is to construct a high-resolution Fourier transform spectrometer that, instead of using a mechanical Michelson interferometer, consists of cascaded birefringent crystals or films for phase delay and achromatic phase switches to achieve a solid-state programmable phase delay without any moving parts. This will represent a substantial improvement in reliability, mission duration, and performance. It also promises to be much smaller in size and mass.
[0043] The EOIFTS is built upon a sequence of the time-delay unit. The EOIFTS consists of an input polarizer, a quarter wave achromatic switch, a series of N liquid crystal based electro-optic switches interlaced with a series of passive birefringent phase retarders. The basic building block of the system is the unit consisting of a single achromatic half-wave switch between two neighboring passive wave retarders. The principle is that one can select between the sum or difference in total retardation of the wave passing through these two passive wave retarders by rotating the in-between achromatic half-wave switch. With parallel passive retarders oriented at 45 degrees to the input polarization, an achromatic half-wave retarder oriented at zero degrees gives the difference in retardation, while an orientation of 45 degrees gives the sum. By stacking multiple passive retarders interlaced with achromatic half-wave switches, a long time delay can be achieved that is essential for achieving a high-resolution spectrometer. By using a geometric relationship of passive retarder thicknesses (i.e. 1 wavelength, 2 wavelengths, 4 wavelengths, etc.), an arithmetic progression in time delay steps is achieved.
[0044] The output of the spectrometer is a periodic representation of the original bandlimited spectrum of input light. This periodicity results from the fact that the spectrometer samples the autocorrelation of the light's electric field to recover the spectrum. Due to the limited number of time-samples, the output spectrum is more accurately described as a smoothed periodic representation of the input. Knowing this, one can consider the input as a single cycle of the resulting periodic output spectrum.
[0045] The total power on the detector is the integral of the input spectrum modulated by the transmission function of the EOIFTS. The achromatic quarter wave switch and the last achromatic half wave switch can separate four measurements of the input spectrum, three of which are independent and necessary to fully reconstruct the input spectrum.
[0046] The achromatic switches are well-known the art, but, as a concrete example, achromatic half-wave switches in one embodiment of the present invention were constructed by sandwiching a ferroelectric liquid crystal with 90 degree polarization rotation at 1120 nanometers wavelength, the input director oriented at 74 degrees, between two retardation films, each film possessing a full-wave retardance at 600 nanometers wavelength. These achromatic half-wave switches were substantially a half wave in a 1.5 micron band centered near 1.75 microns wavelength. | An Electro-Optic Imaging Fourier Transform Spectrometer (EOIFTS) for Hyperspectral Imaging is described. The EOIFTS includes an input polarizer, an output polarizer, and a plurality of birefringent phase elements. The relative orientations of the polarizers and birefringent phase elements can be changed mechanically or via a controller, using ferroelectric liquid crystals, to substantially measure the spectral Fourier components of light propagating through the EIOFTS. When achromatic switches are used as an integral part of the birefringent phase elements, the EIOFTS becomes suitable for broadband applications, with over 1 micron infrared bandwidth. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to talc for paint products. The invention relates also to the method of producing said talc product.
BACKGROUND OF THE INVENTION
[0002] Talc products for paints are manufactured by milling specific talc ores in dry milling processes to the talc powders with desired particle size distribution. Typical median particle size for paint talc product is 1 to 25 μm and upper top cut is from 10 μm to 200 μm. Median particle size for talc powder used in paints cause different decorative properties to paints, e.g. high median particle size decreases gloss and low median size increases covering power. Median particle size also has influence on mechanical properties, e.g. on wet scrub resistance, of paints.
[0003] Dry powders are then dispersed in water during the production of water based paints. This causes problems because it is difficult to get homogenous dispersion of solid particles. Talc powders also cause dusting problems during storing and handling stages.
GENERAL DESCRIPTION OF THE INVENTION
[0004] It is the object of the present invention to improve the processability of talc for paint products.
[0005] For achieving this aim, the invention is characterized by features that are enlisted in the independent claims. Other claims represent preferred embodiments of the invention.
[0006] According to invention the talc product is talc slurry having total solids (TS) 40% and comprising a dispersant agent and/or a thickener. Said thickener improves the wetting of talc surfaces and improves the stability of talc slurry. Said dispersant agent improves the dispersing of talc in water. Said dispersant agent also makes grinding of talc easier. This kind of talc is ready dispersed in water and it makes a homogenous dispersion of talc in water. Users don't need to disperse the talc and so this new product is ready to use and can be added in any phase of the paint production, which increases the paint production capacity and makes the process more flexible.
[0007] The slurried talc also reduces the storage space needed compared with storing of same amount of dry powder. Talc slurry is also pumpable. The paint production process is thus easier to get automated by using talc slurry instead of dry power form talc. So it increases the production capacity of paint producers. Waste of packing material is also avoided by using talc slurry. When the talc is in slurry form, there is no dusting problem during storing and handling stages.
[0008] According to one aspect of the invention total solids (TS) of said talc slurry is 50% or higher. Advantageously total solids (TS) of said talc slurry is 60% or higher. This kind of talc slurry further reduces the storage space needed compared with storing of same amount of dry powder.
[0009] According to one aspect of the invention viscosity of talc slurry is 300 to 600 mPas (Brookfield Br100). This kind talc slurry is easy to pump.
[0010] According to one aspect of the invention storage stability of said talc product is 10%, which is measured as the sedimentation of talc particles in one month storing test in container where is no mixing. This kind of talc slurry is especially suitable talc for paint products.
[0011] In this document particle size of talc is expressed as an equivalent diameter of spherical particle that has the same falling rate in water as talc particles measured.
[0012] According to one aspect of the invention the talc slurry has unimodal PSD with average particle size (peak value) between 1-50 μm. This kind of talc is easy to pump and makes it possible to use unimodal, conventional or narrow PSD talc. Unimodal, narrow PSD talc has benefits in some specific application, for instance very fine talc (average PS between 1-3 μm) for thin film thickness coatings and lacquers to improve opacity, whiteness and sandability and adjust the gloss. Narrow and unimodal PSD of coarse talc (average PS between 10-30 μm) is beneficial in thick film protective coatings to achieve high enough film thickness (high solid content) without increasing the viscosity of paint.
[0013] According to one aspect of the invention talc slurry has multimodal particle size distribution between 1 to 50 μm. This improves the balance of paint properties. It also improves the stability of slurry compared to conventional unimodal or very narrow PSD talc.
[0014] Talc product having multimodal particle size distribution improves the paint property profile. It improves the paint quality compared to currently available product on the market. All the important decorative paint properties are either improved or kept constant compared to the conventional type of talc product. It makes also production of paints easier. The ready dispersed talc slurry can be added into the paint formulation in any phase of the paint production.
[0015] According to one aspect of the invention the talc product has at least two peaks of particle size distribution between 1 to 50 μm. According to one aspect of the invention the talc product has at least three peaks of particle size distribution between 1 to 50 μm. This bi-modal/multimodal particle size distribution improves the balance of paint properties and decreases gloss, increases covering power and/or increases mechanical properties of paint.
[0016] According to one aspect of the invention the talc product has multimodal PSD with two or more peaks between 1 to 50 μm. The multimodal PSD improves the balance of paint properties. According to one aspect of the invention one of the peaks of particle size distribution is between 1 to 5 μm. The fine particles, peaks between 1 to 5 μm, improve the balance between covering power and whiteness of the paint film. According to one aspect of the invention one of the peaks of particle size distribution is between 5 to 20 μm. The medium fine talc particles, peaks between 5 to 20 μm, improve the mechanical properties like wet scrub resistance and mud cracking resistance of paints. According to one aspect of the invention the slurry has at least one peak of particle size distribution being between 10 to 50 μm. Coarse talc particles, peaks between 10 to 50 μm, reduce the gloss (sheen) of paints. The multimodal (broad) PSD of talc allows the increase of talc content in the slurry without worsening of pumpability and stability of the slurry.
[0017] Talc slurry can be prepared in several different ways. Said talc slurry can be produced e.g. by using of semi-finished goods, e.g. talc concentrate or by milling talc ore and/or pre-slurry talc by wet milling process
[0018] Talc can be milled by using normal conventional type of dry milling techniques like ball mills, impact mills or jet mills (steam or compressed air), to get final fineness for talc. After the milling dry talc powder can be directly dispersed in water by using suitable chemicals or it can be first granulated after which dispersed in water. Finally the talc slurry is stabilized by using suitable stabilizers.
[0019] Another way is to prepare the slurry already during the milling phase. This method requires wet milling techniques like wet ball or pearl milling. This method requires the constant feed of chemicals to the mills together with talc raw material and water to get smooth milling and high enough solid content to the final slurry. After the milling the talc slurry is further stabilized, after which it is ready to be used for paint production. The particle size distribution (PSD) of talc is controlled by filling rate of milling pieces (balls or pearls) in the mills. Different size (diameter) of milling balls or pearls gives different size of talc. The PSD of talc wanted is achieved by adjusting the ratio of different size of grinding pieces. The residence time of talc slurry in mills affects also the particle size of talc. There can be several mills in series if needed. The wet milling is an advantageous technique to prepare talc slurry for paints because there is no need to dry the product during the manufacturing, which reduces the production costs. Thus the preparation of the talc product into slurry form is technically easy and thus production costs are low. Wet milling process also enables the production of the special type of products.
[0020] Advantageous wet milling is made by wet pearled mill. It has been also seen that wet pearl milling gives the possibility to prepare multi-modal PSD talc. The multi-modal PSD is beneficial for storage stability of talc slurry and it improves the balance or paint properties.
[0021] The multi-modal talc slurry product can be prepared also by using the normal unimodal, dry milled, products as a mixture in slurry preparation.
[0022] The talc slurry can be delivered either in reusable containers or by silo trucks, which reduces the amount of packing materials.
[0023] Production process of talc slurry comprises e.g. the steps:
pregrinding of talc ore for producing talc, wet milling of pregrinded talc to end products, during the wet milling additives like dispersing and thickening agents and pH, regulator can be added, stabilizing the slurry by cellulose based or synthetic thickener
[0028] Production process of talc slurry produced from pregrined starting material or from ready milled end product comprises e.g. the steps:
producing pre-slurry talc by adding of water and talc to process tank, and adding of base, e.g. NaOH, to water or to pre-slurry talc in order to achieve pH-value 9.0 or higher adding of a thickener to pre-slurry talc adding of a dispersant to pre-slurry talc milling said pre-slurry talc by wet milling process sieving milled pre-slurry talc
[0035] An example of process flow sheet of the invention is shown in FIG. 7 .
[0036] Wet grinding can reduce the whiteness of end product e.g. by 4-5 whiteness %-units compared if the same product is made by dry milling. So it is advantageous to use very high whiteness starting material, e.g. talc lumps, in wet pearl milling to get optimum product.
[0037] Talc product can be used in e.g. in following paint products:
Interior and exterior flat emulsion paints Multi purpose interior/exterior emulsion paints Semigloss emulsion paints Out door wood coatings Wood primers Textured paints Silk and eggshell paints
DETAILED DESCRIPTION OF THE INVENTION
[0045] An embodiment of the invention is explained in more detail below, with reference to the appended drawing.
[0046] Talc Slurry—milling and stabilisation trial
Materials
[0047] Talc—Finntalc P60 SL (d 50 around 84 μm).
[0048] Dispersing agent—specific dispersing agent where wetting property is also involved.
[0049] NaOH (Solvay, >98%) at 10% in water was used to neutralise the dispersing agent.
[0050] Cellulose thickeners for the stabilization of the slurry: Celfow and Finnfix 2000G from CP Kelco.
[0051] Biocide—Thor MBF 28.
Initial Target Compositions
[0052]
[0000]
TABLE 1
Composition with Celflow
Component
w-%
Comments
1. Water
38.40
2. Dispersing agent,
0.96
0.50% dry on dry
(solids = 26 w-%)
3. Biocide (Acticide BX)
0.20
4. NaOH (10 w-%)
1.04
=> pH ~9.0
5. Talc (Finntalc M20SL -
50.10
Mix by circumferential speed =
lab trial)
15 m/s.
6. Celflow S-50 Dry
0.40
0.8% dry on dry Mixing for 20
minutes by circumferential speed =
15 m/s
7. Rest water
8.90
Total
100.0
[0000]
TABLE 2
Composition with Finnfix 2000G
Component
w-%
Comments
1. Water
38.4
2. Dispersing agent, (solid
0.96
0.50% dry on dry
s = 26 w-%)
3. Biocide (Acticide BX)
0.2
4. NaOH (10 w %)
1.04
=> pH ~9.0
5. Talc, (Finntalc M20SL -
50.1
Mix by circumferential speed =
lab trial)
15 m/s.
6. CMC Finnfix 2000G Dry
0.54
1.08% dry on dry Mixing for
20 minutes by circumferential
speed = 15 m/s
7. Rest water
8.8
[0053] In the industrial test was used 0.7% of the dispersing agent.
Industrial Trial
[0054] Pre-slurry was made in a 3 m 3 tank equipped with a cutting type agitator. To make the pre-slurry, water was added first, then NaOH (10%), dispersing agent and finally the talc P60 SL. All the dispersant was added in the pre-slurry—no addition of dispersant was made to the mills. The quantity of dispersant was always 0.7% (d/d).
[0055] The flow sheet of the process is shown in FIG. 7 .
[0056] The pH of the final pre-slurry was measured and was corrected when necessary, to achieve a value above 9. During the trial, several mixes of pre-slurry were made to make it available for the milling process.
[0057] In the first trial, the pre-slurry was introduced in a first mill. The product from the first mill was then introduced in a second mill. After the second mill, no other actions were performed to the slurry.
[0058] Samples were taken from the first (samples 1 and 2) and the second mill (sample 3).
[0059] A second trial was performed with pre-slurry at 60% of solid content. Samples were taken from the first (sample 5) and the second mill (sample 6).
[0060] A third test was done with similar conditions to the first one. The difference was that the slurry after the mill was sieved using 100 μm nets. The rejected was going back to the mill, with some losses due to the high flow rate and viscosity of the rejected product.
[0061] The sieving presented severe problems, with the rejected product from the sieves being about 70% of the feeding. The dispersant does not permit an efficient sieving of the slurry. A sample of the sieved slurry was taken (sample 6).
[0062] Talc slurry samples were stabilized.
[0063] Table 3 shows the final composition of the samples, after stabilisation.
[0064] The making of each sample is described in Appendix 1, with the actions described by chronological order.
Conclusions:
[0000]
Talc slurries with d 50 between 1.45 and 7.36 μm and solids content between 40.3 and 60.1% were made.
The making of the pre-slurry presented no major problems, although corrections of the pH had to be performed.
The operation of the mills was stable after solving some initial problems. Even at 60% solids, the mills presented no problems.
Samples were taken from the mills at 50 and 60% solids content.
The samples of the slurries were stabilized with two cellulose thickeners. The Celflow product shown a good effect on increasing viscosity at low shear rates and decreasing it at high shear rates.
[0000]
TABLE 3
Talc slurry samples
Solids
NaOH
Finnfix
Particles
Slurry
content
d 50
Biocide
(10%)
Celflow
2000G
η 10 rpm
η 100 rpm
above 63
Sample
(kg)
(%)
(μm)
(%)
(%)
(%)
(%)
(cP)
(cP)
μm (%)
1
120
51.7
3.1
0.2
0.08
0.3
—
930
260
13.1
2
120
51.7
3.2
0.2
0.04
—
0.5
1320
310
13.1
3
200
55.0
1.6
0.2
0.03
—
—
1440
1248
3.8
4
260
58.6
8.4
0.2
0.04
0.15
—
680
412
21.9
5
200
60.1
3.3
0.2
0.05
—
—
930
995
10.2
6
545
40.3
2.4
0.2
—
0.2
—
360
110
2.4
Sample 1
[0070] Description: sample from the first mill, with pre-slurry at 50% solid content.
[0071] 120 kg of slurry.
[0072] Mass population vs. particle size of talc in sample 1 is expressed in FIG. 1 . Said talc product has following peaks of particle size distribution:
1.5 μm 3.8 μm 9.3 μm 19.5 μm 37 μm
[0078] Solids content: 51.7%
[0079] Granulometry:
[0080] d 50 =3.09 μm
[0081] Viscosity at 25° C.:
[0082] η 10 rpm =200 cP η 100 rpm =386 cP
[0083] Celflow—125 g (0.1% of talc)
[0084] η 10 rpm =900 cP η 100 rpm =265 cP
[0085] pH=8.6
[0086] NaOH (10%)—100 mL
[0087] η 10 rpm =200 cP η 100 rpm =160 cP
[0088] pH=9.5
[0089] Thor MBF28—0.2 kg
[0090] Celflow—0.0625 kg
[0091] η 10 rpm =930 cP η 100 rpm =260 cP
Sample 2
[0092] Description: sample from the first mill, with pre-slurry at 50% solid content.
[0093] 120 kg of slurry. Characteristics equal to sample 1.
[0094] Mass population vs. particle size of talc in sample 2 is expressed in FIG. 2 . Said talc product has following peaks of particle size distribution:
2.4 μm 5.2 μm 13 μm 28 μm
[0099] Finnfix 2000G—0.125 kg
[0100] η 10 rpm =215 cP η 100 rpm =173 cP
[0101] Finnfix 2000G—0.0625 kg
[0102] η 10 rpm =450 cP η 100 rpm =190 cP
[0103] Finnfix 2000G—0.0625 kg
[0104] η 10 rpm =1020 cP η 100 rpm =272 cP
[0105] Thor MBF 28—0.2 kg
[0106] pH=9.0
[0107] NaOH (10%)—50 mL
[0108] pH=9.5
[0109] η 10 rpm =430 cP η 100 rpm =176 cP
[0110] Finnfix 2000G—0.0625 kg
[0111] η 10 rpm =1320 cP η 100 rpm =310 cP
Sample 3
[0112] Description: sample from the second mill, with pre-slurry at 50% solid content.
[0113] 200 kg of slurry.
[0114] Mass population vs. particle size of talc in sample 3 is expressed in FIG. 3 . Said talc product has following peaks of particle size distribution:
3.8 μm 8.0 μm 18 μm
[0118] Solids content: 55.0%
[0119] Granulometry:
[0120] d 50 =1.45 μm
[0121] Thor MBF 28—0.4 kg
[0122] pH=9.3
[0123] NaOH (10%)—50 mL
[0124] pH=9.5
[0125] Viscosity at 25° C. (spl 4):
[0126] η 10 rpm =1440 cP η 100 rpm =1248 cP
[0127] No cellulose was added to this slurry.
Sample 4
[0128] Description: sample from the first mill, with pre-slurry at 60% solid content.
[0129] 260 kg of slurry.
[0130] Mass population vs. particle size of talc in sample 4 is expressed in FIG. 4 . Said talc product has following peaks of particle size distribution:
1.5 μm 9.6 μm 20 μm 38 μm
[0135] Solids content: 58.6%
[0136] Granulometry:
[0137] d 50 =7.36 μm
[0138] Thor MBF 28—0.5 kg
[0139] pH=9.1
[0140] NaOH (10%)—100 mL
[0141] pH=9.5
[0142] NaOH (10%)—15 mL
[0143] pH=9.5
[0144] Viscosity at 25° C.:
[0145] η 10 rpm =400 cP η 100 rpm =510 cP
[0146] Celfow—0.1300 kg
[0147] η 10 rpm =620 cP η 100 rpm =386 cP
[0148] Celfow—0.0650 kg
[0149] η 10 rpm =680 cP η 100 rpm =412 cP
Sample 5
[0150] Description: sample from the second mill, with pre-slurry at 60% solid content.
[0151] 200 kg of slurry.
[0152] Mass population vs. particle size of talc in sample 5 is expressed in FIG. 5 . Said talc product has following peaks of particle size distribution:
1.3 μm 3.8 μm 8.5 μm 16 μm 27 μm
[0158] Solids content: 60.1%
[0159] Granulometry:
[0160] d 50 =3.30 μm
[0161] Viscosity at 25° C. (spl 6):
[0162] η 10 rpm =1200 cP η 100 rpm =1840 cP
[0163] Thor MBF 28—0.4 kg
[0164] pH=8.9
[0165] NaOH (10%)—100 mL
[0166] pH=9.4
[0167] Viscosity at 25° C. (spl 3):
[0168] η 10 rpm =930 cP η 100 rpm =995 cP
[0169] No cellulose was added to this sample.
Sample 6
[0170] Description: Sieved sample from the mill, with pre-slurry at 50% solid content.
[0171] 545 kg of slurry.
[0172] Mass population vs. particle size of talc in sample 6 is expressed in FIG. 6 . Said talc product has following peaks of particle size distribution:
4.0 μm 9.0 μm
[0175] Solids content: 40.3%
[0176] Granulometry:
[0177] d 50 =2.83 μm
[0178] Thor MBF 28—1.1 kg
[0179] pH=9.4
[0180] Celflow—218 g
[0181] η 10 rpm =130 cP η 100 rpm =81 cP
[0182] Celflow—218 g
[0183] η 10 rpm =360 cP η 100 rpm =110 cP | A talc slurry and a method of producing the talc slurry. A talc product includes the talc slurry having total solids (TS) 40% or higher and a dispersant agent and/or a thickener. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of non provisional application Ser. No. 12/184,716, entitled Enhanced Water Treatment for Reclamation of Waste Fluids and Increased Efficiency Treatment of Potable Waters, filed Aug. 1, 2008 which in turn is a continuation-in-part of provisional application 60/953,584, entitled Enhanced Water Treatment for Reclamation of Waste Fluids and Increased Efficiency Treatment of Potable Water, filed Aug. 2, 2007, the contents of which is hereby expressly incorporated by reference.
FIELD OF THE INVENTION
This invention related to the field of water treatment and, in particular to a process for reducing the need for off-site treatment such as in the case of reclaiming drilling fluids, flowback fluids, subterranean oil and gas wells using produced water, and enhancing ozone injection processes for potable water.
BACKGROUND OF THE INVENTION
Worldwide, oil and gas companies spend more than $40 billion annually dealing with produced water from wells. The global direct costs from hauling water for treatment off-site alone will surpass $20 billion in 2007, with expenses skyrocketing in the next few years.
The US Department of Energy (DOE) has called produced water “by far the largest single volume byproduct or waste stream associated with oil and gas production.” The DOE further terms its treatment a serious environmental concern and a significantly growing expense to oil and gas producers.
In 2007, the world's oil and gas fields will produce over 80 billion barrels of water needing processing. The average is now almost nine barrels of produced water for each barrel of oil extracted. And the ratio of water to hydrocarbons increases over time as wells become older. That means less oil or gas and more contaminated water as we attempt to meet rising global energy needs.
By way of example, in rotary drilling a by-product of the drilling process is a waste fluid commonly referred to as “drilling fluids” which carries cuttings and other contaminants up through the annulus. The drilling fluid reduces friction between the drilling bit and the sides of the drilling hole; and further creates stability on the side walls of an uncased drilling hole. The drilling fluid may include various constituents that are capable of creating a filter cake capable of sealing cracks, holes, and pores along the side wall to prevent unwanted intrusion from the side wall into the drilled shaft opening. Water based drilling fluid's result in solid particles that are suspended in the water that makes up the fluid characteristics of the drilling fluid. Drilling fluid's can be conditioned to address various processes that may include water soluble polymers that are synthesized or naturally occurring to try to be capable of controlling the viscosity of the drilling fluid. The drilling fluid principle is used to carry cuttings from beneath the drilling bit, cool and clean the drill bit, reducing friction between the drill string and the sides of the drill hole and finally maintains the stability of an uncased section of the uncased hole.
Of particular interest in this example of a drilling fluid is the commonly referred to 9 lb drilling mud. Once this fluid is expelled, for purposes of on-site discharge the specific gravity of water separated need to be about 8.34 lbs per gallon to meet environmental discharge levels. One commonly known process is to use a centrifuge which is capable of lowering the 9 pound drilling mud to approximately 8.5 pounds per gallon. However, this level is unacceptable for environmental discharge limit and it would then be necessary to induce chemical polymers to flocculate the slurry and further treat the volatile organic compounds (VOC's) which are emitted as gases from certain solids or liquids. The VOC's are known to include a variety of chemicals some of which may have short or long term adverse health effects and is considered an unacceptable environmental discharge contaminant. Unfortunately, the use of polymers and a settling time is so expensive that it economically it becomes more conducive to treat the waste off-site which further adds to the cost of production by requiring off-site transport/treatment or shipped to a hazardous waste facility where no treatment is performed.
Thus, what is need in the industry is a reclamation process for reducing the need to treat industrial waste off-site and further provide an on-site treatment process for use in reclaiming water.
In addition there are many gas fields, most notably in North America, that contain enormous amounts of natural gas. This gas is trapped in shale formations that require stimulating the well using a process known as fracturing or fracing. The fracing process uses large amounts of water and large amounts of particulate fracing material (frac sands) to enable extraction of the gas from the shale formations. After the well site has been stimulated the water pumped into the well during the fracing process is removed. The water removed from the well is referred to as flowback fluid or frac water. A typical fracing process uses from one to four million gallons of water to fracture the formations of a single well. Water is an important natural resource that needs to be conserved wherever possible. One way to conserve water is to clean and recycle this flowback or frac water. The recycling of frac water has the added benefit of reducing waste product, namely the flowback fluid, which will need to be properly disposed. On site processing equipment, at the well, is the most cost effective and environmentally friendly way of recycling this natural resource.
It takes approximately 4.5 million gallons of fresh water to fracture a horizontal well. This water may be available from local streams and ponds, or purchased from a municipal water utility. This water must be trucked to the well site by tanker trucks, which carry roughly five thousand gallons per trip. During flowback operations, approximately 300 tanker trucks are used to carry away more than one million gallons of flowback water per well for offsite disposal. For a 3 well frac site these numbers will increase by a factor of three.
The present invention provides a cost-effective onsite water recycling service that eliminates the need to truck flowback to a disposal pit, a holding pond, or recycling facility miles away.
SUMMARY OF THE INVENTION
The instant invention is directed to a reclamation process that introduces high intensity acoustic energy and triatomic molecules into a conditioning container to provide a mechanical separation of materials by addressing the non-covalent forces of particles or van der Waals force. The conditioning tank provides a first level of separation including an oil skimmer through an up flow configuration with discharge entering a centrifuge. The conditioning container and centrifuge addressing a majority of drilling fluid recovery operations, fluid cleaning, barite recovery, solids control, oily wastes, sludge removal, and so forth.
Water from the centrifuge is directed through a filtration process, sand or multimedia, for removal of large particulates before introduction through activated carbon filters for removal of organics and excess ozone. Discharge from the carbon filters is directed to a clean water tank for distribution to utilities as well as for water makeup for the ozone injection process and filtration backwash.
The instant invention also discloses a cost efficient and environmentally friendly process and apparatus for cleaning and recycling of flowback, or frac water, which has been used to stimulate gas production from shale formations. The invention also has the ability to conserve water and reduce the amount of waste disposal. The ability to perform this process adjacent the well head eliminates transportation costs to a central processing facility and eliminates the vehicular impact on the areas surrounding the gas fields.
Thus an objective of the invention is to provide an on-site process to treat waste fluids.
Still another objective of the invention is to provide an on-site process that will lower the cost of oil products by reducing the current and expensive processes used for off-site treatment of waste fluids.
Another objective of the invention is to provide an on-site process that will extend the life of fields and increase the extraction rate per well.
Yet still another objective of the instant invention is to lower the specific gravity of the 9 pound mud to approximately the specific gravity of water allowing for reclamation and reuse.
Still another objective of the instant invention is to eliminate the need to recycling all drilling fluid due to current cost burdens created by the need of polymers for further settlement of contaminants.
Still another objective of the instant invention is to teach the combination of ultrasonic and hydrodynamic agitation in conjunction with ozone introduction into a closed pressurized container whereby the cavitations cause disruption of the materials allowing the ozone to fully interact with the contaminated flow back water for enhancement of separation purposes. In addition, anodes in the container provide DC current to the flow back water to drive the electro precipitation reaction for the hardness ions present with the flow back water.
Yet another objective of the instant invention is to reduce 9 pound drilling mud into a separation process wherein the water separated has a specific gravity of about 8.34.
Still another objective is to teach a process of enhanced ozone injection wherein ozone levels can be reduced be made more effective.
Another objective of the invention is to provide a cost effective and environmentally friendly process and apparatus for cleaning and recycling frac water at the well site using transportable equipment that is packaged within a trailer in a modular fashion to minimize down time and make repair easier and more cost efficient.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A & 1B is a flow schematic of drawing fluid reclamation process.
FIGS. 2A & 2B is a floor layout illustrating equipment placement within a 20 ft container.
FIGS. 3A , 3 B, and 3 C illustrate the flow diagram for processing flowback water at the well site.
FIG. 4A is a front perspective view of the containerized apparatus for treating flowback water.
FIG. 4B is a rear perspective view of the containerized apparatus for treating flowback water.
FIG. 4C is a top view of the containerized apparatus for treating flowback water.
FIG. 5A is a perspective view of the containerized reverse osmosis (RO) equipment.
FIG. 5B is a top view of the containerized reverse osmosis (RO) equipment.
FIGS. 6A , 6 B and 6 C illustrate an alternative flow diagram for processing flow back water at the well site.
FIG. 7 illustrates the reactor tank used in the flow processing shown in FIGS. 6 a through 6 C.
FIG. 8 is a cutaway perspective view of a truck trailer containing the equipment necessary for processing the flow back water at the well site.
FIG. 9 show data tables representing two samples of flow back water. Each data table sets forth the contaminants within the flow back water prior to treatment in the main reaction tank as compared to the same contaminants subsequent to treatment in the main reaction tank.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now referring to FIG. 1 set forth is the preferred drawing fluid reclamation process ( 10 ) having an inlet ( 12 ) shown with a 3 inch section hose and a shutoff valve ( 14 ). Pressurized drilling fluid is directed through an inlet pipe ( 16 ) monitored by a pressure gauge ( 18 ) and inserted into conditioning tank ( 20 ) along a lower end ( 22 ) wherein the drilling fluid fills the conditioning container ( 20 ) on an upward flow. Ultrasonic acoustic transducers ( 24 ) and ( 26 ) are depicted at different locations in the conditioning container, the ultrasonic transducers powered by a control panel ( 28 ) and monitored by a conductivity sensor ( 30 ).
The ultrasonic sensors are operated by use of an air compressor ( 32 ) with pressurized air stored within a tank ( 34 ) monitored by a low pressure switch ( 36 ) and solenoid ( 38 ) for control of flow for production of the acoustic energy into the transducers ( 24 ) and ( 26 ). An ozone generator ( 40 ) is used to introduce ozone through an injector ( 42 ) in storage into an ozone contact tank ( 44 ) before introduction into the lower end ( 22 ) of the conditioning container ( 20 ) and inlet manifold ( 46 ). The preferred ultrasonic device is driven by silver braised magnetostrictive transducers, with all wetted surfaces being 316 stainless steel. The resonant frequency of the immersible is preferably between 16 kHz or 20 kHz. When multiple generators are used they can be synchronized to operate at a single resident frequency. The use of the immersible configuration allows placement within the conditioning container so as to allow for continuous treatment thereby placing an intense ultrasonic energy into the controlled volume of material as it passes by the multiple vibrating surfaces.
By way of example, drilling fluid ( 16 ) introduced into the conditioning container is ozonated through the manifold ( 46 ) with the ozonated drilling fluid passing through the acoustic energy provided by the transducers ( 24 ) and ( 26 ) with conditioned drilling fluid removed from the conditioning container at outlet ( 48 ). A second outlet ( 50 ) is provided for removal of petroleum products such as oil that form along the surface and can be collected through the manifold ( 50 ) and directed to an oil outlet ( 52 ) for collection and disposal. The ozonated and ultrasonically treated drilling fluid that is directed through outlet ( 48 ) is placed into the inlet ( 54 ) of a centrifuge ( 56 ) which allows for solid waste removal ( 60 ).
The slurry is the directed to an open container ( 62 ) for use in post treatment. Post treatment is made possible by repressurization of the slurry by transfer pump ( 64 ) for introduction into a sand filter ( 66 ) at inlet ( 68 ). The sand filter permits removal of the remaining particulates into a micron level and the filtered slurry is passed through directional valve ( 70 ) to outlet ( 72 ) and introduction into parallel position activated carbon filters ( 80 ), ( 82 ) and ( 84 ). The activated carbon filters provide removal of any remaining organics as well as reduces and eliminates any excess ozone with the effluent collected by manifold ( 90 ) replacement into a clean water filter tank ( 92 ). The clean water tank is expected to have water with a specific gravity of approximately 8.34 making it available for environmental discharge or other uses with the utilities ( 94 ). The level float ( 96 ) provides operation of the transferred pump ( 64 ) from maintaining a level in the clean water tank for distribution to the utilities. The clean water tank further allows for use of the reclaimed water for regeneration of the activation carbon by use of transfer pump ( 96 ) wherein backwashing of the sand filter ( 66 ) and carbon filters ( 82 ) and ( 84 ) is made possible through directional valve ( 70 ), ( 81 ), ( 83 ), and ( 85 ). Manifold collecting the backwashed water ( 100 ) is returned to the inlet pipe ( 16 ) for introduction in the conditioning container ( 20 ) for purposes of polishing and recycling of the fluid. The clean water tank ( 92 ) further provides ozonator makeup by use of booster pump ( 110 ) which draws from the clean water tank ( 92 ) placement into the conditioning container ( 20 ) wherein the clean water is injected with ozone as previously mentioned by injector ( 42 ) for storage and ozone contact tank ( 44 ).
It should be noted that the use of drilling fluid is only an example. Produced water from an oil or gas well, or even enhancement of potable water benefits from the process.
Now referring to FIG. 2 set forth is a layout of a container depicting the conditioning container ( 20 ) having the ozone contact tank ( 44 ) and booster pump ( 110 ). Following the conditioning container ( 20 ) the effluent is directed to the centrifuge ( 56 ) located outside of the container and placed in a water holding tank ( 62 ) not shown but also placed outside of the container. The water from the tank ( 62 ) is repressurized by booster pump ( 64 ) and directed through sand filter ( 66 ) followed by activated carbon filters ( 80 ) and ( 82 ). Also placed within the shipping container ( 200 ) is the ozone generator ( 40 ) and ultrasonic generator ( 28 ). A central control panel ( 111 ) allows central control operation of all components. A repressurization pump ( 96 ) can also be placed within the container ( 200 ) for use in backwashing the activated carbon and sand filter. The conventional container has access doors on either end with a walkway ( 202 ) in a central location. The walkway allows access by either door ( 204 ) or ( 206 ). Access to the activated carbon and sand filters as well as the pressurization pumps can be obtained through access doors ( 208 ) and ( 210 ).
FIGS. 3A , 3 B, and 3 C illustrate the frac water fluid treatment process. This apparatus used in this process is designed to be mounted within a standard shipping container or truck trailer such that it can be moved from location to location to treat the frac water on site. Frac water enters frac water process tank 302 through inlet 304 . The effluent is removed from tank 302 by pump 306 through flow meter 308 and then through back wash filter 310 . Filter 310 removes substances such as frac sands and foreign particles in the range of 25 to 50 microns. From the filter 310 , seventy percent of the effluent is saturated with ozone in ozone contact tank 316 , via line 315 , and the remaining thirty percent is introduced into main reactor tank 318 , via line 319 . Reactor tank is maintained at an internal pressure greater than atmospheric. Oxygen generator 312 feeds ozone generator 314 which in turn feeds into ozone contact tank 316 . Line 317 feeds the effluent leaving ozone contact tank 316 to the main reactor tank 318 . The effluent from the ozone contact tank 316 is introduced through a manifold 321 within the reactor tank 318 . The manifold includes orifices designed to create hydrodynamic cavitations with the main reactor tank 318 . In addition the reactor tank 318 also includes ultrasonic transducers 322 positioned as various elevations within the reactor tank 318 . These ultrasonic transducers 322 are designed to create acoustic cavitations. Aluminum sulfate from tank 326 is introduced to in line mixer 328 via line 327 . The effluent from pressurized main reactor tank 312 is carried by line 325 to in line 328 where it mixes with the aluminum sulfate. The effluent then flows through tanks 330 and 332 prior to entering disc bowl centrifuges 334 and 336 . To remove total organic carbon from the effluent it is passed through an ultraviolet light source having a wavelength 185 nm in vessel 338 . The total organic compound breaks down into CO2 in the presence of hydroxyl radical present in the effluent.
The effluent is then passed through three media tanks 342 each containing activated carbon. These filters will polish the effluent further and remove any leftover heavy metals. They will also break down any remaining ozone and convert it into oxygen. The effluent will then be conveyed to tank 344 prior to being introduced to micron filters 346 . Each filter is capable of filtering material down to one to five microns. The effluent leaving the micron filters is then pressurized via pumps 348 prior to entering the reverse osmosis membranes 350 . Each pump 348 can operate up to 1000 psi separating clean permeate and reject the brine. Outlet 352 carries the concentrated waste product to be conveyed to a reject water tank for reinjection or other suitable disposal. Outlet 354 carries the RO product water to be conveyed to a clean water frac tank for storage and distribution.
FIG. 4A is a perspective side view of the containerized frac water purification apparatus with the side walls and top removed for clarity. Container 400 is a standard container typically used to ship freight, and the like, by truck, rail or ship. Each container will be brought to the well site by truck and installed to process the flowback frac water. The container is partitioned into two separate areas. One area includes the ozone generator 314 a main control panel 402 and an ultra sonic panel 404 . The other section includes the three media tanks 342 , the pressurized main reactor tank 318 , the air separation unit 312 , centrifuge feed pumps 333 and centrifuges 334 and 336 .
FIG. 4B illustrates the ozone booster pump 309 , the reaction tank 330 , the air tank 313 , the air compressor and dryer 311 and the ozone booster pump 309 .
FIG. 4C is a top view of the container 400 and shows control room 406 , and equipment room 408 .
FIG. 5A shows a perspective view of a second container 410 that houses the reverse osmosis pumps 348 , the micron filters 346 and osmosis membrane filters 350 . FIG. 5B is a top view the second container that shows how the second container is partitioned into two separate areas; an office/store room 412 and an equipment area 414 .
FIGS. 6A , 6 B, and 6 C illustrate an alternative frac water fluid treatment process. This apparatus used in this process is designed to be mounted within a truck trailer such that it can be moved from location to location to treat the frac water on site. Frac water enters frac water process tank 602 through inlet 604 . The effluent is removed from tank 602 by pump 606 through flow meter 608 and then through back wash filter 610 . Filter 610 removes substances such as frac sands and foreign particles in the range of 25 to 50 microns. From the filter 610 the effluent proceeds via line 615 to ozone treatment tank 616 where it is saturated with ozone. Air enters compressor 613 through dryers 611 . Oxygen generator 612 receives compressed air from compressor 613 and feeds ozone generator 614 which in turn feeds ozone to a high efficiency, venturi type, differential pressure injector 607 which mixes the ozone gas with the flowback water. The flowback water enters the injector at a first inlet and the passageway within the injector tapers in diameter and becomes constricted at an injection zone located adjacent the second inlet. At this point the flowback flow changes into a higher velocity jet stream. The increase in velocity through the injection zone results in a decrease in pressure thereby enabling the ozone to be drawn in through the second inlet and entrained into the flowback water. The flow path down stream of the injection zone is tapered outwards towards the injector outlet thereby reducing the velocity of the flowback water. Within injector 607 ozone is injected through a venturi at vacuum of 5 inches of Hg. The pressure drop across the venturi is approximately 60 psi which ensures good mixing of the ozone gas with the effluent and small ozone bubble generation. An ozone booster pump 609 feeds effluent and ozone into injector 607 . Line 617 then conveys the output of ozone treatment tank 616 to an in line static mixer 628 . The inline static mixture 628 ensures that the bubbles are maintained at the 1 to 2 micron level. Aluminum sulfate from tank 626 is introduced to in line static mixer 628 via line 627 . The inline static mixer 628 is comprised of a series of geometric mixing elements fixed within a pipe which uses the energy of the flow stream to create mixing between two or more fluids. The output of in line mixer 628 is then introduced into chemical mixing tank 630 . The alum is a coagulating agent with a low pH that coagulates suspended solids and also keeps iron in suspension. The output of mixing tank 630 is then conveyed via line 631 to main reactor tank 618 . The output is introduced through a manifold 621 within the main reactor tank 618 .
The manifold 621 includes orifices designed to create hydrodynamic cavitations with the main reactor tank 618 . By way of example, the diameters of the holes within the manifold 621 are approximately 5 mm and the pressure difference across the manifold is approximately 20 psi. In addition, the main reactor tank 618 also includes four submersible ultrasonic transducers 622 A and 622 B positioned at various elevations within the reactor tank 618 . These ultrasonic transducers 622 A and 622 B are designed to create acoustic cavitations. Each transducer includes a diaphragm that is balanced with the help of a pressure compensation system so that a maximum amount of ultrasonic energy is released into the effluent. The main reactor tank 618 includes a pair of 16 KHz and a pair of 20 KHz frequency ultrasonic horns ( 622 A and 622 B, respectively). The ultrasonic horns 622 A and 622 B are installed around the periphery of the tank creating a uniform ultrasonic environment which helps to increase the mass transfer efficiency of the ozone. In addition, the 16 KHz and 20 KHZ horns 622 A and 622 B are installed opposite to each other inside the tank to create a dual frequency filed that continuously cleans the internal tank surface. The acoustic cavitations generated by the ultrasonic generators 622 A and 622 B also greatly enhance the oxidation rate of the organic material with ozone bubbles and ensure uniform mixing of the oxidant with the effluent. As shown in FIGS. 6A and 7 main reactor tank 618 also includes a plurality of anodes 619 within the tank that provides DC current to the effluent and thereby creates oxidants in the water. In this process the DC current drives the electro precipitation reaction for the hardness ions present in the effluent. During this treatment the positively charged cations move towards the electron emitting (negative) cathode which is the shell of the main reactor tank 618 . The negatively charged anions move towards the positive anodes 619 . In this process sulfate ions are fed to the cations which either form a scale or are transformed into a colloidal from and remain suspended in the effluent. Some heavy metals are oxidized to an insoluble dust while others combine with sulfate or carbonate ion to make a precipitate under the influence of the electrode. The carbonate and sulfate salt precipitate on the return cathode surface. The ultrasound continuously cleans the precipitation on the return cathode surface and produces small flakes which are removed later in the process during centrifuge separation. The cations which precipitate with sulfate ions are in colloidal form have fewer tendencies to form any scaling and remain in colloidal form through out the process notwithstanding the temperature and pressure. The coagulated suspended solids are then removed in centrifuge separation later in the process. The anodes 619 are made of titanium and are provided with a coating of oxides of Rh and Ir to increase longevity. The anodes 619 are powered by a DC power supply whose power output can be up to 100 volts DC and up to 1000 amps current. The DC power supply can be varied according to targeted effluent. For example, for water effluent with a higher salt content the power supply output would provide less DC voltage and more DC current than water with low levels of salt. The main Reactor tank 618 is maintained at an internal pressure greater than atmospheric.
The effluent then flows through line 624 and into tank 632 and then through feed pump 633 into centrifuge 634 and then into intermediate process tank 636 .
The effluent is then passed through three media tanks 642 each containing activated carbon. These filters will polish the effluent further and remove any leftover heavy metals. They will also break down any remaining ozone and convert it into oxygen. The effluent will then be conveyed to tank 644 prior to being introduced to micron filter 646 . The filter is capable of filtering material down to one to five microns. The effluent leaving the micron filter passes through an accumulator and is then pressurized via pump 648 prior to entering the reverse osmosis membranes 650 . The pump 648 can operate up to 1000 psi separating clean permeate and reject the brine. Outlet 652 carries the concentrated waste product to be conveyed to a reject water tank for reinjection or other suitable disposal. Outlet 654 carries the RO product water to be conveyed to a clean water frac tank for storage and distribution.
FIG. 8 illustrates a cut away view of a modified truck trailer 660 that is designed to transport the frac water processing equipment for the system such as the one disclosed in FIGS. 6A-6C . The trailer is partitioned into discrete areas. As shown, area 662 is designated as the area for the RO equipment and the centrifuge. Area 664 is the area designated for the media and cartridge filters. Similarly, area 666 would contain the ozone producing and treatment equipment as well as the main treatment tank. The control room is installed in compartment 668 and an electrical generator (typically 280 Kw) is installed in compartment 670 . The equipment is assembled in a modular fashion. Module 672 includes a centrifuge and RO and ancillary equipment mounted on a skid. Module 674 includes the media and cartridge filters and ancillary equipment that is also mounted on a skid. A third module 676 includes the ozone producing and treatment equipment, the main treatment tank and other supporting equipment also mounted on a moveable skid. By configuring the processing equipment in a modular fashion and placing them on skids that are removable from the truck trailer the system components can be readily replaced. The ability to swap out system component modules substantially minimizes system down time and improves the ability to repair the processing equipment in a quick and efficient manner.
FIG. 9 shows data tables representing two samples of flow back water. Each data table sets forth the contaminants within the flow back water prior to treatment in the main reaction tank as compared to the same contaminants subsequent to treatment in the main reaction tank. As can be seen from the tables, the main treatment tank will remove substantial amounts of contaminant from the flow back water.
The theory of operation behind the main treatment is as follows. The mass transfer of ozone in the flow back water is achieved by hydrodynamic and acoustic cavitations. In the pressurized tank the ozonated flow back water is mixed with incoming flow back water by a header having many small orifices. The phenomenon of hydrodynamic cavitations is created as the pressurized flow back water leaves the small orifices on the header. The dissolved ozone forms into millions of micro bubbles which are mixed and reacted with the incoming flow back water. As the flow back water flows upwards through the reaction tank ultrasonic transducers located around the periphery of the tank at different locations emit 16 KHz and 20 KHz waves in the flow back water.
A sonoluminescence effect is observed due to acoustic cavitation as these ultrasonic waves propagate in the flow back water and catch the micro bubbles in the valley of the wave. Sonoluminescence occurs whenever a sound wave of sufficient intensity induces a gaseous cavity within a liquid to quickly collapse. This cavity may take the form of a pre-existing bubble, or may be generated through hydrodynamic and acoustic cavitation. Sonoluminescence can be made to be stable, so that a single bubble will expand and collapse over and over again in a periodic fashion, emitting a burst of light each time it collapses. A standing acoustic wave is set up within a liquid by four acoustic transducers and the bubble will sit at a pressure anti node of the standing wave. The frequencies of resonance depend on the shape and size of the container in which the bubble is contained. The light flashes from the bubbles are extremely short, between 35 and few hundred picoseconds long, with peak intensities of the order of 1-10 mW. The bubbles are very small when they emit light, about 1 micrometer in diameter depending on the ambient fluid, such as water, and the gas content of the bubble. Single bubble sonoluminescence pulses can have very stable periods and positions. In fact, the frequency of light flashes can be more stable than the rated frequency stability of the oscillator making the sound waves driving them. However, the stability analysis of the bubble shows that the bubble itself undergoes significant geometric instabilities, due to, for example, the Bjerknes forces and the Rayleigh-Taylor instabilities. The wavelength of emitted light is very short; the spectrum can reach into the ultraviolet. Light of shorter wavelength has higher energy, and the measured spectrum of emitted light seems to indicate a temperature in the bubble of at least 20,000 Kelvin, up to a possible temperature in excess of one mega Kelvin. The veracity of these estimates is hindered by the fact that water, for example, absorbs nearly all wavelengths below 200 nm. This has led to differing estimates on the temperature in the bubble, since they are extrapolated from the emission spectra taken during collapse, or estimated using a modified Rayleigh-Plesset equation. During bubble collapse, the inertia of the surrounding water causes high speed and high pressure, reaching around 10,000 K in the interior of the bubble, causing ionization of a small fraction of the noble gas present. The amount ionized is small enough for the bubble to remain transparent, allowing volume emission; surface emission would produce more intense light of longer duration, dependent on wavelength, contradicting experimental results. Electrons from ionized atoms interact mainly with neutral atoms causing thermal bremsstrahlung radiation. As the ultrasonic waves hit a low energy trough, the pressure drops, allowing electrons to recombine with atoms, and light emission to cease due to this lack of free electrons. This makes for a 160 picosecond light pulse for argon, as even a small drop in temperature causes a large drop in ionization, due to the large ionization energy relative to the photon energy.
By way of example, the instant invention can be used to treat produced water containing water soluble organic compounds, suspended oil droplets and suspended solids with high concentration of ozone and ultrasonic waves resulting in degrading the level of contaminants.
Case 1: Processing Fluid (Effluent) from Oil Drilling Well
Objective: To increase the efficiency of mechanical centrifugal Separation by treating effluent generated from oil drilling operation with Ozone and Ultrasonic waves.
The main constituent of effluent is bentonite. Bentonite consists predominantly of smectite minerals montmorillonite. Smectite are clay minerals of size less than 2˜5 microns. Mainly traces of silicon (Si), aluminum (Al), Magnesium (Mg), calcium (Ca) salts found in the bentonite.
The percentage of solids (bentonite) in effluent varies from 40% to 60%. Also contaminants oil, grease, VOC are found in the effluent.
Anticipated Effect of Ozone and Ultrasonic on Effluent:
Ozone 40 is introduced into the tank 20 in form of micro bubbles which starts oxidation reactions where the organic molecules in the effluent are modified and re-arranged. The bonding between bentonite molecules with water is broken down by hydrodynamic cavitations caused by imploding micro bubbles of ozone with bentonite.
The mass transfer of ozone into effluent is further enhanced by subjecting the effluent with ultrasonic submersible transducers 24 and 26 located at various elevations in the tank. The ultrasonic wave (range from 14 KHz to 20 KHz) propagates through water causing acoustic cavitations. This helps ozone to react with bentonite irrespective of temperature and pH, coverts into collided slimy sludge mass, suspended in water.
The oxidation process of ozone improves color of the water from grey to white. During the process soluble organic compounds broke down into carbon dioxide and oxygen molecules.
As water travels from bottom 22 to the top 23 of the tank 20 , volatile organic compounds are collected at the top of the tank, which can be drained out with the help of outlet 50 provided.
Main effluent is piped 48 to centrifuge where the efficiency of separation is expected to increase by 30˜40%.
Case II: Produced Water from Offshore Drilling Well
Main properties of this effluent is
Color/Appearance: Black.
Total suspended solids: 9500 ppm
Total dissolved solids: 3290 ppm
Chemical Oxygen demand: 3370 ppm
Biological Oxygen Demand: 580 ppm
pH: 7.88
Oil and Grease: 17.2 mgHX/l
The effluent2 has peculiar H2S odor.
Effect of Ozone and Ultrasonic Waves:
Ozone 40 is introduced into the tank 20 in the form of micro bubbles which starts oxidation reactions where the organic molecules in the effluent are modified and re-arranged. The suspended solids are separated and are broken down by hydrodynamic cavitations caused by imploding micro bubbles of ozone. This helps suspended solids coagulate. The oxidation process of ozone improves the color, eliminate the odder and convert suspended solids into inert particle.
The mass transfer of ozone into effluent is further enhanced by subjecting the effluent with ultrasonic submersible transducers 24 & 26 located at various elevations in the tank. Greater mass transfer of ozone into effluent is achieved irrespective of temperature or pH of water. The ultrasonic wave (range from 14 KHz to 20 KHz) propagates through water causing acoustic cavitations. This helps ozone to react better separating volatile organic compounds, suspended solids from water molecule. During the process soluble organic compounds broke down into carbon dioxide and oxygen molecules.
The expected results after Ozonix® Process on effluent 2 are:
Color/Appearance: pale yellow, colorless
Total suspended solids: less than 40 ppm
Total dissolved solids: less than 30 ppm
Chemical Oxygen demand: less than 10 ppm
Biological Oxygen Demand: less than 10 ppm
pH: 7
Oil and Grease: less than 5 ppm
Odorless.
Case III: Treatment of Flowback or Frac Water with Mobile Equipment
The typical flowback fluid contains the following contaminants:
Iron
60.2
mg/L
Manganese
1.85
mg/L
Potassium
153.0
mg/L
Sodium
7200
mg/L
Turbidity
599
NTU
Barium
14.2
mg/L
Silica
36.9
mg/L
Stontium
185
mg/L
Nitrate
0.0100
U mg/L
Nitrite
0.0200
U mg/L
TSS
346
mg/L
TDS
33800
mg/L
Oil + Grease
9.56
mgHx/L
(HEM)
Calcium Hardness
4690
mg/L
Magnesium Hardness
967
mg/L
Specific Conductance
51500
umhos/cm
Ammonia (as N)
67.8
mg/L
Unionized
Chloride
19300
mg/L
Sulfate
65.0
mg/L
Total Phosphorous
2.07
mg/L
(as P)
TOC
163
mg/L
Bicarbonate CaCO3
404
mg/L
Bicarbonate HCO3
247
mg/L
Carbonate CO3
0.100
U mg/L
Carbonate CaCO3
0.100
U mg/L
All of the contaminants are eliminated at various stages of the filtration system.
During the pretreatment stage the frac, flowback water, is pumped through 50 micron filter 310 which includes an automatic backwash feature. This filter removes substances like frac sands, and foreign particles above 50 microns in size. Approximately 70 percent of the frac water is then saturated with ozone in the ozone contact tank 316 with the remainder, approximately 30 percent, directed to the main reactor tank 318 . The effluent from the ozone contact tank 316 is introduced through a manifold 321 within the reactor tank 318 . The manifold includes orifices designed to create hydrodynamic cavitations with the main reactor tank. In addition the reactor tank 318 also includes ultrasonic transducers 322 positioned as various elevations within the reactor tank 318 . These ultrasonic transducers 322 are designed to create acoustic cavitations. The combination of both acoustical and ultrasonic cavitations causes the maximum mass transfer of ozone within the treatment tank in the shortest period of time. This process oxidizes all the heavy metals and soluble organics and disinfects the effluent. The process within the main reactor tank 318 also causes the suspended solid to coagulate thereby facilitating their separation during centrifugal separation. Additionally, to coagulate all the oxidized metals and suspended solids aluminum sulfate (Alum) is added after the main reactor tank 318 and before the centrifugal separation.
All suspended solids are removed in the disc bowl centrifuge. The suspended solids are collected at the periphery of the disc bowl centrifuge 334 and intermittently during de-sludging cycles. At this point in the process the effluent is free from all suspended solids, heavy metals, and soluble organics. The effluent is then passed through an ultra-violet light 338 using 185 nm wavelength to remove all organic carbon. The total organic carbon (TOC) is broken down into CO2 in the presence of hydroxyl radical present in the affluent.
The effluent is then passed through three media tanks 342 containing activated carbon. These filters serve to further polish the effluent and remove any left over heavy metals. In addition the media tanks also break down any remaining ozone and convert it into oxygen. At this stage of filtration the effluent is free from soluble and insoluble oils, heavy metals, and suspended solids.
The effluent is then passed through reverse osmosis (RO) filtration. The RO feed pump passes the effluent through a 1 micron filter 346 which is then fed to five high pressure RO pumps. The RO pumps 348 can operate up to 1000 psi thereby separating permeate and rejecting the brine. To avoid scaling the RO membranes 350 anti-scalant material is fed into the suction inlet of the RO pump. The clean permeate has total dissolved salts in the range of 5˜50 PPM. By way of example, is the system is processing 45,000 PPM TDS effluent the resultant TDS in RO reject water will be approximately 80,000 PPM.
It is to be understood that while certain forms of the invention is illustrated, it is not to be limited to the specific form or process herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings. | Disclosed is a process for reclamation of waste fluids. A conditioning container is employed for receipt of waste material on a continuous flow for treatment within the container by immersible transducers producing ultrasonic acoustic waves in combination with a high level of injected ozone. The treated material exhibits superior separation properties for delivery into a centrifuge for enhanced solid waste removal. The invention discloses a cost efficient and environmentally friendly process and apparatus for cleaning and recycling of flowback, or frac water, which has been used to stimulate gas production from shale formations. The apparatus is mobile and containerized and suitable for installation at the well site. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part Application of pending U.S. patent application Ser. No. 09/852,209, filed May 10, 2001, which is a continuation-In-Part Application of pending U.S. patent application Ser. No. 09/410,349, filed Sep. 30, 1999, which in turn claims the benefit of U.S. Provisional Application No. 60/102,461, filed Sep. 30, 1998; U.S. Provisional Application No. 60/108,109, filed Nov. 12, 1998; U.S. Provisional Application No. 60/110,749, filed Dec. 3, 1998; U.S. Provisional Application No. 60/113,002, filed Dec. 18, 1998; U.S. Provisional Application No. 60/135,426, filed May 21, 1999; and U.S. Provisional Application No. 60/144,022, filed Jul. 15, 1999.
FIELD OF THE INVENTION
[0002] This invention relates to growth factors for connective tissue cells, fibroblasts, myofibroblasts and glial cells and/or to growth factors for endothelial cells, and in particular to a novel platelet-derived growth factor/vascular endothelial growth factor-like growth factor, a polynucleotide sequence encoding the factor, and to pharmaceutical and diagnostic compositions and methods utilizing or derived from the factor.
BACKGROUND OF THE INVENTION
[0003] In the developing embryo, the primary vascular network is established by in situ differentiation of mesodermal cells in a process called vasculogenesis. It is believed that all subsequent processes involving the generation of new vessels in the embryo and neovascularization in adults, are governed by the sprouting or splitting of new capillaries from the pre-existing vasculature in a process called angiogenesis (Pepper et al., Enzyme & Protein, 1996 49 138-162; Breier et al., Dev. Dyn. 1995 204 228-239; Risau, Nature, 1997 386 671-674). Angiogenesis is not only involved in embryonic development and normal tissue growth, repair, and regeneration, but is also involved in the female reproductive cycle, establishment and maintenance of pregnancy, and in repair of wounds and fractures.
[0004] In addition to angiogenesis which takes place in the normal individual, angiogenic events are involved in a number of pathological processes, notably tumor growth and metastasis, and other conditions in which blood vessel proliferation, especially of the microvascular system, is increased, such as diabetic retinopathy, psoriasis and arthropathies. Inhibition of angiogenesis is useful in preventing or alleviating these pathological processes. On the other hand, promotion of angiogenesis is desirable in situations where vascularization is to be established or extended, for example after tissue or organ transplantation, or to stimulate establishment of perivascular and/or collateral circulation in tissue infarction or arterial stenosis, such as in coronary heart disease and thromboangitis obliterans.
[0005] The angiogenic process is highly complex and involves the maintenance of the endothelial cells in the cell cycle, degradation of the extracellular matrix, migration and invasion of the surrounding tissue and finally, tube formation. The molecular mechanisms underlying the complex angiogenic processes are far from being understood.
[0006] Because of the crucial role of angiogenesis in so many physiological and pathological processes, factors involved in the control of angiogenesis have been intensively investigated. A number of growth factors have been shown to be involved in the regulation of angiogenesis; these include fibroblast growth factors (FGFs), platelet-derived growth factor (PDGF), transforming growth factor alpha (TGFα), and hepatocyte growth factor (HGF). See for example Folkman et al., J. Biol. Chem., 1992 267 10931-10934 for a review.
[0007] It has been suggested that a particular family of endothelial cell-specific growth factors, the vascular endothelial growth factors (VEGFs), and their corresponding receptors is primarily responsible for stimulation of endothelial cell growth and differentiation, and for certain functions of the differentiated cells. These factors are members of the PDGF family, and appear to act primarily via endothelial receptor tyrosine kinases (RTKs).
[0008] Nine different proteins have been identified in the PDGF family, namely two PDGFs (A and B), VEGF and six members that are closely related to VEGF. The six members closely related to VEGF are: VEGF-B, described in International Patent Application PCT/US96/02957 (WO 96/26736) and in U.S. Pat. Nos. 5,840,693 and 5,607,918 by Ludwig Institute for Cancer Research and The University of Helsinki; VEGF-C, described in Joukov et al., EMBO J., 1996 15 290-298 and Lee et al., Proc. Natl. Acad. Sci. USA, 1996 93 1988-1992; VEGF-D, described in International Patent Application No. PCT/US97/14696 (WO 98/07832), and Achen et al., Proc. Natl. Acad. Sci. USA, 1998 95 548-553; the placenta growth factor (PlGF), described in Maglione et al., Proc. Natl. Acad. Sci. USA, 1991 88 9267-9271; VEGF2, described in International Patent Application No. PCT/US94/05291 (WO 95/24473) by Human Genome Sciences, Inc; and VEGF3, described in International Patent Application No. PCT/US95/07283 (WO 96/39421) by Human Genome Sciences, Inc.
[0009] Each VEGF family member has between 30% and 45% amino acid sequence identity with VEGF. The VEGF family members share a VEGF homology domain which contains the six cysteine residues which form the cysteine knot motif. Functional characteristics of the VEGF family include varying degrees of mitogenicity for endothelial cells, induction of vascular permeability and angiogenic and lymphangiogenic properties.
[0010] Vascular endothelial growth factor (VEGF) is a homodimeric glycoprotein that has been isolated from several sources. VEGF shows highly specific mitogenic activity for endothelial cells. VEGF has important regulatory functions in the formation of new blood vessels during embryonic vasculogenesis and in angiogenesis during adult life (Carmeliet et al., Nature, 1996 380 435-439; Ferrara et al., Nature, 1996 380 439-442; reviewed in Ferrara and Davis-Smyth, Endocrine Rev., 1997 18 4-25). The significance of the role played by VEGF has been demonstrated in studies showing that inactivation of a single VEGF allele results in embryonic lethality due to failed development of the vasculature (Carmeliet et al., Nature, 1996 380 435-439; Ferrara et al., Nature, 1996 380 439-442).
[0011] In addition VEGF has strong chemoattractant activity towards monocytes, can induce the plasminogen activator and the plasminogen activator inhibitor in endothelial cells, and can also induce microvascular permeability. Because of the latter activity, it is sometimes referred to as vascular permeability factor (VPF). The isolation and properties of VEGF have been reviewed; see Ferrara et al., J. Cellular Biochem., 1991 47 211-218 and Connolly, J. Cellular Biochem., 1991 47 219-223. Alterative mRNA splicing of a single VEGF gene gives rise to five isoforms of VEGF.
[0012] VEGF-B has similar angiogenic and other properties to those of VEGF, but is distributed and expressed in tissues differently from VEGF. In particular, VEGF-B is very strongly expressed in heart, and only weakly in lung, whereas the reverse is the case for VEGF. This suggests that VEGF and VEGF-B, despite the fact that they are co-expressed in many tissues, may have functional differences.
[0013] A comparison of the PDGF/VEGF family of growth factors reveals that the 167 amino acid isoform of VEGF-B is the only family member that is completely devoid of any glycosylation. Gene targeting studies have shown that VEGF-B deficiency results in mild cardiac phenotype, and impaired coronary vasculature (Bellomo et al., Circ. Res. 86:E29-35 (2000)). VEGF-B knock out mice were demonstrated to have impaired coronary vessel structure, smaller hearts and impaired recovery after cardiac ischemia (Bellomo, D. et al., Circulation Research ( Online ), 86:E29-35 (2000)).
[0014] Human VEGF-B was isolated using a yeast co-hybrid interaction trap screening technique by screening for cellular proteins which might interact with cellular retinoic acid-binding protein type I (CRABP-I). The isolation and characteristics including nucleotide and amino acid sequences for both the human and mouse VEGF-B are described in detail in PCT/US96/02957, in U.S. Pat. Nos. 5,840,693 and 5,607,918 by Ludwig Institute for Cancer Research and The University of Helsinki and in Olofsson et al., Proc. Natl. Acad. Sci. USA 93:2576-2581 (1996). The nucleotide sequence for human VEGF-B is also found at GenBank Accession No. U48801. The entire disclosures of the International Patent Application PCT/US97/14696 (WO 98/07832), U.S. Pat. Nos. 5,840,693 and 5,607,918 are incorporated herein by reference.
[0015] The mouse and human genes for VEGF-B are almost identical, and both span about 4 kb of DNA. The genes are composed of seven exons and their exon-intron organization resembles that of the VEGF and PlGF genes (Grimmond et al., Genome Res. 6:124-131 (1996); Olofsson et al., J. Biol. Chem. 271:19310-19317 (1996); Townson et al., Biochem. Biophys. Res. Commun. 220:922-928 (1996)).
[0016] VEGF-C was isolated from conditioned media of the PC-3 prostate adenocarcinoma cell line (CRL1435) by screening for ability of the medium to produce tyrosine phosphorylation of the endothelial cell-specific receptor tyrosine kinase VEGFR-3 (Flt4), using cells transfected to express VEGFR-3. VEGF-C was purified using affinity chromatography with recombinant VEGFR-3, and was cloned from a PC-3 cDNA library. Its isolation and characteristics are described in detail in Joukov et al., EMBO J., 1996 15 290-298.
[0017] VEGF-D was isolated from a human breast cDNA library, commercially available from Clontech, by screening with an expressed sequence tag obtained from a human cDNA library designated “Soares Breast 3NbHBst” as a hybridization probe (Achen et al., Proc. Natl. Acad. Sci. USA, 1998 95 548-553). Its isolation and characteristics are described in detail in International Patent Application No. PCT/US97/14696 (WO 98/07832).
[0018] The VEGF-D gene is broadly expressed in the adult human, but is certainly not ubiquitously expressed. VEGF-D is strongly expressed in heart, lung and skeletal muscle. Intermediate levels of VEGF-D are expressed in spleen, ovary, small intestine and colon, and a lower expression occurs in kidney, pancreas, thymus, prostate and testis. No VEGF-D mRNA was detected in RNA from brain, placenta, liver or peripheral blood leukocytes.
[0019] PlGF was isolated from a term placenta cDNA library. Its isolation and characteristics are described in detail in Maglione et al., Proc. Natl. Acad. Sci. USA, 1991 88 9267-9271. Presently its biological function is not well understood.
[0020] VEGF2 was isolated from a highly tumorgenic, oestrogen-independent human breast cancer cell line. While this molecule is stated to have about 22% homology to PDGF and 30% homology to VEGF, the method of isolation of the gene encoding VEGF2 is unclear, and no characterization of the biological activity is disclosed.
[0021] VEGF3 was isolated from a cDNA library derived from colon tissue. VEGF3 is stated to have about 36% identity and 66% similarity to VEGF. The method of isolation of the gene encoding VEGF3 is unclear and no characterization of the biological activity is disclosed.
[0022] Similarity between two proteins is determined by comparing the amino acid sequence and conserved amino acid substitutions of one of the proteins to the sequence of the second protein, whereas identity is determined without including the conserved amino acid substitutions.
[0023] PDGF/VEGF family members act primarily by binding to receptor tyrosine kinases. Five endothelial cell-specific receptor tyrosine kinases have been identified, namely VEGFR-1 (Flt-1), VEGFR-2 (KDR/Flk-1), VEGFR-3 (Flt4), Tie and Tek/Tie-2. All of these have the intrinsic tyrosine kinase activity which is necessary for signal transduction. The essential, specific role in vasculogenesis and angiogenesis of VEGFR-1, VEGFR-2, VEGFR-3, Tie and Tek/Tie-2 has been demonstrated by targeted mutations inactivating these receptors in mouse embryos.
[0024] The only receptor tyrosine kinases known to bind VEGFs are VEGFR-1, VEGFR-2 and VEGFR-3. VEGFR-1 and VEGFR-2 bind VEGF with high affinity, and VEGFR-1 also binds VEGF-B and PlGF. VEGF-C has been shown to be the ligand for VEGFR-3, and it also activates VEGFR-2 (Joukov et al., The EMBO Journal, 1996 15 290-298). VEGF-D binds to both VEGFR-2 and VEGFR-3. A ligand for Tek/Tie-2 has been described in International Patent Application No. PCT/US95/12935 (WO 96/11269) by Regeneron Pharmaceuticals, Inc. The ligand for Tie has not yet been identified.
[0025] Recently, a novel 130-135 kDa VEGF isoform specific receptor has been purified and cloned (Soker et al., Cell, 1998 92 735-745). The VEGF receptor was found to specifically bind the VEGF 165 isoform via the exon 7 encoded sequence, which shows weak affinity for heparin (Soker et al., Cell, 1998 92 735-745). Surprisingly, the receptor was shown to be identical to human neuropilin-1 (NP-1), a receptor involved in early stage neuromorphogenesis. PlGF-2 also appears to interact with NP-1 (Migdal et al., J. Biol. Chem., 1998 273 22272-22278).
[0026] VEGFR-1, VEGFR-2 and VEGFR-3 are expressed differently by endothelial cells. Both VEGFR-1 and VEGFR-2 are expressed in blood vessel endothelia (Oelrichs et al., Oncogene, 1992 8 11-18; Kaipainen et al., J. Exp. Med., 1993 178 2077-2088; Dumont et al., Dev. Dyn., 1995 203 80-92; Fong et al., Dev. Dyn., 1996 207 1-10) and VEGFR-3 is mostly expressed in the lymphatic endothelium of adult tissues (Kaipainen et al., Proc. Natl. Acad. Sci. USA, 1995 9 3566-3570). VEGFR-3 is also expressed in the blood vasculature surrounding tumors.
[0027] Disruption of the VEGFR genes results in aberrant development of the vasculature leading to embryonic lethality around midgestation. Analysis of embryos carrying a completely inactivated VEGFR-l gene suggests that this receptor is required for functional organization of the endothelium (Fong et al., Nature, 1995 376 66-70). However, deletion of the intracellular tyrosine kinase domain of VEGFR-l generates viable mice with a normal vasculature (Hiratsuka et al., Proc. Natl. Acad. Sci. USA 1998 95 9349-9354). The reasons underlying these differences remain to be explained but suggest that receptor signalling via the tyrosine kinase is not required for the proper function of VEGFR-1. Analysis of homozygous mice with inactivated alleles of VEGFR-2 suggests that this receptor is required for endothelial cell proliferation, hematopoesis and vasculogenesis (Shalaby et al., Nature, 1995 376 62-66; Shalaby et al., Cell, 1997 89 981-990). Inactivation of VEGFR-3 results in cardiovascular failure due to abnormal organization of the large vessels (Dumont et al. Science, 1998 282 946-949).
[0028] VEGFRs are expressed in many adult tissues, despite the apparent lack of constitutive angiogenesis. VEGFRs are however clearly upregulated in endothelial cells during development and in certain angiogenesis-associated/dependent pathological situations including tumor growth [see Dvorak et al., Amer. J. Pathol., 146:1029-1039 (1995); Ferrara et al., Endocrine Rev., 18:4-25 (1997)]. The phenotypes of VEGFR-1-deficient mice and VEGFR-2-deficient mice reveal an essential role for these receptors in blood vessel formation during development.
[0029] Although VEGFR-1 is mainly expressed in endothelial cells during development, it can also be found in hematopoetic precursor cells during early stages of embryogenesis (Fong et al., Nature, 1995 376 66-70). In adults, monocytes and macrophages also express this receptor (Barleon et al., Blood, 1996 87 3336-3343). In embryos, VEGFR-1 is expressed by most, if not all, vessels (Breier et al., Dev. Dyn., 1995 204 228-239; Fong et al., Dev. Dyn., 1996 207 1-10).
[0030] The receptor VEGFR-3 is widely expressed on endothelial cells during early embryonic development but as embryogenesis proceeds becomes restricted to venous endothelium and then to the lymphatic endothelium (Kaipainen et al., Cancer Res., 1994 54 6571-6577; Kaipainen et al., Proc. Natl. Acad. Sci. USA, 1995 92 3566-3570). VEGFR-3 is expressed on lymphatic endothelial cells in adult tissues. This receptor is essential for vascular development during embryogenesis. Targeted inactivation of both copies of the VEGFR-3 gene in mice resulted in defective blood vessel formation characterized by abnormally organized large vessels with defective lumens, leading to fluid accumulation in the pericardial cavity and cardiovascular failure at post-coital day 9.5.
[0031] On the basis of these findings it has been proposed that VEGFR-3 is required for the maturation of primary vascular networks into larger blood vessels. However, the role of VEGFR-3 in the development of the lymphatic vasculature could not be studied in these mice because the embryos died before the lymphatic system emerged. Nevertheless it is assumed that VEGFR-3 plays a role in development of the lymphatic vasculature and lymphangiogenesis given its specific expression in lymphatic endothelial cells during embryogenesis and adult life. This is supported by the finding that ectopic expression of VEGF-C, a ligand for VEGFR-3, in the skin of transgenic mice, resulted in lymphatic endothelial cell proliferation and vessel enlargement in the dermis. Furthermore this suggests that VEGF-C may have a primary function in lymphatic endothelium, and a secondary function in angiogenesis and permeability regulation which is shared with VEGF (Joukov et al., EMBO J., 1996 15 290-298).
[0032] VEGFR-1-deficient mice die in utero at mid-gestation due to inefficient assembly of endothelial cells into blood vessels, resulting in the formation of abnormal vascular channels [Fong et al., Nature, 376:66-70 (1995)]. Analysis of embryos carrying a completely inactivated VEGFR-1 gene suggests that this receptor is required for functional organization of the endothelium (Fong et al., Nature, 376: 66-70, 1995). However, deletion of the intracellular tyrosine kinase domain of VEGFR-1 generates viable mice with a normal vasculature (Hiratsuka et al., Proc. Natl. Acad. Sci. USA, 95: 9349-9354, 1998). The reasons underlying these differences remain to be explained but suggest that receptor signalling via the tyrosine kinase is not required for the proper function of VEGFR-1.
[0033] VEGFR-2-deficient mice die in utero between 8.5 and 9.5 days post-coitum, and in contrast to VEGFR-1, this appears to be due to abortive development of endothelial cell precursors (Shalaby et al., Nature 376:62-66 (1995); Shalaby et al., Cell, 89: 981-990 (1997)), suggesting that this receptor is required for endothelial cell proliferation, hematopoesis and vasculogenesis. The importance of VEGFR-2 in tumor angiogenesis has also been clearly demonstrated by using a dominant-negative approach (Millauer et al., Nature, 367:576-579 (1994); Millauer et al., Cancer Res. 56:1615-1620 (1996)).
[0034] The phenotype of VEGFR-3-deficient mice has been reported in Dumont, et al., Cardiovascular Failure in Mouse Embryos Deficient in VEGF Receptor-3 , Science, 282:946-949 (1998). VEGFR-3 deficient mice die in utero between 12 and 14 days of gestation due to defective blood vessel development. On the basis of these findings it has been proposed that VEGFR-3 is required for the maturation of primary vascular networks into larger blood vessels. However, the role of VEGFR-3 in the development of the lymphatic vasculature could not be studied in these mice because the embryos died before the lymphatic system emerged. Nevertheless it is assumed that VEGFR-3 plays a role in development of the lymphatic vasculature and lymphangiogenesis given its specific expression in lymphatic endothelial cells during embryogenesis and adult life.
[0035] This is supported by the finding that ectopic expression of VEGF-C, a ligand for VEGFR-3, in the skin of transgenic mice, resulted in lymphatic endothelial cell proliferation and vessel enlargement in the dermis (Makinen et al., Nature Med, 7:199-205, 2001). Furthermore this suggests that VEGF-C may have a primary function in lymphatic endothelium, and a secondary function in angiogenesis and permeability regulation which is shared with VEGF (Joukov et al., EMBO J., 15: 290-298, 1996).
[0036] Some inhibitors of the VEGF/VEGF-receptor system have been shown to prevent tumor growth via an anti-angiogenic mechanism; see Kim et al., Nature, 1993 362 841-844 and Saleh et al., Cancer Res., 1996 56 393-401.
[0037] As mentioned above, the VEGF family of growth factors are members of the PDGF family. PDGF plays a important role in the growth and/or motility of connective tissue cells, fibroblasts, myofibroblasts and glial cells (Heldin et al., “Structure of platelet-derived growth factor: Implications for functional properties”, Growth Factor, 1993 8 245-252). In adults, PDGF stimulates wound healing (Robson et al., Lancet, 1992 339 23-25). Structurally, PDGF isoforms are disulfide-bonded dimers of homologous A- and B-polypeptide chains, arranged as homodimers (PDGF-AA and PDGF-BB) or a heterodimer (PDGF-AB).
[0038] PDGF isoforms exert their effects on target cells by binding to two structurally related receptor tyrosine kinases (RTKs). The alpha-receptor binds both the A- and B-chains of PDGF, whereas the beta-receptor binds only the B-chain. These two receptors are expressed by many in vitro grown cell lines, and are mainly expressed by mesenchymal cells in vivo. The PDGFs regulate cell proliferation, cell survival and chemotaxis of many cell types in vitro (reviewed in Heldin et al., Biochim Biophys Acta., 1998 1378 F79-113). In vivo, they exert their effects in a paracrine mode since they often are expressed in epithelial (PDGF-A) or endothelial cells (PDGF-B) in close apposition to the PDGFR expressing mesenchyme.
[0039] In tumor cells and in cell lines grown in vitro, coexpression of the PDGFs and the receptors generate autocrine loops which are important for cellular transformation (Betsholtz et al., Cell, 1984 39 447-57; Keating et al., J. R. Coll Surg Edinb., 1990 35 172-4). Overexpression of the PDGFs have been observed in several pathological conditions, including maligancies, arteriosclerosis, and fibroproliferative diseases (reviewed in Heldin et al., The Molecular and Cellular Biology of Wound Repair, New York: Plenum Press, 1996, 249-273).
[0040] The importance of the PDGFs as regulators of cell proliferation and survival are well illustrated by recent gene targeting studies in mice that have shown distinct physiological roles for the PDGFs and their receptors despite the overlapping ligand specificities of the PDGFRs. Homozygous null mutations for either of the two PDGF ligands or the receptors are lethal. Approximately 50% of the homozygous PDGF-A deficient mice have an early lethal phenotype, while the surviving animals have a complex postnatal phenotype with lung emphysema due to improper alveolar septum formation because of a lack of alveolar myofibroblasts (Bostrom et al., Cell, 1996 85 863-873). The PDGF-A deficient mice also have a dermal phenotype characterized by thin dermis, misshapen hair follicles and thin hair (Karlsson et al., Development, 1999 126 2611-2).
[0041] PDGF-A is also required for normal development of oligodendrocytes and subsequent myelination of the central nervous system (Fruttiger et al., Development, 1999 126 457-67). The phenotype of PDGFR-alpha deficient mice is more severe with early embryonic death at E10, incomplete cephalic closure, impaired neural crest development, cardiovascular defects, skeletal defects, and odemas (Soriano et al., Development, 1997 124 2691-70).
[0042] The PDGF-B and PDGFR-beta deficient mice develop similar phenotypes that are characterized by renal, hematological and cardiovascular abnormalities (Leveen et al., Genes Dev., 1994 8 1875-1887; Soriano et al., Genes Dev., 1994 8 1888-96; Lindahl et al., Science, 1997 277 242-5; Lindahl, Development, 1998 125 3313-2), where the renal and cardiovascular defects, at least in part, are due to the lack of proper recruitment of mural cells (vascular smooth muscle cells, pericytes or mesangial cells) to blood vessels (Leveen et al., Genes Dev., 1994 8 1875-1887; Lindahl et al., Science, 1997 277 242-5; Lindahl et al., Development, 1998 125 3313-2).
[0043] PDGF-C and PDGF-D have only recently been discovered (Li, X., et al, PDGF-C is a New Protease Activated Ligand for the PDGF alpha Receptor, Nat Cell Ciol., 2000 2(5):302-309; Bergsten, E., et al., PDGF-D is a Specific, Protease-Activated Ligand for the PDGF beta Receptor, Nat Cell Biol., 2001 3(5):512-516). PDGF-C is produced as a 95 kD homodimer, PDGF-CC, and needs to be proteolytically activated to bind and activate PDGF receptor alpha. PDGF-C displays a unique protein structure by processing a so-called CUB domain, which has high homology to the same domain in the neutropilin 1 (NP-1) gene (Hamada, T., et al., A Novel Gene Derived from Developing Spinal Cords, SCDGF, is a Unique Member of the PDGF/VEGF Family, FEBS Lett, 2000 475(2):97-102)
[0044] PDGF-C is widely expressed in mesenchymal precursor cells, epithelial cells, muscular tissues, vascular smooth muscle cells of the larger arteries, spinal cord and developing skeleton system, supporting a role in organogenesis (Tsai, Y. J., et al., Identification of a Novel Platelet-Derived Growth Factor-Like Gene, Fallotein, in the Human Reproductive Tract, Biochim Biophys Acta, 2000 1492(1): 196-202; Ding, H. et al., The Mouse PDGFC Gene: Dynanic Expression in Embryonic Tissues During Organogenesis, Mech Dev, 2000 96(2):209-213).
[0045] Over expression of PDGF-C in the heart leads to cardiomyocyte hypertrophy and fibrosis, suggesting a requirement for a fine-tuned control of PDGF-C expression in the heart under normal conditions. PDGF-C has also recently been shown to be a potent angiogenic factor in both the mouse cornea and the chorion allantoic membrane (CAM) assays by stimulating the formation of long and slender vessels, much like those induced by FGF-2. PDGF-C promoted SMC growth in aortic ring outgrowth assay and wound healing (Gilbertson, D. G., et al., Platelet-Derived Growth Factor C (PDGF-C) a Novel Growth Factor that Binds to PDGF (alpha) and (beta) Receptor, J Biol Chem, 2001 276:27406-27414). PDGF-C has recently been shown to be an EWS/FLI induced transforming growth factor (Zwerner, J. P. and May, W. A., PDGF-C is an EWS/FLI Induced Transforming Growth Factor in Ewing Family Tumors, Oncogene, 2001 20(5):626-633), and expressed in many cell lines (Uutela, M., et al., Chromosomal Location, Exon Structure, and Vascular Expression Patterns of the Human PDGFC and PDGFD Genes, Circulation, 2001 103(18):2242-2247), indicating a role in tumorigenesis.
[0046] PDGF-D is produced as a latent homodimer similar to PDGF-C and binds and activates PDGF-R beta upon proteolytic activation. It is highly expressed in the heart, pancreas, ovary, and to a less extent, in most other organs. The biological role of PDGF-D is not yet exhaustively explained.
[0047] Acute and chronic myocardial ischemia are the leading causes of morbidity and mortality in the industralized society caused by coronary thrombosis (Varbella, F., et al., Subacute Left Ventricular Free-Wall Rupture in Early Course of Acute Myocardial Infarction. Climical Report of Two Cases and Review of the Literature, G Ital Cardiol, 1999 29(2)163-170). Immediately after heart infarction, oxygen starvation causes cell death of the infarcted area, followed by hypertrophy of the remaining viable cardiomyocytes to compensate the need of a normal contractile capacity (Heymans, S., et al., Inhibition of Plasminogen Activators or Matrix Metalloproteinases Prevents Cardiac Rupture but Impairs Therapeutic Angiogenesis and Causes Cardiac Failure, Nature Medicine, 1999 5(10):1135-1142).
[0048] Prompt post-infarction reperfusion of the infarcted left ventricular wall may significantly reduce the early mortality and subsequent heart failure by preventing apoptosis of the hypertrophied viable myocytes and pathological ventricular remodelling (Dalrymple-Hay, M. J., et al., Postinfarction Ventricular Septal Rupture: the Wessex Experience, Semin Thorac Cardiovasc Surg, 1998 10(2):111-116). Despite the advances in clinical treatment and prevention, however, insufficient post-infarction revascularization remains to be the major cause of the death of the otherwise viable myocardium and leads to progressive infarct extension and fibrous replacement, and ultimately heart failure. Therefore, therapeutic agents promoting post-infarction revascularization with minimal toxicity are still needed.
SUMMARY OF THE INVENTION
[0049] The invention generally provides an isolated novel growth factor which has the ability to stimulate and/or enhance proliferation or differentiation and/or growth and/or motility of cells expressing a PDGF-C receptor including, but not limited to, endothelial cells, connective tissue cells, myofibroblasts and glial cells, an isolated polynucleotide sequence encoding the novel growth factor, and compositions useful for diagnostic and/or therapeutic applications.
[0050] According to one aspect, the invention provides an isolated and purified nucleic acid molecule which comprises a polynucleotide sequence having at least 85% identity, more preferably at least 90%, and most preferably at least 95% identity to at least nucleotides 37-1071 of the sequence set out in FIG. 1 (SEQ ID NO:2), at least nucleotides 6-956 of the sequence set out in FIG. 3 (SEQ ID NO:3) or at least nucleotides 196 to 1233 of the sequence set out in FIG. 5 (SEQ ID NO:6). The sequence of at least nucleotides 37-1071 of the sequence set out in FIG. 1 (SEQ ID NO:2) or at least nucleotides 196 to 1233 of the sequence set out in FIG. 5 (SEQ ID NO:6) encodes a novel polypeptide, designated PDGF-C (formally designated “VEGF-F”), which is structurally homologous to PDGF-A, PDGF-B, VEGF, VEGF-B, VEGF-C and VEGF-D. In a preferred embodiment, the nucleic acid molecule is a cDNA which comprises at least nucleotides 37-1071 of the sequence set out in FIG. 1 (SEQ ID NO:2), at least nucleotides 6-956 of the sequence set out in FIG. 3 (SEQ ID NO:3) or at least nucleotides 196 to 1233 of the sequence set out in FIG. 5 (SEQ ID NO:6). This aspect of the invention also encompasses DNA molecules having a sequence such that they hybridize under stringent conditions with at least nucleotides 37-1071 of the sequence set out in FIG. 1 (SEQ ID NO:2), at least nucleotides 6-956 of the sequence set out in FIG. 3 (SEQ ID NO:3) or at least nucleotides 196 to 1233 of the sequence set out in FIG. 5 (SEQ ID NO:6) or fragments thereof.
[0051] According to a second aspect, the polypeptide of the invention has the ability to stimulate and/or enhance proliferation and/or differentiation and/or growth and/or motility of cells expressing a PDGF-C receptor including, but not limited to, endothelial cells, connective tissue cells, myofibroblasts and glial cells and comprises a sequence of amino acids corresponding to the amino acid sequence set out in FIG. 2 (SEQ ID NO:3), FIG. 4 (SEQ ID NO:5) or FIG. 6 (SEQ ID NO:7), or a fragment or analog thereof which has the ability to stimulate and/or enhance proliferation and/or differentiation and/or growth and/or motility of cells expressing a PDGF-C receptor including, but not limited to, endothelial cells, connective tissue cells (such as fibroblasts), myofibroblasts and glial cells. Preferably the polypeptides have at least 85% identity, more preferably at least 90%, and most preferably at least 95% identity to the amino acid sequence of in FIG. 2 (SEQ ID NO:3), FIG. 4 (SEQ ID NO:5) or FIG. 6 (SEQ ID NO:7), or a fragment or analog thereof having the biological activity of PDGF-C. A preferred fragment is a truncated form of PDGF-C comprising a portion of the PDGF/VEGF homology domain (PVHD) of PDGF-C. The minimal domain is residues 230-345. However, the domain can extend towards the N terminus up to residue 164. Herein the PVHD is defined as truncated PDGF-C. The truncated PDGF-C is an activated form of PDGF-C. The invention also provides compositions and methods for the treatment of conditions associated with PDGF-C over or under expression.
[0052] In one preferred embodiment, the invention provides a method for regulating receptor-binding specificity of PDGF-C, comprising (1) expressing an expression vector comprising a polynucleotide encoding a polypeptide having a biological activity of PDGF-C and comprising at least 85% identity with the amino acid sequence of SEQ ID NO:3 or SEQ ID NO:7, or a fragment or analog thereof having a biological activity of PDGF-C, and (2) supplying a proteolytic amount of at least one enzyme for processing the expressed polypeptide to generate an activated truncated form of PDGF-C. Preferably, the enzyme is a protease, more preferably a serine protease, and still preferably trypsin.
[0053] In another preferred embodiment, the invention provides a method for selectively activating a polypeptide having a growth factor activity, by expressing an expression vector comprising (1) a polynucleotide encoding a polypeptide having a growth factor activity, (2) a CUB domain and (3) a proteolytic site between the polypeptide and the CUB domain, and then supplying a proteolytic amount of at least one enzyme for processing the expressed polypeptide to generate an active polypeptide having a growth factor activity.
[0054] In still another preferred embodiment, it is provided a method for producing an activated truncated form of PDGF-C, comprising the steps of expressing an expression vector comprising a polynucleotide encoding a polypeptide having a biological activity of PDGF-C and comprising at least 85% identity with the amino acid sequence of SEQ ID NO:3 or SEQ ID NO:7, and supplying a proteolytic amount of at least one enzyme for processing the expressed polypeptide to generate the activated truncated form of PDGF-C.
[0055] The instant invention also provides a pharmaceutical composition, comprising an effective PDGF-C activity reducing amount of a protease inhibitor, and a pharmaceutically acceptable carrier, and a method of treating a patient having a condition characterized by PDGF-C overactivity, comprising administering an effective amount of the above pharmaceutical composition. Preferably, the condition is ischemia, hypertrophy, fibrosis and tumorgenesis. The pharmaceutical composition and treatment method is especially effective in treating hyper cardiac hypertrophy, cardiac fibrosis, choriocarcinoma, Wilms tumor, megakaryoblastic leukemia, lung carcinoma and erythroleukemia.
[0056] According to one embodiment of the invention, a pharmaceutical composition is provided which comprises an effective PDGF-C activity reducing amount of a protease inhibitor. A preferred protease inhibitor is a serine protease inhibitor, which can be grouped into several families, including the Kunitz, serpin, Kazal, and mucous protein inhibitor families, based on conserved structural features. All members of the Kunitz domain protein family have the same number (six) and spacing of cysteine residues. Numerous serine proteinase inhibitors from families other than that of the Kunitz family have been reported to inhibit neutral serine proteinases, including those secreted by activated neutrophils, such as alpha-l-proteinase and alpha-2-macroglobulin, members of the serpin proteinase inhibitor family, inhibit elastase, cathepsin G and proteinase 3.
[0057] The serine protease inhibitor can optionally be a trypsin inhibitor, chymotrypsin inhibitor, cathepsin D inhibitor, and subtilisin inhibitor. A preferred inhibitor is a trypsin inhibitor, particularly a bovine trypsin inhibitor. The composition can also contain one or more pharmaceutical carriers, adjuvants, diluents, and the like.
[0058] In yet another embodiment, a serine protease inhibitor is used in conjunction with at least one inhibitor of metalloproteinases, acid proteases and/or thiol proteases. For example, it may be used in conjunction with one or more of ethylene diamine tetraacetic acid (EDTA), pepstatin, and N-ethyl maleimide (NEM).
[0059] In still another embodiment, a serine protease is used in conjunction with a combination of at least one other protease inhibitor and at least one other inhibitor of metalloproteinases, acid proteases and/or thiol proteases.
[0060] Inhibitors of serine and thiol proteases, and of acid proteases and metalloproteases, are well known in the art, and many are commercially available, for example, from Boehringer Mannheim (Indianapolis, Ind.), Promega Madison, Wis.), and Calbiochem (La Jolla, Calif.), ther inhibitors are described in well-known texts on enzymology, for example, Fersht, ENZYME STRUCTURE AND MECHANISM, 2d ed. W. H. Freeman and Co., 1985, and references therein.
[0061] According to another embodiment of the present invention, a method of treating a condition characterized by PDGF-C over activity is provided which comprises administering an effective amount of the inventive serine protease inhibitor pharmaceutical composition. The method can be used for conditions such as, inter alia, ischemia, hypertrophy, fibrosis and tumorgenesis.
[0062] According to another embodiment of the present invention, an antibody specifically reactive against a PDGF-C polypeptide of the present invention is also provided.
[0063] According to another embodiment of the present invention, a method of treating a condition characterized by insufficient PDGF-C activity is provided, which comprises administering an effective amount of an antagonist of the inventive serine protease inhibitor pharmaceutical composition.
[0064] According to another embodiment of the present invention, a method of promoting revascularization is provided, which comprises administering a revascularization promoting amount of a pharmaceutical composition according to the present invention. This treatment method may be used for, inter alia, promoting revascularization in post-infarction tissue or promoting revascularization with small vessels.
[0065] According to another embodiment of the present invention, a method of increasing vessel density is provided, comprising administering an effective vessel density increasing amount of the pharmaceutical composition of the present invention.
[0066] As used in this application, percent sequence identity is determined by using the alignment tool of “MEGALIGN” from the Lasergene package (DNASTAR, Ltd. Abacus House, Manor Road, West Ealing, London W130AS United Kingdom) and using its preset conditions. The alignment is then refined manually, and the number of identities are estimated in the regions available for a comparison.
[0067] Preferably the polypeptide or the encoded polypeptide from a polynucleotide has the ability to stimulate one or more of proliferation, differentiation, motility, survival or vascular permeability of cells expressing a PDGF-C receptor including, but not limited to, vascular endothelial cells, lymphatic endothelial cells, connective tissue cells (such as fibroblasts), myofibroblasts and glial cells. Preferably the polypeptide or the encoded polypeptide from a polynucleotide has the ability to stimulate wound healing. PDGF-C can also have antagonistic effects on cells, but are included in the biological activities of PDGF-C. These abilities are referred to hereinafter as “biological activities of PDGF-C” and can be readily tested by methods known in the art.
[0068] As used herein, the term “PDGF-C” collectively refers to the polypeptides of FIG. 2 (SEQ ID NO:3), FIG. 4 (SEQ ID NO:5) or FIG. 6 (SEQ ID NO:7), and fragments or analogs thereof which have the biological activity of PDGF-C as defined above, and to a polynucleotide which can code for PDGF-C, or a fragment or analog thereof having the biological activity of PDGF-C. The polynucleotide can be naked and/or in a vector or liposome.
[0069] In another preferred aspect, the invention provides a polypeptide possessing an amino acid sequence: PXCLLVXRCGGXCXCC (SEQ ID NO:1) which is unique to PDGF-C and differs from the other members of the PDGFIVEGF family of growth factors because of the insertion of the three amino acid residues (NCA) between the third and fourth cysteines (see FIG. 9—SEQ ID NOs:8-17).
[0070] Polypeptides comprising conservative substitutions, insertions, or deletions, but which still retain the biological activity of PDGF-C are clearly to be understood to be within the scope of the invention. Persons skilled in the art will be well aware of methods which can readily be used to generate such polypeptides, for example the use of site-directed mutagenesis, or specific enzymatic cleavage and ligation.
[0071] As used herein, the term “conservative substitution” denotes the replacement of an amino acid residue by another, biologically similar residue. Examples of conservative substitutions include the substitution of one hydrophobic residue such as isoleucine, valine, leucine, alanine, cysteine, glycine, phenylalanine, proline, tryptophan, tyrosine, norleucine or methionine for another, or the substitution of one polar residue for another, such as the substitution of arginine for lysine, glutamic acid for aspartic acid, or glutamine for asparagine, and the like. Neutral hydrophilic amino acids which can be substituted for one another include asparagine, glutamine, serine and threonine. The term “conservative substitution” also includes the use of a substituted amino acid in place of an unsubstituted parent amino acid.
[0072] As such, it should be understood that in the context of the present invention, a conservative substitution is recognized in the art as a substitution of one amino acid for another amino acid that has similar properties. Exemplary conservative substitutions are set out in the following Table A from WO 97/09433.
TABLE A Conservative Amino Acid Substitutions I SIDE CHAIN CHARACTERISTIC AMINO ACID Aliphatic G A P Non-polar I L V Polar-uncharged C S T M N Q Polar-charged D E K R Aromatic H F W Y Other N Q D E
[0073] Alternatively, conservative amino acids can be grouped as described in Lehninger, (Biochemistry, Second Edition; Worth Publishers, Inc. NY:N.Y. (1975), pp.71-77) as set out in the following Table B.
TABLE B Conservative Amino Acid Substitutions II SIDE CHAIN CHARACTERISTIC AMINO ACID Non-polar (hydrophobic) A. Aliphatic: A L I V P B. Aromatic: F W C. Sulfur-containing: M D. Borderline: G Uncharged-polar A. Hydroxyl: S T Y B. Amides: N Q C. Sulfhydryl: C D. Borderline: G Positively Charged (Basic): K R H Negatively Charged (Acidic): D E
[0074] Exemplary conservative substitutions are set out in the following Table C.
TABLE C Conservative Substitutions III Original Residue Exemplary Substitution Ala (A) Val, Leu, Ile Arg (R) Lys, Gln, Asn Asn (N) Gln, His, Lys, Arg Asp (D) Glu Cys (C) Ser Gln (Q) Asn Glu (E) Asp His (H) Asn, Gln, Lys, Mg Ile (I) Leu, Val, Met, Ala, Phe, Leu (L) Ile, Val, Met, Ala, Phe Lys (K) Mg, Gln, Asn Met (M) Leu, Phe, Ile Phe (F) Leu, Val, Ile, Ala Pro (P) Gly Ser (S) Thr Thr (T) Ser Trp (W) Tyr, Phe Tyr (Y) Trp, Phe, Thr, Ser Val (V) Ile, Leu, Met, Phe, Ala
[0075] If desired, the cyclic peptidomimetric peptides of the invention can be modified, for instance, by glycosylation, amidation, carboxylation, or phosphorylation, or by the creation of acid addition salts, amides, esters, in particular C-terminal esters, and N-acyl derivatives of the peptides of the invention. The peptides also can be modified to create peptide derivatives by forming covalent or noncovalent complexes with other moieties. Covalently-bound complexes can be prepared by linking the chemical moieties to functional groups on the side chains of amino acids comprising the peptides, or at the N- or C-terminus.
[0076] In particular, it is anticipated that the aforementioned peptides can be conjugated to a reporter group, including, but not limited to a radiolabel, a fluorescent label, an enzyme (e.g., that catalyzes a colorimetric or fluorometric reaction), a substrate, a solid matrix, or a carrier (e.g., biotin or avidin).
[0077] The skilled person will also be aware that peptidomimetic compounds or compounds in which one or more amino acid residues are replaced by a non-naturally occurring amino acid or an amino acid analog may retain the required aspects of the biological activity of PDGF-C. Such compounds can readily be made and tested by methods known in the art, and are also within the scope of the invention.
[0078] In addition, possible variant forms of the PDGF-C polypeptide which may result from alternative splicing, as are known to occur with VEGF and VEGF-B, and naturally-occurring allelic variants of the nucleic acid sequence encoding PDGF-C are encompassed within the scope of the invention. Allelic variants are well known in the art, and represent alternative forms or a nucleic acid sequence which comprise substitution, deletion or addition of one or more nucleotides, but which do not result in any substantial functional alteration of the encoded polypeptide.
[0079] Such variant forms of PDGF-C can be prepared by targeting non-essential regions of the PDGF-C polypeptide for modification. These non-essential regions are expected to fall outside the strongly-conserved regions indicated in FIG. 9 (SEQ ID NOs:8-17). In particular, the growth factors of the PDGF family, including VEGF, are dimeric, and VEGF, VEGF-B, VEGF-C, VEGF-D, PlGF, PDGF-A and PDGF-B show complete conservation of eight cysteine residues in the N-terminal domains, i.e. the PDGF/VEGF-like domains (Olofsson et al., Proc. Natl. Acad. Sci. USA, 1996 93 2576-2581; Joukov et al., EMBO J., 1996 15 290-298). These cysteines are thought to be involved in intra- and inter-molecular disulfide bonding. In addition there are further strongly, but not completely, conserved cysteine residues in the C-terminal domains. Loops 1, 2 and 3 of each subunit, which are formed by intra-molecular disulfide bonding, are involved in binding to the receptors for the PDGF/VEGF family of growth factors (Andersson et al., Growth Factors, 1995 12 159-164).
[0080] Persons skilled in the art thus are well aware that these cysteine residues should be preserved in any proposed variant form, and that the active sites present in loops 1, 2 and 3 also should be preserved. However, other regions of the molecule can be expected to be of lesser importance for biological function, and therefore offer suitable targets for modification. Modified polypeptides can readily be tested for their ability to show the biological activity of PDGF-C by routine activity assay procedures such as the fibroblast proliferation assay of Example 6.
[0081] It is contemplated that some modified PDGF-C polypeptides will have the ability to bind to PDGF-C receptors on cells including, but not limited to, endothelial cells, connective tissue cells, myofibroblasts and/or glial cells, but will be unable to stimulate cell proliferation, differentiation, migration, motility or survival or to induce vascular proliferation, connective tissue development or wound healing. These modified polypeptides are expected to be able to act as competitive or non-competitive inhibitors of the PDGF-C polypeptides and growth factors of the PDGF/VEGF family, and to be useful in situations where prevention or reduction of the PDGF-C polypeptide or PDGF/VEGF family growth factor action is desirable.
[0082] Thus such receptor-binding but non-mitogenic, non-differentiation inducing, non-migration inducing, non-motility inducing, non-survival promoting, non-connective tissue development promoting, non-wound healing or non-vascular proliferation inducing variants of the PDGF-C polypeptide are also within the scope of the invention, and are referred to herein as “receptor-binding but otherwise inactive variant”. Because PDGF-C forms a dimer in order to activate its only known receptor, it is contemplated that one monomer comprises the receptor-binding but otherwise inactive variant modified PDGF-C polypeptide and a second monomer comprises a wild-type PDGF-C or a wild-type growth factor of the PDGF/VEGF family. These dimers can bind to its corresponding receptor but cannot induce downstream signaling.
[0083] It is also contemplated that there are other modified PDGF-C polypeptides that can prevent binding of a wild-type PDGF-C or a wild-type growth factor of the PDGF/VEGF family to its corresponding receptor on cells including, but not limited to, endothelial cells, connective tissue cells (such as fibroblasts), myofibroblasts and/or glial cells. Thus these dimers will be unable to stimulate endothelial cell proliferation, differentiation, migration, survival, or induce vascular permeability, and/or stimulate proliferation and/or differentiation and/or motility of connective tissue cells, myofibroblasts or glial cells. These modified polypeptides are expected to be able to act as competitive or non-competitive inhibitors of the PDGF-C growth factor or a growth factor of the PDGF/VEGF family, and to be useful in situations where prevention or reduction of the PDGF-C growth factor or PDGF/VEGF family growth factor action is desirable.
[0084] Such situations include the tissue remodeling that takes place during invasion of tumor cells into a normal cell population by primary or metastatic tumor formation. Thus such the PDGF-C or PDGF/VEGF family growth factor-binding but non-mitogenic, non-differentiation inducing, non-migration inducing, non-motility inducing, non-survival promoting, non-connective tissue promoting, non-wound healing or non-vascular proliferation inducing variants of the PDGF-C growth factor are also within the scope of the invention, and are referred to herein as “the PDGF-C growth factor-dimer forming but otherwise inactive or interfering variants”.
[0085] An example of a PDGF-C growth factor-dimer forming but otherwise inactive or interfering variant is where the PDGF-C has a mutation which prevents cleavage of CUB domain from the protein. It is further contemplated that a PDGF-C growth factor-dimer forming but otherwise inactive or interfering variant could be made to comprise a monomer, preferably an activated monomer, of VEGF, VEGF-B, VEGF-C, VEGF-D, PDGF-C, PDGF-A, PDGF-B or PlGF linked to a CUB domain that has a mutation which prevents cleavage of CUB domain from the protein. Dimers formed with the above mentioned PDGF-C growth factor-dimer forming but otherwise inactive or interfering variants and the monomers linked to the mutant CUB domain would be unable to bind to their corresponding receptors.
[0086] A variation on this contemplation would be to insert a proteolytic site between an activated monomer of VEGF, VEGF-B, VEGF-C, VEGF-D, PDGF-C, PDGF-A, PDGF-B or PlGF and the mutant CUB domain linkage which is dimerized to an activated monomer of VEGF, VEGF-B, VEGF-C, VEGF-D, PDGF-C, PDGF-A, PDGF-B or PlGF. An addition of the specific protease(s) for this proteolytic site would cleave the CUB domain and thereby release an activated dimer that can then bind to its corresponding receptor. In this way, a controlled release of an activated dimer is made possible.
[0087] The invention also relates to a purified and isolated nucleic acid encoding a polypeptide or polypeptide fragment of the invention as defined above. The nucleic acid may be DNA, genomic DNA, cDNA or RNA, and may be single-stranded or double stranded. The nucleic acid may be isolated from a cell or tissue source, or of recombinant or synthetic origin. Because of the degeneracy of the genetic code, the person skilled in the art will appreciate that many such coding sequences are possible, where each sequence encodes the amino acid sequence shown in FIG. 2 (SEQ ID NO:3), FIG. 4 (SEQ ID NO:5) or FIG. 6 (SEQ ID NO:7), a bioactive fragment or analog thereof, a receptor-binding but otherwise inactive or partially inactive variant thereof or a PDGF-C-dimer forming but otherwise inactive or interfering variants thereof.
[0088] Further, the invention provides vectors comprising the cDNA of the invention or a nucleic acid molecule according to the third aspect of the invention, and host cells transformed or transfected with nucleic acids molecules or vectors of the invention. These may be eukaryotic or prokaryotic in origin. These cells are particularly suitable for expression of the polypeptide of the invention, and include insect cells such as Sf9 cells, obtainable from the American Type Culture Collection (ATCC SRL-171), transformed with a baculovirus vector, and the human embryo kidney cell line 293-EBNA transfected by a suitable expression plasmid.
[0089] Preferred vectors of the invention are expression vectors in which a nucleic acid according to the invention is operatively connected to one or more appropriate promoters and/or other control sequences, such that appropriate host cells transformed or transfected with the vectors are capable of expressing the polypeptide of the invention. Other preferred vectors are those suitable for transfection of mammalian cells, or for gene therapy, such as adenoviral-, vaccinia- or retroviral-based vectors or liposomes. A variety of such vectors is known in the art.
[0090] The invention also provides a method of making a vector capable of expressing a polypeptide encoded by a nucleic acid according to the invention, comprising the steps of operatively connecting the nucleic acid to one or more appropriate promoters and/or other control sequences, as described above.
[0091] The invention further provides a method of making a polypeptide according to the invention, comprising the steps of expressing a nucleic acid or vector of the invention in a host cell, and isolating the polypeptide from the host cell or from the host cell's growth medium.
[0092] In yet a further aspect, the invention provides an antibody specifically reactive with a polypeptide of the invention or a fragment of the polypeptide. This aspect of the invention includes antibodies specific for the variant forms, immunoreactive fragments, analogs and recombinants of PDGF-C. Such antibodies are useful as inhibitors or agonists of PDGF-C and as diagnostic agents for detecting and quantifying PDGF-C. Polyclonal or monoclonal antibodies may be used.
[0093] Specifically, antibodies suitable for this invention can be produced by any one of several well-known methods. E.g., Yoshida et al., Experientia 43:329, 1987; Yoshida and Ichiman, J. Clin. Microbiol. 20:461, 1984; and U.S. Pat. No. 5,770,208. Classically, antigen-specific antibodies are produced by immunizing a host animal with the antigen, and later collecting the antibody-containing serum from the animal. Purified antigens can be a homogenous preparation of one antigen or a combination of several different antigens. To enhance the immune response, antigens (especially small peptide antigens) may be made more immunogenic by coupling to a carrier protein, such as keyhole limpet hemocyanin (KLH). See, e.g., Ausebel et al., Current Protocols in Molecular Biology, John Wiley & Sons, Inc., N.Y., 1989.
[0094] Any animal capable of producing antibodies in response to an antigen may be used in the invention. Commonly used animals include: mice, rats, horses, cows, goats, sheep, rabbits, cats, dogs, guinea pigs, and chickens. Host animals are immunized by injection with purified or whole antigen. Preferably, after the first immunization, the host animal receives one or more booster injections of antigen to augment antibody production and affinity.
[0095] To enhance the immunologic response, antigens, are typically mixed with adjuvant before injection into a host animal. Adjuvants useful in augmenting antibody production include Freund's adjuvant (complete and incomplete), mineral gels such as aluminum hydroxide, surface active substances such as lysolecithin, pluronic polyols, polyanions, peptides, oil emulsions, KLH, and dinitrophenol (DNP). Antigens can also be cross-linked or incorporated into lipid vesicles to enhance their antigenicity.
[0096] Antibodies within the invention include without limitation polyclonal antibodies, monoclonal antibodies, humanized, and chimeric antibodies. Polyclonal antibodies can be isolated by collecting sera from immunized host animals. Monoclonal antibodies can be prepared using the whole protein or peptide antigens discussed above and standard hybridoma technology. See, e.g., Coligan et al., Current Protocols in Immunology, John Wiley & Sons, N.Y., 1997. Human monoclonal antibodies are prepared by immortalizing a human antibody secreting cell (e.g., a human plasma cell). See, e.g., U.S. Pat. No. 4,634,664. To obtain monoclonal antibodies, hybridomas or other immortalized antibody secreting cells are cultivated in vitro (e.g., in tissue culture) or in vivo (e.g., in athymic or SCID mice). Antibodies are isolated by collecting the in vitro culture medium or bodily fluids (e.g., serum or ascites) from the in vivo cultures.
[0097] Additionally, chimeric antibodies, which are antigen-binding molecules having different portions derived from different animal species (e.g., variable region of a rat immunoglobulin fused to the constant region of a human immunoglobulin), are expected to be useful in the invention. Such chimeric antibodies can be prepared by methods known in the art. E.g., Morrison et al., Proc. Nat'l. Acad. Sci. USA, 81:6851, 1984; Neuberger et al., Nature, 312:604, 1984; Takeda et al., Nature, 314:452, 1984. Similarly, antibodies can be humanized by methods known in the art. For example, monoclonal antibodies with a desired binding specificity can be commercially humanized (Scotgene, Scotland; Oxford Molecular, Palo Alto, Calif.) or as described in U.S. Pat. Nos. 5,693,762; 5,530,101; or 5,585,089.
[0098] Once isolated, antibodies can be further purified by conventional techniques including: salt cuts (e.g., saturated ammonium sulfate precipitation), cold alcohol fractionation (e.g., the Cohn-Oncley cold alcohol fractionation process), size exclusion chromatography, ion exchange chromatography, immunoaffinity chromatography (e.g., chromatography beads coupled to anti-human immunoglobulin antibodies can be used to isolate human immunoglobulins) and antigen affinity chromatography. See, e.g., Coligan et al., supra.
[0099] Standard techniques in immunology and protein chemistry can be used to analyze and manipulate the antibodies of the invention. For example, dialysis can be used to alter the medium in which the antibodies are dissolved. The antibodies may also be lyophilized for preservation. Antibodies can be tested for the ability to bind specific antigens using any one of several standard methods such as Western Blot, immunoprecipitation analysis, enzyme-linked immunosorbent assay (ELISA), and radioimmunoassay (RIA). See, e.g., Coligan et al., supra.
[0100] In addition the polypeptide can be linked to an epitope tag, such as the FLAG® octapeptide (Sigma, St. Louis, Mo.), to assist in affinity purification. For some purposes, for example where a monoclonal antibody is to be used to inhibit effects of PDGF-C in a clinical situation, it may be desirable to use humanized or chimeric monoclonal antibodies. Such antibodies may be further modified by addition of cytotoxic or cytostatic drugs. Methods for producing these, including recombinant DNA methods, are also well known in the art. This aspect of the invention also includes an antibody which recognizes PDGF-C and is suitably labeled.
[0101] Polypeptides or antibodies according to the invention may be labeled with a detectable label, and utilized for diagnostic purposes. Similarly, the thus-labeled polypeptide of the invention may be used to identify its corresponding receptor in situ. The polypeptide or antibody may be covalently or non-covalently coupled to a suitable supermagnetic, paramagnetic, electron dense, ecogenic or radioactive agent for imaging. For use in diagnostic assays, radioactive or non-radioactive labels may be used. Examples of radioactive labels include a radioactive atom or group, such as 125 I or 32 P. Examples of non-radioactive labels include enzymatic labels, such as horseradish peroxidase or fluorimetric labels, such as fluorescein-5-isothiocyanate (FITC). Labeling may be direct or indirect, covalent or non-covalent.
[0102] Clinical applications of the invention include diagnostic applications, acceleration of angiogenesis in tissue or organ transplantation, or stimulation of wound healing, or connective tissue development, or to establish collateral circulation in tissue infarction or arterial stenosis, such as coronary artery disease, and inhibition of angiogenesis in the treatment of cancer or of diabetic retinopathy and inhibition of tissue remodeling that takes place during invasion of tumor cells into a normal cell population by primary or metastatic tumor formation.
[0103] Quantitation of PDGF-C in cancer biopsy specimens may be useful as an indicator of future metastatic risk.
[0104] PDGF-C may also be relevant to a variety of lung conditions. PDGF-C assays could be used in the diagnosis of various lung disorders. PDGF-C could also be used in the treatment of lung disorders to improve blood circulation in the lung and/or gaseous exchange between the lungs and the blood stream. Similarly, PDGF-C could be used to improve blood circulation to the heart and O 2 gas permeability in cases of cardiac insufficiency. In a like manner, PDGF-C could be used to improve blood flow and gaseous exchange in chronic obstructive airway diseases.
[0105] Thus the invention provides a method of stimulation of angiogenesis, lymphangiogenesis, neovascularization, connective tissue development and/or wound healing in a mammal in need of such treatment, comprising the step of administering an effective dose of PDGF-C, or a fragment or an analog thereof which has the biological activity of PDGF-C to the mammal. Optionally the PDGF-C, or fragment or analog thereof may be administered together with, or in conjunction with, one or more of VEGF, VEGF-B, VEGF-C, VEGF-D, PlGF, PDGF-A, PDGF-B, FGF and/or heparin.
[0106] Conversely, PDGF-C antagonists (e.g. antibodies and/or competitive or noncompetitive inhibitors of binding of PDGF-C in both dimer formation and receptor binding) could be used to treat conditions, such as congestive heart failure, involving accumulation of fluid in, for example, the lung resulting from increases in vascular permeability, by exerting an offsetting effect on vascular permeability in order to counteract the fluid accumulation. PDGF-C can also be used to treat fibrotic conditions including those found in the lung, kidney and liver. Administrations of PDGF-C could be used to treat malabsorptive syndromes in the intestinal tract, liver or kidneys as a result of its blood circulation increasing and vascular permeability increasing activities.
[0107] Thus, the invention provides a method of inhibiting angiogenesis, lymphangiogenesis, neovascularization, connective tissue development and/or wound healing in a mammal in need of such treatment, comprising the step of administering an effective amount of an antagonist of PDGF-C to the mammal. The antagonist may be any agent that prevents the action of PDGF-C, either by preventing the binding of PDGF-C to its corresponding receptor on the target cell, or by preventing activation of the receptor, such as using receptor-binding PDGF-C variants. Suitable antagonists include, but are not limited to, antibodies directed against PDGF-C; competitive or non-competitive inhibitors of binding of PDGF-C to the PDGF-C receptor(s), such as the receptor-binding or PDGF-C dimer-forming but non-mitogenic PDGF-C variants referred to above; compounds that bind to PDGF-C and/or modify or antagonize its function, and anti-sense nucleotide sequences as described below.
[0108] A method is provided for determining agents that bind to an activated truncated form of PDGF-C. The method comprises contacting an activated truncated form of PDGF-C with a test agent and monitoring binding by any suitable means. Agents can include both compounds and other proteins.
[0109] The invention provides a screening system for discovering agents that bind an activated truncated form of PDGF-C. The screening system comprises preparing an activated truncated form of PDGF-C, exposing the activated truncated form of PDGF-C to a test agent, and quantifying the binding of said agent to the activated truncated form of PDGF-C by any suitable means. This screening system can also be used to identify agents which inhibit the proteolytic cleavage of the full length PDGF-C protein and thereby prevent the release of the activated truncated form of PDGF-C. For this use, the full length PDGF-C must be prepared.
[0110] Use of this screen system provides a means to determine compounds that may alter the biological function of PDGF-C. This screening method may be adapted to large-scale, automated procedures such as a PANDEX® (Baxter-Dade Diagnostics) system, allowing for efficient high-volume screening of potential therapeutic agents.
[0111] For this screening system, an activated truncated form of PDGF-C or full length PDGF-C is prepared as described herein, preferably using recombinant DNA technology. A test agent, e.g. a compound or protein, is introduced into a reaction vessel containing the activated truncated form of or full length PDGF-C. Binding of the test agent to the activated truncated form of or full length PDGF-C is determined by any suitable means which include, but is not limited to, radioactively- or chemically-labeling the test agent. Binding of the activated truncated form of or full length PDGF-C may also be carried out by a method disclosed in U.S. Pat. No. 5,585,277, which is incorporated by reference. In this method, binding of the test agent to the activated truncated form of or full length PDGF-C is assessed by monitoring the ratio of folded protein to unfolded protein. Examples of this monitoring can include, but are not limited to, monitoring the sensitivity of the activated truncated form of or full length PDGF-C to a protease, or amenability to binding of the protein by a specific antibody against the folded state of the protein.
[0112] Those of skill in the art will recognize that IC 50 values are dependent on the selectivity of the agent tested. For example, an agent with an IC 50 which is less than 10 nM is generally considered an excellent candidate for drug therapy. However, an agent which has a lower affinity, but is selective for a particular target, may be an even better candidate. Those skilled in the art will recognize that any information regarding the binding potential, inhibitory activity or selectivity of a particular agent is useful toward the development of pharmaceutical products.
[0113] Where a composition is to be used for therapeutic purposes, the dose(s) and route of administration will depend upon the nature of the patient and condition to be treated, and will be at the discretion of the attending physician or veterinarian. Suitable routes include oral, subcutaneous, intramuscular, intraperitoneal or intravenous injection, parenteral, topical application, implants etc. Topical application may be used. For example, where used for wound healing or other use in which enhanced angiogenesis is advantageous, an effective amount of the truncated active form of PDGF-C (or an “activated truncated” form”) is administered to an organism in need thereof in a dose between about 0.1 and 1000 mg/kg body weight.
[0114] The compounds may be employed in combination with a suitable pharmaceutical carrier. The resulting compositions comprise a therapeutically effective amount of a compound, and a pharmaceutically acceptable solid or liquid carrier or adjuvant. Examples of such a carrier or adjuvant include, but are not limited to, saline, buffered saline, Ringer's solution, mineral oil, talc, corn starch, gelatin, lactose, sucrose, microcrystalline cellulose, kaolin, mannitol, dicalcium phosphate, sodium chloride, alginic acid, dextrose, water, glycerol, ethanol, thickeners, stabilizers, suspending agents and combinations thereof.
[0115] Such compositions may be in the form of solutions, suspensions, tablets, capsules, creams, salves, elixirs, syrups, wafers, ointments or other conventional forms. The formulation to suit the mode of administration. Compositions which comprise PDGF-C may optionally further comprise one or more of PDGF-A, PDGF-B, VEGF, VEGF-B, VEGF-C, VEGF-D, PlGF and/or heparin. Compositions comprising PDGF-C will contain from about 0.1% to 90% by weight of the active compound(s), and most generally from about 10% to 30%.
[0116] For intramuscular preparations, a sterile formulation can be dissolved and administered in a pharmaceutical diluent such as pyrogen-free water (distilled), physiological saline or 5% glucose solution. A suitable insoluble form of the compound may be prepared and administered as a suspension in an aqueous base or a pharmaceutically acceptable oil base, e.g. an ester of a long chain fatty acid such as ethyl oleate.
[0117] According to yet a further aspect, the invention provides diagnostic/prognostic devices typically in the form of test kits. For example, in one embodiment of the invention there is provided a diagnostic/prognostic test kit comprising an antibody to PDGF-C and a means for detecting, and more preferably evaluating, binding between the antibody and PDGF-C. In one preferred embodiment of the diagnostic/prognostic device according to the invention, a second antibody (the secondary antibody) directed against antibodies of the same isotype and animal source of the antibody directed against PDGF-C (the primary antibody) is provided. The secondary antibody is coupled to a detectable label, and then either an unlabeled primary antibody or PDGF-C is substrate-bound so that the PDGF-C/primary antibody interaction can be established by determining the amount of label bound to the substrate following binding between the primary antibody and PDGF-C and the subsequent binding of the labeled secondary antibody to the primary antibody. In a particularly preferred embodiment of the invention, the diagnostic/prognostic device may be provided as a conventional enzyme-linked immunosorbent assay (ELISA) kit.
[0118] In another alternative embodiment, a diagnostic/prognostic device may comprise polymerase chain reaction means for establishing sequence differences of a PDGF-C of a test individual and comparing this sequence structure with that disclosed in this application in order to detect any abnormalities, with a view to establishing whether any aberrations in PDGF-C expression are related to a given disease condition.
[0119] In addition, a diagnostic/prognostic device may comprise a restriction length polymorphism (RFLP) generating means utilizing restriction enzymes and genomic DNA from a test individual to generate a pattern of DNA bands on a gel and comparing this pattern with that disclosed in this application in order to detect any abnormalities, with a view to establishing whether any aberrations in PDGF-C expression are related to a given disease condition.
[0120] In accordance with a further aspect, the invention relates to a method of detecting aberrations in PDGF-C gene in a test subject which may be associated with a disease condition in the test subject. This method comprises providing a DNA or RNA sample from said test subject; contacting the DNA sample or RNA with a set of primers specific to PDGF-C DNA operatively coupled to a polymerase and selectively amplifying PDGF-C DNA from the sample by polymerase chain reaction, and comparing the nucleotide sequence of the amplified PDGF-C DNA from the sample with the nucleotide sequences shown in FIG. 1 (SEQ ID NO:2) or FIG. 3 (SEQ ID NO:5). The invention also includes the provision of a test kit comprising a pair of primers specific to PDGF-C DNA operatively coupled to a polymerase, whereby said polymerase is enabled to selectively amplify PDGF-C DNA from a DNA sample.
[0121] The invention also provides a method of detecting PDGF-C in a biological sample, comprising the step of contacting the sample with a reagent capable of binding PDGF-C, and detecting the binding. Preferably the reagent capable of binding PDGF-C is an antibody directed against PDGF-C, particularly preferably a monoclonal antibody. In a preferred embodiment the binding and/or extent of binding is detected by means of a detectable label; suitable labels are discussed above.
[0122] In another aspect, the invention relates to a protein dimer comprising the PDGF-C polypeptide, particularly a disulfide-linked dimer. The protein dimers of the invention include both homodimers of PDGF-C polypeptide and heterodimers of PDGF-C and VEGF, VEGF-B, VEGF-C, VEGF-D, PlGF, PDGF-A or PDGF-B.
[0123] According to a yet further aspect of the invention there is provided a method for isolation of PDGF-C comprising the step of exposing a cell which expresses PDGF-C to heparin to facilitate release of PDGF-C from the cell, and purifying the thus-released PDGF-C.
[0124] Another aspect of the invention involves providing a vector comprising an anti-sense nucleotide sequence which is complementary to at least a part of a DNA sequence which encodes PDGF-C or a fragment or analog thereof that has the biological activity of PDGF-C. In addition the anti-sense nucleotide sequence can be to the promoter region of the PDGF-C gene or other non-coding region of the gene which may be used to inhibit, or at least mitigate, PDGF-C expression.
[0125] According to a yet further aspect of the invention such a vector comprising an anti-sense sequence may be used to inhibit, or at least mitigate, PDGF-C expression. The use of a vector of this type to inhibit PDGF-C expression is favored in instances where PDGF-C expression is associated with a disease, for example where tumors produce PDGF-C in order to provide for angiogenesis, or tissue remodeling that takes place during invasion of tumor cells into a normal cell population by primary or metastatic tumor formation. Transformation of such tumor cells with a vector containing an anti-sense nucleotide sequence would inhibit or retard growth of the tumor or tissue remodeling.
[0126] Another aspect of the invention relates to the discovery that the full-length PDGF-C protein is a latent growth factor that needs to be activated by proteolytic processing to release an active PDGF/VEGF homology domain (or “activated truncated” form of PDGF/VEGF). A putative proteolytic site is found in residues 231-234 in the full-length protein, residues -RKSR-. This is a dibasic motif. This site is structurally conserved in the mouse PDGF-C. The -RKSR-putative proteolytic site is also found in PDGF-A, PDGF-B, VEGF-C and VEGF-D. In these four proteins, the putative proteolytic site is also found just before the minimal domain for the PDGF/VEGF homology domain. Together these facts indicate that this is the proteolytic site.
[0127] Preferred proteases include, but are not limited, to plasmin, Factor X and enterokinase. The N-terminal CUB domain may function as an inhibitory domain which might be used to keep PDGF-C in a latent form in some extracellular compartment and which is removed by limited proteolysis when PDGF-C is needed.
[0128] According to this aspect of the invention, a method is provided for producing an activated truncated form of PDGF-C or for regulating receptor-binding specificity of PDGF-C. These methods comprise the steps of expressing an expression vector comprising a polynucleotide encoding a polypeptide having the biological activity of PDGF-C and supplying a proteolytic amount of at least one enzyme for processing the expressed polypeptide to generate the activated truncated form of PDGF-C.
[0129] This aspect also includes a method for selectively activating a polypeptide having a growth factor activity. This method comprises the step expressing an expression vector comprising a polynucleotide encoding a polypeptide having a growth factor activity, a CUB domain and a proteolytic site between the polypeptide and the CUB domain, and supplying a proteolytic amount of at least one enzyme for processing the expressed polypeptide to generate the activated polypeptide having a growth factor activity.
[0130] In addition, this aspect includes the isolation of a nucleic acid molecule which codes for a polypeptide having the biological activity of PDGF-C and a polypeptide thereof which comprises a proteolytic site having the amino acid sequence RKSR or a structurally conserved amino acid sequence thereof.
[0131] Also this aspect includes an isolated dimer comprising an activated monomer of PDGF-C and an activated monomer of VEGF, VEGF-B, VEGF-C, VEGF-D, PDGF-C, PDGF-A, PDGF-B or PlGF linked to a CUB domain, or alternatively, an activated monomer of VEGF, VEGF-B, VEGF-C, VEGF-D, PDGF-C, PDGF-A, PDGF-B or PlGF and an activated monomer of PDGF-C linked to a CUB domain. The isolated dimer may or may not include a proteolytic site between the activator monomer and the CUB domain linkage.
[0132] Polynucleotides of the invention such as those described above, fragments of those polynucleotides, and variants of those polynucleotides with sufficient similarity to the non-coding strand of those polynucleotides to hybridize thereto under stringent conditions all are useful for identifying, purifying, and isolating polynucleotides encoding other, non-human, mammalian forms of PDGF-C. Thus, such polynucleotide fragments and variants are intended as aspects of the invention. Exemplary stringent hybridization conditions are as follows: hybridization at 42° C. in 5× SSC, 20 mM NaPO 4 , pH 6.8, 50% formamide; and washing at 42° C. in 0.2× SSC. Those skilled in the art understand that it is desirable to vary these conditions empirically based on the length and the GC nucleotide base content of the sequences to be hybridized, and that formulas for determining such variation exist. See for example Sambrook et al, “Molecular Cloning: A Laboratory Manual,” Second Edition, pages 9.47-9.51, Cold Spring Harbor, N.Y.: Cold Spring Harbor Laboratory (1989).
[0133] Moreover, purified and isolated polynucleotides encoding other, non-human, mammalian PDGF-C forms also are aspects of the invention, as are the polypeptides encoded thereby and antibodies that are specifically immunoreactive with the non-human PDGF-C variants. Thus, the invention includes a purified and isolated mammalian PDGF-C polypeptide and also a purified and isolated polynucleotide encoding such a polypeptide.
[0134] It will be clearly understood that nucleic acids and polypeptides of the invention may be prepared by synthetic means or by recombinant means, or may be purified from natural sources.
[0135] It will be clearly understood that for the purposes of this specification the word “comprising” means “included but not limited to.” The corresponding meaning applies to the word “comprises.”
BRIEF DESCRIPTION OF THE DRAWINGS
[0136] [0136]FIG. 1 (SEQ ID NO:2) shows the complete nucleotide sequence of cDNA encoding a human PDGF-C (hPDGF-C)(2108 bp);
[0137] [0137]FIG. 2 (SEQ ID NO:3) shows the deduced amino acid sequence of full-length hPDGF-C which consists of 345 amino acid residues (the translated part of the cDNA corresponds to nucleotides 37 to 1071 of FIG. 1);
[0138] [0138]FIG. 3 (SEQ ID NO:4) shows a cDNA sequence encoding a fragment of human PDGF-C (hPDGF-C)(1536 bp);
[0139] [0139]FIG. 4 (SEQ ID NO:5) shows a deduced amino acid sequence of a fragment of hPDGF-C(translation of nucleotides 3 to 956 of the nucleotide sequence of FIG. 3);
[0140] [0140]FIG. 5 (SEQ ID NO:6) shows a nucleotide sequence of a murine PDGF-C (mPDGF-C) cDNA;
[0141] [0141]FIG. 6 (SEQ ID NO:7) shows the deduced amino acid sequence of a fragment of mPDGF-C(the translated part of the cDNA corresponds to nucleotides 196 to 1233 of FIG. 5);
[0142] [0142]FIG. 7 shows a comparative sequence alignment of the hPDGF-C amino acid sequence of FIG. 2 (SEQ ID NO:3) with the mPDGF-C amino acid sequence of FIG. 6 (SEQ ID NO:7);
[0143] [0143]FIG. 8 shows a schematic structure of mPDGF-C with a signal sequence (striped box), a N-terminal Clr/Cls/embryonic sea urchin protein Uegf/bone morphogenetic protein 1 (CUB) domain and the C-terminal PDGF/VEGF-homology domain (open boxes);
[0144] [0144]FIG. 9 shows a comparative sequence alignment of the PDGF/VEGF-homology domains in human and mouse PDGF-C with other members of the VEGF/PDGF family of growth factors (SEQ ID NOs:8-17, respectively);
[0145] [0145]FIG. 10 shows a phylogenetic tree of several growth factors belonging to the VEGF/PDGF family;
[0146] [0146]FIG. 11 provides the amino acid sequence alignment of the CUB domain present in human and mouse PDGF-Cs (SEQ ID NOs:18 and 19, respectively) and other CUB domains present in human bone morphogenic protein-1 (hBMP-1, 3 CUB domains CUB1-3)(SEQ ID NOs:20-22, respectively) and in human neuropilin-1 (2 CUB domains)(SEQ ID NOs:23 and 24, respectively);
[0147] [0147]FIG. 12 shows a Northern blot analysis of the expression of PDGF-C transcripts in several human tissues;
[0148] [0148]FIG. 13 shows the regulation of PDGF-C mRNA expression by hypoxia;
[0149] [0149]FIG. 14 shows the expression of PDGF-C in human tumor cell lines;
[0150] [0150]FIG. 15 shows the results of immunoblot detection of full length human PDGF-C in transfected COS-1 cells;
[0151] [0151]FIG. 16 shows isolation and partial characterization of full length PDGF-C;
[0152] [0152]FIG. 17 shows isolation and partial characterization of a truncated form of human PDGF-C containing the PDGF/VEGF homology domain only;
[0153] [0153]FIG. 18 provides a standard curve for the binding of labeled PDGF-BB homodimers to PAE-1 cells expressing PDGF alpha receptor;
[0154] [0154]FIG. 19 provides a graphic representation of the inhibition of binding of labeled PDGF-BB to PAE-1 cells expressing PDGF alpha receptor by increasing amounts of purified full length and truncated PDGF-CC proteins;
[0155] [0155]FIG. 20 shows the effects of the full length and truncated PDGF-CC homodimers on the phosphorylation of PDGF alpha-receptor;
[0156] [0156]FIG. 21 shows the mitogenic activities of the full length and truncated PDGF-CC homodimers on fibroblasts;
[0157] [0157]FIG. 22 graphically presents the results of the binding assay of truncated PDGF-C to the PDGF receptors;
[0158] [0158]FIG. 23 shows the immunoblot of the undigested full length PDGF-C protein and the plasmin-generated 26-28 kDa species;
[0159] [0159]FIG. 24 graphically presents the results of the competitive binding assay of full-length PDGF-C and truncated PDGF-C for PDGFR-alpha receptors;
[0160] [0160]FIG. 25 shows the analyses by SDS-PAGE of the human PDGF-C CUB domain under reducing and non-reducing conditions;
[0161] FIGS. 26 A- 26 V show PDGF-C expression in the developing mouse embryo;
[0162] FIGS. 27 A- 27 F show PDGF-C, PDGF-A and PDGFR-alpha expression in the developing kidney;
[0163] FIGS. 28 A- 28 F show histology of E 16.5 kidneys from wildtype (FIGS. 28A and 28C), PDGFR-alpha −/− (FIGS. 28B and 28F, PDGF-A −/− (FIG. 28D) and PDGF-A/PDGF-B double −/− (FIG. 28E) kidneys;
[0164] [0164]FIG. 29 shows a polyacrylamide gel analysis of dimeric and monomeric forms of PDGF-C.
[0165] FIGS. 30 A-D show results of a chick embryo chorioallantoic membrane assay demonstrating stimulation of angiogenesis and vessel sprouts by PDGF-CC.
[0166] FIGS. 31 A-G show a comparison of corneal neovascularization induced by PDGF-CC, FGF-2 and VEGF.
[0167] FIGS. 32 A-G show a comparison of angiogenic responses induced by various members of the PDGF growth factor family.
[0168] FIGS. 33 A-E show the results of immunochemical analyses of mouse corneas implanted with members of the PDGF family.
[0169] [0169]FIG. 34 shows an immunoblot analysis of conditioned medium from 1523 fibroblasts.
[0170] [0170]FIG. 35 shows an immunoblot analysis of recombinant full length PDGF-C and conditioned medium from 1523 fibroblasts using an antibody to the His 6 epitope.
[0171] [0171]FIG. 36 shows results of protease inhibitor profiling for processing of full length PDGF-C.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0172] [0172]FIG. 1 (SEQ ID NO:2) shows the complete nucleotide sequence of cDNA encoding a human PDGF-C (hPDGF-C)(2108 bp), which is a new member of the VEGF/PDGF family. A clone #4 (see FIGS. 3 and 4—SEQ ID NOs:4 and 5) encoding hPDGF-C was not full length and lacked approximately 80 base pairs of coding sequence when compared to the mouse protein (corresponding to 27 amino acids). Additional cDNA clones were isolated from a human fetal lung cDNA library to obtain an insert which included this missing sequence. Clone #10 had a longer insert than clone #4. The insert of clone #10 was sequenced in the 5′ region and it was found to contain the missing sequence. Clone #10 was found to include the full sequence of human PDGF-C. Some 5′-untranslated sequence, the translated part of the cDNA encoding human PDGF-C and some 3′-untranslated nucleotide sequence are shown in FIG. 1 (SEQ ID NO:2). A stop codon in frame is located 21 bp upstream of the initiation ATG (the initiation ATG is underlined in FIG. 1).
[0173] Work to isolate this new human PDGF/VEGF began after a search of the expressed sequence tag (EST) database, dbEST, at the National Center for Biotechnology Information (NCBI) in Washington, D.C., identified a human EST sequence (W21436) which appears to encode part of the human homolog of the mouse PDGF-C. Based on the human EST sequence, two oligonucleotides were designed:
5′-GAA GTT GAG GAA CCC AGT G-3′ for- (SEQ ID NO:25) ward 5′-CTT GCC AAG AAG TTG CCA AG-3′ re- (SEQ ID NO:26) verse.
[0174] These oligonucleotides were used to amplify by polymerase chain reaction (PCR) a polynucleotide of 348 bps from a Human Fetal Lung 5′-STRETCH PLUS λgt10 cDNA library, which was obtained commercially from Clontech. The PCR product was cloned into the pCR 2.1-vector of the Original TA Cloning Kit (Invitrogen). Subsequently, the 348 bps cloned PCR product was used to construct a hPDGF-C probe according to standard techniques.
[0175] 10 6 lambda-clones of the Human Fetal Lung 5′-STRETCH PLUS λgt10 cDNA Library (Clontech) were screened with the hPDGF-C probe according to standard procedures. Among several positive clones, one, clone #4 was analyzed more carefully and the nucleotide sequence of its insert was determined according to standard procedures using internal and vector oligonucleotides. The insert of clone #4 contains a partial nucleotide sequence of the cDNA encoding the full length human PDGF-C (hPDGF-C). The nucleotide sequence (1536 bp) of the clone #4 insert is shown in FIG. 3 (SEQ ID NO:4). The translated portion of this cDNA includes nucleotides 6 to 956. The deduced amino acid sequence of the translated portion of the insert is illustrated in FIG. 4 (SEQ ID NO:5). A polypeptide of this deduced amino acid sequence would lack the first 28 amino acid residues found in the full length hPDGF-C polypeptide. However, this polypeptide includes a proteolytic fragment which is sufficient to activate the PDGF alpha receptors. It should be noted that the first glycine (Gly) of SEQ ID NO:5 is not found in the full length hPDGF-C.
[0176] A mouse EST sequence (AI020581) was identified in a database search of the dbEST database at the NCBI in Washington, D.C., which appears to encode part of a new mouse PDGF, PDGF-C. Large parts of the mouse cDNA was obtained by PCR amplification using DNA from a mouse embryo λgt10 cDNA library as the template. To amplify the 3′ end of the cDNA, a sense primer derived from the mouse EST sequence was used (the sequence of this primer was 5′-CTT CAG TAC CTT GGA AGA G, primer 1 (SEQ ID NO:27)) To amplify the 5′end of the cDNA, an antisense primer derived from the mouse EST was used (the sequence of this primer was 5′-CGC TTG ACC AGG AGA CAA C, primer 2 (SEQ ID NO:28)). The λgt10 vector primers were sense 5′-ACG TGA ATT CAG CAA GTT CAG CCT GGT TAA (primer 3 (SEQ ID NO:29)) and antisense 5′-ACG TGG ATC CTG AGT ATT TCT TCC AGG GTA (primer 4 (SEQ ID NO:30)). Combinations of the vector primers and the internal primers obtained from the mouse EST were used in standard PCR reactions. The sizes of the amplified fragments were approx. 750 bp (3′-fragment) and 800 bp (5′-fragment), respectively. These fragments were cloned into the pCR 2.1 vector and subjected to nucleotide sequences analysis using vector primers and internal primers. Since these fragments did not contain the full length sequence of mPDGF-C, a mouse liver ZAP cDNA library was screened using standard conditions. A 261 bp 32 P-labeled PCR fragment was generated for use as a probe using primers 1 and 2 and using DNA from the mouse embryo λgt10 library as the template (see above). Several positive plaques were purified and the nucleotide sequence of the inserts were obtained following subcloning into pBluescript. Vector specific primers and internal primers were used. By combining the nucleotide sequence information of the generated PCR clones and the isolated clone, the full length amino acid sequence of mPDGF-C could be deduced (see FIG. 6)(SEQ ID NO:7).
[0177] [0177]FIG. 7 shows a comparative sequence alignment of the mouse and human amino acid sequences of PDGF-C (SEQ ID NOS:6 and 2, respectively). The alignment shows that human and mouse PDGF-Cs display an identity of about 87% with 45 amino acid replacements found among the 345 residues of the full length proteins. Almost all of the observed amino acid replacements are conservative in nature. The predicted cleavage site in mPDGF-C for the signal peptidase is between residues G19 and T20. This would generate a secreted mouse peptide of 326 amino acid residues.
[0178] [0178]FIG. 8 provides a schematic domain structure of mouse PDGF-C with a signal sequence (striped box), a N-terminal CUB domain and the C-terminal PDGF/VEGF-homology domain (open boxes). The amino acid sequences denoted by the lines have no obvious similarities to CUB domains or to VEGF-homology domains.
[0179] The high sequence identity suggests that human and mouse PDGF-C have an almost identical domain structure. Amino acid sequence comparisons revealed that both mouse and human PDGF-C display a novel domain structure. Apart from the PDGF/VEGF-homology domain located in the C-terminal region in both proteins (residues 164 to 345), the N-terminal region in both PDGF-Cs have a domain referred to as a CUB domain (Bork and Beckmann, J. Mol. Biol., 1993 231, 539-545). This domain of about 110 amino acids (amino acid residues 50-160) was originally identified in complement factors C1r/C1s, but has recently been identified in several other extracellular proteins including signaling molecules such as bone morphogenic protein 1 (BMP-1) (Wozney et al.,Science, 1988 242, 1528-1534) as well as in several receptor molecules such as neuropilin-1 (NP-1) (Soker et al., Cell, 1998 92 735-745). The functional roles of CUB domains are not clear but it may participate in protein-protein interactions or in interactions with carbohydrates including heparin sulfate proteoglycans.
[0180] [0180]FIG. 9 shows the amino acid sequence alignment of the C-terminal PDGF/VEGF-homology domains of human and mouse PDGF-Cs with the C-terminal PDGF/VEGF-homology domains of PDGF/VEGF family members, VEGF 165 , PlGF-2, VEGF-B 167 , Pox Orf VEGF, VEGF-C, VEGF-D, PDGF-A and PDGF-B (SEQ ID NOs:8-17). Some of the amino acid sequences in the N- and C-terminal regions in VEGF-C and VEGF-D have been deleted in this figure. Gaps were introduced to optimize the alignment. This alignment was generated using the method of J. Hein, (Methods Enzymol. 1990 183 626-45) with PAM250 residue weight table. The boxed residues indicate amino acids which match the PDGF-Cs within two distance units.
[0181] The alignment shows that PDGF-C has the expected pattern of invariant cysteine residues, a hallmark of members of this family, with one exception. Between cysteine 3 and 4, normally spaced by 2 residues there is an insertion of three extra amino acids (NCA). This feature of the sequence in PDGF-C was highly unexpected.
[0182] Based on the amino acid sequence alignments in FIG. 9, a phylogenetic tree was constructed and is shown in FIG. 10. The data show that the PDGF-C homology domain is closely related to the PDGF/VEGF-homology domains of VEGF-C and VEGF-D.
[0183] As shown in FIG. 11, the amino acid sequences from several CUB-containing proteins were aligned (SEQ ID NOs:18-24). The results show that the single CUB domain in human and mouse PDGF-C (SEQ ID NOs:18 and 19, respectively) displays a significant identify with the most closely related CUB domains. Sequences from human BMP-1, with 3 CUB domains (CUB1-3 (SEQ ID NOs:20-22)) and human neuropilin-1 with 2 CUB domains (CUB1-2)(SEQ ID NOs:23 and 24, respectively) are shown. Gaps were introduced to optimize the alignment. This alignment was generated using the method of J. Hein, (Methods Enzymol., 1990 183 626-45) with PAM250 residue weight table.
[0184] [0184]FIG. 12 shows a Northern blot analysis of the expression of PDGF-C transcripts in several human tissues. The analysis shows that PDGF-C is encoded by a major transcript of approximately 3.8-3.9 kb, and a minor of 2.8 kb. The numbers to the right refer to the size of the mRNAs (in kb). The tissue expression of PDGF-C was determined by Northern blotting using a commercial Multiple Tissue Northern blot (MTN, Clontech). The blots were hybridized at according to the instructions from the supplier using ExpressHyb solution at 68° C. for one hour (high stringency conditions), and probed with a 353 bp hPDGF-C EST probe from the fetal lung cDNA library screening as described above. The blots were subsequently washed at 50° C. in 2× SSC with 0.05% SDS for 30 minutes and at 50° C. in 0.1× SSC with 0.1% SDS for an additional 40 minutes. The blots were then put on film and exposed at −70° C. The blots show that PDGF-C transcripts are most abundant in heart, liver, kidney, pancreas and ovary while lower levels of transcripts are present in most other tissues, including placenta, skeletal muscle and prostate. PDGF-C transcripts were below the level of detection in spleen, colon and peripheral blood leucocytes.
[0185] [0185]FIG. 13 shows the regulation of PDGF-C mRNA expression by hypoxia. Size markers (in kb) are indicated to the left in the lower panel. The estimated sizes of PDGF-C mRNAs is indicated to the left in the upper panel (2.7 and 3.5 kbs, respectively). To explore whether PDGF-C is induced by hypoxia, cultured human skin fibroblasts were exposed to hypoxia for 0, 4, 8 and 24 hours. Poly(A)+ mRNA was isolated from cells using oligo-dT cellulose affinity purification. Isolated mRNAs were electrophoresed through 12% agarose gels using 4 μg of mRNA per line. A Northern blot was made and hybridized with a probe for PDGF-C. The sizes of the two bands were determined by hybridizing the same filter with a mixture of hVEGF, hVEGF-B and hVEGF-C probes (Enholm et al. Oncogene, 1997 14 2475-2483), and interpolating on the basis of the known sizes of these mRNAs. The results shown in FIG. 13 indicate that PDGF-C is not regulated by hypoxia in human skin fibroblasts.
[0186] [0186]FIG. 14 shows the expression of PDGF-C mRNA in human tumor cells lines. To explore whether PDGF-C was expressed in human tumor cell lines, poly(A)+ mRNA was isolated from several known tumor cell lines, the mRNAs were electrophoresed through a 12% agarose gel and analyzed by Northern blotting and hybridization with the PDGF-C probe. The results shown in FIG. 14 demonstrate that PDGF-C mRNA is expressed in several types of human tumor cell lines such as JEG3 (a human choriocarcinoma, ATCC #HTB-36), G401 (a Wilms tumor, ATCC #CRL-1441), DAMI (a megakaryoblastic leukemia), A549 (a human lung carcinoma, ATCC #CCL-185) and HEL (a human erythroleukemia, ATCC #TID-180). It is contemplated that further growth of these PDGF-C expressing tumors can be inhibited by inhibiting PDGF-C, as well as using PDGF-C expression as a means of identifying specific types of tumors.
EXAMPLE 1
Generation of Specific Antipeptide Antibodies to Human PDGF-C
[0187] Two synthetic peptides were generated and then used to raise antibodies against human PDGF-C. The first synthetic peptide corresponds to residues 29-48 of the N-terminus of full length PDGF-C and includes an extra cysteine residue at the N- and C-terminus: CKFQFSSNKEQNGVQDPQHERC (SEQ ID NO:31). The second synthetic peptide corresponds to residues 230-250 of the internal region of full length PDGF-C and includes an extra cysteine residue at the C-terminus: GRKSRVVDLNLLTEEVRLYSC (SEQ ID NO:32). The two peptides were each conjugated to the carrier protein keyhole limpet hemocyanin (KLH, Calbiochem) using N-succinimidyl 3-(2-pyridyldithio)propionate (SPDP) (Pharmacia Inc.) according to the instructions of the supplier. 200-300 micrograms of the conjugates in phosphate buffered saline (PBS) were separately emulsified in Freunds Complete Adjuvant and injected subcutaneously at multiple sites in rabbits. The rabbits were boostered subcutaneously at biweekly intervals with the same amount of the conjugates emulsified in Freunds Incomplete Adjuvant. Blood was drawn and collected from the rabbits. The sera were prepared using standard procedures known to those skilled in the art.
EXAMPLE 2
Expression of Full Length Human PDGF-C in Mammalian Cells
[0188] The full length cDNA encoding human PDGF-C was cloned into the mammalian expression vector, pSG5 (Stratagene, La Jolla, Calif.) that has the SV40 promoter. COS-1 cells were transfected with this construct and in separate transfections, with a pSG5 vector without the cDNA insert for a control, using the DEAE-dextran procedure. Serum free medium was added to the transfected COS-1 cells 24 hours after the transfections and aliquots containing the secreted proteins were collected for a 24 hour period after the addition of the medium. These aliquots were subjected to precipitation using ice cold 10% trichloroacetic acid for 30 minutes, and the precipitates were washed with acetone. The precipitated proteins were dissolved in SDS loading buffer under reducing conditions and separated on a SDS-PAGE gel using standard procedures. The separated proteins were electrotransferred onto Hybond filter and immunoblotted using a rabbit antiserum against the internal peptide of full length PDGF-C, the preparation of which is described above. Bound antibodies were detected using enhanced chemiluminescence (ECL, Amersham Inc.). FIG. 15 shows the results of this immunoblot. The sample was only partially reduced and the monomer of the human PDGF-C migrated as a 55 kDa species (the lower band) and the dimer migrated as a 100 kDa species (upper band). This indicates that the protein is secreted intact and that no major proteolytic processing occurs during secretion of the molecule in mammalian cells.
EXAMPLE 3
Expression of Full Length and Truncated Human PDGF-C in Baculovirus Infected Sf9 Cells
[0189] The full length coding part of the human PDGF-C cDNA (970 bp) was amplified by PCR using Deep Vent DNA polymerase (Biolabs) using standard conditions and procedures. The full length PDGF-C was amplified for 30 cycles, where each cycle consisted of one minute denaturization at 94° C., one minute annealing at 56° C. and two minutes extension at 72° C. The forward primer used was 5′CGGGATCCCGAATCCAACCTGAGTAG3′ (SEQ ID NO:33). This primer includes a BamHI site (underlined) for in frame cloning. The reverse primer used was:
(SEQ ID NO:34) 5′G GAATTC CTAATGGTGATGGTGATGATGTTTGTCATCGTCATCTCCTC CTGTGCTCCCTCT3′.
[0190] This primer includes an EcoRI site (underlined) and sequences coding for a C-terminal 6× His tag preceded by an enterokinase site. In addition, residues 230-345 of the PDGFIVEGF homology domain (PVHD) of human PDGF-C were amplified by PCR using Deep Vent DNA polymerase (Biolabs) using standard conditions and procedures. The residues 230-345 of the PVHD of PDGF-C were amplified for 25 cycles, where each cycle consisted of one minute denaturization at 94° C., four minutes annealing at 56° C. and four minutes extension at 72° C. The forward primer used was
[0191] 5′C GGATCC CGGAAGAAAATCCA GAGTGGTG3′ (SEQ ID NO:35).
[0192] This primer includes a BamHI site (underlined) for in frame cloning. The reverse primer used was
(SEQ ID NO:36) 5′G GAATTC CTAATGGTGATGGTGATGATGTTTGTCATCGTCATCTCCTC CTGTGCTCCCTCT-3′.
[0193] This primer includes an EcoRI site (underlined) and sequences coding for a C-terminal 6× His tag preceded by an enterokinase site. The PCR products were digested with BamHI and EcoRI and subsequently cloned into the baculovirus expression vector, pAcGP67A. Verification of the correct sequence of the PCR products cloned into the constructs was by nucleotide sequencing. The expression vectors were then co-transfected with BaculoGold linearized baculovirus DNA into Sf9 insect cells according to the manufactures protocol (Pharmingen). Recombined baculovirus were amplified several times before beginning large scale protein production and protein purification according to the manual (Pharmingen).
[0194] Sf9 cells, adapted to serum free medium, were infected with recombinant baculovirus at a multiplicity of infection of about 7. Media containing the recombinant proteins were harvested 4 days after infection and were incubated with Ni-NTA-Agarose beads(Qiagen). The beads were collected in a column and after extensive washing with 50 mM sodium phosphate buffer pH 8, containing 300 mM NaCl (the washing buffer), the bound proteins were eluted with increasing concentrations of imidazole (from 100 mM to 500 mM) in the washing buffer. The eluted proteins were analyzed by SDS-PAGE using 12.5% polyacrylamide gels under reducing and non-reducing conditions. For immunoblotting analyses, the proteins were electrotransferred onto Hybond filters for 45 minutes.
[0195] FIGS. 16 A-C show the isolation and partial characterization of full length human PDGF-C protein. In FIG. 16A, the recombinant full-length protein was visualized on the blot using antipeptide antibodies against the N-terminal peptide (described above). In FIG. 16B, the recombinant full-length protein was visualized on the blot using antipeptide antibodies against the internal peptide (described above). The separated proteins were visualized by staining with Coomassie Brilliant Blue (FIG. 16C). The numbers at the bottom of FIGS. 16 A-C refer to the concentration of imidazole used to elute the protein from the Ni-NTA column and are expressed in molarity (M). FIGS. 16 A-C also show that the full length protein migrates as a 90 kDa species under non-reducing conditions and as a 55 kDa species under reducing conditions. This indicates that the full length protein was expressed as a disulfide-linked dimer.
[0196] FIGS. 17 A-C show the analysis of the isolation and partial characterization of a truncated form of human PDGF-C containing the PDGF/VEGF homology domain only. In FIG. 17A, the immunoblot analysis of fractions eluted from the Ni-agarose column demonstrates that the protein could be eluted at imidazole concentrations ranging between 100-500 mM. The eluted fractions were analyzed under non-reducing conditions, and the truncated human PDGF-C was visualized on the blot using antipeptide antibodies against the internal peptide (described above). FIG. 17B shows the Coomassie Brilliant Blue staining of the same fractions as in FIG. 17A. This shows that the procedure generates highly purified material migrating as a 36 kDa species. FIG. 17C shows the Coomassie Brilliant Blue staining of non-reduced (non-red.) and reduced (red.) truncated human PDGF-C protein. The data show that the protein is a secreted dimer held together by disulfide bonds and that the monomer migrates as a 24 kDa species.
EXAMPLE 4
Receptor Binding Properties of Full Length and Truncated PDGF-C
[0197] To assess the interactions between full length and truncated PDGF-C and the VEGF receptors, full length and truncated PDGF-C were tested for their capacity to bind to soluble Ig-fusion proteins containing the extracellular domains of human VEGFR-1, VEGFR-2 and VEGFR-3 (Olofsson et al., Proc. Natl. Acad. Sci. USA, 1998 95 11709-11714). The fusion proteins, designated VEGFR-1-Ig, VEGFR-2-Ig and VEGFR-3-Ig, were transiently expressed in human 293 EBNA cells. All Ig fusion proteins were human VEGFRs. Cells were incubated for 24 hours after transfection, washed with Dulbecco's Modified Eagle Medium (DMEM) containing 0.2% bovine serum albumin and starved for 24 hours. The fusion proteins were then precipitated from the clarified conditioned medium using protein A-Sepharose beads (Pharmacia). The beads were combined with 100 microliters of 1OX binding buffer (5% bovine serum albumin, 0.2% Tween 20 and 10 g/ml heparin) and 900 microliter of conditioned medium from 293 cells that had been transfected with mammalian expression plasmids encoding full length or truncated PDGF-C or control vector, then metabolically labeled with 35 S-cysteine and methionine (Promix, Amersham) for 4 to 6 hours. After 2.5 hours, at room temperature, the Sepharose beads were washed 3 times with binding buffer at 4° C., once with phosphate buffered saline and boiled in SDS-PAGE buffer. Labeled proteins that were bound to the Ig-fusion proteins were analyzed by SDS-PAGE under reducing conditions. Radiolabeled proteins were detected using a phosphorimager analyzer. In all these analyses, radiolabeled PDGF-C failed to show any interaction with any of the VEGF receptors.
[0198] Next, full length and truncated PDGF-C were tested for their capacity to bind to human PDGF receptors alpha and beta by analyzing their abilities to compete with PDGF-BB for binding to PDGF receptors. The binding experiments were performed on porcine aortic endothelial-1 (PAE-1) cells stably expressing the human PDGF receptors alpha and beta (Eriksson et al., EMBO J, 1992, 11, 543-550). Binding experiments were performed essentially as in Heldin et al. (EMBO J, 1988, 7 1387-1393). Different concentrations of human full-length and truncated PDGF-C, or human PDGF-BB were mixed with 5 ng/ml of 125 I-PDGF-BB in binding buffer (PBS containing 1 mg/ml of bovine serum albumin). Aliquots were incubated with the receptor expressing PAE-1 cells plated in 24-well culture dishes on ice for 90 minutes. After three washes with binding buffer, cell-bound 125 I-PDGF-BB was extracted by lysis of cells in 20 mM Tris-HCl, pH 7.5, 10% glycerol, 1% Triton X-100. The amount of cell bound radioactivity was determined in a gamma-counter. A standard curve for the binding of 125 I-labeled PDGF BB homodimers to PAE-1 cells expressing PDGF alpha-receptor is shown in FIG. 18. An increasing excess of the unlabeled protein added to the incubations competed efficiently with cell association of the radiolabeled tracer.
[0199] [0199]FIG. 19 graphically shows that the truncated PDGF-C efficiently competed for binding to the PDGF alpha-receptor, while the full length protein did not. Both the full length and truncated proteins failed to compete for binding to the PDGF beta-receptor.
EXAMPLE 5
PDGF Alpha-Receptor Phosphorylation
[0200] To test if PDGF-C causes increased phosphorylation of the PDGF alpha-receptor, full length and truncated PDGF-C were tested for their capacity to bind to the PDGF alpha-receptor and stimulate increased phosphorylation. Serum-starved porcine aortic endothelial (PAE) cells stably expressing the human PDGF alpha-receptor were incubated on ice for 90 minutes with PBS supplemented with 1 mg/ml BSA and 10 ng/ml of PDGF-AA, 100 ng/ml of full length human PDGF-CC homodimers (flPDGF-CC), 100 ng/ml of truncated PDGF-CC homodimers (cPDGF-CC), or a mixture of 10 ng/ml of PDGF-AA and 100 ng/ml of truncated PDGF-CC. Full length and truncated PDGF-CC homodimers were produced as described above. Sixty minutes after the addition of the polypeptides, the cells were lysed in lysis buffer (20 mM tris-HCl, pH 7.5, 0.5% Triton X-100, 0.5% deoxycholic acid, 10 mM EDTA, 1 mM orthovanadate, 1 mM PMSF 1% Trasylol). The PDGF alpha-receptors were immunoprecipitated from cleared lysates with rabbit antisera against the human PDGF alpha-receptor (Eriksson et al., EMBO J, 1992 11 543-550). The precipitated receptors were applied to a SDS-PAGE gel. After SDS gel electrophoresis, the precipitated receptors were transferred to nitrocellulose filters, and the filters were probed with anti-phosphotyrosine antibody PY-20, (Transduction Laboratories). The filters were then incubated with horseradish peroxidase-conjugated anti-mouse antibodies. Bound antibodies were detected using enhanced chemiluminescence (ECL, Amersham Inc). The filters were then stripped and reprobed with the PDGF alpha-receptor rabbit antisera, and the amount of receptors was determined by incubation with horseradish peroxidase-conjugated anti-rabbit antibodies. Bound antibodies were detected using enhanced chemiluminescence (ECL, Amersham Inc). The probing of the filters with PDGF alpha-receptor antibodies confirmed that equal amounts of the receptor were present in all lanes. PDGF-AA is included in the experiment as a control. FIG. 20 shows that truncated, but not full length PDGF-CC, efficiently induced PDGF alpha-receptor tyrosine phosphorylation. This indicates that truncated PDGF-CC is a potent PDGF alpha-receptor agonist.
EXAMPLE 6
Mitogenicity of PDGF-C for Fibroblasts
[0201] [0201]FIG. 21 shows the mitogenic activities of truncated and full length PDGF-CC on fibroblasts. The assay was performed essentially as described in Mori et al., J. Biol. Chem., 1991 266 21158-21164. Serum starved human foreskin fibroblasts were incubated for 24 hours with 1 ml of serum-free medium supplemented with 1 mg/ml BSA and 3ng/ml, 10ng/ml or 30ng/ml of full length PDGF-CC (flPDGF-CC), truncated PDGF-CC (cPDGF-CC) or PDGF-AA in the presence of 0.2 μmCi [3H]thymidine. After trichloroacetic acid (TCA) precipitation, the incorporation of [3H]thymidine into DNA was determined using a beta-counter. The results show that truncated PDGF-CC, but not full length PDGF-CC, is a potent mitogen for fibroblasts. PDGF-AA is included in the experiment as a control.
[0202] PDGF-C does not bind to any of the known VEGF receptors. PDGF-C is the only VEGF family member, thus far, which can bind to and increase phosphorylation of the PDGF alpha-receptor. PDGF-C is also the only VEGF family member, thus far, to be a potent mitogen of fibroblasts. These characteristics indicate that the truncated form of PDGF-C may not be a VEGF family member, but instead a novel PDGF. Furthermore, the full length protein is likely to be a latent growth factor that needs to be activated by proteolytic processing to release the active PDGF/VEGF homology domain. A putative proteolytic site is the dibasic motif found in residues 231-234 in the full length protein, residues -R-K-S-R-. This site is structurally conserved in a comparison between mouse and human PDGF-Cs (FIG. 7). Preferred proteases include, but are not limited to, Factor X and enterokinase. The N-terminal CUB domain may be expressed as an inhibitory domain which might be used to localize this latent growth factor in some extracellular compartment (for example the extracellular matrix) and which is removed by limited proteolysis when need, for example during embryonic development, tissue regeneration, tissue remodelling including bone remodelling, active angiogenesis, tumor progression, tumor invasion, metastasis formation and/or wound healing.
EXAMPLE 7
PDGF Receptors Binding of Truncated PDGF-C
[0203] To assess the interactions between truncated PDGF-C and the PDGF alpha and beta receptors, truncated PDGF-C was tested for its capacity to bind to porcine aortic endothelial-1 (PAE-1) cells expressing PDGF alpha or beta receptors, respectively (Eriksson et al., EMBO J, 1992, 11 543-550). The binding experiments were performed essentially as described in Heldin et al. (EMBO J, 1988, 7 1387-1393). Five micrograms of truncated PDGF-C protein in ten microliters of sodium borate buffer was radiolabeled using the Bolton-Hunter reagent (Amersham) to a specific activity of 4×10 5 cpm/ng. Different concentrations of radiolabeled truncated PDGF-C, with or without added unlabeled protein, in binding buffer (PBS containing 1 mg/ml of bovine serum albumin) was added to the receptor expressing PAE-1 cells plated in 24-well culture dishes on ice for 90 minutes. After three washes with binding buffer, cell-bound 125 I-labeled PDGF-C was extracted by lysis of cells in 20 mM Tris-HCl, pH 7.5, 10% glycerol, 1% Triton X-100. The amount of cell-bound radioactivity was determined in a gamma-counter. Non-specific binding was estimated by including a 100-fold molar excess of truncated PDGF-C in some experiments. All binding data represents the mean of triplicate analyses and the experimental variation in the experiment varied between 10-15%. As seen in FIG. 22, truncated PDGF-C binds to cells expressing PDGF alpha receptors, but not to beta receptor expressing cells. The binding was specific as radiolabeled PDGF-C was quantitatively displaced by a 100-fold molar excess of unlabeled protein.
EXAMPLE 8
Protease Effects on Full length PDGF-C
[0204] To demonstrate that full length PDGF-C can be activated by limited proteolysis to release the PDGF/VEGF homology domain from the CUB domain, the full length protein was digested with different proteases. For example, full length PDGF-C was digested with plasmin in 20 mM Tris-HCl (pH 7.5) containing 1 mM CaCl 2 , 1 mM MgCl 2 and 0.01% Tween 20 for 1.5 to 4.5 hours at 37° C. using two to three units of plasmin (Sigma) per ml. The released domain essentially corresponded in size to the truncated PDGF-C species previously produced in insect cells. Plasmin-digested PDGF-C and undigested full length PDGF-C were applied to a SDS-PAGE gel under reducing conditions. After SDS-PAGE gel electrophoresis, the respective proteins were transferred to a nitrocellulose filter, and the filter was probed using a rabbit antipeptide antiserum to residues 230-250 in full length protein (residues GRKSRVVDLNLLTEEVRLYSC (SEQ ID NO:37) located in just N-terminal to the PDGF/VEGF homology domain). Bound antibodies were detected using enhanced chemiluminescence (ECL, Amersham Inc). FIG. 23 shows the immunoblot with a 55 kDa undigested full length protein and the plasmin-generated 26-28 kDa species.
EXAMPLE 9
PDGF Alpha Receptors Binding of Plasmin-Digested PDGF-C
[0205] To assess the interactions between plasmin-digested PDGF-C and the PDGF alpha receptors, plasmin-digested PDGF-C was tested for its capacity to bind to porcine aortic endothelial-1 (PAE-1) cells expressing PDGF alpha receptors (Eriksson et al., EMBO J, 1992, 11 543-550). The receptor binding analyses were performed essentially as in Example 7 using 30 ng/ml of 125 I-labeled truncated PDGF-C as the tracer. As seen in FIG. 24, increasing concentrations of plasmin-digested PDGF-C efficiently competed for binding to the PDGF alpha receptors. In contrast, undigested full length PDGF-C failed to compete for receptor binding. These data indicate that full length PDGF-C is a latent growth factor unable to interact with PDGF alpha receptors and that limited proteolysis, which releases the C-terminal PDGF/VEGF homology domain, is necessary to generate an active PDGF alpha receptor ligand/agonist.
EXAMPLE 10
Cloning and Expression of the Human PDGF-C CUB Domain
[0206] A human PDGF-C 430 bp cDNA fragment encoding the CUB domain (amino acid residues 23-159 in full length PDGF-C) was amplified by PCR using Deep Vent DNA polymerase (Biolabs) using standard conditions and procedures. The forward primer used was
[0207] 5′C GGATCC CGAATCCAACCTGAGTAG3′ (SEQ ID NO:38).
[0208] This primer includes a BamHI site (underlined) for in clone frame cloning. The reverse primer used was
(SEQ ID NO:39) 5′CCG GAATTC CTAATGGTGATGGTGATGATGTTTGTCATCGTCGTCGAC AATGTTGTAGTG3′.
[0209] This primer includes an EcoRI site (underlined) and sequences coding for a C-terminal 6× His tag preceded by an enterokinase site. The amplified PCR fragment was subsequently cloned into a pACgp67A transfer vector. Verification of the correct sequence of the expression construct, CUB-pACgp67A, was by automatic nucleotide sequencing. The expression vectors were then co-transfected with BaculoGold linearized baculovirus DNA into Sf9 insect cells according to the manufacture's protocol (Pharmingen). Recombined baculovirus were amplified several times before beginning large scale protein production and protein purification according to the manual (Pharmingen).
[0210] Sf9 cells, adapted to serum free medium, were infected with recombinant baculovirus at a multiplicity of infection of about 7. Media containing the recombinant proteins were harvested 72 hours after infection and were incubated with Ni-NTA-Agarose beads(Qiagen) overnight at 4° C. The beads were collected in a column and after extensive washing with 50 mM sodium phosphate buffer pH 8, containing 300 mM NaCl (the washing buffer), the bound proteins were eluted with increasing concentrations of imidazole (from 100 mM to 400 mM) in the washing buffer. The eluted proteins were analyzed by SDS-PAGE using a polyacrylamide gel under reducing and non-reducing conditions.
[0211] [0211]FIG. 25 shows the results from Coomassie blue staining of the gel. The human PDGF-C CUB domain is a disulfide-linked homodimer with a molecular weight of about 55 KD under non-reducing conditions, while two monomers of about 25 and 30 KD respectively are present under reducing conditions. The heterogeneity is probably due to heterogenous glycosylation of the two putative N-linked glycosylation sites present in the CUB domain at amino acid positions 25 and 55. A protein marker lane is shown to the left in the figure.
EXAMPLE 11
Localization of PDGF-C Transcripts in Developing Mouse Embryos
[0212] To gain insight into the biological function of PDGF-C, PDGF-C expression in mouse embryos was localized by non-radioactive in situ hybridization in tissue sections from the head (FIGS. 26 A- 26 S) and urogenital tract (FIGS. 26 T- 26 V) regions. The non-radioactive in situ hybridization employed protocols and PDGF-A and PDGFR-alpha probes are described in Bostrom et al., Cell, 1996 85 863-873, which is hereby incorporated by reference. The PDGF-C probe was derived from a mouse PDGF-C cDNA. The hybridization patterns shown in FIGS. 26 A- 26 V are for embryos aged E16.5, but analogous patterns are seen at E14.5, E15.5 and E17.5. Sense probes were used as controls and gave no consistent pattern of hybridization to the sections.
[0213] [0213]FIG. 26A shows the frontal section through the mouth cavity at the level of the tooth anlagen (t). The arrows point to sites of PDGF-C expression in the oral ectoderm. Also shown is the tongue (to). FIGS. 26 B- 26 D show PDGF-C expression in epithelial cells of the developing tooth canal. Individual cells are strongly labeled in this area (arrow in FIG. 26D), as well as in the developing palate ectoderm (right arrow in FIG. 26C). FIG. 26E shows the frontal section through the eye, where PDGF-C expression is seen in the hair follicles (double arrow) and in the developing eyelid. Also shown is the retina (r). In FIGS. 26F and 26G, the PDGF-C expression is found in the outer root sheath of the developing hair follicle epithelium. In FIG. 26H, PDGF-C expression is shown in the developing eyelid. There is an occurrence of individual strongly PDGF-C positive cells in the developing opening. Also shown is the lens (1). In FIG. 26I, PDGF-C expression in the developing lacrimal gland is shown by the arrow. In FIG. 26J, PDGF-C expression in the developing external ear is shown. Expression is seen in the external auditory meatus (left arrow) and in the epidermal cleft separating the prospective auricle (e). FIGS. 26K and 26L show PDGF-C expression in the cochlea. Expression is seen in the semi-circular canals (arrows in 26 K). There is a polarized distribution of PDGF-C mRNA in epithelial cells adjacent to the developing hair cells (arrow in 26 L). FIGS. 26M and 26N show PDGF-C expression in the oral cavity. Horizontal sections show expression in buccal epithelium (arrows in 26 M) and in the forming cleft between the lower lip buccal and the gingival epithelium (arrows in 26 N). Also shown is the tooth anlagen (t) and the tongue (to). FIGS. 26O and 26P show PDGF-C expression in the developing nostrils, shown on horizontal sections. PDGF-C expression appears strongest before stratification of the epithelium and the formation of the canal proper (arrows in 26 O and 26 P). Also shown is the developing nostrils (n). FIGS. 26 Q- 26 S show PDGF-C expression in developing salivary glands and ducts. FIG. 26Q is the sublingual gland. FIGS. 26R and 26S show the maxillary glands, the salivary gland (sg) and the salivary duct (sd). FIGS. 26 T- 26 V show the expression of PDGF-C in the urogenital tract. FIG. 26T shows the expression of PDGF-C in the developing kidney metanephric mesoderm. FIG. 26U shows the expression of PDGF-C in the urethra (ua) and in epithelium surrounding the developing penis. FIG. 26V shows the PDGF-C expression in the developing ureter (u).
EXAMPLE 12
PDGF-C, PDGF-A and PDGFR-Alpha Expression in the Developing Kidney
[0214] One of the strongest sites of PDGF-C expression is the developing kidney and so expression of PDGF-C, PDGF-A and PDGFR-alpha was looked at in the developing kidney. FIGS. 27 A- 27 F show the results of non-radioactive in situ hybridization demonstrating the expression (blue staining in unstained background visualized using DIC optics) of mRNA for PDGF-C (FIGS. 27A and 27B), PDGF-A (FIGS. 27C and 27D) and PDGFR-alpha (FIGS. 27E and 27F) in E16.5 kidneys. The white hatched line in FIGS. 27B, 27D and 27 F outlines the cortex border. The bar in FIGS. 27A, 27C and 27 E represents 250 μm, and in FIGS. 27B, 27D and 27 F represents 50 μm.
[0215] PDGF-C expression is seen in the metanephric mesenchyme (mm in FIG. 27A), and appears to be upregulated in the condensed mesenchyme (arrows in FIG. 27B) undergoing epithelial conversion as a prelude to tubular development, which is situated on each side of the ureter bud (ub). PDGF-C expression remains at lower levels in the early nephronal epithelial aggregates (arrowheads in B), but is absent from mature glomeruli (gl) and tubular structures.
[0216] PDGF-A expression is not seen in these early aggregates, but is strong in later stages of tubular development (FIGS. 24C and 24D). PDGF-A is expressed in early nephronal epithelial aggregates (arrowheads in FIG. 27D), but once the nephron is developed further, PDGF-A expression becomes restricted to the developing Henle's loop (arrow in FIG. 27D). The strongest expression is seen in the Henle's loops in the developing marrow (arrows in FIG. 27C). The branching ureter (u) and the ureter bud (ub) is negative for PDGF-A.
[0217] Thus, the PDGF-C and PDGF-A expression patterns in the developing nephron are spatially and temporally distinct. PDGF-C is expressed in the earliest stages (mesenchymal aggregates) and PDGF-A in the latest stages (Henle's loop formation) of nephron development.
[0218] PDGFR-alpha is expressed throughout the mesenchyme of the developing kidney (FIGS. 27E and 27F) and may hence be targeted by both PDGF-C and PDGF-A. PDGF-B expression is also seen in the developing kidney, but occurs only in vascular endothelial cells. PDGFR-beta expression takes place in perivascular mesenchyme, and its activation by PDGF-B is critical for mesangial cell recruitment into glomeruli.
[0219] These results demonstrate that PDGF-C expression occurs in close spatial relationship to sites of PDGFR-alpha expression, and are distinct from the expression sites of PDGF-A or PDGF-B. This indicates that PDGF-C may act through PDGFR-alpha in vivo, and may have functions that are not shared with PDGF-A and PDGF-B.
[0220] Since the unique expression pattern of PDGF-C in the developing kidney indicates a function as a PDGFR-alpha agonist separate from that of PDGF-A or -B, a comparison was made to the histology of embryonic day 16.5 kidneys from PDGFR-alpha knockout mice (FIGS. 28B and 28F) with kidneys from wildtype (FIGS. 28A and 28C), PDGF-A knockout (FIG. 28D) and PDGF-A/PDGF-B double knockout (FIG. 28E) mice. The bar in FIGS. 28A and 28B represents 250 μm, and in FIGS. 28 C- 28 F represents 50 μm.
[0221] Heterozygote mutants of PDGF-A, PDGF-B and PDGFR-alpha (Bostrom et al., Cell, 1996 85 863-873; Levéen et al., Genes Dev., 1994 8 1875-1887; Soriano et al., Development, 1997 124 2691-70) were bred as C57Bl6/129sv hybrids and intercrossed to produce homozygous mutant embryos. PDGF-A/PDGF-B heterozygote mutants were crossed to generate double PDGF-A/PDGF-B knockout embryos. Due to a high degree of lethality of PDGF-A −/− embryos before E10 (Bostrom et al., Cell, 1996 85 863-873), the proportion of double knockout E16.5 embryos obtained in such crosses were less than 1/40. The histology of kidney phenotypes was verified on at least two embryos of each genotype, except the PDGF-A/PDGF-B double knockout for which only a single embryo was obtained.
[0222] It is interesting that there is lack of interstitial mesenchyme in the cortex of PDGFR-alpha −/− kidney (arrows in FIG. 28A and asterisk in FIG. 28F) and the presence of interstitial mesenchyme in all other genotypes (asterisks in FIG. 28C-E). The branching ureter (u) and the metanephric mesenchyme (mm) and its epithelial derivatives appear normal in all mutants. The abnormal glomerulus in the PDGF-A/PDGF-B double knockout reflect failure of mesangial cell recruitment into the glomerular tuft due to the absence of PDGF-B.
[0223] These results indicate that PDGFR-alpha knockouts have a kidney phenotype, which is not seen in PDGF-A or PDGF-A/PDGF-B knockouts, hence potentially reflecting loss of signaling by PDGF-C. The phenotype consists of the marked loss of interstitial mesenchyme in the developing kidney cortex. The cells lost in PDGFR-alpha −/− kidneys are thus normally PDGFR-alpha positive cells adjacent to the site of expression of PDGF-C.
EXAMPLE 13
Chick Embryo Chorioallantoic Membrane (CAM) Assay for Angiogenic Activity
[0224] Recombinant human PDGF-CC core domain protein was expressed as described above (Cf. Li et al., Nat Cell Biol 2000 2 302-9) and purified to homogeneity. Two micrograms of the purified PDGF-CC were analyzed on a 4-12% gradient BisTris NUPAGE (Norex) polyacrylamide gel followed by staining with Coomassie Blue. The results are shown in FIG. 29. Dimeric (lane 2) and monomeric (lane 3) forms of PDGF-CC were detected under non-reducing and reducing/alkylating conditions, respectively. Molecular mass markers are indicated on the left (lane 1). Under non-reducing conditions the core domain of PDGF-CC appeared as dimers with the expected molecular mass of 31 kDa (lane 2). The dimeric forms of PDGF-CC were converted to monomers under reducing conditions in the presence of DTT (lane 3).
[0225] The chick embryo chorioallantoic membrane (CAM) assay was performed according to previously published methods (Cao et al., Proc Natl Acad Sci USA 1998 95 14389-94; Cao et al., Proc Natl Acad Sci USA 1999 96 5728-33). Three-day-old fertilized white Leghorn eggs (OVA Production, Sorgarden, Sweden) were cracked, and chick embryos with intact yolks were carefully placed in 20×100 mm plastic petri-dishes. After 6 days of incubation in 3% CO 2 at 37° C., a disk of methylcellulose containing 2.5 μg of truncated PCGF-C homodimer (PDGF-CC) or BSA alone dried on a nylon mesh (3×3 mm) was implanted on the CAM of individual embryos. The nylon mesh disks were made by desiccation of 10 gl of 0.45% methylcellulose in H 2 O. After 4-5 days of incubation, embryos and CAMs were examined for the formation of new blood vessels in the field of the implanted disks using a stereoscope. Disks of methylcellulose containing 2.5 μg of BSA were used as negative controls. The experiments were carried out three times, and 9 embryos/sample were used for each experiment.
[0226] The CAM assay, which detects angiogenic activity of compounds during embryonic development, is one of the most widely used in vivo angiogenesis assays (Jain et al., Nat Med 1997 3 1203-8). The early embryos in this angiogenesis assay avoid immune reactions and inflammatory influences on growing vessels. To demonstrate that PDGF-CC could induce angiogenesis in vivo, the core domain of PDGF-CC protein was implanted onto the chick chorioallantoic membrane in the developing embryo.
[0227] Nylon meshes (9 mm 2 ) coated with 0.45% methylcellulose containing 2.5 μg of PDGF-CC or BSA were implanted on CAMs of 6-day-old chick embryos. After 5 days of implantation, the formation of new blood vessels was examined under a stereoscope. FIGS. 30A, 30B show a CAM with a methylcellulose mesh containing BSA alone, which served as a negative control. FIGS. 30C, 30D show an example of 2.5 μg of PDGF-CC-implanted CAM. New blood vessels and sprouts are marked with arrows in FIGS. 30C and 30D.
[0228] It can be seen that PDGF-CC at the dose of 2.5 μg/disk was able to stimulate microvessel growth in each implanted chick embryo. A significant increase of neovascularization with a high vessel density was observed in the surrounding areas of PDGF-CC implant. Notably, PDGF-CC induced the formation of new branches and induced vessel sprouts (small arrows in FIGS. 30C and 30D) from the existing vessels that grew toward the implanted disks. These vessel sprouts appeared as “red dots” budding from blood vessels adjacent to the implanted factors. In contrast, disks without growth factors did not seem to stimulate neovascularization in chick embryos (FIGS. 30A, 30B).
[0229] The results clearly demonstrate that the truncated PDGF-C homodimer exhibits marked angiogenic activity in vivo.
EXAMPLE 14
Mouse Corneal Micropocket Assay for Angiogenic Activity
[0230] The mouse corneal micropocket assay was performed according to procedures previously described (Cao et al., Proc Natl Acad Sci USA 1998 95 14389-94; Cao et al., Nature 1999 398 381). Male 5-6 week-old C57BI6/J mice were acclimated and caged in groups of six or less. Animals were anaesthetized by injection of a mixture of dormicum and hypnorm (1:1) before all procedures. Corneal micropockets were created with a modified von Graefe cataract knife in both eyes of each male 5-6-week-old C57BI6/J mouse. A micropellet (0.35×0.35 mm) of sucrose aluminum sulfate (Bukh Meditec, Copenhagen, Denmark) coated with slow-release hydron polymer type NCC (IFN Sciences, New Brunswick, N.J.) containing various amounts of truncated PDGF-C homodimer (PDGF-CC) was surgically implanted into each cornal pocket. For comparison purposes corresponding amounts of PDGF-AA, PDGF-AB, PDGF-BB, VEGF 165 (all obtained commercially from R&D Systems of Minnepolis, MN) or FGF-2 (Pharmacia & Upjohn, Milan, Italy) were similarly implanted into corneal pockets of test mice. In each case, the pellet was positioned 0.6-0.8 mm from the corneal limbus. After implantation, erythromycin/ophthalmic ointment was applied to each eye. On day 5 after growth factor implantation, animals were sacrificed with a lethal dose of CO 2 , and corneal neovascularization was measured and photographed with a slit-lamp stereomicroscope. In FIGS. 31 and 32, arrows point to the implanted pellets. The photographs represent 20× amplification of the mouse eye. Vessel length and clock hours of circumferential neovascularization were measured. Quantitation of corneal neovascularization is presented as maximal vessel length (FIG. 31E), clock hours of circumferential neovascnlarization (FIG. 31F), and area of neovascularization (FIG. 31G). Graphs represent mean values (Å SEM) of 11-16 eyes (6-8 mice) in each group.
[0231] The corneal angiogenesis model is one of the most rigorous mammalian angiogenesis models that requires a putative compound to be sufficiently potent in order to induce neovascularization in the corneal avascular tissue. Potent angiogenic factors including FGF-2 and VEGF have profound effects in this system.
[0232] The angiogenic response of corneas stimulated by 160 ng of PDGF-CC was robust with a high number of capillaries (FIG. 31B). The newly formed as well as the limbal vessels were markedly dilated in the PDGF-CC-implanted corneas. The capillary vessel length of about 0.8 mm in corneas implanted with PDGF-CC was similar to that found in VEGF-induced vessels (FIGS. 31B, 31D and 31 E).
[0233] The overall angiogenic response induced by PDGF-CC (FIG. 31B) was similar to that induced by FGF-2 (FIG. 31C), albeit less potent than FGF-2. Both PDGF-CC- and FGF-2-induced microvessels were well organized and separated (FIGS. 31B and 31C). In contrast, the VEGF-induced blood vessels (FIG. 31D) seemed to be leaky, hemorrhagic and likely to rupture. At the front edge, the VEGF-induced capillaries were fused to into disorganized and sinusoidal structures. Thus, angiogenic responses induced by PDGF-CC and VEGF are markedly different from those induced by VEGF but similar to those induced by FGF-2.
[0234] The growth factor-implanted mouse eyes were enucleated at day 6 after implantation and immediately frozen on dry ice and stored at −80° C. before use. Tissue sections of 12 gm were dissected by a cryostat and were immersed in acetone for 10 min. Tissue slices were washed with PBS, blocked with 30% rabbit serum in PBS for 20 min. and incubated for 1 hour with a monoclonal rat anti-mouse antibody against CD31 antigen (PharMingen). After washing with PBS, a secondary FITC-conjugated rabbit anti-rat IgG was incubated with the tissue sections for 1 hour. The immuno-stained signals were examined under a fluorescence microscope. Corneal microvessels were counted in at least 6 sections at 20× magnification. FIGS. 33 A-D show histological sections of PDGF-AA (FIG. 33A), PDGF-AB (FIG. 33B), PDGF-BB (FIG. 33C) and PDGF-CC (FIG. 33D) implanted corneas which were incubated with an anti-CD31 antibody and stained with a FITC-conjugated secondary antibody. Microvessels are present in all sections. Vessel counts (FIG. 33E) per 20× field are presented as mean determinants (ÅSEM) of 6-8 serial sections in each group.
[0235] The results again clearly demonstrate that the truncated PDGF-C homodimer exhibits marked angiogenic activity in vivo.
[0236] As can be seen in FIG. 32D, truncated PDGF-C homodimer (PDGF-CC) is able to induce angiogenesis in the mouse cornea similar to other dimeric isoforms of PDGFs including PDGF-AA, PDGF-AB, and PDGF-BB. Homodimers of PDGF-BB (FIG. 32C) and PDGF-CC (FIG. 32D), and the heterodimer PDGF-AB (FIG. 32B) induced a similar angiogenic pattern in the mouse cornea. The measured vessel length (FIG. 32E), clock hours (FIG. 32F), and area of neovascularization (FIG. 32G) stimulated by the same amount of these three isoforms were indistinguishable from each other. Consistent with the area of vascularization, the immunohistological studies with the anti-CD31 antibody revealed that microvessel densities induced by PDGF-AB, PDGF-BB and PDGF-CC were virtually identical (FIG. 33B-E). In contrast, the vessel length (FIG. 32E) vessel clock hours (FIG. 32F), vascular area (FIG. 32G) and vessel density (FIGS. 33A and 33E) stimulated by PDGF-AA were significantly less than those induced by PDGF-AB, PDGF-BB or PDGF-CC (FIGS. 32 and 33). All four isoforms of the PDGFs stimulated blood vessels that were dilated (FIGS. 32 A- 32 D).
[0237] The test results show that although PDGF-AA also induces angiogenesis in vivo, it does so to a lesser extent than PDGF-CC. It also has been shown that PDGF-AA lacks the ability to directly induce endothelial cell proliferation, migration, and tube formation in vitro (Smits et al., Growth Factors 1989 2 1-8); Marx et al., J Clin Invest 1994 93 131-9); Koyama et al., J Cell Physiol 1994 158 1-6); Sato et al., Am J Pathol 1993 142 1119-30); Plate et al., Lab Invest 1992 67 529-34). Because PDGF-CC, like PDGF-AA, only activates the PDGFR-A receptor, the different angiogenic activity of PDGF-CC in vivo must be regarded as unexpected.
[0238] In light of the foregoing test results, which demonstrate the in vivo angiogenesis inducing activity of PDGF-CC, treatments with PDGF-CC alone, or in combination with other angiogenic factors such as VEGF and FGF-2, provides an attractive approach for therapeutic angiogenesis of ischemic heart and limb disorders.
EXAMPLE 15
Proteolytic Processing of PDGF-C by Human Fibroblastic 1523 Cells
[0239] Endogenous PDGF-C from human fibroblastic AG1523 cells is expressed as two principal species of about M r 25K, corresponding to processed PDGF-C, and a minor species of M r 55K, corresponding to the full-length protein. To obtain further information on the proteolytic process, serum-free medium was collected from ˜80% confluent AG1523 cells. TCA-precipitated proteins from 1 ml of medium were subjected to SDS-page using a 12% polyacrylamide gel (BioRad) under reducing conditions and then immunoblotted. Endogenous PDGF-C was detected using a rabbit anti-peptide antiserum against an internal peptide located in the human PDGF-CC core domain (Li et al., 2000). Bound antibodies were observed using enhanced chemiluminiscence Plus (ECL+; Amersham).
[0240] As seen in FIG. 34, two principal M r 25 kDa species can be seen, as well as a weak band of M r 55 kDa corresponding to full length PDGF-C. The results show that conditioned medium from the AG1523 fibroblasts produced proteolytic activity that will process full length PDGF-C into active and receptor-competent PDGF-C.
EXAMPLE 16
Expression of Recombinant Human PDGF-C in Sf9 Insect Cells
[0241] Recombinant full-length human PDGF-C was expressed in Sf9 insect cells using the baculovirus expression system (see, e.g., Example 3). Recombinant full-length PDGF-C is expressed as a major species of M r 55K in baculovirus-infected Sf9 cells. Serum-free medium was collected. TCA-precipitated proteins from 0.2 ml of the medium were subjected to SDS-page using a 12% polyacrylamide gel (BioRad) under reducing conditions and then immunoblotted. The HiS 6 -tagged PDGF-C was detected using an anti-His 6 epitope monoclonal antibody (C-terminal, InVitrogen). No protein was detected in 1523 medium with this anti-His 6 epitope monoclonal antibody. Bound antibodies were observed using enhanced chemiluminiscence Plus (ECL+; Amersham)
[0242] As seen in FIG. 35, there is a light band at about 25 K, indicating a low but nonetheless significant endogenous processing of full length PDGF-C. Further, it can be seen that His 6 epitopes in proteins in the medium are absent from AG1523 cells.
EXAMPLE 17
Protease Inhibitor Analysis
[0243] To elucidate the mechanism of the proteolysis of PDGF-C a protease inhibitor analysis was conducted. Various protease inhibitors (see Table 1, source: Sigma) were pre-incubated with 0.9ml of AG1523 serum-free medium at room temperature for 30 minutes, then incubated with 0.2ml of recombinant full-length PDGF-C (Sf9 serum-free medium) at 37° C., O/N. TCA-precipitated proteins were subjected to SDS-page under reducing conditions and then immunoblotted. Recombinant PDGF-C was detected using an anti-His 6 epitope monoclonal antibody (C-terminal) (InVitrogen).
TABLE 1 Protease inhibitors Final Name Inhibitor Of Concentration Solvent AEBSF Serine Proteases 1 mM Water Bestatin Aminoprptodases 100 μM Water Leupeptin Serine & Cysting 100 μM Water Proteases Pepstatin A Acid Proteases 10 μM <1% DMSO E64 Cystine & Thiol 100 μM Water Proteases Aprotinin Serine Proteases 100 μM (˜3TIU) Water EDTA Metalloproteases 50 mM Water Phosphoramidon Metalloendoproteases 100 μM Water
[0244] By increasing the amount of conditioned AG1523 medium and varying the co-incubated protease inhibitors, recombinant full-length PDGF-CC was cleaved in a dose-dependent manner. This indicates that the involved protease is present in the AG1523 medium and that the processing occurs extracellularly.
[0245] The serine protease inhibitors were able to decrease the proteolysis as compared to control, indicating the serine proteases are those involved in the processing of PDGF-C. In particular, Aprotinin showed a capacity to inhibit proteolytic processing, thus a serine protease is expected to be trypsin-like. Trypsin-like serine proteases are proteases containing trypsin like domains.
[0246] As seen in corresponding FIG. 36, conditioned medium from AG1523 fibroblasts contains a serine protease with trypsin-like properties that processes PDGF-C.
EXAMPLE 18
Bioassays to Determine the Function of PDGF-C
[0247] Assays are conducted to evaluate whether PDGF-C has similar activities to PDGF-A, PDGF-B, VEGF, VEGF-B, VEGF-C and/or VEGF-D in relation to growth and/or motility of connective tissue cells, fibroblasts, perivascular, myofibroblasts and glial cells; to endothelial cell function; to angiogenesis; and to wound healing. Further assays may also be performed, depending on the results of receptor binding distribution studies.
[0248] I. Mitogenicity of PDGF-C for Endothelial Cells
[0249] To test the mitogenic capacity of PDGF-C for endothelial cells, the PDGF-C polypeptide is introduced into cell culture medium containing 5% serum and applied to bovine aortic endothelial cells (BAEs) propagated in medium containing 10% serum. The BAEs are previously seeded in 24-well dishes at a density of 10,000 cells per well the day before addition of the PDGF-C. Three days after addition of this polypeptide the cells were dissociated with trypsin and counted. Purified VEGF is included in the experiment as positive control.
[0250] II. Assays of Endothelial Cell Function
[0251] a) Endothelial Cell Proliferation
[0252] Endothelial cell growth assays are performed by methods well known in the art, e.g. those of Ferrara & Henzel, Nature, 1989 380 439-443, Gospodarowicz et al., Proc. Natl. Acad. Sci. USA, 1989 86 7311-7315, and/or Claffey et al., Biochem. Biophys. Acta, 1995 1246 1-9.
[0253] b) Cell Adhesion Assay
[0254] The effect of PDGF-C on adhesion of polymorphonuclear granulocytes to endothelial cells is tested.
[0255] c) Chemotaxis
[0256] The standard Boyden chamber chemotaxis assay is used to test the effect of PDGF-C on chemotaxis.
[0257] d) Plasminogen Activator Assay
[0258] Endothelial cells are tested for the effect of PDGF-C on plasminogen activator and plasminogen activator inhibitor production, using the method of Pepper et al., Biochem. Biophys. Res. Commun., 1991 181 902-906.
[0259] e) Endothelial Cell Migration Assay
[0260] The ability of PDGF-C to stimulate endothelial cells to migrate and form tubes is assayed as described in Montesano et al., Proc. Natl. Acad. Sci. USA, 1986 83 7297-7301. Alternatively, the three-dimensional collagen gel assay described in Joukov et al., EMBO J., 1996 15 290-298 or a gelatinized membrane in a modified Boyden chamber (Glaser et al., Nature, 1980 288 483-484) may be used.
[0261] III. Angiogenesis Assay
[0262] The ability of PDGF-C to induce an angiogenic response in chick chorioallantoic membrane is tested as described in Leung et al., Science, 1989 246 1306-1309. Alternatively the rat cornea assay of Rastinejad et al., Cell, 1989 56 345-355 may be used; this is an accepted method for assay of in vivo angiogenesis, and the results are readily transferrable to other in vivo systems.
[0263] IV. Wound Healing
[0264] The ability of PDGF-C to stimulate wound healing is tested in the most clinically relevant model available, as described in Schilling et al., Surgery, 1959 46 702-710 and utilized by Hunt et al., Surgery, 1967 114 302-307.
[0265] V. The Hemopoietic System
[0266] A variety of in vitro and in vivo assays using specific cell populations of the haemopoietic system are known in the art, and are outlined below. In particular a variety of in vitro murine stem cell assays using fluorescence-activated cell sorter to purified cells are particularly convenient:
[0267] a) Repopulating Stem Cells
[0268] These are cells capable of repopulating the bone marrow of lethally irradiated mice, and have the Lin-, Rh h1 , Ly-6A/E + , c-kit + phenotype. PDGF-C is tested on these cells either alone, or by co-incubation with other factors, followed by measurement of cellular proliferation by 3 H-thymidine incorporation.
[0269] b) Late Stage Stem Cells
[0270] These are cells that have comparatively little bone marrow repopulating ability, but can generate D13 CFU-S. These cells have the Lin − , Rh h1 , Ly-6A/E + , c-kit + phenotype. PDGF-C is incubated with these cells for a period of time, injected into lethally irradiated recipients, and the number of D13 spleen colonies enumerated.
[0271] c) Progenitor-Enriched Cells
[0272] These are cells that respond in vitro to single growth factors and have the Lin − , Rh h1 , Ly-6A/E + , c-kit + phenotype. This assay will show if PDGF-C can act directly on haemopoietic progenitor cells. PDGF-C is incubated with these cells in agar cultures, and the number of colonies present after 7-14 days is counted.
[0273] VI. Atherosclerosis
[0274] Smooth muscle cells play a crucial role in the development or initiation of atherosclerosis, requiring a change of their phenotype from a contractile to a synthetic state. Macrophages, endothelial cells, T lymphocytes and platelets all play a role in the development of atherosclerotic plaques by influencing the growth and phenotypic modulations of smooth muscle cell. An in vitro assay using a modified Rose chamber in which different cell types are seeded on to opposite cover slips measures the proliferative rate and phenotypic modulations of smooth muscle cells in a multicellular environment, and is used to assess the effect of PDGF-C on smooth muscle cells.
[0275] VII. Metastasis
[0276] The ability of PDGF-C to inhibit metastasis is assayed using the Lewis lung carcinoma model, for example using the method of Cao et al., J. Exp. Med., 1995 182 2069-2077.
[0277] VIII. Migration of Smooth Muscle Cells
[0278] The effects of the PDGF-C on the migration of smooth muscle cells and other cells types can be assayed using the method of Koyama et al., J. Biol. Chem., 1992 267 22806-22812.
[0279] IX. Chemotaxis
[0280] The effects of the PDGF-C on chemotaxis of fibroblast, monocytes, granulocytes and other cells can be assayed using the method of Siegbahn et al., J. Clin. Invest., 1990 85 916-920.
[0281] X. PDGF-C in Other Cell Types
[0282] The effects of PDGF-C on proliferation, differentiation and function of other cell types, such as liver cells, cardiac muscle and other cells, endocrine cells and osteoblasts can readily be assayed by methods known in the art, such as 3 H-thymidine uptake by in vitro cultures. Expression of PDGF-C in these and other tissues can be measured by techniques such as Northern blotting and hybridization or by in situ hybridization.
[0283] XI. Construction of PDGF-C Variants and Analogs
[0284] PDGF-C is a member of the PDGF family of growth factors which exhibits a high degree of homology to the other members of the PDGF family. PDGF-C contains eight conserved cysteine residues which are characteristic of this family of growth factors. These conserved cysteine residues form intra-chain disulfide bonds which produce the cysteine knot structure, and inter-chain disulfide bonds that form the protein dimers which are characteristic of members of the PDGF family of growth factors. PDGF-C interacts with a protein tyrosine kinase growth factor receptor.
[0285] In contrast to proteins where little or nothing is known about the protein structure and active sites needed for receptor binding and consequent activity, the design of active mutants of PDGF-C is greatly facilitated by the fact that a great deal is known about the active sites and important amino acids of the members of the PDGF family of growth factors.
[0286] Published articles elucidating the structure/activity relationships of members of the PDGF family of growth factors include for PDGF: Oestman et al., J. Biol. Chem., 1991 266 10073-10077; Andersson et al., J. Biol. Chem., 1992 267 11260-1266; Oefner et al., EMBO J., 1992 11 3921-3926; Flemming et al., Molecular and Cell Biol., 1993 13 4066-4076 and Andersson et al., Growth Factors, 1995 12 159-164; and for VEGF: Kim et al., Growth Factors, 1992 7 53-64; Potgens et al., J. Biol. Chem., 1994 269 32879-32885 and Claffey et al., Biochem. Biophys. Acta, 1995 1246 1-9. From these publications it is apparent that because of the eight conserved cysteine residues, the members of the PDGF family of growth factors exhibit a characteristic knotted folding structure and dimerization, which result in formation of three exposed loop regions at each end of the dimerized molecule, at which the active receptor binding sites can be expected to be located.
[0287] Based on this information, a person skilled in the biotechnology arts can design PDGF-C mutants with a very high probability of retaining PDGF-C activity by conserving the eight cysteine residues responsible for the knotted folding arrangement and for dimerization, and also by conserving, or making only conservative amino acid substitutions in the likely receptor sequences in the loop 1, loop 2 and loop 3 region of the protein structure.
[0288] The formation of desired mutations at specifically targeted sites in a protein structure is considered to be a standard technique in the arsenal of the protein chemist (Kunkel et al., Methods in Enzymol., 1987 154 367-382). Examples of such site-directed mutagenesis with VEGF can be found in Potgens et al., J. Biol. Chem., 1994 269 32879-32885 and Claffey et al., Biochem. Biophys. Acta, 1995 1246 1-9. Indeed, site-directed mutagenesis is so common that kits are commercially available to facilitate such procedures (e.g. Promega 1994-1995 Catalog., Pages 142-145).
[0289] The connective tissue cell, fibroblast, myofibroblast and glial cell growth and/or motility activity, the endothelial cell proliferation activity, the angiogenesis activity and/or the wound healing activity of PDGF-C mutants can be readily confirmed by well established screening procedures. For example, a procedure analogous to the endothelial cell mitotic assay described by Claffey et al., (Biochem. Biophys. Acta., 1995 1246 1-9) can be used. Similarly the effects of PDGF-C on proliferation of other cell types, on cellular differentiation and on human metastasis can be tested using methods which are well known in the art.
[0290] The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations falling within the scope of the appended claims and equivalents thereof. | PDGF-C, a new member of the PDGF/VEGF family of growth factors, is described, as well as nucleotide sequences, its method of production, antibodies and antagonists. Also disclosed are transfected and transformed host cells expressing same and pharmaceutical compositions, and uses thereof in medical and diagnostic applications. Proteolytic processing of PDGF-C is accomplished by a serine protease. Methods for inhibiting PDGF-C activities and for treating disease caused by PDGF-C over-activity of over-expression are also disclosed. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to machines for applying double-coated pressure-sensitive adhesive tape strips.
2. Prior Art
U.S. Pat. No. 3,472,724 issued Oct. 14, 1969 to J. H. Casey discloses an apparatus which is suitable for feeding a length of tape to an applying pad, across a severing member, which will sever and apply the tape to a substrate. This device will apply double-coated pressure-sensitive adhesive tape strips. It is often desirable when applying double-coated tape, especially a double-coated foam tape, that the tape strip after it is applied not have a liner on one surface. In order to apply the tape however it is necessary to contact one surface of the tape. With double coated tape this would require contact with one adhesive surface if the liner were previously removed. In a device as illustrated in the above mentioned patent the pad is supplied with gripping means or a vacuum to hold the cut strips and the liner adhered thereto while the exposed opposite surface of the tape is applied to the receptor surface.
BRIEF SUMMARY OF THE INVENTION
The present invention solves the problems of prior art devices by providing a tape applicating head wherein a release liner carries the double-coated tape to an applicating station and holds the tape in position during application to a substrate. This permits the double-coated tape to be applied without the liner on one surface. The device of the present invention has a frame supporting a convolutely wound roll of double-coated tape disposed on a release liner. The tape is carried to severing means by the release liner where the tape, but not the liner, is cut transversely into strips. The liner carries the severed tape strips to an applicating station where an applicating arm places the strips on the surface of a moving substrate. The applicating arm has an applicating end and a rotating end, the rotating end being mounted on a driven eccentric. The arm has a cam track associated therewith which extends along a portion of the length of said arm. A cam member, mounted on a driven eccentric, engages the cam track at a point between the applicating end and the rotating end of the cam.
Means is provided to move the liner with the tape strips thereon from the severing means to an applicating position at the end of the applicating arm and to move the liner past the applicating position to a disposal station after application of the tape. Indexing means register the cut strips of tape at the end of the applicating arm in position for application to the substrate. As the rotating end and cam member rotate on their eccentrics, the applicating end of said applicating arm is moved in a narrow foil shaped biconvex path when viewed in plan.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be fully understood after reading the following description which refers to the accompanying drawing wherein
FIG. 1 is a plan view of an applicator constructed according to this invention with the applicating arm in the applying position;
FIG. 2 is an elevational view of the applicator of FIG. 1;
FIG. 3 is a fragmentary plan view illustrating the applicating arm upon completion of an applicating cycle;
FIG. 4 is a fragmentary plan view illustrating the applicating arm as it returns to start an applicating cycle;
FIG. 5 is a fragmentary plan view illustrating the applicating arm as the arm is starting an applicating cycle;
FIG. 6 is a fragmentary sectional view of the applicator illustrating the drive gears; and
FIG. 7 is a diagrammetric plan view illustrating the path of the tip of the applicating arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawing in which like numerals refer to like parts throughout the several views, one adhesive coated surface of a double-coated pressure-sensitive adhesive tape 10 is in contact with a tape metering roller 16 which draws the tape and associated release liner 12 from a convolutely wound supply roll 14 of tape and liner. The metering roller 16 will be formed of a release material such as silicone rubber. A uniform pressure is maintained between the tape metering roller 16 and tape 10 by means of a pressure roller 18. The roller 18 is mounted on a link 20 pivoted to the frame 17 by a stud 21. The link 20 is urged towards the metering roller 16 by means of a spring 19 to maintain a firm contact between the tape 10 and the tape metering roller 16.
To dispense tape, the tape metering roller 16 is rotated stepwise or is indexed a fractional amount of a revolution stripping tape from the supply roll 14. As shown, the metering roller 16 is intermittently driven by means including a driven shaft 79 rotating a pair of cams 22 which have axially spaced lobes. Each lobe has a depression 23, the depressions being spaced at 180°. As the cam 22 is driven at a constant rate of speed, the depressions 23 make contact with opposed pins 25 in an intermittent drive wheel 24. As shown, there are 8 pins in a star arrangement so that the tape metering roller 16 will be advanced 1/8 revolution each time the intermittent drive wheel is advanced by a cam 22 through a gear train shown in FIG. 6.
After being withdrawn by the tape metering roller 16, the liner and tape pass across a roller 26 which cooperates with severing means. As shown, the severing means comprises a heated elongate thin blade 30 mounted on a pivotable arm 32 which is rotatably mounted on pin 33 attached to the frame 17. The arm 32 and the associated knife 30 are oscillated by eccentric 31 which includes a bushing 34 with rod 35 rigidly attached thereto. The end of this rod 35 opposite said eccentric 31 is in the form of a piston 37 slideably mounted in a housing 38. As the eccentric 31 rotates the piston 37 moves in the housing 38. A chamber 39 formed by the piston 37 and housing 38 nearest the eccentric is normally maintained under a small positive pressure applied by a valve 29 which adjusts the air and therefore the cutting pressure of the blade. As the rod 35 is pulled towards the tape 10 the air in chamber 39 is compressed causing the housing 38 and arm 32 to which it is attached pivotally by a pin 36 to move towards the tape. The heated blade 30 severs the tape and adhesive by rapid brief contact with the tape to sever or melt the adhesive layers and the tape backing which may be a polyethylene foam. As the eccentric 31 continues to rotate the piston 37 moves away from the tape and the piston acting in the chamber opposite chamber 39 causes housing 38 to move arm 32 and blade 30 to a retracted position.
The valve 29 permits compressed air to be directed through one line to the chamber in the housing 38 opposite chamber 39. The build up of pressure causes housing 38 to draw the arm 32 and blade 30 farther away from the cooperating roller 26. This effectively moves the knife away from the tape and is used when the unit is not operating to prevent burning the tape or liner. The valve 29 is designed so that the knife is automatically retracted in this manner whenever the taping head is not operating.
Where the tape 10 to be dispensed has a soft foam backing, such as a polyethylene, the hot blade 30 will melt the foam and adhesive layers but not cut or burn the liner. This forms severed transversely extending strips of tape which remain on the liner. Thus, the liner is used to transport the severed strips of tape to an applicating position. Each strip having a length corresponding to the original width of the tape.
From the cutter, the tape passes a pin 40 extending perpendicular to the planer surface of the frame 17, the pin 40 being rotatable with the eccentric 31. The eccentric 31 moves in such a manner that the distance between the pin 40 and an applicating tip 56 of an applicating member such as arm .tbd.remains constant thereby insuring that the severed piece of tape to be applied will be at the tip of the applicating arm and that the severed strip of tape will not oscillate back and forth around the tip of the applicating arm 57 as the tip moves in a biconvex or thin foil shaped path the ends of which are cusps as shown in FIG. 7. The pin 40 is mounted on the eccentric 31 about 180° from the axis of the drive shaft which rotates eccentric 31.
The liner 12 with the severed pieces of tape 10 thereon passes across a tape location adjuster 58 which can be adjusted so that the tape strip to be applied is centered at the end of the applicating arm. The liner 12 and tape pieces move across the applicating tip 56 of the applicating arm 57 where the pieces are applied, one at a time as the tip moves through a cycle, to a substrate 60. The applicating tip 56 as shown is an oblong planar surface, or surface conforming to the shape of the strip and profile of the substrate, to support a strip of tape. The substrate shown is a can. The device of this invention is particularly useful in applying strips of a tape comprising of a soft foam backing having adhesive on both sides thereof to beverage cans which can then be assembled into groups, e.g., a "six pack."
The applicating arm 57 has one end 59 mounted for movement on a rotating eccentric wheel 41 which will give the applicating tip 56 and applicating arm 57 an in-and-out motion pushing the applicating tip out from the housing 17 to make contact with the substrate 60 to which a tape strip is to be applied while the applicating tip is moving in the same direction and at the same rate as the moving substrate 60. After application of the tape strip, the tip 56 is pulled in toward the housing so that as the tip moves backwards, to begin another applicating cycle, it will not come in contact with the substrate.
Near the center of the applicating arm 57 is a cam race 42 in which a cam 43 moves. Cam 43 is an eccentric pin mounted on a wheel 44 and gives the applicating arm 57 a sweeping motion. The combination of the motion of the rotating end 59 on eccentric wheel 41 and wheel 44 and pin 43 moves the applicating tip 56 in a long-thin foil shaped path or biconvex path. The applicating arm in an extended position is suitable for applying tape to a moving substrate and in a retracted position returns the applicating end 56 of the arm 57 to the beginning of the cycle without touching the substrate. By use of the proper arm length and eccentric size, the speed of the applicating tip 56 is matched to that of the substrate 60. As shown in FIG. 4, the eccentric pin 43 and axis supporting the end 59 on wheel 41 will be closest together when the tape is being applied to the substrate as shown in FIG. 1. This is also the point of maximum speed for the applicating tip allowing the substrate to move past the applicating head at the maximum possible speed.
After the tape has been applied to the moving substrate 60, the liner 12 will move around a scavenging roller 46 which will pick up any pieces of tape remaining on the liner and the spent liner, cleaned of any residual tape, is pulled by a driven roller 48 to a disposal area. The roller 48 is driven through an adjustable slip clutch.
A constant pressure is applied to roller 48 by means of a pressure roller 50 mounted by a bracket on a shaft which in turn is mounted in a frame 52 which pivots about stud 54 mounted to the frame 17. The tension on roller 50 is supplied by a spring 61. The roller 50 and driven roller 48 hold the liner tightly therebetween maintaining tension on the liner from the metering roller 16 past eccentric pin 40 around the applicating tip 56 and through the rollers 48 and 50. This tension maintains the liner in a straight line as it travels about the rollers and tip through the taping head.
The various shafts driving the eccentrics can be driven by various drive means, such as chains or gears. A gear train is preferred since it is compact and requires the minimum amount of space. The drive for the applicator is illustrated in FIGS. 2 and 6. The drive for the applicator is matched to the movement of the conveying mechanism for the substrate to keep the two pieces in proper timed sequence. This is obtained by a drive belt or chain 70 driven from a drive pulley (not shown) supported on the conveyor frame 71 and rotatable therewith. The belt 70 drives a pulley 72 which drives a shaft 75 in the applicator as shown in FIG. 6. Fixed to shaft 75 is a first gear 76 and a second gear 74 and roller 48 via a slip clutch as above-described. The gear 76 drives a gear 77 which drives the eccentric 31 to control the cutting and tape position and drive therethrough a gear 78 and shaft 79 which drives the cams 22. The cams 22 drive the wheel 24 to incrementally drive a shaft 80, a gear 81, idler 82 and a drive gear 83 for the roller 16. The second gear 77 drives the shaft 85 coupled to the eccentric wheel 41 and gear 86 and a gear 87 driving a shaft 88 coupled to the wheel 44 carrying eccentric pin 43.
The gears illustrated in FIG. 6 are suitably formed to drive the applicating arm along its path so it will apply a strip of tape to the substrate, to index the tape and to operate the tape cutter or slicer. During application the movement of the tip 56 and tape strip match the speed of movement of the substrate to place the strip thereon and transfer it from the liner 12. The arm will then position another strip of tape at the tip and return to the start position to begin another cycle.
Having described the present invention with reference to the preferred embodiment, it is to be understood that changes can be made to the several parts without departing from the spirit of the invention as recited in the appended claims. | An apparatus for applying severed strips of double-coated adhesive tape to a substrate from the face of a carrier liner. A length of tape having adhesive on both sides and disposed on a release liner is fed continuously past a severing means which cuts the tape into strips but does not sever the liner. The tape strips are then carried by the liner to an applicating member where the strips of tape are applied to a moving substrate. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/846,912 filed on Jul. 16, 2013 of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to methods of enhancing visual function and for treating ocular conditions resulting from low or poor visual function by administration of an inhibitor of hyperpolarization-activated cyclic nucleotide-gated (HCN) channel.
BACKGROUND OF THE INVENTION
[0003] Hyperpolarization-activated Cyclic Nucleotide gated (HCN)were identified in the late 1970s and early 1980s in sinoatrial node cells and neurons, respectively (Brown et al., 1979; halliwell and Adams, 1982). HCN channels are members of the pore loop cation channels superfamily (yu et al., 2005). In mammals the HCN channel family includes 4 members (HCN1-4) that are differentially expressed in different types of excitable tissues (for review see: Biel et al., 2009; Kaup and Seifert, 2001) and share approximately 60% sequence identity with each other and are present in all vertebrates (Ludwig et al., 1998). HCN channels form tetrameric complexes consisting of homomeric or heteromeric subunit compositions with each subunit consisting of six transmembrane alpha helices. Similar to other voltage-gated channels, HCN channels possess voltage sensors (Manniko et al., 2002). HCN channels are activated by membrane hyperpolarization and upon opening give rise to a depolarizing mixed cation current termed I h , I f or I q , which cause the re-depolarization of the membrane potential to near resting potentials. HCN channels contain a cyclic nucleotide binding domain in the carboxyl terminus. Following the binding of cyclic AMP or cyclic GMP, the activation kinetics of the channels are shifted to become more sensitive to membrane hyperpolarization (Wainger et al., 2001). Aside from their role as pacemakers in the sino-atrial node of the heart, HCN channels perform important functions in neuronal cells including determination of resting membrane potential, dendritic integration, action potential rhythmicity, synaptic transmission and synaptic plasticity (for review see: Robinson and Siegelbaum, 2003).
[0004] Different HCN channel subtypes are expressed throughout the central nervous system (Biel et al., 2009) including the retina where all isoforms are expressed, with HCN1 and HCN4 showing dominant expression (Muller et al., 2003). HCN1 is expressed in all major retinal neuronal subtypes whereas HCN4 is expressed predominantly in bipolar and ganglion cell (Stradleigh et al., 2011). Targeted deletion of HCN1 from the mouse retina results in prolonged light responses as seen in electroretinogram flicker responses suggesting an important function of these channels in rod and cone photoreceptors since B-wave amplitude, which result from ON-bipolar cell function, remained unaltered, or slightly reduced in these animals (Knop et al., 2008). Both HCN1 and HCN4 are expressed in retinal ganglion cells where most cells show a mosaic of expression pattern (Stradleigh et al., 2011). Although strongly expressed in ganglion cells, the function of these channels in ganglion cells and overall visual physiology is unclear.
[0005] WO2011000915A1 refers to isoform-selective HCN blockers.
[0006] U.S. Pat. No. 8,076,325 B2 refers to 1,2,4,5-tetrahydro-3H-benzazepine compounds as blockers of HCN channels, a process for their preparation and pharmaceutical compositions containing them.
[0007] WO 2008/121735 refers to methods of identifying modulators of HCN channels.
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SUMMARY OF THE INVENTION
[0023] The present invention provides a method of enhancing visual function in a subject, comprising administering to the subject in need of such enhancement, a therapeutically effective amount of a compound that is an inhibitor of a hyperpolarization-activated cyclic nucleotide-gated (HCN) channel.
[0024] The present invention also provides a method of treating an ocular condition resulting from low/poor visual function in a subject, comprising administering to said subject in need of such treatment, a therapeutically effective amount of a compound that is an inhibitor of a hyperpolarization-activated cyclic nucleotide-gated (HCN) channel.
[0025] The present invention also provides an ocular implant comprising a therapeutically effective amount of a compound that is an inhibitor of a hyperpolarization-activated cyclic nucleotide-gated (HCN) channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 shows that in the middle of the retina there is a small pit, the fovea, with which we see sharply. Only a few millimeters from the fovea (arrows) the visual acuity is 20/200 (6/60 or 0.1) even in a normal person.
[0027] FIG. 2 shows the visual pathways from the eyes to the visual cortex. Note that there are also connections to the central parts of the brain. Note also that in the optic radiation, the pathway from the LGN (lateral geniculate nucleus) to the primary visual cortex there are marked arrows in the direction from the primary visual cortex to the LGN. Actually, there are some ten times more fibres bringing information from the primary visual cortex to the LGN than in the opposite direction. From the primary visual cortex information flows “backwards” also to the superior colliculus (SC).
[0028] FIG. 3 illustrates visual field. 3 A shows visual field of both eyes. 3 B shows that the central part of the visual field (white area) is seen by both eyes.
[0029] FIG. 4 illustrates contrast sensitivity. 4 A shows the contrast sensitivity curve. 4 B shows visual information at different contrasts in different sizes. Note that large numbers are visible at a fainter contrast than smaller numbers.
[0030] FIG. 5 illustrates eye muscles seen from above. The left outer muscle has developed palsy, the left eye turns inward.
[0031] FIG. 6 illustrates RGC profile changes due to ZD7288. As observed in the receptive field profile of RGC in the figure, ZD7288 enhances the response near the receptive field center without affecting the surround.
[0032] FIG. 7 shows the effects of 1 uM ZD7288 on OFF retinal ganglion cell receptive field profile using multifocal stimulus probe. The receptive field profile of OFF RGCs under control conditions and in the presence 1 uM ZD7288 and 1 uM ZD7288. ZD7288 significantly enhanced the receptive field profile of RGCs near the center of the receptive field.
[0033] FIG. 8 shows the effects of 5 uM ZD7288 on retinal ganglion cell HCN current. HCN mediated Ih current was attenuated by ZD7288. All data were significantly different (p<0.05) as compared to control (N=6).
[0034] FIG. 9 shows the effects of 5 uM ZD7288 on retinal ganglion input resistance. It was hypothesized that HCN mediated Ih current gives rise to a leak conductance in retinal ganglion cells and blockade of this conductance would give rise to increased input resistance in these cells. The data clearly showed an enhancement of input resistance in ganglion cell (P<0.05, N=6).
[0035] FIG. 10 shows the effects low (1 uM) and high (30 uM) ZD7288 on sweep vision evoked potential (VEP). Intravitreal dosing of rabbit with different doses of ZD7288 gave rise to opposite effects on sweep VEP acuity. At a low intravitreal dose of 1 uM, sweep VEP acuity was enhanced whereas at a high dose of 30 uM, sweep VEP acuity was attenuated (* P<0.05, N=4). The data strongly suggest that blockade of HCN channels with low doses targets the inner retina which gives rise to enhancement in acuity; whereas at higher doses, the outer retina is also affected because of better diffusion of the drug to the outer retina.
[0036] FIG. 11 shows the effect of different concentrations of Ivabradine on retinal ganglion cell HCN (I h ) current. Ganglion cell were voltage clamped at −60 mV and stepped to −80, −100 and −120mV for 1 second. The HCN mediated current was recorded (control) and different concentrations of Ivabradine were perfused into the recording chamber with every concentration at every voltage step there was statistically significant decrease in the HCN mediated current as compared to control (indicated by asterisks).
[0037] FIG. 12 shows the effect of different concentrations of Ivabradine on Retinal ganglion cell input resistance. Ganglion cell were voltage clamped at −60 mV and stepped to −55 mV. The steady-state current was recorded and the input resistance of the ganglion cell was calculated using Ohms law (V=IR). The input resistance of the ganglion cell increased with every concentration of Ivabradine in a linear manner as compared to control (asterisks indicate statistical significance).
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the Invention
[0038] Vision is composed of many simultaneous functions. If vision is normal, seeing is so effortless that we do not notice the different visual functions.
[0039] The different components of the visual image are: forms, colors and movement. Thus we have form perception, color perception and motion perception.
[0040] We see both during the day light and during very dim light. In day light, photopic vision, we perceive colors because of function of the cone cells; in very dim light, scotopic vision, we see only shades of gray, since rod cells respond only to luminance differences. In twilight, when both rod and cone cells function, we have mesopic vision.
[0041] Vision is measured with many different tests, such as tests for visual acuity, visual field, contrast sensitivity, color vision, visual adaptation to different luminance levels, binocular vision and stereoscopic vision.
[0042] The term “visual function” as used herein includes all of the above, namely visual acuity, visual field, contrast sensitivity, color vision, visual adaptation to different luminance levels, binocular vision and three dimensional (stereoscopic) vision.
[0043] In another embodiment of the present invention, the visual function is visual acuity.
[0044] A good article on different visual functions is available on the web at http://www.lea-test.fi/en/eyes/visfunct.html.
[0045] “Visual acuity” is measured with visual acuity charts at distance and at near. The test measures what is the smallest letter, number or picture size that the patient still sees correctly. Visual acuity is good only in the very middle of the retina. See FIG. 1 .
[0046] When a person with normal vision looks straight forward without moving the eyes, (s)he sees also on both sides. The area visible at once, without moving the eyes, is called “visual field”. Nerve fibres from both eyes are divided so that fibers from the right half of both eyes reach the right half of the brain and fibers from the left half of both eyes the left half of the brain. See FIG. 2 .
[0047] Visual information coming from both eyes is fused in the visual cortex in the back of the brain. The central part of the visual field is seen by both eyes ( FIG. 3 ). On both sides of this central, binocular field there are half moon formed parts of visual field that are seen by only one eye. See FIG. 3 .
[0048] We use our peripheral or side vision when moving around. The most central part of the visual field is used in sustained near work, e.g., reading. When the visual field is measured with the clinical instruments these instruments measure what the weakest light is that the eye still can see in different parts of the visual field. A measurement like this gives valuable information on diseases of the visual pathways related to glaucoma or neurologic diseases. It does not give information on how the person sees forms or perceives movement in the different parts of the visual field.
[0049] The visual field can change in many ways. Therefore it is often difficult to understand how a visually impaired person sees. If the side parts of the visual field function poorly the person may need to use a white cane in order to move around safely, but (s)he may be able to read without glasses. On the other hand, if the side parts function well and the central field functions poorly, the person may walk like a normally sighted person, but may be able to read only the headings of a newspaper.
[0050] “Contrast sensitivity” can be depicted, for example, by a curve (See FIG. 4A ). Under the curve there are the objects that we can see, above and to the right of the slope of the curve is the visual information that we cannot see. Contrast sensitivity can be measured using striped patterns, gratings, or symbols at different contrast levels.
[0051] When we measure hearing, an audiogram depicts which are the weakest tones at different frequencies that we still can hear. The measurements are made at low, intermediate and high frequencies. When we measure contrast sensitivity we measure what is the faintest grating or symbol still visible when the symbols are large, medium size or small ( FIG. 4B ).
[0052] If a visually impaired person has poor contrast sensitivity (s)he cannot see small contrast differences between adjacent surfaces. Everything becomes flat. It is difficult to perceive facial features and expressions. Text in the newspapers seems to have less contrast than before and it is difficult to recognize the edge of the pavement and the stairs.
[0053] Contrast sensitivity decreases in several common diseases, diabetes, glaucoma, cataract and diseases of the optic nerve.
[0054] Visual adaptation to different luminance levels: A normally sighted person can read by one candle's light and (s)he can read in bright sun light. The difference in the amount of light present in these two situations is million times. The normal person can adapt his/her vision to function at the different luminance levels.
[0055] The rod cells of the retina see best in twilight. If they do not function, the person is night blind. Night blindness is the first symptom that develops in many retinal diseases. First the child with a retinal disease starts to see in dim light after an abnormally long waiting. Therefore (s)he will have difficulties in finding his/her clothing in a closet or in a drawer if there is no extra illumination directed into these places. Later (s)he loses night vision completely, even when waiting for a long time (s)he does not start to see in the dark. Changes in visual adaptation time can be easily detected with the CONE Adaptation Test.
[0056] Photophobia and delayed adaptation to bright light are often additional symptoms of abnormal visual adaptation. When normally sighted persons enter from a darker room into a bright light, they also see very little for a second, sometimes it even hurts their eyes. They are dazzled. A visually impaired person may be dazzled for a long time. It is possible to decrease the problem by using absorptive glasses and a hat with wide brim or a visor.
[0057] Color vision: There are three different types of the retinal cone cells: some cells are most sensitive to red light, other to green light and the third type is most sensitive to blue light. Also the “normally sighted” individuals may have minor difficulties with color perception. It is often called color blindness but the term is poorly chosen because these persons are not blind, many of them are unaware that they have anything abnormal with their vision. However, if they compare such colors as moss green, snuff brown, dark purple, and dark grey, all these color may look more or less the same. Small deviations from normal affect only some specific working conditions. That is why color vision is examined at school before students get advice in career planning.
[0058] The screening examination uses pseudoisochromatic plates. Most commonly used test is called Ishihara's test. Screening tests are very sensitive and detect even minor deviations from normal color perception. They do not measure the degree of deviation. For the diagnosis of deviant color perception another test is necessary, a quantitative test in form of small caps with color surfaces in all colors of the spectrum. The diagnosis of color deficiency should never be based on a screening test. If a child seems to have any confusion with colors, color vision should be examined carefully. It can be started with clear basic colors to teach the concepts similar/different in relation to colors, after which quantitative testing is possible. Young children may train for the quantitative test by playing the Color Vision Game. Major color vision deficiencies are revealed already in this game but the diagnose requires proper measurement using pigment tests.
[0059] Binocular vision and three dimensional vision: We have two eyes but see only one picture, image. Visual information coming from the two eyes is fused into one image in the visual cortex. Not all normally sighted have binocular vision. They do not use both eyes simultaneously, together. Some persons look alternatingly with their right or left eye. They are usually unaware that they use their eyes separately. It does not disturb them.
[0060] Stereovision or three dimensional vision means that we have depth perception in near vision. When we look far away we have another kind of depth perception. We pay attention to the relative size of objects and which object is partially hidden behind another object. The speed of movement with which an object seems to move when we move our head or move around (called parallax) gives us clues on the distance. Therefore persons who do not have stereovision can still assess depth.
[0061] Dominant eye: Dominant or leading eye is the eye that we use when we look very carefully at near or at far and can use only one eye. Even when both eyes are used simultaneously one of the eyes is more dominant than the other. We have hand, foot, and eye preference.
[0062] Eye motility and its disturbances: Eye movements are usually well controlled. The eyes look at the same object. Eyes turn because of the function of six eye muscles. If one of the eye muscles is paralysed, the eye turns in an abnormal position, the person sees double images ( FIG. 5 )
[0063] If an eye muscle is not functioning properly the person sees double when trying to look in the direction where the muscle should function. When the eyes are turned in the opposite direction the double image is fused again. The eye with the disturbed motility is covered until the muscle function returns to normal.
[0064] Sometimes there is no disturbance in the muscles themselves but the command to turn eyes in a certain direction is not handled normally because of changes in brain function.
[0065] Variation in the nature of visual disability: Different visual functions may become impaired independent of each other. Therefore there are many different types of visual impairment and disability. Sometimes a visually impaired person seems to function in a very confusing way. One moment (s)he seems to function like a normally sighted person and in the next moment like a blind person. A visually impaired person seldom pretends to see less than what (s)he actually sees.
[0066] One reason for variation in visual behavior might be changes in illumination. Another may be that (s)he knows the surroundings so there is no difficulty in orientation. Normally sighted persons move about the same way at home in the dark. They move confidently and securely as long there is nothing unexpected in their way. If somebody leaves an object on the usual path they may trip over it. In the very same way a visually impaired person needs only a few visual cues in a well-known place in order to be able to move freely.
[0067] If it is difficult to understand how a visually impaired person sees it is quite proper to ask him/her about his/her vision. Most visually impaired people are able to describe the nature of their impairment so well that it is possible to understand their situation better. Some persons say that they have only 10% vision left. Such a number does not describe the degree of visual impairment. The person may be able to move freely relying on his/her vision or may function like a nearly blind. That number (10%) usually means that his/her visual acuity is 20/200 (6/60 or 0.1) and it describes only one of many visual functions.
[0068] If the loss of visual functioning is caused by brain damage, the behavior of the person may look even more perplexing than when the loss is caused by changes in the eyes. In the higher visual functions, perceptual functions, small specific areas of the brain cortex are responsible for specific perceptions. If such an area with specific function is damaged, the corresponding function is either weak or completely lost. Thus an otherwise normally sighted person may not recognize people, not even close relatives. (S)he sees faces but cannot connect the visual information with pictures of faces in his/her memory.
[0069] There can be an isolated loss of motion perception, so that the person cannot tell whether a car is moving or not, or in milder cases, may perceive some movement but not how fast the car may be approaching. Color perception may be disturbed. Recognition of geometric forms may be lost and thus learning letters and numbers may be impossible.
[0070] The structure of egocentric space may be lost and thus concepts like ‘on the right’, ‘on the left’, ‘in the middle’, ‘next’, may be difficult. Also drawing of simple pictures or even copying pictures of angles may be impossible.
[0071] It is important that these children/adult persons are not diagnosed as intellectually disabled if they have other functions where they function normally. An uneven profile of functions should always lead to a thorough assessment of all cognitive visual functions and auditory perception. Children with loss of recognition of facial features or facial expressions are sometimes diagnosed as autistic, which is a tragic error and may negatively affect the child's future.
[0072] In another embodiment of the invention, the inhibitor of the HCN channel is a selective inhibitor of HCN1 and/or HCN4.
[0073] In another embodiment, the inhibitor of the HCN channel is a selective inhibitor of HCN4.
[0074] In another embodiment, the HCN channel inhibitor is a selective bradycardic agent selected from the group consisting of alinidine (ST567), ZD-7288, zatebradine (UL-F549), cilobradine (DK-AH269), and ivabradine (Procorolan), or a pharmaceutically acceptable salt thereof.
[0075] Alinidine (ST567), available from Santa Cruz Biotechnology, Inc., is also known by the chemical names: —(N-Allyl-2,6-dichloroanilino)-2-imidazoline, and N-(2,6-dichlorophenyl)-4,5-dihydro-N-2-propenyl-1H-imidazol-2-amine; and has the chemical structure:
[0000]
[0076] ZD 7288 (ICI D7288), in the form of the hydrochloride salt is available from Tocris Bioscience has the chemical name: 4-Ethylphenylamino-1,2-dimethyl-6-methylaminopyrimidinium chloride, and the chemical structure:
[0000]
[0077] The term “ZD 7288” herein refers to base compound or any pharmaceutically acceptable salt of the base compound.
[0078] Zatebradine (UL-FS-49), has the chemical names: 3-(3-((3,4-Dimethoxyphenethyl)methylamino)propyl)-1,3,4,5-tetrahydro-7,8-dimethoxy-2H-3-benzazepin-2-one, and 3-[3-[2-(3,4-dimethoxyphenyl)ethyl-methylamino]propyl]-7,8-dimethoxy-2,5-dihydro-1H-3-benzazepin-4-one, and has the following chemical structure:
[0000]
[0079] Zatebradine hydrochloride (the hydrochloride salt of zatebradine) is available from Tocris Bioscience and Sigma-Adrich.
[0080] Cilobradine, available from Leancare Ltd., 2A PharmaChem USA and 3B Scientific Corporation, has following chemical structure:
[0000]
[0081] Cilobradine hydrochloride, the hydrochloride salt of cilobradine (chemical name: (S)-(+)-7,8-Dimethoxy-3-[[1-(2-(3,4-dimethoxyphenyl)ethyl)-3-piperidinyl]methyl]-1,3,4,5-tetrahydro-2H-3-benzazepin-2-one hydrochloride), has the following chemical structure:
[0000]
[0000] and is available from Sigma-Adrich.
[0082] Ivabradine has the chemical name: 3-[3-({[(7S)-3,4-dimethoxybicyclo[4.2.0]octa-1,3,5-trien-7-yl]methyl}(methyl)amino)propyl]-7,8-dimethoxy-2,3,4,5-tetrahydro-1H-3-benzazepin-2-one, and the chemical structure:
[0000]
[0083] It is used for the symptomatic management of angina pectoris, and is marketed under the trade name “Procoralan” by Servier.
[0084] In another embodiment, the HCN channel inhibitor is an ivabridine derivative selected from the group consisting of MEL57A and EC18.
[0085] MEL57A has the following structure:
[0000]
[0086] It's synthesis and pharmacological properties are disclosed in WO2011/000915A1.
[0087] EC18 has the following structure:
[0000]
[0088] It's synthesis and pharmacological properties are disclosed in WO2011/000915A1.
[0089] In another embodiment, the HCN channel inhibitor is selected from the group consisting of ivabridine and ZD-7288.
[0090] In another embodiment, the visual function in the present invention is measured by sweep vision evoked potential (sVEP).
[0091] In another embodiment, the subject in need of the visual enhancement in the present invention is one who has low or poor visual function resulting from a retinal disorder or retinal damage.
[0092] In another embodiment, the ocular condition resulting from the low/poor visual function in the present invention is selected from the group consisting of glaucoma, low-tension glaucoma, intraocular hypertension, wet and dry age related macular degeneration (AMD), geographic atrophy, macula edema, Stargardt's disease cone dystrophy, and pattern dystrophy of the retinal pigmented epithelium, macular edema, retinal detachment and tears, retinal trauma, retinitis pigmentosa, retinal tumors and retinal diseases associated with said tumors, congenital hypertrophy of the retinal pigmented epithelium, acute posterior multifocal placoid pigment epitheliopathy, optic neuritis, acute retinal pigment epithelitis, diabetic retinopathy and optic neuropathies.
[0093] In another embodiment, the ocular condition resulting from the low/poor visual function in the present invention is selected from the group consisting of glaucoma, macular degeneration, wet and dry age related macular degeneration (AMD), geographic atrophy, and diabetic retinopathy.
[0094] In another embodiment, the administration of the HCN inhibitor enhances the receptive field profile of the retinal ganglion cells near the center of the receptive field.
[0095] In another embodiment, the administration of the HCN channel inhibitor attenuates HCN-mediated I h current.
[0096] In another embodiment, the administration of the HCN channel inhibitor results in an enhancement of input resistance in retinal ganglion cells by blockade of leak conductance in these cells.
[0097] The HCN-channel inhibitors of the present invention can form salts which are also within the scope of this invention. Reference to an HCN inhibitor herein is understood to include reference to salts thereof, unless otherwise indicated. The term “salt(s)”, as employed herein, denotes acidic salts formed with inorganic and/or organic acids, as well as basic salts formed with inorganic and/or organic bases. In addition, when an HCN inhibitor contains both a basic moiety, such as, but not limited to a pyridine or imidazole, and an acidic moiety, such as, but not limited to a carboxylic acid, zwitterions (“inner salts”) may be formed and are included within the term “salt(s)” as used herein. Pharmaceutically acceptable (i.e., non-toxic, physiologically acceptable) salts are preferred, although other salts are also useful. Salts of the HCN inhibitors may be formed, for example, by reacting a such an antagonist with an amount of acid or base, such as an equivalent amount, in a medium such as one in which the salt precipitates or in an aqueous medium followed by lyophilization.
[0098] Exemplary acid addition salts include acetates, ascorbates, benzoates, benzenesulfonates, bisulfates, borates, butyrates, citrates, camphorates, camphorsulfonates, fumarates, hydrochlorides, hydrobromides, hydroiodides, lactates, maleates, methanesulfonates, naphthalenesulfonates, nitrates, oxalates, phosphates, propionates, salicylates, succinates, sulfates, tartarates, thiocyanates, toluenesulfonates (also known as tosylates,) and the like. Additionally, acids which are generally considered suitable for the formation of pharmaceutically useful salts from basic pharmaceutical compounds are discussed, for example, by P. Stahl et al, Camille G. (eds.) Handbook of Pharmaceutical Salts. Properties, Selection and Use. (2002) Zurich: Wiley-VCH; S. Berge et al, Journal of Pharmaceutical Sciences (1977) 66(1) 1-19; P. Gould, International J. of Pharmaceutics (1986) 33 201-217; Anderson et al, The Practice of Medicinal Chemistry (1996), Academic Press, New York; and in The Orange Book (Food & Drug Administration, Washington, D.C. on their website). These disclosures are incorporated herein by reference thereto.
[0099] Exemplary basic salts include ammonium salts, alkali metal salts such as sodium, lithium, and potassium salts, alkaline earth metal salts such as calcium and magnesium salts, salts with organic bases (for example, organic amines) such as dicyclohexylamines, t-butyl amines, and salts with amino acids such as arginine, lysine and the like. Basic nitrogen-containing groups may be quarternized with agents such as lower alkyl halides (e.g. methyl, ethyl, and butyl chlorides, bromides and iodides), dialkyl sulfates (e.g. dimethyl, diethyl, and dibutyl sulfates), long chain halides (e.g. decyl, lauryl, and stearyl chlorides, bromides and iodides), aralkyl halides (e.g. benzyl and phenethyl bromides), and others.
[0100] All such acid salts and base salts are intended to be pharmaceutically acceptable salts within the scope of the invention and all acid and base salts are considered equivalent to the free forms of the corresponding compounds for purposes of the invention.
[0101] The compounds of the present invention can be administered in any one of conventional modes of pharmaceutical delivery, such as oral, intravenous, sublingual, intravitreal, topical, subcutaneous, trans-dermal, buccal, and intrathecal, or suitable combinations thereof. The topical and transdermal compositions can take the form of creams, lotions, aerosols and/or emulsions and can be included in a transdermal patch of the matrix or reservoir type as are conventional in the art for this purpose.
[0102] For preparing pharmaceutical compositions from the HCN-channel inhibitors described by this invention, inert, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, dispersible granules, capsules, cachets and suppositories. The powders and tablets may be comprised of from about 5 to about 95 percent active ingredient. Suitable solid carriers are known in the art, e.g., magnesium carbonate, magnesium stearate, talc, sugar or lactose. Tablets, powders, cachets and capsules can be used as solid dosage forms suitable for oral administration. Examples of pharmaceutically acceptable carriers and methods of manufacture for various compositions may be found in A. Gennaro (ed.), Remington's Pharmaceutical Sciences, 18 th Edition, (1990), Mack Publishing Co., Easton, Pa.
[0103] Liquid form preparations include solutions, suspensions and emulsions. As an example may be mentioned water or water-propylene glycol solutions for parenteral injection or addition of sweeteners and opacifiers for oral solutions, suspensions and emulsions. Liquid form preparations may also include solutions for intranasal administration.
[0104] Aerosol preparations suitable for inhalation may include solutions and solids in powder form, which may be in combination with a pharmaceutically acceptable carrier, such as an inert compressed gas, e.g. nitrogen.
[0105] Also included are solid form preparations that are intended to be converted, shortly before use, to liquid form preparations for either oral or parenteral administration. Such liquid forms include solutions, suspensions and emulsions.
[0106] In addition to the common dosage forms set out above, the compounds of this invention may also be administered by controlled release means and/or delivery devices such as those described in U.S. Pat. Nos. 3,845,770; 3,916,899; 3,536,809; 3,598,123; 3,630,200; 4,008,719; and 5,366,738 the disclosures of which are incorporated herein by reference.
[0107] For use where a composition for intravenous administration is employed, a suitable daily dosage range for anti-inflammatory, anti-atherosclerotic or anti-allergic use is from about 0.001 mg to about 25 mg (preferably from 0.01 mg to about 1 mg) of a compound of this invention per kg of body weight per day and for cytoprotective use from about 0.1 mg to about 100 mg (preferably from about 1 mg to about 100 mg and more preferably from about 1 mg to about 10 mg) of a compound of this invention per kg of body weight per day. For the treatment of diseases of the eye, ophthalmic preparations for ocular administration comprising 0.001-1% by weight solutions or suspensions of the compounds of this invention in an acceptable ophthalmic formulation may be used.
[0108] Preferably, the pharmaceutical preparation is in a unit dosage form. In such form, the preparation is subdivided into suitably sized unit doses containing appropriate quantities of the active component, e.g., an effective amount to achieve the desired purpose.
[0109] The magnitude of prophylactic or therapeutic dose of a compound of this invention will, of course, vary with the nature of the severity of the condition to be treated and with the particular compound and its route of administration. It will also vary according to the age, weight and response of the individual patient. It is understood that a specific daily dosage amount can simultaneously be both a therapeutically effective amount, e.g., for treatment to slow progression of an existing condition, and a prophylactically effective amount, e.g., for prevention of condition. The quantity of active compound in a unit dose of preparation may be varied or adjusted from about 0.001 mg to about 500 mg. In one embodiment, the quantity of active compound in a unit dose of preparation is from about 0.01 mg to about 250 mg. In another embodiment, the quantity of active compound in a unit dose of preparation is from about 0.1 mg to about 100 mg. In another embodiment, the quantity of active compound in a unit dose of preparation is from about 1.0 mg to about 100 mg. In another embodiment, the quantity of active compound in a unit dose of preparation is from about 1.0 mg to about 50 mg. In still another embodiment, the quantity of active compound in a unit dose of preparation is from about 1.0 mg to about 25 mg.
[0110] The actual dosage employed may be varied depending upon the requirements of the patient and the severity of the condition being treated. Determination of the proper dosage regimen for a particular situation is within the skill of the art. For convenience, the total daily dosage may be divided and administered in portions during the day as required.
[0111] The amount and frequency of administration of the compounds of the invention and/or the pharmaceutically acceptable salts thereof will be regulated according to the judgment of the attending clinician considering such factors as age, condition and size of the patient as well as severity of the symptoms being treated. A typical recommended daily dosage regimen for oral administration can range from about 0.01 mg/day to about 2000 mg/day of the compounds of the present invention. In one embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 1000 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 500 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 100 mg/day to 500 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 250 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 100 mg/day to 250 mg/day. In still another embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 100 mg/day. In still another embodiment, a daily dosage regimen for oral administration is from about 50 mg/day to 100 mg/day. In a further embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 50 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 25 mg/day to 50 mg/day. In a further embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 25 mg/day. The daily dosage may be administered in a single dosage or can be divided into from two to four divided doses.
[0112] In an especially preferred embodiment of this invention, the HCN-channel inhibitor of this invention is administered intraviteally (e.g., by injection into the back of the eye).
[0113] For intravitreal administration, the weight of the device (i.e., drug plus carrier/vehicle/excipient) is typically 1 mg (which for example may be administered with a 22 G needle) and the drug load is normally 10-50%. The drug dose range for intravitreal administration is normally about 100-500 μg. However, the drug load can be stretched to 2-65%, i.e., a drug dose range of 20-650 μg can be used. However, the device weight may be 1.5 mg, and for this a drug dose range of 20-975 μg can be used.
[0114] Another way of intravitreal delivery is by injecting drug suspension formulation. For this, the dose range is 10-600 ug.
[0115] The intraocular implant of the present invention typically comprises a therapeutically effective amount of the presently disclosed HCN-channel inhibitor (the therapeutic component; the active pharmaceutical ingredient (API)), and a drug release sustaining polymer component associated with the therapeutic compound. As used herein, an “intraocular implant” refers to a device or element that is structured, sized, or otherwise configured to be place in an eye. Intraocular implants are generally biocompatible with physiological conditions of an eye and do not cause adverse side effects. Intraocular implants may be place in an eye without disrupting vision of the eye.
[0116] The implant may be solid, semisolid, or viscoelastic. The drug release sustaining component is associated with the therapeutic component to sustain release of an amount of the therapeutic component into an eye in which the implant is placed.
[0117] The therapeutic component may be released from the implant by diffusion, erosion, dissolution or osmosis. The drug release sustaining component may comprise one or more biodegradable polymers or one or more non-biodegradable polymers. Examples of biodegradable polymers of the present implants may include poly-lactide-co-glycolide (PLGA and PLA), polyesters, poly (ortho ester), poly(phosphazine), poly(phosphate ester), polycaprolactone, natural polymers such as gelatin or collagen, or polymeric blends. The amount of the therapeutic component is released into the eye for a period of time greater than about one week after the implant is placed in the eye and is effective in reducing or treating an ocular condition.
[0118] In one embodiment, the intraocular implant comprises a therapeutic component and a biodegradable polymer matrix. The therapeutic component is associated with a biodegradable polymer matrix that degrades at a rate effective to sustain release of an amount of the therapeutic component from the implant effective to treat an ocular condition. The intraocular implant is biodegradable or bioerodible and provides a sustained release of the therapeutic component in an eye for extended periods of time, such as for more than one week, for example for about one month or more and up to 5 about six months or more. The implant may be configured to provide release of the therapeutic component in substantially one direction, or the implant may provide release of the therapeutic component from all surfaces of the implant.
[0119] The biodegradable polymer matrix of the foregoing implant may be a mixture of biodegradable polymers or the matrix may comprise a single type of biodegradable polymer. For example, the matrix may comprise a polymer selected from the group consisting of polylactides, poly(lactide-co-glycolides), polycaprolactones, and combinations thereof.
[0120] In another embodiment, the intraocular implant comprises the therapeutic component and a polymeric outer layer covering the therapeutic component. The polymeric outer layer includes one or more orifices or openings or holes that are effective to allow a liquid to pass into the implant, and to allow the therapeutic component to pass out of the implant.
[0121] The therapeutic component is provided in a core or interior portion of the implant, and the polymeric outer layer covers or coats the core. The polymeric outer layer may include one or more non-biodegradable portions. The implant can provide an extended release of the therapeutic component for more than about two months, and for more than about one year, and even for more than about five or about ten years. One example of such a polymeric outer layer covering is disclosed in U.S. Pat. No. 6,331,313.
[0122] In one embodiment, the present implant provides a sustained or controlled delivery of the therapeutic component at a maintained level despite the rapid elimination of the therapeutic component from the eye. For example, the present implant is capable of delivering therapeutically effective amounts of the therapeutic component for a period of at least about 30 days to about a year despite the short intraocular half-lives that may be associated with the therapeutic component. Plasma levels of the therapeutic component obtained after implantation may be extremely low, thereby reducing issues or risks of systemic toxicity. The controlled delivery of the therapeutic component from the present implants would permit the therapeutic component to be administered into an eye with reduced toxicity or deterioration of the blood-aqueous and blood-retinal barriers, which may be associated with intraocular injection of liquid formulations containing the therapeutic component.
[0123] A method of making the present implant involves combining or mixing the therapeutic component with a biodegradable polymer or polymers. The mixture may then be extruded or compressed to form a single composition. The single composition may then be processed to form individual implants suitable for placement in an eye of a patient.
[0124] Another method of making the present implant involves providing a polymeric coating around a core portion containing the therapeutic component, wherein the polymeric coating has one or more holes. The implant may be placed in an ocular region to treat a variety of ocular conditions, such as treating the conditions disclosed herein.
[0000] The daily dose may be administered as single dose or in divided doses and, in addition, the upper limit can also be exceeded when this is found to be indicated
Assays
[0125] Retinal Ganglion Cell Receptive Field Recordings. Six month old male Dutch belted rabbits were anesthetized using intramuscular injection of ketamine and were placed under deep isofluorane anesthesia. The eyes were enucleated under dim lighted conditions and transferred to a dark room where the anterior of the eye along with the vitreous humor were removed. An 11 mm circular punch of the central retina, below the optic nerve head, was made and the inverted eyecup preparation with the ganglion-cell layer facing upward was transferred to the recording chamber. The retina was dark adapted for one hour and subsequently experiments were performed in the dark at 35° C. Following enucleation, the animals were euthanized with an intravenous injection of euthasol. All animal procedures conformed to the Allergan Animal Care and Use Committee.
[0126] The retinal preparation was continuously perfused with Ames' solution saturated with 95% O 2 and 5% CO 2 maintained at a pH of 7.4. Receptive fields profiles of retinal ganglion cells were probed using the VERIS™ multifocal stimulus and analysis system. 2 ms white light flashes (hexagons at 140 μm in diameter) were induced using m-sequence stimulation at the beginning of each frame with a 38 ms delay between flashes at an intensity of 7.56×10 9 hv/flash·cm 2 . Data analysis of the ganglion cell receptive field was performed using VERIS™ (EDI, Redwood City, Calif.).
[0127] HCN channel Current (Ih) and Input Resistance measurements. Isolated retina preparations were made from 6 to 12 month old Brown Norway rats following decapitation. All animal procedures conformed to the Allergan Animal Care and Use Committee. The retina was transferred to a recording chamber with the retinal ganglion cell layer facing up and individual cells were patch clamped for voltage clamp recordings. A combination of 100 uM Picrotoxin and 20 uM DNQX were perfused into the chamber to isolate ganglion cell responses from presynaptic cells. The membrane potential of ganglion cells were clamped at −60 mV and a 10 ms 5 mV depolarizing step at the beginning of the recording was made to measure the cells input resistance followed by 1 second step to −80, −100 and −120 mV to measure the HCN mediated Ih current. Following control recordings, ZD7288 and Ivabradine (see figures for concentrations) were perfused into the recording chamber and the electrophysiological measures were repeated to assess the effects of the drugs on input resistance and Ih.
[0128] Sweep Vision Evoked Potential (sVEP) measurements. sVEP is an indirect measure of visual acuity and is highly correlated with snellen acuity in humans (Ridder 2004). sVEP is a tool that is often used to assess visual function in human infants and animal models since these subjects can't read a Snellen chart or communicate with the test administrator (Norcia et al., 1985; Guire et al., 1999). sVEP measurements were made from awake Dutch-belted rabbits using a spatial frequency range from 0.3 to 5 cycles per degree at 80% contrast using the Power-Diva system. Following control recordings, an intravitreal injection of 1 uM ZD7288 was made and the recording was repeated for 7 days post injection (see figure for more details). After the response returned to baseline a 30 uM intravitreal dose of ZD7288 was made and the measurements were repeated for 6 days post injection (see figure for more details). 50 uL Intravitreal injections of concentrated dose (24 fold to account for rabbit vitreal dilution) of the drug were made with a 30 gauge hypodermic needle and a Hamilton syringe. | The present invention is directed to a method of enhancing visual function in a subject, comprising administering to the subject in need of such enhancement, a therapeutically effective amount of an inhibitor of a hyperpolarization-activated cyclic nucleotide-gated (HCN) channel. The present invention is also directed to an ocular implant comprising a therapeutically effective amount of the HCN channel inhibitor. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to lamp assemblies and, more particularly, to lamp assemblies particularly suited for automotive applications.
A myriad of lamp assembly designs have been proposed and/or utilized for automotive lamp applications such, for example, as tail light assemblies. While these prior art devices have in general provided satisfactory and reliable lighting, they have also each embodied certain limitations. Specifically, automotive lamp applications dictate rather strong moisture sealing requirements. Moisture sealing in prior art designs have been accomplished either by encapsulating or "potting" the entire lamp assembly in a plastic substance, or by packing the various lamp cavities with a grease compound. Both prior art sealing concepts embody two basic shortcomings. Specifically, the sealed lamp is difficult to work with in the original automobile assembly process since, once assembled as a sealed unit, it must thereafter be handled as a single, non-divisible, sealed entity and special care must be taken to avoid derogation of the seal. Further, if the lamp is thereafter disassembled for any reason, the seal is destroyed and cannot be readily reestablished.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a lamp assembly for automotive applications or the like in which the lamp may be selectively assembled in the specific manner and sequence that is most compatible with the original automobile assembly process and which may thereafter be readily disassembled and/or reassembled without derogation of the seal.
This object is accomplished in accordance with the present invention by the provision of a lamp assembly in which moisture sealing is accomplished throughout the assembly by resealable mechanical means. The invention lamp assembly includes a socket assembly, a base, and a plurality of elongated conductors. One end of the socket assembly is sealingly but releasably mounted in one face of the base with contacts on the mounted socket assembly end positioned in a socket cavity in the base, and the elongated conductors pass sealingly through a wall of the base to position their inboard ends in the socket cavity in respective electrical connection with the contacts of the socket assembly.
According to a further feature of the invention, the lamp assembly further includes a connector having a plurality of terminals adapted to respectively electrically connect with the outboard ends of the conductors. In the disclosed preferred embodiment of the invention, the connector terminals are positioned in one end of the connector; that end of the connector is sized and configured to be inserted into a connector cavity defined in the base and separated from the socket cavity by the base wall through which the elongated conductors pass; and the outboard ends of the elongated conductors are positioned in the connector cavity for respective electrical connection to the connector terminals upon insertion of the connector into the connector cavity.
According to another feature of the invention, the socket assembly includes a hollow socket and a retainer element positioned within the socket and defining a rectangular cavity for receipt of a wedge base bulb. In the disclosed embodiment of the invention, the rectangular bulb cavity is defined by a pair of opposing walls and at least one of the walls is defined by a yieldable finger which wedges open upon insertion of the bulb to allow passage of the leading edge of a collar on the base of the bulb and thereafter snaps back to releasably grasp the bulb collar.
According to another feature of the invention, an electrical assembly is provided in which an elongated electrical conductor element extends through a passage in a partition of a housing assembly for electrical contact at its inboard end with an electrical terminal disposed within a sealed cavity defined by the housing assembly. The passage tapers inwardly at its inboard end to form inwardly extending lip means and the conductor element has a thickness slightly greater than the width of the passage at the lip means and slightly less than the width of the outboard end of the passage so that the conductor element, upon insertion through the passage into the cavity, coacts with the lip means to form a tight seal for the cavity at the partition and to resist withdrawal of the conductor element through the passage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the invention lamp assembly;
FIG. 2 is an elevational view, in cross section, of the invention lamp assembly;
FIGS. 2A and 2B are enlarged views of selected portions of FIG. 2;
FIG. 3 is a top view of the invention lamp assembly with certain elements of the assembly omitted for clarity of illustration;
FIG. 4 is a bottom perspective view of a bulb retainer element employed in the invention lamp assembly;
FIG. 5 is a perspective view of electrical contact elements employed in the invention lamp assembly;
FIG. 6 is a partially fragmentary view of the invention lamp assembly shown in association with a lamp housing and parabola; and
FIGS. 7 and 8 are views of a modified moisture sealing construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention lamp assembly, broadly considered, comprises a base 10, a connector 12, a socket 14, a bulb 16, and a bulb retainer 18.
Base 10 is formed of a resilient, plastic material such, for example, as a polyurethane or an acrylamide. Base 10 includes a socket cavity 10a opening at the upper face 10b of the base, and a connector cavity 10c opening in an end face 10d of the base. Connector cavity 10c is separated from socket cavity 10a by a wall or partition 10e. Three elongated conductor bars 20, 22, 24 of rectangular conductor bar stock, extend in parallel fashion within base 10. Bars 20, 22, 24 may, for example, be formed of beryllium copper material. One end 20a, 22a, 24a of each conductor bar is positioned in connector cavity 10c and the other end 20b, 22b, 24b of each conductor bar is supported on a platform surface 10f provided on the bottom of socket cavity 10a. Intermediate their ends, conductor bars 20, 22, 24 pass through passages 26 (FIG. 2A) extending longitudinally through partition 10e. Each passage 26 is rectangular in cross section and is necked down adjacent socket cavity 10a to form opposing lip portions 26a which taper outwardly in the direction of connector cavity 10b to blend with the main body portion 26b of the passage. Conductor bars 20, 22, 24 have a thickness that is slightly greater than the height of the opening defined between the relaxed lip portions 26a and slightly less than the height of passage portion 26b and a width that is slightly greater than the width of passage 26 so that, as the bars are selectively inserted through connector cavity 10c and through passages 26, lip portions 26a are splayed resiliently outwardly to pass the bars and allow the ends 20b, 22b, 24b to be seated on platform surface 10f. With the bars thus inserted in base 10, lip portions 26a coact with the respective upper and lower surfaces of the conductor bars and the side edges of the bars form an interference fit with the adjacent material of the base. Bars 20, 22, 24 thus form a moisture seal for socket cavity 10a at partition 10e. Lip portions 26a also coact with the engaged bar surfaces to resist withdrawal of the bars since any attempted withdrawal of a bar will tend to pivot lip portions 26a toward a more tightly closed clamping configuration. This arrangement prevents inadvertent withdrawal or displacement of the conductor bars while yet permitting withdrawal upon the application of a delibrate withdrawl force and, if desired, subsequent reinsertion for reassembly purposes.
A modified sealing and clamping construction is shown in FIGS. 7 and 8 for use in applications requiring round cross section conductors rather than the flat, rectangular conductor bar stock used for conductor bars 20, 22, 24. In the FIGS. 7 and 8 construction, circular passages 28 are provided in a partition 30 for coaction with round cross section conductors 32. Each passage 28 is necked down at one end to form an annular lip portion 28a which tapers outwardly toward the other end of the passage to blend with the main body cylindrical portion 28b of the passage. The round cross section conductor 32 has a diameter that is slightly greater than the relaxed inner diameter of annular lip portion 28a and slightly less than the diameter of main body passage portion 28b. As conductor 32 is inserted into passage 28 from the left, as seen in FIG. 7, lip portion 28a is splayed elastically outwardly to pass the conductor element (not shown) positioned in a cavity defined to the right of partition 30. Lip portion 28a thus coacts with the outer periphery of conductor 32 to form a moisture seal at the partition. Lip portion 28a also acts to resist withdrawal of conductor 32 since any attempted withdrawal will tend to pivot lip portion 28a toward a more tightly closed clamping configuration. This arrangement prevents inadvertent withdrawal or displacement of the conductor bars while yet permitting withdrawal upon the application of a deliberate withdrawal force and, if desired, subsequent reinsertion for reassembly purposes.
Connector 12 is formed of a hard, rigid, plastic material such, for example, as a polyester, phenolic or the like. Connector 12 is generally hollow and includes an upper wall 12a, a lower wall 12b, sidewalls 12c and 12d, partitions 12e and 12f, and a locking tab 12g upstanding from top wall 12a. Partitions 12e and 12f coact with sidewalls 12c and 12d to define three parallel through passages 12h, 12i and 12j. A terminal 34 is positioned at the forward end of each passage 12h, 12i and 12j. A resilient tab 12k coacts with a detent in the top wall of each terminal 34 to maintain the terminal in its forward position within the connector upon insertion of a suitable tool into the forward end of the connector to resiliently raise the respective tab 12k. Three wires 36, 38, 40 are crimped at their forward ends to a respective terminal 34 and extend rearwardly therefrom through the appropriate passage 12h, 12i, 12j. Connector 12 is sized and configured to slide snugly into the connector cavity 10c of base 10 with conductor bar ends 20a, 22a, 24a each pressing firmly into a respective terminal 34 to establish a firm electrical connection between wires 36, 38, 40 and bars 20, 22, 24. As connector 12 slides into base cavity 10c, locking tab 12 g cams upwardly over raised base portion 10g and then snaps downwardly to firmly embrace base portion 10g, firmly seat the connector in the base cavity, and preclude inadvertent withdrawal of the connector from the base. Also, as connector 12 slides into cavity 10c, resilient lip portions 10h (FIG. 2B), formed around the entire perimeter of the opening of cavity 10c in end face 10d, slidably and sealing wipe along upper and lower connector walls 12a, 12b and along connector sidewalls 12c and 12d to form a moisture seal between connector 12 and base 10 at the entrace to cavity 10c. The resilient polyurethane or the like material of lip portions 10h yield to allow insertion of the connector and conform snugly to the walls of the connector to optimize the mositure seal. If desired, wires 36, 38 and 40 may be potted into connector 12 to preclude the entry of moisture through the hollow interior of the connector.
Socket 14 is formed of a hard, rigid, plastic material such, for example, as a polyester, phenolic or the like. Socket 14 has a tubular configuration and includes a cylindrical sidewall 14a, defining a central bore 14b, and an external collar 14c. Socket 14 is received with a snap press fit in socket opening 10a of base 10. Specifically, as socket 14 is pressed downwardly into opening 10a, the chamfered leading edge portion 14d of the socket presses resiliently past an annular lip 10i in socket opening 10a and seats in an annular seat 10j defined immediately below lip 10i. At the same time, lip 10i seats in an annular notch seat 14e defined on socket 14 immediately above leading edge portion 14d, and collar 14c seats on the upper annular edge 10k of base rim portion 10l with a notch 14f in collar 14c embracing an upstanding post 10m on base 10 to insure proper indexing of socket 14 relative to base 10 during assembly and preclude subsequent inadvertent rotation of socket 14 relative to base 10. The resilient urethane or the like material of base 10 yields to allow insertion of socket 14 and conforms snugly to the inserted end of the socket to ensure an effective moisture seal for cavity 10a.
Bulb 16 is of the wedge base type and includes a glass envelope 16a housing a double filament, a glass wedge base 16b receiving and selectively exposing elements 16c of both filaments, and an external plastic collar 42 positioned at the necked down interface of the envelope 16a and wedge base 16b.
Bulb retainer 18 is formed of a hard, rigid, plastic material such, for example, as polyester, phenolic or the like. Bulb retainer 18 has a cylindrical, plug-like configuration and is received with a press fit in socket bore 14b to form a socket assembly. In assembled relation, the lower end 18a of the retainer projects slightly below the lower end of the socket. Retainer 18 includes an upstanding finger portion 18b and a rigid post portion 18c. Confronting lips 18d on finger portion 18c coact to define a generally rectangular opening 18e for receipt of bulb 16. As bulb 16 is pressed downwardly into retainer 18, wedge base 16b passes freely through opening 18e and through the opening defined between confronting rib portions 18f on post portion 18c and finger portion 18b. As the leading edge of collar 42 reaches opening 18e, collar 42 splays finger portion 18b outwardly to allow the collar to pass, whereafter finger portion 18b snaps back to firmly grasp the collar. In the inserted position of the bulb, confronting lips 18d embrace the bulb envelope 16a immediately above collar 42, confronting ribs 18f embrace the bulb base 16b immediately below collar 42, and wedge base 16b extends downwardly into a bulb cavity 18g defined between post portion 18c and finger portion 18b below ribs 18f.
The lower end of the inserted bulb coacts with three electrical contacts 44, 46, 48 (FIG. 5) encapsulated or potted in the lower end of retainer 18 to provide selective electrical communication between bulb 16 and conductor bars 20, 22, 24. Specifically, contact 44 includes a yoked upper end 44a, a bridge portion 44b, and a lower end 44c. Yoked upper end 44a embraces both sides of bulb base 16 and establishes electrical connection with exposed elements 16c of both bulb filaments. Lower end 44c establishes electrical connection with conductor bar 20. Contact 46 includes an upper end 46a, a bridge portion 46b, and a lower end 46c. Upper end 46a is positioned at one side of bulb base 16 to establish electrical connection with an exposed filament 16c of one of the bulb filaments and lower end 46c contacts conductor bar 22. Contact 46 thus establishes electrical connection between conductor bar 22 and one filament of bulb 16. Contact 48 includes an upper end 48a, a bridge portion 48b, and a lower end 48c. Upper end 48a is positioned at the other side of bulb base 16 to establish electrical connection with an exposed element 16c of the other bulb filament and lower end 48c contacts conductor bar 24. Contact 48 thus establishes electrical connection between conductor bar 24 and the other filament of bulb 16. Either filament of bulb 16 may thus be powered by powering the appropriate wire 38, 40. Contacts 44, 46, 48 are preferably formed of a beryllium copper material.
The invention lamp assembly is seen in FIG. 6 in a typical lamp environment such, for example, as an automotive tail lamp assembly. The invention lamp assembly is mounted with a twisting movement in the housing 50 of the tail lamp with cam members 14g on socket 14 coacting with suitable grooves in housing 50 to securely mount the lamp assembly in the housing. In assembled position, envelope portion 16a of bulb 16 is positioned within lamp parabola 52 to provide the required tail lamp illumination.
In operation, the heat generated by bulb 16 has the effect of heating the lamp assembly and, specifically, significantly elevating the temperature of the air in cavity 10a. When the lamp is subsequently extinguished, the air in cavity 10a cools and contracts to form a vacuum condition in the cavity. The vacuum condition in cavity 10a operates to attempt to suck moisture laden air into the cavity. If moisture is thus introduced into the cavity, galvanic action occurs at the interface of contacts 44, 46, 48 and conductors 20, 22, 24 and the resulting corrosion eventually renders the lamp inoperative. Introduction of moisture into cavity 10a is effectively precluded, however, in the invention lamp assembly by the mechanical interference seal formed at the interface of socket 14 in base 10 and at the point of passage of conductors 20, 22, 24 through partition 10e. Moisture sealing of the lamp assembly is further facilitated by the mechanical interference fit between the base and the connector.
The invention lamp assembly thus achieves effective moisture sealing by purely mechanical means and provides component parts which are readily assembled and disassembled. Since the invention lamp assembly achieves effective moisture sealing without resort to potting or grease packing, the lamp assembly may be selectively assembled in the specific manner or sequence that is most compatible with the assembly process of the apparatus or machine of which the lamp assembly will become a part. In the case of a tail lamp assembly for an automobile where the location of the lamp housing and of the vehicular wiring harness are essentially givens dictated by various automotive design and styling parameters, the various components of the invention lamp assembly may be selectively assembled, either by the parts supplier or by the orginal equipment manufacturer, in whatever sequence is most compatible with the total automotive assembly process and may be selectively connected to the lamp housing and to the wiring harness in whatever manner is most consistent with optimal assembly efficiency. The invention lamp assembly also allows later disassembly for repair without destroying the moisture seal, since the moisture seal is reestablished whenever the various components are reassembled. As compared to prior art encapsulated or grease packed lamp assemblies, the invention lamp assembly provides greater flexibility in the original assembly process, allows later repair without destruction of the moisture seal, provides a more effective moisture seal, and allows economy of manufacture by eliminating the labor and materials required to achieve the encapsulation or packing.
While preferred embodiments of the invention have been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention. | A lamp assembly for automotive tail lamps or the like comprising a base member of a relatively soft elastomeric material, a connector of a relatively hard material adapted to be sealingly but releasably plugged into a cavity opening in one face of the base member, and a bulb socket of a relatively hard material adapted to be sealingly but releasably plugged into another cavity in the base opening in a face which is normal to the face in which the connector is received. A plurality of conductors extend in parallel fashion in the base member between the socket cavity and the connector cavity. The conductors make electrical connection at their one ends with contacts on the lower end of the socket and pass sealingly through a partition separating the two cavities where their other ends make electrical contact with terminals carried by the connector. The connector, base, and socket are effective to provide a moisture sealed lamp assembly with each assembly or reassembly. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
Reference is made to copending application entitled METHOD AND APPARATUS FOR WRAPPING THERMOPLASTIC MATRIX COMPOSITE TAPE ON A MANDREL, U.S. patent application Ser. No. 07/277,571, filed concurrently and assigned to the same assignee as the present application.
1. Background of the Invention
This invention relates to an automated tape laminator head for thermoplastic composite material and method of using such head and, more particularly, to an improved laminator head for dispensing thermoplastic matrix composite material onto a rotating mandrel in a pre-programmed fashion for the formation of sheets of pre-form material.
2. Description Of The Background Art
Thermoplastic matrix composite (TMC) materials represent one of the latest materials innovations finding utility in the aero-space industry. These materials consist of fibers,, typically made of graphite or glass, in a thermoplastic resin binder or matrix. Such materials are considered an advance in technology since they provide engineering and manufacturing advantages not possible with conventional aero-space composite materials. Engineering advances provided by such materials include improved damage tolerance providing for longer aircraft part life and improved resistance to chemical solvents and improved material strength in hot, wet, humid operating environments. With regard to manufacturing, the advantages are that pre-processing material refrigeration, normally required for conventional composite materials, is not required. Further, TMC part manufacturing processes have reduced cure cycles of from 6 to 15 hours down to less than 1 hour.
Thermoplastic resin impregnation with continuous fibers was not possible until the beginning of this decade. The implications of these advantages are obvious to the aircraft manufacturing and design engineer. They involve improved aircraft performance which can be achieved at lower manufacturing costs The U.S. Air Force recognizes the potential of this technology and is actively promoting the development of automatic manufacturing processes to support production of aircraft parts from TMC materials.
Several TMC forming processes under development within the aero-space industry require TMC pre-form sheets. Such pre-form serves as sheet stock or as a billet with the final forming operation. Present pre-form is typically made from strips of TMC material in tape form. Depending on the
manufacturer, TMC tape can vary from one-eighth (1/8) inch to twelve (12) inches in width, 0.004 to 0.010 inches in thickness. It can currently be supplied in lengths up to one-hundred and fifty (150) feet.
Manual pre-form fabrication is time consuming. A five (5) by (15) fifteen foot pre-form requires two (2) people working from ten (10) to twelve (12) hours. Such manual fabrication is prone to inconsistencies and defects due to operator mistakes. It is also somewhat dangerous since operators must use a heat wand at temperatures of eight-hundred (800) degrees Fahrenheit or greater. For these reasons, a TMC tape to aircraft part manufacturing process might not be feasible based on known manual pre-form fabrication processes. The need for an automatic pre-form fabrication process is apparent.
The automated TMC tape dispensing laminator head of the instant invention solves the problem of automatically creating a pre-form from vendor supplied TMC tape.
The subject automatic TMC tape laminator head is considered a significant advance since (a) The machine automatically creates a TMC pre-form from vendor-supplied TMC tape; (b) The machine utilizes a simple but novel approach to laminating TMC strips and includes an integrally heated metal roller serves to not only heat the TMC material to its melt temperature (680-800 degrees Fahrenheit) but it also serves to apply the pressure needed to laminate the tape to other pieces of TMC tape; (c) The heated roller enables the machine to process the TMC materials at faster speeds and with less defects than other industry approaches to the automatic TMC tape laminator; and (d) The automated TMC tape laminator head utilizes a conventional interface film dispensing take up capability wherein the interface film prevents the heated roller from sticking to the TMC tape and provides a visually appealing surface finish to the final pre-form.
The background literature discloses many methods and apparatus which apply heat and/or pressure to laminate tape material into a composite product. The background literature, however, is different from the automated TMC tape laminator of the subject invention. More specifically, the patent literature fails to show the structure and function of the instant inventive method and apparatus. Note, for example, Jensen U.S. Pat. No. 2,972,369, Penman U.S. Pat. No. 3,150,023; King U.S. Pat. No. 3,239,399; Bratton U.S. Pat. No. 3,449,193; James U.S. Pat. No. 3,539,438; and Kahn U.S. Pat. No. 4,548,856. Similar disclosures are found wherein the laminate is provided with an intermediate member supplied in roll or cut sheet form. Note Armstrong U.S. Pat. No. 2,793,677; Hannon U.S. Pat. No. 3,143,454; Dresser U.S. Pat. No. 3,309,983; and Columbo U.S. Pat. No. 3,823,047. In addition, similar disclosures are found in Butz U.S. Pat. No. 3,849,226 and Goton U.S. Pat. No. 4,662,973. In these last two (2) patents, however, a release layer is utilized in association with at least one of the sheets being laminated. In no case, however, is there a disclosure of an automated tape laminator head method and apparatus wherein the deposited material is layered upon itself as disclosed herein nor is there any disclosure of thermoplastic composite matrix materials being automatically laminated as in the present invention.
As illustrated by the great number of prior patents and commercial devices, efforts are continuously being made in an attempt to form TMC pre-form materials. None of these previous efforts, however, provides the benefits attendant with the present invention. Additionally, prior techniques and apparatus do not suggest the present inventive combination of component elements and method steps, arranged and configured as disclosed and claimed herein. The present invention achieves its intended purposes, objectives and advantages over the prior art through a new, useful and unobvious combination of method steps and component elements which are simple to use, with the utilization of a minimum number of functioning parts, at a reasonable cost to manufacture and utilize and by employing only readily available materials.
Therefore, it is an object of this invention to provide an improved automated tape laminator head for thermoplastic composite material which includes apparatus for dispensing a tape of thermoplastic matrix composite material onto a recipient surface moving in a pre-programmed fashion for the formation of sheets of pre-form material on the recipient surface.
It is another object of this invention to provide an improved method of utilizing a tape laminator head in the formation of thermoplastic matrix composite materials.
It is a further object of the invention to dispense lengths of thermoplastic matrix composite material in tape form onto a rotating mandrel for the fabrication of pre-form sheets.
Lastly, it is an object of this invention to form sheets of thermoplastic matrix composites more accurately, conveniently and economically through the utilization of an automated tape laminator head.
The foregoing has outlined some of the more pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
The invention is defined by the appended claims with the specific embodiment shown in the attached drawings. For the purposes of summarizing the invention, the invention may be incorporated into an improved apparatus for dispensing tape onto a recipient surface comprising in combination support means for mounting a reel of tape; feed means for unwinding the tape from the reel and advancing it to the mandrel; a pre-heater for the tape for providing initial heat to the tape; a heated pressure roller for providing additional heat to the tape and for applying the required pressure to the tape for lamination of the tape onto the recipient surface; cooling means for reducing the heat of the laminated tape on the recipient surface; and additional means operatively positioned with respect to the pressure roller, tape and recipient surface for placing an interference film between the pressure roller and the tape.
The apparatus further includes a guillotine knife in the path of travel of the tape for cutting the tape at a predetermined angle following the lamination of the recipient surface. The cooling means contacts the tape on the recipient surface for smoothing it to thereby obtain the desired surface finish. The film is of an adhesive material to prevent sticking of the tape to the pressure roller, preferably Kapton. The tape is of a thermoplastic matrix composite material and is laminated onto the recipient surface so that the tape is partially disposed over a previously laminated segment of tape.
The invention may further be incorporated into apparatus for dispensing tape of a thermoplastic matrix composite material onto a recipient surface comprising in combination support means for mounting a reel of tape; feed means for unwinding the tape from the reel and advancing it along a path of travel to the mandrel; a guillotine knife in the path of travel for cutting the tape at a predetermined angle with respect to the path of travel; a slotted, box-type pre-heater for the tape located in the path of travel following the knife for providing heat to the tape; a heated pressure roller located in the path of travel following the pre-heater for providing additional heat to the tape for effecting a process operating temperature and for applying the required pressure to the tape for lamination of the tape onto the recipient surface; cooling means located in the path of travel beyond the pressure roller for reducing the process heat from the laminated tape on the recipient surface and to smoothing it for thereby obtain the desired surface finish; and additional means operatively positioned with respect to the pressure roller, tape and recipient surface for placing an interference film between the pressure roller and the tape to prevent sticking of the tape to the pressure roller.
Lastly, the invention may be incorporated into a method for dispensing tape of a thermoplastic matrix composite material onto a recipient surface comprising in combination the steps of supporting a reel of tape in operative proximity to the recipient surface; unwinding the tape from the reel and feeding it along a path of travel to the mandrel; pre-heating the fed tape along the path of travel between the reel and the recipient surface; applying heat and pressure to the tape fed from the preheater by a heated pressure roller in the path of travel at the recipient surface for the lamination of the tape onto the recipient surface; cooling the tape in the path of travel beyond the pressure roller and smoothing the freshly laminated tape on the recipient surface; and placing an interference film between the pressure roller and the tape to prevent sticking of the heated tape to the pressure roller.
The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiment may be readily utilized as a basis for modifying or designing other structures and method steps for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions and methods do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective illustration of a the tape laminator system constructed in accordance with the principles of the present invention.
FIGS. 2, 3 and 4 are a plan view, side elevational view and front elevational view of the headstock assembly;
FIGS. 5, 6 and 7 are a plan view, side elevational view and front elevational view of the tailstock assembly.
FIG. 8 is a schematic illustration of the controller for the tape laminator system.
FIG. 9 is a front elevational view of the tape laminator system shown in FIG. 1.
FIGS. 10A, 10B, 10C, 10D, 10E and 10F are front elevational views similar to that shown in FIG. 9 but illustrate the movement of the head and the mandrel.
FIG. 11 is an enlarged perspective illustration of the tape laminator head.
FIG. 12 is a partially schematic front elevational view of the tape laminator head of FIG. 11.
Similar referenced characters refer to similar parts throughout the several Figures.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the Figures, there is shown an improved tape laminator system 10 constructed in accordance with the principles of the present invention. The entire tape laminator system 10 is shown in FIG. 1. It is configured and operated for laminating tape of thermoplastic matrix composite (TMC) material onto a recipient surface such as a mandrel 12. TMC materials are defined as engineering thermoplastic materials consisting of continuous, engineering fibers, as opposed to randomly oriented fibers, embedded in the thermoplastic resin binder or matrix. The fibers and resins may preferably be supplied by the vendor as a single uniform product form.
The system 10 consists of the tape support assembly 14 and the mandrel support assembly 16. The tape support assembly 14 includes a head 18 for feeding tape 20 onto the mandrel 12. The mandrel support assembly 16 consists of a five (5) axis gantry positioner 20. The two assemblies 14 and 16 interface through the control assembly 22, preferably a computer numerical control (CNC), with a controller 24 such as an AllenBradley controller, through digital input/output (1/0) lines and additional controls 26. Software for the system operation is preferably resident in the CNC controller.
The mandrel support assembly 16 is a lathe-type device which includes a bed 30, a headstock assembly 32 and tailstock assembly 34. The headstock and tailstock assemblies constitute a cradle 36 for supporting and rotating the mandrel 12 about its longitudinal axis 38. Side walls 42 extend upwardly from the sides of the bed 30. The headstock assembly 32 is more specifically seen in FIGS. 2, 3 and 4. It includes a weldment 44 which supports a DC servo motor (MOT-1) 46, gear box 48, drive shaft 50 as well as a chuck 52 which will support and rotate the mandrel 12 while its peripheral surface 56 is being laminated by the tape 20. The headstock assembly 32 also includes a pair of spaced support blocks or shoes 58 receiving bolts in channels slots 62 at the forward and rearward ends for securing the shoes 58 and entire headstock assembly 32 in parallel the longitudinal channels or slots 62 of the bed. Upstanding from the supports is a frame 64 having secured thereto, in laterally offset relationship, the gear box 48 and motor 46 for rotating the drive shaft 50. At the end of the drive shaft 50 facing the central region of the assembly is a plate 66 having bolts for secure element to one end of the mandrel 12.
Also adjustably secured to the bed 30 is a tailstock assembly 34. Note FIGS. 5, 6 and 7. The tailstock assembly 34 also is provided with a pair of longitudinal extending shoes 70 with slots at each end for adjustable securement to the channels or slots 62 in the bed through a bolt arrangement. An alignment pin 72 is centrally located front and back of the tailstock 34 as well as the headstock 32. The tailstock 34 includes a central rotatable pin 74 for receiving the end of the mandrel 12 remote from the headstock 32 and is freely rotatable on a bearing assembly beneath frame 76. In this manner activation of the motor 46 under command of the controller assembly 22 will effect the appropriate timed rotational sequence of the mandrel in operative relationship with the tape support assembly 14.
Upstanding from opposite side edges of the bed are the side walls 42, the upper surfaces 80 of which support the ends 82 of a reciprocating gantry 84 movable along a first axis from one end of the bed 30 to the other parallel with the centerline 38 of the mandrel 12. Movement is effected through a motor MOT-2 and chain adjacent one end of one side walls. Operation of the motor MOT-2 and movement of the gantry 84 are controlled by the control assembly 22 for operation in a sequence coordinated with the rotation of the mandrel 12 and dispensing of the tape by the tape support assembly 14.
Slidably coupled with and with respect to the gantry 84 is the tool plate 88 which is adapted for movement along the first axis with the movement of the gantry 84. A third drive means MOT-3 is provided for moving the tool plate 88 along rail 90 of the gantry 84 along a second axis, transverse with respect to the first axis toward and away from the elevated sides 42.
A chuck 94 is secured within, and slidably coupled to the tool plate 88. The chuck 94 is adapted for movement with the tool plate 88 in the first and second axes. A fourth drive means MOT-4 is coupled to the chuck 94 for moving the chuck 94 along a third axis toward and away from the bed. The third axis is transverse to the first and second axes. The tape lamination head assembly 14 is adjustably secured with respect to the lower face of the chuck 94.
The main components of the tape support assembly 14 supported by the chuck 94 is the laminator head 18 which includes a base plate 102 and a tape supply spool or reel 104, a tape advance mechanism 106, a variable angle shear or knife 108, a pre-heater 110, a heated pressure roller 112, a cold shoe 114, a temporary starting clamp 116, and a film payout and take-up system 118. These components are mounted on a framework on the base plate 102 which is attached to the chuck 94, tool plate 88 and gantry 84 preferably standardized. The chuck 94, tool plate 88 and gantry 84 have the necessary mechanical movement and alignment hardware, electrical connectors and pneumatic actuator, PA, for effecting the desired programmed functions with the mandrel 12 as will be described hereinafter. Temperature controls and pneumatic valving, of generally standard design, are mounted on the laminator head 18 while motor controls are mounted in the cabinet with the controller assembly 22.
The supply spool 104 holds the tape, shown as three (3) inch wide tape 20, of a thermoplastic matrix composite (TMC) material which is to be bonded in layers to form a thick sheet or panel 122 constituting the pre-form sheets. The supply spool 104 is back driven by a gear motor to hold tension on the tape as it is pulled from the spool and bonded to the panel. The amount of tension is adjustable. Both three (3) inch and six (6) inch inside diameter supply spools can be accommodated.
The tape advance mechanism 106 consists of an idler roller 126 and a driven pinch roller 128. The pinch roller 128 is actuated toward the idler 126 to clamp the tape 20 and feed it through the knife 108 and pre-heater 110 and under the heated pressure roller 112 and cold shoe 114 to the start clamp 116. The pinch roller 128 is normally retracted for a free tape path from the spool 104 to the mandrel 12.
The variable angle knife 108 is a mechanical guillotine-type shear which can be rotated plus or minus sixty (60) degrees from a right angle tape cut. The shear rotation is driven by a servo motor for programmed shear angles. The shear knife is actuated by dual air cylinders 130 through the pneumatic actuators, PA.
The pre-heater 110 is used for thermal transfer to the new tape 20 to warm it before it contacts the heated roller 112 and mandrel 12. It is a box-type arrangement with a slot 132 therethrough and with a flat heater on the top and on the bottom sides. It normally operates at about five-hundred (500) degrees Fahrenheit.
The heater pressure roller 112 is preferably four (4) inches in diameter and has a plurality, preferably six (6), internal cartridge heaters which bring the roller surface temperature to between approximately seven-hundred and fifty (750) to eight-hundred and fifty (850) degrees Fahrenheit under normal operation. Air cylinder actuators 136 press the roller 112 against the surface so that the combination of heat and pressure causes the new tape 20 to bond to the surface of the mandrel 12 below. Various surface pressures may be selected depending upon the resilience of the bonding surface. The roller is insulated with a metal radiation shield and ceramic conduction end caps to retain heat and maintain an even temperature distribution. The roller assembly is supported on linear bearings 138 for retraction from the surface. The roller itself is planar compliant in order to maintain flat contact with the surface.
Following the heated roller 112 is a cold shoe 114 which cools and smooths the freshly laid tape to obtain the proper surface finish. This is a conventional aluminum cavity through which chilled water passes to sink the heat from the tape surface. The cold shoe is retractable through pneumatic cylinder 142, and the shoe pressure against the surface is adjustable independently from the roller pressure.
The start clamp 116 is used only temporarily during the start of a tape lamination run to hold the tape 20 against the surface of the mandrel 12 and keep the end from slipping as the laminator head is initially moved. After a short travel of the laminator head 18 and after the tape bonding under the roller 112 has begun, the clamp 116 is retracted and remains out of the way during the remainder of the lamination pass.
The film system 118 is used to prevent plastic material transfer from the TMC tape 20 to the surface of the heated roller 112. The film 146, preferably Kapton, is supplied from a payout spool or reel 148 with a clutch drag for tensioning. The film passes below the roller 112 between the roller and the tape 20, and is removed from the surface onto a driven, back tensioned take-up spool or reel 150. The Kapton film 146, at three and one-half (31/2) inches, is slightly wider than the TMC tape 20 to provide some edge overlap. The Kapton is reusable by exchanging the spools when the payout spool is empty.
In operation and use, the movement of the various components can be understood with reference to FIGS. 10A-10F inclusive. In FIG. 10A, the mandrel 12 is rotated to fixedly position one flat face of the mandrel 12 immediately beneath the head. In this position the tape 20 feed is located above one edge of the mandrel 12 and the tape head 18 lowers with the mandrel 12 stationary. In FIG. 10B the tape head 18 moves laterally in a first direction in a plane parallel with the surface receiving the tape 20 to apply tape to the upwardly positioned horizontal surface of the mandrel. Motors 1 and 4 are inactivated so the mandrel is fixed and the head is not raising or lowering. Motors 2 and 3 are activated to move the head across the mandrel surface and along its length for the diagonal application of tape. Initiation of the mandrel is rotated by the controller. Before the roller reaches the corner, the tape head 18 raises from the surface of the mandrel 12 so as to allow no interference as caused by rotation of the mandrel. At the same time the head moves in a second direction opposite from the first. With the head 18 raised, the compaction pressure cannot distort the fibers of the tape 20 at the corners of the mandrel 12. As the mandrel 12 rotates from fifteen (15) to thirty (30) degrees, the head once again lowers to contact the mandrel for the application of tape around the corner. During the cornering, motors 1, 3 and 4 are activated to rotate the mandrel, to raise and lower the head and to move the head from one side of the bed to the other. Motor 2 is inactivated so that the head remains at the same location along the centerline of the mandrel. The mandrel 12 then continues its rotation through forty-five (45), seventy-five (75) to ninety (90) degrees where the second surface of the mandrel is in an upwardly disposed horizontal relationship with the head 18 located above the mandrel 12. The head 12 then moves to deposit tape 20 on the facing surface of the mandrel. Thereafter, steps 10A through 10F are repeated for the application of the tape 20 around the second corner and the second drive of the mandrel 12. The process is then repeated in a continuing cycle of operation with tape dispensing and the head moving appropriately laterally of the mandrel for the deposition of the tape 20 for the generation of the pre-form fabric 56.
The steps to tape wrapping and the process parameters required to perform those steps include first layering the mandrel 12 with an insulator 154 consisting of a 120 glass cloth. The mandrel is preferably a vacuum structure penetrations for mechanical hold down of the Kapton film 146 referred to in the next following step.
Thereafter, the mandrel 12 is then layered with a Kapton film 146 used for first ply adhesion. The material makes a mechanical bond to the film.
For first ply adhesion the roller 112 must be set at about eight-hundred and sixty (860) degrees Fahrenheit and the pre-heater set at about six-hundred (600) degrees Fahrenheit. The pressure for the roller 112 is about one-hundred and twenty (120) psi and cold shoe pressure is about sixty (60) psi. The first ply speed should be set at about eighty (80) inches per minute. If a higher consolidation is desired, the speed should be reduced by about ten (10) inches per minute for each additional ply until about fifty (50) inches per minute is achieved. This will give the material more time above the glass transition temperature which will give high consolidation levels approaching ninety (90) percent.
The present disclosure includes that contained in the appended claims as well as that of the foregoing description. Although this invention has been described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
Now that the invention has been described, | Improved apparatus for dispensing tape of a thermoplastic matrix composite material onto a recipient surface comprising in combination support means for mounting a reel of tape; feed means for unwinding the tape from the reel and advancing it along a path of travel to the mandrel; a guillotine knife in the path of travel for cutting the tape at a predetermined angle with respect to the path of travel; a slotted, box-type pre-heater for the tape located in the path of travel following the knife for providing heat to the tape; a heated pressure roller located in the path of travel following the pre-heater for providing additional heat to the tape for effecting a process operating temperature and for applying the required pressure to the tape for lamination of the tape onto the recipient surface; cooling means located in the path of travel beyond the pressure roller for reducing the process heat from the laminated tape on the recipient surface and to smoothing it for thereby obtain the desired surface finish; and additional means operatively positioned with respect to the pressure roller, tape and recipient surface for placing an interference film between the pressure roller and the tape to prevent sticking of the tape to the pressure roller. Also disclosed is the method of operating such apparatus. | 1 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to a cylindrical baling press used in agriculture for the forming of cylindrical bales of harvested crop material. More specifically, it relates to an improvement that reduces jamming and tracking problems by freeing entrapped crop material from a belt of the baling press.
[0003] 2. Description of Related Art
[0004] Cylindrical baling presses have a baling chamber enclosed by lateral walls, with the other surfaces being enclosed in part by one or more belts guided around rollers so as to form loops and an opening for crop material. At the locations where the belt(s) move away from the cylindrical bale, crop material tends to become entrapped within interior spaces of the loops. This can lead to problems with jamming and/or tracking of the belt(s). In the book “Fundamentals of machine operations, hay and forage harvesting”, FMO 141B, D-00, p. 153, it is suggested that the lateral surfaces be left open. However, this solution is not effective until the baling process is nearly complete, at which point the risk of jamming and tracking problems is greatly reduced. In addition, this solution is most effective where the belt(s) are approaching the cylindrical bale, in which location the above problems rarely occur.
[0005] The present invention seeks to solve these issues by providing a general means to avoid accumulations of crop material in loops or between belt sections of a cylindrical baling press.
SUMMARY
[0006] The present invention provides a means by which crop material accumulated in a belt loop against a lateral wall, and engaged by peripheral surfaces of a rotating cylindrical bale, is removed from the interior space of the belt loop. The present invention is not limited to belts, but encompasses any tensile means which may surround a baling chamber.
[0007] According to one embodiment, the lateral wall includes an opening near a roller where crop material then accumulates. Removal occurs between a forward edge of the lateral wall opening and the space between the lateral wall and the roll. Crop material presses directly against an end face of the rotating cylindrical bale and is carried along by the bale and ejected through the opening.
[0008] In an alternate embodiment, a recess or outward bulge of the lateral wall, rather than an opening, is provided. As a result, the crop material will be fed to the end face of the cylindrical bale and be held adjacent to the end face until it becomes absorbed into the bale. The shape of the recess may be, for example, a wedge shape, which progressively approaches a peripheral surface, where the crop material is forced against the bale.
[0009] While most of the crop material is withdrawn from within the belt loop, not all of the crop material is necessarily fed to the end face of the cylindrical bale. To move all of the crop material to the end face, a conveying device may be provided to feed it back into the bale. The conveying device may be of an active type (for example screws, paddles, blowers, or the like) or may be passive (for example a chute or the like). Screw conveyors may convey in the axial direction or the tangential direction.
[0010] In addition, removed material may be re-fed into the bale by depositing the removed material onto the baler's intake and feed device. The intake and feed device is usually located below the opening or recess. This makes it simple for said crop material to be conveyed back into the baling process.
[0011] In order to successfully handle particularly tough, wet, and/or rigid crop material, a fragmenting device may also be provided near the end of the roller. This device will cut up long stalks and the like and enable them to be incorporated into the bale. The fragmenting device may be fixed to the roller itself, or may cooperate with the roller, for example, by means of blades on the roll and/or apart from the roll. Alternatively, chopping devices, rotary blades, or the like may be provided which are separately driven but which provide the same function.
[0012] Further objects, features and advantages of this invention will become readily apparent to persons skilled in the art after a review of the following description, with reference to the drawings and claims that are appended to and form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] An exemplary embodiment of the present invention is illustrated in the drawings, which embodiment will be described in more detail hereinbelow.
[0014] FIG. 1 is a side view of a cylindrical baling press according to the present invention;
[0015] FIG. 2 is a top detail view of the baling press of FIG. 1 showing the end of a roller and a protruding section of a lateral wall;
[0016] FIG. 3 is a top view of the cylindrical baling press of FIG. 1 showing a conveying device near the end of the roller; and
[0017] FIG. 4 is a side view of the roll of FIG. 2 of the cylindrical baling press showing a fragmenting device and an open section of the lateral wall.
DETAILED DESCRIPTION
[0018] A conventional, towed cylindrical baling press according to the present invention is illustrated in FIG. 1 and designated at 10 . It includes a vehicle frame 12 , lateral walls 14 , rollers 16 and 16 ′, a belt 18 , an intake and feed device 20 and a baling chamber 24 . The baling chamber 24 creates bales out of crop materials, for example, hay, straw, silage, or other crops. The baling chamber 24 is capable of varying in size, although other embodiments may have a baling chamber 24 with fixed dimensions. In the present embodiment, the size of the baling chamber 24 is varied by shifting the position of the rollers 16 and 16 ′ in response to the size of a cylindrical bale 28 being formed within the baling chamber 24 . In some embodiments the baling press 10 may be industrial in scale and stationary, used, for example, to process wastes, wood, or any other material where forming into a bale may be useful for storage, transport or disposal.
[0019] Looking more closely at the vehicle chassis 12 of the towed embodiment shown in FIG. 1 , it includes an axle with wheels, and a tow shaft for coupling it behind a tractor vehicle, for example, a farm tractor. The vehicle frame 12 also includes a framework 22 which supports lateral walls 14 , the rollers 16 and 16 ′ and other devices (not illustrated), such as holding, confining, and positioning and binding devices.
[0020] The lateral walls 14 are large enough to approximately cover the end faces of the baling chamber 24 . Depending on the general configuration of the apparatus, the lateral walls 14 may be segmented parts of the vehicle chassis 12 or may be separate metal plates which cover the entire end face and may be movable or even controllable. Regardless of the configuration of the lateral walls 14 , the present invention includes an open section 26 located near the outboard end of the roller 16 . The open section 26 is configured to avoid contact with an end face of a cylindrical bale 28 .
[0021] The rollers 16 and 16 ′ have various functions and therefore different designs and configurations. In general, all of the rollers 16 and 16 ′ have a roller body 30 rotatably mounted to the framework 22 or lateral walls 14 , by a shaft 32 (see FIG. 2 ). Some of the rollers 16 and 16 ′ are disposed on a stressing arm (not shown), configured to move the rollers 16 and 16 ′ and hold the belt 18 under constant tension.
[0022] According to the present invention, the roller 16 is of primary significance. The roller 16 is configured such that, after being routed around the baling chamber 24 , the belt 18 is guided over and partially around the roller 16 and up to one of the other rollers 16 ′. Consequently, two belt sections 34 and 36 (see FIG. 2 ) are formed, defining a space 38 in between. The roller 16 is arranged such that one of the belt sections 34 and 36 moves away from the outer circumferential surface of the cylindrical bale 28 . This presents the risk that the belt 18 will carry away crop material and cause it to enter the space 38 , leading jamming of the rollers 16 and 16 ′ and/or tracking problems with the belt 18 . Jamming regularly occurs near the end of the roller 16 toward the lateral walls 14 .
[0023] The rollers 16 and 16 ′ may have different lengths. However, at least the shaft 32 of the roller 16 extends laterally beyond the baling chamber 24 . In FIG. 4 , an embodiment is illustrated wherein the end region of the roller 16 includes a fragmenting device 40 , described below in more detail.
[0024] The belt 18 may be a full-surfaced belt 18 which extends over nearly the entire width of the baling chamber 24 . Alternatively, it may be configured as a plurality of belts 18 arranged in parallel with a minimal separation between the belts such that nearly the entire width of the baling chamber 24 is covered (see FIG. 3 ). In either configuration, the belt 18 is guided by the roller 16 , and redirected by approximately 180°.
[0025] At the beginning of the baling process the belt 18 contacts the roller 16 directly, because they extend from below the roller 16 to the side of the neighboring roller 16 ′ adjacent to the baling chamber 24 . Initially the baling chamber 24 is kept to a minimal size. Increasing resistance applied to a lower belt by a tensioning device (not shown) forms a dense bale. The belts 18 cannot extend fully to the lateral walls 14 and, if a plurality of belts 18 are employed, the belts 18 may even move away from the lateral walls 14 . This creates the possibility that the crop material may leave the baling chamber 24 and enter the space 38 . In addition, there is a risk that the crop material will penetrate in between the belts 18 and the respective rollers 16 and 16 ′ and become trapped within the space 38 . A conveying device 42 may also be provided ( FIG. 3 ), near the roller 16 .
[0026] The intake and feed device 20 is of a conventional design. It includes a pick-up and, in the embodiment illustrated, a rotor (which may be in the form of a crop cutting device) which conveys the pressed crop material from the pick-up into the baling chamber 24 . The intake and feed device 20 is disposed below the tow roller 16 and, in the embodiment shown, is wider than the baling chamber 24 .
[0027] The fragmenting device 40 (see FIG. 4 ) includes cutters 46 (with cutting edges) which extend radially and run along the axis of the roller body 30 . In the present embodiment, these cutters 46 are positioned relative to a cooperating cutter 48 to cut plant stalks and the like into smaller pieces. The cooperating cutter 48 may be mounted to either the framework 22 or the lateral walls 14 . Instead of mounting the cutters 46 , along the axis of the roller body 30 , they may also be aligned at an angle to the axis or along a spiral or helical path. The cutters 46 are an optional feature included only if conditions so require.
[0028] The conveying device 42 is in the form of a screw conveyor driven, for example, by belts, a gear drive, electrical motor, or hydraulic motor. In other embodiments, the conveying device 42 may be undriven if configured to rotate by contacting the crops being fed into the baling chamber 24 by the intake and feed device 20 . If the conveying device 42 is in the form of a screw conveyor (as shown in FIGS. 1 and 4 ), it moves the crop material along its axial length toward the center of the baling press 10 . The conveying device 42 may be arranged to move crops on either its upper or lower side, depending on where the crops are to be deposited. For most applications, other than particularly difficult conditions, the conveying device 42 is not necessary.
[0029] The open section 26 is located on the lateral wall 14 relative to the space 38 and the end of the roller 16 . In the embodiment illustrated, the open section 26 is configured as a protrusion in the lateral wall 14 defining an opening. The protrusion is arranged to extend away from the end face of the cylindrical bale 28 and the lateral wall 14 and directed toward the end of the roller 16 . The opening within the open section 26 permits the crop material trapped within the space 38 , which is being moved or agitated by the belt 18 , to be ejected either downward onto the intake and feed device 20 or be directed by the protrusion into the cylindrical bale 28 . The intake and feed device 20 conveys the crop material formerly trapped within the space 38 to be conveyed back into the chamber 24 , where it is picked up by the cylindrical bale 28 , preventing it from causing further problems or being wasted.
[0030] In an alternate embodiment (not shown), the open section 26 does not include the protrusion extending away from the lateral wall 14 , but rather just includes the opening. In this embodiment, a forward edge 44 (see FIG. 4 ) of the lateral wall 14 extends through an arc across the circular surface formed by the side of the cylindrical bale 28 , creating an open circular segment in the lateral wall 14 . The shape of the opening need not be that of an arc; any shape suitable to allow entrapped crop material to escape the space 38 may be provided. In this embodiment, all crop material feed from the space 38 is ejected onto the intake and feed device 20 and returned to the baling chamber 24 . In FIG. 4 , the open section 26 is shown only in a partial view to show the edge 44 and illustrate the embodiment described above.
[0031] As a person skilled in the art will readily appreciate, the above description is meant as an illustration of implementation of the principles this invention. This description is not intended to limit the scope or application of this invention in that the invention is susceptible to modification, variation and change, without departing from spirit of this invention, as defined in the following claims. | A cylindrical baling press including a roller around which a belt is arranged to partially surround a baling chamber. In the region of the roller, the belt relinquishes contact with a cylindrical bale being formed within the baling chamber. In this region of the roller, a lateral wall enclosing the pressing chamber is provided with a bulge or an opening, which makes it possible for material present in a space between two belt sections to be engaged by the rotating cylindrical bale and expelled through the opening or back into the bale. This configuration avoids, or at least reduces, the chance of jamming caused by crop materials around the roller. | 0 |
BACKGROUND
This invention relates to sub-sea wells and more particularly to adjustable conductor guides and methods and tools for adjustment thereof.
Early offshore production can be achieved by means of the template tieback system, wherein development drilling and platform construction can run concurrently. Development wells are pre-drilled through a sub-sea template from a floating rig and the wells tied back to the production platform following its installation over the template. The major advantage of the tieback concept is that return on investment can be quicker than for wells drilled conventionally from a fixed platform.
There is a risk of misalignment when the platform is positioned over the template. The risk increases at greater water depths and is such that the ultimate success of a drilling venture may be vitiated by positional inaccuracies with substantial loss of investment.
The Applicants' studies in this field have indicated that the main cause of failure is likely to be excessive bending stresses in the tieback conductor. This bending stress depends partly on lateral offset between platform and well head, angular offset, and "environmental loadings". By way of example, it may be necessary to maintain the platform vertical to within ±0.5° and lateral misalignment within ±0.65 m (±26"): these figures are given by way of example only.
The invention accordingly provides a conductor guide assembly comprising an outer ring supporting an inner guide, the axes of ring and guide being spaced apart. The ring is mounted on the platform about an aperture and the platform is positioned over the template so that as far as possible the aperture is vertically aligned with the well head. Rotation of the assembly in the aperture moves the axis of the inner guide in relation to the well head axis and enables any spacing between those axes to be minimized.
Conveniently means are provided on the outer ring for location with respect to the aperture in one of a number of possible angular positions. Preferably means are provided on the outer ring for rolling contact with an annular area about the aperture to resist upward force on the assembly.
Turning broadly to the method aspect, the invention provides a method of aligning with a sub-sea well head, a conductor guide mounted in a platform above the well head, the conductor guide being the inner guide of an assembly comprising an outer ring supported in an aperture in the platform and said inner guide supported eccentrically thereon, the method comprising the steps of:
(a) lowering through the guide an adjusting tool having a projection to extend substantially to the well head;
(b) by means of the adjusting tool, rotating the conductor guide assembly in its aperture to bring the axis of the inner guide as near as possible into alignment with the well head; and
(c) locking the conductor guide assembly in angular position within the aperture and removing the adjusting tool.
Preferably the tool is lowered, manipulated and subsequently removed by drill string. The adjusting tool can be rotated first on the axis of the inner guide to engage means to lock the tool to the guide, and then on the axis of the outer ring to rotate the tool and assembly as one.
In a preferred system, the tool has a body to locate in the inner guide and to lock releasably thereto for rotation of the assembly, and the drill string is connected to a block mounted on the body and rotatable with respect thereto between limits and lockable thereto. In this preferred system, the method of the invention further comprises the steps of rotating the drill string to move the block with respect to the body to a limit position where the string axis coincides with that of the inner guide, further rotating the drill string thereby to lock the body to the inner guide, rotating the drill string back to another limit position where the string axis coincides with the axis of the outer ring, lifting the string to lock the block to the body and release the assembly for rotation, and thereafter rotating the tool and assembly as one.
As above indicated the invention also provides a tool for use in the system described. In a preferred form the invention provides a tool for adjusting a conductor guide assembly comprising an outer ring supporting an inner guide, the axes of ring and guide being spaced apart, comprising:
(a) a body adapted to enter and locate in the inner guide of the assembly, the body having a generally vertical first axis coincident with that of the inner guide on location therein;
(b) means for establishing coincidence of the first axis with that of a well head;
(c) means for connecting a drill pipe to the body and aligning the pipe, when the body is located in the inner guide, selectively with the axis of the inner guide and the axis of the outer ring;
(d) means to land the body on the assembly and to lock the body thereto for movement together,
whereby on landing the body in the inner guide rotation thereof by rotation of the drill string on the inner guide axis locks the body to the assembly whereupon the drill string may be rotated on the axis of the outer ring to bring the axis of the inner guide as near coincident with the well head as possible.
The main object of the invention is to provide a conductor guide system which allows of some wider tolerance in positioning the platform over the template.
Another object is to provide an improved conductor guide assembly for a sub-sea well head which is easily and quickly aligned with the sub-seal well head.
A further object is to provide an improved method of aligning a conductor guide with a sub-sea well head which can be readily operated from the surface and ensures proper alignment.
Still another object is to provide an improved tool for adjusting the sub-sea conductor guide assembly into aligned position from the surface and to lock the assembly in aligned position.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described with reference to the accompanying diagrammatic drawings, in which one embodiment of the invention is described by way of example. In the drawings:
FIG. 1 is a sectional view of an adjustable conductor guide installed on a platform;
FIG. 2 is a plan view of the FIG. 1 guide, shown partly broken away;
FIG. 3 is a plan view of an adjustable conductor guide in combination with an adjusting tool according to the invention;
FIG. 4 is a vertical section of the guide and tool, showing also part of the supporting platform; and
FIGS. 5a, b, c, d are diagrammatic side views and plans illustrating various steps in the method according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2 of the drawings, an adjustable conductor guide assembly A comprises an outer ring or base designated generally 1 supporting an inner guide designated generally 2, the axes of the ring and guide, respectively 3, 4, being laterally offset. The inner ring 2 is of 50" (1.27 m) interior diameter. The outer ring 1 is supported on a platform shown diagrammatically only at P about an 84" (2.13 m) diameter aperture. Steel rings 5, 6 are fixed to the platform P about the aperture and the upper ring 5 carries four torque pins 7 at 90° angular spacing. The periphery of the outer ring 1 is apertured as shown at 8 to receive the torque pins. It will be appreciated that by lifting the assembly A off the torque pins, turning it and lowering it again, the angular position of the assembly can be varied. Torque pins 7 are bevelled as shown at 9 and the apertures 8 have conical counter-bores 10 so that in whatever positon the ring is lowered, it will engage on the pins. The outer ring 1 is fabricated from a stout upper plate 12 in which the apertures 8 are formed, and a cylindrical side wall 14 engaging with only slight clearance within the aperture in the platform P. I beams 13 having upper and lower flanges 13a and a web 13b are arranged generally radially at intervals and welded to the plate 12, wall 14 and inner ring 2 to rigidify the structure. Side wall 14 depends below the aperture to form a skirt 14' and the skirt carries at intervals around its periphery roller blocks 15 to engage the lower ring 6 of the platform when the assembly A is lifted for rotation as will be described.
The inner guide 2 comprises a cylindrical wall 16 secured in an aperture in the plate 12 and tangential to the side wall 14. The guide 2 has an upper entry consisting of frustoconical portions 17, 18, the first of wide angle and the second of lesser angle. At the bottom of the inner guide 2 is a conical skirt 19. The construction is rigidified with bracing plates 20, 21, 22 as shown.
An adjusting tool for the conductor guide assembly A is shown in FIGS. 3 and 4 and designated generally T. The tool comprises a body designated generally 30 and a block designated generally 31 pivotally connected to the body 30 about a vertical axis 52. The block 31 provides a conventional connection 33 to receive a drill pipe (not shown).
The body 30 of the tool T is designed to enter and locate in the inner guide 2 of the adjustable conductor assembly A. It comprises top and bottom plate 34, 35 adapted to engage with clearance within the cylindrical wall 16 of the assembly A and interconnected by a cylindrical wall 36 set back from the plate edges. A vertical stinger 38 is welded to the bottom plate 35 and extends on the axis 39 of the body, which is also the axis of the inner guide 2 when the body is located within the guide as shown. Bracing plates 40 assist in supporting the stinger 38, which may be composed of drill pipe.
The block 31 comprises a cylindrical housing 42 rotatable on a spigot 43 carried on the upper plate 34 of the tool body. The block further comprises a member 44 welded to the housing 42 and providing the drill pipe connector 33 previously mentioned. A tubular wall 45 surrounds and protects the block 31, being welded to the top plate 34 of the tool body. Bracing plates 46, 47 reinforce the structure. Lugs 50, 51 welded to the top plate 34 provide stops to limit rotation of the block 31 about the axis 32.
The block 31 is shown in the limit position defined by stop 50, and in this position the axis 52 of the drill pipe connector 33 coincides with the axis 4 of the base or outer ring 1 of the adjustable conductor assembly A. The stop 51 defines a limit position for the block 31 where the axis 52 of the drill pipe connector 33 coincides with the axis 3 of the inner guide 2 of assembly A. Drill string connected to the connector 33 can thus swing about the rotational axis 32 of the block between a position where it is aligned with the outer ring axis 4 and a position where it is aligned with the inner guide axis 3. As illustrated, the rotational axis 32 of the block 31 is midway between these axes 3, 4.
The block 31 is movable along the spigot 43 as well as around it. Pins 54 on the spigot 43 are received in slots 55 in the housing 42 when the block 31 is lifted in the position illustrated. The block 31 cannot be lifted in any other position.
The top plate 34 carries on its underside, extending through the side wall 36, three hydraulically operated landing and locating devices designated generally 60. The bottom plate 35 of the tool body carries a spring-loaded torque dog or plunger 61 which is bevelled at top and bottom to engage in a slot 62 formed in the wall 16 of the inner guide. A plate 63 closes the slot and limits outward movement of the plunger.
Devices 60 each provide an outer spring-loaded piston 65 carrying a land-off stop in the form of a plate 66 which, when extended, is adapted to contact the outer entry cone 17 of the inner guide 2. A spring-loaded locating plunger 67 extends coaxially through the outer piston 65 and is adapted to be received in apertures 68 in the inner entry cone 18. There are three of these apertures 68, one for the locating plunger of each of the three devices.
The device 60 is connected by conduits (not shown) to a central duct 70 in the drill pipe connector member 44. The application of pressure within the drill pipe actuates the pistons to the position illustrated where the stops 66 project beyond the tool profile so as to enable it to land within the inner guide 2. The locating plungers 67 then are spring-urged against the inner entry cone 18 until the tool is rotated to align them with the apertures 68. In the absence of hydraulic pressure, stops 66 and plungers 67 are held inactive within the tool profile.
As the torque dog or plunger 61 is positioned to enter its slot 62, so the locating plungers 67 enter their apertures 68. The bevelling on the plunger 61 permits it to cam out of its slot as the tool is lifted out of the inner guide 2; the plunger is not bevelled on its sides, and so can transmit torque to the inner guide.
The operation of the system will now be described with particular reference to FIGS. 5a to 5d. As here illustrated, the platform provides horizontal members of which two, P1, P2, are shown, each with an adjustable guide assembly A1, A2 respectively, as illustrated in FIGS. 1 and 2, assembled in apertures which are so far as possible located over the well head W protruding through the template T'. It will be seen that, as illustrated, the apertures are out of alignment.
A T.V. "eye" 72 is mounted at the bottom of the stinger 38. The tool T is mounted at the bottom of a drill string 71. The tool is lowered through the upper guide assembly A1 and landed on the lower guide assembly A2 (FIG. 5b). For this, hydraulic pressure is applied to the pipe to energize the landing stops 66 and the tool comes to rest in the lower guide assembly A2 as shown generally in FIG. 4. It is arranged that when this happens, the T.V. "eye" is no more than a few feet from the well head W.
The drill pipe 71 is now rotated to the right which brings the block 31 to the stop 51, where the axis of the drill string coincides with that of the tool body 30 and inner ring 2. Further rotation of the drill string 71 rotates the tool body 30 until the plungers 61, 67 locate in their respective openings. Thereafter tool body 30 and assembly A2 move as one.
With the plungers 61, 67 engaged, a light left-hand torque is now applied to the drill string 71 to swing the block 31 around until the drill string axis aligns with that of the outer ring 1. This position is located by the stop 50 on the top plate 34 of the tool.
Lift is now applied to the drill string 71, to lift the block 31 with respect to the tool body 30, thus bringing the pins 54 on the spigot 43 into the slots 55 in the housing 42. The block 31 and tool body 30 are now locked for movement together, and with the assembly A.
Continued lifting of the block 31 lifts the entire tool body 30, and with it the entire assembly A, so that the apertured top plate or outer ring 1 lifts off the pins 7 and the roller blocks 15 engage the lower ring 6 on the platform. Right-hand torque is now applied to the drill string to swing the tool and assembly around the axis 4 of the outer ring until the T.V. "eye" shows the nearest possible correspondence with the well head axis. This condition is illustrated in FIG. 5c. The drill string is now lowered to engage apertures 8 in the outer ring 1 over the pins 9 so that the assembly is now permanently located with the conductor guide 2 in the appropriate position. Hydraulic pressure on the devices 60 is now released and the tool withdrawn by the drill string 71 from the conductor guide assembly A2. Release of the pressure allows the springs to withdraw the landing stops 66 and plungers 67. The plunger 54 withdraws from the slot 62 by camming at the end of the slot as explained.
The process is repeated with the next upper guide assembly A1 in platform member P1, so as to align the axis of the inner guide as near as possible with the axis of the lower guide A2.
It will be appreciated that exact alignment of the adjustable guide with the well head axis may not be possible, for example if the platform aperture is perfectly aligned to start with. However, in that case the misalignment will be within acceptable limits. Normally it will be possible to achieve quite close alignment and the system of the invention allows, therefore, much wider tolerance in the position of the platform with respect to the well head. | An adjustable conductor guide assembly for a sub-sea well which includes an outer ring supported on an inner guide with the axes of the ring and guide being laterally offset so that rotation of the outer ring on its support changes the position of the axis of inner guide. The improved method of aligning a conductor guide with a sub-sea well head includes the steps of supporting the conductor guide assembly on a platform installed over the well head, lowering a tool through the guide and rotating the conductor guide assembly to align the axis of the guide as close as possible with the well head, locking the conductor guide assembly in its set position and retrieving the tool. The improved tool includes a body fo passing through the guide, means for engaging the conductor guide assembly to lift and rotate such assembly, means for limiting the amount of angular movement during rotation and a string on which the body is mounted. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/181,991, filed Feb. 11, 2000.
BACKGROUND OF THE INVENTION
[0002] The personal nature of the services movers supply to the public necessitates that sales consultants frequently meet with a prospect in their home to plan, estimate, and present services. Each quotation and presentation is as individual as the client whose goods are being moved, however, in all cases the pricing is based on a list of goods to be shipped which the representative typically prepares prior to calculating prices and presenting their company's service offerings. Due to the complexity of the variety of pricing methods used (tariffs dictated by regulatory agencies like the DOT and PUC), in most cases the pricing of the proposal takes from fifteen minutes to one hour per job, when done by calculator and hand written on manual forms. To compete effectively in this market, representatives have to prepare these quotations on site. Most clients, after an hour or more of data gathering and waiting for the estimate, are not interested in hearing sales talk and want the representative to deliver the pricing information and let them get on with their business. This is the standard scenario and the paradigm affected by the use of the present invention.
SUMMARY OF THE INVENTION
[0003] In the new scenario, the field rep picks up the customer appointment card and electronic estimate form from the office via e-mail or from the server in the office with a NIC (Network Interface Card) card LAN (Local Area Network) connection, or a wireless network connection. The office personnel can also transmit the file to the outside sales representative by any other electronic means, such as saving the file to a disk. The pickup and delivery information is filled in electronically by the customer service representative during his/her initial conversation with the prospect when customers call to inquire as to the availability of the company to service their transportation needs. By telephone most customers will schedule an appointment with a field salesperson to survey and estimate their needs and the cost of service.
[0004] Frequently some companies receive a commitment over the telephone and the sales call to sign the paperwork is a mere formality. Many clients have previously had estimates and are calling around to get additional rate quotes. The ability of a company to quickly and accurately quote and book shipments with the customers' supplied information often results in booking the order over the phone. Even the most complicated estimate, from anywhere to anywhere, can be generated by this invention, without reference to tariff schedules, mileage calculations, or tables, or manual calculations, as the invention supplies all necessary lookups for accurately pricing a shipment. In less than two minutes, if clients can answer specific questions regarding their service needs, the order can be generated and faxed to them for their approval. From the first call, this invention can create a perception of a higher level of competence in the eyes of the client. This gives a company a decided advantage over any other company the customer may have contacted. If the client prefers a sales call with a contract for an exact price, the phone sales representative then sets an appointment and saves the clients file. The file is then transmitted to the rep via one of the methods outlined above.
[0005] The sales rep then arrives at the residence and gathers the survey information on screen via the touch screen interface and an electronic model of the piece count form they have previously always filled out manually.
[0006] The form factor of the computing device for in-home estimating (pen input via touch screen interface) is ideally suited to this task and almost eliminates the learning curve and fear factor that handicaps many technophobic reps in the implementation of sales automation systems. Input is almost entirely done through push buttons on the screen. Since all the calculations are automated, the sales rep is almost completely done with the estimate when they finish walking through the home. This creates the perception that the expertise level of the rep (an important subconscious factor in the decision to purchase) is far superior to that of other reps.
[0007] This also allows an average of 30 additional minutes per appointment for the representative to spend selling. To that end, a full multimedia (video with sound) presentation can be used to demonstrate the high-end materials and techniques to be used to protect the client's valuable possessions.
[0008] The estimating is done before the shippers very eyes, in fact, it becomes an interactive process with most clients who are usually fascinated by the computer and the video images of moves in progress. The representative then asks for the client's signature and prints the hard copy for the client via the IFR port to a portable color printer. The color order printout has a great deal of appeal to the eye in comparison to most of the forms used by others, another subtle competitive advantage.
[0009] The goal is product differentiation, a difficult task when selling intangible services. The combined software and hardware can go a long way towards illustrating the dedication of a company to exemplary service. More efficient and effective automated representatives often average over 10% more volume from the same number of sales leads. They can also make more sales calls per day with less fatigue and greater enthusiasm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1: Main Menu.
[0011] [0011]FIG. 2: Form Menu.
[0012] [0012]FIG. 3: Customer Database.
[0013] [0013]FIG. 4: Customer File Folder.
[0014] [0014]FIG. 5: Find Files.
[0015] [0015]FIG. 6: Appointment Card.
[0016] [0016]FIG. 7: Cube Sheet.
[0017] [0017]FIG. 8: Packing Worksheet.
[0018] [0018]FIG. 9: Messages Directory.
[0019] [0019]FIG. 10: Estimate worksheet.
[0020] [0020]FIG. 11: Estimate Menu.
[0021] [0021]FIG. 12: Cube Sheet.
[0022] [0022]FIG. 13: Pack Worksheet.
[0023] [0023]FIG. 14: Pricing Worksheet.
[0024] [0024]FIG. 15: Order for Service (Estimate tab).
[0025] [0025]FIG. 16: Auto Presentation.
[0026] [0026]FIG. 17: Fujitsu Mini-Notebook.
[0027] [0027]FIG. 18: Block diagram of the information flow by participant.
[0028] [0028]FIG. 19: Block diagram of the interaction of the system for information flow.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Data gathering, estimating, preparation of order forms, client letters and proposals, marketing pieces and presentations, and internal company communications, are all addressed by the software of this invention and have all been automated to a greater or lesser degree.
[0030] The sales process begins with marketing pieces designed to target market via direct mail to potential clients in order to increase the likelihood that a potential client will call in to inquire as to the services of the company. To this end several templates have been designed to be sent to a client list that is usually procured by the company from a list of homes for sale or other public information sources.
[0031] Some companies may wish to have outside sales people gather this information in a targeted manner as they identify neighborhoods they wish to do more business in. In that case the information can be manually gathered and input into a data file for use in the marketing effort. This is especially effective in the case of For Sale by Owner homes or apartment neighborhoods where no published information is available.
[0032] Having imported this client list into a prospect database the sales representative or their support staff can use mail merge automation to produce form letters that will motivate these clients to call in. These pieces are available from the sub menu called Form Letters after opening the Main Menu shown in FIG. 1 from the desktop icon. Several pieces are available from this hyper-linked sub menu and more templates can be added to the program's sub menu as they are developed or customized for the company's particular market.
[0033] The pieces are identified by descriptive names on the Form Letters sub-menu shown in FIG. 2. There are also prospecting letters available for a similar purpose from this sub menu, (also available from the programs main menu). These letters are typically used to make introductions to professionals who might have business or leads to tender to the company, such as realtors and building managers.
[0034] The data gathering process on call in prospects who may have been identified as described above or who are calling for some other reason starts as close to the first point of contact as possible. Ideally, a customer service representative or inside or outside sales person will take their call and begin inputting their specific information into the customer prospects database illustrated in FIG. 3.
[0035] This information, such as where they are moving from and too and when they are planning to move, along with as much other pertinent detail as can be determined is input in the prospects database while the customer is on the phone. If the client requests a ballpark quotation at this point, the record is imported into the appropriate estimating document and a file is begun on this prospective client as the ball park quotation is being given. Should the prospect request an in home appointment at this time this file is stored with the ballpark quotation and a customer file folder FIG. 4 to hold all the customer documents is begun.
[0036] Storing the pending customers folder of FIG. 4 on the hard drive of the computer, or on the hard drive of a server allows a company to keep track of all pending customers who have either called in for information, requested a ball park quotation or requested an estimate. The program is set to default to the customer's directory of the hard drive or server when a file is being saved.
[0037] Any pending customer who has already called in can be found from the Windows™ Start button via the find files option. As this technique is extremely fast and useful all representatives should be taught the file naming convention in the table below so the files can be easily identified by their file name.
File Folder Last name First name Appoint. Card Last name First/apt Estimate File Last name First/est Prospect letter Last name First/prospect Proposal Last name First/proposal Etc. Etc. Etc.
[0038] The customer's directory of FIG. 4 should be further segmented into four sub-directories. These sub directories are respectively named: Pending, Booked, Storage and Delivered. The find feature on Windows 98 and Windows NT machines can be preset to search the Customers folder and all sub-folders, thus speeding the file search process to an almost instantaneous process.
[0039] When the find feature returns the customers file folder and the documents within, the naming convention illustrated above allows the user to recognize the appropriate document and double click on the document in the list to instantly access the information within. For instance, if the customer were calling to reset the appointment date and time, seen in FIG. 3 the customer service representative would open the Last name First name apt file to access the appropriate information within. If the appointment is reset the representative can be notified by copying the revised appointment card of FIG. 6 to their messages folder with a message to alert them that the appointment has been rescheduled and the appointment time can be changed in their schedule application.
[0040] The salesperson or sales coordinator imports the customer info from the prospect database into the appointment card of FIG. 6 for the outside sales representative's use. A hard copy is usually printed out for distribution or faxing and a copy is saved to the customers folder to document the appointment. Also, a note is inserted into the outside salespersons schedule regarding the appointment day and time.
[0041] Currently, the sales persons' schedules are kept in a program called MS Schedule plus, however any scheduling program can be used. In future versions, the scheduling of representative will be integrated into pre-programmed modules and further automated.
[0042] The inside sales representative then copies the prepared folder with estimate form and appointment card to the outside salespersons message directory. In this way, the outside sales representative, while moving his electronic messages as seen in FIG. 7 from the server to his laptop can get a prepared copy of the clients folder, appointment card and a prepared copy of the estimate to use during his call on the prospect. Any pertinent notes on the inside salesperson's conversation with the prospect are noted in the remarks on the appointment card of FIG. 6. At the same time, they pick up their messages from other clients or anyone who called for them while they were out.
[0043] After transferring the information to their laptop message directory via the Local Area Network connection, the file folder and contents are saved for use at residence on the sales representative's hard drive in their Pending customer directory of FIG. 4.
[0044] Rand McNally's™ Mile Maker program supplies the correct household goods mileage (see FIG. 8) automatically from the user input of origin and destination city and state information supplied by the client. No need to call the office for a tariff pull from the slow and complex client server on-line information system. No need to initiate a ten-minute lookup process in the mileage guide and five sections of the interstate tariff.
[0045] Four thousand five hundred major cities and their associated counties have been input into a database and those counties are returned automatically to the appointment card for complete automation of all required look-ups. The correct county at origin and destination must be input for small town's that are not in the computers' database of major cities.
[0046] When Rand McNally's™ Mile Maker for Excel program is completed all cities in the United States will be associated with their correct counties and all county look-ups will be entirely automated from data supplied by Rand McNally™. This will provide the users of the program the completely automated estimating tool desired.
[0047] This complete and automatic estimating process is unique in a stand-alone PC based estimating and rating tool, and is believed never to have been accomplished in a non-network dependent or client server system. What is more, all lookups and automation in this system are virtually instantaneous. This is the key to the usefulness of this tool; instantaneous information available to all users for the benefit of their clients.
[0048] No longer does it require extensive training in complex tariffs to provide clients with accurate, automatic, deliverable quotations. New hires and entry-level personnel can now deliver accurate quotations quickly, accurately and easily without extensive training. There are estimating applications available for all types of estimates that a sales representative has opportunity to quote on. They all are designed with similar interfaces and push button automation of all look-ups, calculations and estimating functions. All output forms are designed as replicas of the estimate and order forms that sales people in the movers system already use so that they can be printed and used as executable orders.
[0049] From the counties at origin and destination, the program looks up the correct service codes, cost schedules and item 170s, which is a designation in the trade for “extra labor”. Once the representative inputs an actual or approximate shipping weight, the pricing for transportation charges is immediately complete and available by clicking on the estimate sheet tab (FIG. 8).
[0050] Even the percentage of discount to be applied to the shipment is automated. The sales manager for the company can set the levels of discount that are appropriate for their market in a table on the pricing sheet tab of the interstate estimating template. If the representative wants to change the discount level on a particular shipment to a level differing from the defaults that are preset, they merely click on the cell where the default discount is returned and type in the discount that they wish to quote on. All discounted items are instantly re-calculated according to this new discount level. Should the sales manager wish to prevent this level of user control and retain complete control over the price quotes for the office they can protect this cell and prevent user level changes.
[0051] The field salesperson does a walk-through at residence and inputs the pieces (via touch screen and stylus) to the Cube Sheet (FIG. 10). It is easy because it looks exactly like the cube sheet they have used to manually collect information.
[0052] The program totals the cubes and calculates weight, instantly recalculating the estimate as they input more pieces or cartons. They can see what they have input and check to make sure they have each piece recorded properly.
[0053] The Cube input toolbar helps the user jump from room to room to keep up with their fast talking client. This automation is based on an implementation of Visual Basic for Applications Macro's that have been assigned to coded buttons on the custom cube menu toolbar. In order to make the cube sheet easier to use, Zoom buttons are also assigned to this toolbar. When used in the field during an estimate walkthrough the representative can zoom in with the touch of a button to make the screen larger and easier to use while walking.
[0054] Even in the darkest of homes, the lighted screen is easy to read. When the representative is finished with the cube menu toolbar, they can touch the Hide Menu command button on the Main Menu bar to clear the screen and remove the Cube Menu toolbar.
[0055] The salesperson checks packing totals that have posted forward from the carrier pack portion of the cube sheet to the Packing Worksheet (FIG. 11).
[0056] P.B.O. (Pack By Owner) boxes can be added in the customer column without changing the calculated cube or weight. If the client desires a quote on unpacking, the salesperson can input “Y” in the Unpack Y/N field and unpacking charges for the shipment are instantly added. All rates are based on the appropriate cost schedule for origin and destination counties based on the input on the Appt Card worksheet and will shift to the correct rates if those entries are changed at any time.
[0057] The salesperson then inputs any Accessorials to be charged in the unit's column of the Pricing Worksheet form (FIG. 12).
[0058] All calculations are automatic and instantaneous. All common estimating situations have been anticipated and automated as much as possible. All calculations are based on the correct cost schedule item based on the county of origin and destination.
[0059] Both of these forms are almost exact replicas of familiar standard movers' paperwork. The input goes into the same fields on the digital forms as it was written into the manual forms.
[0060] Even the charges for Storage In Transit at origin and destination are calculated and available at the bottom of the Pricing Worksheet form.
[0061] Showing presentation videos can be part of the closing process as needed, because the estimate takes only moments. Blue underlined words on the Packing and Pricing worksheets are hyper linked to appropriate multi-media presentations by context in the same manner that this technology is used on the Internet.
[0062] For example, when the representative touches the hyper linked word, “Bulky Handling—Auto” on the Pricing worksheet (FIG. 12) a video presentation on loading automobiles on to the moving van is made available. When the static picture (FIG. 13) comes up on the screen the representative touches the picture to start the audio video presentation. If they would prefer to do their own narration they can turn down the audio volume on their laptop and explain the video to the client themselves. When the representative is finished showing this piece to the client they merely touch the blue arrow pointing backwards on the Web Toolbar of the presentation and they are returned to the estimate exactly where they were previously working.
[0063] There are many other presentation pieces such as this available from the Presentations sub-menu of the Main Menu application.
[0064] After adding the accessorial items to the Pricing worksheet (FIG. 12) the representative brings up the Order for Service form (FIG. 14) by touching the Estimates tab on the bottom of the screen. The salesperson can, check the delivery guide, do what if scenarios, etc. The estimate is almost ready by the end of the walkthrough.
[0065] The salesperson can also check the calculated minimums and pricing on valuation by touching the Valuation worksheet tab. Transit time guidelines are available on the Transit Guide tab. Should the representative need to find a destination agent for the shipment they can touch the Dest. Agent hyper-link and search the agency directory for an appropriate destination agent number to input on the Appt Card tab. Inputting the destination agent number in the correct field calls up that agent's information from the directory and fills out the appropriate area on the Order For Service.
[0066] The order can be printed wirelessly via the infrared data transfer port to any printer that accepts IRDA data transfer.
[0067] This computing device provides the optimal interface for field salespeople (lightweight, pen-input, color screen). Of course, the software will run on any computer with a Windows operating system and sufficient processor speed and RAM. Presenting your companies offering in the most attractive format is the main goal with clients in their home or business.
[0068] Additional software can be added for voice and handwriting recognition. This will allow fast preparation of custom letters or proposals.
[0069] Infrared data transfer port (for wireless printing of orders), port replicator for easy connection to external keyboard and monitor or other peripheral devices and internal network interface card for LAN connections and modem for e-mail and Internet connectivity allows a person to work where he/she needs to when he/she needs to: in the car, at a restaurant, at home, in a meeting, even at the beach or on a yacht. There is no need to connect to dial up information systems to get mileage or tariff rates.
[0070] The information flow is illustrated in FIGS. 16 and 17. Initially, the customer 50 contacts the phone sales rep 60 in step 101 to inquire as to available services. The phone sales rep 60 records the information regarding the customer's specific needs in the office computer 70 in step 102 , sets an appointment with the field sales rep 80 and transmits the client info file to the field sales rep 80 in step 103 . The field sales rep 80 meets with the customer 50 to estimate the job parameters and propose custom service for the customer 50 in step 104 , all the time making entries in his/her laptop computer 90 . The field sales rep 80 secures the customer's order and transmits from his/her laptop computer 90 to the office computer 70 in step 105 for further processing.
[0071] Interaction takes place between the field sales rep 80 laptop computer 90 and the office computer 70 in the manner described in greater detail above. | A process, method, and program for automating the gathering and processing of customer information and an automated estimating-communication device and mobile presentation platform for the field sales representative and office support staff in the moving and storage industry. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 102014001700.1 filed Feb. 8, 2014, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to a gas detection device, which comprises a functional device fixed to a platform and pivotable about at least two pivot axes.
BACKGROUND OF THE INVENTION
[0003] Gas detection devices are used, for example, in units for delivering and processing combustible and/or toxic gases in order to detect gases released in an unintended manner.
[0004] Gas detection devices that measure the concentration of harmful substances locally, i.e., in the immediate surrounding area, and are usually interlinked with one another in order to make it possible to monitor larger areas, are known.
[0005] There also are gas detection devices with an open measuring section, which are called open-path gas detection devices. The measuring section may range from a few m to a few hundred m. Open-path gas detection devices analyze electromagnetic or light radiation, which has passed through a defined monitoring range. The electromagnetic or light radiation is analyzed with respect to a possible interaction with a gas being released in an unintended manner, which is associated with a change in the properties of the radiation. This makes possible the continuous monitoring of a relatively large monitoring area with respect to an unintended release of gas, and the quantity and the species of the gas or gases being released can also be inferred from an analysis of the altered properties of the radiation. The radiation used for the monitoring may be, for example, thermal radiation of the background, or this radiation originates from a source of the gas detection device itself.
[0006] The functional devices used in gas detection devices have, as a rule, a limited field of view, i.e., these must be oriented relatively accurately towards the radiation source or the area to be monitored. This also applies to open-path gas detection devices, which comprise as functional devices, as a rule, at least one transmitter with a radiation source and a receiver with a radiation detector, to which the radiation emitted by the radiation source is focused. The radiation source may be, for example, a thermal radiator, for example, a xenon flash lamp, or a semiconductor radiator, for example, a tunable laser. Such open-path gas detection devices require orientation of both the transmitter and the radiation source integrated therein in order to direct a sufficient amount of radiation output to the inlet aperture of the receiver and the receiver in order for the radiation falling on the inlet aperture to reach the radiation detector as centrally as possible.
[0007] Another type of open-path gas detection device comprises a reflector, which is positioned at a distance of usually up to 50 m from a combined transmitter/receiver unit and onto which the radiation emitted by a radiation source is projected. The reflector reflects the radiation in the direction of the transmitter/receiver unit, as a result of which this can be detected by a radiation detector of the unit.
[0008] Another type of an open-path gas detection device is the so-called gas camera, whose spectral sensitivity is set to the absorption bands of a gas and which makes the gas being released from a leak visible or recognizes that gas by means of image processing and sends a warning signal.
[0009] Dräger Safety AG & Co. KGaA commercially offers an open-path gas detection device, in which both the transmitter and the receiver are connected with a baseplate by means of a joint arrangement each, which forms two pivot axes directed at right angles to one another. The joint arrangement is designed such that the two pivot axes intersect the optical axis of the radiation source and of the radiation receiver, respectively, approximately in the center of the housing of the respective functional device. Eight locking screws, four for the transmitter and four for the receiver, must be loosened and tightened after orientation to orient the transmitter or the receiver. The orientation itself is performed manually and can be checked by means of crosshairs, which is represented graphically on a hand-held device. A minimum signal is necessary for the analysis for displaying the crosshairs, so that a coarse orientation must be performed prior to the fine orientation by an optical direction finding, which can be carried out with the support of a telescope, which must be fastened to the housing of the transmitter or receiver in a defined manner. Once the orientation has been performed, the locking screws are tightened, so that the orientation is maintained unchanged for a rather long time period. Fine adjustment with strong holding force is advantageous for the accuracy of the orientation and for preserving the angle when tightening the locking screws.
[0010] Some open-path gas detection devices have adjusting screws with fine thread, which are used to orient the transmitter or the receiver with the locking screws loosened and transmit the translatory component of the screw motion to the transmitter or receiver in the process. As a consequence of the small pitch of the thread, accurate orientability of the transmitter and receiver can be achieved with these. If the adjusting screws are also used as locking screws at the same time, strong holding forces can, moreover, be brought about with these. This is especially advantageous when the adjusting/locking screws are arranged comparatively close to the respective axes of rotation. Adjusting or locking screws with fine thread are less suitable for use in an industrial environment because of the stresses due to contamination and corrosive media that are associated with them.
SUMMARY OF THE INVENTION
[0011] Based on this state of the art, a basic object of the present invention is to provide an advantageous possibility for orienting an open-path gas detection device.
[0012] According to the invention, a gas detection device is provided comprising a functional device comprising at least one of a radiation emitter, a radiation receiver and a radiation reflector. The radiation varies in an analyzable manner due to a presence of a detectable gas. A pivot mount arrangement is provided mounting the functional device pivotably to a support platform for pivoting about at least two pivot axes relative to the platform. An adjusting device is provided comprising a fixing device for a temporary fixation of the adjusting device relative to the platform and an application device for a defined application of forces to the functional device that lead to a pivoting of the functional device about the pivot axes.
[0013] The basic idea of the present invention is to carry out the exact orientation of a functional device, i.e., of a transmitter or of a receiver or of a combined transmitter/receiver unit or optionally of a reflector, which orientation is necessary for the correct function of an (open-path) gas detection device, by means of an adjusting device, which is connected with the respective functional device for the process of orientation only.
[0014] A gas detection device according to the present invention correspondingly comprises at least one functional device, which is fixed to a platform, is pivotable about at least two pivot axes relative to the platform and is designed to emit and/or receive or reflect an oriented radiation, which is analyzably variable due to the presence of a gas to be detected, and additionally an adjusting device, which has fixing means for temporary fixation to the platform and an application device for the defined application to the functional device of forces that lead to a pivoting about the pivot axes, wherein the application device is detachably connected to the functional device.
[0015] “Connected” is defined here such that the adjusting device cooperates with the platform or the functional device such that at least the transmission of the forces provided for pivoting the functional device about the pivot axis can take place.
[0016] The “platform” is a structure (designed such that it is immobile in relation to the intended detection area) to which the functional device can be or is permanently or detachably fixed. It may be, for example, a wall or an earth-fixed ground structure (e.g., a ground surface or a post anchored in the ground) or a baseplate that can be fastened to a wall or to an earth-fixed ground structure. A platform in the form of a stand that can be erected on the ground, e.g., a tripod.
[0017] The detachability according to the present invention of the adjusting device from the rest of the gas detection device makes it possible, on the one hand, to use an individual adjusting device for a plurality of functional devices, as a result of which the total costs for a gas detection device having a plurality of functional devices and/or for a gas detection system comprising a plurality of gas detection devices can be kept low. In addition, provisions may advantageously be made for the fixing device not to remain at a functional device of the gas detection device over a longer period of time. This makes it possible to design the adjusting device, regardless of the requirements that are dictated by a necessary long-term functionality in an environment characterized by adverse conditions, especially highly contaminated and/or highly corrosive environment, even though the gas detection device is intended, in principle, for use in such an environment. Construction details that are not suitable for long-term use in such an environment characterized by such adverse conditions can thus be implemented in the adjusting device. In particular, a relatively precise orientation mechanism can thus be used, whose components may be expensive and do not have to be suitable for long-term use in an environment characterized by adverse conditions.
[0018] Since the adjusting device is not preferably intended to remain permanently on the functional device, devices should be additionally provided for securing an orientation of the functional device set by means of the adjusting device. These may be integrated especially in pivot bearings (forming the pivot axes). In particular, these devices for securing an orientation may act in a non-positive manner and/or be based on fixing screws integrated in the pivot bearing. Provisions may, in this case, be made for the devices to be designed such that even during the orientation by means of the adjusting device, these generate a frictional resistance, which is so high that the orientation set is maintained after removal of the adjusting device. As an alternative, these may, however, also be designed such that these bring about only comparatively low frictional resistances during the orientation and are tightened only after completion of the orientation of the functional device (but with the adjusting device not yet removed).
[0019] The (open-path) gas detection device is preferably designed such that this has a first functional device, designed to emit the radiation, i.e., a transmitter, and a second functional device designed to receive the radiation, i.e., a receiver, which are each fixed to a platform and are provided at a defined distance (e.g., between about 4 m and about 200 m) for positioning in which they are oriented towards each other. Both functional devices may be preferably designed to be oriented by means of the same adjusting device, and to form for this the same connection points for the adjusting device.
[0020] However, the use of the adjusting device, which is detachable according to the present invention, is also advantageous in such an (open-path) gas detection device in which the functional device is designed to emit and to receive the radiation, i.e., as a transmitter/receiver unit, and, moreover, a reflector, which can be positioned independently from this functional device, is present (as a second functional device). Provisions may advantageously be made in case of such a design of the detection device as well to design both functional devices for being oriented by means of the same adjusting device, and to form the same connection points for the adjusting device for this.
[0021] An especially exact orientation of the functional device or of one of the functional devices can be achieved if the pivot axes are directed at right angles to one another. These may be oriented vertically and horizontally (in the position of the platform that is intended for the operation of the gas detection device).
[0022] Furthermore, provisions may advantageously be made for the application device to be designed such that the lines of application of the forces that can be generated by the application device are directed at right angles to one of the pivot axes. All the forces generated by the application devices can thus be used for the pivoting of the functional device, which pivoting brings about the orientation about the at least two pivot axes. Force components that are oriented in the direction of the pivot axes are largely avoided hereby, as a result of which stressing of the pivot bearings with these force components is, moreover, avoided. The pivot bearings may as a result possibly be dimensioned as relatively weak pivot bearings, as a result of which costs can be saved.
[0023] Provisions may be made in a preferred embodiment of the gas detection device according to the present invention for the application devices to be designed such that the lines of application of the forces that can be generated by these are located at the greatest possible distance of especially between 10 mm and 300 mm from the respective corresponding pivot axis. A comparatively high torque can thus be generated with comparatively weak forces. It may also be advantageous that as a consequence of the great distance, relatively large motions of the application devices lead to an only relatively small rotation of the functional device. A sufficiently precise orientation of the functional device may possibly be achieved as a result with an application device working relatively imprecisely and/or with a largely dimensioned application device. For example, designing the application device with a fine thread can be eliminated in case of an application device that is designed in the form of an adjusting screw.
[0024] Provisions may be made in another preferred embodiment of the gas detection device according to the present invention for the adjusting device to comprise a first carriage guided displaceably in a stand by a first adjusting element and a second carriage guided displaceably by a second adjusting element on the first carriage. This is an embodiment of the adjusting device with a simple design, with which exact adjustment paths of the application device can, moreover, be achieved along with easy handling. The adjusting elements may be designed, for example, as adjusting screws in a cost-effective manner.
[0025] An embodiment of the adjusting device with an especially simple design can be obtained if the application device comprises at least one pair and preferably two pairs of adjusting elements, especially adjusting screws, which act on opposite sides of the detection device. A precise orientation of the functional device can be achieved by simultaneous, opposite adjustment of the pairs of adjusting elements.
[0026] Besides cost-effective adjusting elements in the form of adjusting screws, the application device may preferably (also) have adjusting actuators, which make it possible to orient the functional device even without manual action. As a result, it is possible to create especially a gas detection device that can be oriented fully automatically. This may also have for this a control device for determining the adjusting deviation from a desired orientation. This control device may then be connected with the adjusting actuators of the application device in a signal-carrying manner and designed for automatic orientation of the functional device as a function of the adjusting deviation determined.
[0027] The adjusting actuators may be designed, for example, in the form of electric stepper motors, servomotors, motor/gear combinations and/or piezo motors. Pneumatic or hydraulic actuators may be used as well.
[0028] The adjusting actuators may be supplied with control signals by the control device. The adjusting deviation can be determined from a measurement of the intensity of the radiation output transmitted. If only this is available as an actuating variable, the control unit may have an algorithm, with which the orientation of the functional device that corresponds to the maximum radiation output can be determined. Such algorithms are known. If measured values concerning a deflection of the functional device from the optical axis are additionally available, a usual control algorithm, e.g., with a proportional-integral-differential component (PID controller) may also be sufficient.
[0029] The adjusting actuators and/or the control device can be supplied with energy via an energy supply unit intended for the functional device (especially the radiation source and/or the detector) and/or a separate energy supply unit. A separate energy may be embodied by means of a supply line connected temporarily for connection to an electric supply network and/or by means of batteries.
[0030] The present invention will be explained in more detail below on the basis of exemplary embodiments shown in the drawings. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a front view of a first embodiment of a gas detection device according to the present invention;
[0032] FIG. 2 is a perspective view of the gas detection device according to FIG. 1 ;
[0033] FIG. 3 is a perspective view of the adjusting device of the gas detection device according to FIGS. 1 and 2 ;
[0034] FIG. 4 is a front view of a second embodiment of a gas detection device according to the present invention;
[0035] FIG. 5 is a perspective view of the gas detection device according to FIG. 4 ;
[0036] FIG. 6 is a perspective view of the adjusting device of the gas detection device according to FIGS. 4 and 5 ;
[0037] FIG. 7 is a front view of a third embodiment of a gas detection device according to the present invention;
[0038] FIG. 8 is a perspective view of the gas detection device according to FIG. 7 ;
[0039] FIG. 9 is a schematic view showing two functional devices at ends of a defined measuring section;
[0040] FIG. 10 is a schematic view showing two functional devices at ends of a defined measuring section;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] Referring to the drawings, the gas detection device of the invention comprises a detection unit shown in FIGS. 1 through 3 comprising a functional device 1 , which is connected with a platform pivotably about two pivot axes 2 , 3 . The platform comprises a baseplate 4 and a mounting frame rigidly connected to it.
[0042] The mounting frame comprises a pivot bearing arrangement (pivot mount arrangement) 50 with two pairs of pivot bearings 5 . The two pivot bearings 5 of each pair are arranged coaxially and form one of the pivot axes 2 , 3 as a result. Via a first pair of pivot bearings 5 , the functional device 1 is mounted rotatably about a first pivot axis 2 , which is directed at right angles in the figures, within a bearing ring 6 . The bearing ring 6 is mounted, in turn, between two beams 7 of the mounting frame via a second pair of pivot bearings 5 about the second pivot axis 3 , which is directed at right angles to the first pivot axis 2 . The functional device 1 can thus be pivoted, i.e., rotated within limits, relative to the bearing ring 6 about the first pivot axis 2 and together with this about the second pivot axis 3 , but always relative to the baseplate 4 (and the beam 7 ). The pivot bearing arrangement permits a superposition of these two pivoting motions, so that the functional device 1 can be pivoted, in principle, in any desired directions.
[0043] The functional device 1 may be a transmitter, a receiver or a transmitter/receiver unit of the gas detection device. If it is a transmitter or a receiver, the gas detection device also comprises another functional device 1 , which is not shown in the figures and which may be mounted corresponding to the functional device 1 shown. In particular, provisions may be made for the additional functional device 1 to differ only concerning the equipment with functional elements accommodated in a housing 8 of the functional device 1 . While a functional device 1 designed as a transmitter has especially a radiation source for directed radiation, especially light radiation, for example, a xenon lamp or a laser, a functional device 1 designed as a receiver comprises especially a detector for the corresponding radiation. The two functional devices 1 are intended in this case for positioning at the two ends of a defined measuring section 120 , in which case the most exact orientation possible in relation to one another, especially coaxiality of the optical axes of the radiation source and detector, shall be provided.
[0044] In addition, one or more computer units 110 , which may act as control and/or analyzing devices, may be integrated in both types of functional devices 1 . However, these computer units 110 may also be arranged outside the housing 8 of the functional device 1 and connected especially with the radiation source and the detector in a signal-carrying manner (in a wired or wireless manner).
[0045] The functional device 1 may be a transmitter/receiver unit, which thus comprises a radiation source and a corresponding detector and optionally a computer unit. Such a functional device 1 may be combined with a reflector 101 , which is arranged at the corresponding other end of the defined measuring section and reflects radiation from the radiation source into the detector. This also requires the most exact orientation possible of the functional device 1 and of the reflector 101 in relation to one another.
[0046] The baseplate 4 is provided for being placed on or in contact with a ground surface or a wall. FIGS. 1-8 show an orientation of the gas detection device in case it is placed on a ground surface. The baseplate 4 may have a fastening device, which can be used for fastening on the ground surface (or a wall). The fastening device may be, for example, access openings, through which extend the screws that can be screwed with a thread formed or to be formed in the ground surface or a wall.
[0047] An adjusting device 9 of the gas detection device is connected with the baseplate 4 , on the one hand, and with the housing 8 of the functional device 1 , on the other hand. The adjusting device 9 comprises a stand 10 , which is detachably connected with the baseplate 4 via a fastening device with one or more fastening elements. The fastening elements in the exemplary embodiment shown in FIGS. 1 through 3 are designed in the form of spring shackles 23 , which are elastically deformed when sections of a foot 13 of the stand 10 are pushed into the gap formed between the spring shackles 23 and the top side of the baseplate 4 , as a result of which the stand 10 is pressed against the baseplate 4 and is held on same.
[0048] Alternative fastening elements, for example, fastening screws 11 extending through passage openings of the stand 10 and meshing with threads of the baseplate 4 , as they are shown in the exemplary embodiment according to FIGS. 4 through 6 , are equally possible. Threaded bolts, which are rigidly connected with the baseplate 4 , extend through passage openings of the stand 10 and are screwed onto the nuts (not shown), may be provided as well.
[0049] An adjusting screw 12 or spindle is mounted rotatably in the foot 13 and a head 14 of the stand 10 . The adjusting screw 12 cooperates with a first carriage 15 of the adjusting device 9 such that its rotation leads to a translatory displacement of the first carriage 15 along the longitudinal axis of the adjusting screw 12 and thus at right angles to (and at a spaced location from) the second pivot axis 3 of the bearing arrangement. The first carriage 15 is guided nonrotatably by a guide projection 22 of the stand 10 , which meshes (engages) with a guiding groove of the first carriage 15 .
[0050] A second carriage 16 is mounted movably on the first carriage 15 , and a motion of the second carriage 16 is directed at right angles to a motion of the first carriage 15 , which can be brought about by the adjusting screw 12 , and thus at right angles to (and at a spaced location from) the first axis of rotation 2 of the bearing arrangement.
[0051] The end face of the second carriage 16 facing the functional device 1 contacts the housing 8 of the functional device 1 and is detachably connected with this via fasteners, not shown. The fastening device should be designed in this case such that these forces can be transmitted in all directions of motion made possible by the adjusting device 9 for the second carriage 16 thereof. The fastening device may be designed, for example, in the form of a screw connection.
[0052] Due to a rotation of the adjusting screw 12 brought about manually, the first carriage 15 can be displaced along the longitudinal axis of the adjusting screw 12 , which leads to a partial rotation or a pivoting of the functional device 1 about this second pivot axis 3 as a consequence of the force-transmitting connection between the adjusting device 9 and the functional device 1 and the distance between the connection point and said second pivot axis 3 . The adjusting screw 12 has a rotary knob 17 on the head side for this.
[0053] Displacement of the second carriage 16 on the first carriage 15 leads, by contrast, to a pivoting of the functional device ( 1 ) about the first pivot axis 2 . The displacement of the second carriage 16 is likewise brought about by manual rotation of a rotary knob (not shown) in the exemplary embodiment according to FIGS. 1 through 3 . This rotation is reduced via a gear mechanism mounted in the second carriage 16 to a toothed gear 18 , which meshes with a toothed rack contour 19 of the first carriage 15 . The gear mechanism is designed such that a displacement of the second carriage 16 is possible by turning the rotary knob, while a direct displacement of the second carriage 16 (and a turning of the rotary knob associated therewith), which is brought about by external forces, is prevented by a self-locking device.
[0054] Instead of the actuating drive of the second carriage 16 , which is shown in FIGS. 1 through 3 and comprises a combination of the rotary knob, gear mechanism, toothed gear 18 and toothed rack contour 19 , an adjusting screw (not shown), which is mounted rotatably in the first carriage 15 and cooperates with the second carriage 16 , may also be provided for this second carriage 16 .
[0055] By turning the two rotary knobs, the functional device 1 can be pivoted such that the desired orientation relative to the additional functional device 1 , not shown here, is achieved. As soon as the desired orientation is achieved and secured, the adjusting device 9 can be separated from the baseplate 4 and the functional device 1 , by loosening the fastening elements of the fastening device, and the adjusting device 9 can be removed. This adjusting device 9 is available in this case for orienting another functional device 1 of the said gas detection device or of another gas detection device, which said functional device 1 has corresponding interfaces for the adjusting device.
[0056] Securing of the orientation of the functional device 1 , once achieved, can be achieved, for example, by means of fixing screws (not shown), which are integrated in the pivot bearing 5 and which are tightened in advance, before removal of the adjusting device 9 and increase the friction in the pivot bearings 5 to the extent that an unintended change in the set orientation is prevented in case of forces normally acting on the functional device during the operation of said functional device. Instead of fixing screws, it is also possible to use other fixing devices, especially quick-closing devices, for example, bayonet catches or tension levers. As an alternative, the pivot bearings 5 may also be designed such that these generate basically a relatively high frictional resistance, which can be overcome by the action of the adjusting device 9 without problems, but it prevents an unintended adjustment after removal of the adjusting device 9 .
[0057] The second embodiment of a gas detection device according to the present invention shown in FIGS. 4 through 6 differs from the first embodiment according to FIGS. 1 through 3 —besides in the type of the fastening elements for fastening the stand 10 on the baseplate 4 —essentially only in respect to the adjusting elements used to displace the first carriage 15 and the second carriage 16 . Electric adjusting actuators are used here. An electric servo motor (not visible) each, whose drive shafts are connected directly or indirectly with a respective toothed gear 18 for rotation in unison, and which mesh with toothed rack contours 19 of the stand 10 as well as of the first carriage 15 , is integrated in both the first carriage 15 and the second carriage 16 .
[0058] FIGS. 7 and 8 show an embodiment of an adjusting device 9 having an especially simple design for a gas detection device that otherwise corresponds to the exemplary embodiments according to FIGS. 1 through 6 .
[0059] The adjusting device 9 comprises a strap-shaped frame 20 , whose two free ends form feet 13 , which are connected with the baseplate 4 via detachable fastening elements of the fastening device, in the form of fastening screws 11 , which pass through passage openings of the frame 20 and mesh with threads of the baseplate 4 . The frame 20 spans over the corresponding section of the housing 8 of the functional device 1 at a sufficiently great distance in order to make possible the pivoting of the functional device 1 in a defined pivoting range. At three points, the frame 20 forms internal threads, into which adjusting screws 21 are screwed. By rotating the adjusting screws 21 , these can be moved in the direction of the housing 8 of the functional device 1 or away from same. Two of the three adjusting screws 21 are oriented coaxially. This pair of adjusting screws 21 thus forms a common (here horizontal) axis of motion, which is directed in parallel to the second pivot axis 3 and hence at right angles to the first pivot axis 2 of the bearing arrangement. The functional device 1 can be pivoted about the first pivot axis 2 by screwing in one adjusting screw 21 and unscrewing the other adjusting screw 21 of this pair simultaneously.
[0060] Pivoting of the functional device 1 about the second pivot axis 3 can be brought about by screwing in or unscrewing the third, central adjusting screw 21 , whose axis of motion is directed at right angles to the axis of motion of the other adjusting screw 21 . To ensure contact at all times between the contact end of the central adjusting screw 21 and the housing 8 of the functional device 1 , provisions may be made for the housing 8 to be acted on by means of a spring element, whose spring force brings about a pivoting motion about the second pivot axis 3 in the direction of the central adjusting screw 21 (insofar as permitted by this) (not shown). It is likewise possible to provide a fixation between the central adjusting screw 21 and the housing 8 , which fixation is detachable, allows a relative rotation, and can also transmit tensile forces besides forces of pressure (the same adjusting screw 21 can pull and push the functional device 1 ).
[0061] Provisions may also be made in another embodiment, not shown, for the frame 20 to be additionally provided with a strap, which surrounds the lower half of the housing 8 and in which a fourth adjusting screw, which is arranged coaxially with the upper, central adjusting screw 21 , is integrated. Pivoting of the functional device 1 about the second pivot axis 3 could now be brought about by screwing these adjusting screws 21 in and out simultaneously, such as this is also provided for in the exemplary embodiment according to FIGS. 7 and 8 for pivoting about the first pivot axis 2 .
[0062] FIG. 9 shows a detection unit 100 at a platform 4 at a first location and another detection unit 100 ′ is shown at a platform 4 that is at a second location. The platforms 4 are shown with different orientations, but the particulars as to each platform 4 are not important in the schematic showing. The locations of the platforms 4 are spaced apart and are at ends of a measuring section 120 . The functional unit 1 of the detection unit 100 is a transmitter and the functional unit 1 of the detection unit 100 ′ is a receiver. Each detection units 100 and 100 ′ is supported by a pivot arrangement 50 comprising pivot bearings 5 , bearing ring 6 and beams 7 as described with reference to FIGS. 1-8 . Each of the detection units 100 and 100 ′ has an adjusting device 9 as shown in 4 - 6 . The adjusting device 9 is shown with a connected computer unit 110 , which may be used as a control device for the automatic orientation of the functional device 1 as a function of the adjusting deviation determined. The orientation of the functional units 1 is established by controlling the adjusting actuators (servo motors) of the adjusting device 9 . As noted above, the connection 130 may be a wired or wireless connection and the computer 110 may instead be integrated in or attached with the adjusting device 9 or the functional unit 1 . Also, as mentioned, only one adjusting device 9 may be used to establish the orientation of the functional device 1 of the detection unit 100 at the first location and the same adjusting device 9 may be used to establish the orientation of the functional device 1 of the detection unit 100 ′ at the second location.
[0063] FIG. 10 shows a configuration of detection units at a defined measuring section 120 that is similar to the configuration shown in FIG. 9 . However, in FIG. 10 , the detection unit 100 ″ has a functional unit 1 that is a transmitter/receiver that interacts with a detection unit 111 that has a functional unit 101 that is a reflector.
[0064] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
[0000]
APPENDIX
List of Reference Numbers
1
Functional device
2
First pivot axis
3
Second pivot axis
4
Baseplate
5
Pivot bearing
6
Bearing ring
7
Beam
8
Housing
9
Adjusting device
10
Stand
11
Fastening screw
12
Adjusting screw
13
Foot of stand
14
Head of stand
15
First carriage
16
Second carriage
17
Rotary knob
18
Toothed gear
19
Toothed rack contour
20
Frame
21
Adjusting screw
22
Guiding projection
23
Spring shackle
50
Pivot mount arrangement
100, 100′ 100″
Detection unit
101
Functional device (reflector)
111
Detection unit (with reflector)
110
Computer unit
120
Measuring section
130
connection | A gas detection device with at least one functional device ( 1 ), which is fixed to a platform, is pivotable about at least two pivot axes ( 2, 3 ) relative to the platform. The functional device ( 1 ) is designed to emit and/or receive or reflect radiation that is analyzably variable due to the presence of a gas to be detected. The gas detection device has an adjusting device ( 9 ), which has a fixing device for temporary fixation to the platform and an application device for the defined application on the functional device ( 1 ) of forces that lead to a pivoting about the pivot axes ( 2, 3 ). The application device acts detachably on the functional device ( 1 ). | 6 |
[0001] This application claims priority from provisional application No. 60/268,528 filed Feb. 14, 2001.
BACKGROUND OF THE INVENTION
[0002] The emulsion polymerization at moderate pressure of vinylidene fluoride using fluorinated surfactant and, as a free-radical initiator, diisopropyl peroxydicarbonate (hereinafter referred to as IPP) is taught in U.S. Pat. No. 3,475,396 dated Oct. 28, 1969. The same patent teaches that the amount of fluorinated surfactant necessary in the system can be reduced if a chain transfer agent is present in the reaction system. The process was refined in U.S. Pat. No. 3,857,827 dated Dec. 31, 1974 wherein a particularly high molecular weight product was produced in a relatively fast reaction by the use of IPP initiator dissolved in a solution of acetone (the acetone acting as a chain transfer agent).
[0003] The process was further refined in U.S. Pat. No. 4,360,652 dated Nov. 23, 1982, which taught that high quality polymers were achieved when IPP (as an aqueous emulsion using a fluoroalkyl surfactant), isopropyl alcohol (hereinafter, IPA; used as the chain transfer agent) and monomer are added separately but simultaneously to an aqueous solution of the surfactant, either incrementally or continuously over the polymerization cycle.
[0004] In EP-387,938 vinylidene fluoride polymerization using peroxy disulfate as initiator and an alkyl acetate as a chain transfer agent (molecular weight regulator) is shown. Use of polar compounds as chain transfer agents introduces polar end-groups onto the molecular chains which causes the phenomenon of product discoloration and possibly cavities at the high temperatures encountered during the melt processing stage where the temperature can be in the vicinity of 550° F. (about 288° C.).
[0005] U.S. Pat. No. 4,569,978 disclosed the use of trichlorofluoromethane as a chain transfer agent to reduce or eliminate the discoloration and cavity formation phenomenon but this is an ozone depleting material and its use is being banned worldwide.
[0006] U.S. Pat. No. 5,473,030 proposes the substitution of 1,1,1-trifluoro 2,2-dichloroethane (HCFC-123) as a chain transfer agent to replace trichlorofluoromethane (CFC-11), but in practice this has not proven to be the answer, particularly to the discoloration problem.
[0007] U.S. Pat. No. 3,635,926 dated Jan. 18, 1972 discloses an aqueous process for making TFE/PVE copolymers in presence of chain transfer agents such as hydrogen and methane in combination with CFCs and HCFCs. In this patent only perfluoro-monomers (mainly TFE) were considered and methane was the most preferred chain transfer agent since it exhibited a reasonable chain transfer activity in the polymerization of perfluoro-monomers; however, high alkanes, including ethane were reported to be too active to be used in polymerization due to undesired (slowing) effect on polymerization rate.
[0008] EP 617058 demonstrates that combinations of branched aliphatic alcohols with lower alkanes in the polymerization of perfluoro-monomers (mainly TFE) were an effective chain regulator and improved melt flow index of perfluoro-polymers.
[0009] In contrast to above disclosures regarding perfluorinated monomers, surprisingly, it has been found that the use of the hydrocarbon ethane as a chain transfer agent in the vinylidene fluoride polymerization process results, particularly in the case of vinylidene fluoride homopolymers, in a product which has a reduced tendency to generate cavities at the high temperatures encountered in typical forming processes and which has a greater tendency to resist discoloration at those same temperatures.
[0010] Addition of ethane to the polymerization of VF2 introduces a number of ethyl group chain terminations. The ethyl group is non-polar, inert, and not heat degradable and as a result the vinylidene fluoride polymers with such ethyl chain ends exhibit greater tendency to resist discoloration at the normal processing temperature of PVDF.
[0011] The introduction of hydrocarbons in general into any polymerization reaction is known to have an unpredictable effect. For any given reaction, any particular hydrocarbon may have no effect. In fluorocarbon polymer synthetic reactions it has always been thought that hydrocarbons would simply slow down the reaction rate to unacceptable levels even though the effect of hydrocarbons on vinylidene fluoride polymerizations has not been previously reported to applicants' knowledge. Neither has the fact that ethane is unique in being an efficient chain transfer agent been previously suggested. Still more surprisingly, in the present work, ethane has been shown to be about four times as efficient as trichlorofluoromethane. The initiator consumption is also independent of ethane concentration in the process and the need for any other chain transfer agent is eliminated. In the previously disclosed polymerization of perfluoromonomers where hydrocarbons were employed, more active chain transfer agents such as branched alcohol, chlorocarbons, etc., were present.
SUMMARY OF THE INVENTION
[0012] The invention provides in a first composition aspect, a vinylidene fluoride polymer containing at least some molecular chains having ethyl groups on at least one chain end.
[0013] The products of the first composition aspect of the invention, particularly vinylidene fluoride homopolymers, are light colored polymers which resist discoloration and cavitation at normal temperatures for extrusion or other fabrication techniques. Such products have the inherent applied use characteristics known for vinylidene fluoride polymers.
[0014] The invention provides in a first process aspect, a process for the preparation of vinylidene fluoride polymers, optionally in the presence of other fluorinated olefins, in an aqueous medium in the presence of a radical initiator and of ethane as a chain transfer agent.
[0015] Special mention is made of processes of the first process aspect of the invention wherein vinylidene fluoride homopolymer is produced. Special mention is also made of processes of the first process aspect of the invention wherein free radical initiators such as n-propyl peroxydicarbonate or diisopropyl peroxydicarbonate are used.
DETAILED DESCRIPTION
[0016] The manner of practicing the invention will now be generally described with respect to a specific embodiment thereof, namely polyvinylidene fluoride based polymer prepared in aqueous emulsion polymerization.
[0017] The polymers are conveniently made by an emulsion polymerization process, but suspension and solution processes may also be used. In an emulsion polymerization process, a reactor is charged with deionized water, water-soluble surfactant capable of emulsifying the reactant mass during polymerization and paraffin antifoulant.
[0018] The mixture is stirred and deoxygenated. A predetermined amount of ethane is then introduced into the reactor, the reactor temperature raised to the desired level and vinylidene fluoride fed into the reactor. Once the initial charge of vinylidene fluoride is introduced and the pressure in the reactor has reached the desired level, an initiator emulsion is introduced to start the polymerization reaction. The temperature of the reaction can vary depending on the characteristics of the initiator used and one of skill in the art will know how to do so. Typically the temperature will be from about 60° to 120° C., preferably from about 70° to 110° C.
[0019] Similarly, the polymerization pressure may vary, but, typically it will be within the range 40 to 50 atmospheres. Following the initiation of the reaction, the vinylidene fluoride is continuously fed along with additional initiator to maintain the desired pressure. Once the desired amount of polymer has been reached in the reactor, the monomer feed will be stopped, but initiator feed is continued to consume residual monomer. Residual gases (containing unreacted monomer and ethane) are vented and the latex recovered from the reactor. The polymer may then be isolated from the latex by standard methods, such as, acid coagulation, freeze thaw or high shear.
[0020] Although the process of the invention has been generally illustrated with respect to the polymerization of vinylidene fluoride homopolymer, one of skill in the art will recognize that analogous polymerization techniques can be applied to the preparation of copolymers of vinylidene fluoride with coreactive monomers fluorinated or unfluorinated such as hexafluoropropylene and the like. Analogous techniques can also be applied using ethane as a chain transfer agent in the polymerization of other fluorinated polymers both homopolymers and copolymers, although the processes of U.S. Pat. No. 3,635,926 should be avoided.
[0021] When copolymerization of vinylidene fluoride and hexafluoropropylene are performed, or copolymerization of any two coreactive fluorinated monomers having differing reaction rates, the initial monomer charge ratio and the incremental monomer feed ratio during polymerization can be adjusted according to apparent reactivity ratios to avoid compositional drift in the final copolymer product.
[0022] Surfactants suitable for use in the polymerization are well known in the art and are typically water soluble halogenated surfactants, especially fluorinated surfactants such as the ammonium, substituted quaternary ammonium or alkali metal salts of perfluorinated or partially fluorinated alkyl carboxylates, the perfluorinated or partially fluorinated monoalkyl phosphate esters, perfluorinated or partially fluorinated alkyl ether or polyether carboxylates, the perfluorinated or partially fluorinated alkyl sulfonates, and the perfluorinated or partially fluorinated alkyl sulfates. Some specific, but not limiting examples are the salts of the acids described in the U.S. Pat. No. 2,559,752 of the formula X (CF 2 ) n COOM, wherein X is hydrogen or fluorine, M is an alkali metal, ammonium, substituted ammonium (e.g., alkylamine of 1 to 4 carbon atoms), or quaternary ammonium ion, and n is an integer from 6 to 20; sulfuric acid esters of polyfluoroalkanols of the formula X (CF 2 ) n CH 2 OSO 3 M, where X and M are as above; and salts of the acids of the formula CF 3 (CF 2 ) n (CX 2 ) m SO 3 M, where X and M are as above; n is an integer from 3 to 7, and m is an integer from 0 to 2, such as in potassium perfluoroctyl sulfonate. The use of a microemulsion of perfluorinated polyether carboxylate in combination with neutral perfluoropolyether in vinylidene fluoride polymerization can be found in EP0816397AI and EP722882. The surfactant charge is from 0.05% to 2% by weight on the total monomer weight used, and most preferably the surfactant charge is from 0.1% to 0.2% by weight.
[0023] The paraffin antifoulant is optional, and any long-chain, saturated, hydrocarbon wax or oil may be used. Reactor loadings of the paraffin typically are from 0.01% to 0.3% by weight on the total monomer weight used.
[0024] The ethane may be added all at once at the beginning of the reaction, or it may be added in portions, or continuously throughout the course of the reaction. The amount of ethane added as a chain transfer agent and its mode of addition depends on the desired molecular weight characteristics.
[0025] The amount of ethane added depending on desired molecular weight may be from about 0.05% based on total monomer weight used, preferably from about 0.1% to about 5%. It has been found that substitution of methane for ethane shows no chain transfer effect in polyvinylidene fluoride polymerizations and substitution of propane and higher hydrocarbons significantly slows the polymerization rate to levels that are totally unacceptable for practical use.
[0026] The reaction can be started and maintained by the addition of any suitable initiator known for the polymerization of fluorinated monomers including inorganic peroxides, “redox” combinations of oxidizing and reducing agents, and organic peroxides. Examples of typical inorganic peroxides are the ammonium or alkali metal salts of persulfates, which have useful activity in the 65° C. to 105° C. temperature range. “Redox” systems can operate at even lower temperatures and examples include combinations of oxidants such as hydrogen peroxide, t-butyl hydroperoxide, cumene hydroperoxide, or persulfate, and reductants such as reduced metal salts, iron (II) salts being a particular example, optionally combined with activators such as sodium formaldehyde sulfoxylate, metabisulfite, or ascorbic acid. Among the organic peroxides which can be used for the polymerization are the classes of dialkyl peroxides, diacyl-peroxides, peroxyesters, and peroxydicarbonates. Exemplary of dialkyl peroxides is di-t-butyl peroxide, of peroxyesters are t-butyl peroxypivalate and t-amyl peroxypivalate, and of peroxydicarbonate, and di(n-propyl) peroxydicarbonate, diisopropyl peroxydicarbonate, di(sec-butyl) peroxydicarbonate, and di(2-ethylhexyl) peroxydicarbonate. The use of diisopropyl peroxydicarbonate for vinylidene fluoride polymerization and copolymerization with other fluorinated monomers is taught in U.S. Pat. No. 3,475,396 and its use in making vinylidene fluoride/hexafluoropropylene copolymers is further illustrated in U.S. Pat. No. 4,360,652. The use of di(n-propyl) peroxydicarbonate in vinylidene fluoride polymerizations is described in the Published Unexamined Application (Kokai) JP 58065711. The quantity of an initiator required for a polymerization is related to its activity and the temperature used for the polymerization. The total amount of initiator used is generally between 0.05% to 2.5% by weight on the total monomer weight used. Typically, sufficient initiator is added at the beginning to start the reaction and then additional initiator may be optionally added to maintain the polymerization at a convenient rate. The initiator may be added in pure form, in solution, in suspension, or in emulsion, depending upon the initiator chosen. As a particular example, peroxydicarbonates are conveniently added in the form of an aqueous emulsion.
[0027] The term “vinylidene fluoride polymer” used herein for brevity includes both normally solid, high molecular weight homopolymers and copolymers within its meaning. Such copolymers include those containing at least 50 mole percent of vinylidene fluoride copolymerized with at least one comonomer selected from the group consisting of tetrafluoroethylene, trifluoroethylene, chlorotrifluoroethylene, hexafluoropropene, vinyl fluoride, pentafluoropropene, and any other monomer that would readily copolymerize with vinylidene fluoride. Particularly preferred are copolymers composed of from at least about 70 and up to 99 mole percent vinylidene fluoride, and correspondingly from 1 to 30 percent tetrafluoroethylene, such as disclosed in British Patent No. 827,308; and about 70 to 99 percent vinylidene fluoride and 1 to 30 percent hexafluoropropene (see for example U.S. Pat. No. 3,178,399); and about 70 to 99 mole percent vinylidene fluoride and 1 to 30 mole percent trifluoroethylene. Terpolymers of vinylidene fluoride, hexafluoropropene and tetrafluoroethylene such as described in U.S. Pat. No. 2,968,649 and terpolymers of vinylidene fluoride, trifluoroethylene and tetrafluoroethylene are also representatives of the class of vinylidene fluoride copolymers which can be prepared by the process embodied herein.
[0028] The following Example is provided to further illustrate the best mode of practicing the invention and is not to be construed in limitation thereof.
EXAMPLE
[0029] Following the general procedure described above, polyvinylidene fluoride was polymerized in a horizontal reactor in a series of comparative runs using as a control a run where no ethane or other chain transfer agent was employed, varying amounts of ethane and as another control an amount of ethyl acetate (EA).
[0030] The results of these runs are shown in the Table.
[0031] In the Table, melt viscosity was determined by ASTM D3835 at the temperature and time indicated. Melting points were determined by Differential Scanning Colorimetry using ASTM 3418.
TABLE Effects of ethane concentration on melt viscosity and melting temperature. g of Melt Viscosity ethane/2000 g @230° C. Run No. VF2 &100 s −1 Tm ° C. 1 0 39.6 163.4 2 5.2 28.3 164.4 3 10.7 24.3 164.2 4 19.1 12.1 163.5 5 25.3 5.8 163.5 6 9.1 (EA) 16.8 165.4
[0032] The subject matter which applicants regard as their invention is particularly pointed out and distinctly claimed as follows: | Vinylidene fluoride polymers are produced by using ethane as a chain transfer agent in the emulsion polymerization process. Vinylidene fluoride homopolymers made by the process have a significantly reduced tendency to generate cavities at high temperatures and a greater resistance to discoloration at high temperatures. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a device and a method for the physiological frequency control of a heart pacemaker equipped with a stimulating electrode by means of a control unit as well as to a method for operating such a device.
The most common applications of pacemaker therapy are the permanent and the temporary electrostimulation of the heart. On occassion, a combination of both methods may be necessary in cases which cannot be judged unequivocally. Permanent electrostimulation of the heart is used if Adams-Strokes attacks occur or in the event of total AV block (AV=atrioventricular node). In cases of bradycardic heart arrhythmia, temporary electrostimulation of the heart must be provided so that the physical capacity of the patient is improved.
For the permanent electrostimulation of the heart, heart pacemakers are known which contain a fixed frequency generator which delivers, for instance, 70 current pulses per minute at a constant rate. These heart pacemakers are of simple design and have a long service life even with standard chemical batteries. Such heart pacemakers can be used particularly for older people for whom a heart time-volume on the basis of 70 beats per minute is sufficient for their still tolerable extent of physical stress. In addition, the rhythm of the patient's heart itself is suppressed at least approximately. If spontaneous actions by the patient occur from one or several automation centers, the parasystolic behavior can lead not only to an irregular beat sequence with bunched occurrence of disturbed pacemaker pulses; it also can trigger, in particular, tachycardic states all the way to chamber fibrillation if the artificial stimuli fall into the valnerable phase, i.e., the T-wave of the intrinsic preceding action.
In addition, different types of so-called demand pacemakers are known. In demand sets, the pulse of the heart pacemaker is inhibited via an electrode located in the ventricle by the potential of the R-spike of the intrinsic actions as long as its frequency is above, for instance, 70 beats per minute. If it drops below this value, the device is switched on automatically and takes over the stimulation. In the "stand-by-pacer," the R-spike of the intrinsic rhythm acts, via the electrode, as a trigger pulse, to which the pacemaker is subordinated in the frequency range, for instance, of between 70 and 150 beats per minute with matched signal lapse. If intrinsic pulses are missing or if the R-spike spacings are smaller than between 300 and 400 msec, artificial stimulation is applied. If, however, the latter exceeds an upper predetermined pulse per minute value of, for instance, 150, the heart pacemaker cuts the frequency in half, i.e., it takes over the electrical stimulation of the heart with a correspondingly reduced pulse delivery. With these two types of demand pacemakers, the parasystolic state is avoided and an orderly side by side arrangement of the internal rhythm and artifical stimulation is obtained.
Furthermore, an electrochemical device for determining the oxygen content of a liquid is known. The measuring cell of this device consists of a tubular body in which a cathode and an anode are arranged in an electrolyte. The one end face of the measuring cell is provided with a diaphragm which is fastened by a sealing ring and a cap provided with an opening. This diaphragm separates the liquid to be examined from the electrode arrangement. The measurement principle consists of the electrochemical reduction of oxygen (O 2 ) where an oxygen diffusion limiting current is brought about at the electrode through the diaphragm. Thereby a measuring signal proportional to the concentration if obtained (U.S. Pat. No. 2,913,386). With a measuring cell of such a design, the oxygen concentration in the blood or tissue can be measured in vivo, however, only for a short time, for instance, for several days since the measuring cell becomes surrounded by developing connective tissue layers, and the measuring signal is thereby falsified.
It is, thus, an object of the present invention to describe a heart pacemaker which makes possible a mode of operation which is adapted to the physiology, is simple and trouble-free.
SUMMARY OF THE INVENTION
According to the present invention this problem is solved by a pacemaker to which an oxygen measuring electrode is connected. A control unit senses the potential between the charged oxygen electrode and either the stimulating electrode or a reference electrode and utilizes the measuring oxygen level to set a desired heart rate with appropriate outputs then provided to the pacemaker so that the stimulating electrode is stimulated at the desired rate.
In a first embodiment of the device according to the present invention, the O 2 measuring electrode is always loaded by a stimulating pulse in parallel with the stimulating electrode. In each instance, prior to the next loading of the O 2 measuring electrode (and of the stimulating electrode) the potential of the O 2 measuring electrode is measured referred to a reference electrode. The measured potential corresponds to the oxygen concentration of the blood or the heart muscle tissue. An electronic processing circuit assigns to each potential of the O 2 measuring electrode, an oxygen concentration level and regulates the frequency, i.e., the number of beats per minute of the heart, as an inverse function of oxygen concentration. Thus, a heart pacemaker with an implantable oxygen sensor which makes possible a mode of operation adapted to the physiology is obtained.
The invention also includes a method for physiological frequency control of heart pacemaker device having a stimulating electrode, a heart pacemaker and an oxygen level measuring electrode connected in parallel and coupled to the heart pacemaker. The method comprises the steps of placing the oxygen level measuring electrode in the blood or the body tissue, loading the oxygen level measuring electrode in the stimulating electrode with stimulating voltage pulses at a variable frequency, measuring the potential of the oxygen level measuring electrode relative to the stimulating electrode between stimulating voltage pulses and controlling the stimulating voltage pulse frequency of the pacemaker as an inverse function of the measured potential.
In a second embodiment of the device according to the present invention, the O 2 measuring electrode is likewise loaded in parallel with the stimulating electrode by a stimulating pulse. In this case, however, the potential difference between the O 2 measuring electrode and the stimulating electrode prior to the next loading of the O 2 measuring electrode is sensed. The O 2 measuring electrode preferably is comprised of smooth vitreous carbon and the stimulating electrode preferably of activated vitreous carbon. Such a stimulating electrode has a large double-layer capacity, which results in low polarization. If the oxygen concentrations in the blood or the tissue change quickly, the stimulating electrode of activated vitreous carbon maintains its potential, but the O 2 measuring electrode of smooth vitreous carbon changes its potential as a function of the oxygen concentration. By forming the difference of the potentials, possible influences which may become active for both electrodes, of substances of the body, the concentrations of which change more slowly than those of the oxygen, are eliminated. Thus, oxygen concentrations in the blood or the tissue which change quickly can be measured and the frequency of the heart pacemaker can be controlled accordingly.
In the device according to the present invention, the heart pacemaker and the control unit advantageously form a common structural unit. In addition, the lines of the O 2 measuring electrode and of the reference electrode can be arranged together with the line of the stimulating electrode in an electrode cable. In this manner, a physiologically controlled heart pacemaker is obtained, the design of which is not appreciably larger than known heart pacemaker designs. Furthermore, the operative intervention does not become more complicated by this design.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a device according to the present invention.
FIG. 1A is a partial block diagram showing an alternative to the embodiment of FIG. 1.
FIG. 2 illustrates calibration curves for the oxygen sensor of FIG. 1.
FIG. 3 is a wave form diagram for the device according to FIG. 1.
FIG. 4 is a flow diagram of the program in the processor of FIG. 1.
DETAILED DESCRIPTION
FIG. 1 illustrates the device of the present invention which is generally indicated by the elements within the dotted block 100. Included is a heart pacemaker 2 of conventional design and a control unit 4. Within the control unit 4 is a processor 101, a sample and hold circuit 103, an analog to digital converter 105, and switches indicated as S2 and S3. Associated with the pacemaker is a counter electrode 6 and a stimulating electrode 10 each at the end of a line 24. These are both connected to the patient's body 8, the stimulating electrode being arranged in the heart muscle tissue 14. Also provided is an oxygen sensor electrode or measuring electrode 12 which is also disposed in body 8 or heart muscle tissue 14. All three lines 24 can be formed into a single cable 26. In the embodiment of FIG. 1 the stimulating electrode 10 and oxygen measuring electrode 12 are coupled as inputs to the sample and hold circuit. In the alternative embodiment of FIG. 1A, there is also provided a reference electrode 18 at the end of a line 24 in cable 26 which is also inserted in the body tissue. In that case, it is the reference electrode 18 and the oxygen electrode 12 which are provided as inputs to the sample and hold circuit 103. The stimulating electrode 10 is coupled to an output of the pacemaker 2 through switch S2. Similarly, the oxygen electrode is coupled to the pacemaker through switch S3.
In operation, as shown in FIG. 3, during a first time period between t 0 and t 2 , a switch S1 in the pacemaker 2 is closed to allow a capacitor C within the pacemaker to charge from a battery B through a resistor R1. The upper curve of FIG. 3 illustrates the capacitor current which will initially be high and then drop off as the capacitor becomes fully charged. After the capacitor is charged, at an appropriate time t 2 , an output from the processor 101 opens switch S1 and closes the switch S2 to provide a stimulating pulse 107 to the stimulating electrode 10. This is conventional operation in the pacemaker. However, as illustrated by FIG. 3, switch S3, which was closed at time t 1 , is still closed at this time. Thus, the oxygen electrode 12 is also provided with the stimulating pulse.
The oxygen measuring electrode 12 preferably consists of smooth vitreous carbon, and the stimulating electrode 10 consists preferably of activated vitreous carbon. Although various shapes are possible, preferably both of these electrodes have a hemispheric shape. During the stimulating pulse, low current also initially flows through the oxygen measuring electrode 12. The small amount of current is due to the smooth surface and very low capacitance of electrode 12. This low current is however sufficient for measurement without adversely affecting stimulation.
In operation, the stimulating electrode 10 and the oxygen measuring electrode 12 are thus loaded in parallel by the cathodic stimulating pulses of the heart pacemaker 2. After this stimulation, and after the switch S2 has been opened and the switch S3 opened, at time t 3 , the processor 101 directs the sample and hold circuit 103 to take a sample of the voltage between the stimulating electrode 10 and the oxygen sensor 12 or alternatively in the case of FIG. 1A between the sensor electrode 12 and the reference electrode 18. This is done between stimulating pulses, i.e., before the next stimulating pulse loads the oxygen measuring electrode 12. The time interval during which the potential of the oxygen measuring electrode can be measured is, for example, 0.5 to 1 msec. Within this time span the potential of the oxygen measuring electrode 12 is at least approximately constant. In accordance with stored data which comprises a digitized form of the curves of FIG. 2 to be explained below, the microprocessor 101 assigns a pulse rate based on the measured potential.
The flow of the program in the processor 101 is illustrated by FIG. 4. As indicated, the potential is sampled by providing an output to sample and hold circuit 103 as indicated by block 120. For this sampled potential, as indicated by block 122 a pulse rate is calculated using stored data. The pulse rate is then used, as indicated in block 124, to calculate opening and closing times for the switches. The nature of the data stored and from which the pulse rate is calculated is that with increasing oxygen concentration in the blood, the number of beats per minute of the pacemaker 2 drops. Conversely, with decreasing oxygen concentration in the blood, the rate of the pacemaker is increased. Once the opening and closing times are calculated, in accordance with block 124, the program can then cause the opening and closing of the switches as indicated by FIG. 3. During the sampling, S1 was closed to allow charging. Now using the calculated pulse time, switch S1 is opened and switch S2 closed to provide an output to the stimulating electrode and to the oxygen electrode. This is shown by block 126. As shown by block 128, switch S3 is then opened and, as indicated by block 130, S1 is closed and S2 opened to carry out charging. Thereafter, switch S3 is again closed as indicated by block 132. Switch S3 is closed during a portion of the charging in order to avoid potential drift of the sensor electrode. The program then loops back to block 120.
In the calibration curves according to FIG. 2, the potential φ/AgCl of the O 2 measuring electrode 1 is plotted versus the oxygen concentration. A straight line a with positive slope represents the course of the potential of the O 2 measuring electrode 12 in an electrolyte which is loaded with cathodic stimulating pulses of, for instance, 5V and a pulse length of about 0.5 msec. This electrolyte contains, for instance, 0.9% sodium chloride (NaCl) and, for instance, 0.1% sodium hydrogen carbonate (NaHCO 3 ) and forms the base electrolyte. A straight line b with positive slope likewise represents the course of the potential of the O 2 measuring electrode 12. There, however, physiological substances such as glucose, urea and amino acid mixtures at their physiologically maximal concentration were added to the base electrolyte. The straight line a and b always start from the same origin but have different slopes. The straight line b, for instance, has a slope of about 50 mV/20% oxygen. The straight line b, which does not deviate substantially from the straight line a, shows that the oxygen concentration can be measured by this measuring method in vivo over an extended period of time in blood or tissue even in the presence of accompanying physiological substances. | Physiological frequency control of a heart pacemaker having a stimulating electrode is accomplished by providing an oxygen measuring electrode and placing it in the body tissue, loading the oxygen measuring electrode with stimulating pulses in parallel with the stimulating electrode, measuring the potential of the oxygen measuring electrode relative to another electrode between stimulating pulses, and controlling the frequency of the pacemaker as a function of the measured potential. | 0 |
BACKGROUND OF THE INVENTION
The majority of today's oil filters is the spin-on variety which has a centrally embedded female threaded portion that complements a male threaded portion on the engine mounting plate, in a recognized manner. Installation and removal of the oil filter unit is accomplished by rotating the filter body in the clockwise and counter-clockwise direction, respectively. Most present day oil filter housings are also constructed with axially aligned grooves around the closed end of the body, for the purpose of facilitating hand installation and removal. Hand spinning of the oil filter unit is achieved by grasping the filter body with the fingers and turning with the hand.
In theory, the use of hand in all phases of oil filter change is possible. In practice, this method is virtually impossible. A large, oil free hand with great finger and hand strength is required for hand spinning. Great strength is needed, in particular, during removal when the filter housing often sticks to the engine mounting plate. Also the filter unit is often too large to be easily grasped by small hands. Furthermore, keeping the hands oil free during all phases of filter change is difficult. These are practical reasons why present day oil filters can not easily be mounted nor dismounted by hand.
To circumvent the above problems in hand spinning, filter wrenches of various types have been devised. In addition to wrenches, new oil filter housings with accompanying tools have likewise been proposed to solve these problems. In reference to U.S. Pat. Ser. Nos. 4,364,829; 3,722,691; 3,473,666 and 3,279,609, there exist numerous inventions in filter constructions to facilitate oil filter installation and removal. All of the above cited inventions however require the use of external tools in conjunction to the proposed filter body construction.
There are numerous limitations in the use of filter wrenches and other tools. The use of these tools recently has been complicated by the automotive industry designers installing the oil filters in either virtually inaccessible areas, or close tolerance locations. This is particularly true in the case of most front wheel drive vehicles manufactured both here and abroad. The use of the filter wrenches and tools, under these circumstances, is usually met with poor performance, and often times results in damaged filters. Even when filters are located in accessible locations, frequently a given tool can only be used on a selected few types of filters. Most multiple automobile owners are required to purchase multiple oil filter tools.
An attempt to solve the close tolerance oil filter change problem was devised in U.S. Pat. No. 4,416,776. This invention proposed using two strips of material counter wrapped around the filter cylinder body. By pulling the appropriate tape, the filter body will spin on and off. This approach is only feasible provided sufficient torque can be generated and ample room exists for pulling the tapes.
None of the references teach the new and novel use in combination of elements in the environment set forth hereinafter and defined as turning device and construction for oil filter. Neither do they provide the benefits and advantages associated therewith the following proposed embodiment. Whereas the previous invention all have limited applications, as will become obvious from the figures and detailed description below, the proposed invention will have broad applications. The hereinafter embodiment allows hand installation and removal of oil filters in all hand accessible situations, while requiring neither great finger and hand strength nor oil free hands.
SUMMARY AND OBJECTIVES OF THE INVENTION
An object of this invention is to provide a means of hand spinning-on and spinning-off a threaded oil filter in open tolerance situations.
A further object of this invention is to provide a means of hand spinning-on and spinning-off a threaded oil filter in close tolerance situations.
Another object of the present invention is to provide means which can easily be incorporate into the fabrication of oil filter housing to facilitate the hand installation and removal therefore.
Still another object of the present invention is to provide means which can easily be adapted to any existing oil filter housing to facilitate the hand installation and removal therefore.
An additional object of the present invention is to obviate the need for filter wrenches in installing and removing oil filter.
A still additional object of the present invention is to provide an improvement which allows changing oil filters without the need for separation or additional tools.
Yet another object of the present invention is to provide an oil filter construction or attachment that perform the above said functions with minimal change in oil filter body dimensions, thus allowing use of oil filter wrenches if desired.
These and other objects, advantages and novel features of the invention will become apparent from the detailed description which follows, when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of one form of the preferred embodiment.
FIG. 2 is a top view of the preferred embodiment shown in FIG. 1.
FIG. 3 is a side view of a second form of the preferred embodiment.
FIG. 4 is a top view of the preferred embodiment shown in FIG. 3.
FIG. 5 is a side view of a third form of the preferred embodiment.
FIG. 6 is a top view of the preferred embodiment shown in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a standard elongated cylindrical oil filter housing, which is designated generally as 10. The typical oil filter container consists of a closed top 11 and an open bottom 12. The threaded aperture, which is dimensioned to mate with a complementing threaded member on the engine housing, in a well known manner, is located at the open bottom 12.
FIG. 1 and FIG. 2 teach an embodiment of the device. In reference to FIG. 1 and FIG. 2, it can be seen that the external closed end of the oil filter housing 11 is provided with a centrally fixed rib 20, or a plurality of centrally fixed ribs. The rib 20 serves as a handle. When turned, the rib 20 will impart a rotary motion to the oil filter unit. The rib 20 is formed such that afforded for the turning of the oil filter body by the twisting of the thumb in the counter direction to the fingers against such said device, by the twisting of the thumb in the counter direction to the index finger against such said device, or locking the thumb and the index finger about such said device and turning with the hand. To engage or disengage the oil filter body requires the clock-wise or counter-clock-wise rotation against the same said device using either one or all of the above mentioned motions.
The rib 20, in the preferred embodiment, is formed during the oil filter housing as a pressed out portion of the closed end of the cylinder. Alternatively, the rib 20 can be a rigid body attached to the closed end of completed oil filter housing. As a rigid body attachment, rib 20 is secured to the filter body through welds, screws or the use of high temperature epoxy adhesives. While these methods are mentioned, it is to be understood that other attachment methods are possible.
The primary considerations in the form of the rib 20 as a rigid attached device are strength, dimension and attachability with the filter housing material. The rib 20 must be secured and rigid enough to be twisted without deforming and in term impart a rotary motion to the filter body. The height of the rib 20 must provide ample surface to ensure non-slipperage of the thumb and fingers when rotating. The width and length of the said device must provide ample leverage to generate the required torque for rotating the filter unit.
FIG. 3 and FIG. 4 teach another embodiment of the device. In reference to FIG. 3 and FIG. 4, it can be seen that the external closed end of the oil filter container 11 is provided with a centrally fixed cam 30. The cam 30 could have a multiplicity of sides other than four. The cam 30 serves as a handle. When turned the cam 30 will impart a rotary motion to the oil filter unit. The cam 30 is formed such that afforded for the turning of the oil filter body by the twisting of the thumb in the counter direction to the fingers against such said device, by the twisting of the thumb in the counter direction to the index finger against such said device, or locking the thumb and index finger about such said device and turning with the hand. To engage or disengage the oil filter body requires the clock-wise or counter-clock-wise rotation against the same said device using either one or all of the above mentioned motions.
The cam 30, in the preferred embodiment, is formed during the oil filter housing as a pressed out portion of the closed end of the cylinder. Alternatively, the cam 30 can be a rigid body attached to the closed end of completed oil filter body. As a rigid body attachment, cam 30 is secured to the filter body through welds, screws or the use of high temperature epoxy adhesives. While these methods are mentioned, it is to be understood that other attachment methods are possible.
The primary considerations in the form of the cam 30 as a rigid attached device are strength, dimension and attachability with the filter housing material. The cam 30 must be secured and rigid enough to be twisted without deforming and in term impart a rotary motion to the filter body. The height of the cam 30 must provide ample surface to ensure non-slipperage of the thumb and fingers when rotating. The width and length of the said device must provide ample leverage to generate the required torque for rotating the filter body.
FIG. 5 and FIG. 6 teach a third embodiment of the device. In reference to FIG. 5 and FIG. 6, it can be seen that the external closed end of the oil filter container 11 is provided with a centrally fixed bail 40. The bail 40 serves as a handle. When turned the bail 40 will impart a rotary motion to the filter unit. The bail 40, an attached rigid device, is sufficiently wide and high to allow the insertion of fingers. The bail 40 is formed strong enough such that afforded for the turning of the oil filter housing by the insertion of fingers into the bail 40 accompanied by the turning of the hand. To engage or disengage the oil filter body requires the clock-wise or counter-clock-wise repeat of the insertion and turning motions.
As a rigid body attachment, the bail 40 is secured to the filter body through welds, screws or the use of high temperature epoxy adhesives. While these methods are mentioned, it is to be understood that other attachment methods are possible.
The primary considerations in the form of the bail 40 as a rigid attached device are strength, dimension and attachability with the filter housing material. The bail 40 must be secured and rigid enough to be twisted without deforming and in term impart a rotary motion to the filter body. The height and length of the bail 40 must provide ample room for the insertion of fingers. | A spin-on type oil filter with an improvement to the normal filter body that allows non-tool assisted, easy hand installation and removal of the filter unit in open and close tolerance situations. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/817,313, filed on Jun. 17, 2010, which is a divisional of U.S. patent application Ser. No. 11/025,623, filed on Dec. 29, 2004, now U.S. Pat. No. 7,762,040, which claims priority to U.S. provisional patent application Ser. No. 60/600,845 filed on Aug. 12, 2004. The disclosures of these applications are hereby fully incorporated by reference in their entirety.
FIELD OF THE INVENTION
The invention is related to an insulated fiber cement siding.
BACKGROUND OF THE INVENTION
A new category of lap siding, made from fiber cement or composite wood materials, has been introduced into the residential and light commercial siding market during the past ten or more years. It has replaced a large portion of the wafer board siding market, which has been devastated by huge warranty claims and lawsuits resulting from delamination and surface irregularity problems.
Fiber cement siding has a number of excellent attributes which are derived from its fiber cement base. Painted fiber cement looks and feels like wood. It is strong and has good impact resistance and it will not rot. It has a Class 1(A) fire rating and requires less frequent painting than wood siding. It will withstand termite attacks. Similarly composite wood siding has many advantages.
Fiber cement is available in at least 16 different faces that range in exposures from 4 inches to 10.75 inches. The panels are approximately 5/16 inch thick and are generally 12 feet in length. They are packaged for shipment and storage in units that weigh roughly 5,000 pounds.
Fiber cement panels are much heavier than wood and are hard to cut requiring diamond tipped saw blades or a mechanical shear. Composite wood siding can also be difficult to work with. For example, a standard 12 foot length of the most popular 8¼ inch fiber cement lap siding weighs 20.6 pounds per piece. Moreover, installers report that it is both difficult and time consuming to install. Fiber cement lap siding panels, as well as wood composite siding panels, are installed starting at the bottom of a wall. The first course is positioned with a starter strip and is then blind nailed in the 1¼ inch high overlap area at the top of the panel (see FIG. 1 ). The next panel is installed so that the bottom 1¼ inch overlaps the piece that it is covering. This overlap is maintained on each successive course to give the siding the desired lapped siding appearance. The relative height of each panel must be meticulously measured and aligned before the panel can be fastened to each subsequent panel. If any panel is installed incorrectly the entire wall will thereafter be miss-spaced.
Current fiber cement lap siding has a very shallow 5/16 inch shadow line. The shadow line, in the case of this siding, is dictated by the 5/16 inch base material thickness. In recent years, to satisfy customer demand for the impressive appearance that is afforded by more attractive and dramatic shadow lines virtually all residential siding manufacturers have gradually increased their shadow lines from ½ inch and ⅝ inch to ¾ inch and 1 inch.
SUMMARY OF THE INVENTION
Disclosed herein are embodiments of foam backing panels for use with lap siding and configured for mounting on a building. One such embodiment of the foam backing panel comprises a rear face configured to contact the building, a front face configured for attachment to the lap siding, alignment means for aligning the lap siding relative to the building, means for providing a shadow line, opposing vertical side edges, a top face extending between a top edge of the front face and rear face and a bottom face extending between a bottom edge of the front face and rear face.
Also disclosed herein are embodiments of lap board assemblies. One such assembly comprises the foam backing panel described above, with the alignment means comprising alignment ribs extending a width of the front face, the alignment ribs spaced equidistant from the bottom edge to the top edge of the front face. A plurality of lap boards is configured to attach to the foam backing panel, each lap board having a top edge and a bottom edge, the top edge configured to align with one of the alignment ribs such that the bottom edge extends beyond an adjacent alignment rib.
Also disclosed herein are methods of making the backing and lap board. One such method comprises providing a lap board and joining a porous, closed cell foam to a substantial portion of a major surface of the fiber cement substrate, the foam providing a drainage path through cells throughout the foam.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 is a sectional view of a prior art fiber cement panel installation;
FIG. 2 is a plan view of a contoured alignment installation board according to a first preferred embodiment of the present invention;
FIG. 2 a is a portion of the installation board shown in FIG. 2 featuring interlocking tabs;
FIG. 3 is a sectional view of a fiber cement or wood composite installation using a first preferred method of installation;
FIG. 4 is a rear perspective view of the installation board of FIG. 2 ;
FIG. 5 is a plan view of an installation board according to a first preferred embodiment of the present invention attached to a wall;
FIG. 6 is a plan view of an installation board on a wall;
FIG. 7 is a sectional view of the installation board illustrating the feature of a ship lap utilized to attach multiple EPS foam backers or other foam material backers when practicing the method of the first preferred embodiment of the present invention;
FIG. 7 a is a sectional view of an upper ship lap joint;
FIG. 7 b is a sectional view of a lower ship lap joint;
FIG. 8 a is a sectional view of the fiber cement board of the prior art panel;
FIGS. 8 b - 8 d are sectional views of fiber cement boards having various sized shadow lines;
FIG. 9 is a second preferred embodiment of a method to install a fiber cement panel;
FIG. 10 a shows the cement board in FIG. 8 b installed over an installation board of the present invention;
FIG. 10 b shows the cement board in FIG. 8 c installed over an installation board of the present invention;
FIG. 10 c shows the cement board in FIG. 8 d installed over an installation board of the present invention;
FIG. 11 illustrates the improved fiber cement or wood composite panel utilizing an installation method using a cement starter board strip;
FIG. 12 is a sectional view of a starter board strip having a foam backer; and
FIG. 13 illustrates a method for installing a first and second layer of fiber cement or wood composite panels.
DETAILED DESCRIPTION
The invention outlined hereinafter addresses the concerns of the aforementioned shortcomings or limitations of current fiber cement siding 10 .
A shape molded, extruded or wire cut foam board 12 has been developed to serve as a combination installation/alignment tool and an insulation board. This rectangular board 12 , shown in FIG. 2 is designed to work with 1¼ inch trim accessories. The board's 12 exterior dimensions will vary depending upon the profile it has been designed to incorporate, see FIG. 3 .
With reference to FIG. 2 there is shown a plan view of a contoured foam alignment backer utilized with the installation method of the first preferred embodiment. Installation and alignment foam board 12 includes a plurality or registration of alignment ribs 14 positioned longitudinally across board 12 . Alignment board 12 further includes interlocking tabs 16 which interlock into grooves or slots 18 . As illustrated in FIG. 2 a , and in the preferred embodiment, this construction is a dovetail arrangement 16 , 18 . It is understood that the dovetail arrangement could be used with any type of siding product, including composite siding and the like where it is beneficial to attach adjacent foam panels.
Typical fiber cement lap siding panels 10 are available in 12 foot lengths and heights ranging from 5¼ inches to 12 inches. However, the foam boards 12 are designed specifically for a given profile height and face such as, Dutch lap, flat, beaded, etc. Each foam board 12 generally is designed to incorporate between four and twelve courses of a given fiber cement lap siding 10 . Spacing between alignment ribs 14 may vary dependent upon a particular fiber cement siding panel 10 being used. Further size changes will naturally come with market requirements. Various materials may also be substituted for the fiber cement lap siding panels 10 .
One commercially available material is an engineered wood product coated with special binders to add strength and moisture resistance; and further treated with a zinc borate-based treatment to resist fungal decay and termites. This product is available under the name of LP SmartSide® manufactured by LP Specialty Products, a unit of Louisiana-Pacific Corporation (LP) headquartered in Nashville, Tenn. Other substituted materials may include a combination of cellulose, wood and a plastic, such as polyethylene. Therefore, although this invention is discussed with and is primarily beneficial for use with fiber board, the invention is also applicable with the aforementioned substitutes and other alternative materials such as vinyl and rubber.
The foam boards 12 incorporate a contour cut alignment configuration on the front side 20 , as shown in FIG. 3 . The back side 22 is flat to support it against the wall, as shown in FIG. 4 . The flat side 22 of the board, FIG. 4 , will likely incorporate a drainage plane system 24 to assist in directing moisture runoff, if moisture finds its way into the wall 12 . It should be noted that moisture in the form of vapor, will pass through the foam from the warm side to the cold side with changes in temperature. The drainage plane system is incorporated by reference as disclosed in Application Ser. No. 60/511,527 filed on Oct. 15, 2003.
To install the fiber cement siding, according to the present invention, the installer must first establish a chalk line 26 at the bottom of the wall 28 of the building to serve as a straight reference line to position the foam board 12 for the first course 15 of foam board 12 , following siding manufacturer's instructions.
The foam boards 12 are designed to be installed or mated tightly next to each other on the wall 28 , both horizontally and vertically. The first course foam boards 12 are to be laid along the chalk line 26 beginning at the bottom corner of an exterior wall 28 of the building (as shown FIG. 5 ) and tacked into position. When installed correctly, this grid formation provided will help insure the proper spacing and alignment of each piece of lap siding 10 . As shown in FIGS. 5 and 6 , the vertical edges 16 a , 18 a of each foam board 12 are fabricated with an interlocking tab 16 and slot 18 mechanism that insure proper height alignment. Ensuring that the tabs 16 are fully interlocked and seated in the slots 18 , provides proper alignment of the cement lap siding. As shown in FIGS. 7 , 7 a , 7 b , the horizontal edges 30 , 32 incorporate ship-lapped edges 30 , 32 that allow both top and bottom foam boards 12 to mate tightly together. The foam boards 12 are also designed to provide proper horizontal spacing and alignment up the wall 28 from one course to the next, as shown in phantom in FIGS. 7 and 7 a.
As the exterior wall 28 is covered with foam boards 12 , it may be necessary to cut and fit the foam boards 12 as they mate next to doorways, windows, gable corners, electrical outlets, water faucets, etc. This cutting and fitting can be accomplished using a circular saw, a razor knife or a hot knife. The opening (not shown) should be set back no more than ⅛ inches for foundation settling.
Once the first course 15 has been installed, the second course 15 ′ of foam boards 12 can be installed at any time. The entire first course 15 on any given wall should be covered before the second course 15 ′ is installed. It is important to insure that each foam board 12 is fully interlocked and seated on the interlocking tabs 16 to achieve correct alignment.
The first piece of fiber cement lap siding 10 is installed on the first course 15 of the foam board 12 and moved to a position approximately ⅛ inches set back from the corner and pushed up against the foam board registration or alignment rib 14 (see FIG. 8 ) to maintain proper positioning of the panel 10 . The foam board registration or alignment rib 14 is used to align and space each fiber cement panel 10 properly as the siding job progresses. Unlike installing the fiber cement lap siding in the prior art, there is no need to measure the panel's relative face height to insure proper alignment. All the system mechanics have been accounted for in the rib 14 location on the foam board 12 . The applicator simply places the panel 10 in position and pushes it tightly up against the foam board alignment rib 14 immediately prior to fastening. A second piece of fiber cement lap siding can be butted tightly to the first, pushed up against the registration or alignment rib and fastened securely with fasteners 17 with either a nail gun or hammer. Because the alignment ribs 14 are preformed and pre-measured to correspond to the appropriate overlap 30 between adjacent fiber cement siding panels 10 , no measurement is required. Further, because the alignment ribs 14 are level with respect to one another, an installer need not perform the meticulous leveling tasks associated with the prior art methods of installation.
With reference to FIGS. 7 , 7 a , 7 b , vertically aligned boards 20 include a ship lap 30 , 32 mating arrangement which provides for a continuous foam surface. Furthermore, the interlocking tabs 16 , 18 together with the ship lap 30 , 32 ensures that adjacent fiber boards 12 , whether they be vertically adjacent or horizontally adjacent, may be tightly and precisely mated together such that no further measurement or alignment is required to maintain appropriate spacing between adjacent boards 12 . It is understood that as boards 12 are mounted and attached to one another it may be necessary to trim such boards when windows, corners, electrical outlets, water faucets, etc. are encountered. These cuts can be made with a circular saw, razor knife, or hot knife.
Thereafter, a second course of fiber cement siding 10 ′ can be installed above the first course 10 by simply repeating the steps and without the need for leveling or measuring operation. When fully seated up against the foam board alignment rib 14 , the fiber cement panel 10 ′ will project down over the first course 10 to overlap 34 by a desired 1¼ inches, as built into the system as shown in FIG. 3 . The next course is fastened against wall 28 using fasteners 36 as previously described. The foam board 12 must be fully and properly placed under all of the fiber cement panels 10 . The installer should not attempt to fasten the fiber cement siding 10 in an area that it is not seated on and protected by a foam board 12 .
The board 12 , described above, will be fabricated from foam at a thickness of approximately 1¼ inch peak height. Depending on the siding profile, the board 12 should offer a system “R” value of 3.5 to 4.0. This addition is dramatic considering that the average home constructed in the 1960's has an “R” value of 8. An R-19 side wall is thought to be the optimum in thermal efficiency. The use of the foam board will provide a building that is cooler in the summer and warmer in the winter. The use of the foam board 12 of the present invention also increases thermal efficiency, decreases drafts and provides added comfort to a home.
In an alternate embodiment, a family of insulated fiber cement lap siding panels 100 has been developed, as shown in FIG. 9 , in the interest of solving several limitations associated with present fiber cement lap sidings. These composite panels 100 incorporate a foam backer 112 that has been bonded or laminated to a complementary fiber cement lap siding panel 110 . Foam backing 112 preferably includes an angled portion 130 and a complementary angled portion 132 to allow multiple courses of composite fiber cement siding panels 100 to be adjoined. Foam backer 112 is positioned against fiber cement siding 110 in such a manner as to leave an overlap region 134 which will provide for an overlap of siding panels on installation.
The fiber cement composite siding panels 100 of the second preferred embodiment may be formed by providing appropriately configured foam backing pieces 132 which may be adhesively attached to the fiber cement siding panel 110 .
The composite siding panels 100 according to the second preferred embodiment may be installed as follows with reference to FIGS. 10 b , 10 c and 13 . A first course 115 is aligned appropriately against sill plate 40 adjacent to the foundation 42 to be level and is fastened into place with fasteners 36 . Thereafter, adjacent courses 115 ′ may be merely rested upon the previous installed course and fastened into place. The complementary nature of angled portions 130 , 132 will create a substantially uniformed and sealed foam barrier behind composite siding panels 100 . Overlap 134 , which has been pre-measured in relation to the foam pieces allows multiple courses to be installed without the need for measuring or further alignment. This dramatic new siding of the present invention combines an insulation component with an automatic self-aligning, stack-on siding design. The foam backer 112 provides a system “R” value in the range of 3.5 to 4.0. The foam backer 112 will also be fabricated from expanded polystyrene (EPS), which has been treated with a chemical additive to deter termites and carpenter ants.
The new self-aligning, stack-on siding design of the present invention provides fast, reliable alignment, as compared to the time consuming, repeated face measuring and alignment required on each course with the present lap design.
The new foam backer 112 has significant flexural and compressive strength. The fiber cement siding manufacturer can reasonably take advantage of these attributes. The weight of the fiber cement siding 110 can be dramatically reduced by thinning, redesigning and shaping some of the profiles of the fiber cement 110 . FIG. 8 a shows the current dimensions of fiber cement boards, FIGS. 8 b , 8 c , and 8 c show thinner fiber cement board. Experience with other laminated siding products has shown that dramatic reductions in the base material can be made without adversely affecting the product's performance. The combination of weight reduction with the new stack-on design provides the installers with answers to their major objections. It is conceivable that the present thickness (D′) of fiber cement lap siding panels 110 of approximately 0.313 inches could be reduced to a thickness (D′) of 0.125 inches or less.
The fiber cement siding panel may include a lip 144 which, when mated to another course of similarly configured composite fiber cement siding can give the fiber cement siding 110 the appearance of being much thicker thus achieving an appearance of an increased shadow line. Further, it is understood although not required, that the fiber cement siding panel 110 may be of substantially reduced thickness, as stated supra, compared to the 5/16″ thickness provided by the prior art. Reducing the thickness of the fiber cement siding panel 110 yields a substantially lighter product, thereby making it far easier to install. A pair of installed fiber cement composite panels having a thickness (D′) of 0.125″ or less is illustrated in FIGS. 8B-8D and 10 B and 10 C. Such installation is carried out in similar fashion as that described in the second preferred embodiment.
The present invention provides for an alternate arrangement of foam 112 supporting the novel configuration of fiber cement paneling. In particular, the foam may include an undercut recess 132 which is configured to accommodate an adjacent piece of foam siding. As shown in FIGS. 10 a , 10 b and 10 c , the new, thinner, insulated fiber cement lap siding panel 110 will allow the siding manufacturers to market panels with virtually any desirable shadow line, such as the popular new ¾ inch vinyl siding shadow line with the lip 144 formation. The lip 144 can have various lengths such as approximately 0.313 inch (E), 0.50 inch (F), and 0.75 (G) inch to illustrate a few variations as shown in FIGS. 8 b , 8 c , and 8 d , respectively. This new attribute would offer an extremely valuable, previously unattainable, selling feature that is simply beyond the reach with the current system.
No special tools or equipment are required to install the new insulated fiber cement lap siding 100 . However, a new starter adapter or strip 150 has been designed for use with this system, as shown in FIGS. 11 and 12 . It is preferable to drill nail holes 152 through the adapter 150 prior to installation. The installer must first establish a chalk line 26 at the bottom of the wall 28 to serve as a straight reference line to position the starter adapter 150 for the first course of siding and follow the siding manufacturer's instructions.
The siding job can be started at either corner 29 . The siding is placed on the starter adapter or strip 150 and seated fully and positioned, leaving a gap 154 of approximately ⅛ inches from the corner 29 of the building. Thereafter, the siding 100 is fastened per the siding manufacturer's installation recommendations using a nail gun or hammer to install the fasteners 36 . Thereafter, a second course of siding 115 ′ can be installed above the first course 115 by simply repeating the steps, as shown in FIG. 13 . Where practical, it is preferable to fully install each course 115 before working up the wall, to help insure the best possible overall alignment. Installation in difficult and tight areas under and around windows, in gable ends, etc. is the same as the manufacturer's instruction of the current fiber cement lap siding 10 .
The lamination methods and adhesive system will be the same as those outlined in U.S. Pat. Nos. 6,019,415 and 6,195,952B1.
The insulated fiber cement stack-on sliding panels 100 described above will have a composite thickness of approximately 1¼ inches. Depending on the siding profile, the composite siding 100 should offer a system “R” value of 3.5 to 4.0. This addition is dramatic when you consider that the average home constructed in the 1960's has an “R” value of 8. An “R-19” side wall is thought to be the optimum in energy efficiency. A building will be cooler in the summer and warmer in the winter with the use of the insulated fiber cement siding of the present invention.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the fiber cement siding board disclosed in the invention can be substituted with the aforementioned disclosed materials and is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law. | Disclosed herein are embodiments of foam backing panels for use with lap siding and configured for mounting on a building. Also disclosed are lap siding assemblies and products of lap sidings. One such embodiment of the foam backing panel comprises a rear face configured to contact the building, a front face configured for attachment to the lap siding, alignment means for aligning the lap siding relative to the building, means for providing a shadow line, opposing vertical side edges, a top face extending between a top edge of the front face and rear face and a bottom face extending between a bottom edge of the front face and rear face. | 8 |
RELATED APPLICATIONS
[0001] The present application relates to, and claims priority of, U.S. Provisional Patent Application Ser. No. 60/197,498 filed on Apr. 18, 2000, commonly assigned to the same assignee as the present application and having the same title which is also incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to music playback systems and, more particularly, to a music playback system which interactively alters the character of the played music in accordance with user input.
DESCRIPTION OF THE RELATED ART
[0003] Prior to the widespread availability of the prerecorded music, playing music was generally an interactive activity. Families and friends would gather around a piano and play popular songs. Because of the spontaneous nature of these activities, it was easy to alter the character and emotional quality of the music to suit the present mood of the pianist and in response to the reaction of others present. However, as the prevalence of broadcast and prerecorded music became widespread, the interactive nature of in-home music slowly diminished. At present, the vast majority of music which is played is pre-recorded. While consumers have access to a vast array of recordings, via records, tapes, CD and Internet downloads, the music itself is fixed in nature and the playback of any given piece is the same each time it is played.
[0004] Some isolated attempts to produce interactive media products have been made in the art. These interactive systems are generally of the form of a virtual mixing studio in which a user can re-mix music from a set of prerecorded audio tracks or compose music by selecting from a set of audio riffs using a pick-and-choose software tool. Although these systems in the art allow the user to make fairly complex compositions, they do not interpret user input to produce the output. Instead, they are manual in nature and the output has a one-to-one relationship to the user inputs.
[0005] Accordingly, there is a need to provide an interactive musical playback system which responds to user input to dynamically alter the music playback. There is also a need to provide an intuitive interface to such a system which provides a flexible way to control and alter playback in accordance with a user's emotional state.
SUMMARY OF THE INVENTION
[0006] An interactive music system in accordance with various aspects of the invention lets a user control the playback of recorded music according to gestures entered via an input device, such as a mouse. The system includes modules which interpret input gestures made on a computer input device and adjust the playback of audio data in accordance with input gesture data. Various methods for encoding sound information in an audio data product with meta-data indicating how it can be varied during playback are also disclosed.
[0007] More specifically, a gesture input system receives user input from a device, such as a mouse, and interprets this data as one of a number of predefined gestures which are assigned an emotional or interpretive meaning according to a “character” hierarchy or library of gesture descriptions. The received gesture inputs are used to alter the character of music which is being played in accordance with the meaning of the gesture. For example, an excited gesture can effect the playback in one way, while a quiet playback may affect it in another. The specific result is a combination of the gesture made by the user, its interpretation by the computer, and a determination of how the interpreted gesture should effect the playback. Entry of a excited gesture thus may brighten the playback, e.g., by changing increasing the tempo, changing from a minor to major key, varying the instruments used for the style in which they are played, etc. In addition, the effects can be cumulative, allowing a user to progressively alter the playback. To further enhance the interactive nature of the system, users can be given the ability to alter the effect of a given gesture or assign a gesture to specific places in the character hierarchy.
[0008] In a first playback embodiment, the system uses gestures to select music to play back from one of a set of prerecorded tracks or musical segments. Each segment has associated data which identifies the emotional content of the segment. The system can use the data to select which segments to play and in what order and dynamically adjust the playback sequence in response to the received gestures. With a sufficiently rich set of musical segments, a user can control the playback from soft and slow to fast and loud to anything in between as often as for as long as they wish. The degree to which the system reacts to gestural user input can be varied from very responsive, wherein each gesture directly selects the next segment to play, to only generally responsive where, for example, the system presents an entire composition including multiple segments related to a first received gesture and subsequent additional gestures alter or color the same composition instead of initiating a switch to new or other pieces of music.
[0009] According to another aspect of the system, the music (or other sound) input is not fixed but is instead encoded, e.g., in a Musical Instrument Digital Interface (MIDI) format, perhaps with various indicators which are used to determine how the music can be changed in response to various gestures. Because the audio information is not prerecorded, the system can alter the underlying composition of the musical piece itself, as opposed to selecting from generally unchangeable audio segments. The degree of complexity of the interactive meta-data can vary depending on the application and the desired degree of control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings of illustrative embodiments of the invention, not necessarily dawn to scale, in which:
[0011] [0011]FIG. 1 is a block diagram of a system for implementing the present invention;
[0012] [0012]FIG. 2 is a flowchart illustrating one method for interpreting gestural input;
[0013] [0013]FIG. 3 is a flowchart illustrating operation of the playback system in “DJ” mode;
[0014] [0014]FIG. 4 is a flowchart illustrating operating of the playback system in “single composition mode”; and
[0015] [0015]FIG. 5 is a diagram illustrating an audio exploration feature of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Turning to FIG. 1, there is shown a high-level diagram of an interactive music playback system 10 . The system 19 can be implemented in software on a general purpose or specialized computer and comprises a number of separate program modules. The music playback is controlled by a playback module 12 . A gesture input module 14 receives and characterizes gestures entered by a user and makes this information available to the playback module 12 . Various types of user-input systems can be used to capture the basic gesture information. In a preferred embodiment, a conventional two-dimensional input device is used, such as a mouse, joystick, trackball, or tablet (all of which are generally referred to as a mouse or mouse-like device in the following discussion). However any other suitable device or combination of input devices can be used, including data gloves, and electronic conducting baton, optical systems, such as video motion tracking systems, or even devices which register biophysical data, such as blood pressure, heart rate, or muscle tracking systems.
[0017] The meaning attributed to a specific gesture can be determined with reference to data stored in a gesture library 16 and is used by the playback module 12 to appropriately select or alter the playback of music contained in the music database 18 . The gesture-controlled music is then output via an appropriate audio system 20 . The various subsystems will be discussed in more detail below.
[0018] [0018]FIG. 2 is a flowchart illustration the general operation of one embodiment of the gesture input module 14 . The specific technique used to implement the module depends upon the computing environment and the gesture input device(s) used. In a preferred embodiment, the module is implemented using a conventional high-level programming language or integrated environment.
[0019] Initially, the beginning of a gesture is detected. (Step 22 ). In the preferred mouse-input implementation, a gesture is initiated by depressing a mouse button. When the mouse button depression is detected, the system begins to capture the mouse movement. (Step 24 ). This continues until the gesture is completed (step 26 ), as signaled, e.g., by a release of the mouse button. Various other starting and ending conditions can alternatively be used, such as the detection of the start and end of input motions generally or motions which exceed a specified speed or distance threshold.
[0020] During the gesture capture period, the raw gesture input is stored. After the gesture is completed, the captured data is analyzed, perhaps with reference to data in the gesture library 16 , to produce one or more gesture characterization parameters (step 28 ). Alternatively, the input gesture data can be analyzed concurrently with capture and the analysis completed when the gesture ends.
[0021] Various gesture parameters can be generated from the raw gesture data. The specific parameters which are generated depend on how the gesture input is received and the number of general gestures which are recognized. In a preferred embodiment based on mouse-input gesture, the input gesture data is distilled into values which indicate overall bentness, jerkiness, and length of the input. These parameters can be generated in several ways.
[0022] In one implementation the raw input data is first used to calculate (a) the duration of time between the MouseDown and the MouseUP signals, (b) the total length of the line created by the mouse during capture time (e.g., the number of pixels traveled), (c) The average speed (velocity) of the mouse movement, (d) variations in mouse velocity within the gesture, and (e) the general direction or aim of the mouse movement throughout the gesture, perhaps at rough levels of precision, such as N, NE E, SE, S, SW, W, and NW.
[0023] The aim data is used to determine the number and possibly location of horizontal and vertical direction changes present in the gesture, which is used to determine the number of times the mouse track make significant direction changes during the gesture. This value is then used as an indication of the bentness of the gesture. The total bentness value can be output directly. To simplify the analysis, however, the value can be scaled, e.g., to a value of 1-10, perhaps with reference to the number of bends per unit length of the mouse track. For example, a bentness value of 1 can indicate a substantially straight line while a bentness value of 10 indicates that the line very bent. Such scaling permits the bentness of differently sized gestures to be more easily compared.
[0024] In a second valuation (which is less precise but easier to work with), bentness can simply be characterized one a 1-3 scale, representing little bentness, medium bentness, and very bent, respectively. In a very simple embodiment, if there is no significant change of direction (either horizontally or vertically), the gesture has substantially no bentness e.g., bentness=1. Medium bentness can represent a gesture one major direction change, either horizontal or vertical (bentness=2). If there are two or more changes in direction, the gesture is considered very bent (bentness=3).
[0025] The changes in the speed of the gesture can also be analyzed to determine the number of times the mouse changes velocity over the course of the gesture input. This value can then be used to indicate the jerkiness or jaggedness of the input. Preferably, jerkiness is scaled in a similar manner as bentness, such as a 1-10 scale of little jerkiness, some jerkiness, and very jerky (e.g., a 1-3 scale). Similarly, the net overall speed and length of the gesture can also be represented as general values of slow, medium, fast and short, medium, or long, respectively.
[0026] For the various parameters, the degree of change required to register a change in direction or change in speed can be predefined or set by the user. For example a minimum speed threshold can be established wherein motion below the threshold is considered equivalent to being stationary. Further, speed values can be quantized across specific ranges and represented as integral multiples of the threshold value. Using this scheme, the general shape or contour of the gesture can be quantified by two basic parameters—its bentness and length. Further quantification is obtained by additionally considering a gesture's jerkiness and average speed, parameters which indicate how the gesture was made, as opposed to what it look like.
[0027] Once the gesture parameters are determined, these parameters are used to define a specific value or attribute to the gesture, which value can be mapped directly to an assigned meaning, such as an emotional attribute. There are various techniques which can be used to combine and map the gesture parameters. Gesture characterization according to above technique results in a fixed number of gestures according to the granularity of the parameterization process.
[0028] In one implementation of this method, bentness and jerkiness are combined to form a general mood or emotional attribute indicator. This indicator is than scaled according to the speed and/or length of the gesture. The resulting combination of values can be associated with an “emotional” quality which is used to determine how a given gesture should effect musical playback. As shown in FIG. 1, this association can be stored in a gesture library 16 which can be implemented as simple lookup table. Preferably, the assignments are adjustable by the user and can be defined during an initial training or setup procedure.
[0029] For example, Jerkiness=1 and Bentness 1 can indicate “Max gentle, Jerkiness=2 and Bentness-2=can indicated “less gentle”, Jerkiness=3 and Bentness=3 can indicate “somewhat aggressive”, and Jerkiness=4 and Bentness 4 can indicate “very aggressive”. Various additional general attributes can be specified for situations where bentness and jerkiness are now equal. Further, each general attribute are scaled according to the speed and/or length of the gesture. For example, if only length of values for 1-4 are considered, each general attribute can have four different scales in accordance with the gesture length, such as “max gentle” through “max gentle 4 ”.
[0030] As will be recognized by those of skill in the art, using this scheme, even a small number of attributes can be combined t defined a very large number of gestures. Depending on the type of music and the desired end result, the number of gestures can be reduced, fo example to two states, such as gentle vs aggressive, and two or three degrees or scales for each. In another embodiment, a simple set of 16 gestures can be defined specifying two values for each parameter, e.g., straight or bent, smooth or jerky, fast or slow, and long or short, and defining the gestures as a combination of each parameter.
[0031] According to the above methods, the gestures are defined discretely, e.g., there are a fixed total number of gestures. In an alternative embodiment, the gesture recognition process can be performed with the aid of an untrained neural network, a network with a default training, or other types of “artificial intelligence” routines. In such an embodiment, a user can train the system to recognize a users unique gestures and associate these gestures with various emotional qualities or attributes. Various training techniques are known to those of skill in the art and the specific implementations used can vary according to design considerations. In addition, while the preferred implementation relies upon only a single gesture input device, such as a mouse, gesture training (as opposed to post-training operation) can include other types of data input, particularly when a neutral network is used a part of the gesture recognition system. For example, the system can receive biomedical input, such as pulse rate, blood pressure, EEG and EKG data, etc., for use in distinguishing between different types of gestures and associating them with specific emotional states.
[0032] As will be appreciated by those of skill in the art, the specific implementation and sophistication of the gesture mapping procedure and the various gesture parameters considered can vary according to the complexity of the application and the degree of playback control made available to the user. In addition, users can be given the option of defining gesture libraries of varying degrees of specificity. Regardless of how the gestures are captured and mapped, however, once a gesture has been received and interpreted, the gesture interpretation is used by the playback module (step 32 ) to alter the musical playback.
[0033] There are various methods of constructing a playback module 12 to adjust playback of musical data in accordance with gesture input. The musical data generally is stored in a music database, which can be a computer disc, a CD ROM, computer memory such as random access memory (RAM), networked storage systems, or any other generally randomly accessible storage device. The segments can be stored in any suitable format. Preferably, music segments are stored as digital sound files in formats such as AU, WAV, QT, or MP3. AU, short for audio, is a common format for sound files on UNIX machines, and the standard audio file format for the Java programming language. WAV is the format for storing sound in files developed jointly by Microsoft™ and IBM™, which is a de facto standard for sound files on Windows™ applications. QT, or QuickTime, is a standard format for multimedia content in Macintosh™ applications developed by Apples. MP3, or MPEG Audio Layer-3, is a digital audio coding scheme used in distributing recorded music over the Internet.
[0034] Alternatively, musical segments can be stored in a Musical Instrument Digital Interface (MIDI) format wherein the structure of the music is defined but the actual audio must be generated by appropriate playback hardware. MIDI is a serial interface that allows for the connection of music synthesizers, musical instruments and computers
[0035] The degree to which the system reacts to received gestures can be varied. Depending on the implementation, the user can be given the ability to adjust the gesture responsiveness. The two general extremes of responsiveness will be discussed below as “DJ” mode and “single composition” mode.
[0036] In “DJ mode”, the system is the most responsive to received gestures, selecting a new musical segment to play for each gesture received. The playback module 12 outputs music to the audio system 20 which corresponds to each gesture received. In a simple embodiment, and with reference to the flowchart of FIG. 3, a plurality of musical segments are stored in the music database 18 . Each segment is associated with a specific gesture, i.e., gentle, moderate, aggressive, soft, loud, etc. The segments do not need to be directly related to each other (as, for example, movements in a musical composition are related), but instead can be discrete musical or audio phrases, songs, etc. (thus permitting the user act like a “DJ but using gestures to select appropriate songs to play, as opposed to identifying the songs specifically).
[0037] [0037]FIG. 3 is a flow diagram that illustrates operation of the playback system in “DJ” mode. As a gesture is received (step 36 ), the playback module 12 selects a segment which corresponds to the gesture (step 38 ) and ports it to the audio system 20 (step 40 ). If more than one segment is available, a specific segment can be selected at random or in accordance with a predefined or generated sequence. If a segment ends prior to the receipt of another gesture another segment corresponding to that gesture can be selected, the present segment can be repeated, or the playback terminated. If one or more gestures are received during the playback of a given segment, the playback module 12 preferably continuously revises the next segment selection in accordance with the received gestures and plays that segment when the first one completes. Alternatively, the presently playing segment can be terminated and the segment corresponding to the newly entered gesture started immediately or after only a short delay. In yet another alternative the system can queue the gestures for subsequent interpretation in sequence as each segment's play back completes. In this manner a user can easily request, for example, three exciting songs followed by a relaxed song by entering the appropriate four gestures. Advantageously, the user does not need to identify (or even know) the specific songs played for the system to make an intelligent and interpretative selection. Preferably, the user is permitted to specify the default behaviors in these various situations.
[0038] The association between audio segments and gesture meanings can be made in a number of ways. In one implementation, the gesture associated with a given segment, or at least the nature of segment, is indicated in a segment-tag a gesture “tag” which can be read by the playback system and used to determine when it is appropriate to play a given segment. The tag can be embedded within the segment data itself, e.g., within a header data or block, or reflected externally, e.g., as part of the segment's file name or file directory entry.
[0039] Tag data can also be assigned to given segments by means of a look-up table or other similar data structure stored within the playback system or audio library, which table can be easily updated as new segments are added to the library and modified by the user so that the segment-gesture or segment-emotion associations reflects their personal taste. Thus, for example, a music library containing a large number of songs may be provided and include an index which lists the songs available on the system and which defines the emotional quality of each piece.
[0040] In one exemplary implementation, downloadable audio files, such as MP3 files, can include a non-playable header data block which includes tag information recognized by the present system but in a form which does not interfere with conventional playback. The downloaded file can added to the audio library, at which time the tag is processed and the appropriate information added to the library index. For a preexisting library or compilation of audio files, such as may be present on a music compact disc (CD) or MP3 song library, an interactive system can be established which receives lists of audio files (such as songs) from a user, e.g., via e-mail or the Internet, and then returns an index file to the user containing appropriate tag information for the identified audio segments. With such an index file, a user can easily select a song having a desired emotional quality from a large library of musical pieces by entering appropriate emotional gestures without having detailed knowledge of the precise nature of each song in the library, or even the contents of the library.
[0041] In “single composition mode”, the playback module 12 generates or selects an entire musical composition related to an initial composition and alters or colors the initial composition in accordance with subsequent gesture's meaning. One method for implementing this type of playback is illustrated in the flow chart of FIG. 4. A given composition is comprised of a plurality of sections or phrases. Each defined phrase or section of the music is given a designation, such as a name or number, and is assigned a particular emotional quality or otherwise associated with the various gestures or gesture attributes which can be received. Upon receipt of an initial gesture (step 50 ), the meaning of the gesture is used to construct a composition playback sequence which includes segments of the composition which are generally consistent with the initial gesture (step 52 ). For example, if the initial gesture is slow and gentle, the initial composition will be comprised of sections which also are generally slow and gentle. The selected segments in the composition are then output to the audio system (step 54 ).
[0042] Various techniques can be used to construct the initial composition sequence. In one embodiment, only those segments which directly correspond to the meaning of the received gesture are selected as elements in the composition sequence. In a more preferred embodiment, the segments are selected to provide an average or mean emotional content which corresponds to the received gesture. However, the pool of segments which can be added to the sequence is made of segments which vary from the meaning of the received gesture by no more than a defined amount, which amount can be predefined or selected by the user.
[0043] Once the set of segments corresponding to the initial gesture is identified, specific segments are selected to form a composition. The particular order of the segment sequence can be randomly generated, based on an initial or predefined ordering of the segments within the master composition, based on additional information which indicates which segments go well with each other, based on other information or a combination of various factors. Preferably a sequence of a number of segments is generated to produce the starting composition. During playback, the sequence can be looped and the selected segments combined in varying orders to provide for continuous and varying output.
[0044] After the initial composition sequence has been generated, the playback system uses subsequent gesture inputs to modify the sequence to reflect the meaning of the new gestures. For example, if an initial sequence is gentle and an aggressive gesture is subsequently entered, additional segments will be added to the playback sequence so that the music becomes more aggressive, perhaps getting louder, faster, increased vibrato, etc. Because the composition includes a number of segments, the transition between music corresponding to different gestures does not need to be abrupt, as in DJ mode, discussed above. Rather, various new segments can be added to the playback sequence and old ones phased out such that the average emotional content of the composition gradually transitions from one state to the next.
[0045] It should be noted that, depending on the degree of control over the individual segments which is available to the playback system, the manner in which specific segments themselves are played back can be altered in additional to or instead of selecting different segments to add to the playback. For example, a given segment can have a default quality of “very gentle”. However, by increasing the volume and/or speed at which the segment is played or introducing acoustic effects, such as flanging, echos, noise, distortions, vibrato, etc., its emotional quality can be made more aggressive or intense. Various digital signal processing tools known to those of skill in the art can be used to alter “prerecorded” audio to introduce these effects. For audio segments which are coded as MIDI data, the transformation can be made using MIDI software tools, such as Beatnick™. MIDI transformations can also include changes in the orchestration of the piece, e.g., by selecting different instruments to play various parts in accordance with the desired effect, such as using flutes for gentle music and trumpets for more aggressive tones.
[0046] To support this playback mode, a source composition must be provided which contains a plurality of audio segments which are defined as to name and/or position within an overall piece and have an associated gesture tag. In one contemplated embodiment, a customized composition is written and recorded specifically for use with the present system. In another environment, a conventional recording, such as a music CD has an associated index file which defines the segments on the CD, which segments do not need to correspond to CD tracks. The index file also defines a gesture tag for each segment. Although the segment definitions can be embedded within the audio data itself, a separate index file is easier to process and can be stored in a manner which does not interfere with playback of the composition using conventional systems.
[0047] The index file can also be provided separately from the initial source of the audio data. For example, a library of index files can be generated for various preexisting musical compositions, such as a collection of classical performances. The index files can then be downloaded as needed stored in, e.g., the music database, and used to control playback of the audio data in the manner discussed above.
[0048] In a more specific implementation, a stereo component, such as a CD player, can include an integrated gesture interpretation system. An appropriate gesture input, such as a joystick, mouse, touch pad, etc. is provided as an attachment to the component. A music library is connected to the component. If the component is a CD player, the library can comprise a multi-disk cartridge. Typical cartridges can contain one hundred or more separate CDs and thus “library” can have several thousand song selections available. Another type of library comprises a computer drive containing multiple MP3 or other audio files. Because of the large number of song titles available, the user may find it impossible to select songs which correspond to their present mood. In this specific implementation, the gesture system would maintain an index of the available songs and associated gesture tag information. (For the CD example, the index can be built by reading gesture tag data embedded within each CD and storing the data internally. If gesture tag data is not available, information about the loaded CDs can be gathered and then transmitted to a web server which returns the gesture tag data, if available). The user can then play the songs using the component simply by entering a gesture which reflects the type of music they feel like hearing. The system will then select appropriate music to play.
[0049] In an additional embodiment, gesture-segment associations can be hard-coded in the playback system software itself wherein, for example, the interpretation of a gesture inherently provides the identification of one segments or a set of segments to be played back. This alternative embodiment is well suited for environments where the set of available audio segments are predefined and are generally not frequently updated or added to by the user. One such environment is present in electronic gaming environments, such as computer or video games, particularly those having “immersive” game play. The manner in which a user interacts with the game, e.g., via a mouse, can be monitored and that input characterized in a manner akin to gesture input. The audio soundtrack accompanying the game play can then be adjusted according to emotional characteristics present in the input.
[0050] According to a further aspect of the invention, in addition to using gestures to select the specific musical segments which are played, a non-gesture mode can also be provided in which the user can explore a piece of music. With reference FIG. 5, a composition is provided as a plurality of parts, such as parts 66 a - 66 d , each of which is synchronized with each other, e.g., by starting playback at the same time. Each part represents a separate element of the music, such as vocals, percussive, bass, etc.
[0051] In this aspect of the system, each defined part is played internally simultaneously and the user input is monitored for non-gesture motions. These motions can be in the form of, e.g., moving a curser 64 within areas 62 of a computer display 60 . Each area of the display is associated with a respective part. The system mixes the various parts according to where the cursor is located on the screen. For example, the vocal aspects of the music can be most prevalent in the upper left corner while the percussion is most prevalent in the lower right. By moving the cursor around the screen, the user can explore the composition at will. In addition, the various parts can be further divided into parallel gesture-tagged segments 68 . When a gesture based input is received, the system will generate or modify a composition comprising various segments in a manner similar to when only a single track is present. When the user switches to non-gesture inputs, such as when the mouse button is released, the various parallel segments can be explored. It should be noted that when a plurality of tracks is provided, the playback sequence of the separate tracks need not remain synchronized or be treated equally once gesture-modified playback beings. For example, to increase the aggressive nature of a piece, the volume of a percussion part can be increased while playback of the remaining parts.
[0052] Various techniques will be know to those of skill in the art to provide play of multiple audio parts simultaneously and to variably mix the strength of each part in the audio output. However, because realtime processing of multiple audio files can be computationally intense, a home computer may not have sufficient resources to handle more than one or two parts. In this situation, the various parts can be pre-processed to provide a number of premixed tracks, each of which corresponds to a specific area on the screen. For example, the display can be divided into a 4×4 matrix and 16 separate tracks provided.
[0053] The present inventive concepts have been discussed with regards t gesture based selection of audio segments, with specific regard for music. However, the present invention is not limited to purely musical-based applications but can be applied to the selection and/or modification of any type of media files. Thus, the gesture-based system can be used to select and modify media segments generally, which segments can be directed to video data, movies, stories, real-time generated computer animation, etc.
[0054] The above described gesture interpretation method and system can be used as part of a selection device used to enable the selection of one or more items from a variety of different items which are amenable to being grouped or categorized according to emotional content. Audio and other media segments are simply one example of this. In a further alternative embodiment, a gesture interpretation system is implemented as part of a stand-alone or Internet based catalog. A gesture input module is provided to receive user input and output a gesture interpretation. For an Internet-based implementation, the gesture input module and associated support code can be based largely on the server side with a Java or ActiveX applet, for example, provided to the user to capture the raw gesture data and transmit it in raw or partially processed form to the server for analysis. The entire interpretation module could also be provided to the client and only final interpretations returned to the server. The meaning attributed to a received gesture is then used to select specific items to present to the user.
[0055] For example, a gesture interpretation can be used to generate a list of music or video albums which are available for rent or purchase and which have an emotional quality corresponding to the gesture. In another implementation, the gesture can be sued to select clothing styles, individual clothing items, or even complete outfits which match a specific mood corresponding to the gesture. A similar system can be used to for decorating, wherein the interpretation of a received gesture is used to select specific decorating styles, types of furniture, color schemes, etc., which correspond to the gesture, such as cal, excited agitated, and the like.
[0056] In yet a further implementation, gesture-based interface can be integrated into a device with customizable settings or operating parameters wherein a gesture interpretation is used to adjust the configuration accordingly. In a specific application, the Microsoft Windows™ “desktop settings” which define the color schemes, font types, and audio cues used by the windows operating system can be adjusted. In conventional systems, these settings are set by user using standard pick-and-choose option menus. While various packaged settings or “themes” are provided, the user must still manually select a specific theme. According t this aspect of the invention, the user can select a gesture-input option and enter one or more gestures. The gestures are interpreted and an appropriate set of desktop settings is retrieved or generated. In this manner, a user can easily and quickly adjust the computer settings to provide for a calming display, an exciting display, or anything in between. Moreover, the system is not limited to predefined themes but can vary any predefined themes which are available, perhaps within certain predefined constraints, to more closely correspond with a received gesture.
[0057] 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. The embodiments described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. Similarly, any process steps described herein may be interchangeable with other steps to achieve substantially the same result. All such modifications are intended to be encompassed within the scope of the invention, which is defined by the following claims and their equivalents. | An interactive music system in accordance with various aspects of the invention lets a user control the playback of recorded music according to gestures entered via an input device, such as a mouse. The system includes modules which interpret input gestures made on a computer input device and adjust the playback of audio data in accordance with input gesture data. Various methods for encoding sound information in an audio data produce with meta-data indicating how it can be varied during playback are also disclosed. More specifically, a gesture input system receives user input from a device, such as a mouse, and interprets this data as one of a number of predefined gestures which are assigned an emotional or interpretive meaning according to a “character” hierarchy or library of gesture descriptions. The received gesture inputs are used to alter the character of music which is being played in accordance with the meaning of the gesture. For example, an excited gesture can effect the playback in one way, while a quiet playback may affect it in another. The specific result is a combination of the gesture made by the user, its interpretation by the computer, and a determination of how the interpreted gesture should effect the playback. Entry of a excited gesture thus may brighten the playback, e.g., by changing increasing the tempo, changing from a minor to major key, varying the instruments used or the style in which they are played, etc. In addition, the effects can be cumulative, allowing a user to progressively alter the playback. To further enhance the interactive nature of the system, users can be given the ability to alter the effect of a given gesture or assign a gesture to specific places in the character hierarchy. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention describes the precision processing of curved surfaces of the cardiocle and expanded cardioid casing in springless eccentric rotor vane pumps.
2. Description of the Prior Art
In general, vanes used in eccentric rotor vane pumps are fitted with springs so that their length can vary in line with casing surfaces. However, the eccentric rotor vane pump discussed here has a solid vane of constant length. For this type of eccentric rotor vane pump, the key technology is the accuracy of the casing surface curvatures, to allow the edges of a sliding vane match the surface curves as closely as possible no matter what the rotation angle and the eccentricity of the rotor may be.
However, the exact mathematical descriptions which accurately represent the curves drawn by the movements of the vane edges in an eccentric rotor vane pump have not been found until now. Thus processing of curved casing surfaces has been possible only via the recopy method. This method has several significant weaknesses: (1) Curved surfaces have to be retraced and remodelled each time eccentricity or casing size needs to be changed. (2) Precision processing is not quite possible, especially for large-sized casings. (3) The entire surface of the casing has to be processed at one time. (4) The edges of scraping, sliding vanes make poor contact with casing surfaces.
Moreover, with this recopy method, the accuracy of casing surface processing varies with the eccentricity of the pump, the angle of rotation of the vane, and the distance the vane travels. As there have been no geometrical equations which exactly describe the curves drawn by the vane rotation, such advanced manufacturing techniques as CNC, and processing in sections, have not been available. The only possible manufacturing method was the recopy method, using a prototype curved action.
SUMMARY OF THE INVENTION
In this invention, however, the following equations (A) and (B), which represent the curves drawn by the movement of vanes of fixed length in eccentric rotor vane pumps, are derived on the basis of these curves always falling into two categories, cardiocle and expanded cardioid curves, regardless of rotor eccentricity and vane length: P = 2 a { 1 + ( R - r ) sin θ 2 a - R 2 - ( R - r ) 2 cos 2 θ 2 a } for cardiocles ( A ) P = 2 a { 1 + ( R - r ) sin θ 2 a } for expanded cardioids ( B )
Nomenclature in the equations will be discussed in detail later, in reference to FIGS. 1, 3 , 5 and 6 .
These two equations represent in terms of analytic geometry the curved surfaces of eccentric rotor pump casings, and thereby alow the precision processing of casings using CNC techniques. As the equations do not depend on rotor eccentricity and vane length, casings of any size can be manufactured to the highest levels of accuracy current engineering technology permits; and even further, more processing in sections is now possible.
As a result, not only precision processing, but also mass production, of large-sized springless eccentric rotor vane pumps of 1-meter or larger diameter is now possible, thus making feasible the supply to customers of eccentric rotor vane pumps at more reasonable prices.
In other current eccentric rotor vane pumps, the center of eccentricity of the rotor is set at the upper section or sides of the casing center for better ventilation and smooth valve movement. But the movement of a vane causes friction with the casing surfaces, as the centrifugal force generated by the rotating vane is in the same direction as the gravitation force exerted on the rotor. Therefore the rotation speed of the rotor has to be kept low. However, the vane of the eccentric rotor vane pump being discussed here makes large-area contact with the casing surfaces when sliding on surfaces; and thus the center of eccentricity of the rotor can be placed in the lower section of the casing center. Additionally, the centrifugal force produced by the rotation of the vane is reduced by the weight of the vane. Therefore the rotation speed of the rotor can be sped up.
In particular, as shown in FIG. 10, existing thrust bearings may be used for the processing of large-sized casings of 1-meter or greater diameter, so that the rotor axis can be designed vertically, reducing gravitational pull due to the weight of the rotating vane and increasing operational life.
As the casing diameter increases, the weight of the vane increases and so, too, does the friction produced by the vane when sliding and scraping along the casing surface. For this reason the manufacture of large-sized eccentric rotor vane pumps was regarded as impractical in the past.
By positioning the rotor shaft vertically, it is possible to reduce the friction between the ends of the vane and the casing surface, and thus to increase the size of eccentric rotor pumps. Furthermore the mathematical descriptions of cardiocle and expanded cardioid curves derived and shown in this invention allows the implementation of CNC techniques in the manufacture of casings, and subsequent increase in casing surface accuracy. CNC processing makes possible both mass production and cost reduction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a geometric representation of the movement of an eccentric rotor as contained in the invention referred to in this invention.
FIG. 2 compares a cardiocle with a simple cardioid.
FIG. 3 shows the operation of an eccentric rotor vane pump with a cardiocle casing.
FIG. 4 is the actual description of an eccentric rotor vane pump with a cardiocle casing.
FIG. 5 compares the curvatures of cardiocle and expanded cardioid casings.
FIG. 6 shows the relationship between the size of an eccentric rotor and an expanded cardioid.
FIG. 7 shows the operation of an eccentric rotor vane pump with an expanded cardioid casing.
FIG. 8 describes section processing of a pump casing using the methodology introduced in this invention.
FIG. 9 describes an eccentric rotor vane pump of horizontal design.
FIG. 10 describes an eccentric rotor vane pump of vertical design.
FIG. 11 displays the components of the eccentric rotor vane pump described in this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The derivation of the two equations for cardiocles and expanded cardioids, in reference to the figures and in terms of analytic geometry, are shown below.
FIG. 1 shows a cross-section of an eccentric rotor pump in Cartesian coordinates, for geometric analysis of the casing surfaces of the pump. The surface of circular rotor {circle around ( 2 )} touches basic circle {circle around ( 1 )} at point internally Ĉ. When rotor {circle around ( 2 )} rotates anticlockwise by θ° around the axis of eccentricity, which goes through point Oe, vane {circle around ( 3 )}, which is inserted in rotor {circle around ( 2 )}, also rotates in the same direction as the vane, sliding and scraping along the casing surface. One end of vane {circle around ( 3 )}, P 1 (X 1 , Y 1 ), then moves along the arc of basic circle {circle around ( 1 )}, i.e. J 1 →Ĉ→J 2 . Vane {circle around ( 3 )} moves in the direction of the diameter along the two guides between the two crescent halves of the assembled rotor {circle around ( 2 )}, passing through the eccentricity center Oe. The other end, P 2 (X 2 , Y 2 ), describes the dotted curve {circle around ( 4 )}.
The length of vane {circle around ( 3 )} is constant; ie., the distance between P 1 (X 1 , Y 1 ) and P 2 (X 2 , Y 2 ), 2{square root over ( r +L (2 R −r +L ))}=2 a , is also constant. This means that the distance between the two points J 1 and J 2 on the x-axis, and the distance between the two points on the y-axis, Ĉ of the perigee and {circle around (m)} of the apogee, are constant. Here, an idealized curve {circle around ( 4 )} is produced, where the distance between any two points on the curve passing through the center is always constant. If the radius of basic circle {circle around ( 1 )}, R, and the radius of rotor {circle around ( 2 )}, r, are determined, a mathematical equation describing the motion of the two ends of vane {circle around ( 3 )}, P 1 and P 2 , can be derived, with the angle of rotation, θ°, as the only variable.
Then the equation which describes the curve {circle around ( 4 )} is written in Cartesian coordinates as:
X 2 +Y 2 ={2{square root over ( r +L ( 2 R−r +L ))}+( R−r )sin θ−{square root over ( R 2 +L −( R−r +L ) 2 +L cos 2 +L θ)}} 2 (1),
where 0°≦θ≦180°.
In this equation, r denotes the radius of rotor {circle around ( 2 )}, R denotes the radius of basic circle {circle around ( 1 )}, and θ is the angle of rotation of vane {circle around ( 3 )}. This equation, in polar coordinates, is:
P= 2{square root over ( r +L ( 2 R−r +L ))}+( R−r )sin θ−{square root over ( R 2 +L −( R−r +L ) 2 +L cos 2 +L θ)} (2)
The equation describing the basic circle {circle around ( 1 )} can be written as:
X 2 +Y 2 ={{square root over ( R 2 +L −( R−r +L ) 2 +L cos 2 +L θ)}−( R−r )sin θ} 2 (3)
in Cartesian coordinates, and
P={square root over (R 2 +L −( R−r +L ) 2 +L cos 2 +L θ)}−( R−r )sin θ (4)
in polar coordinates.
If half of the length of the vane, {square root over (r(2+L R−r),)} is replaced with a into Equations (1) or (2), the equation becomes: P = 2 a { 1 + ( R - r ) sin θ . 2 a - R 2 - ( R - r ) 2 cos 2 θ 2 a } ( 5 )
This equation is equivalent to Equations (2) and (4) for curve {circle around ( 1 )} and {circle around ( 4 )}, i.e., the equation for cardiocles. Equation (5) resembles the equation for a simple cardioid, P=a (1+sin θ), for dotted curve 4 ′ in FIG. 2 . But, Equation (5) is smaller by its third term, {square root over (R 2 +L −( R−r +L ) 2 +L cos 2 +L θ)}, than that describing curve 4 ′. In other words, equation (5) shows a curve 4′ as a cardioid flattened by the amount {square root over ( R 2 +L −( R−r +L ) 2 +L cos 2 +L θ)} in comparison with an ordinary cardioid 4 ′ in the range, 0°≦θ≦180°. And this cardioid curve connects at the two points J 1 and J 2 with the arc of circle {circle around ( 1 )} in the range 180°≦θ≦360°. This composite curve describes the curve drawn by the full rotation of vane {circle around ( 3 )}. It is named “cardiocle” for being a flattened cardioid in the range, 0°≦θ≦180°, and for being a circle in the range, 180°≦θ≦360°.
FIG. 2 gives graphical comparison of the composite cardiocle curve {circle around ( 4 )} with an ordinary cardioid 4 ′, calculated and drawn using a computer in accordance with the widely-known cardioid equation and the cardiocle equation (5) derived here. As shown in FIG. 2, the distance between the y-intercept of the cardioid 4 ′ and the lower point Oe is 2 a =2 r {square root over (r(2+L R−r))}; and thus dotted cardiocle curve {circle around ( 4 )} is the flattened down by r, the radius of the rotor {circle around ( 2 )}, along the y-axis in the range y≧0; and expanded below Oe, also by the amount r. Along the y-axis in the range of yso--; Curve {circle around ( 4 )}, a cardiocle, has the composition of a cardioid in the J 1 -m-J 2 section and of a circular arc in the J 1 -C-J 2 section.
FIG. 3 is a mechanical drawing, which describes the movement of an eccentric rotor pump with a cardiocle casing. An exact equation, in which the only variable is θ, the angle of rotation of vane {circle around ( 3 )} or rotor {circle around ( 2 )}, can be derived to represent the above-mentioned cardiocle curve drawn by rotation of the vane. Using this equation, accurate casing surfaces can not be processed through CNC techniques.
As shown in FIGS. 3 and 4, the casing is fitted with an inlet, {circle around ( 13 )}, and an outlet, {circle around ( 14 )}, for the flow of liquid into and out of the pump. The inlet and outlet are shown in the fourth and third quadrangles in FIGS. 3 . The outer periphery of the casing is surrounded by a cooling chamber, to the outer side of which water jackets are attached.
When the vane mounted on the rotor, as in FIGS. 3 and 4, is rotated anticlockwise, suction force is produced in the casing section containing inlet {circle around ( 13 )}, due to pressure decrease, and drainage force in the section containing outlet {circle around ( 14 )}, due to pressure increase. Fluid inflow and outflow are repeated in tandem with the rotation of the rotor.
In addition to the heat generated by friction between rotating rotor {circle around ( 2 )} and vane {circle around ( 3 )} and the casing surface {circle around ( 4 )}, additional heat is generated due to the continuous kinetic movement of fluid molecules during the repeated inflow and outflow of the liquid. This problem can be solved by applying current water-cooling or air-cooling techniques. Other current eccentric rotor vane pumps require substantial amounts of high-viscosity sealing oil, as their vane ends do not closely or uniformly scrape along tne casing surfaces due to their inaccurately processed casings. However, the equations for curve {circle around ( 4 )} derived in this invention make possible the processing of casing surfaces to the highest possible degree of accuracy, thus requiring only small amounts of low-viscosity sealing oil and making operations more economical.
In order to acquire different curvatures, a curve was drawn using Equation (5) minus the last term, {square root over (R 2 +L −(R−r) 2 +L cos 2 +L θ)}. This new curve also shows that the length of the vane, or casing diameter, remains constant during full rotations. From this, a new equation (6), for what we will call an “expanded cardioid” from now on, is derived. P = 2 a { 1 + ( R - r ) 2 a sin θ } ( 6 )
This new equation is represented by curve 4 ″ in FIG. 5 . This curve is not defined as an ellipse by mathematical definition, although it looks like one. Equation (6) shows that it is an expanded form of the ordinary cardioid ( P=a (1+sin θ)); and is thus named an “expanded cardioid”. As shown in FIG. 5, the expanded cardioid curve 4 ″ is an enlargement, by R the radius of basic circle {circle around ( 1 )}, of the cardiocle curve {circle around ( 4 )}, in both directions along the y-axis. The length of the vane for this curve, as shown in FIG. 6, is exactly twice that for the cardiocles as shown in FIGS. 1 and 2. This equation can be effectively and ideally applied in the precision processing of another type of eccentric rotor vane pump with expanded cardioid casing. As this expanded cardioid curve is closer to a circle than a cardiocle, rotor movement is expected to be smoother.
In the case of the expanded cardioid curve 4 ″ shown in FIG. 6, the radius of the rotor is 2{square root over (r(2+L R−r))}−R+r. The rotor is positioned symmetrically, (2{square root over (r(2+L R−r))}−R+r) above the lower y-intercept and (2{square root over (r(2+L R−r))}+R−r) below the upper y-intercept, on the y-axis. Thus the center of the rotor can be exactly determined.
An interesting comparison can be made here; Equation (6) for the expanded cardioid suffices for the range 0°≦θ≦360°, while Equation(5) for the cardiocle suffices only for the range 0≦θ≦180°.
The equations (1) through (6) derived in this invention form a mathematical basis for computer numerical controlled manufacturing of casings of eccentric rotor vane pumps. On the basis of these equations, part processing and assembly of casings of sizes far surpassing the limits set by currently available machine tool technology is now possible for any R and r, the respective radii of any arbitrary primary circle and any eccentric rotor. As CNC techniques become used instead of the tradtional recopy method, mass production becomes possible, thus reducing production costs and allowing the production good quality pumps at reasonable prices. Furthermore, as manufacturing in sections becomes possible, no additional processing equipment is required for large-size casings.
As one practical example of this, invention, FIG. 7 illustrates the operation of a springless eccentric rotor vane pump with an expanded cardioid casing. FIG. 8 describes section processing of a pump casing where the radius R of the basic circle {circle around ( 1 )} is 1,000 mm and the radius r of the eccentric rotor {circle around ( 2 )} is 600 mm. The shaded areas in sectors A, B and C are the parts to be processed in sections using the methodology introduced in this invention. The following table 1 shows the coordinates (x, y) calculated with the equations which describe the two-dimensional cross section of the casing (FIG. 8 ), over the range 0≦θ≦90°.
TABLE 1
X
Y
0° ≦ θ ≦ 30°
0.327692
0.120531
0.655831
0.240369
0.984415
0.359512
1.313441
0.477958
1.642910
0.595706
1.972818
0.712755
2.303164
0.829101
2.633947
0.944745
2.965165
1.059685
3.296817
1.173918
3.628899
1.287444
3.961412
1.400260
4.294353
1.512366
4.627720
1.623759
4.961512
1.734439
5.295727
1.844403
5.630364
1.953650
5.965420
2.062180
6.300894
2.169989
6.636784
2.277076
6.973088
2.383441
7.309805
2.489081
7.646933
2.593996
7.984470
2.698183
8.322415
2.801641
8.660765
2.904369
8.999519
3.006365
9.338676
3.107628
9.678233
3.208156
10.018189
3.307948
10.358541
3.407003
10.699289
3.505318
11.040429
3.602893
11.381962
3.699726
11.723883
3.795816
12.066193
3.891162
12.408889
3.985761
12.751969
4.079612
13.095432
4.172715
13.439275
4.265068
13.783497
4.356669
14.128096
4.447516
14.473070
4.537610
14.818417
4.626948
15.164135
4.715528
15.510223
4.803350
15.856679
4.890413
16.203500
4.976714
16.550685
5.062252
16.898233
5.147027
17.246140
5.231037
17.594406
5.314281
17.943028
5.396756
18.292005
5.478463
18.641335
5.559399
18.991015
5.639564
19.341044
5.718956
19.691420
5.797573
20.042140
5.875415
20.393204
5.952481
20.744610
6.028768
21.096354
6.104277
21.448436
6.179005
21.800853
6.252951
22.153604
6.326114
22.506686
6.398494
22.860097
6.470088
23.213837
6.540895
23.567901
6.610914
23.922290
6.680145
24.277000
6.748586
24.632031
6.816235
24.987379
6.883092
25.343042
6.949155
25.699020
7.014423
26.055310
7.078895
26.411909
7.142570
26.766816
7.205447
27.126030
7.267524
27.483547
7.328801
27.841366
7.389276
28.199487
7.448948
28.557905
7.507817
28.916620
7.565881
29.275628
7.623138
29.634929
7.679589
29.994519
7.735231
30.354397
7.790063
30.714561
7.844085
31.075008
7.897296
31.435738
7.949694
31.796747
8.001279
32.158033
8.052049
32.519596
8.102003
32.881432
8.151140
33.243539
8.199460
33.605916
8.246961
33.968560
8.293642
34.331470
8.339502
34.694643
8.384541
35.058077
8.428756
35.421770
8.472148
35.785720
8.514715
36.149926
8.556457
36.514384
8.597372
36.879093
8.637459
37.244051
8.676718
37.609255
8.715147
37.974704
8.752745
38.340396
8.789513
38.706327
8.825448
39.072498
8.860550
39.438904
8.894817
39.805544
8.928250
40.172416
8.960846
40.539519
8.992606
40.906848
9.023528
41.274404
9.053612
41.642183
9.082856
42.010183
9.111260
42.378403
9.138823
42.746839
9.165543
43.115491
9.191421
43.484355
9.216455
43.853431
9.240645
44.222714
9.263989
44.592205
9.286458
44.961899
9.308139
45.331796
9.328943
45.701892
9.348898
46.072187
9.368003
46.442677
9.386259
46.813361
9.403664
47.184236
9.420217
47.555300
9.435918
47.926551
9.450766
48.297987
9.464759
48.669606
9.477899
49.041406
9.490183
49.413384
9.501610
49.785638
9.512181
50.157866
9.521895
50.530366
9.530751
50.903036
9.538747
51.275873
9.545884
51.648875
9.552161
52.022041
9.557577
52.395368
9.562131
52.768853
9.565823
53.142495
9.568652
53.516291
9.570618
53.890239
9.571719
54.264338
9.571956
54.638584
9.571327
55.012976
9.569833
55.387511
9.567471
55.762187
9.564243
56.137002
9.560146
56.511954
9.555181
56.887041
9.549347
57.262260
9.542644
57.637609
9.535070
58.013086
9.526625
58.388688
9.517310
58.764415
9.507122
59.140262
9.496062
59.516228
9.484130
59.892312
9.471323
60.268509
9.457643
60.644820
9.443089
61.021240
9.427659
61.397763
9.411354
61.774402
9.394173
62.151139
9.376116
62.527978
9.357182
62.904916
9.337370
63.281950
9.316681
63.659079
9.295113
64.036300
9.272667
64.413612
9.249341
64.791011
9.225136
65.168495
9.200050
65.546063
9.174085
65.923712
9.147238
66.301440
9.119510
66.679245
9.090900
67.057124
9.061409
67.435075
9.031035
67.813096
8.999778
68.191184
8.967638
68.569338
8.934614
68.947555
8.900706
69.325833
8.865914
69.704170
8.830238
70.082563
8.793676
70.461010
8.756229
70.839508
8.717897
71.218057
8.678678
71.596653
8.638574
71.975294
8.597583
72.353978
8.555705
72.732702
8.512939
73.111465
8.469287
73.490263
8.424747
73.869096
8.379318
74.247960
8.333002
74.626854
8.285797
75.005774
8.237704
75.384719
8.188721
75.763687
8.138849
76.142675
8.088088
76.521681
8.036438
76.900703
7.983897
77.279738
7.930467
77.658784
7.876146
78.037840
7.820934
78.416902
7.764833
78.795968
7.707840
79.175036
7.649956
79.554105
7.591181
79.933171
7.531515
80.312232
7.470958
80.691287
7.409509
81.070332
7.347168
81.449366
7.283935
81.828386
7.219811
82.207390
7.154794
82.586376
7.088885
82.965341
7.022084
83.344283
6.954391
83.723201
6.885804
84.102091
6.816326
84.480952
6.745955
84.859781
6.674691
85.238575
6.602534
85.617333
6.529485
85.996053
6.455542
86.374732
6.380707
86.753367
6.304979
87.131957
6.228358
87.510500
6.150843
87.888992
6.072436
88.267432
5.993136
88.645818
5.912943
89.024147
5.831857
89.402417
5.749877
89.780626
5.667005
90.158771
5.583240
90.536850
5.498582
90.914861
5.413031
91.292802
5.326588
91.670670
5.239251
92.048464
5.151022
92.426180
5.061900
92.803817
4.971886
93.181372
4.880979
93.558844
4.789180
93.336229
4.696488
94.313526
4.602904
94.690732
4.508428
95.067845
4.413060
95.444863
4.316801
95.821784
4.219649
96.198605
4.121606
96.575324
4.022671
96.951938
3.922846
97.328447
3.822128
97.704847
3.720520
98.081135
3.618021
98.457311
3.514632
98.833371
3.410352
99.209313
3.305181
99.585136
3.199121
99.960836
3.092170
100.336412
2.984330
100.711861
2.875600
101.087181
2.765981
101.462370
2.655473
101.837426
2.544076
102.212346
2.431791
102.587128
2.318617
102.961771
2.204555
103.336270
2.089605
103.710625
1.973768
104.084834
1.857043
104.458893
1.739431
104.832801
1.620933
105.206555
1.501548
105.580154
1.381277
105.953595
1.260120
106.326875
1.138077
106.699993
1.015149
107.072946
0.891337
107.445733
0.766639
107.818350
0.641058
108.190796
0.514592
108.563069
0.387243
108.935165
0.259011
109.307084
0.129896
30° ≦ θ ≦ 60°
0.371910
0.129871
0.744227
0.258937
1.116948
0.387199
1.490071
0.514655
1.863596
0.641303
2.237519
0.767143
2.611839
0.892174
2.986553
1.016395
3.361661
1.139804
3.737159
1.262401
4.113046
1.384184
4.489319
1.505153
4.865978
1.625307
5.243019
1.744643
5.620441
1.863163
5.998241
1.980864
6.376419
2.097745
6.754971
2.213805
7.133896
2.329045
7.513192
2.443461
7.892849
2.557052
8.272873
2.669819
8.653262
2.781760
9.034014
2.892875
9.415126
3.003162
9.796596
3.112621
10.178424
3.221251
10.560605
3.329051
10.943140
3.436020
11.326025
3.542157
11.709258
3.647461
12.092838
3.751931
12.476762
3.855566
12.861028
3.958365
13.245635
4.060329
13.630580
4.161454
14.015861
4.261742
14.401477
4.361190
14.787424
4.459798
15.173701
4.557565
15.560307
4.654490
15.947238
4.750573
16.334493
4.845812
16.722070
4.940207
17.109967
5.033756
17.498181
5.126460
17.886711
5.218317
18.275554
5.309326
18.664709
5.399487
19.054173
5.488798
19.443945
5.577259
19.834021
5.664870
20.224401
5.751628
20.615082
5.837535
21.006062
5.922588
21.397338
6.006786
21.788910
6.090131
22.180774
6.172619
22.572928
6.254252
22.965372
6.335027
23.358101
6.414945
23.751115
6.494004
24.144411
6.572203
24.537987
6.649543
24.931841
6.726022
25.325971
6.801640
25.720375
6.876395
26.115050
6.950288
26.509996
7.023317
26.905208
7.095482
27.300686
7.166782
27.696427
7.237216
28.092429
7.306784
28.488691
7.375485
28.885209
7.443319
29.281982
7.510284
29.679007
7.576380
30.076283
7.641607
30.473808
7.705964
30.871579
7.769450
31.269593
7.832064
31.667850
7.893806
32.066347
7.954676
32.465082
8.014672
32.864052
8.073795
33.263256
8.132042
33.662691
8.189415
34.062356
8.245912
34.462247
8.301533
34.862364
8.356277
35.262703
8.410144
35.663263
8.463133
36.064042
8.515243
36.465037
8.566474
36.866246
8.616825
37.267667
8.666297
37.669299
8.714887
38.071138
8.762597
38.473183
8.809424
38.875431
8.855370
39.277881
8.900432
39.680530
8.944612
40.083376
8.987907
40.486417
9.030319
40.889651
9.071845
41.293076
9.112486
41.696689
9.152242
42.100488
9.191111
42.504472
9.229094
42.908637
9.266190
43.312983
9.302398
43.717506
9.337718
44.122205
9.372149
44.527077
9.405692
44.932120
9.438345
45.337332
9.470109
45.742711
9.500983
46.148255
9.530965
46.553962
9.560057
46.959829
9.588258
47.365854
9.615567
47.772035
9.641983
48.178370
9.667507
48.584857
9.692138
48.991494
9.715876
49.398278
9.738720
49.805207
9.760671
50.212279
9.781726
50.619492
9.801887
51.026844
9.821153
51.434333
9.839524
51.841955
9.856998
52.249710
9.873577
52.657595
9.889259
53.065608
9.904045
53.473747
9.917933
53.882009
9.930925
54.290393
9.943018
54.698896
9.954214
55.107515
9.964511
55.516250
9.973910
55.925097
9.982410
56.334055
9.990012
56.743121
9.996714
57.152293
10.002516
57.561569
10.007418
57.970947
10.011421
58.380425
10.014523
58.790000
10.016725
59.199670
10.018025
59.609433
10.018425
60.019288
10.017924
60.429231
10.016521
60.839260
10.014217
61.249374
10.011011
61.659570
10.006903
62.069846
10.001892
62.480200
9.995979
62.890629
9.989164
63.301132
9.981446
63.711707
9.972825
64.122350
9.963300
64.533060
9.952873
64.943836
9.941542
65.354673
9.929308
65.765572
9.916170
66.176528
9.902128
66.587540
9.887182
66.998607
9.871332
67.409725
9.854578
67.820892
9.836919
68.232107
9.818357
68.643367
9.798889
69.054670
9.778517
69.466014
9.757241
69.877396
9.735059
70.288815
9.711973
70.700268
9.687982
71.111754
9.663086
71.523269
9.637284
71.934812
9.610578
72.346381
9.582966
72.757972
9.554450
73.169586
9.525027
73.581218
9.494700
73.992867
9.463467
74.404531
9.431329
74.816207
9.398286
75.227894
9.364337
75.639589
9.329483
76.051290
9.293723
76.462994
9.257058
76.874701
9.219488
77.286407
9.181012
77.698110
9.141631
78.109808
9.101344
78.521499
9.060152
78.933182
9.018055
79.344852
8.975053
79.756510
8.931145
80.168151
8.886333
80.579775
8.840615
80.991379
8.793993
81.402960
8.746465
81.814517
8.698032
82.226048
8.648695
82.637550
8.598453
83.049021
8.547307
83.460459
8.495255
83.871862
8.442300
84.283227
8.388440
84.694553
8.333676
85.105837
8.278008
85.517078
8.221436
85.928272
8.163960
86.339419
8.105580
86.750515
8.046297
87.161558
7.986110
87.572547
7.925020
87.983480
7.863027
88.394353
7.800131
88.805165
1.736332
89.215914
7.671630
89.626597
7.606026
90.037214
7.539520
90.447760
7.472112
90.858234
7.403801
91.268635
7.334589
91.678959
7.264476
92.089205
7.193461
92.499371
7.121545
92.909454
7.048728
93.319452
6.975011
93.729363
6.900393
94.139186
6.824875
94.548917
6.748457
94.958555
6.671139
95.368097
6.592922
95.777542
6.513805
96.186888
6.433790
96.596131
6.352876
97.005270
6.271063
97.414303
6.188352
97.823228
6.104744
98.232043
6.020237
98.640745
5.934834
99.049332
5.848533
99.457803
5.761336
99.866155
5.673243
100.274385
5.584253
100.682493
5.494367
101.090475
5.403586
101.498330
5.311910
101.906055
5.219339
102.313648
5.125874
102.721108
5.031514
103.128432
4.936261
103.535618
4.840114
103.942664
4.743074
104.349567
4.645142
104.756326
4.546317
105.162939
4.446600
105.569403
4.345991
105.975716
4.244492
106.381876
4.142101
106.787882
4.038820
107.193730
3.934649
107.599420
3.829588
108.004948
3.723638
108.410312
3.616799
108.815512
3.509072
109.220543
3.400456
109.625406
3.290954
110.030096
3.180563
110.434612
3.069287
110.838953
2.957124
111.243116
2.844075
111.647098
2.730141
112.050898
2.615321
112.454514
2.499618
112.857944
2.383030
113.261185
2.265559
113.664235
2.147205
114.067093
2.027968
114.469756
1.907849
114.872223
1.786849
115.274490
1.664967
115.676556
1.542205
116.078420
1.418563
116.480078
1.294041
116.881529
1.168640
117.282771
1.042361
117.683802
0.915203
118.084619
0.787168
118.485221
0.658256
118.885605
0.528468
119.285769
0.397804
119.685712
0.266264
120.085432
0.133850
120.484925
0.000561
60° ≦ θ ≦ 90°
0.400229
0.131263
0.800795
0.261688
1.201698
0.391276
1.602934
0.520024
2.004502
0.647934
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3.211179
1.026617
3.614056
1.151160
4.017254
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1.397717
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6.038005
1.880689
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2.117092
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2.350099
8.066506
2.465328
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2.579706
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2.693232
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2.805905
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2.917726
10.102504
3.028693
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3.356465
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3.464010
12.145749
3.570699
12.555245
3.676530
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3.781503
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19.971694
5.434153
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24.126448
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6.984068
28.303254
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28.722068
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29.141080
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29.979690
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30.819066
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31.239036
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31.659192
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32.079531
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32.920751
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33.762681
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1.033327
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A pump casing can be divided into convenient sizes and manufactured in sections. Finished parts can be assembled with nuts and bolts provided in the package, following instructions, to form a casing of the desired curvature.
FIG. 9 describes the disassembled parts of an eccentric rotor vane pump of horizontal design, and FIG. 10 describes the disassembled parts of an eccentric rotor vane pump of vertical design. FIG. 11 shows the components of the eccentric rotor vane pump described in this invention. In the manufacture of large-sized casings using the existing manufacturing method, the entire casing is manufactured as a single piece and the size of the rotor increases in proportion to the size of the casing. In this case the processing of the accurate guide surface which meets with the sliding, scraping vane is severely disabled. In order to overcome this limitation, two semi-circular rotors ( 5 and 5 ′) are separately manufactured, as shown in FIG. 11 . On the inside of each semi-circular rotor, guide grooves ( 7 ′) are formed to match the projecting parts {circle around ( 7 )} on both sides of vane {circle around ( 3 )}, so that the projecting parts can move along the grooves when the vane slides back and forth. The casing parts ( 1 and 6 ) are held together with bolts and side covers ( 9 and 9 ′) are tightly placed on the open sides of the casing also using bolts. The rotating discs ( 8 and 8 ′) drives the eccentric rotor ( 2 ) to otates in close contact with the inner surface of the casing. The sealing parts ( 10 and 10 ′) are fitted inside the side covers ( 9 and 9 ′), and sealing liquid is applied to the contacting surfaces between the sealing parts and the rotating discs ( 8 and 8 ′) and shafts ( 12 and 12 ′). The bearing boxes ( 11 and 11 ′) are attached to the sealing parts using bolts, to support the rotating shafts ( 12 and 12 ′).
The reference number 13 denotes the fluid inlet and the number 14 , the fluid outlet. The number 16 , 17 and 18 in the figures refer to bolts and nuts provided in the package. The number 15 in FIG. 10 denotes the thrust bearing which is used to support the weight of an eccentric rotor oI vertical shaft.
In an eccentric rotor vane pump of vertical shaft as shown in FIG. 10, the rotor experiences increasing weight as casing size increases. In addition to the lower shaft and the bearing in the bearing box, therefore, a large-sized pump as an in-built thrust bearing to support the weight and thus allow smooth rotations regardless of the rotor weight. As casing size increases, weight of the vane also increases. For this reason, vane {circle around ( 3 )} is designed to reciprocate horizontally, along the guide faces of the vertical axial rotor. So the vane can slide and scrape the inner surface of the casing in close contact, no matter how large casing size and vane weight may be. Friction and centrifugal force generated by the rotating vane of a large-sized pump can also be greatly reduced. The weight of vane {circle around ( 3 )} still affects the horizontal movement of the vane, while due to horizontal rotations the two ends of the vane, sliding and scraping in contact with the curved surface of the casing, can no longer affect the gravitational pull on the vane. Therefore vane {circle around ( 3 )} is designed to contain the appropriate number of convex parts ( 7 ), and the semi-circular rotors, the same number of grooves ( 7 ′) as convex parts. Or a suitable device such as beating is installed at the center of mass on the upper or bottom side of the vane, so as to absorb and reduce the weight of vane {circle around ( 3 )}. As a result, the eccentric rotor vane pump of this design can undertake smooth horizontal movement, which is one of the major purports of this invention.
Springless eccentric rotor vane pumps (of either horizontal or vertical shaft) with cardiocle and expanded cardioid casings derived from Equations (5) and (6), as explained above, solve the limitations of, and problems posed by, current eccentric rotor vane pumps. Processing of large-size pumps is now possible with mathematical formation of casing curatures, hitherto regarded as impossible. In addition, as these pumps can perform more revolutions per unit time, pump size can be greatly reduced; pumps one-fifth the size of curtent large-size, large-output pumps can produce the same amounts of output. Moreover the achievement of exact mathematical descriptions of the cardiocle and expanded cardioid is opening a new chapter in pump technology in terms of analytic geometry.
The following section on ‘what is claimed’ merely suggests a few applications of this invention. Further changes or corrections are still possible, but these are conceptually part of the invention. | This invention includes the derivation of the exact mathematical expressions for the curvature, either cardiocle or expanded cardioid, of the casing of the springless eccentric rotor vane pump, thereby facilitating the precision manufacture of the curved surfaces of the casing using CNC techniques. As a result, the capacity and accuracy of the eccentric rotor vane pump is greatly improved. As the section manufacture and assembly of the casing becomes possible, the mass production of large-sized pumps of 1-meter or larger diameter is now attainable, hitherto regarded as almost impossible, and therefore production cost is also reduced. The unique design which positions the axis of eccentricity in the lower central part of the axis of rotor rotation results in increase in the rotation speed of the rotor, and leads to reduction of friction between the vane ends and the curved surface of the casing as the weight of the vane does not affect the movement of the rotor. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of co-pending application Ser. No. 11/104,429 filed or Apr. 13, 2005, and for which priority is claimed under 35 U.S.C. § 120; and this application claims priority benefit of Taiwan Patent Application No. 93134142, filed on Nov. 9, 2004 under 35 U.S.C. § 119; the entire contents of all are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a semi-conductor memory, and more particular, to a multilevel phase-change memory.
[0004] 2. Background of the Invention
[0005] Most electronic equipment uses different types of memories, such as a DRAM, SRAM and Flash memory or the combination of these different types' memories based on the requirements of the application, the operating speed, the memory size and the cost consideration of the equipment. The current new developments in the memory field include FeRAM, MRAM and phase-change memory.
[0006] A Phase-change memory records data by changing the material of the semi-conductor circuit to different phase states due to the resistance changes inside of the circuit. Many materials, such as Ge 2 Sb 2 Te 5 and others, have the characteristics of changing to different crystallization states with different temperatures and different crystallization states have different resistance. Therefore, a phase-change memory using electrical heating can change materials, such as Ge 2 Sb 2 Te 5 , into different crystallization states, each having different resistance, where each different state can represent a different recording state, i.e., 0 or 1. Moreover, a phase-change memory is non-volatile, it will retain data recorded even if the power is off. Therefore, during a data writing operation in a phase-change memory, the electrical current has to be supplied to the selected memory cells, which will cause phase transition after being heated up by heating electrodes.
[0007] The current phase-change memory technology uses contact to make a phase area method, such as a structure combining phase-change memory and a CMOS transistor disclosed by Samsung Electronics Co., Ltd in IEDM 2003, which connects heating electrodes to the phase-change layer and uses the contact as a phase-change area. Also in IEDM 2003, STMicroelectronics & Ovonyx Inc. recommended another structure using the via as phase-change region, which fills the phase-change layer in the via to obtain a smaller switching current.
[0008] The above-referenced technology using the via to connect a heating electrode to a phase-change region will prevent making a high capacity memory. Therefore, the increase of a phase-change memory density is one key focus in the current memory technology development.
SUMMARY OF THE INVENTION
[0009] The present invention provides a multilevel phase-change memory and its associated manufacture method, which will solve several existing problems in the prior art.
[0010] Accordingly, the multilevel phase-change memory of the present invention includes a first phase-change layer, a second phase-change layer, a first heating layer formed on a first surface of the first phase-change layer, a second heating layer formed between the first phase-change layer and the second phase-change layer, a first top electrode formed on a second surface of the first phase-change layer, a second top electrode formed on a second surface of the second phase-change layer, and a bottom electrode formed on a second surface of the first heating layer opposite to the second heating layer.
[0011] The multilevel phase-change memory further includes a substrate with a transistor, and the bottom electrode is formed on the substrate.
[0012] Further, the manufacture method of a multilevel phase-change memory includes providing a substrate with a transistor formed thereon, forming a bottom electrode on the substrate, forming a first heating layer on top of the bottom electrode, forming a second heating layer on top of the first heating layer, forming a phase-change layer on top of the second heating layer, etching the phase-change layer to form a first phase-change layer and a second phase-change layer, and forming a first top electrode and a second electrode on top of the second phase-change layer opposite to the first phase-change layer.
[0013] Furthermore, the present invention provides an operating method of a multilevel phase-change memory including grounding the first top electrode and the second top electrode, and applying a pulse current to the bottom electrode, to make the first phase-change layer and the second phase-change layer change states thereof according to the pulse current. Moreover, the operation method further includes converting the first phase-change layer and the second phase-change layer into a non-crystal state before applying the pulse current.
[0014] Another operating method of a multilevel phase-change memory according to the present invention includes grounding the first top electrode and the second top electrode, and applying a pulse current to one of the first top electrodes and the second top electrodes.
[0015] The present invention utilizes a single transistor to control two different contact regions of phase-change area, which can achieve a higher recording density by realizing multiple recordings in a single memory cell, and increases the density of the memory and reduces the power consumption.
[0016] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0018] FIG. 1 is a structure of phase-change memory of the present invention.
[0019] FIGS. 2A-2J illustrate different structures of the phase-change memory of the present invention during the manufacture process.
[0020] FIGS. 3A-3B illustrate other different structures of the phase-change memory of the present invention during the manufacture process.
[0021] FIG. 4 is the writing operation of the phase-change memory of the present invention.
[0022] FIG. 5 is the reading operation of the phase-change memory of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention will now be described in detail with reference to the accompanying drawings, wherein the same reference numerals will be used to identify the same or similar elements throughout the several views. It should be noted that the drawings should be viewed in the direction of orientation of the reference numerals.
[0024] With reference to FIG. 1 , the present invention multilevel phase-change memory comprises a first phase-change layer 10 , a second phase-change layer 20 , a bottom electrode 30 , a first top electrode 41 and a second top electrode 42 , a first heating layer 51 and a second heating layer 52 .
[0025] As shown in FIG. 1 , the bottom electrode is formed on a substrate 100 . There is a transistor 70 formed on the substrate 100 using a compatible manufacturing process. For example, the transistor can be either a P-type or an N-type MOSFET. If it is a P-type MOSFET, a P-type substrate is formed with the Group III element added in the substrate 100 and an N-type region formed with the Group V element is added in the transistor, which is connected to the bottom electrode 30 for signal transmitting. On the other hand, for an N-type MOSFET, an N-type substrate formed with a Group V element is added in the substrate 100 , while a P-type region (P-well) formed with a Group III element is added in the transistor which is connected to the bottom electrode 30 .
[0026] Furthermore, on top of the bottom electrode 30 , a first heating layer 51 is formed, and then a second heating layer 52 is formed above. In the example shown in the FIG. 1 , the area size of the first heating layer 51 is different from the area size of the second heating layer 52 . However, in the other examples, the area size between the first heating layer 51 and the second heating layer 52 can be the same. As far as the material used for making the heating layer, it can be poly-Si, SiC, TiW, TiN and/or TiAlN.
[0027] The first phase-change layer 10 contacts the first heating layer 51 , and the second phase-change layer 20 is formed on the second heating layer. On top of the first phase-change layer 10 is the first top electrode 41 , and the second top electrode 42 is on top of the second phase-change layer 20 . In one embodiment, the first phase-change layer 10 and the second phase-change layer can be made in the same step with similar material. In another embodiment, different material can be used in different steps, so each phase-change layers and the selections of different materials can be GeSbTe, AgInSbTe, or GeInSbTe, etc. The bottom electrode 30 , the first top electrode 41 and the second top electrode 42 can be made from a metal material. In addition, between each layer, there is an insulation layer 60 (such as, SiO 2 , Si 3 N 4 , polymer etc) to separate them.
[0028] As the structure shown in the examples, when the memory is chosen by an outside control circuit through the transistor, the first phase-change layer 10 is heated by the first heating layer 51 , and the second phase-change layer 20 is heated by the first heating layer 51 and the second heating layer 52 such, that due to characteristic of the material used in them, the heating will induce phase changes both in the first phase-change layer 10 and the second phase-change layer 20 . According to the principle of the present invention, using two phase-change layers and a transistor form a memory cell, each phase-change layer has two states: crystal and non-crystal, and each phase-change layer can change its state by heating, therefore, two phase-change layers can form a multilevel phase-change memory.
[0029] Referring to FIG. 2A-2J , they is a manufacture process for multilevel phase-change memory of the present invention.
[0030] First, in a substrate 100 , preferably a silicon substrate, a transistor may be formed if chosen; then an insulation layer 101 is laid on the top of the substrate 100 ; next, a guiding hole is etched on the insulation layer 101 and metal is filled into the hole to form the bottom electrode 102 as shown in FIG. 2A .
[0031] Then the first heating layer 103 is formed above the bottom electrode 102 , and an insulation layer 104 is placed on top of the heating layer 103 , as shown in FIG. 2B .
[0032] Next, a guiding hole 105 is etched on the insulation layer 104 which is also aligned with the bottom electrode 102 ; then the second heating layer 106 is formed on top of the insulation layer 104 , as shown in FIGS. 2C and 2D ; through the guiding hole, the first heating layer 103 makes contact with the second heating layer 106 to be able to heat the phase-change layer in various degrees.
[0033] Then, after etching the second heating layer 106 , the first heating layer 103 and the insulation layer 104 are etched into a form shown in 2 E and 2 F.
[0034] Next, a phase-change layer 107 is formed on top of the second heating layer 106 as shown in FIG. 2F and then it is etched into the first phase-change layer 107 A and the second phase-change layer 107 B; Then, an insulation layer 108 is formed and two guiding holes 109 , 110 are etched, as shown in FIGS. 2G-2I .
[0035] In this embodiment, the first phase-change layer and the second phase-change layer are made from the same material. In other embodiments, they can be made from different material. Finally, the first electrode 111 and second electrode 112 are formed as shown in FIG. 2J .
[0036] With reference to FIGS. 3A and 3B , another example of forming the second heating layer. The second heating layer 113 is formed by depositing and etching into a specified size, as shown in FIGS. 3A and 3B . Then, an insulation layer 114 is formed after etching above the second heating layer 114 , as shown in FIG. 2E .
[0037] Assuming the phase-change ratios of two different phase-change layers (represented by PC 1 and PC 2 ) are PC 1 = 1/10, PC 2 =⅕, and assuming the phase-change material is Ge 2 Sb 2 Te 5 , its resistance in the crystal state is 10 −2 Ω-cm, and its resistance in the non-crystal state is 100 Ω-cm; the resistances in crystal and non-crystal state of two different regions of phase-change layers during operation are shown in Table 1, where the component sizes are evaluated according to the TSMC manufacturing standard of 0.18 μm CMOS.
[0000]
TABLE 1
Resistances
Crystal
Non-Crystal
PC1
714.3 Ω
7.14 × 10 5 Ω
PC2
148 Ω
2.96 × 10 5 Ω
[0038] Also, assuming the electrode material of the first heating layer is TiN and its resistance is 28.6Ω, and the electrode material of the second heating layer is SiC and its resistance is 2.4×10 4 Ω, then the resistance ratio between two corresponding conductors (two electrical current paths: An electrical current path is from the bottom electrode 30 via the first heating layer 51 and then to the first phase-change layer 10 . Another electrical current path is from the bottom electrode 30 , via the first heating layer 51 and the second heating layer 52 and then to the second phase-change layer 20 ) at non-crystal states are:
[0000] PC 1 : PC 2=(7.14×10 5 +28.6):(2.96×10 5 +2.4×10 4 )=2.23:1
[0039] Based on this resistance ratio, four different operation currents can be obtained; the phase-change relationship between the first phase-change layer and the second phase-change layer is as shown in Table 2:
[0000]
TABLE 2
Operation current and phase-change
Current(mA),
Current
Pulse interval
Phase-change layer
Density(mA/μm 2 )
States
0.42, 50 nS
First PC Layer
30
Crystal
Second PC Layer
13.8
No Change
0.7, 30 nS
First PC Layer
50
Non-Crystal
Second PC Layer
23
No Change
2.0, 50 nS
First PC Layer
64
Crystal
Second PC Layer
30
Crystal
3.38, 30 nS
First PC Layer
108
Non-Crystal
Second PC Layer
50
Non-Crystal
[0040] Therefore, by applying different current pulse signals, four kinds of recording states can be achieved via the structure of two different phase-change layers.
[0041] According to the principle of the present invention, the first phase-change layer and the second phase-change layer shall be set to a non-crystal state, then by applying with different writing current pulses, it produces different beating resistances at the contact areas, having different phase changes of the first and the second phase-change layers, therefore, it achieves a multilevel recording operation. When in a memory writing operation, the two phase-change layers are connected in parallel; and when in a memory reading operation, the two layer's resistances are read in serial.
[0042] Referring to FIG. 4 , the operation of a writing signal for the phase-change memory is shown. To write, the phase-change layers are changed to different crystal states by the pulse current provided by the transistor, which will generate four different levels. While writing, by grounding the first top electrode 41 and the second top electrode 42 , and then applying the writing signal through the bottom electrode 30 , the data is written through state changes in the first phase-change layer 10 and the phase-change layer 20 . In one embodiment, before writing data, a first control signal is applied to change both the states of the first phase-change layer 10 and the phase-change layer 20 to a non-crystal state; then the writing signal is applied.
[0043] Referring to FIG. 5 , the operation of a reading signal for the phase-change memory is shown, and the area resistance states of two phase-change layers are taken in serial. That is, the first top electrode 41 is grounded and the pulses current is applied through the second top electrode 42 , by measuring the current passing through the first phase-change layer 10 and the phase-change layer 20 , the crystal states of the first phase-change layer 10 and the phase-change layer 20 will be revealed.
[0044] The structure, using one transistor and two phase-change layers of the present invention, takes much less space and power consumption in each cell than the prior art does. The detailed comparison is shown in Table 3, according to the TSMC manufacturing standard of 0.18 μm CMOS.
[0000]
TABLE 3
Previous Technology
Present Invention
Reset current (mA)
3.38
4.89
Reset current per cell (mA)
3.38
2.45
Reset current ratio
1
0.723
Transistor width and length
14/0.18
20/0.18
ratio
Memory cell area (μm 2 )
0.56 × 0.56 = 0.31
1.18 × 0.56 = 0.66
Memory cell area per cell
0.31
0.33
(μm 2 )
Transistor area (μm 2 )
3.5 × 2.81 = 9.84
4.0 × 3.36 = 13.44
Transistor area per cell
9.84
6.72
(μm 2 )
Area ratio
1
0.683
[0045] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A manufacture method of a multilevel phase-change memory and operating method thereof are provided. The method includes providing a substrate, forming a bottom electrode on the substrate, forming a first heating layer on top of the bottom electrode, forming a second heating layer on top of the first heating layer, forming a first phase-change layer and a second phase-change layer respectively on the first heating layer and the second heating layer, and forming a first top electrode and a second electrode respectively on the first phase-change layer and the second phase-change layer. Hence, the bottom electrode, the first heating layer and the first phase-change layer constitute an electrical current path, the bottom electrode, the first heating layer, the second heating layer and the second phase-change layer constitute another electrical current path, and the resistances of the two electrical current path are different, thereby increasing the memory density. | 6 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Nos. 60/381,012, 60/381,021, 60/380,894, 60/380,910, 60/380,880, 60/381,017, 60/380,895, 60/380,903, 60/381,013, 60/380,878 and 60/380,909, all of which were filed May 15, 2002. This application also claims the benefit of U.S. Provisional Application No. 60/392,833, filed Jun. 27, 2002. The entire teachings of the above-referenced applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Alpha-amino acids are useful starting materials in the synthesis of peptides, as well as non-peptidal, pharmaceutically active peptidomimetic agents. In order to enable the synthesis of a large number of compounds from an amino acid precursor, it is advantageous to have naturally occurring and non-naturally occurring amino acids. Non-naturally occurring amino acids typically differ from natural amino acids by their stereochemistry (e.g., enantiomers), by the addition of alkyl groups or other functionalities, or both. At this time, the enantiomers of naturally occurring amino acids are much more expensive than the naturally occurring amino acids. In addition, there are only a limited number of commercially available amino acids that are functionalized or alkylated at the alpha-carbon, and often syntheses involve the use of pyrophoric or otherwise hazardous reagents. Moreover, the syntheses are often difficult to scale up to a commercially useful quantity. Consequently, there is a need for new methodologies of producing such non-naturally occurring amino acids.
[0003] Non-naturally occurring amino acids of interest include the (R)- and (S)-isomers of 2-methylcysteine, which are used in the design of pharmaceutically active moieties. Several natural products derived from these isomers have been discovered in the past few years. These natural products include desferrithiocin, from Streptomyces antibioticus ; as well as tantazole A, mirabazole C, and thiangazole, all from blue-green algae. These compounds have diverse biological activities ranging from iron chelation to murine solid tumor-selective cytotoxicity to inhibition of HIV-1 infection.
[0004] Desferrithiocin, deferiprone, and related compounds represent an advance in iron chelation therapy for subjects suffering from iron overload diseases. Present therapeutic agents such as desferroxamine require parenteral administration and have a very short half-life in the body, so that patient compliance and treatment cost are serious problems for subjects receiving long-term chelation therapy. Desferrithiocin and related compounds are effective when orally administered, thereby reducing patient compliance issues. Unfortunately, (S)-2-methylcysteine, which is a precursor to the more active forms of desferrithiocin and related compounds, remains a synthetic challenge. Therefore, there is a need for novel methods of producing 2-methylcysteine at a reasonable cost, and means of isolating the desired enantiomer.
SUMMARY OF THE INVENTION
[0005] The present invention includes a method of preparing a 2-alkylated cysteine represented by Structural Formula (I):
[0006] or salts thereof;
[0007] wherein R 2 is a substituted or unsubstituted alkyl group; comprising the steps of:
[0008] a.) reacting a compound represented by Structural Formula (II):
[0009] with a substituted or unsubstituted aryl nitrile of the formula Ar—CN, wherein Ar is a substituted or unsubstituted aryl group; thereby forming a substituted thiazoline represented by Structural Formula (III):
[0010] b.) alkylating the substituted thiazoline with one or more bases and R 2 X, wherein X is a leaving group and R 2 is as defined above; thereby forming an alkylated substituted thiazoline represented by Structural Formula (IV):
[0011] c.) reacting the alkylated substituted thiazoline with acid (preferably an inorganic acid such as HCl, HBr or sulfuric acid), thereby forming the 2-alkylated cysteine represented by Structural Formula (I).
[0012] The present invention also includes a method of preparing a compound represented by Structural Formula (V):
[0013] comprising the steps of:
[0014] a.) reacting a compound represented by Structural Formula (II):
[0015] with a substituted or unsubstituted aryl nitrile of the formula Ar—CN, wherein Ar is a substituted or unsubstituted aryl group; thereby forming a substituted thiazoline represented by Structural Formula (III):
[0016] b.) alkylating the substituted thiazoline with one or more bases and CH 3 X, wherein X is a leaving group; thereby forming an alkylated substituted thiazoline represented by Structural Formula (IV):
[0017] c.) resolving the alkylated substituted thiazoline into (R)-4-methyl-2-arylthiazoline-4-carboxylic acid and (S)-4-methylthiazoline-4-carboxylic acid;
[0018] d.) isolating (S)-4-methyl-2-arylthiazoline-4-carboxylic acid;
[0019] e.) reacting (S)-4-methyl-2-arylthiazoline-4-carboxylic acid with acid, thereby forming (S)-2-methylcysteine; and
[0020] f.) coupling (S)-2-methylcysteine with 2,4-dihydroxybenzonitrile, thereby forming the compound represented by Structural Formula (V).
[0021] In another embodiment, an analogous compound to that shown in the previous embodiment can be synthesized by coupling 2-hydroxybenzonitrile and (S)-2-methylcysteine or a salt or an ester thereof. Similar syntheses can be conducted with other substituted benzonitriles.
[0022] Advantages of the present invention include the facile synthesis of a 2-alkyl cysteine from cysteine, an inexpensive and readily available starting material. 2-Methylcysteine prepared by the method of the present invention can be coupled to 2,4-dihydroxybenzonitrile to form 4′-hydroxydesazadesferrithiocin, also referred to as 4,5-dihydro-2-(2,4-dihydroxyphenyl)-4-methylthiazole-4(S)-carboxylic acid, an iron chelating agent.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A useful and efficient method of preparing 2-alkylcysteine involves condensing cysteine with an aryl nitrile to form a 2-arylthiazoline-4-carboxylic acid, followed by alkyation at the 4-position of the thiazoline ring. The resulting racemic 2-alkylcysteine product can be resolved and isolated into a pure or substantially pure enantiomer by a number of methods.
[0024] The condensation of an aryl nitrile and cysteine typically occurs in a polar, protic solvent (e.g., water, methanol, ethanol, formamide, formic acid, acetic acid, dimethylformamide, N-ethylacetamide, formaldehyde diethyl acetal) in the presence of an excess of base. Typically, the aryl nitrile and cysteine are refluxed together for several hours, such as 1-20 hours, 2-15 hours, 4-10 hours, or 6-8 hours. Refluxing preferably occurs in an inert atmosphere, such as nitrogen or argon. An alcohol such as methanol or ethanol is a preferred solvent. Preferred aryl nitriles include aryl nitriles where the aryl group is a substituted or unsubstituted phenyl group. Phenyl is a preferred aryl group. Suitable bases include secondary and tertiary amines such as dimethylamine, diethylamine, trimethylamine, diphenylamine, diisopropylamine, diisopropylethylamine, 1,4-diazabicyclo[2.2.2]octane (DABCO), 1,5-diazabicyclo[4.3.0]non-5-ene (DBN), and triethylamine. Suitable amounts of base have at least about one equivalent of base, and range from about 1 to about 10, about 1 to about 5, about 1 to about 3, and about 1 to about 2 equivalents, relative to the amount of cysteine.
[0025] Alternatively, an aryl imidate (e.g., a benzimidate, where the benzene ring can have one or more substituents, as described below) can be condensed with cysteine. Typically, the aryl imidate is reacted with cysteine under basic conditions. Acceptable bases include those named above. Aryl imidates can be prepared, for example, for aryl nitriles, aryl carboxylic acids, and aryl amides. Examples of aryl imidate preparation can be found, for example, in U.S. application Ser. No. 60/380,909, filed May 15, 2002, the contents of which are incorporated herein by reference. In one example, an aryl carboxylic acid (e.g., benzoic acid) is converted into an acid chloride, then an amide, followed by reaction with a trialkyloxonium hexafluorophosphate or a trialkyloxonium tetrafluoroborate to form the aryl imidate. In a second example, an aryl nitrile is converted into an aryl imidate through reaction with an alcohol in the presence of an acid, as is described below.
[0026] The 2-arylthiazoline-4-carboxylic acid can be alkylated in the presence of one or more bases, an alkylating agent, and optionally a phase transfer catalyst. Typically, the 2-arylthiazoline-4 carboxylic acid is reacted with one or more equivalents (e.g., about 1 to about 10 equivalents, about 1 to about 5 equivalents, about 1 to about 3 equivalents, or about 1.5 to about 2.5 equivalents) of base and one or more equivalents (e.g., about 1 to about 5 equivalents, about 1 to about 2 equivalents, about 1 to about 1.5 equivalents, about 1 to about 1.1 equivalents) of an alkylating agent in a polar, aprotic solvent (e.g., acetone, acetonitrile, dimethylformamide, dioxane, ethyl acetate, ethyl ether, hexamethylphosphoramide, tetrahydrofuran) at about −80° C. to about 40° C., about −50° C. to about 25° C., about −20° C. to about 10° C., or about −5° C. to about 5° C. Alkylating agents are of the formula R 2 X, where R 2 and X are as defined above. Preferred R 2 groups include substituted or unsubstituted C1-C4 alkyl groups; methyl and benzyl are preferred R 2 . The leaving group X is typically a weak base. Suitable leaving groups include halogen, tosyl, triflyl, brosyl, p-nitrophenyl, 2,4-dinitrophenyl, and mesyl groups. Halogens include bromine, chlorine, and iodine. Iodine is a preferred leaving group. Preferred bases include potassium t-butoxide, sodium methoxide, sodium ethoxide, sodium amide, and other alkali and alkaline earth metal alkoxides.
[0027] Examples of phase transfer catalysts include benzyl triethyl ammonium chloride, benzyl trimethyl ammonium chloride, benzyl tributyl ammonium chloride, tetrabutyl ammonium bromide, tetraethyl ammonium bromide, tetrabutyl ammonium hydrogen sulfate, tetramethyl ammonium iodide, tetramethyl ammonium chloride, triethylbutyl ammonium bromide, tributyl ethyl ammonium bromide, tributyl methyl ammonium chloride, 2-chloroethylamine chloride HCl, bis(2-chloroethyl)amine HCl, 2-dimethylaminoethyl chloride HCl, 2-ethylaminoethyl chloride HCl, 3-dimethylaminopropyl chloride HCl, methylamine HCl, dimethylamine HCl, trimethylamine HCl, monoethylamine HCl, diethylamine HCl, triethylamine HCl, ethanolamine HCl, diethanolamine HCl, triethanolamine HCl, cyclohexylamine HCl, dicyclohexylamine HCl, cyclohexylamine HCl, diusopropylethylamine HCl, ethylenediamine HCl, aniline HCl, methyl salicylate, ethyl salicylate, butyl salicylate amyl salicylate, isoamyl salicylate, 2-ethylsalicylate, and benzyl salicylate.
[0028] In a preferred embodiment of the present invention, enantiomers of an alkylated substituted thiazoline are resolved. The alkylated substituted thiazoline can be resolved by emulsion crystallization or by reacting the alkylated substituted thiazoline with one enantiomer of a 1-alkyl-1-aminoalkane or a 1-aryl-1-aminoalkane (i.e., to form a diastereomeric salt). Resolution of chiral compounds using diastereomeric salts is further described in CRC Handbook of Optical Resolutions via Diastereomeric Salt Formation by David Kozma (CRC Press, 2001), which is incorporated herein by reference in its entirety. Following resolution, the (R) enantiomer or, preferably, the (S) enantiomer of the alkylated substituted thiazoline is isolated. The enantiomer is subsequently hydrolyzed with an acid (e.g., HCl, HBr, dilute H 2 SO 4 ) to obtain, for example, a (S)-2-alkylcysteine. Alternatively, the alkylated substituted thiazoline can first be hydrolyzed with acid to form an amino acid and the resultant amino acid can be resolved by, for example, one of the above-named methods.
[0029] When forming a diastereomeric salt, suitable chiral amines include arylalkylamines such as 1-alkyl-1-aminoalkanes and 1-aryl-1-aminoalkanes. Examples include (R)-1-phenylethylamine, (S)-1-phenylethylamine, (R)-1-tolylethylamine, (S)-1-tolylethylamine, (R)-1-phenylpropylamine, (S)-1-propylamine, (R)-1-tolylpropylamine, and (S)-1-tolylpropylamine.
[0030] Diastereomers or entantiomers of amino acids or functionalized derivatives thereof (e.g., esters) can also be resolved by emulsion crystallization. Emulsion crystallization is described in U.S. Pat. Nos. 5,872,259, 6,383,233 and 6,428,583, which are incorporated herein by reference. Briefly, emulsion crystallization is a process for separating a desired substance from an aggregate mixture. The process involves forming a three phase system, the first phase comprising the aggregate mixture, the second phase being liquid and comprising a transport phase, and the third phase comprising a surface upon which the desired substance can crystallize. A chemical potential exists for crystal growth of the desired substance in the third phase of the system, thereby creating a flow of the desired substance from the first phase through the second phase to the third phase, where the desired substance crystallizes and whereby an equilibrium of the activities of the remaining substances in the aggregate mixture is maintained between the first phase and the second phase.
[0031] In one example of emulsion crystallization, a solution of the racemic mixture is supersaturated (by either cooling, adding a solvent in which one or more components are sparingly soluble or by evaporation of the solution). Ultrasonication eventually helps the process of forming an emulsion. The mixture is then seeded with crystals of the desired, optically active acid along with an additional quantity of surfactant and an anti-foaming agent. The desired product usually crystallizes out and can be separated by filtration. Further details of emulsion crystallization for an amino acid derivative can be found in Example 4.
[0032] Cysteine or a 2-alkylcysteine such as (S)-2-methylcysteine can be coupled to a substituted or unsubstituted aryl nitrile such as a substituted or unsubstituted benzonitrile. Preferably, the substituents on benzonitrile will not interfere with the coupling reaction. In a preferred embodiment, (S)-2-methylcysteine is coupled to 2,4-dihydroxybenzonitrile to form 4,5-dihydro-2-(2,4-dihydroxyphenyl)-4-methylthiazole-4(S)-carboxylic acid (also known as 4′-hydroxydesazadesferrithiocin).
[0033] Typically, coupling of cysteine or a 2-alkylcysteine and a substituted or unsubstituted benzonitrile includes converting the benzonitrile into a benzimidate. The benzimidate can be formed, for example, by reacting the benzonitrile with an alcohol such as methanol, ethanol, n-propanol, or isopropanol in the presence of an acid such as hydrochloric acid. Alternatively, cysteine or a related compound can be coupled directly with a benzimidate. The benzimidate is then reacted with the cysteine (or related compound) under basic conditions. Acceptable bases include those listed above. The reaction between the benzimidate and the cysteine results in the thiazoline (or 4,5-dihydrothiazole) containing product. When forming the benzimidate from a hydroxylated benzonitrile (e.g., 2,4-dihydroxybenzonitrile), the hydroxyl groups are advantageously protected (e.g., with a substituted or unsubstituted alkyl or arylalkyl group such as a benzyl group). The protecting groups are subsequently cleaved, typically by catalytic hydrogenation.
[0034] The methods of the claimed invention can be used to manufacture other related desferrithiocin analogs and derivatives. Examples of such analogs include those described in U.S. Pat. Nos. 5,840,739, 6,083,966, 6,159,983, 6,521,652 and 6,525,080 to Raymond J. Bergeron, Jr., the contents of which are incorporated herein by reference. Additional examples can be found in PCT/US93/10936, PCT/US97/04666, and PCT/US99/19691, the contents of which are incorporated by reference.
[0035] Suitable benzonitriles and benzimidates for use in the above coupling reaction can be synthesized by methods described in U.S. application Ser. Nos. 60/381,013, 60/380,878 and 60/380,909, filed May 15, 2002, the entire teachings of which are incorporated herein by reference.
[0036] An alkyl group is a hydrocarbon in a molecule that is bonded to one other group in the molecule through a single covalent bond from one of its carbon atoms. Alkyl groups can be cyclic or acyclic, branched or unbranched, and saturated or unsaturated. Typically, an alkyl group has one to about 24 carbons atoms, or one to about 12 carbon atoms.
[0037] Lower alkyl groups have one to four carbon atoms and include methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl and tert-butyl.
[0038] Aromatic (or aryl) groups include carbocyclic aromatic groups such as phenyl, p-tolyl, 1-naphthyl, 2-naphthyl, 1-anthracyl and 2-anthracyl. Aromatic groups also include heteroaromatic groups such as N-imidazolyl, 2-imidazole, 2-thienyl, 3-thienyl, 2-furanyl, 3-furanyl, 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyrimidyl, 4-pyrimidyl, 2-pyranyl, 3-pyranyl, 3-pyrazolyl, 4-pyrazolyl, 5-pyrazolyl, 2-pyrazinyl, 2-thiazolyl, 4-thiazolyl, 5 -thiazolyl, 2-oxazolyl, 4-oxazolyl and 5-oxazolyl.
[0039] Aromatic groups also include fused polycyclic aromatic ring systems in which a carbocyclic, alicyclic, or aromatic ring or heteroaryl ring is fused to one or more other heteroaryl or aryl rings. Examples include 2-benzothienyl, 3-benzothienyl, 2-benzofuranyl, 3-benzofuranyl, 2-indolyl, 3-indolyl, 2-quinolinyl, 3-quinolinyl, 2-benzothiazole, 2-benzooxazole, 2-benzimidazole, 2-quinolinyl, 3-quinolinyl, 1-isoquinolinyl, 3-quinolinyl, 1-isoindolyl and 3-isoindolyl.
[0040] Suitable substituents for alkyl groups include —OH, halogen (—Br, —Cl, —I and —F), —O(R′), —O—CO—(R′), —CN, —NO 2 , —COOH, ═O, —NH 2 , —N—H(R′), —N(R′) 2 , —COO(R′), —CONH 2 , —CONH(R′), —CON(R′) 2 , —SH, —S(R′), and guanidine. Each R′ is independently an alkyl group or an aryl group. Alkyl groups can additionally be substituted by a aryl group (e.g. an alkyl group can be substituted with an aromatic group to form an arylalkyl group). A substituted alkyl group can have more than one substituent.
[0041] Suitable substituents for aryl groups include —OH, halogen (—Br, —Cl, —I and —F), —O(R′), —O—CO—(R′), —CN, —NO 2 , —COOH, ═O, —NH 2 , —NH(R′), —N(R′) 2 , —COO(R′), —CONH 2 , —CONH(R′), —CON(R′) 2 , —SH, —S(R′), and guanidine. Each R′ is independently an alkyl group or an aryl group. Aryl groups can additionally be substituted by an alkyl or cycloaliphatic group (e.g. an aryl group can be substituted with an alkyl group to form an alkylaryl group such as tolyl). A substituted aryl group can have more than one substituent.
[0042] Also included in the present invention are salts of the disclosed amino acids. For example, amino acids can also be present in the anionic, or conjugate base, form, in combination with a cation. Suitable cations include alkali metal ions, such as sodium and potassium ions, alkaline earth ions, such as calcium and magnesium ions, and unsubstituted and substituted (primary, secondary, tertiary and quaternary) ammonium ions. Suitable cations also include transition metal ions such as manganese, copper, nickel, iron, cobalt, and zinc. Basic groups such as amines can also be protonated with a counter anion, such as hydroxide, halogens (chloride, bromide, and iodide), acetate, formate, citrate, ascorbate, sulfate or phosphate.
EXAMPLE 1
[0043] Cysteine, benzonitrile, and 5 equivalents of triethylamine were refluxed in ethanol for 6-8 hours to obtain a 66-70% yield of 2-phenylthiazoline-4-carboxylic acid. The 2-phenylthiazoline-4 carboxylic acid was reacted with 2.05 equivalents of base and 1 equivalent of methyl iodide in tetrahydrofuran at 0° C. to form 2-phenyl-4-methylthiazoline-4 carboxylic acid. The 2-phenyl-4-methylthiazoline-4 carboxylic acid can be resolved and isolated as the (S)-enantiomer using emulsion crystallization, and subsequently hydrolyzed with hydrochloric acid, thereby obtaining (S)-2-methylcysteine hydrochloride.
EXAMPLE 2
[0044] Cysteine, benzonitrile, and 5 equivalents of triethylamine were refluxed in ethanol for 6-8 hours to obtain a 66-70% yield of 2-phenylthiazoline-4-carboxylic acid. The 2-phenylthiazoline-4 carboxylic acid was reacted with 2.05 equivalents of base and 1 equivalent of methyl iodide in tetrahydrofuran at 0° C. to form 2-phenyl-4-methylthiazoline-4 carboxylic acid. The 2-phenyl-4-methylthiazoline-4-carboxylic acid can be hydrolyzed with hydrochloride acid, thereby obtaining a mixture of (R)- and (S)-2-methylcysteine hydrochloride.
EXAMPLE 3
[0045] The procedure of Example 2 is followed, such that a mixture of (R)- and (S)-2-methylcysteine hydrochloride is obtained. Classical chemical resolution with (R)-phenylethylamine at a suitable pH is able to resolve the (R)- and (S)-enantiomers of 2-methylcysteine. Subsequent isolation of the resolved products yields substantially enantiomerically pure (R)-2-methylcysteine and (S)-2-methylcysteine.
EXAMPLE 4
[0046] All compounds were used without further purification. The surfactants Rhodafac RE 610 and Soprophor FL were obtained from Rhône-Poulenc, Surfynol 465 from Air Products, Synperonic NP 10 from ICI and sodium lauryl sulfate from Fluka. For agitation a shaking machine was used (Buhler KL Tuttlingen). Purities of the resulting crystals were measured by using a PolarMonitor polarimeter (IBZ Hannover).
[0047] Ethanol was used as the solvent. The total crystal quantity was dissolved in a 1 mL cell at 20° C.).
[0048] 45 mg of (R,R)- and (S,S)-amino acid derivatives were dissolved in 1 ml of a mixture of 20% v/v 2-hexanol, 12% v/v Rhodafac RE 610, 6% v/v Soprophor FL and 62% v/v water by heating to 80° C. in a 5 mL vial. After the organic derivative was completely dissolved the microemulsion was cooled down to room temperature and agitated using a shaking machine (420 rpm). During two hours no spontaneous crystallization was observed. The mixture was then seeded with two drops of a dilute, finely ground suspension of pure (S,S)-(—) amino acid or its ester crystals grown under similar conditions. After 2 hours of agitation the resulting crystals were filtered off, washed with water and dried in a gentle nitrogen stream.
EXAMPLE 5
[0049] 35 mg of R- and S-4,5-dihydro-2-(2,4-dihydroxyphenyl)-4-methylthiazole-4-carboxylic acid were dissolved in 1 ml of a mixture of 9% N-methyl-pyrrolidone, 9% v/v 2-hexanol, 10% v/v Rhodafac RE 610, 5% v/v Soprophor FL and 68% v/v water by heating to 50° C. in a 5 mL vial. After the product was completely dissolved, the microemulsion was cooled down to room temperature and agitated with a shaking machine (350 rpm). During two hours, no spontaneous crystallisation was observed. The mixture was then seeded with two drops of a dilute, finely ground suspension of pure S-product crystals grown under similar conditions. After two hours of shaking, the resulting crystals were filtered off, washed with water and dried in a gentle nitrogen stream. The procedure yielded 5.4 mg (15.4%) of colorless crystals, with a greater than 90% purity of the S entantiomer.
EXAMPLE 6
[0050] 4.00 g (S)-2-methylcysteine hydrochloride (23.3 mmol, 1.0 meq) and 3.14 g 2,4-dihydroxy benzonitrile (23.3 mmol, 1.0 meq) were suspended in 40 mL ethanol. After degassing this mixture with nitrogen (30 min) 4.95 g triethylamine (6.8 mL, 48.9 mmol, 2.05 meq) were added. The obtained suspension was heated under reflux in an atmosphere of nitrogen for 20 hours and then cooled to room temperature. From this suspension ethanol was evaporated under reduced pressure until an oil (20% of the initial volume) was obtained. This oil was dissolved in 50 mL water. The solution was adjusted to pH 7.5 with 1.20 ml 20% KOH and was extracted two times each with 20 mL methyl t-butyl ether (MTBE). The aqueous layer was separated, adjusted with 20% KOH to pH 11 and again extracted two times each with 20 mL MTBE. After separating the aqueous layer the pH was set with concentrated HCl to 7.5 and traces of MTBE were distilled off. Then the aqueous solution was acidified with 1.50 ml concentrated HCl to pH 1.5. The product precipitated. This suspension was stirred at 4° C. for 1 hour. Then the precipitate was filtered, washed two times each with 10 mL water (5° C.) and dried at 45° C. under vacuum. The reaction yielded 5.17 g (87.6%) of crude 4,5-dihydro-2-(2,4-dihydroxyphenyl)-4-methylthiazole-4(S)-carboxylic acid product. ′H-NMR showed no significant impurity.
EXAMPLE 7
[0051] A single-neck 500 mL round-bottomed flask was flushed with nitrogen. (R)-(+)-L-cysteine hydrochloride monohydrate (12.0 g, 68.32 mmol) was transferred to the flask. Ethanol (240 mL) was added to give a suspension. Anhydrous triethylamine (34.6 g, 47.7 mL, 341.6 mmol, 5.0 equiv.) was then added via a syringe over a period of 10 min. at room temperature. A white precipitate of triethylamine hydrochloride formed immediately. After stirring this thick white turbid solution for 30 min. at room temperature, benzonitrile (7.05 g, 68.32 mmol) was added and the reaction mixture was refluxed for 6 hours. TLC (CH 2 Cl 2 as eluent) indicated that all benzonitrile was consumed. The reaction mixture was cooled to room temperature and the solvent was removed in vacuo. Water (25 mL) was added followed by the addition of solid KOH (5 g) with stirring. This reddish clear aqueous solution (pH˜11-12) was extracted with ethyl acetate (3×100 mL) and the organic layer was discarded. The aqueous layer was acidified with dropwise addition of 6M HCl to pH 1.5-2.0 to obtain an off-white to tan colored precipitate. This solid was filtered through a Buchner funnel. After drying under high vacuum, the solid was triturated with ethyl acetate to remove any traces of colored impurities. After filtration and drying, the off-white to white solid was stirred over dichloromethane to remove any traces of triethylamine hydrochloride and then filtered. After drying under vacuum, a white powdery solid was obtained (10.49 g, 74%).
EXAMPLE 8
[0052] 2,4-Dibenzyloxybenzonitrile (0.121 mol) was dissolved in 5.85 g (0.127 mol) ethanol and 19.4 ml 1,2-dimethoxyethane in a double walled reactor. This solution was cooled to −5° C., stirred and saturated with dry HCl gas over 5 hours at 0-3° C. The reaction mixture was stirred overnight at 2-4° C. under nitrogen. During this time, a product crystallized. The white crystals were filtered off, washed with 1,2-dimethoxyethane (5° C., three times each with 13 ml) and dried. A total of 30 of the protected ethyl benzimidate was isolated (Yield 88.4%, purity 98.9%).
[0053] The protected ethyl benzimidate described above was dissolved in methanol to generate a 10% solution and was catalytically hydrogenated at room temperature using 5% Pd/C as a catalyst. The reaction was completed after 8 hours. The solution was filtered and the solvent evaporated to yield the deprotected product as an orange-yellow solid. The reaction yielded 19.6 g (94%) of product.
[0054] In contrast, the formation of the imidate with 2,4 dihydroxybenzonitrile was a low yielding process, generating the desired product in only 20% yield and with less than desired purity.
[0055] While this invention has been particularly shown and described with references 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 scope of the invention encompassed by the appended claims. | Non-natural amino acids such as 2-alkylated amino acids allow for the synthesis of a wider variety of peptidal and non-peptidal pharmaceutically active agents. A method of preparing a 2-alkylcysteine involves condensing cysteine with an aryl nitrile to form a 2-arylthiazoline-4-carboxylic acid, followed by alkylating the 2-arylthiazoline-4-carboxylic acid at the 4-position. The present invention also discloses a method of preparing a class of iron chelating agents related to desferrithiocin, all of which contain a thiazoline ring. In this method, an aryl nitrile or imidate is condensed with cysteine or a 2-alkyl cysteine. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of PCT Application No. PCT/CN02/00943, filed Dec. 31, 2002, which claims priority of People's Republic of China Application No. 02109966.9, filed Jan. 4, 2002, which is hereby incorporated herein in its entirety by reference.
TECHNICAL FIELD
This invention relates to a certain type of textile material and the method of manufacture thereof. To be precise, it relates to a certain type of synthetic textile fibre containing phytoprotein and the methods of producing this synthetic fibre.
BACKGROUND ART
Apart from natural silk, textile threads composed of fibres containing protein of which there is general knowledge include a certain type of lactose composite silk which was disclosed in Japan in “Fibrous Protein Chemistry” and which was based on protein extracted from cow's milk. This protein was mixed with acrylonitrile to form a composite lactose silk. Due to the use of animal proteins as raw material in this type of composite silk this product was extremely expensive.
In order to make the best use of available resources, and in order to reduce the cost of composite silk whilst ensuring that products retain acceptable characteristics, the present inventor has already disclosed a certain type of phytoprotein composite silk and the method of its manufacture in Chinese patent 99116636.1, and this type of composite silk possessed characteristics similar to silk; the phytoprotein content of this type of composite silk was between 23-55 of the overall content. However, after further research and trial-production by the present inventor, it was discovered that there was a still greater potential for development of composite silk based on phytoprotein; the synthetic fibres thus produced exhibited even better properties than current composite silks, for instance in terms of breathability. In addition, due to the relatively long duration of the production cycle involved in the manufacturing method outlined by the above-mentioned patent, the yield was relatively low.
SUMMARY OF THE INVENTION
The main object of this invention relating to phytoprotein synthetic fibre is to provide a synthetic fibre with optimum breathability, exhibiting characteristics similar to cashmere.
The main object of the phytoprotein synthetic fibre manufacturing method provided by this invention is to resolve the problems of the lengthy production cycle and low yield associated with current manufacturing methods.
The phytoprotein synthetic fibre provided by this invention is composed of phytoprotein and polyvinyl alcohol, phytoprotein making up A parts of the two materials, where A is equal to or greater than 5 parts and less than 23 parts, and polyvinyl alcohol making up B parts, where B is greater than 77 parts and equal to or less than 95 parts.
Furthermore, a preferable proportion of phytoprotein to the total content of materials is A parts, where A is equal to or greater than 5 parts and equal to or less 22 parts; polyvinyl alcohol constitutes B parts of the total content of materials, where B is equal to or greater than 78 parts and equal to or less than 95 parts. The optimum proportion of phytoprotein to the total content of materials is A parts, where A is equal to or greater than 10 and equal to or less than 18; polyvinyl alcohol making up B parts of the total content of materials, where B is equal to or greater than 82 parts and equal to or less than 90 parts.
Most preferably, apart from the aforementioned phytoprotein being a protein extracted from soya beans, peanuts, or cottonseed or rapeseed cake or maize germ or walnuts or sunflower seeds, it may also rely on protein isolated and extracted directly from soya beans or peanuts or cottonseed or rapeseed by soaking and wet grinding, or it may also rely on protein isolated and extracted by crushing, degreasing and soaking, or it may also rely on protein isolated and extracted by germ pressing, followed by fragmentation and decreasing.
The phytoprotein synthetic fibre manufacturing method provided by this invention encompasses a semi-finished product manufacturing process and a semi-finished product acetalization and finishing process which yield the finished product and can be characterised as follows: the steps for manufacturing the semi-finished product are:
a. Preparation of a proportioned spinning dope of phytoprotein and polyvinyl alcohol, such proportioning resulting in phytoprotein making up A parts of the total content of the two components, where A is equal to or greater than 5 parts and less than 23 parts, and polyvinyl alcohol making up B parts of the total content of the two components, where B is greater than 77 parts and equal to or less than 95 parts;
b. Wet-spinning on a wet-spinning frame after deaerating the spinning dope;
c. Introduction of the synthetic fibre obtained from the spinning frame to a coagulant bath, then air drafting, wet bath drafting, drying, dry heat drafting and heat fixing to obtain the semi-finished product.
In the aforementioned phytoprotein synthetic fibre manufacturing method,
The spinning dope mentioned is prepared according to the following steps: weighing out pure protein and polyvinyl alcohol according to proportions, followed by formation of a solution by direct addition of these two raw-materials to distilled water, followed by the addition of borax or boric acid, then mixing at a temperature T4, T4 being equal to or greater than 40° C. and less than 98° C., yielding the spinning dope;
In the aforementioned step b the deaeration of the spinning dope may be carried out according to the following steps: by allowing the spinning dope to stand at a temperature Tj and at normal atmospheric pressure, Tj being equal to or greater than 50° C. and less than 80° C. for a length of time (tj) equal to or greater than 1.5 hours and less than 4 hours to allow static deaeration, or by carrying out vacuum deaeration at a temperature of between 30° C. and 45° C.; in addition in the aforementioned step c, the coagulant bath through which the synthetic fibre passes is a salt and alkali aqueous solution.
In said phytoprotein synthetic fibre manufacturing method, the spinning dope mentioned in step a is prepared according to the following steps:
firstly taking the extracted purified protein dissolved in distilled water to form a protein solution of concentration As, where As is equal to or greater than 4% and equal to or less than 15%, at the same time dissolving polyvinyl alcohol for a time t1 in distilled water at temperature T1, where T1 is equal to or greater than 40° C. and less than 98° C. and where t1 is greater than 1.5 hours and equal to or less than 3 hours, to form an aqueous solution of concentration Bs, where Bs is greater than 20% and equal to or less than 30%, or where Bs is equal to or greater than 8% and less than 15%; following this, borax is added to the proportioned solution of the two aforementioned materials, which is then mixed thoroughly at a temperature T4, where T4 is equal to or greater than 40° C. and less than 98° C., to yield the spinning dope;
the deaeration of the spinning dope prepared in step b is carried out according to the following steps: allowing the spinning dope to stand at a temperature Tj and at normal atmospheric pressure, Tj being equal to or greater than 50° C. and less than 80° C. for a length of time (tj) equal to or greater than 1.5 hours and less than 4 hours to allow static deaeration, or carrying out vacuum deaeration at a temperature of 30° C.-45° C.;
In steps b and c the wet-spinning spinneret velocity is V, where V is greater than 17 m/min and equal to or less than 30 m/min, and the coagulant bath into which the injected thread enters is a salt and alkali aqueous solution of which the salt content is P, where P is greater than 438 g/L and equal to or less than 480 g/L, and of which the alkali content is P4, where P4 is between 1 g/L and 40 g/L, whilst the temperature of the bath is T3, where T3 is equal to or greater than 32° C. and less than 38° C.
The aforementioned spinning dope may be alkaline, and the coagulant bath may be acidic, whilst the acid within the coagulant bath may be sulphuric acid and/or phosphoric acid.
The aforementioned spinning dope may alternatively be acidic, and the coagulant bath may be alkaline.
In aforementioned phytoprotein synthetic fibre manufacturing method, the alkaline spinning dope may be prepared according to the following steps:
(1) The purified isolated protein is dissolved in an alkaline solution at a temperature T2, that alkaline solution having a pH value equal to or greater than 7.5 and less than 8.5, and requiring a solution time of t2, where t2 is equal to or greater than 1 hour and less than 3 hours; and where T2 is equal to or greater than 40° C. and less than 98° C., yielding a protein solution with a concentration As, where As is equal to or greater than 4% and less than 15%; (2) Dissolving the polyvinyl alcohol at a temperature (T1) equal to or greater than 40° C. and less than 98° C., for a duration t1, where t1 is equal to or greater than 1 hour and less than 2 hours, to yield a polyvinyl acetate solution with a concentration Bs, where Bs is equal to or greater than 8% and less than 15%. or greater than 20% and equal to or less than 30%: (3) Finally, the mixing in proportion of the above two solutions, to obtain the spinning dope;
The steps for deaerating the spinning dope in the aforementioned step b are as follows:
allowing the spinning dope to stand at a temperature Tj and at normal atmospheric pressure, Tj being equal to or greater than 50° C. and less than 80° C. for a length of time (tj) equal to or greater than 1.5 hours and less than 4 hours to allow static deaeration, or carrying out vacuum deaeration at a temperature of 30° C.-45° C.; in addition in the aforementioned steps b and c the wet-spinning spinneret velocity is V, where V is greater than 17 /min and equal to or less than 30 m/min, and the coagulant bath into which the injected thread enters is a salt and acid aqueous solution of which the salt content is P, where P is greater than 438 g/L and equal to or less than 480 g/L, and of which the acid content is P1, where P1 is equal to or greater than 0.2 g/L and less than 0.26 g/L, whilst the temperature of the bath is T3, where T3 is equal to or greater than 30° C. and less than 38° C.
In the aforementioned phytoprotein synthetic fibre manufacturing method, the acidic spinning dope is prepared according to the following steps: purified extracted protein and polyvinyl alcohol are mixed together according to proportion in distilled water, and dissolved at a temperature T4 of between 40° C. and 98° C., yielding a solution containing a concentration of protein and polyvinyl alcohol between 8% to 25%, then by adding boric acid/ and/or phosphporic acid and mixing thoroughly yielding the acidic spinning dope with a pH of between 1 and 3.5 is obtained;
the deaeration of the spinning dope prepared in step b is carried out according to the following steps: vacuum deaeration or static deaeration of the spinning dope is carried out at a temperature between 30° C. and 58° C.;
in step c the alkaline coagulant bath into which the injected thread enters is a salt and alkali aqueous solution, the coagulant bath having a pH value of between 9 and 14, and a temperature T3 equal to or greater than 32° C. and less than 38° C.
In the aforementioned phytoprotein synthetic fibre manufacturing method, the alkaline spinning dope is prepare according to the following steps:
(1) A protein solution with a concentration As is prepared, where the concentration As is equal to or greater than 4% and less than 15%, and this solution is made slightly alkaline to a pH value equal to or greater then 7.5 and less than 8.5; (2) Polyvinyl alcohol is measured out according to a proportion, this is then dissolved directly in the protein solution at a temperature Th and for a time t, where Th is equal to or greater than 40° C. and less than 98° C. and where t is equal to or greater than 1 hour and less than 4 hours, yielding a spinning dope with a concentration C2 of the two materials, where C2 is equal to or greater than 8% and less than 15%, or greater than 20% and equal to or less than 30%;
the deaeration of the spinning dope prepared in step b is carried out according to the following steps: vacuum deaeration of the spinning dope is carried out at a temperature of between 30° C. and 45° C., or static deaeration is carried out at a temperature Tj equal to or greater than 35° C. and less than 80° C.;
In the aforementioned step c, the acidic coagulant bath through which the synthetic fibre passes is a salt and acid aqueous solution.
In aforementioned phytoprotein synthetic fibre manufacturing method, the acidic spinning dope mentioned is prepared according to the following steps:
(1) Dissolving the protein in an acidic solution with a pH of between 1 and 3.5, yielding a protein solution with a concentration As, where As is equal to or greater than 4% and less than 15%. (2) Dissolving the polyvinyl alcohol according to proportion directly in the above solution, yielding a spinning dope with a total protein and polyvinyl alcohol content of between 8% and 22%;
The steps for deaerating the spinning dope mentioned in step b are as follows:
carrying out vacuum deaeration of the spinning dope at a temperature of 30° C. to 58° C., or carrying out static deaeration;
in step c the alkaline coagulant bath into which the injected thread enters is a salt and alkali aqueous solution, the coagulant bath having a pH value of between 9 and 14, and a temperature (T3) equal to or greater than 36° C. and less than 38° C.
Apart from this, in the aforementioned phytoprotein synthetic fibre manufacturing method, the total elongation factor applied to the filament bundle as it undergoes air drafting, wet bath drafting and dry heat drafting after passing through the coagulation bath is between 4.5 and 8.5; the acetalizing bath is kept at a temperature T6 during the acetalizing step, where T6 is between 40° C. and 64° C., the acetalizing solution containing aldehyde, acid and ammonium sulphate, the aldehyde content P3 being between 5 g/L and 31.9 g/L, the acid content P10 being between 5 g/L and 239.8 g/L, and the salt content P11 being between 80 g/L and 119 g/L.
Moreover, during the acetalizing step, the aldehyde used in the acetalization solution can be either glyoxal or modified glutaraldehyde.
The synthetic fibre manufactured according to the proportions of phytoprotein and polyvinyl alcohol indicated by this invention exhibits excellent breathability characteristics, exhibits the softness of cashmere. What is more, the duration of the production cycle of the synthetic fibre disclosed here is shorter than that disclosed in Chinese patent 99116636.1. In order to increase yields, techniques suited to the extraction of a variety of different phytoproteins are adopted by this invention, making production of phytoprotein synthetic fibre even more convenient. This invention also has the comprehensive effect of increasing the value attached to agricultural products, whilst also opening up new areas of deep-processing of crops; this invention therefore constitutes an inventive creation with major inherent social benefits.
DETAILED DESCRIPTION
EXAMPLE 1
Firstly take soya beans and soak them in water, then employ wet grinding, then extract the phytoprotein. After this, place the extracted pure phytoprotein in a weak alkaline solution with a pH of 8.4, and dissolve at a temperature T2 of between 40° C. and 50° C., over a solution period t2 of 2.5 hours, to obtain a protein solution with a concentration (As), where As is equal to or greater than 4% and less than 15%. At the same time, add the polyvinyl alcohol to distilled water, and dissolve at a temperature T1 of between 79° C. and 97° C., for a duration t1 of 100 minutes, yielding a polyvinyl alcohol solution with a concentration Bs, where Bs is equal to or greater than 8% and less than 15%.
Taking the above two types of solution, mix in proportions so that the proportion of pure protein to total pure protein and polyvinyl alcohol is A parts, where A is 5 parts, and make the proportion of polyvinyl alcohol to the total solid content of the two materials B parts, where B is 95 parts. Then after mixing the above two solutions together at a temperature T4, where T4 is equal to or greater than 80° C. and less than 95° C., for 40 minutes, the spinning dope is obtained. Then at a temperature Tj of between 50° C. and 70° C. leave standing for a duration tj of between 180 and 200 minutes in order to allow deaeration. After deaeration and further filtration the spinning dope is introduced to the wet-spinning frame for wet-spinning.
The fibre-forming machine spinneret velocity V is 29.8 m/min. After injection the thread enters the coagulant bath, and the coagulant bath comprises a salt and acid aqueous solution, the salt content per liter being P, the acid content per liter being P1, the salt being sodium sulphate, the acid being sulphuric acid. The content P of sodium sulphate within this bath is between 439 g/L and 450 g/L, the content P1 of sulphuric acid in this bath is between 0.2 g/L and 0.25 g/L, and the temperature T3 of the solution is between 30° C. and 36° C. After passing through the coagulant bath the filament bundle is subjected to air drafting to an elongation factor of 2, and after undergoing air drafting the filament bundle enters the fluid bath trough to undergo wet bath drafting, the fluid within the trough consisting of an aqueous solution containing sodium sulphate, the sodium sulphate content of that solution being 440 g/L and the temperature of the solution being between 43.5° C. and 55° C., with the wet drafting elongation factor for the filament bundle in the trough being 1.5. After undergoing wet bath drafting the filament bundle enters the dry heat drafting and heat fixing stage, with the surface temperature of the filament bundle reaching 121° C. in the first heat chamber, 211° C. in the second heat chamber, 228° in the third heat chamber, 240° C. in the fourth heat chamber and 230° C. in the fifth heat chamber, with dry heat drafting taking place between heat chambers two and three, the dry heat drafting elongation factor being 2, yielding a total elongation factor for the three draftings of 5.5, with the semi-finished product being obtained after further heat drafting and heat fixing and the final product being obtained after acetalization and finishing of the semi-finished product. The finishing stages firstly require crimping, cutting and then acetalization, with the acetalization temperature T6 in the case of this example being between 40° C. and 64° C., whilst the acetalizing solution is a solution of aldehyde, sulphuric acid and ammonium sulphate, of which the aldehyde content P3 is between 5 g/L and 31 g/L, the sulphuric acid content P10 is between 150 g/L and 200 g/L and the ammonium sulphate content P11 is 118 g/L. After acetalizing, the filament bundle is rinsed again, and the phytoprotein synthetic fibre obtained after oiling and drying, at which stage it is ready for packaging and distribution.
EXAMPLE 2
Firstly, peanuts are chosen as the raw material for the purpose of extracting the phytoprotein, and pure protein is extracted from the peanuts using crushing, degreasing and soaking methods.
Following this, the purified extracted protein is dissolved in distilled water, giving a protein solution with a concentration As, where As is between 10% and 14.9%.
Polyvinyl alcohol is dissolved in distilled water at a temperature T1 of between 40° C. and 60°, the solution time being 2.8 hours, yielding an aqueous solution with a concentration Bs, where Bs is greater than 20% and equal to or less than 30%.
Taking the proportioned aqueous solutions of the above two materials, a mixed liquor of the two solutions is prepared, the proportion of pure protein to total, pure protein and polyvinyl alcohol being A parts, where A is 5 parts, and the proportion of polyvinyl alcohol to the total content of the two materials being B parts, where B is 95 parts, then by mixing the liquor thoroughly, and adding borax, and stirring at a temperature T4 of between 90° C. and 94° C., the spinning dope is obtained.
The spinning dope, of a viscosity, measured by a gravitational flow viscosimeter, of between 34 and 250 seconds, is subjected to deaeration by standing at a temperature Tj equal to or greater than 70° C. and less than 80° C. for between 180 and 230 minutes. After deaeration the spinning dope is subjected to wet-spinning, whilst spinneret velocity V is greater than 17 m/min and equal to or less than 25 m/min. After injection the thread enters the coagulant bath, the coagulant bath consisting of a salt and alkali aqueous solution, with a salt content per liter P and an alkali content per liter P4. The salt is sodium chloride, P being between 450 g/L and 460 g/L, and the alkali is sodium hydroxide, P4 being between 1 g/L and 40 g/L, with the temperature of the solution being between 32° C. and 36° C. After passing through the coagulant bath the filament bundle is subjected to air drafting to an elongation factor of 2.5, then after undergoing air drafting the filament bundle enters the fluid bath trough to undergo wet bath drafting, the fluid within the trough consisting of an aqueous solution containing sodium chloride, the sodium chloride content of the solution being 380 g/L and the temperature of the bath fluid being 88° C., with the wet drafting elongation factor for the filament bundle passing through the trough being 2. After undergoing wet bath drafting the filament bundle enters the heating and drying stage, with the surface temperature of the filament bundle reaching between 131° C. and 140° C. in the first heat chamber, between 220° C. and 230° C. in the second heat chamber, between 237° and 250° C. in the third heat chamber, between 241° C. and 250° C. in the fourth heat chamber and between 231° C. and 240° C. in the fifth heat chamber, with dry heat drafting taking place between heat chambers two and three, the dry heat drafting elongation factor being 2, yielding a total elongation factor for the three draftings of 6.5, with the semi-finished product being obtained after further heat drafting and heat fixing, the final product being obtained after acetalization and finishing of the semi-finished product. The finishing stages firstly require crimping, cutting and then acetalization, with the acetalization temperature T6 in the case of this example being equal to or greater than 50° C. and less than 64° C., whilst the acetalizing solution uses a solution of sulphuric acid, anhydrous sodium sulphate and modified glutaraldehyde, of which the salt content per liter is P11, the aldehyde content per liter is P3 and the acid content per liter is P10, where the aldehyde content P3 is equal to or greater than 15 g/L and less than 31 g/L, the sulphuric acid content P10 is between 18 g/L and 150 g/L and the anhydrous sodium sulphate content P11 is between 80 and 100 g/L. After acetalizing, the filament bundle is rinsed again, and the final product obtained after oiling and drying, at which stage it is ready for packaging and distribution.
EXAMPLE 3
Soya beans are chosen as the raw material for the purpose of extracting the phytoprotein, and protein is isolated and extracted from the peanuts using crushing, degreasing and soaking methods.
Taking the pure protein and polyvinyl alcohol, they are dissolved together in distilled water to a proportion of A parts of pure protein, where A is 7 parts, and B parts of polyvinyl alcohol, where B is 93 parts, and the two materials are mixed together at a temperature T4, where T4 is equal to or greater than 90° C. and less than 98° C., yielding a solution with a concentration C2 of protein and polyvinyl alcohol, where C2 is between 20% and 25%, then by adding borax and mixing the spinning dope with a pH value of between 1 and 2 is obtained. The spinning dope of a viscosity, measured by a gravitational flow viscosimeter, of between 34 and 250 seconds, is subjected to deaeration by standing at atmospheric pressure at a temperature Tj between 50° C. and 60° C. and for a time tj equal to or greater than 230 minutes and less than 240 minutes. After deaeration the spinning dope is subjected to filtration, and then enters the wet-spinning frame. Spinneret velocity V of the wet-spinning frame is 24 m/min. After injection the thread enters the coagulant bath, the coagulant bath being alkaline, and being an aqueous solution of a salt and an alkali, the salt being sodium sulphate, the alkali being potassium hydroxide. The pH of the coagulant bath is between 0.9 and 12, with the temperature T3 of the solution being equal to or greater than 36° C. and less than 38° C. After passing through the coagulant bath the filament bundle is subjected to air drafting to an elongation factor of 3, and after undergoing air drafting, the filament bundle enters the fluid bath trough to undergo wet bath drafting, the fluid within the trough consisting of an aqueous solution containing sodium sulphate, the sodium sulphate content of the solution being 400 g/L and the temperature of the bath fluid being between 38° C. and 80° C., with the wet drafting elongation factor for the filament bundle in the trough being 3. After undergoing wet bath drafting the filament bundle enters the dry heat drafting and heat fixing stage, with the surface temperature of the filament bundle reaching between 141° C. and 180° C. in the first heat chamber, between 231° C. and 250° C. in the second heat chamber, between 251° C. and 260° C. in the third heat chamber, between 351° C. and 260° C. in the fourth heat chamber and between 241° C. and 250° C. in the fifth heat chamber, with dry heat drafting taking place between the second and the third heat chamber, the dry heat drafting elongation factor being 1.5, yielding a total elongation factor for the three draftings of 7.5, with the semi-finished product being obtained after dry heat drafting, heat fixing, rinsing and acetalization, with the acetalization temperature T6 in the case of this example being equal to or greater than 54° C. and less than 64° C. and the acetalizing solution having a formaldehyde content P3, where P3 is equal to or greater than 20 g/L and less than 32 g/L, and having a sulphuric acid content P10, where P10 is between 200 g/L and 239 g/L, and an anhydrous sodium sulphate content P11, where P11 is between 80 g/L and 110 g/L. After acetalizing, the filament bundle is rinsed again, and the final product obtained after oiling, drying, crimping, fixing and cutting, at which stage it is ready for packaging and distribution.
EXAMPLE 4
Protein extracted and isolated from cottonseed cake is chosen and added to an acidic solution with a PH of between 1 and 2, and allowed to dissolve at a temperature T2 of between 60° C. and 90° C., the concentration As of the protein solution being between 4% and 10%. A certain quantity of the protein solution is taken, and a quantity of B part of polyvinyl alcohol, where B part is 90 parts of the total content of pure protein and polyvinyl alcohol, (pure protein being 10 parts of the total quantity), is measured out. The pure polyvinyl alcohol is added to the protein solution, and mixing then takes place at a temperature T4, where T4 is equal to or greater than 75° C. and less than 96° C., causing the pure polyvinyl alcohol to dissolve in the protein solution, yielding a spinning dope consisting of a solution of protein and polyvinyl alcohol with a total concentration C2 of between 8% and 18%, After deaeration for 3.5 hours at atmospheric pressure at a temperature tj equal to or greater than 30° C. and less than 58° C., or after vacuum deaeration, and after filtration, the spinning dope enters the wet-spinning frame and wet-spinning is carried out, with a spinneret velocity V of between 18 m/min and 28 m/min. After injection the thread enters the coagulant bath, the coagulant bath consisting of a salt and alkali aqueous solution, the salt being sodium sulphate, the alkali being potassium hydroxide, the temperature of fluid bath T3 being between 36° C. and 37.9° C., and the pH being between 9 and 12. After passing through the coagulant bath the filament bundle is subjected to air drafting to an elongation factor of 2.4, and after undergoing air drafting the filament bundle enters the fluid bath trough to undergo wet bath drafting, the fluid within the trough consisting of an aqueous solution containing ammonium sulphate, the ammonium sulphate content of the solution being 380 g/L and the temperature of the solution being between 35° C. and 38° C., with the wet drafting elongation factor for the filament bundle in the trough being 3. After undergoing wet bath drafting the filament bundle enters the dry heat drafting and heat fixing stage, with the surface temperature of the filament bundle reaching between 181° C. and 200° C. in the first heat chamber, between 251° C. and 260° C. in the second heat chamber, 261° C. in the third heat chamber, between 254° C. and 258° C. in the fourth heat chamber and 245° C. in the fifth heat chamber, with dry heat drafting taking place between the second and the third heat chamber, the elongation factor being 1.6, yielding a total elongation factor for the three draftings of 8, the steps and technical parameters employed following the heat drying and drafting being identical to example 2 and not requiring further detailed explanation.
EXAMPLE 5
In this case, use is made of protein extracted and isolated by pressing, degreasing and soaking cottonseed germ, the proportions of pure protein and polyvinyl alcohol being such that pure protein is A parts of the total content of both materials, where A is 13 parts, and polyvinyl alcohol is B parts, where B is 87 parts. These are dissolved together in distilled water, and mixed at a temperature T4 of between 40° C. and 78° C., forming a solution with a concentration C2 of total protein and polyvinyl alcohol of between 8% and 16%. After the addition of boric acid and further stirring, the pH of the solution then being between 1 and 2.5, the spinning dope is obtained at a temperature of between 40° C. and 58° C., the spinning dope being deaerated by standing for a time tj of between 100 and 238 minutes at atmospheric pressure, or by vacuum deaeration at a temperature of between 30° C. and 40° C., the spinning dope then being subjected to wet-spinning after deaeration and filtration, with a spinneret velocity V of between 17 m/min and 25 m/min. After injection the thread enters the coagulant bath, the coagulant bath consisting of a salt and alkali aqueous solution, the salt being sodium sulphate, the alkali being sodium hydroxide. The content P of sodium sulphate in the fluid bath is between 428 g/L and 450 g/L, and the content P4 of sodium hydroxide contained in the bath fluid is between 1 g/L and 40 g/L, yielding a total elongation factor of 4.5 for this example, the air drafting elongation factor being 1.5, the wet drafting elongation factor being 1.5 and the elongation factor occurring between heat chambers 2 and 3 being 1.5, and the remaining steps and technical conditions employed being identical to example 3, and not requiring further detailed explanation. The boric acid used in this implementation may be replaced by borax and/or phosphoric acid.
EXAMPLE 6
A protein solution with a concentration As, where As equal to or greater than 4% and less than 15%, is first prepared, the pH of the solution being greater than 7.5 and less than 8.5. A proportion of polyvinyl alcohol is then measured out and dissolved directly in the prepared protein solution, with the result that protein is A parts of the total content of these two materials, where A is 13, and polyvinyl alcohol is B parts, where B is 87 parts. Dissolution is then allowed to take place at a temperature Th of between 40° C. and 98° C. for a time t, where t is equal to or greater than 1 hour and less than 4 hours, yielding a spinning dope with a concentration C2, where C2 is equal to or greater than 8% and less than 15%, or where C2 is greater than 20% and equal to or less than 30%. Vacuum deaeration is then carried out at a temperature of between 20° C. and 35° C. or static deaeration is carried out at a temperature Tj greater than or equal to 35° C. and less than 80° C. Finally wet-spinning is carried out, the fibre output from the fibre forming machine entering an acidic solution, and the remaining steps of this example being the same as in example 1.
In addition, the protein used in this example is a mixture of phytoproteins extracted and isolated from soya beans, cottonseed and rapeseed which have been individually soaked and wet ground.
EXAMPLE 7
Pure protein and polyvinyl alcohol are measured out in proportion, with pure protein being A parts of the total content of these two materials, where A is 17 parts, and polyvinyl alcohol being B parts, where B is 83 parts. Then, by dissolving the two together in distilled water, and after the addition of borax, and after mixing at a temperature T4 of between 40° C. and 98° C., the spinning dope is obtained after the solution has been static deaerated by being left to stand for between 1.5 and 4 hours at a temperature Tj of between 50° C. and 79.5° C. at normal atmospheric pressure or vacuum deaerated by being left to stand at a temperature of between 35° C. and 40° C. The coagulant bath that the injected thread enters is a salt and alkali aqueous solution, the content P of sodium chloride in the fluid bath being between 450 g/L and 460 g/L, and the content P4 of sodium hydroxide contained in the fluid bath being between 1 g/L and 40 g/L, whilst the fluid bath temperature T3 is between 32° C. and 36° C. The other steps and technical conditions in this example are the same as in example 2.
EXAMPLE 8
The protein used in this case is the phytoprotein isolated, extracted and produced from cottonseed cake. The pure protein is added to a weak alkaline solution with a pH value of 7.5, and dissolved at a temperature T2 of between 55° C. and 75° C. for a period t2 of 1.5 hours, to yield a pure protein solution with a concentration As between 12% and 14.9%; polyvinyl alcohol is dissolved in distilled water at a temperature T1 of between 40° C. and 60° C. for 110 minutes, to yield a solution with Bs of between 25% and 29.5%.s
The above two solutions are mixed in a certain proportion, with pure protein forming 22 (A) parts of the total pure protein and polyvinyl alcohol, and with polyvinyl alcohol forming 78 (B) parts of the total by weight; at a temperature T4 of 94° C. and mixing for 50 minutes, to yield the spinning dope. Vacuum deaeration is then carried out at a temperature between 35° C. and 45° C., and the deaerated and filtered spinning dope then enters the wet-spinning frame to undergo wet-spinning. The fibre-forming machine spinneret velocity V is 19 m/min, the injected thread then entering a coagulant bath, the coagulant bath being a salt and acid aqueous solution, the salt used being sodium sulphate, the acid being sulphuric acid. The content of sodium sulphate P in the fluid bath is between 450 g/L and 480 g/L, the content of sulphuric acid P1 is between 0.25 g/L and 0.258 g/L, and the bath temperature is T3, where T3 is equal to or greater than 32° C. and less than 38° C. The remaining processing stages and technical conditions being identical to those in example 1.
EXAMPLE 9
The protein used in this case is the phytoprotein isolated and extracted by pressing, grinding and degreasing cottonseed germ. The protein obtained is added to a weak alkaline solution with a pH of 8, and allowed to dissolve at a temperature T2 of between 80° C. and 98° C. for 2 hours, yielding a pure protein solution with a concentration As, where As is equal to or greater than 12% and less than 15%; polyvinyl alcohol is dissolved at a temperature T1 of between 55° C. and 75° C. for 1 hour, to yield a solution with a concentration Bs, where Bs is equal to or greater than 10% and less than 15%.
The above two solutions are mixed in a certain proportion, with pure protein forming A parts of the total pure protein and polyvinyl alcohol, where A is 18 parts, and with polyvinyl alcohol forming B parts of the total content, where B is 82 parts, at a temperature T4 of 94° C. to yield the spinning dope. Deaeration is then carried out by standing at normal atmospheric pressure for between 180 and 200 minutes at a temperature Tj equal to or greater than 70° C. and less than 80° C. The deaerated spinning dope is then subjected to filtration and enters the wet-spinning frame to undergo wet-spinning.
The fibre-forming machine spinneret velocity V is between 20 m/min and 25 m/min, the injected thread then entering a coagulant bath, the coagulant bath being a salt and acid aqueous solution, the salt used being sodium sulphate, the acid being sulphuric acid. The content of sodium sulphate P in the fluid bath is between 440 g/L and 450 g/L, the content of sulphuric acid P1 is between 0.2 g/L and 0.25 g/L, and the bath temperature is T3, where T3 is equal to or greater than 32° C. and less than 38° C. The remaining processing stages and technical conditions are identical to those in example 1.
EXAMPLE 10
The pure protein used in this case is the phytoprotein isolated and extracted by the grinding, degreasing and soaking of rapeseed, the extracted protein being dissolved in distilled water, resulting in a protein concentration As of between 4% and 8%.
By dissolving polyvinyl alcohol in distilled water for 1.5 hours at a temperature T1 of between 60° C. and 80° C., an aqueous solution with a concentration Bs is obtained, where Bs is equal to or greater than 8% and less than 15%.
Mixing the above two solutions in a certain proportion, with pure protein forming A parts of the total pure protein and polyvinyl alcohol, where A is 21 parts, and with polyvinyl alcohol forming B parts of the total, where B is 79 parts, and by adding borax, and mixing at a temperature T4 of between 40° C. and 90° C., the spinning dope is obtained.
The spinning dope, of a viscosity, measured by a gravitational flow viscosimeter, of between 34 and 150 seconds, is subjected to static deaeration by standing at a temperature Tj of between 50° C. and 70° C. for between 1.5 and 3 hours at normal atmospheric pressure (or is subjected to vacuum deaeration at a temperature of between 30° C. and 40° C.). After deaeration the spinning dope is subjected to wet-spinning, whilst spinneret velocity V is equal to or greater than 25 m/min and less than 30 m/min. The injected thread then enters a coagulant bath consisting of a salt and alkali aqueous solution. The sodium chloride content is between 450 g/L and 460 g/L, the sodium hydroxide content P4 is between 1 g/L and 40 g/L, and the fluid bath is at a temperature T3, where T3 is equal to or greater than 36° C. and less than 38° C. The remaining processing stages and technical conditions are identical to those in example 2.
EXAMPLE 11
The pure protein used in this case is the phytoprotein isolated and extracted by the grinding, degreasing and soaking of soya beans.
Pure protein and polyvinyl alcohol, with pure protein forming A parts of the total pure protein and polyvinyl alcohol, where A is 10 parts, and with polyvinyl alcohol forming B parts, where B is 90 parts, are taken and dissolved in distilled water, and mixed at a temperature T4 of between 40° C. and 79° C., to yield a solution containing a concentration C2 of protein and polyvinyl alcohol of between 14% and 18%, and by adding boric acid and mixing, spinning dope with a pH of between 2 and 3.5 is obtained.
The spinning dope, of a viscosity, measured by a gravitational flow viscosimeter, of between 34 and 250 seconds, is subjected to vacuum deaeration at a temperature of between 30° C. and 45° C., and after deaeration and filtration the spinning dope enters the wet-spinning frame. Spinneret velocity V is 20 m/min, the injected thread then entering a coagulant bath, the coagulant bath fluid consisting of a salt and alkali aqueous solution, where the salt is sodium sulphate and the alkali is sodium hydroxide, the fluid bath having a pH of between 12 and 14, and a temperature T3 of 36° C. The remaining processing stages and technical conditions are identical to those in example 3.
EXAMPLE 12
Protein extracted from cottonseed cake is used, and added to an acidic solution with a pH of between 2 and 3.5, and allowed to dissolve at a temperature T2 of between 45° C. and 60° C., this protein solution having a concentration As, where As is equal to or greater than 10% and less than 15%. Pure polyvinyl alcohol is added directly to the protein solution in the proportion of B parts of the total protein and polyvinyl alcohol, where B is 84 parts (with the proportion of protein being 16 parts). This is then mixed at a temperature T4 of between 60° C. and 75° C., causing the pure polyvinyl alcohol to dissolve in the protein solution, yielding a spinning dope containing a total protein and polyvinyl alcohol content of between 18% and 22%, and a viscosity of between 34 and 250/sec. This is then subjected to static deaeration at normal atmospheric pressure at a temperature of between 30° C. and 58° C. for 3.5 hours or is subjected to vacuum deaeration, to yield the spinning dope. After filtration this then enters the wet-spinning frame to undergo wet-spinning, spinneret velocity v being between 18 m/min and 29.5 m/min. The injected thread then enters a coagulant bath, the coagulant bath fluid consisting of a salt and alkali aqueous solution, where the salt is sodium sulphate, and the alkali potassium hydroxide. The temperature T3 of the bath is equal to or greater than 36° C. and less than 38° C., and the pH is between 12 and 14. The remaining processing stages and technical conditions are identical to those in example 4.
EXAMPLE 13
The pure protein used in this case is that isolated and extracted by the pressing, soaking and degreasing of rapeseed,
Pure protein and polyvinyl alcohol are then measured out, with pure protein being A parts of the total content of these two materials, where A is 19 parts, and polyvinyl alcohol being B parts, where B is 81 parts, then by dissolving the two together in distilled water, and after mixing at a temperature T4 of between 78° C. and 97° C., a solution with a total protein and polyvinyl alcohol concentration of between, 15% and 22% is obtained. Boric acid is added to this solution, and mixing continued, giving a pH of between 2.5 and 3.5, after which the spinning dope is obtained at a temperature Tj, where Tj is equal to or greater than 58° C. and less than 80° C. This is then subjected to deaeration by standing at normal atmospheric pressure for a period tj of between 100 and 240 minutes, or alternatively vacuum deaeration may be carried out at a temperature between 30° C. and 45° C. Then, after filtration, the spinning dope enters the wet-spinning frame to undergo wet-spinning, spinneret velocity V being greater than 17 m/min and less than 30 m/min. The injected thread then enters a coagulant bath consisting of a salt and alkali aqueous solution, where the salt is sodium sulphate, and the alkali is sodium hydroxide. The content P of sodium sulphate in the fluid bath is between 428 g/L and 450 g/L, and the sodium hydroxide content P4 is between 1 g/L and 40 g/L, yielding a total elongation factor for this example of 8.5, of which air drafting contributes 3 elongation factors, wet bath drafting contributing 2.5 elongation factors and drafting occurring between the second and third heat chambers contributing an elongation factor of 1.5.
The remaining processing stages and technical conditions are identical to those in example 5.
In all of the examples disclosed by this invention the protein used may be that isolated and extracted directly from soya beans, peanuts, cottonseed or rapeseed by soaking and wet grinding, or that protein isolated and extracted by crushing, degreasing and soaking, or that protein isolated by germ pressing, fragmentation and degreasing. It is also possible to use protein isolated and extracted from soya bean or peanut or cottonseed or rapeseed cake. In addition, protein obtained and prepared in any other form may be used. The quantities of protein and polyvinyl alcohol in the solutions is based on pure dry solid content. | This invention relates to a phytoprotein synthetic fiber and the method for the manufacture thereof. This synthetic fiber is composed of phytoprotein and polyvinyl alcohol, the phytoprotein comprising A parts of the two components, where A is equal to or greater than 5 parts and less than 23 parts, and the polyvinyl alcohol comprising B parts, where B is greater than 77 parts and equal to or less than 95 parts. The methods of manufacturing the synthetic fiber comprise a semi-finished product manufacturing process and a semi-finished product acetalization and finishing process. The sequence of processing of the semi-finished product is as follows: taking a spinning dope prepared from proportions of phytoprotein and polyvinyl alcohol, and after deaeration introducing the spinning dope to a wet-spinning frame to undergo wet-spinning; the synthetic fiber output by the spinning frame then entering a coagulant bath, the semi-finished product being obtained after air drafting, wet bath drafting, drying, dry heat drafting and heat fixing. The synthetic fibers produced as a result of the adoption of this method exhibit good breathability characteristics and require a production period of short duration, thus increasing productivity. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to valve apparatus and, more particularly, to a double valve apparatus usable in a swimming pool environment for introducing chlorine gas into a water line when the swimming pool motor is on to pump water for the filtration system.
2. Description of the Prior Art
Chlorine gas is typically introduced into a swimming pool through a venturi. The venturi is disposed in the swimming pool water system generally downstream of the filter, the heater, and any other elements which may be in series with the swimming pool pump. Depending on the particular system, back pressure may allow water to flow into the chlorine line, or the system may lose prime if air is introduced into the system. That is, when the pump turns off, the venturi may cause air to be introduced into the system, thus allowing air to flow backwards through the pump, and the pump will then lose its prime.
The apparatus of the present invention overcomes the problems of the prior art by using pool water pressure to open a pilot valve, and the valve closes when the pressure is removed from the pilot valve. Positive pressure from the pump is required to open the valve. However, the valve closes merely by the vacuum pressure of the head of water in the line to prevent the introduction of air into the system. At the same time, a second valve also closes. Moreover, any back pressure in the system will also cause the second valve to close to prevent water from flowing backwards into the chlorine gas line.
SUMMARY OF THE INVENTION
The invention described and claimed herein comprises a double valve system coupled to a venturi in a swimming pool water line using positive pump pressure to open a pilot valve, and the pilot valve is closed by low pressure of vacuum pressure of the head of water draining in the system when the pump turns off. Back pressure is prevented from causing water to flow into the chlorine gas line by a second valve utilizing a second valve element. The valve elements move between two valve seats.
Among the objects of the present invention are the following:
To provide new and useful valve apparatus;
To provide new and useful double acting valve apparatus;
To provide new and useful valve apparatus having two valve elements movable between two valve seats;
To provide new and useful valve apparatus for controlling the flow of gas in a swimming pool water system;
To provide new and useful gas system in a swimming pool circuit;
To provide new and useful water system for a swimming pool; and
To provide new and useful chlorination system for swimming pools.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of the apparatus of the present invention in its use environment.
FIG. 2 is an enlarged view in partial section of the apparatus of the present invention taken generally from ellipse 2 of FIG. 1.
FIG. 3 is a view in partial section illustrating the sequential operation of the apparatus of FIG. 2.
FIG. 4 is a view in partial section taken generally along line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic diagram illustrating the valve and venturi apparatus 70 of the present invention it its use environment. The use environment includes ground 2 in which is located a swimming pool 4. About the periphery of the swimming pool 4 is a trough 6. Water 8 is disposed within the swimming pool 4. A deck 12 surrounds the swimming pool, and may, if desired, extend outwardly therefrom.
A swimming pool water system 20 is schematically illustrated in conjunction with the pool 4. The swimming pool water system 20 includes a motor powered pump 22. A water line or conduit 24 extends through the trough 6 to the pump 22. For residential swimming pools, the water is typically pumped from a drain located at the bottom of the pool. Water 8 is pumped by the pump 22 from the trough 6 (or drain) through the water line 24. From the pump 22, a water line or conduit 26 extends to a filter 32. From the filter 32, a water line or conduit 34 is shown extending to a heater 36. From the heater 36, a water line or conduit 38 extends back to the swimming pool 4. It will be understood that all pools may not include a heater, and some pools may include other elements. However, such is immaterial to the present invention. The layout in FIG. 1 is merely schematic for purposes of illustrating a typical use environment for the apparatus of the present invention.
The pump 22 is an electrical pump, and is accordingly connected to a source of electrical current by appropriate electrical conductor(s) 28.
A branch water line or conduit 40 is connected to the line or conduit 26 to provide water from the pump 40 to the valve and venturi apparatus 70. The water line or conduit 40 extends specifically to the venturi portion of the apparatus 70.
A chlorine generator 60 generates chlorine for the swimming pool 4. Chlorine flows from the generator 60 through a conduit 62 to the valve and venturi apparatus 70 of the present invention. Chlorine flowing from the generator 60 to the valve and venturi apparatus 70 flows to the swimming pool 4 with the flow of water from the water line 40, as will be discussed in detail below in conjunction with FIGS. 2 and 3.
FIG. 2 is an enlarged view in partial section of the valve and venturi apparatus 70, taken generally from ellipse 70 of FIG. 1. In FIG. 2, the apparatus 70 is in its "off" state, as when no water or chlorine is flowing.
FIG. 3 is an enlarged view in partial section of the apparatus 70 of FIG. 2 in its "on" or operational state when the water and chlorine are both flowing.
For the following discussion of the operation of the valve and venturi apparatus 70 of the present invention, reference will primarily be made to FIGS. 2 and 3.
The valve and venturi apparatus 70 includes a valve body 72. The valve body 72 includes an end portion 74. The end portion 74 includes a bore 76 extending axially through it. The bore 76 terminates in an end wall 78. Extending radially outwardly from the end portion 74 is a connecting portion 80. The connecting portion 80 includes a bore 82 which communicates with the bore 76.
An adapter cap 140 is secured to the end portion 74. The adapter cap 140 includes an end wall 142. A boss 144 extends from the end wall 142 into the bore 76. The boss 144 includes a bore 146. A bore 152 extends through the end wall 142 and communicates with the bore 146. The bores 146 and 152 are axially aligned. The bore 146 has a larger diameter than that of the bore 152.
The bore 152 extends through the end wall 142 and outwardly through an external boss 150 of the cap 140. the boss 150 is externally threaded. A sensor 50 is secured to the boss 150. An electrical conductor(s) 52 extends from the sensor to the chlorine generator 60. The cap 140 is threadedly connected to the end portion 74.
The valve body 72 also includes a central portion 90. The central portion 90 is connected to the end portion 74 adjacent to the end wall 78. The central portion includes an axially extending bore 92. The axially extending bore 92 extends through the central portion 90 and through the end wall 78 of the end portion 74 to provide communication with the bore 76.
The valve body 72 also includes a central connecting portion 110. The central connecting portion 110 includes a bore 112 which in turn communicates with the bore 92 in the central portion 90. The bore 112 includes a top portion 114 which extends above the bore 92. This is also shown in FIG. 4.
The central portion 90 includes a boss 94 which extends into an end bore 98. The boss 94 includes an end face 96. The end face 96 is substantially perpendicular to the longitudinal axis of the bore 92. The end face 96 comprises a valve seat for a pilot valve.
At the outer end of the bore 98 is a shoulder or groove 100. The shoulder 100 extends circumferentially inwardly from an end face 102. The end face 102 comprises the outer end of the central portion 90 of the valve body 72.
An adapter block 120 matingly engages the end face 102. The adapter block 120 comprises a connecting portion between the valve body 72 and the conduit 62 from the chlorine generator 60. The adapter block 120 includes an end face 122 which is disposed against the end face 102 of the central portion 90. A shoulder 124 or groove extends inwardly from the end face 122. The shoulder 124 is substantially identical to, and accordingly comprises a mirror image of, the shoulder 100.
A bore 126 extends rearwardly from the shoulder 124. A boss 128 extends outwardly slightly into the bore 126. The boss 128 terminates in an end face 130. The end face 130 comprises a valve seat for a second valve. The boss 128, and its end face 130, are substantially identical to the boss 94 and its end face 96. As with the shoulders 100 and 124, the bosses 94 and 128 and the end faces 96 and 130, and the bores 98 and 126, are virtually mirror images of each other.
A bore 132 extends through the adapter block 120 and communicates with the bores 98 and 126.
The adapter block 120 is secured to the valve body 72 by a coupling element or union 136 by appropriately engaging threads.
Appropriately secured to the valve body 72 is a venturi block 160. The venturi block 160 includes an end portion 162. A bore 164 extends through the end portion 162. The conduit 40 is appropriately secured to the end portion 162 and communicates with the bore 164.
A connecting portion 166 extends upwardly from the venturi block 160 The connecting portion 166 includes a bore 168, and the connecting portion 80 of the valve body 72 extends into the bore 168. A bore 170 extends through the connecting portion 166 to provide communication between the bore 164 of the venturi block 160 and the bore 82 of the connecting portion 80.
The venturi block 160 also includes a central connecting portion 172 which receives the connecting portion 110 of the valve body 72. A bore 174 extends through the connecting portion 172 to provide communication with the bore 112 of the connecting portion 110.
Within the venturi block 160 and extending from the bore 164 is an inwardly tapering portion 180. The inwardly tapering portion 180 extends to a reduced diameter throat portion 182. From the throat portion 182, an outwardly tapering portion 184 extends to a cylindrical bore 186. The cylindrical bore portion 186 is generally of the same diameter as the bore 164, which is also of a generally cylindrical configuration.
A groove 178 extends radially outwardly and upwardly from about the center of the throat 182. A tapering bore portion 176 extends from the groove 178 to the bore 174.
It will be noted that the length of the throat 182 is relatively short as compared to the lengths of the tapering venturi bore portions 180 and 184. Moreover, it will be noted that the length of the slot or groove 178 is relatively large as compared to the length of the throat 182. As a matter of relative lengths, the slot is about two-thirds the length of the throat.
The slot or groove 178 is shown extending only about half way about the throat. However, the relative extent of the groove or slot 178 may vary, as desired or as practical.
A conduit 42 is appropriately connected to the bore 186 and extends from the venturi block 160 to the conduit or water line 38. (See FIG. 1.)
A pair of diaphragm elements 200 and 220 are disposed respectively in the shoulders 100 and 124 to control communication from the bores 92 and 132, respectively.
The diaphragm elements 200 and 220 are substantially identical. They are installed as mirror images of each other. They each include an outer ring 202 and 222, respectively, and a central diaphragm valve element 204 and 224, respectively. The diaphragm valve elements 204 and 224 are connected respectively to the rings 202 and 222 by a plurality of connecting webs 206 and 226, respectively. The plurality of webs 206 and 226 are flexible, thus allowing the central diaphragm elements 204 and 224 to move or to flex. However, the webs also provide a bias on the diaphragms to move the diaphragms to seat on the end faces of the bosses, as shown in FIG. 2.
The diameter of the central diaphragm valve elements 204 and 224 is slightly larger than the outer diameters of the bosses 94 and 128. the diaphragms 204 and 224 are disposed on the bosses, or rather on the end faces 96 and 130 of the bosses 94 and 128, respectively, in the closed position, as shown in FIG. 2.
A piston 240 is disposed in the bore 76 and is movable therein. A piston rod 242 is connected to one side of the piston 240 and extends through the bore 92. A second piston rod 244 is connected to the other side of the piston 240 and it extends through the bore 76 and into the bore 146 of the boss 144 of the cap 140.
The rods 242 and 244 are square, thus allowing fluid flow about them in their respective or various bores. FIG. 4, which is a view in partial section taken generally along line 4--4 of FIG. 3, shows the square configuration of the rod 242 in the bore 92.
FIG. 4 also shows the relative diameter of the bores 92 and 112, including the upper portion 114 of the bore 112. The diameter of the bore 112 is substantially greater than the diameter of the bore 92 to make certain that the flow of chlorine gas is free in the bore 92 and to the bore 112.
The rod 242 abuts the diaphragm valve element 204 to move the diaphragm valve element 204 off its seat. The rod 244 abuts the end wall 148, as required, as when the pump 22 is turned off an the piston 240 moves to the left, as viewed in FIG. 3, to the position shown in FIG. 2.
In operation, when the motor and pump 22 are operating, water flows from the trough 6 through the line 24 to the motor/pump 22, water is then pumped through the line 26 to the filter 32, the line 34, the heater 36, and the line 38 back to the swimming pool 4. Water also flows in the water line 40 from the water line 26 to the venturi block 160. The water flows through the bore 164, and through the venturi elements 180, 182, and 184 and to the bore 186 and to the conduit 42. The conduit 42 then flows to the conduit 38.
Water pressure from the bore 164 is communicated through the bore 170 to the bore 82, and to the bore 76, where the water pressure moves the piston 240 to the right, as viewed in FIG. 2. As the piston 240 moves to the right, the piston rod 242 bears against the diaphragm valve element 204. the diaphragm valve element 204 is then moved away from the end face 96 of the boss 94 as shown in FIG. 3. At the same time, water pressure from the bore 76 is communicated through the bores 146 and 152 to the sensor element 50. The sensor element 50 in turn provides an electrical signal through the conductor 52 to the chlorine generator 60.
A piston 240, and its piston rod 242, act as a pilot valve to actuate the diaphragm valve element 204.
The low pressure generated by the venturi elements 180, 182, and 184, causes the vacuum pressure to be transmitted through the slot or groove 178, the tapered bore 176, and the bore 112. The vacuum pressure is then transmitted through the bore 92 and into the bore 98. The vacuum pressure is also transmitted from the bore 98 to the bore 126. The vacuum pressure causes the diaphragm valve element 224 to unseat from against the end face or valve seat 130, and accordingly allows chlorine gas, which is under atmospheric pressure, to flow from the chlorine generator 60 and through the conduit 62.
With vacuum pressure on one side of the diaphragm valve element 224, and atmospheric pressure in bore 132 on the other side of the valve element 132, the valve element 132 moves against its inherent bias to open the bores 132 and 126 to each other. The bores 98 and 92 are also then in communication with the bores 126 and 132 for the flow of chlorine gas.
The chlorine gas is then drawn through the bores 126, 98, 92, 112, and 176, and the slot or groove 178 into the venturi at the throat 182. The gas, or course, moves into the water and flows with the water into the swimming pool 4.
When the pump 22 is turned off, water ceases to flow through the lines 26 and 40. The head of water in the valve apparatus 70 drains from the bore 76 and the bore 82 to the bore 164 and into the line 40. In place of the draining water, sufficient low pressure or vacuum pressure is pulled against atmospheric pressure to cause the piston 240 to move in the bore 76 to the left as shown in FIGS. 2 and 3, and thus the piston rod 242 is withdrawn from the bore 98 and allows the valve element 204 to seat against the end face 96. At the same time, the valve element 224 seats against its end face 130 by its own inherent bias, thus sealing off the bores 98 and 126. This, of course, prevents air from entering into the line 40 and accordingly prevents the pump 22 from losing its prime.
In case of a blockage virtually anywhere in the system that disturbs the vacuum, back pressure in the venturi elements causes water pressure to flow upwardly into the bore 112 and into the bore 92. The water pressure is also be communicated into the bore 76 between the piston 240 and the end wall 78. This would essentially put the same water pressure on both sides of the piston 240. The result is that the piston 240 again moves away from the valve element 204, and the valve element 204 of its own inherent bias seats against the end face 96. At the same time, the valve element 224 also seats against its end face 130, thus again sealing the bores 98 and 126.
As best illustrated in FIG. 4, which is a view in partial section taken generally along line 4--4 of FIG. 3, the square cross section of the piston rod 242 allows it to move in the bore 92 without sealing off the bore 92 to the flow of a fluid, such as chlorine gas, or a liquid such as water. At the same time, the larger diameter of the bore 112 and the extension 114 of the bore 112 above the bore 92, assures at all times that there will be communication between the bore 112 and the bore 92. Similarly, the square configuration to the piston rod 244 assures that there will be fluid communicating in the bore 146 and thus to the bore 152 and to the sensor 50.
The sensor 50 insures that the chlorine generator 60 is on, and generating chlorine, only when the pump 22 is operating. Only when there is a positive pressure communicated from the bore 76 to the bores 146 and 152 to the sensor 50 will the chlorine generator be on.
It will be noted that the sensor 50 is connected directly to the cap 140. However, it will be noted that a water line may be connected to the cap 140 and may extend from the cap 140 to the chlorine generator. The sensor 50 may then be located at the chlorine generator rather than at the valve and venturi apparatus 70, remotely from the chlorine generator. In either case, the function of the sensor is the same. The real issue is convenience and cost.
While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, within the limits only of the true spirit and scope of the invention. | Double valve apparatus is used in a swimming pool chlorinating system for injecting chlorine gas into a swimming pool when a swimming pool pump is operating. Two valve elements move on and off two valve seats for preventing air from bleeding back to the water pump when the pump is not operating and for preventing back pressure in the system from introducing water into the chlorine gas line. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional application of application Ser. No. 12/856,718, filed Aug. 16, 2010, which is incorporated by reference herein.
FIELD OF INVENTION
The present invention relates to semiconductor nanowire field effect transistors.
DESCRIPTION OF RELATED ART
A nanowire field effect transistor (FET) includes doped portions of nanowire that contact the channel region and serve as source and drain regions of the device. Previous fabrication methods that used ion-implantation to dope the small diameter nanowire may result in undesirable amorphization of the nanowire or an undesirable junction doping profile.
BRIEF SUMMARY
In one aspect of the present invention, a method for forming a nanowire field effect transistor (FET) device includes forming a nanowire over a semiconductor substrate, forming a gate stack around a portion of the nanowire, forming a capping layer on the gate stack, forming a spacer adjacent to sidewalls of the gate stack and around portions of nanowire extending from the gate stack, forming a hardmask layer on the capping layer and the first spacer, forming a metallic layer over the exposed portions of the device, depositing a conductive material over the metallic layer, removing the hardmask layer from the gate stack, and removing portions of the conductive material to define a source region contact and a drain region contact.
In another aspect of the present invention, a nanowire field effect transistor (FET) device includes a channel region including a silicon nanowire portion having a first distal end extending from the channel region and a second distal end extending from the channel region, the silicon portion is partially surrounded by a gate stack disposed circumferentially around the silicon portion, a source region including the first distal end of the silicon nanowire portion, a drain region including the second distal end of the silicon nanowire portion, a metallic layer disposed on the source region and the drain region, a first conductive member contacting the metallic layer of the source region, and a second conductive member contacting the metallic layer of the drain region.
Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with the advantages and the features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The forgoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIGS. 1-4 are cross-sectional views illustrating exemplary methods for forming contacts for field effect transistor (FET) devices, in which:
FIG. 1 illustrates the formation of gate stacks about nanowires;
FIG. 2 illustrates the formation of a first metallic layer;
FIG. 3 illustrates the formation of a contact material; and
FIG. 4 illustrates the removal of a portion of the contact material.
FIG. 5 is a top-down view of the devices of FIG. 4 .
DETAILED DESCRIPTION
FIG. 1 illustrates a cross-sectional view of a plurality of FET devices. A silicon on insulator (SOI) pad region 106 , pad region 108 , and nanowire portion 109 are defined on a buried oxide (BOX) layer 104 that is disposed on a silicon substrate 100 . The pad region 106 , pad region 108 , and nanowire portion 109 may be patterned by the use of lithography followed by an etching process such as, for example, reactive ion etching (RIE). Once the pad region 106 , pad region 108 , and nanowire portion 109 are patterned, an isotropic etching process suspends the nanowires 109 above the BOX layer 104 . Following the isotropic etching, the nanowire portions 109 may be smoothed to form elliptical shaped (and in some cases, cylindrical shaped) nanowires 109 that are suspended above the BOX layer 104 by the pad region 106 and the pad region 108 . An oxidation process may be performed to reduce the diameter of the nanowires 109 to desired dimensions.
Once the nanowires 109 are formed, a gate stack 103 including layers 120 , 122 and 124 is formed around the nanowires 109 , as described in further detail below, and may be capped with a polysilicon layer 102 . A hardmask layer 107 , such as, for example silicon nitride (Si 3 N 4 ) is deposited over the polysilicon layer 102 . The polysilicon layer 102 and the hardmask layer 107 may be formed by depositing polysilicon material over the BOX layer 104 and the SOI portions (all which are covered by the gate stack 103 ), depositing the hardmask material over the polysilicon material, and etching by reactive ion etching (RIE) to form the polysilicon layer (capping layer) 102 and the hardmask layer 107 illustrated in FIG. 1 . The etching of the hardmask 107 , the polysilicon layer 102 , and the gate stack 103 may be performed by directional etching that results in straight sidewalls of the gates 103 . Following the directional etching, polysilicon 102 remains under the nanowires 109 including regions that may not be masked by the hardmask 107 . Isotropic etching may be performed to remove polysilicon 102 from under the nanowires 109 .
In an alternate embodiment, a metal gate may be formed in a similar manner as described above, however, the polysilicon layer 102 and gates 103 are replaced by metal gate materials resulting in a similar structure. The material substituting the polysilicon 102 is conductive and serves as a barrier for oxygen diffusion to minimize regrowth of the interfacial layer between the nanowire and the gate dielectric. The material is sufficiently stable to withstand various processes that may include elevated temperatures.
The fabrication of the arrangement shown in FIG. 1 may be performed using similar methods as described above for the fabrication of a single row of gates. The methods described herein may be used to form any number of devices on a nanowire between pad regions 106 and 108 .
The gate stack 103 is formed by depositing a first gate dielectric layer 120 , such as silicon dioxide (SiO 2 ) around the nanowire 109 . A second gate dielectric layer 122 such as, for example, hafnium oxide (HfO 2 ) is formed around the first gate dielectric layer 120 . A metal layer 124 such as, for example, tantalum nitride (TaN) is formed around the second gate dielectric layer 122 . The metal layer 124 is surrounded by polysilicon layer 102 . Doping the polysilicon layer 102 with impurities such as boron (p-type), or phosphorus (n-type) makes the polysilicon layer 102 conductive.
A first set of spacers 110 are formed along opposing sides of the etched polysilicon layer 102 . The spacers 110 are formed by depositing a blanket dielectric film such as silicon nitride and etching the dielectric film from all horizontal surfaces by RIE. The spacers 110 are formed around portions of the nanowire 109 that extend from the polysilicon layer 102 and surround portions of the nanowires 109 . Depending upon the process used to etch the spacers 110 , a residual portion of spacer 110 may remain under the nanowire 109 .
The source and drain diffusion regions may include either N type (for NMOS) or P type (for PMOS) doped with, for example, As or P (N type) or B (P type) at a concentration level typically 1e19 atoms/cm 3 or greater.
FIG. 2 illustrates a resultant structure following a blanket deposition of a first metallic layer 202 . The first metallic layer is, for example, less than 30 nanometers thick, and is deposited over the exposed surfaces of the device. The first metallic layer may include a metallic material such as, for example, tungsten or tantalum. The metal selected for the first metallic layer may be selected based on the properties of the material. Since forming a silicide from the first metallic layer is undesirable, and the fabrication process may expose the device to high temperatures after the formation of the first metallic layer, a metallic material should be selected that has a threshold for forming a silicide that is higher than the temperatures that will be used in subsequent fabrication processes.
FIG. 3 illustrates an example of the resultant structure following the deposition of contact material 302 such as, for example, W, Cu, Ag, or Al on the first metallic layer 202 .
FIG. 4 illustrates an example of the resultant structure where a portion of the contact material 302 (of FIG. 3 ) and the hardmasks 107 are removed by, for example, a chemical mechanical polishing (CMP) or etching process. Once the polysilicon 102 is exposed by the CMP process, a silicide 402 may be formed on the exposed polysilicon 102 to improve conductivity in the gate region (G). Alternatively, for metallic gates, the CMP process may remove the hardmasks 107 and expose the metallic gate. The resultant contacts 404 define current paths to the source (S) and drain (D) regions of the devices.
FIG. 5 illustrates a top view of the resultant structure of the illustrated embodiment of FIG. 4 following the isolation of the devices with a material 802 such as, for example, an oxide or nitride dielectric material. Following the formation of the contact material 302 and the contacts 404 , a mask layer (not shown) is patterned on the devices to define a trench area around the devices. An etching process is used to remove contact 302 material from the trench area. The trench area is filled with the material 802 as illustrated in FIG. 5 to form an isolation region around the device. Alternatively, the isolation region defined by the material 802 may be formed by forming a mask over the devices in the illustrated embodiment. Once the mask is formed, an etching process may be performed to remove metal 302 and 202 . The etching defines the length of the contacts 404 and electrically isolates the source and drain regions.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one ore more other features, integers, steps, operations, element components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
The diagrams depicted herein are just one example. There may be many variations to this diagram or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
While the preferred embodiment to the invention had been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described. | A nanowire field effect transistor (FET) device includes a channel region including a silicon nanowire portion having a first distal end extending from the channel region and a second distal end extending from the channel region, the silicon portion is partially surrounded by a gate stack disposed circumferentially around the silicon portion, a source region including the first distal end of the silicon nanowire portion, a drain region including the second distal end of the silicon nanowire portion, a metallic layer disposed on the source region and the drain region, a first conductive member contacting the metallic layer of the source region, and a second conductive member contacting the metallic layer of the drain region. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to composite panel or shape forming apparatus and more particularly, it concerns an improved apparatus for continuously forming flat sheets or shapes from a composite of reinforcing fibers and particulate filler in a matrix of thermosetting resinous material by the applying of the materials of the composite between a pair of continuous sheet-like carriers and pulling the sheets and material through a linear series of successive compacting, treating shaping and curing stations in a manner such that the flat sheet or shape being so continuously formed may be finished and severed into panels ready for use.
Various forms of apparatus are known in the prior art by which the individual components of a fiber reinforced board or sheet to be formed are distributed either simultaneously or successively onto a continuously moving surface, such as an endless conveyor or elongated carrier sheet, and then passed through successive treatment stations by which a continuous form of the board or sheet being manufacturing emerges for cut-off and stock piling. See, for example, U.S. Pat. Nos. 3,071,180 and 3,109,763 issued to Joseph S. Finger et al. While prior forms of such apparatus are admirably suited to high speed production of structural panels and the like, specific apparatus heretofore available have been generally deficient from the standpoint of adaptability to different constituent materials to be employed in the composite board, diverse cross-sectional shapes in the board, sheet or panel being formed as well as capability for providing a truly uniform distribution of composite material components throughout the resulting panel or board product. For example, relatively high percentages of inexpensive particularized inorganic fillers have been found desirable in structural panels both from the standpoint of reduced costs and enhanced nonflammability. Such materials, however, have been difficult to handle in prior apparatus because of the extent to which they increase viscosity of their mixture in resins. Also, composite boards are conventionally formed in a corrugated cross-section for use in various structural applications where longitudinal rigidity as a result of the corrugated cross-sectional configuration is needed. Quite often, however, it is either necessary or desirable to change the specific cross-sectional configuration. In prior apparatus, however, this could be accomplished only by the substitution of costly dies and molds and involves a time consuming and tedious procedure.
From the standpoint of component intermixing and uniformity of distribution, such prior apparatus has been found to lack facility for varying percentages of components incorporated in a continuously formed board and also have demonstrated deficiencies in achieving a uniform distribution of the components throughout the product. In this latter respect, fibrous components employed principally as reinforcement in a matrix resin pose problems of distribution as a result of interfiber adherence due either to electrostatic traction or surface tension and further are subject to non-uniform distribution as a result of non-uniform directional forces imposed on the fibers as they are distributed onto the matrix.
In light of these exemplary deficiencies, a need for improvements in both methods and apparatus for forming such composites board is apparent.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, an improved apparatus for continuously forming composite material flat sheets or shapes is provided in which an elongated sheet of flexible carrier material is continuously payed out from the supply roll and drawn past successive lower matrix, reinforcing fiber and particularized earth dispensing units each synchronized with the linear speed of carrier travel in accordance with predetermined composite flat sheet or shape design criterion so as to achieve a precisely determined percentage of each composite material component uniformly across the width of the carrier. After receiving an upper layer of essentially liquid matrix material an upper sheet carrier or covering, substantially identical to the lower sheet carrier, is brought into overlying coextensive with the lower sheet carrier and the composite materials deposited thereon. The composite material thus sandwiched between the two carriers is then advanced through an unique compactor unit in which air entrapped between the carrier sheets is removed and also the material is worked or kneaded. Thereafter, the material is passed through curing ovens each equipped with an inexpensive lower sheet metal die to which the composite is conformed by an unique arrangement of wiper blades. The easily interchangeable forming arrangement in the curing ovens is followed by a puller also having a facility for adaptability to different cross-sectional configurations of board being formed. Following the puller, the carrier sheets are recovered on means adapted to be substituted for the initial carrier supply rolls thereby enabling reuse of the carrier sheets. The essentially rigid and formed board of any shape passing the carrier recovery station is then appropriately finished, trimmed and cut into discrete lengths to provide panels ready for use.
Among the objects of the present invention are, therefore, the provision of an improved apparatus for the continuous formation of composite material flat sheets or shapes; the provision of such an apparatus having a novel and unique material distribution system by which the quantity of materials incorporated in the board may be accurately controlled; the provision of such a material distribution system by which uniformity of material throughout the board is assured; the provision of an unique system in such apparatus for removing air as well as volatiles that may develop during polymerization of a resin matrix; the provision of an inexpensive and versatile forming mold organization for such an apparatus; and the provision of pulling and finishing units for such an apparatus by which diverse cross-sectional configurations of the formed panel may be readily accommodated.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description to follow taken in conjunction with the accompanying drawings in which like parts are designated by like reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a divided perspective view illustrating the overall apparatus of the invention;
FIG. 2 is an enlarged fragmentary cross-section illustrating the general organization of a lower matrix dispenser forming a component of the apparatus illustrated in FIG. 1;
FIG. 3 is a fragmentary plan view as seen on line 3--3 of FIG. 2;
FIG. 4 is an enlarged fragmentary cross-section taken on line 4--4 of FIG. 3;
FIG. 5 is an enlarged fragmentary cross-section taken on line 5--5 of FIG. 2;
FIG. 6 is a fragmentary cross-section taken on line 6--6 of FIG. 5;
FIG. 7 is an enlarged fragmentary cross-section illustrating a reinforcing fiber cutting and distributing assembly forming part of the apparatus of the invention;
FIG. 8 is a fragmentary cross-section on line 8--8 of FIG. 7;
FIG. 9 is an enlarged fragmentary cross-section taken on line 9--9 of FIG. 8;
FIG. 10 is a fragmentary plan view as seen from line 10--10 of FIG. 9;
FIG. 11 is a fragmentary elevation as seen on line 11--11 of FIG. 9;
FIG. 12 is an enlarged fragmentary cross-section taken on line 12--12 of FIG. 8;
FIG. 13 is a fragmentary cross-section illustrating the filler dispenser, upper matrix dispenser and material compactor components of the apparatus;
FIG. 14 is a plan view in partial section taken on line 14--14 of FIG. 13;
FIG. 15 is an enlarged side elevation in partial cross-section illustrating curing ovens forming a portion of the apparatus of this invention;
FIG. 16 is an enlarged fragmentary cross-section taken on line 6--6 of FIG. 15;
FIG. 17 is a similarly enlarged cross-section taken on line 17--17 of FIG. 15;
FIG. 18 is a plan view illustrating the wiper blade organization illustrated in FIG. 15;
FIG. 19 is an enlarged cross-section illustrating respectively the material pulling assembly, the carrier recovery components as well as the surface preparation elements of the apparatus;
FIG. 20 is an enlarged fragmentary cross-section taken on line 20--20 of FIG. 19;
FIG. 21 is an enlarged fragmentary cross-section on line 21--21 of FIG. 19;
FIG. 22 is an enlarged fragmentary cross-section taken on line 22--22 of FIG. 19.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 of the drawings, the overall apparatus of the invention is shown to include a linear series of components beginning with a material dispensing tower 10 and ending with a part receiving conveyor table 12 from which finished panels P manufactured by the apparatus are removed and assembled in stacks S for shipment. The panels P, which may be corrugated as shown flat or any other shape, are preferably a substantially rigid laminate or composite of fiber reinforcement and particularized earth filler in a thermosetting resin matrix. The manner in which the panels are formed by the apparatus of this invention can be appreciated from the general illustration of successive components illustrated in FIG. 1. Hence, at the material dispensing tower 10, a lower carrier 14 of mylar or similar sheet material is payed out from a lower carrier supply roll 16 and passed under a lower matrix dispenser 18 to receive a uniform coating of uncured resin or resin-filler mixture in a manner to be described in more detail below. The coated lower carrier 14 then proceeds under a fiber dispenser 20 and a filler dispenser 22. Following the filler dispenser 22, an upper carrier 24 of the same material as the lower carrier 14 and stored in an upper carrier supply roll 26 is passed forwardly under an upper matrix dispenser 28 to be uniformally coated also with a layer of uncured resin after which it is passed downwardly over a guide roller 30 so that the coating thereon overlies the filler material and fibers previously deposited on the lower matrix. At a point under the guide roller 30, therefore, the composite of the upper and lower matrix coatings deposited on the upper and lower carriers 24 and 14, respectively, together with the filler and fiber reinforcement is sandwiched between the upper and lower carriers.
Upon leaving the material dispensing tower 10, the carrier supported composite is first passed through a material compactor 32 to complete an intermixing of the composite ingredients and remove air which may be trapped between the carriers. Following the compactor 32, the material passes through a preliminary polymerization oven 34, a final polymerization oven 36 to a puller 38 having a drive motor 40 of sufficient power to draw the carriers 14 and 24 from the supply rolls 16 and 36 through the several components aforementioned. Following the puller 38, the fully cured and formed composite passes a carrier recovery component 42 at which the carrier sheets 14 and 24 are separated from the formed composite and recovered on take-up rolls 44 and 46, respectively.
After the carriers are removed, the cured composite passes a surface finishing component 48, an edge trimmer 50 and a cut-off component 52 in the form of a transversely moving saw 54 supported on a carriage 56 mounted for longitudinal movement with the composite being formed to sever the final panel P. The panels P are thus continuously formed until the ends of the carrier supply rolls 16 and 26 are reached, at which point, new carrier supply rolls are placed into position and the process reinitiated. Also in this context, it is to be noted that the carrier sheets are reusable and that the recovery rolls 44 and 46 are designed to be interchanged with the supply rolls 16 and 26 in a manner to be described more fully below.
Structural organization and detail of the lower matrix dispenser 18 is illustrated most clearly in FIGS. 2-6 of the drawings. As shown in FIGS. 2 and 3, the dispenser 18 includes a puddling box 58 supported in vertically spaced relation over the lower carrier 14 which, at this point in its overall travel, is supported in horizontal planar relation by a table 60 carried by frame members 62 and 64 forming part of the material dispensing tower 10. The puddling box 58 is formed by a leading transverse wall 66 from which a pair of side walls 68 extend as integral projections in the direction of lower carrier travel. The side wall 68 as well as the leading wall 66 are of the same height and are positioned above the upper surface of the table 60 by vertical standards 70 welded or otherwise suitably affixed to the horizontal frame member 64 to provide a running clearance with the lower carrier 14. The trailing end of the puddling box 58 is closed by an adjustable gauge blade 72 supported at opposite ends by vertical standards 74 in turn supported by the frame members 64 through calibrated adjustable couplings 76. Details of the couplings are shown in FIGS. 5 and 6 to include a rotatable coupling sleeve 78 internally threaded at its upper end to engage external threads at the lower end each standard 74 and an internal enlargement near its lower end to receive a ball stud 79 mounted on the frame member 64 thereby to enable rotation of the sleeve without axial displacement with respect to the frame member 64. Also as shown in FIG. 5, the sleeve 78 is provided with an indicating projection 80 cooperable with calibrations 82 on the upper surface of the frame member 64. The gauge blade 72, thus supported for vertical adjustability on the standards 74, is further supported against lateral displacement by slide brackets 82 welded or otherwise suitably secured to the vertical frame members 62 and through which the vertical standards extend as shown in FIGS. 2 and 3. Suitable means such as mortises in the gauge blade 72 are provided to effect a sliding liquid seal with the trailing ends of the side members 68.
As shown in FIGS. 2 and 4, the lower side of the gauge blade 72 is provided with a linear horizontal strike 86 which functions to gauge the thickness of the lower matrix layer M 1 applied to the lower carrier 14. The means by which the matrix material is supplied essentially viscous liquid form to the puddling box is shown in these figures to include a plurality of discharge pipes 88 operated under the control of an automatic valve 90. The valve 90, in turn, is controlled electrically by a float gauge 92 shown in FIG. 4 to include a variable resistor 94 supported directly by the gauge blade 72 and engaged by a point contact 96 supported at the upper end of a float rod 98. As a result of this organization, the level of matrix material in the puddling box or on the upstream side of the gauge blade 72 may be maintained at a predetermined level above the strike 86. The specific thickness of the matrix layer M 1 applied to the lower carrier 14 is a function of carrier velocity, height of the strike 86 above the upper surface of the carrier and height of the matrix puddle within the box 56 above the strike 86 as sensed by the float gauge 92. In light of the organization of components illustrated in FIGS. 2-6, it will be appreciated that each of these functions may be accomodated to enable accurate control over the thickness of matrix applied to the lower carrier 14. It is to be noted that in some instances, the matrix material will be a highly viscous mixture of uncured resin and filler. In such instances the correlation of matrix level and strike blade setting to carrier travel become essential to the achievement of the layer M 1 on the carrier.
As pointed out above with respect to the general organization illustrated in FIG. 1 of the drawing, following the application of the lower matrix M 1 to the lower carrier 14 in the manner aforementioned, the carrier supported matrix is advanced past the fiber dispenser 20. Although the constructional details of the fiber dispenser 20 are shown most clearly in FIGS. 7-12 of the drawings, reference is first made against to FIG. 1 in which the supply of fibers is illustrated in somewhat schematic form to include a bank of storage reels 100 from which a large number of individual rovings or strands 102 are fed past a tension control brake 104 directly to the fiber dispenser 20. As shown in FIGS. 7 and 8, the continuous strands 102 are severed into short lengths to form fibers F by passage between a rotatable cutting knife 104 and a pliable friction roller 106 extending transversely across the mouth 108 of an aerodynamically designed fiber dispensing chute 110. The structural details of the cutting knife 104 can be appreciated by reference to FIGS. 7, 8 and 12 of the drawings. Specifically, the cutter knife is shown to include a relatively solid cylindrical body 111 having a plurality of radial grooves 112 extending in generally helical fashion along the length of the body, each groove 112 receiving a plurality of discrete cutting knives resembling conventional razor blades and retained in the grooves by spring clips 114. The body 111 is keyed on a shaft 115 adapted to be driven by an electric motor 116 through appropriate mechanical transmission means including a pulley driven belt 117 and a coupling gear 118 so that the cutting knife 104 and the roller 106 are driven in opposite directions as depicted by the arrows in FIG. 7 of the drawings. Because of the manner in which the individual blades 113 are mounted in the cutter knife body 111, replacement either of individual cutting blades 113 or pull of the blades is readily accommodated.
The motor 116 is regulated by a control unit 118 having a manual control knob 119 as well as a provision for regulating the speed of the motor 116 and thus the cutting knife 104 automatically in accordance with the linear velocity of the carrier 14. This automatic control function is effected by a velocity sensing unit 120 electrically connected to the control unit 118 through a line depicted at 122 in FIG. 7. In light of this control organization, it will be appreciated that the quantity of fibrous material drawn from the storage reel bank 100 and severed into short lengths by the cutting knife 104 may be controlled very accurately in accordance with the linear velocity at which the carrier 14 is passed under the overall fiber dispenser.
An important aspect of the fiber dispenser is the provision of means to insure that the individual fibers F passing the cutter knife 104 are caused to fall as discrete units umimpaired by any directional force onto the lower matrix M 1 on the carrier 14. This function is carried out by the combined effects of the shape and dimensions of the fiber discharge chute 110 and the successive actions on the downwardly falling fibers F brought about by a fiber sorter and tumbler 124, electromagnetic field generating coils 126 and a specially designed air distributor 128 all as shown generally in FIGS. 7 and 8 of the drawings. Specifically, the sorter-tumbler, with which the downwardly falling fibers F first come in contact, is rotated in a direction opposite from that of the cutter knife 104 to neutralize the downwardly oriented dynamic force of the falling fibers. After passing the sorter-tumbler, the fibers are subjected to an electromagnetic field generated by the pair of spaced coils 126 supplied with electric circuit by appropriate circuitry including current regulating and reversal means (not shown) so that the static charge existing on the cut fibers may be fully neutralized, thereby to avoid any adherence of the fibers to each other as a result of such static electricity. Finally, the downwardly falling fibers are acted upon by the air distributor 128 which, because of its specific structural design to be described in more detail below, develops a generally swirling air cushion capable of both parting any fibers adhered to each other by surface tension and effecting a cancellation of any directional force experienced by the discrete fibers. Hence, after passing the level of the air distributor 128, the discrete fibers F are caused to fall gently onto the lower carrier supported matrix in an extremely uniform manner.
The structural organization of the air distributor 128 is most clearly understood by reference to FIGS. 8-11 of the drawings. As shown in FIGS. 8 and 9, the air distributor is formed by an elongated manifold 130 supplied at one end by a variable capacity air blower 132 or piped air supply, closed at its opposite end and having a plurality of equally spaced nozzles 134 uniformly spaced in a radial plane a extending throughout the length of the manifold 130. The location of the manifold axis in relation to the vertical duct section and an outwardly flared hood section 136 of the fiber chute 110 is best shown in FIG. 9. Specifically, the axis of the manifold is located in the vertical plane of the vertical duct wall on the downstream side of the distributor and spaced from the inclined hood wall 136 by a distance x. Also it is seen in this figure that the discharge axis of the nozzles 134 as defined by the radial plane a is displaced from the vertical by an angle θ 1 . Located between each five nozzles 134 along the length of the manifold 130 are circular fins 138 projecting radially from the outside of the manifold. Each of the circular fins 138 supports a plurality of mixer fins 140 and 142 as well as a relatively large angularly disposed aerodynamic fin 144. The shape of the individual mixer fins is established by a simple rectangular plate whereas the shape of the aerodynamic fins is in the nature of the a parallelogram having a length L, a width W, the longer sides being displaced by an angle θ 2 from a line perpendicular to the end edges.
Although the specific dimensions and angular relations of the components forming the air distributor 128 may be varied without departure from the spirit and scope of the present invention, the following ranges of specifc dimensions and angular relations of these components are believed optimum where the depth D of the vertical duct section of the fiber distributing chute 110 is equal to approximately 12 inches, where the hood portion at an angle θ 3 in the range of 35° to 55° and where the distance x is equal to approximately 4 inches: the radius r of the manifold 130 is 1 inch; five equally spaced nozzles 134 defining 1/8 to 1/4 inch diameter orifices (depending on available input pressure) are positioned in a 6 inch length between the circular fins 138; the radius r' of the circular fins is 2.4 times the radius of the manifold or in this case 2.4 inches; the radii r" and r'" establishing the inner and outer positions of the mixer fins 140 and 142 are 11/8 inches and 21/8 inches respectively but are in proportion to 2:4 to 1 above; the length of the mixer fins is equal to the diameter of the manifold or in this case 2 inches; four of the mixer fins 140 on each of the circular fins 138 are oriented at approximately 45° ± 5° with respect to the nozzle discharge plane a whereas the other two of the mixer fins 142 are disposed at an angle α with respect to a plane normal to the nozzle discharge plane, the angle αranging from 30° to 50°. The aerodynamic plates 144 illustrated are sized so that the length L is approximately six times the manifold radius or in this case 6 inches whereas the width W is approximately L/2 or 3 inches and the angle θ 2 equal to approximately 5° ± 1/2°. The plates 144 are welded or other wise fixed in tangential relation to the outer circumference to the circular fins 138 normal to an angle θ 4 with respect to the nozzle discharge plane a, θ 4 being in the range of 27°to 29°. Also, the plates 144 are disposed at an angle θ 5 with respect to the longitudinal axis of the manifold, the angle θ 5 in the specific example being 10° ± 1°. With the components of the air distributor 128 thus disposed in relation to each other and to the discharge chute 110 an extremely uniform distribution of fibers resulted on the matrix M 1 supported on the lower carrier.
Following the application of the fibers F to the lower matrix M.sub. 1 the lower carrier 14 passes under the filler dispenser at which a particularized earth filler E is added to the composite of the lower matrix and fibers. As shown in FIGS. 1, 13 and 14, the filler dispenser 22 includes a hopper 145 opening at its upper end at a level substantially the same as a floor 146 in the dispensing tower 10. The filler dispenser functions to disperse uniformly over the top of the lower matrix M 1 and fibers F a precise quantity of filler material per unit length of lower carrier travel. To this end, the lower end of the hopper 145 is provided with an opening defined by a pair of transverse lips 148 which bear against a rotatable perforated drum or cylinder 150 driven by a variable speed motor 152, the output speed of which is controlled by the carrier velocity sensing unit 120. Upon rotation of the perforated cylinder 150 in accordance with linear velocity of the carrier 14, the particularized earth filler is passed from the hopper into the cylinder 150 from which it is discharged under the influence of centrifugal force. The amount of material thus discharged from the dispensing perforate cylinder 150 is therefore, directly proportional to the speed at which the cylinder is rotated by the motor 152. After passing from the perforate drum, the filler is thrown by centrifugal force against a pair of inclined shields 154 coupled to vibrator units 156. Vibration of the shields 154 by the vibrating units 156 eliminates any adherence of the filler to the shields by surface tension or moisture. The discharge of filler E from the funnel-like gap between the shields 154 impinges the filler against the fibers F and lower matrix M 1 in a manner such that the matrix M 1 is forced into the essential shear areas between the fibers F and also, the impinging force of the filler E forces any non-wetted fibers into the lower matrix M 1 .
After the filler E is distributed over the composite of the fibers F and the lower matrix M 1 , an upper matrix layer M u having been deposited on the upper surface of the upper carrier 24 is inverted about the idler roller 30 and brought into contact with the composite of the filler, fibers and lower matrix. The upper matrix dispenser 28, as shown in FIGS. 13 and 14, is identical in all respects to the lower matrix dispenser 18 previously described. Accordingly, further description of the upper matrix dispenser 28 is deemed unnecessary.
After passing the idler roller 30, the composite materials, at this time sandwiched between the upper and lower carriers 24 and 14, respectively, passes the material compactor 32 to remove any entrapped air, to densify the composite and to further distribute the matrix material throughout the composite. As also shown in FIGS. 13 and 14 of the drawings, the material compactor 13 takes the form of three successive roller pairs 158, 160 and 162. The upper and lower rollers in each of the aforementioned roller pairs are coupled to each other by gearing (not shown) and to a variable speed motor 164 through appropriate power transmission means such as endless belts 166. The motor 164 is operated also under control of the carrier speed sensing unit 120 so that the tangential velocity of the roller pairs will be slightly slower than the linear speed of the carriers and the composite between the carriers. As a result, each of the roller pairs effect a blading action against the carriers and composite material. At least the upper roller in each of the roller pairs 158, 160 and 162 is biased to develop a compressive pressure against the respective lower roller by suitable means such as helical compression springs 168, 169 and 170 rendered adjustable by set screws 171, 172 and 173, respectively. Although the pressures set in the springs may vary depending on composite thickness and formulation, the pressure exerted by the roller pair 158 is slightly greater than by the roller pair 160 and less than the pressure exerted by the final roller pair 162. Because of this pressure variation between the three roller pairs, a kneadidng action is imposed on the composite. Also, the pressure exerted by the first roller pair 158 will serve as the barrier for air trapped between the carriers 14 and 24 and cause such entrapped air to back to the roller 30. The lessening of pressure by the roller pair 160, on the other hand, permits some realignment of the composite components while at the same time, because of the blading action brought about as a result of the speed at which these rollers are driven, will serve to remove further air. Also it will be noted by reference to FIG. 14 that both roller pairs 158 and 160 are aligned angularly with respect to the transverse dimension of composite being formed so that air passing these roller pairs will be moved outwardly also to the edges of the carriers 14 and 24. The highest pressure being exerted by the final roller pair 162 serves as a final barrier or screen for any entrapped air so that the material after passing the roller pair 162 is fully intermixed and devoid of any entrapped air.
The assembly of the composite material and the carriers 14 and 24 thus passing from the material compactor 32 are drawn through successive preliminary and final polymerization ovens 34 and 36, respectively. Although these ovens appear linearly spaced in light of the broken perspective view of FIG. 1, in practice it is contemplated that they will be very closely spaced or abutting one another as illustrated in FIGS. 15-18 of the drawings. The ovens 34 and 36, in and of themselves, are conventional to the extent that they are comprised of four sided enclosures and having a source of heat (not shown) by which the composite entering the preliminary polymerization oven 34 in essentially liquid form leaves the final polymerization oven 36 in polymerized or in a solid and rigid form. The preliminary polymerization oven 34, therefore, functions primarily to supply adequate heat energy to the composite so as to remove substantially all of the volatiles generated by the polymerization process and to advance the polymerization process so that the composite is converted from the essentially liquid condition to a maleable solid condition. An important feature of the present invention is the provision of means within both of the ovens 34 and 36 by which the material is drawn into the desired ultimate cross-sectional configuration and also by which the removal of volatiles from the composite is facilitated.
With reference to FIGS. 1 and 15-18 of the drawings, both ovens 34 and 36 are shown to include a generally planar floor 176 spanning the distance between a pair of vertical side walls 178. An essentially continuous sheet metal mold 180 is supported by the floor 176 and shaped as desired to conform with the continuous cross-sectional configuration desired in the panels P, in this instance a corrugated configuration as shown in FIG. 17. The forming mold is formed in inexpensive sheet metal and is adapted to be clipped removably by suitable means such as spring clips 182 to the floor 176 of the ovens. Hence, it will be seen that different configurations of molds may be usedd or the molds may be removed entirely in the event a flat or planar shaped composite material panel is desired.
Positioned downstream from the entrance end of the preliminary polymerization oven 34, in terms of the carrier and material travel, is the first set 184 of a succession of forming wipers. The first set of wipers 184 is positioned in the ovens 34 such that the length of time for the composite material to pass from the entrance of the oven 34 to the first set of wipers 184 is sufficient to impart enough thermal energy to initiate polymerization. As shown in FIGS. 15 and 16, the wiper set 184 includes structurally a plurality of flexible blade-like wipers 186 supported at the lower end of spring rods 188 which in turn are fixed at their upper ends to a torque tube 190. The torque tube is supported for rotation in the side walls and rendered adjustable by a crank 192 having a pin latching mechanism 194 by which it can be retained in an angle to impose a preselected stress on the rods 188 and the wiper pads 186. Subsequent wiper pad sets are supported in identical fashion on other torque tubes 196-199 essentially as shown in FIGS. 15 and 18 of the drawings. It will be noted that the wiper pads on the respective torque tubes can be positioned to be staggered so that the entire surface of the carrier supported composite will be contacted by one or the other of the several wiper pads at some time during its travel throughout the polymerization of ovens 34 and 36. For example, the wiper pads supported from the torque tubes 190 and 196 are arranged to advance the composite into the valleys of the corrugated forming mold 180 whereas the wipers supported on the torque tubes 197 and 198 engage the top and sloping surfaces of the corrugated cross-section respectively.
In addition to functioning as means for conforming the partially polymerized composite to the configuration of the forming mold 180, the wipers serve to prevent the passage of any volatile vapor pockets in the composite which may result from the polymerization process. Specifically, the respective torque tubes are adjusted so that the wipers impose enough pressure on the carrier supported composite to achieve this function. Moreover, the wipers may be angularly placed in order that any vapor pockets which exist would pass to the open sides of the composite. Also, the organization of wipers and removable forming molds enables an infinite variety of cross-sectional shape possibilities and the cost of tooling or tooling changes is minimized. Further, it is contemplated that both shaped and flat panels may be formed by the invention simply by inserting the molds 180 and adjusting the compression wipers when a corrugated cross-section is required and removing the mold 180 and lifting the wipers where a relatively flat panel component is to be formed. In this latter instance, the volatile pocket removing function of the wipers might be served, for example, by substituting the individual wiper pads 186 with a continuous bar-like wiper supported uniformly by the several spring bars 188 from the respective torque bars.
Upon leaving the outlet of the final polymerization of oven 36, the fully cured, essentially rigid and formed composite board retained between the upper and lower carrier sheets 24 and 14, respectively, passes between and is tractionally engaged by cooperating sets of pulling wheels forming the primary components of the puller 38 described above with respect to FIG. 1, but shown in more detail in FIGS. 19 and 20 of the drawings. In the specific embodiment illustrated, an upper set of five traction wheels 200 adjustably fixed on a drive shaft 202 driven by the motor 40 by way of drive pulley 204. As shown most clearly in FIG. 19, the drive shaft 202 is journaled at opposite ends in pivotal arms 206 underlying adjustable screws 208 so that the pressure of the upper set of rollers 200 may be increased or decreased in a downward direction against the upper carrier 24. Vertically aligned with the upper set of rollers 200 is an essentially identical set of lower rollers 208 keyed to a drive shaft 210 also driven by the motor 40 but journaled in fixed bearings so as to receive the downward compressive loading of the upper rollers 200.
Each of the traction rollers 200 is of identical construction and includes a sleeve hub 211 adjustably fixed against axial and rotational displacement with respect to the drive shaft 202 or 210 by a set screw 212. Each sleeve carries an annular bearing member 214 keyed by pins 216 for rotation with the sleeve. The external surface of each bearing member 214 is spherically convex to enable a limited degree of angular movement of the wheels 200 or 208 about an axis normal to the axis of the drive shafts 202 and 210. A second pin 218 extends between the insert 214 and the wheel to ensure a rotary driving connection between the shaft 202 and the wheel. The pin 218 engages in an arcuate key slot to allow a rocking action about the aforementioned axis normal to the shaft axis. Also each of the rollers 200 and 210 is provided with an outer traction tire 220 to insure a firm pulling grip on the assembly of upper and lower carriers as well as the cured composite panel. Because of the permitted axial adjustment of the sleeves 211 on the shafts 202 and 210 and also the angular freedom of the wheels with respect to the sleeves 211, the puller 38 can accommodate many diverse cross-sectional shapes of composite boards formed.
Following the puller 38, and also as above mentioned, the carriers 14 and 24 are separated from the composite panel shape and recovered by the take-up rolls 44 and 46. As shown more clearly in FIGS. 19 and 22 than in FIG. 1, the upper carrier 24 is trained at a diverging angle with respect to formed composite travel about an arcuate guide rod 222 functioning to maintain a centering relation between the carrier and the take-up roll 46. Similarly, the lower carrier 14 is directed downwardly about a centering arcuate guide rod 224 and then onto the lower take-up roll 44. To enable a sufficient driving rotation of the take-up rolls 44 and 46 by power drive means (not shown) without change in tangential velocity at which the carriers are taken up on the rolls 44 and 46 constantly varying radii, the take-up rollers are each provided with a spindle 224 having a traction roll spaced from the end of the carrier sheets as shown in FIG. 22. The rollers 226 are cradled between drive rollers 228 as shown in FIGS. 19 and 22 so that they may be driven by a constant speed motor. In this way, any reduction in angular velocity of the spindle 225 due to the increasing diameters of the take-up rolls may be accomodated by slippage between the rollers 226 and the drive rollers 228.
Also and perhaps more significantly, this arrangement enables the take-up rolls 44 and 46 merely to be removed from the cradling drive rollers 228 and substituted for the supply rolls 14 and 26 of reuse of the carriers. This position of the bearings of the supply rolls as shown in phantom lines in FIG. 22 and designated by the reference numeral 230.
The details of the surface finishing component 48 are shown more clearly also in FIGS. 19 and 21 to include a plurality of vertically adjustable paddle sanding wheels 232 and 234 driven by a motor 236. As shown in FIG. 21, the respective upper and lower paddle sanding wheels are displaced so that the outwardly facing crests of the corrugated cross-section only may be smoothly finished principally to facilitate the corrugated shape to be sandwiched between a pair of flat skin panels by bonding, thereby to provide a structurally sound building panel.
As mentioned above with respect to FIG. 1, the trimming and cut-off saws 50 and 52, respectively, operate to trim and cut off the successive panels from the continually formed composite board. The details of these components is believed clear from the description given above with respect to FIG. 1.
Thus it will be seen that by this invention there is provided an highly effective method and apparatus for the production of composite material panels. Also it will be appreciated that minor variations can be made in the apparatus as disclosed without departure from the true spirit and scope of the present invention. Accordingly, it is expressly intended that the foregoing decription is illustrative of a preferred embodiment only, not limiting, and that the true spirit and scope of the present invention will be determined by reference to the appended claims. | Apparatus for continuously forming flat sheets or shapes from a composite of resin, reinforcing fibers and a particularized filler including a series of successive material deposition and treating stations through which the composite is pulled while sandwiched between upper and lower flexible and essentially continuous carrier sheets. The apparatus particularly suited for such composites where a high percentage of filler is used and is applicable to the formation of diverse flat sheet or shaped cross-sectional configurations. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. application Ser. No. 10/345,791 filed Jan. 16, 2003 now abandoned entitled “Dynamic Bandwidth Allocation to Transmit a Wireless Protocol Across a Code Division Multiple Access (CDMA) Radio Link, which is a Continuation of U.S. application Ser. No. 09/596,425 filed Jun. 19, 2000 now U.S. Pat. No. 6,526,281 entitled “Dynamic Bandwidth Allocation to Transmit a Wireless Protocol Across a Code Division Multiple Access (CDMA) Radio Link,” which in turn is a Continuation of U.S. application Ser. No. 08/992,760 filed Dec. 17, 1997, now U.S. Pat. No. 6,081,536 entitled “Dynamic Bandwidth Allocation to Transmit a Wireless Protocol Across a Code Division Multiple Access (CDMA) Radio Link,” which itself claims the benefit of U.S. Provisional Application No. 60/050,338 filed Jun. 20, 1997 entitled “Dynamic Bandwidth Allocation to Transmit a Wireless Protocol Across a Code Division Multiple Access (COMA) Radio Link,” and U.S. Provisional Application No. 60/050,277 filed Jun. 20, 1997 entitled “Protocol Conversion and Bandwidth Reduction Technique Providing Multiple nB+D ISDN Basic Rate Interface Links Over a Wireless Code Division Multiple Access Communication System,” the entire teachings of all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The increasing use of wireless telephones and personal computers by the general population has led to a corresponding demand for advanced telecommunication services that were once thought to only be meant for use in specialized applications.
For example, in the late 1980's, wireless voice communication such as available with cellular telephony had been the exclusive province of the businessman because of expected high subscriber costs. The same was also true for access to remotely distributed computer networks, whereby until very recently, only business people and large institutions could afford the necessary computers and wireline access equipment.
However, the general population now increasingly wishes to not only have access to networks such as the Internet and private intranets, but also to access such networks in a wireless fashion as well. This is particularly of concern for the users of portable computers, laptop computers, hand-held personal digital assistants and the like who would prefer to access such networks without being tethered to a telephone line.
There still is no widely available satisfactory solution for providing low cost, high speed access to the Internet and other networks using existing wireless networks. This situation is most likely an artifact of several unfortunate circumstances. For example, the typical manner of providing high speed data service in the business environment over the wireline network is not readily adaptable to the voice grade service available in most homes or offices. In addition, such standard high speed data services do not lend themselves well to efficient transmission over standard cellular wireless handsets.
Furthermore, the existing cellular network was originally designed only to deliver voice services. At present, the wireless modulation schemes in use continue their focus on delivering voice information with maximum data rates only in the range of 9.6 kbps being readily available. This is because the cellular switching network in most countries, including the United States, uses analog voice channels having a bandwidth from about 300 to 3600 Hertz. Such a low frequency channel does not lend itself directly to transmitting data at rates of 28.8 kilobits per second (kbps) or even the 56.6 kbps that is now commonly available using inexpensive wire line modems, and which rates are now thought to be the minimum acceptable data rates for Internet access.
Switching networks with higher speed building blocks are just now coming into use in the United States. Although certain wireline networks, called Integrated Services Digital Networks (ISDN), capable of higher speed data access have been known for a number of years, their costs have only been recently reduced to the point where they are attractive to the residential customer, even for wireline service. Although such networks were known at the time that cellular systems were originally deployed, for the most part, there is no provision for providing ISDN-grade data services over cellular network topologies.
ISDN is an inherently circuit switched protocol, and was, therefore, designed to continuously send bits in order to maintain synchronization from end node to end node to maintain a connection. Unfortunately, in wireless environments, access to channels is expensive and there is competition for them; the nature of the medium is such that they are expected to be shared. This is dissimilar to the usual wireline ISDN environment in which channels are not intended to be shared by definition.
SUMMARY OF THE INVENTION
In view of the foregoing background, an object of the present invention is to provide high speed data and voice service over standard wireless connections via a unique integration of ISDN protocols and existing cellular signaling such as is available with Code Division Multiple Access (CDMA) type digital cellular systems.
This and other objects, advantages and features in accordance with the present invention are provided by a method for operating a CDMA user device comprising establishing a communication session with at least one base station, with the communication session comprising a plurality of layers including a physical layer. A service configuration may be negotiated with the at least one base station, with the user device receiving at least one assigned subchannel from the at least one base station.
A physical layer connection may be established with the at least one base station on the at least one assigned subchannel, with the physical layer connection corresponding to the physical layer. The method may further comprises releasing the at least one assigned subchannel so that the physical layer connection is terminated, and maintaining a state of at least one other layer during the communication session after termination of the physical layer.
The at least one assigned subchannel may comprise a plurality of assigned subchannels. The releasing may occur when the user device does not have any data to transmit. The method may further comprise releasing all assigned subchannels so that the user device is in a dormant state.
A second service configuration may be negotiated with the at least one base station so that the user device receives at least one second assigned subchannel. The second negotiation may be performed after the user device has been in the dormant state. Negotiating the second service configuration does not require reestablishment of the state of the at least one other layer being maintained during the communication session.
Negotiating the service configuration may also comprise communicating a requested bandwidth allocation to the base station. The assigned subchannel may be less than the requested bandwidth. The at least one assigned subchannel may comprise a first assigned subchannel having a first bandwidth, and a second assigned subchannel having a second bandwidth less than the first bandwidth. The user device transmits voice and data on the at least one assigned subchannel.
The method may further comprise monitoring a data buffer associated with the second service connection. In addition, the method may further comprise monitoring a data buffer associated with the physical layer connection. The plurality of layers may include a network layer, and the state of the at least one other layer being maintained during the communication session is the network layer. A bandwidth associated with the service connection may be different than a bandwidth associated with the second service configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views.
FIG. 1 is a block diagram of a wireless communication system making use of a bandwidth management scheme according to the invention.
FIG. 2 is an Open System Interconnect (OSI) type layered protocol diagram showing where the bandwidth management scheme is implemented in terms of communication protocols.
FIG. 3 is a diagram showing how subchannels are assigned within a given radio frequency (RF) channel.
FIG. 4 is a more detailed block diagram of the elements of a subscriber unit.
FIG. 5 is a state diagram of the operations performed by a subscriber unit to request and release subchannels dynamically.
FIG. 6 is a block diagram of a portion of a base station unit necessary to service each subscriber unit.
FIG. 7 is a high level structured English description of a process performed by the base station to manage bandwidth dynamically according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning attention now to the drawings more particularly, FIG. 1 is a block diagram of a system 100 for providing high speed data and voice service over a wireless connection by seamlessly integrating a digital data protocol such as, for example, Integrated Services Digital Network (ISDN) with a digitally modulated wireless service such as Code Division Multiple Access (CDMA).
The system 100 consists of two different types of components, including subscriber units 101 , 102 and base stations 170 . Both types of these components 101 and 170 cooperate to provide the functions necessary in order to achieve the desired implementation of the invention. The subscriber unit 101 provides wireless data services to a portable computing device 110 such as a laptop computer, portable computer, personal digital assistant (PDA) or the like. The base station 170 cooperates with the subscriber unit 101 to permit the transmission of data between the portable computing device 110 and other devices such as those connected to the Public Switched Telephone Network (PSTN) 180 .
More particularly, data and/or voice services are also provided by the subscriber unit 101 to the portable computer 110 as well as one or more other devices such as telephones 112 - 1 , 112 - 2 (collectively referred to herein as telephones 112 . (The telephones 112 themselves may in turn be connected to other modems and computers which are not shown in FIG. 1 ). In the usual parlance of ISDN, the portable computer 110 and telephones 112 are referred to as terminal equipment (TE). The subscriber unit 101 provides the functions referred to as a network termination type 1 (NT-1). The illustrated subscriber unit 101 is in particular meant to operate with a so-called basic rate interface (BRI) type ISDN connection that provides two bearer or “B” channels and a single data or “D” channel with the usual designation being 2B+D.
The subscriber unit 101 itself consists of an ISDN modem 120 , a device referred to herein as the protocol converter 130 that performs the various functions according to the invention including spoofing 132 and bandwidth management 134 , a CDMA transceiver 140 , and subscriber unit antenna 150 . The various components of the subscriber unit 101 may be realized in discrete devices or as an integrated unit. For example, an existing conventional ISDN modem 120 such as is readily available from any number of manufacturers may be used together with existing CDMA transceivers 140 . In this case, the unique functions are provided entirely by the protocol converter 130 which may be sold as a separate device. Alternatively, the ISDN modem 120 , protocol converter 130 , and CDMA transceiver 140 may be integrated as a complete unit and sold as a single subscriber unit device 101 .
The ISDN modem 120 converts data and voice signals between the terminal equipment 110 and 112 to format required by the standard ISDN “U” interface. The U interface is a reference point in ISDN systems that designates a point of the connection between the network termination (NT) and the telephone company.
The protocol converter 130 performs spoofing 132 and basic bandwidth management 134 functions, which will be described in greater detail below. In general, spoofing 132 consists of insuring that the subscriber unit 101 appears to the terminal equipment 110 , 112 that is connected to the public switched telephone network 180 on the other side of the base station 170 at all times.
The bandwidth management function 134 is responsible for allocating and deallocating CDMA radio channels 160 as required. Bandwidth management also includes the dynamic management of the bandwidth allocated to a given session by dynamically assigning sub-portions of the CDMA channels 160 in a manner which is more fully described below.
The CDMA transceiver 140 accepts the data from the protocol converter 130 and reformats this data in appropriate form for transmission through a subscriber unit antenna 150 over CDMA radio link 160 - 1 . The CDMA transceiver 140 may operate over only a single 1.25 MHZ radio frequency channel or, alternatively, in a preferred embodiment, may be tunable over multiple allocatable radio frequency channels.
CDMA signal transmissions are then received at the base station and processed by the base station equipment 170 . The base station equipment 170 typically consists of multichannel antennas 171 , multiple CDMA transceivers 172 , and a bandwidth management functionality 174 . Bandwidth management controls the allocation of CDMA radio channels 160 and subchannels. The base station 170 then couples the demodulated radio signals to the Public Switch Telephone Network (PSTN) 180 in a manner which is well known in the art. For example, the base station 170 may communicate with the PSTN 180 over any number of different efficient communication protocols such as primary rate ISDN, or other LAPD based protocols such as IS-634 or V5.2.
It should also be understood that data signals travel bidirectionally across the CDMA radio channels 160 , i.e., data signals originate at the portable computer 110 are coupled to the PSTN 180 , and data signals received from the PSTN 180 are coupled to the portable computer 110 .
Other types of subscriber units such as unit 102 may be used to provide higher speed data services. Such subscriber units 102 typically provide a service referred to as nB+D type service that may use a so-called Primary Rate Interface (PRI) type protocol to communicate with the terminal equipment 110 , 112 . These units provide a higher speed service such as 512 kbps across the U interface. Operation of the protocol converter 130 and CDMA transceiver 140 are similar for the nB+D type subscriber unit 102 as previously described for subscriber unit 101 , with the understanding that the number of radio links 160 to support subscriber unit 102 are greater in number or each have a greater bandwidth.
Turning attention now to FIG. 2 , the invention may be described in the context of a Open Systems Interconnect multilayer protocol diagram. The three protocol stacks 220 , 230 , and 240 are for the ISDN modem 120 , protocol converter 130 , and base station 170 , respectively.
The protocol stack 220 used by the ISDN modem 120 is conventional for ISDN communications and includes, on the terminal equipment side, the analog to digital conversion (and digital to analog conversion) 221 and digital data formatting 222 at layer one, and an applications layer 223 at layer two. On the U interface side, the protocol functions include Basic Rate Interface (BRI) such as according to standard 1.430 at layer one, a LAPD protocol stack at layer two, such as specified by standard Q.921, and higher level network layer protocols such as Q.931 or X.227 and high level end to end signaling 228 required to establish network level sessions between modes.
The lower layers of the protocol stack 220 aggregate two bearer (B) channels to achieve a single 128 kilobits per second (kbps) data rate in a manner which is well known in the art. Similar functionality can be provided in a primary rate interface, such as used by subscriber unit 102 , to aggregate multiple B channels to achieve up to 512 kbps data rate over the U interface.
The protocol stack 230 associated with the protocol converter 130 consists of a layer one basic rate interface 231 and a layer two LAPD interface 232 on the U interface side, to match the corresponding layers of the ISDN modem stack 220 .
At the next higher layer, usually referred to as the network layer, a bandwidth management functionality 235 spans both the U interface side and the CDMA radio link side of the protocol converter stack 230 . On the CDMA radio link side 160 , the protocol depends upon the type of CDMA radio communication in use. An efficient wireless protocol referred to herein as EW[x] 234 , encapsulates the layer one 231 and layer two 232 ISDN protocol stacks in such a manner that the terminal equipment 110 may be disconnected from one or more CDMA radio channels without interrupting a higher network layer session.
The base station 170 contains the matching CDMA 241 and EW[x] 242 protocols as well as bandwidth management 243 . On the PSTN side, the protocols may convert back to basic rate interface 244 and LAPD 245 or may also include higher level network layer protocols as Q.931 or V5.2 246 .
Call processing functionality 247 allows the network layer to set up and tear down channels and provide other processing required to support end to end session connections between nodes as is known in the art.
The spoofing function 132 performed by the EW[x] protocol 234 includes the necessary functions to keep the U interface for the ISDN connection properly maintained, even in the absence of a CDMA radio link 160 being available. This is necessary because ISDN, being a protocol originally developed for wire line connections, expects to send a continuous stream of synchronous data bits regardless of whether the terminal equipment at either end actually has any data to transmit. Without the spoofing function 132 , radio links 160 of sufficient bandwidth to support at least a 192 kbps data rate would be required throughout the duration of an end to end network layer session, whether or not data is actually presented.
EW[x] 234 therefore involves having the CDMA transceiver 140 loop back these synchronous data bits over the ISDN communication path to spoof the terminal equipment 110 , 112 into believing that a sufficiently wide wireless communication link 160 is continuously available. However, only when there is actually data present from the terminal equipment to the wireless transceiver 140 is wireless bandwidth allocated. Therefore, unlike the prior art, the network layer need not allocate the assigned wireless bandwidth for the entirety of the communications session. That is, when data is not being presented upon the terminal equipment to the network equipment, the bandwidth management function 235 deallocates initially assigned radio channel bandwidth 160 and makes it available for another transceiver and another subscriber unit 101 .
In order to better understand how bandwidth management 235 and 243 accomplish the dynamic allocation of radio bandwidth; turn attention now to FIG. 3 . This figure illustrates one possible frequency plan for the wireless links 160 according to the invention. In particular, a typical transceiver 170 can be tuned on command to any 1.25 MHZ channel within a much larger bandwidth, such as up to 30 MHZ. In the case of location in an existing cellular radio frequency bands, these bandwidths are typically made available in the range of from 800 to 900 MHZ. For personal communication systems (PCS) type wireless systems, the bandwidth is typically allocated in the range from about 1.8 to 2.0 GigaHertz (GHz). In addition, there are typically two matching bands active simultaneously, separated by a guard band, such as 80 MHZ; the two matching bands form forward and reverse full duplex link.
Each of the CDMA transceivers, such as transceiver 140 in the subscriber unit 101 and transceivers 172 in the base station 170 , are capable of being tuned at any given point in time to a given 1.25 MHZ radio frequency channel. It is generally understood that such 1.25 MHZ radio frequency carrier provides, at best, a total equivalent of about 500 to 600 kbps maximum data rate transmission within acceptable bit error rate limitations.
In the prior art, it was thus generally understood that in order to support an ISDN type like connection which may contain information at a rate of 128 kbps that, at best, only about (500 kbps/128 kbps) or only 3 ISDN subscriber units could be supported at best.
In contrast to this, the present invention subdivides the available approximately 500 to 600 kbps bandwidth into a relatively large number of subchannels. In the illustrated example, the bandwidth is divided into 64 subchannels 300 , each providing an 8 kbps data rate. A given subchannel 300 is physically implemented by encoding a transmission with one of a number of different assignable pseudorandom codes. For example, the 64 subchannels 300 may be defined within a single CDMA RF carrier by using a different orthogonal Walsh codes for each defined subchannel 300 .
The basic idea behind the invention is to allocate the subchannels 300 only as needed. For example, multiple subchannels 300 are granted during times when a particular ISDN subscriber unit 101 is requesting that large amounts of data be transferred. These subchannels 300 are released during times when the subscriber unit 101 is relatively lightly loaded.
Before discussing how the subchannels are preferably allocated and deallocated, it will help to understand a typical subscriber unit 101 in greater detail. Turning attention now to FIG. 4 , it can be seen that an exemplary protocol converter 130 consists of a microcontroller 410 , reverse link processing 420 , and forward link processing 430 . The reverse link processing 420 further includes ISDN reverse spoofer 422 , voice data detector 423 , voice decoder 424 , data handler 426 , and channel multiplexer 428 . The forward link processing 430 contains analogous functions operating in the reverse direction, including a channel multiplexer 438 , voice data detector 433 , voice decoder 434 , data handler 436 , and ISDN forward spoofer 432 .
In operation, the reverse link 420 first accepts channel data from the ISDN modem 120 over the U interface and forwards it to the ISDN reverse spoofer 432 . Any repeating, redundant “echo” bits are removed from data received and, once extracted, sent to the forward spoofer 432 . The remaining layer three and higher level bits are thus information that needs to be send over a wireless link.
This extracted data is sent to the voice decoder 424 or data handler 426 , depending upon the type of data being processed.
Any D channel data from the ISDN modem 120 is sent directly to voice data detection 423 for insertion on the D channel inputs to the channel multiplexer 428 . The voice data detection circuit 423 determines the content of the D channels by analyzing commands received on the D channel.
D channel commands may also be interpreted to control a class of wireless services provided. For example, the controller 410 may store a customer parameter table that contains information about the customers desired class of service which may include parameters such as maximum data rate and the like. Appropriate commands are thus sent to the channel multiplexer 428 to request one or more required subchannels 300 over the radio links 160 for communication. Then, depending upon whether the information is voice or data, either the voice decoder 424 or data handler 426 begins feeding data inputs to the channel multiplexer 428 .
The channel multiplexer 428 may make further use of control signals provided by the voice data detection circuits 423 , depending upon whether the information is voice or data.
In addition, the CPU controller 410 , operating in connection with the channel multiplexer 428 , assists in providing the necessary implementation of the EW[x] protocol 234 between the subscriber unit 101 and the base station 170 . For example, subchannel requests, channel setup, and channel tear down commands are sent via commands placed on the wireless control channel 440 . These commands are intercepted by the equivalent functionality in the base station 170 to cause the proper allocation of subchannels 300 to particular network layer sessions.
The data handler 426 provides an estimate of the data rate required to the CPU controller 410 so that appropriate commands can be sent over the control channel. 440 to allocate an appropriate number of subchannels. The data handler 426 may also perform packet assembly and buffering of the layer three data into the appropriate format for transmission.
The forward link 430 operates in analogous fashion. In particular, signals are first received from the channels 160 by the channel multiplexer 438 . In response to receiving information on the control channels 440 , control information is routed to the voice data detection circuit 433 . Upon a determination that the received information contains data, the received bits are routed to the data handler 436 . Alternatively, the information is voice information, and routed to the voice decoder 434 .
Voice and data information are then sent to the ISDN forward spoofer 432 for construction into proper ISDN protocol format. This assembly of information is coordinated with the receipt of echo bits from the ISDN reverse spoofer 422 to maintain the proper expected synchronization on the U interface with the ISDN modem 120 .
It can now be seen how a network layer communication session may be maintained even though wireless bandwidth initially allocated for transmission is reassigned to other uses when there is no information to transmit. In particular, the reverse 422 and forward 432 spoofers cooperate to loop back non-information bearing signals, such as flag patterns, sync bits, and other necessary information, so as to spoof the data terminal equipment connected to the ISDN modem 120 into continuing to operate as though the allocated wireless path over the CDMA transceiver 150 is continuously available.
Therefore, unless there is an actual need to transmit information from the terminal equipment being presented to the channel multiplexers 428 , or actual information being received from the channel multiplexers 438 , the invention may deallocate initially assigned subchannel 300 , thus making them available for another subscriber unit 101 of the wireless system 100 .
The CPU controller 410 may also perform additional functions to implement the EW[x] protocol 234 , including error correction, packet buffering, and bit error rate measurement.
The functions necessary to implement bandwidth management 235 in the subscriber unit 101 are carried out in connection with the EW[x] protocol typically by the CPU controller 410 operating in cooperation with the channel multiplexers 428 , 438 , and data handlers 420 , 436 . In general, bandwidth assignments are made for each network layer session based upon measured short term data rate needs. One or more subchannels 300 are then assigned based upon these measurements and other parameters such as amount of data in queue or priority of service as assigned by the service provider. In addition, when a given session is idle, a connection is preferably still maintained end to end, although with a minimum number of, such as a single subchannel being assigned. For example, this single subchannel may eventually be dropped after a predetermined minimum idle time is observed.
FIG. 5 is a detailed view of the process by which a subscriber unit 101 may request subchannel 300 allocations from the base station 170 according to the invention. In a first state 502 , the process is in an idle state. At some point, data becomes ready to transmit and state 504 is entered, where the fact that data is ready to be transmitted may be detected by an input data buffer in the data handler 426 indicated that there is data ready.
In state 504 , a request is made, such as via a control channel 440 for the allocation of a subchannel to subscriber unit 101 . If a subchannel is not immediately available, a pacing state 506 may be entered in which the subscriber unit simply waits and queues its request for a subchannel to be assigned.
Eventually, a subchannel 300 is granted by the base station and the process continues to state 508 . In this state, data transfer may then begin using the single assigned subchannel. The process will continue in this state as long as the single subchannel 300 is sufficient for maintaining the required data transfer and/or is being utilized. However, if the input buffer should become empty, such as notified by the data handler 426 , then the process will proceed to a state 510 . In this state 510 , the subchannel will remain assigned in the event that data traffic again resumes. In this case, such as when the input buffer begins to once again become full and data is again ready to transmit, then the process returns to state 508 . However, from state 510 should a low traffic timer expire, then the process proceeds to state 512 in which the single subchannel 300 is released. The process then returns to the idle state 502 . In state 512 , if a queue request is pending from states 506 or 516 , the subchannel is used to satisfy such request instead of releasing it.
Returning to state 508 , if instead the contents of the input buffer are beginning to fill at a rate which exceeds a predetermined threshold indicating that the single subchannel 300 is insufficient to maintain the necessary data flow, then a state 514 is entered in which more subchannels 300 are requested. A subchannel request message is again sent over the control channel 440 or through a subchannel 300 already allocated. If additional subchannels 300 are not immediately available, then a pacing state 516 may be entered and the request may be retried by returning to state 514 and 516 as required. Eventually, an additional subchannel will be granted and processing can return to state 508 .
With the additional subchannels being now available, the processing continues to state 518 where data transfer may be made on a multiple N of the subchannels. This may be done at the same time through a channel bonding function or other mechanism for allocating the incoming data among the N subchannels. As the input buffer contents reduced below an empty threshold, then a waiting state 520 may be entered.
If, however, a buffer filling rate is exceeded, then state 514 may be entered in which more subchannels 300 are again requested.
In state 520 , if a high traffic timer has expired, then one or more of the additional subchannels are released in state 522 and the process returns to state 508 .
FIG. 6 is a block diagram of the components of the base station equipment 170 of the system 100 . These components perform analogous functions to those as already described in detail in FIG. 4 for the subscriber unit 101 . It should be understood that a forward link 620 and reverse link 630 are required for each subscriber unit 101 or 102 needing to be supported by the base station 170 .
The base station forward link 620 functions analogously to the reverse link 420 in the subscriber unit 100 , including a subchannel inverse multiplexer 622 , voice data detection 623 , voice decoder 624 , data handler 626 , and ISDN spoofer 622 , with the understanding that the data is traveling in the opposite direction in the base station 170 . Similarly, the base station reverse link 630 includes components analogous to those in the subscriber forward link 430 , including an ISDN spoofer 632 , voice data detection 633 , voice decoder 634 , data handler 636 , and subchannel multiplexer 638 . The base station 170 also requires a CPU controller 610 .
One difference between the operation of the base station 170 and the subscriber unit 101 is in the implementation of the bandwidth management functionality 243 . This may be implemented in the CPU controller 610 or in another process in the base station 170 .
A high level description of a software process performed by dynamic channel allocation portion 650 of the bandwidth management 243 is contained in FIG. 7 . This process includes a main program 710 , which is continuously executed, and includes processing port requests, processing bandwidth release, and processing bandwidth requests, and then locating and tearing down unused subchannels.
The processing of port requests is more particularly detailed in a code module 720 . These include upon receiving a port request, and reserving a subchannel for the new connection, preferably chosen from the least utilized section of the radio frequency bandwidth. Once the reservation is made, an RF channel frequency and code assignment are returned to the subscriber unit 101 and a table of subchannel allocations is updated. Otherwise, if subchannels are not available, then the port request is added to a queue of port requests. An expected waiting time may be estimated upon the number of pending port requests and priorities, and an appropriate wait message can be returned to the requesting subscriber unit 101 .
In a bandwidth release module 730 , the channel bonding function executing in the multiplexer 622 in the forward link is notified of the need to release a subchannel. The frequency and code are then returned to an available pool of subchannels and a radio record is updated.
The following bandwidth request module 740 may include selecting the request having the highest priority with lowest bandwidth utilization. Next, a list of available subchannels is analyzed for determining the greatest available number. Finally, subchannels are assigned based upon need, priority, and availability. A channel bandwidth bonding function is notified within the subchannel multiplexer 622 and the radio record which maintains which subchannels are assigned to which connections is updated.
In the bandwidth on demand algorithm, probability theory may typically be employed to manage the number of connections or available ports, and the spectrum needed to maintain expected throughput size and frequency of subchannel assignments. There may also be provisions for priority service based upon subscribers who have paid a premium for their service.
It should be understood, for example, that in the case of a supporting 128 kbps ISDN subscriber unit 101 that even more than 16×8 kbps subchannels may be allocated at a given time. In particular, one may allow a larger number, such as 20 subchannels, to be allocated to compensate for delay and reaction in assigning subchannels. This also permits dealing with bursts of data in a more efficient fashion such as typically experienced during the downloading of Web pages.
In addition, voice traffic may be prioritized as against data traffic. For example, if a voice call is detected, at least one subchannel 300 may be active at all times and allocated exclusively to the voice transfer. In that way, voice calls blocking probability will be minimized.
Equivalents
While this invention has been particularly shown and described with references 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 as defined by the appended claims.
For example, instead of ISDN, other wireline digital protocols may be encapsulated by the EW[x] protocol, such as xDSL, Ethernet, and X.25, and therefore may advantageously use the dynamic wireless subchannel assignment scheme described herein.
Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described specifically herein. Such equivalents are intended to be encompassed in the scope of the claims. | A method for operating a CDMA user device includes establishing a communication session with a base station. The communication session includes a plurality of layers including a physical layer. A service configuration is negotiated with the base station, and the user device receives an assigned subchannel from the base station. A physical layer connection is established with the base station on the assigned subchannel. The physical layer connection corresponds to the physical layer. The method further includes releasing the assigned subchannel so that the physical layer connection is terminated, and maintaining a state of at least one other layer during the communication session after termination of the physical layer. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of U.S. application No. 12709509 filed Feb. 21, 2010, which is a Continuation of U.S. application Ser. No. 11/831,961 filed on Aug. 1, 2007 all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present application relates generally to an improved method of synthesizing naphthalocyanines. It has been developed primarily to reduce the cost of existing naphthalocyanine syntheses and to facilitate large-scale preparations of these compounds.
CROSS REFERENCE TO OTHER RELATED APPLICATIONS
The following applications have been filed by the Applicant
7,825,262
7,772,409
The disclosures of these co-pending applications are incorporated herein by reference.
The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference.
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7,593,604
7,660,489
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11/155,557
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11/193,482
11/193,479
7,336,267
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7,245,760
7,649,523
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11/495,823
7,657,128
7,523,672
11/495,820
7,777,911
7,358,697
7,055,739
7,233,320
6,830,196
6,832,717
7,182,247
7,120,853
7,082,562
6,843,420
7,793,852
6,789,731
7,057,608
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6,766,945
7,289,103
7,412,651
7,299,969
7,264,173
7,108,192
7,549,595
7,111,791
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7,564,605
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6,994,264
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7,014,123
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7,150,396
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7,334,739
7,380,727
10/492,169
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7,308,148
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7,630,554
10/510,391
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6,957,768
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7,170,499
7,106,888
7,123,239
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11/754,312
11/754,311
7,771,004
6,454,482
6,808,330
6,527,365
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6,550,997
7,093,923
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BACKGROUND OF THE INVENTION
We have described previously the use of naphthalocyanines as IR-absorbing dyes. Naphthalocyanines, and particularly gallium naphthalocyanines, have low absorption in the visible range and intense absorption in the near-IR region (750-810 nm). Accordingly, naphthalocyanines are attractive compounds for use in invisible inks. The Applicant's U.S. Pat. Nos. 7,148,345 and 7,122,076 (the contents of which are herein incorporated by reference) describe in detail the use of naphthalocyanine dyes in the formulation of inks suitable for printing invisible (or barely visible) coded data onto a substrate. Detection of the coded data by an optical sensing device can be used to invoke a response in a remote computer system. Hence, the substrate is interactive by virtue of the coded data printed thereon.
The Applicant's netpage and Hyperlabel® systems, which makes use of interactive substrates printed with coded data, are described extensively in the cross-referenced patents and patent applications above (the contents of which are herein incorporated by reference).
In the anticipation of widespread adoption of netpage and Hyperlabel® technologies, there exists a considerable need to develop efficient syntheses of dyes suitable for use in inks for printing coded data. As foreshadowed above, naphthalocyanines and especially gallium naphthalocyanines are excellent candidates for such dyes and, as a consequence, there is a growing need to synthesize naphthalocyanines efficiently and in high yield on a large scale.
Naphthalocyanines are challenging compounds to synthesize on a large scale. In U.S. Pat. Nos. 7,148,345 and 7,122,076, we described an efficient route to naphthalocyanines via macrocyclization of naphthalene-2,3-dicarbonitrile. Scheme 1 shows a route to the sulfonated gallium naphthalocyanine 1 from naphthalene-2,3-dicarbonitrile 2, as described in U.S. Pat. No. 7,148,345.
However, a problem with this route to naphthalocyanines is that the starting material 2 is expensive. Furthermore, naphthalene-2,3-dicarbonitrile 2 is prepared from two expensive building blocks: tetrabromo-o-xylene 3 and fumaronitrile 4, neither of which can be readily prepared in multi-kilogram quantities.
Accordingly, if naphthalocyanines are to be used in large-scale applications, there is a need to improve on existing syntheses.
SUMMARY OF THE INVENTION
In a first aspect, there is provided a method of preparing a naphthalocyanine comprising the steps of:
(i) providing a tetrahydronaphthalic anhydride;
(ii) converting said tetrahydronaphthalic anhydride to a benzisoindolenine; and
(iii) macrocyclizing said benzisoindolenine to form a naphthalocyanine.
Optionally, the tetrahydronaphthalic anhydride is of formula (I):
wherein:
R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 aryloxy, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl.
Optionally, R 1 , R 2 , R 3 and R 4 are all hydrogen.
Optionally, step (ii) comprises a one-pot conversion from the tetrahydronaphthalic anhydride to a benzisoindolenine salt. This one-pot conversion facilitates synthesis of naphthalocyanines via the route described above and greatly improves yields and scalability.
Optionally, the benzisoindolenine salt is a nitrate salt although other salts (e.g. benzene sulfonate salt) are of course within the scope of the present invention.
Optionally, the one-pot conversion is effected by heating with a reagent mixture comprising ammonium nitrate.
Optionally, the reagent mixture comprises at least 2 equivalents of ammonium nitrate with respect to the tetrahydronaphthalic anhydride.
Optionally, the reagent mixture comprises urea.
Optionally, the reagent mixture comprises at least one further ammonium salt.
Optionally, the further ammonium salt is selected from ammonium sulfate and ammonium benzenesulfonate
Optionally, the reagent mixture comprises a catalytic amount of ammonium molybdate.
Optionally, the heating is within a temperature range of 150 to 200° C.
The reaction may be performed in the presence of or in the absence of a solvent. Optionally, heating is in the presence of an aromatic solvent. Examples of suitable solvents are nitrobenzene, biphenyl, diphenyl ether, mesitylene, anisole, phenetole, dichlorobenzene, trichlorobenzene and mixtures thereof.
Optionally, the benzisoindolenine is liberated from the benzisoindolenine salt using a base. Sodium methoxide is an example of a suitable base although the skilled person will be readily aware of other suitable bases.
Optionally, the benzisoindolenine is of formula (II):
wherein:
R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 aryloxy, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl.
Optionally, the naphthalocyanine is of formula (III):
wherein:
R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15 and R 16 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 aryloxy, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl; M is absent or selected from Si(A 1 )(A 2 ), Ge(A 1 )(A 2 ), Ga(A 1 ), Mg, Al(A 1 ), TiO, Ti(A 1 )(A 2 ), ZrO, Zr(A 1 )(A 2 ), VO, V(A 1 )(A 2 ), Mn, Mn(A 1 ), Fe, Fe(A 1 ), Co, Ni, Cu, Zn, Sn, Sn(A 1 )(A 2 ), Pb, Pb(A 1 )(A 2 ), Pd and Pt; A 1 and A 2 are axial ligands, which may be the same or different, and are selected from —OH, halogen or —OR q ; R q is selected from C 1-16 alkyl, C 5-20 aryl, C 5-20 arylalkyl, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl or Si(R x )(R y )(R z ); and R x , R y and R z may be the same or different and are selected from C 1-20 alkyl, C 5-20 aryl, C 5-20 arylalkyl, C 1-20 alkoxy, C 5-20 aryloxy or C 5-20 arylalkoxy;
Optionally, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15 and R 16 are all hydrogen.
Optionally, M is Ga(A 1 ), such as Ga(OCH 2 CH 2 OCH 2 CH 2 OCH 2 CH 2 OMe); that is where R q is CH 2 CH 2 OCH 2 CH 2 OCH 2 CH 2 OMe. For the avoidance of doubt, ethers such as CH 2 CH 2 OCH 2 CH 2 OCH 2 CH 2 OMe fall within the definition of alkyl groups as specified hereinbelow. Gallium compounds are preferred since they have excellent lightfastness, strong absorption in the near-IR region, and are virtually invisible to the human eye when printed on a page.
Optionally, step (iii) comprises heating the benzisoindolenine in the presence of a metal compound, such as AlCl 3 or GaCl 3 or a corresponding metal alkoxide. The reaction may be performed in the absence of or in the presence of a suitable solvent, such as toluene, nitrobenzene etc. When a metal alkoxide is used, the reaction may be catalyzed with a suitable base, such as sodium methoxide. Alcohols, such as triethylene glycol monomethyl ether or glycol may also be present to assist with naphthalocyanine formation. These alcohols may end up as the axial ligand of the naphthalocyanine or they may be cleaved from the metal under the reaction conditions. The skilled person will readily be able to optimize the conditions for naphthalocyanine formation from the benzisoindolenine.
Optionally, the method further comprises the step of sulfonating said naphthalocyanine. Sulfonate groups are useful for solubilizing the naphthalocyanines in ink formulations, as described in our earlier U.S. Pat. Nos. 7,148,345 and 7,122,076.
In a second aspect, there is provided a method of effecting a one-pot conversion of a tetrahydronaphthalic anhydride to a benzisoindolenine salt, said method comprising heating said tetrahydronaphthalic anhydride with a reagent mixture comprising ammonium nitrate.
This transformation advantageously obviates a separate dehydrogenation step to form the naphthalene ring system. The ammonium nitrate performs the dual functions of oxidation (dehydrogenation) and isoindolenine formation.
The isoindolenine salts generated according to the second aspect may be used in the synthesis of naphthalocyanines. Hence, this key reaction provides a significant improvement in routes to naphthalocyanines.
In general, optional features of this second aspect mirror the optional features described above in respect of the first aspect.
In a third aspect, there is provided a method of preparing a sultine of formula (V) from a dihalogeno compound of formula (IV)
the method comprising reacting the dihalogeno compound (IV) with a hydroxymethanesulfinate salt in a DMSO solvent so as to prepare the sultine (V);
wherein:
R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen, hydroxyl, C 1-20 alkyl, C 1-20 alkoxy, amino, C 1-20 alkylamino, di(C 1-20 alkyl)amino, halogen, cyano, thiol, C 1-20 alkylthio, nitro, C 1-20 alkylcarboxy, C 1-20 alkylcarbonyl, C 1-20 alkoxycarbonyl, C 1-20 alkylcarbonyloxy, C 1-20 alkylcarbonylamino, C 5-20 aryl, C 5-20 arylalkyl, C 5-20 aryloxy, C 5-20 arylalkoxy, C 5-20 heteroaryl, C 5-20 heteroaryloxy, C 5-20 heteroarylalkoxy or C 5-20 heteroarylalkyl; and X is Cl, Br or I.
The method according to the third aspect surprisingly minimizes polymeric by-products and improves yields, when compared to literature methods for this reaction employing DMF as the solvent. These advantages are amplified when the reaction is performed on a large scale (e.g. at least 0.3 molar, at least 0.4 molar or at least 0.5 molar scale).
Optionally, NaI is used to catalyze the coupling reactions when X is Cl or Br.
Optionally, a metal carbonate base (e.g. Na 2 CO 3 , K 2 CO 3 , Cs 2 CO 3 etc) is present.
Optionally, the hydroxymethanesulfinate salt is sodium hydroxymethanesulfinate (Rongalite™)
Optionally, R 1 , R 2 , R 3 and R 4 are all hydrogen.
Optionally, the method comprises the further step of reacting the sultine (V) with an olefin at elevated temperature (e.g. about 80° C.) to generate a Diels-Alder adduct.
Optionally, the olefin is maleic anhydride and said Diels-Alder adduct is a tetrahydronaphthalic anhydride.
Optionally, the tetrahydronaphthalic anhydride is used as a precursor for naphthalocyanine synthesis, as described herein.
Optionally, the naphthalocyanine synthesis proceeds via conversion of the tetrahydronaphthalic anhydride to a benzisoindolenine, as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail with reference to the following drawings, in which:
FIG. 1 is a 1 H NMR spectrum of the crude sultine 10 in d 6 -DMSO;
FIG. 2 is a 1 H NMR spectrum of the anhydride 8 in d 6 -DMSO;
FIG. 3 is a 1 H NMR spectrum of the crude benzisoindolenine salt 12 in d 6 -DMSO;
FIG. 4 is an expansion of the aromatic region of the 1 H NMR spectrum shown in FIG. 3 ;
FIG. 5 is a 1 H NMR spectrum of the benzisoindolenine 7 in d 6 -DMSO.
FIG. 6 is an expansion of the aromatic region of the 1 H NMR spectrum shown in FIG. 5 ; and
FIG. 7 is a UV-VIS spectrum of naphthalocyanatogallium methoxytriethyleneoxide in NMP.
DETAILED DESCRIPTION
As an alternative to dicarbonitriles, the general class of phthalocyanines is known to be prepared from isoindolenines. In U.S. Pat. No. 7,148,345, we proposed the benzisoindolenine 5 as a possible precursor to naphthalocyanines.
However, efficient syntheses of the benzisoindolenine 5 were unknown in the literature, and it was hitherto understood that dicarbonitriles, such as naphthalene-2,3-dicarbonitrile 2, were the only viable route to naphthalocyanines.
Nevertheless, with the potentially prohibitive cost of naphthalene-2,3-dicarbonitrile 2, the present inventors sought to explore a new route to the benzisoindolenine 5, as outlined in Scheme 2.
Tetrahydronaphthalic anhydride 6 was an attractive starting point, because this is a known Diels-Alder adduct which may be synthesized via the route shown in Scheme 3.
Referring to Scheme 2, it was hoped that the conversion of naphthalic anhydride 7 to the benzisoindolenine 5 would proceed analogously to the known conversion of phthalic anhydride to the isoindolenine 8, as described in WO98/31667.
However, a number of problems remained with the route outlined in Scheme 2. Firstly, the dehydrogenation of tetrahydronaphthalic anhydride 6 typically requires high temperature catalysis. Under these conditions, tetrahydronaphthalic anhydride 6 readily sublimes resulting in very poor yields. Secondly, the preparation of tetrahydronaphthalic anhydride 6 on a large scale was not known. Whilst a number of small-scale routes to this compound were known in the literature, these generally suffered either from poor yields or scalability problems.
The use of sultines as diene precursors is well known and 1,4-dihydro-2,3-benzoxathiin-3-oxide 10 has been used in a synthesis of 6 on a small scale (Hoey, M. D.; Dittmer, D. A. J. Org. Chem. 1991, 56, 1947-1948). As shown in Scheme 4, this route commences with the relatively inexpensive dichloro-o-xylene 11, but the feasibility of scaling up this reaction sequence is limited by the formation of undesirable polymeric by-products in the sultine-forming step. The formation of these by-products makes reproducible production of 6 in high purity and high yield difficult.
Nevertheless, the route outlined in Scheme 4 is potentially attractive from a cost standpoint, since dichloro-o-xylene 11 and maleic anhydride are both inexpensive materials.
Whilst the reaction sequence shown in Schemes 4 and 2 present significant synthetic challenges, the present inventors have surprisingly found that, using modified reaction conditions, the benzisoindolenine 5 can be generated on a large scale and in high yield. Hence, the present invention enables the production of naphthalocyanines from inexpensive starting materials, and represents a significant cost improvement over known syntheses, which start from naphthalene-2,3-dicarbonitrile 2.
Referring to Scheme 5, there is shown a route to the benzisoindolenine 5, which incorporates two synthetic improvements in accordance with the present invention.
Unexpectedly, it was found that by using DMSO as the reaction solvent in the conversion of 11 into 10, the reaction rate and selectivity for the formation of sultine 10 increases significantly. This is in contrast to known conditions (Hoey, M. D.; Dittmer, D. A. J. Org. Chem. 1991, 56, 1947-1948) employing DMF as the solvent, where the formation of undesirable polymeric side-products is a major problem, especially on a large scale. Accordingly, the present invention provides a significant improvement in the synthesis of tetrahydronaphthalic anhydride 6.
The present invention also provides a significant improvement in the conversion of tetrahydronaphthalic anhydride 6 to the benzisoindolenine 5. Surprisingly, it was found that the ammonium nitrate used for this step readily effects oxidation of the saturated ring system as well as converting the anhydride to the isoindolenine. Conversion to a tetrahydroisoindolenine was expected to proceed smoothly, in accordance with the isoindolenine similar systems described in WO98/31667. However, concomitant dehydrogenation under these reaction conditions advantageously provided a direct one-pot route from the tetrahydronaphthalic anhydride 6 to the benzisoindolenine salt 12. This avoids problematic and low-yielding dehydrogenation of the tetrahydronaphthalic anhydride 6 in a separate step. Subsequent treatment of the salt 12 with a suitable base, such as sodium methoxide, liberates the benzisoindolenine 5. As a result of these improvements, the entire reaction sequence from 11 to 5 is very conveniently carried out, and employs inexpensive starting materials and reagents (Scheme 5).
The benzisoindolenine 5 may be converted into any required naphthalocyanine using known conditions. For example, the preparation of a gallium naphthalocyanine from benzisoindolenine 5 is exemplified herein. Subsequent manipulation of the naphthalocyanine macrocycle may also be performed in accordance with known protocols. For example, sulfonation may be performed using oleum, as described in U.S. Pat. Nos. 7,148,345 and 7,122,076.
Hitherto, the use of tetrahydronaphthalic anhydride 6 as a building block for naphthalocyanine synthesis had not previously been reported. However, it has now been shown that tetrahydronaphthalic anhydride 6 is a viable intermediate in the synthesis of these important compounds. Moreover, it is understood by the present inventors that the route shown in Scheme 5 represents the most cost-effective synthesis of benzisoindolenines 5.
The term “aryl” is used herein to refer to an aromatic group, such as phenyl, naphthyl or triptycenyl. C 6-12 aryl, for example, refers to an aromatic group having from 6 to 12 carbon atoms, excluding any substituents. The term “arylene”, of course, refers to divalent groups corresponding to the monovalent aryl groups described above. Any reference to aryl implicitly includes arylene, where appropriate.
The term “heteroaryl” refers to an aryl group, where 1, 2, 3 or 4 carbon atoms are replaced by a heteroatom selected from N, O or S. Examples of heteroaryl (or heteroaromatic) groups include pyridyl, benzimidazolyl, indazolyl, quinolinyl, isoquinolinyl, indolinyl, isoindolinyl, indolyl, isoindolyl, furanyl, thiophenyl, pyrrolyl, thiazolyl, imidazolyl, oxazolyl, isoxazolyl, pyrazolyl, isoxazolonyl, piperazinyl, pyrimidinyl, piperidinyl, morpholinyl, pyrrolidinyl, isothiazolyl, triazolyl, oxadiazolyl, thiadiazolyl, pyridyl, pyrimidinyl, benzopyrimidinyl, benzotriazole, quinoxalinyl, pyridazyl, coumarinyl etc. The term “heteroarylene”, of course, refers to divalent groups corresponding to the monovalent heteroaryl groups described above. Any reference to heteroaryl implicitly includes heteroarylene, where appropriate.
Unless specifically stated otherwise, aryl and heteroaryl groups may be optionally substituted with 1, 2, 3, 4 or 5 of the substituents described below.
Where reference is made to optionally substituted groups (e.g. in connection with aryl groups or heteroaryl groups), the optional substituent(s) are independently selected from C 1-8 alkyl, C 1-8 alkoxy, —(OCH 2 CH 2 ) d OR d (wherein d is an integer from 2 to 5000 and R d is H, C 1-8 alkyl or C(O)C 1-8 alkyl), cyano, halogen, amino, hydroxyl, thiol, —SR v , —NR u R v , nitro, phenyl, phenoxy, —CO 2 R v , —C(O)R v , —OCOR v , —SO 2 R v , —OSO 2 R v , —SO 2 OR v , —NHC(O)R v , —CONR u R v , —CONR u R v , —SO 2 NR u R v , wherein R u and R v are independently selected from hydrogen, C 1-20 alkyl, phenyl or phenyl-C 1-8 alkyl (e.g. benzyl). Where, for example, a group contains more than one substituent, different substituents can have different R u or R v groups.
The term “alkyl” is used herein to refer to alkyl groups in both straight and branched forms. Unless stated otherwise, the alkyl group may be interrupted with 1, 2, 3 or 4 heteroatoms selected from O, NH or S. Unless stated otherwise, the alkyl group may also be interrupted with 1, 2 or 3 double and/or triple bonds. However, the term “alkyl” usually refers to alkyl groups having double or triple bond interruptions. Where “alkenyl” groups are specifically mentioned, this is not intended to be construed as a limitation on the definition of “alkyl” above.
Where reference is made to, for example, C 1-20 alkyl, it is meant the alkyl group may contain any number of carbon atoms between 1 and 20. Unless specifically stated otherwise, any reference to “alkyl” means C 1-20 alkyl, preferably C 1-12 alkyl or C 1-6 alkyl.
The term “alkyl” also includes cycloalkyl groups. As used herein, the term “cycloalkyl” includes cycloalkyl, polycycloalkyl, and cycloalkenyl groups, as well as combinations of these with linear alkyl groups, such as cycloalkylalkyl groups. The cycloalkyl group may be interrupted with 1, 2 or 3 heteroatoms selected from O, N or S. However, the term “cycloalkyl” usually refers to cycloalkyl groups having no heteroatom interruptions. Examples of cycloalkyl groups include cyclopentyl, cyclohexyl, cyclohexenyl, cyclohexylmethyl and adamantyl groups.
The term “arylalkyl” refers to groups such as benzyl, phenylethyl and naphthylmethyl.
The term “halogen” or “halo” is used herein to refer to any of fluorine, chlorine, bromine and iodine. Usually, however, halogen refers to chlorine or fluorine substituents.
Where reference is made herein to “a naphthalocyanine”, “a benzisoindolenine”, “a tetrahydronaphthalic anhydride” etc, this is understood to be a reference to the general class of compounds embodied by these generic names, and is not intended to refer to any one specific compound. References to specific compounds are accompanied with a reference numeral.
Chiral compounds described herein have not been given stereo-descriptors. However, when compounds may exist in stereoisomeric forms, then all possible stereoisomers and mixtures thereof are included (e.g. enantiomers, diastereomers and all combinations including racemic mixtures etc.).
Likewise, when compounds may exist in a number of regioisomeric or tautomeric forms, then all possible regioisomers, tautomers and mixtures thereof are included.
For the avoidance of doubt, the term “a” (or “an”), in phrases such as “comprising a”, means “at least one” and not “one and only one”. Where the term “at least one” is specifically used, this should not be construed as having a limitation on the definition of “a”.
Throughout the specification, the term “comprising”, or variations such as “comprise” or “comprises”, should be construed as including a stated element, integer or step, but not excluding any other element, integer or step.
The invention will now be described with reference to the following drawings and examples. However, it will of course be appreciated that this invention may be embodied in many other forms without departing from the scope of the invention, as defined in the accompanying claims.
EXAMPLE 1
1,4-dihydro-2,3-benzoxathiin-3-oxide 10
Sodium hydroxymethanesulfinate (Rongalite™) (180 g; 1.17 mol) was suspended in DMSO (400 mL) and left to stir for 10 min. before dichloro-o-xylene (102.5 g; 0.59 mol), potassium carbonate (121.4 g; 0.88 mol) and sodium iodide (1.1 g; 7 mmol) were added consecutively. More DMSO (112 mL) was used to rinse residual materials into the reaction mixture before the whole was allowed to stir at room temperature. The initial endothermic reaction became mildly exothermic after around 1 h causing the internal temperature to rise to ca. 32-33° C. The reaction was followed by TLC (ethyl acetate/hexane, 50:50) and found to be complete after 3 h. The reaction mixture was diluted with methanol/ethyl acetate (20:80; 400 mL) and the solids were filtered off, and washed with more methanol/ethyl acetate (20:80; 100 mL, 2×50 mL). The filtrate was transferred to a separating funnel and brine (1 L) was added. This caused more sodium chloride from the product mixture to precipitate out. The addition of water (200 mL) redissolved the sodium chloride. The mixture was shaken and the organic layer was separated and then the aqueous layer was extracted further with methanol/ethyl acetate (20:80; 200 mL, 150 mL, 250 mL). The combined extracts were dried (Na 2 SO 4 ) and rotary evaporated (bath 37-38° C.). More solvent was removed under high vacuum to give the sultine 10 as a pale orange liquid (126 g) that was found by 1 H NMR spectroscopy to be relatively free of by-product but containing residual DMSO and ethyl acetate ( FIG. 1 ).
EXAMPLE 2
Tetrahydronaphthalic Anhydride 6
The crude sultine from above (126 g) was diluted in trifluorotoluene (100 mL) and then added to a preheated (bath 80° C.) suspension of maleic anhydride (86 g; 0.88 mol) in trifluorotoluene (450 mL). The residual sultine was washed with more trifluorotoluene into the reaction mixture and then the final volume was made up to 970 mL. The reaction mixture was heated at 80° C. for 15 h, more maleic anhydride (28.7 g; 0.29 mol) was added and then heating was continued for a further 8 h until TLC showed that the sultine had been consumed. While still at 80° C., the solvent was removed by evaporation with a water aspirator and then the residual solvent was removed under high vacuum. The moist solid was triturated with methanol (200 mL) and filtered off, washing with more methanol (3×100 mL). The tetrahydronaphthalic anhydride 6 was obtained as a fine white crystalline solid (75.4 g; 64% from 10) after drying under high vacuum at 60-70° C. for 4 h.
EXAMPLE 3
The sultine was prepared from dichloro-o-xylene (31.9 g; 0.182 mol), as described in Example 2, and then reacted with maleic anhydride (26.8 g; 0.273 mol) in toluene (300 mL total volume) as described above. This afforded the tetrahydronaphthalc anhydride 6 as a white crystalline solid (23.5 g; 64%).
EXAMPLE 4
1-amino-3-iminobenz[f]isoindolenine nitrate salt 12
Urea (467 g; 7.78 mol) was added to a mechanically stirred mixture of ammonium sulfate (38.6 g; 0.29 mol), ammonium molybdate (1.8 g) and nitrobenzene (75 mL). The whole was heated with a heating mantle to ca. 130° C. (internal temperature) for 1 h causing the urea to melt. At this point the anhydride 6 (98.4 g; 0.49 mol) was added all at once as a solid. After 15 min ammonium nitrate (126.4 g; 1.58 mol) was added with stirring (internal temperature 140° C.) accompanied by substantial gas evolution. The reaction temperature was increased to 170-175° C. over 45 min and held there for 2 h 20 min. The viscous brown mixture was allowed to cool to ca. 100° C. and then methanol (400 mL) was slowly introduced while stirring. The resulting suspension was poured on a sintered glass funnel, using more methanol (100 mL) to rinse out the reaction flask. After removing most of the methanol by gravity filtration, the brown solid was sucked dry and then washed with more methanol (3×200 mL, 50 mL), air-dried overnight and dried under high vacuum in a warm water bath for 1.5 h. The benzisoindolenine salt 12 was obtained as a fine brown powder (154.6 g) and was found by NMR analysis to contain urea (5.43 ppm) and other salts (6.80 ppm). This material was used directly in the next step without further purification.
EXAMPLE 5
1-amino-3-iminobenz[f]isoindolenine 7
The crude nitrate salt 12 (154.6 g) was suspended in acetone (400 mL) with cooling in an ice/water bath to 0° C. Sodium methoxide (25% in methanol; 284 ml; 1.3 mol) was added slowly dropwise via a dropping funnel at such a rate as to maintain an internal temperature of 0-5° C. Upon completion of the addition, the reaction mixture was poured into cold water (2×2 L) in two 2 L conical flasks. The mixtures were then filtered on sintered glass funnels and the solids were washed thoroughly with water (250 mL; 200 mL for each funnel). The fine brown solids were air-dried over 2 days and then further dried under high vacuum to give the benzisoindolenine 5 as a fine brown powder (69.1 g; 73%).
EXAMPLE 6
Naphthalocyanatogallium Methoxytriethyleneoxide
Gallium chloride (15.7 g; 0.089 mol) was dissolved in anhydrous toluene (230 mL) in a 3-neck flask (1 L) equipped with a mechanical stirrer, heating mantle, thermometer, and distillation outlet. The resulting solution was cooled in an ice/water bath to 10° C. and then sodium methoxide in methanol (25%; 63 mL) was added slowly with stirring such that the internal temperature was maintained below 25° C. thereby affording a white precipitate. The mixture was then treated with triethylene glycol monomethyl ether (TEGMME; 190 mL) and then the whole was heated to distill off all the methanol and toluene (3 h). The mixture was then cooled to 90-100° C. (internal temperature) by removing the heating mantle and then the benzisoindolenine 5 from the previous step (69.0 g; 0.35 mol) was added all at once as a solid with the last traces being washed into the reaction vessel with diethyl ether (30 mL). The reaction mixture was then placed in the preheated heating mantle such that an internal temperature of 170° C. was established after 20 min. Stirring was then continued at 175-180° C. for a further 3 h during which time a dark green/brown colour appeared and the evolution of ammonia took place. The reaction mixture was allowed to cool to ca. 100° C. before diluting with DMF (100 mL) and filtering through a sintered glass funnel under gravity overnight. The moist filter cake was sucked dry and washed consecutively with DMF (80 mL), acetone (2×100 mL), water (2×100 mL), DMF (50 mL), acetone (2×50 mL; 100 mL) and diethyl ether (100 mL) with suction. After brief air drying, the product was dried under high vacuum at 60-70° C. to constant weight. Naphthalocyanatogallium methoxytriethyleneoxide was obtained as a microcrystalline dark blue/green solid (60.7 g; 76%); λ max (NMP) 771 nm ( FIG. 7 ). | A method of preparing a sultine from a dihalogeno compound. The method comprises the steps of reacting the dihalogeno compound with a hydroxymethanesulfinate salt in a DMSO solvent so as to prepare the sultine. | 2 |
[0001] This application is a National Stage completion of PCT/EP2011/053114 filed Mar. 2, 2011, which claims priority from German patent application serial no. 10 2010 028 282.0 filed Apr. 28, 2010.
FIELD OF THE INVENTION
[0002] The invention relates to a method for determining a startup gear in a motor vehicle, the drive train of which comprises a drive engine built as an internal combustion engine, a startup element built as an automated friction clutch, and a transmission built as an automatic stepped transmission, wherein a startup gear is determined for startup from standstill while maintaining a load limit of the friction clutch.
BACKGROUND OF THE INVENTION
[0003] For a startup from standstill with a multi-stage stepped transmission, in principle, several gears can be considered for the startup gear. One such startup situation occurs in particular in the case of a startup on a plane and on an incline. With the startup, the engine torque that can be generated by the drive engine and transmitted to the friction clutch as the startup torque must be sufficiently high in order to compensate for the stationary drive resistance of the motor vehicle, which is formed in this situation by the rolling resistance and incline resistance, given the overall transmission ratio determined by the respective startup gear and the efficiency of the drive train, and in addition, to deliver excess torque for startup acceleration of the motor vehicle.
[0004] In the process, it must be considered that active output drive-side power take-offs, that is, power take-offs disposed at the transmission and/or the axle transmission, reduce the engine torque that can be used for startup, which can be considered as a fictional additional resistance for the determination of the startup gear. In contrast, auxiliary consumers driven directly by the drive engine, such as an electric generator, a servo pump of a servo steering, and an air conditioning compressor of an air conditioning system, as well as active drive-side power take-offs, that is, power take-offs disposed directly at the drive engine, reduce, already at the source of the rotational energy, the engine torque that can be delivered by the drive engine to the friction clutch and available for startup.
[0005] Furthermore, the startup acceleration should correspond to the respective power request by the driver, which is given by the gas pedal deflection or the gas pedal position respectively, increasing with increasing gas pedal deflection and decreasing with increasing road incline. With increasing gas pedal deflection at a constant road incline, the driver accordingly expects faster startup acceleration, whereas in contrast with an increasing road incline with a constant gas pedal position the driver expects slower startup acceleration.
[0006] A determination of the startup gear depending only on the startup situation typically occurs using the characteristic curves or characteristic maps, which are modified to the respective vehicle configuration using complex application methods, and which contain at least the vehicle mass, the roadway incline and the gas pedal position as parameters.
[0007] For a startup from standstill the friction clutch can be a passive engageable single or multi-disc dry clutch or an active engageable multi-disc clutch, for bridging the speed difference between the engine speed and the transmission input speed and the transmission input shaft in slipping operation, until the motor vehicle has accelerated to the extent that synchronous running is attained at the input and output sides of the friction clutch so that the clutch can be completely engaged.
[0008] The startup-dependent slipping operation represents a high mechanical and thermal load for the friction clutch that increases with the value of the startup torque, the value of the slip speed and the duration of the slipping operation, and which forms an essential parameter for determining the startup gear.
[0009] If the startup gear is set too low, fast startup acceleration and a correspondingly shorter slipping operation of the friction clutch is possible. Due to the high transmission ratio of the startup gear, noise develops, and due to the high startup speed, the fuel consumption of the internal combustion engine is unfavorably high.
[0010] In addition, due to the fast startup acceleration a shift speed is attained relatively quickly and a shift is triggered to a higher gear. This is considered uncomfortable and particularly at high drive resistance, for instance on a steep incline or on difficult terrain, can lead to a strong delay of the vehicle during the shift-dependent interruption of the tractive force and consequently to an interruption of the startup.
[0011] If in contrast, the startup gear is too high, the slipping speed is relatively high at the friction clutch due to the low transmission ratio of the startup gear. Due to the slow startup acceleration, the duration of the slipping operation can be so long that the friction clutch is thermally overloaded.
[0012] Therefore, the general aim is to perform a startup of a motor vehicle in the highest possible gear, however without mechanically and thermally overloading the friction clutch in the process. Thus, methods for determining a startup gear are known from the documents DE 198 39 837 A1 and U.S. Pat. No. 6,953,410 B2, with which the highest possible startup gear is determined from the present drive resistance of the motor vehicle and the available engine torque of the drive train so that the expected duration of slipping of the friction clutch during the startup and/or the thermal energy created in friction clutch in slipping operation do not exceed predetermined limit values.
[0013] The document U.S. Pat. No. 7,220,215 B2 describes a commercial vehicle with a control device with which the highest possible startup gear is determined so the maximal engine torque that can be generated by the drive engine at idle speed is sufficient for the startup, and the thermal energy created in the process in the friction clutch does not exceed a predetermined limit value.
[0014] In the case of commercial vehicles, the drive engines are usually designed as turbo-charged diesel engines, which have a specific load build-up characteristic. According to the document DE 10 2008 054 802 A1, which was previously unpublished, and which discloses a method for controlling an automatic stepped transmission depending on the dynamic operating characteristics of a turbo-charged internal combustion engine, a turbo-charged internal combustion engine can spontaneously, that is with high torque gradients, only reach an intake torque lying below the full load torque.
[0015] A further increase of the engine torque is briefly possible, although with low torque gradients, only above a boost threshold speed, after which the turbo-charger creates a significant increase of the charge pressure and thus the engine torque. Thus, aside from the idle speed, cut-off speed and the full load torque characteristic curve, the dynamic behavior of a turbo-charged internal combustion engine is also determined by the boost threshold speed and the intake torque characteristic curve as well as by the present torque gradients, at least in certain regions.
[0016] Therefore, the dynamic operating properties of a drive engine built as a turbo-charged internal combustion engine are also significant for determining a startup gear, because starting from the idle speed only the intake torque is spontaneously built up and usable as the startup torque. If the intake torque is not sufficient as startup torque, the engine speed must be increased above the boost threshold speed, in order to be able to increase the engine torque above the intake torque by increasing the charge pressure. In this case however, due to the hereby increased slipping speed and the slowdown of the torque buildup, the mechanical and thermal load of the friction clutch increases significantly.
[0017] With the previously known methods for determining a startup gear, the present load state of the friction clutch, repeated startups without significant cooling of the friction clutch in between, and the dynamic operating properties of the drive engine were not considered, or not sufficiently considered. This can have the consequence that the friction clutch, despite nominally maintaining the intended load limit, is mechanically and/or thermally overloaded, and consequently does not attain an intended service life or is destroyed during a startup procedure.
SUMMARY OF THE INVENTION
[0018] Therefore, the problem addressed by the present invention is to propose a method for determining a startup gear for startup from standstill with a motor vehicle of the initially named type, with which the present operating state and the operating properties of the friction clutch and the drive engine are considered, and thus overload of the friction clutch can be reliably avoided.
[0019] This problem is solved in that a load-independent startup gear G Anf — Typ is determined with which in the case of a startup, this startup would occur under the present starting conditions (m Fzg , α FB , x FP ) without taking into consideration the current load state of the friction clutch and without complying with a load limit of the friction clutch, that at least one load-specific startup gear (G Anf — Max1 , G Anf — MaxN , G Anf — Lim , G Anf —Def ) is determined as the highest startup gear, with which in the case of a startup under the present starting conditions a predefined load limit of the friction clutch would be maintained while taking into consideration the present load state of the friction clutch, and that the startup gear (G Anf ) intended for the present startup is determined in a minimum selection as the lowest startup gear of the load-independent startup gear and the at least one load-specific startup gear, thus (G Anf =min(G Anf — Typ , G Anf — Max1 , G Anf — MaxN , G Anf — Lim , G Anf — Def )).
[0020] Accordingly, the invention assumes a known motor vehicle, a commercial vehicle for example, the drive train of which comprises a drive engine built as an internal combustion engine, a startup element built as an automated friction clutch, and a transmission built as an automatic stepped transmission. For startup from standstill, the provided startup gear G Anf according to the invention is determined from a minimum selection of at least two determined startup gears.
[0021] A first startup gear G Anf — Typ is determined only depending on the present startup conditions, which are given by the present drive resistance of the motor vehicle and the power request of the driver, independent of the load, that is, without taking into consideration the present load state of the friction clutch and without complying with a load limit of the friction clutch. Whereas the drive resistance is determined largely by the vehicle mass m Fzg and the roadway incline α FB , the power request of the driver is largely given by the gas pedal deflection x FP . This load-independent startup gear G Anf — Typ can presently be calculated by means of startup parameters m Fzg , α FB , x FP recorded by sensors or predetermined in a preceding travel cycle, or calculated in a known manner from corresponding characteristic curves and characteristic maps.
[0022] In contrast, at least one additional startup gear G Anf — Max1 , G Anf — MaxN , G Anf — Lim , G Anf — Def is determined however load-specific as the highest startup gear with which startup would occur in the case of a startup under the present startup conditions while adhering to a predetermined load limit of the friction clutch with consideration of the present load state of the friction clutch. The mechanical and thermal load of the friction clutch occurring with the respective startup gear can be calculated relatively precisely from the intended speed and torque progressions.
[0023] Using the proposed minimum selection of the load-independent startup gear G Anf — Typ and the at least one load-specific startup gear G Anf — Max1 , G Anf — MaxN , G Anf — Lim , G Anf — Def , it is guaranteed that the intended load limit of the friction clutch is actually maintained. If the intended load limit of the friction clutch is maintained with the typically used load-independent startup gear G Anf — Typ , the startup occurs with the startup gear expected by the driver, (G Anf =G Anf — Typ ). Otherwise, the startup occurs with the respective lowest, load-specific startup gear G Anf — Max1 , G Anf — MaxN , G Anf — Lim , G Anf — Def .
[0024] Particularly in the case of commercial vehicles, the drive engine is frequently built as a turbo-charge internal combustion engine which has a specific load build-up characteristic. Thus, a turbo-charged internal combustion engine below the boost threshold speed n L — min can spontaneously, that is, with high torque gradients, only reach an intake torque M S lying below the full load torque M VL (n M ). Therefore, with a design of the drive engine as a turbo-charged internal combustion engine, in addition a turbo-specific startup gear G Anf — MS is expediently determined as the highest startup gear with which the intake torque M S of the drive engine is sufficient as startup torque for a startup under the present startup conditions, and the turbo-specific startup gear G Anf — MS is considered in the minimum selection of the startup gears.
[0025] The relevant data which represents the dynamic operating characteristics of the internal combustion engine can be taken either directly from the engine control device or from a data store of the transmission control device. As already described in the document DE 10 2008 054 802 A1, this data that corresponds to the vehicle configuration, can be transferred to the data store of the transmission control device at the end of the production line of the motor vehicle, and later during travel operation can be adapted through comparison with the current operating data, particularly of the drive engine, that is, adapted to the changed operating characteristics. By accessing such updated data, the present method for the determining a startup gear is automatically adapted to the changed operating characteristics of the motor vehicle or of the drive engine.
[0026] A load-specific limit startup gear G Anf — Max1 can be determined as the highest startup gear with which a single startup is possible with startup under the present startup conditions (m Fzg , α FB , x FP ) without exceeding a breakdown-specific load limit of the friction clutch in the process. Because in the case of a startup with the limit startup gear G Anf — Max1 the highest permissible load of the friction clutch would arise, this represents the highest possible startup gear under the present operating conditions (m Fzg , α FB , x FP ).
[0027] A further load-specific startup gear G Anf — MaxN can be determined as the highest startup gear with which an expected number of consecutive startups is possible without substantial cooling phases with startup under the present startup conditions (m Fzg ,α FB , x FP ) without exceeding the breakdown-specific load limit of the friction clutch in the process. Due to immediately consecutive startups and the corresponding load of the friction clutch, in most cases this startup gear G Anf — MaxN lies significantly below the limit startup gear G Anf — Max1 , and the number of possible sequential startups is preferably relatively small.
[0028] The expected number of consecutive startups without substantial cooling phases that is used here can be determined based on the use profile of the motor vehicle and/or from the present driving situation of the motor vehicle. With the motor vehicle, for instance, a garbage truck or a package or postal delivery truck that travels from one house to another or, as in the case of a city bus, that travels from bus stop to bus stop, the expected number of the sequential startups can be specifically predetermined, or adaptively determined from the past operating phases.
[0029] Likewise, the expected number of sequential startups can be determined from the present traffic situation, such as stop-and-go operation in a traffic jam or in inner-city commuter traffic. Here, the load of the friction clutch that occurs in each case depends, in addition to the vehicle mass m Fzg , substantially on the average present roadway incline, α FB , that is, the corresponding topographic data, which can be determined in conjunction with a navigation device in the prior travel operation phases, or can be contained in a digital street map provided with corresponding data.
[0030] A spontaneous failure of the friction clutch is caused largely due to thermal overloading, that is, a friction-dependent introduction of heat that is too large.
[0031] Accordingly, the failure-specific load limit of the friction clutch can be defined as a temperature limit value T K max of the friction clutch that must be maintained for avoiding a spontaneous failure of the friction clutch. Analogous to this, the present load state of the friction clutch is determined before startup in this case using the present clutch temperature T K of the friction clutch. The present clutch temperature T K of the friction clutch can be recorded using a temperature sensor disposed at the friction clutch for example, or can be appropriately calculated. Accordingly, the load of the friction clutch during a startup procedure is determined as the estimated temperature increase ΔT K by which the currently present clutch temperature T K will be increased during the startup procedure.
[0032] The failure-specific load limit of the friction clutch can however also be defined as a thermal capacity limit Q K — max of the friction clutch, which should be maintained for avoiding a spontaneous failure of the friction clutch. Accordingly in this case, the present load state of the friction clutch is determined before the startup using the present thermal content Q K of the friction clutch, which is given by the calculated heat introduction with past startups and the estimated thermal loss during the interspersed cooling phases. The load of the friction clutch due to a startup procedure is then determined as the anticipated increase of the thermal content ΔQ K by which the currently present thermal content Q K is increased during the startup procedure.
[0033] A driving performance oriented load-specific startup gear G Anf — Lim can be determined as the highest startup gear with which startup under the present startup conditions (m Fzg , α FB , x FP ) largely fulfills the driving performance request of the driver, and a service life-specific load limit of the friction clutch is exceeded maximally by a specific tolerance threshold.
[0034] The service life of a friction clutch is determined by the mechanical wear of the friction linings, as long as no thermal overloading has occurred in the meantime. If a specific wear per startup is given as a service life-specific load limit for attaining a designated service life of the friction clutch, this is an average value which must be maintained only on average, that is, averaged over many startups. Accordingly this load limit value, as is intended here with the drive performance-oriented startup gear G Anf — Lim for satisfying the power request of the driver, can be moderately exceeded on a sporadic basis without endangering the maintenance of the service life of the friction clutch.
[0035] This performance-oriented startup gear G Anf — Lim also expediently represents the highest startup gear to which the startup gear G Anf determined in the minimum selection, can be corrected manually by the driver, that is, by an appropriate intervention of the driver in the control of the gear selection, for instance by deviation of a shift lever located in a manual shift gate into an upshift or downshift direction.
[0036] In additional load-specific startup gear G Anf — Def can be determined as the highest startup gear with which the service life-specific load limit of the friction clutch is not exceeded with a startup under the present drive conditions (m Fzg , α FB , x FP ).
[0037] Because the mechanical wear of the friction linings per startup can barely be detected by sensors, the service life-specific load limit of the friction clutch can be defined alternatively as an incremental limit value of the clutch temperature ΔT K — max of the friction clutch, by which the present clutch temperature T K is to be maximally increased during the intended startup procedure for attaining a specified service life goal of the friction clutch. The temperature increase ΔT K of the friction clutch is used in this case as an equivalent for the mechanical wear of the friction linings during startup.
[0038] As an alternative to this, the service life-specific load limit of the friction clutch can also be defined as an incremental limit value of the thermal content ΔQ K — max of the friction clutch, by which the present thermal content Q K of the friction clutch is to be maximally increased during the intended startup procedure for attaining a specified service life goal of the friction clutch. In this case, the increase ΔQ K of the thermal content of the friction clutch is used as an equivalent to the mechanical wear of the friction linings during a startup.
[0039] If necessary, a speed-specific startup gear G Anf — vZiel can be determined in addition as the highest startup gear with which a predetermined target speed can be attained without a downshift with the engaged friction clutch in the case of a startup under the present startup conditions (m Fzg , α FB , x FP ), and this speed-specific startup gear G Anf — vZiel can be considered with the named minimum selection of the startup gears. The startup gear chosen here must not be too high such that the target speed is exceeded already at an idle engine speed and an engaged friction clutch, which would require a downshift and traveling with a slipping friction clutch.
[0040] The consideration the speed-specific startup gear G Anf — vZiel is particularly significant for specific-use vehicles, such as collection vehicles which must travel from loading station to the loading station or concrete mixers which must deposit concrete caterpillars, for which the target speed v Ziel of the respective startup is relatively low. With such applications, the target speed v Ziel to be attained should be as close as possible to the idle speed n idle of the drive engine, that is, the present drive resistance in the case of an intake engine can be compensated by the corresponding full load torque M VL (n M ) of the drive engine, and in the case of a turbo-charged internal combustion engine by the intake torque M S of the drive engine.
[0041] If the startup gear G Anf determined in the minimum selection is not available, expediently the next lowest startup gear (G Anf =G Anf−1 ) is used for the intended startup because overloading of the friction clutch is reliably excluded with this startup gear.
[0042] However, if the startup gear G Anf determined in the minimum selection and the next lowest startup gear G Anf−1 are not available, the next higher startup gear (G Anf =G Anf+1 ) can also be used for the intended startup; the use thereof however under unfavorable operating conditions can be associated with overloading of the friction clutch.
[0043] If neither the startup gear G Anf determined in the minimum selection nor the next lowest startup gear G Anf−1 are available for the intended startup, the search for the next lowest gear continues until the first gear of the stepped transmission is reached. The next higher startup gear (G Anf =G Anf+1 ) for the intended startup is only used if neither the startup gear G Anf determined in the minimum selection nor the next lower startup gear are available up until reaching the first gear of the step transmission as the startup gear.
[0044] A thermal overload of the friction clutch can be assumed particularly if the next higher startup gear G Anf+1 lies above the load specific limit startup gear G Anf — Max1 . Therefore in this case, the startup is typically prevented and this is indicated to the driver by issuing an audible and or visual warning signal.
[0045] The startup with the startup gear G Anf+1 lying above the load-specific limit startup gear G Anf — Max1 can be permissible however in emergency operation, if a specific driver action requires an emergency startup. An emergency startup can be requested by the driver for example by simultaneously activating the gas pedal and an emergency switch, or by holding of the gas pedal in the maximum setting thereof for a prolonged period.
[0046] Such an emergency startup is required for example if the motor vehicle is located in a hazardous location such as in an intersection or on a railroad crossing. In such an emergency situation, an emergency startup is viewed as advantageous even under inclusion of overloading or destruction of the friction clutch in order to avoid even greater damage such as that caused by a collision with another vehicle or with the train.
[0047] With a known maneuvering situation, an additional maneuvering-specific startup gear G Anf — Rang can be determined as the highest startup gear with which under the present startup conditions (m Fzg , α FB , x FP ) the friction power generated at the friction clutch in the continued slipping operation corresponds more or less to the available cooling power of the friction clutch. In this case, this range-specific startup gear G Anf — Rang is also considered with the minimum selection of the startup gears.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] For illustrating the invention, the description is accompanied by a drawing with an example embodiment. The figures show:
[0049] FIG. 1 the determination of a load-independent startup gear for startup from standstill in a transmission ratio/incline graph,
[0050] FIG. 2 a schematic of a drive train of a heavy-duty commercial vehicle,
[0051] FIG. 3 an engine dynamic characteristic curve of a turbo-charged internal combustion engine,
[0052] FIG. 4 a the torque build-up of an internal combustion engine according to FIG. 3 with an engine speed controlled below the boost threshold speed, thus (n M ≦n L — min ), and
[0053] FIG. 4 b the torque build-up of an internal combustion engine according to FIG. 3 with an engine speed controlled above the boost threshold speed, thus (n M >n L — min ).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] A drive train, shown schematically in FIG. 2 , of a heavy-duty commercial vehicle comprises a drive engine designed as a turbo-charged internal combustion engine VM, a startup element designed as an automated friction clutch K, and a transmission designed as an automated stepped transmission G. The stepped transmission G can be connected on the input side, via the friction clutch K, to the drive shaft (crankshaft) of the internal combustion engine VM, and on the output side, via a cardan shaft, to the axle transmission GA (axle differential) of the drive axle.
[0055] At least one auxiliary consumer NA and optionally at least one drive-side power take-off PTO are disposed at the internal combustion engine VM, which in the driven state reduce the engine torque M M of the internal combustion engine VM that can be delivered at the friction clutch and that is available for a startup process. At least two further output-side power takeoff-offs PTO are disposed at the stepped transmission G and the axle transmission GA, and further reduce the engine torque M M transmitted via the friction clutch K into the stepped transmission such that with a startup procedure a correspondingly reduced torque is effective at the drive wheels of the drive axle for overcoming the drive resistance and attaining an at least minimal startup acceleration.
[0056] With a startup procedure, the internal combustion engine VM must therefore be able to instantaneously generate engine torque M M and to deliver the torque at the friction clutch K so that such torque, minus the drive torque for the auxiliary consumers NA and the drive side power take-offs PTO, is sufficient for attaining acceptable startup acceleration. For this purpose, the engine torque M M transferred by the friction clutch K must be sufficiently high that the engine torque, minus the drive torques for the output drive side power take-off PTO, exceeds the drive resistance torque resulting from the present drive resistance, that is, the reduced drive resistance torque M FW given the overall transmission ratio and the efficiency of the drive train at the input shaft of the stepped transmission G, exceeds to such a degree that the excess torque is sufficient at least for a minimal startup acceleration.
[0057] The graph in FIG. 1 shows in general the reciprocal of the transmission ratio i G over the roadway incline α FB , which illustrates the simplified determination of a startup gear G Anf — Typ , which for startup from standstill is determined depending only on the present startup conditions, for instance the vehicle mass m Fzg , the roadway incline α FB and the gas pedal position x FP , that is, without considering a predetermined breakdown-specific or service life-specific load limit of the friction clutch.
[0058] For this purpose, a dash-dotted characteristic line in FIG. 1 shows the reciprocal of the respective transmission ratio i Fw for a specific vehicle mass m Fzg depending on the roadway incline α FB , the maximum engine torque M max that can be spontaneously generated which is necessary to compensate for the specific drive resistance in this situation, formed by the sum of the incline resistance and the rolling resistance.
[0059] Because a higher drive torque is necessary at the drive wheels for the additional generation of sufficient startup acceleration, the respective startup gear G Anf — Typ must have a correspondingly higher transmission ratio. For this purpose, FIG. 1 correspondingly shows the reciprocal values of the transmission ratios of the possible startup gears G 1 -G 5 in a stepped characteristic curve. With the presence of a specific roadway incline α FB * (point a), the dot-dashed characteristic curve provides a transmission ratio i FW (point b) with which the present drive resistance is compensated with the maximum available engine torque M max . For attaining an at least minimum vehicle acceleration the amount of which can be influenced by the driver using the gas pedal position x FP , the third gear G 3 for example is presently determined as a startup gear G Anf — Typ (point c), which has a correspondingly higher transmission ratio.
[0060] In the present method for determining a startup gear, there are, however additional, specifically load-specific startup gears determined according to different criteria. Thus, a further load-specific startup gear G Anf — MaxN can be determined as the highest startup gear with which an expected number of consecutive startups is possible without substantial cooling phases in the case of startup under the present startup conditions (m Fzg , α FB , x FP ) without exceeding a breakdown-specific load limit of the friction clutch in the process.
[0061] Likewise, a load-specific startup gear G Anf — Def can be determined as the highest startup gear with which the service life-specific load limit of the friction clutch is not exceeded with a startup under the present startup conditions (m Fzg , α FB , x FP ).
[0062] With the design of the drive engine as a turbo-charged internal combustion engine, a turbo-specific startup gear G Anf — MS is also preferably determined as the highest startup gear with which the intake torque M S of the drive engine is sufficient as the startup torque in the case of a startup under the present startup conditions (m Fzg , α FB , x FP ), whereby a very low, startup speed n Anf lying near the idle speed n idle is possible.
[0063] The startup gear G Anf provided for the present startup is determined in a minimum selection from the number of specific startup gears G Anf — Typ , G Anf — MaxN , G Anf — Def , G Anf — MS , that is, the lowest of the startup gears is selected.
[0064] The intake torque M S required for the determination of the turbo-specific startup gear M Anf — MS can be read directly from the engine control device or can be taken from an engine dynamic characteristic map, known from the document DE 10 2009 054 802 A1, that can be stored in a data store of the transmission control device, and is shown for example in FIG. 3 .
[0065] The engine dynamic characteristic map represented in FIG. 3 in a torque/speed diagram contains the immediately available maximum torque M max of the internal combustion engine and the maximum torque gradient (dM M /dt) max , with which the immediately available maximum torque M max can be attained as quickly as possible, in each case of a function of the present engine torque M M and the present engine speed n M , thus (M max =f(M M , n M ), (dM M /dt) max =f(M M , n M )).
[0066] The engine dynamic characteristic map is bounded by the stationary full load torque characteristic curve M VL (n M ), the zero torque curve (M M =0), the idle speed n idle and the cut-off speed n lim of the internal combustion engine. The engine dynamic characteristic map is subdivided into four operating regions A, B, C, D by the intake torque characteristic curve M S (n M ) of the intake torque, simplified here as assumed to be constant M S =const., and the boost threshold speed n L — min of the internal combustion engine.
[0067] In the first region A (0≦M M <M S , n idle ≦n M <n L — min ) that is below the intake torque characteristic curve M S =const. and below the boost threshold speed n L — min , the immediately available maximum torque M max (n M ) of the internal combustion engine is formed in each case by the corresponding value of the intake torque M S , thus (M max (n M )=M S ). However, as the intake torque M S in this region is constant (M S =const.), the immediately available maximum torque M max of the internal combustion engine is represented by a single value (M max =M S =const.). Independent of this, the very high maximum torque gradient (dM M /dt) max in operating region A can also be represented by a single value.
[0068] In the second region B (0≦M M <M S , n L — min ≦n M n lim ) lying below the intake torque characteristic curve M S =const. and above the boost threshold speed n L — min , the immediately available maximum torque M max (n M ) of the internal combustion engine is similarly given in each case by the corresponding value of the intake torque M S . Because the intake torque M S in this region has a constant progression (M S =const.), the immediately available maximum torque M max of the internal combustion engine also in the region B is represented by a single value (M max =M S ==const.). As with region A, also in region B, the maximum torque gradient (dM M /dt) max that is also very high beneath the intake torque characteristic curve M S =const. can also be expressed by a single value.
[0069] In the third region C (M S ≦M M <M VL (n M ), n L — min ≦n M <n lim ), adjacent to region B, and lying above the intake torque characteristic curve M S =const. and above the boost threshold speed n L — min , a further increase of the engine torque M M is possible up to the respective value of the stationary full load torque characteristic curve M VL (n M ), however, with a significantly lower maximum torque gradient (dM M /dt) max than in the regions A and B, i.e., below the intake torque characteristic curve M S =const.
[0070] In the fourth region D (M S ≦M M <M VL (n M ), n idle ≦n M <n L — min ), adjoining at the first region A, above the intake torque characteristic curve M S =const. and below the boost threshold speed n L — min , a further rapid increase of the engine torque M M is not possible without an increase of the engine speed n M above the boost threshold speed n L — min . Consequently, in operating region D, the immediately available maximum torque M max (n M ) of the internal combustion engine equals the corresponding value of the intake torque M S , thus (M max (n M )=M S =const.) and the maximum torque gradient (dM M /dt) max equals zero, thus ((dM M /dt) max =0).
[0071] An operating region E which cannot be reached in normal driving operation and thus is not relevant, can be defined above the full load torque characteristic curve M VL (n M ). Below the full load torque characteristic curve M VL (n M ) and the idle speed n idle , there is an undesirable but technically attainable operating region F, into which the internal combustion engine can be pushed dynamically from an engine speed n M lying near the idle speed n idle , for example due to a rapid engagement of the friction clutch, and in which there is a danger of stalling the internal combustion engine. In addition, a nearby region lying immediately below the full load torque characteristic curve M VL (n M ) can be defined as an additional operating region V, in which the internal combustion engine under full load, that is along the full load torque characteristic curve M VL (n M ), can be pushed to a lower engine speed n M or controlled to higher engine speed n M .
[0072] For a startup procedure considered here, with which the drive engine is to be controlled from the idle speed n idle to a startup speed n Anf and from the idle torque M idle ≈0 to the determined startup torque M Anf , it must accordingly be noted that the drive engine can be spontaneously loaded, that is, with high torque gradients dM M /dt, only up to the intake torque M S , if the engine speed n M remains below the boost threshold speed n L — min . This relationship is represented greatly simplified in the torque progression M M (t) in the image insert (a) of FIG. 3 and in the time progression of FIG. 4 a.
[0073] Likewise it is to be noted for the present determination of the startup gear that the drive engine must be accelerated above the boost threshold speed n L — min for the immediate setting of an engine torque M M lying above the intake torque M S , that is, it must be controlled from the operating region A into the operating region B, because a further rapid increase of the engine torque M M is possible only above the boost threshold speed n L — min , even with lower torque gradients dM M /dt. This relationship is illustrated in a greatly simplified manner in the torque progression M M (t) in the image insert (b) of FIG. 3 and in the time progression of FIG. 4 b.
Reference Characters
[0000]
a point in FIG. 1
b point in FIG. 1
c point in FIG. 1
A operating region
B operating region
C operating region
D operating region
E operating region
F operating region
G stepped transmission, transmission
G Anf startup gear
G Anf+1 next higher startup gear
G Anf−1 next lower startup gear
G anf — Def load-specific startup gear
G anf — Lim load-specific startup gear
G Anf — max highest possible startup gear
G Anf — MaxN load-specific startup gear
G Anf — Max1 load-specific limit startup gear
G Anf — min lowest possible startup gear
G anf — MS turbo-specific startup gear
G Anf — Rang maneuvering-specific startup gear
G Anf — Typ load independent startup gear
G Anf — vZiel speed specific startup gear
GA axle transmission, axle differential
G 1 -G 5 possible startup gears
i FW transmission ratio for compensating the drive resistance
i G transmission ratio
K friction clutch, startup element
M Anf startup torque
M FW drive resistance torque
m Fzg vehicle mass
M idle idle speed torque
M M engine torque
M max maximum torque
M S intake torque
M VL full load torque
n Anf startup speed
n idle idle speed of rotation
n L — min boost threshold speed
n lim cut-off speed
n M engine speed
NA auxiliary consumer
PTO power take-off
Q K thermal content in the friction clutch
Q K — max thermal content limit of the friction clutch
t time
t 0 time
T K clutch temperature
T K — max temperature limit value of the friction clutch
V operating region
VM internal combustion engine, startup engine
x FP gas pedal deflection, gas pedal position
α FB roadway incline
α FB * present roadway incline
ΔQ K — max incremental limit value of the thermal content (of K)
ΔT K — max incremental limit value of the clutch temperature
ΔT K temperature increase | A method for determining a startup gear in a motor vehicle for starting from standstill while maintaining a load limit of the clutch in a the drive train which comprises a drive engine built as an internal combustion engine, a friction clutch, and an automatic stepped transmission. To avoid overloading the clutch, the method determines a load-independent startup gear with which startup would occur under the present starting conditions without considering the current load state of the clutch and without complying with a load limit of the clutch. A load-specific startup gear is determined as the highest startup gear, with which during a startup under the present starting conditions, a predefined load limit of the clutch would be maintained with consideration given to the present load state of the clutch. The startup gear is the lowest of the load-independent startup gear and the at least one load-specific startup gear. | 5 |
[0001] This application claims the priority benefit under 35 U.S.C. §119 of Japanese Patent Application No. 2009-135504 filed on Jun. 4, 2009, which is hereby incorporated in its entirety by reference.
BACKGROUND
[0002] 1. Field
[0003] The presently disclosed subject matter relates to a vehicle headlight of a projector type, and more particularly to a projector headlight for a low beam having a favorable light distribution pattern that can conform to a light distribution standard for a headlight with respect to a contrasting difference between the upper and lower sides of a horizontal cut-off line in the light distribution pattern.
[0004] 2. Description of the Related Art
[0005] A projector headlight for a low beam and/or a high beam is frequently incorporated into a vehicle lamp including a position lamp, a turn-signal lamp, etc. The projector headlight may allow a light-emitting area thereof to be reduced and therefore allows a vehicle lamp that includes such a projector headlight to be minimized in comparison with other types of headlights. In addition, when an LED is used as a light source for the projector headlight, a battery friendly and small projector headlight can be achieved.
[0006] A projector headlight is also disclosed in Applicant's co-pending patent application, U.S. patent application Ser. No. 12/794,488, filed on same date, Jun. 4, 2010, Attorney Docket No. ST3001-0255, which is hereby incorporated in its entirety by reference.
[0007] A conventional projector headlight for use as a low beam light is disclosed in patent document No. 1 (Japanese Patent Application Laid Open JP2003-317513). FIG. 12 is a schematic side cross-section view depicting a structure for the conventional projector headlight in patent document No. 1, and an LED is used as a light source of this projector headlight.
[0008] According to the conventional projector headlight 50 shown in FIG. 12 , the projector headlight 50 includes: an LED light source 52 ; an elliptical reflector 54 in which a first focus thereof is located near the LED light source 52 ; a projector lens 56 which has a focus thereof located near a second focus of the elliptical reflector 52 ; and a shade 58 located near the focus of the projector lens 56 . Thus, an optical axis Z 50 approximately corresponds with the respective optical axes of the elliptical reflector 54 and the projector lens 56 , and the LED light source 52 .
[0009] In the projector headlight 50 , light emitted from the LED light source 52 is reflected on the elliptical reflector 54 and can be emitted in a forward direction of the projector headlight 50 via the projector lens 56 . In this case, a part of the light that is reflected on the elliptical reflector 54 can be shielded by the shade 58 . Accordingly, the projector headlight 50 can form a light distribution pattern for a low beam including a cut-off line in accordance with a top shape of the shade 58 .
[0010] However, because the shade 58 is substantially located at the focus of the projector lens 56 , a contrasting difference between the upper and lower sides of a horizontal cut-off line of an oncoming lane and of a driving lane in the light distribution pattern tends to become too clear. When the light-emitting area of the projector headlight 50 becomes smaller and/or the brightness thereof becomes brighter using a high power light source and/or the like, the contrasting difference may be especially enhanced and too clear. Thus, the projector headlight 50 may include a problem in that the excessive contrasting difference thereof causes a decrease of visibility in some cases.
[0011] In order to reduce the contrasting difference, another conventional projector headlight for use as a low beam light is disclosed in patent document No. 2 (Japanese Patent Application Laid Open JP2008-262755). FIG. 13 is a schematic side cross-section view depicting a projector lens for the other conventional projector headlight that is disclosed in patent document No. 2. According to this projector headlight, on a surface towards a focus F 68 of a projector lens 66 , convex surfaces are provided as a means to diffuse light that forms a cut-off line in a light distribution pattern. The convex surfaces may blur the cut-off line, and therefore may improve visibility in the light distribution pattern.
[0012] The above-referenced Patent Documents are listed below and are hereby incorporated with their English abstract in their entirety.
[0013] 1. Patent document No. 1: Japanese Patent Application Laid Open JP2006-317513
[0014] 2. Patent document No. 2: Japanese Patent Application Laid Open JP2008-262755
[0015] However, when diffusing light by a surface of the projector lens like the projector lens that is disclosed in patent document No. 2, the surface of the projector lens may effect a change in light other than that near the cut-off line, and therefore may cause a decrease of a maximum light intensity and/or a glare. In addition, it may be difficult to form convex surfaces on the surface of the projector lens during a manufacturing process, especially when the projector lens is made of a glass material, it may be very difficult because the process may become the last process.
[0016] The disclosed subject matter has been devised to consider the above and other problems, characteristics and features. Thus, an embodiment of the disclosed subject matter can include a projector headlight for a low beam having a favorable light distribution pattern that can conform to a light distribution standard for headlights with respect to a contrast difference between the upper and lower sides of a horizontal cut-off line. In this case, various light sources such as a semiconductor light source, an HID lamp, a halogen bulb and the like can be employed as a light source with a simple structure.
SUMMARY
[0017] The presently disclosed subject matter has been devised in view of the above and other characteristics, desires, and problems in the conventional art, and to make certain changes to existing projector headlights. Thus, an aspect of the disclosed subject matter includes providing a projector headlight for a low beam having a favorable light distribution pattern that can conform to a light distribution standard for headlights with respect to a contrast difference between the upper and lower sides of a horizontal cut-off line, wherein various light sources can be used as a light source with a simple structure and the basically same structure. Another aspect of the disclosed subject matter includes providing a projector headlight using an LED light source, which can result in a battery friendly and small projector headlight having a favorable light distribution pattern so that it can be used for various types of vehicles including an electric car and the like.
[0018] According to an aspect of the disclosed subject matter, a projector headlight can include a light source, at least one ellipsoidal reflector, a projector lens and a shade. At least the ellipsoidal reflector can have a first focus and a second focus, the first focus thereof being located near the light source. The projector lens can have both a focus and an optical axis thereof located substantially on an imaginary line connecting the first focus and the second focus of the at least one ellipsoidal reflector. The shade can comprise a neutral point and first, second and third top edge lines that respectively face first, second and third front edge lines with respect to each other. The shade can have the neutral point located near the focus of the projector. The first, second and third top edge lines can be configured to form a horizontal cut-off line with light emitted from the light source, and an R surface between the first, second and third top edge lines and the first, second and third front edge lines can be configured to slant down in a direction towards the projector lens. The R surface can be configured to form a continuous blur portion on the horizontal cut-off line.
[0019] In the above-described exemplary projector headlight, the light emitted from the light source can form a fundamental light distribution pattern from the projector lens via the ellipsoidal reflector by shielding an upwardly directed light with the shade. In this case, because light that is reflected on the R surface underneath the first, second and third top edge lines that form the horizontal cut-off line can illuminate a position on the horizontal cut-off line, a position on the horizontal cut-off line can become dark. Accordingly, contrast difference between the upper and lower sides of the horizontal cut-off line can be reduced. In addition, because the first top edge line can be located at a higher position than the second top edge line, the first, second and third top edge lines can form a cut-off line for a driving lane, an oncoming lane and an elbow line, respectively.
[0020] In this case, the R surface can be configured to form a circular shape, and a radius and/or a position of the R surface can change. Therefore, according to a light distribution standard for a headlight, characteristics of the blur portion such as width, thickness, brightness and the like can be adjusted. In addition, the R surface can be configured with a reflex surface or a non-reflex surface (i.e., a reflective surface or a non-reflective surface) to match characteristics of various light sources such as a semiconductor light source, an HID lamp, a halogen bulb, etc.
[0021] Furthermore, second focuses of other ellipsoidal reflectors other than at the least one ellipsoidal reflector can be located substantially on the second top edge line of the shade and a virtual extending line of the second top edge line. Thus, the projector headlight of the disclosed subject matter can form a favorable light distribution with a wide range and a simple structure, and the structure can be the basically the same even if various and different light sources are used as a light source(s).
[0022] According to another aspect of the disclosed subject matter, a projector headlight can include: an LED light source having an optical axis located on a base board; at least one ellipsoidal reflector having a first focus and a second focus, and attached to the base board so that the first focus thereof can be located substantially at the LED light source; a projector lens having both a focus and an optical axis located substantially on an imaginary line that connects the first focus and the second focus of the at least one ellipsoidal reflector, and the focus of the projector lens being located substantially at the second focus of the at least one ellipsoidal reflector; a shade; and a housing attaching the projector lens, the shade and the at least one ellipsoidal reflector.
[0023] In the above-described projector headlight, because the structure of the shade, the ellipsoidal reflector and the projector lens can be substantially the same, the projector headlight using the LED light source can perform the features set forth above in paragraphs [0013]-[0016]. In addition, the optical axis of the LED light source can intersect with the imaginary line of the projector lens substantially at the first focus of the at least one ellipsoidal reflector so as to correspond with each other in a vertical direction. An intersecting angle of the optical axis of the LED light source and the imaginary line of the projector lens towards the at least one ellipsoidal reflector can be smaller than the intersecting angle towards the projector lens.
[0024] Therefore, the projector headlight can improve a faraway (or distance) visibility because light emitted from the LED light source can illuminate at the faraway point. Moreover, second focuses of other ellipsoidal reflectors other than at least the ellipsoidal reflector can also be located substantially on the first top edge line of the shade and the second top edge line in order to improve a light use efficiency. Thus, the disclosed subject matter can provide a small projector headlight that can perform a favorable light distribution pattern with a high efficiency and low power consumption, and which can be used for an electrical car and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] These and other characteristics and features of the disclosed subject matter will become clear from the following description with reference to the accompanying drawings, wherein:
[0026] FIG. 1 is a schematic side cross-section view showing an exemplary structure of a vehicle headlight of a projector type for a low beam made in accordance with principles of the disclosed subject matter;
[0027] FIG. 2 is a partial schematic close-up view showing a shade for the projector headlight shown in FIG. 1 and is a perspective view from a front top of the shade;
[0028] FIG. 3 a and FIG. 3 b are schematic diagrams showing fundamental light distribution patterns formed on a virtual screen that is vertically located at 25 meters away from the projector headlight of FIG. 1 , wherein a conventional shade and an exemplary shade made in accordance with the disclosed subject matter are used as shades used in FIG. 3 a and FIG. 3 b , respectively;
[0029] FIG. 4 a and FIG. 4 b are partial close-up side cross-section views showing the exemplary shade made in accordance with the disclosed subject matter and the conventional shade, respectively;
[0030] FIG. 5 is a graph showing a relation between an angle in a horizontal direction and a light intensity of a light distribution near a cut-off line with respect to projector headlights using an exemplary shade according to the disclosed subject matter and a conventional shade;
[0031] FIG. 6 is a partial schematic enlarged view depicting another exemplary shade and is a perspective view from a front top of the shade, which blurs the light intensity within a prescribed range of a cut-off line;
[0032] FIG. 7 is an explanatory schematic diagram showing a fundamental light distribution pattern formed by the shade shown in FIG. 6 ;
[0033] FIG. 8 is a schematic cross-section view depicting another exemplary vehicle headlight of a projector type for a low beam made in accordance with principles of the disclosed subject matter;
[0034] FIG. 9 a and FIG. 9 b are partial close-up side cross-section views showing another exemplary shade made in accordance with the disclosed subject matter and another conventional shade, respectively;
[0035] FIG. 10 is a graph showing a relation between an angle in a horizontal direction and a light intensity of a light distribution near a cut-off line with respect to projector headlights using the exemplary shade of FIG. 9 a and the conventional shade of FIG. 9 b;
[0036] FIG. 11 is a schematic diagram showing a fundamental light distribution pattern formed on a virtual screen that is vertically located at 25 meters away from the projector headlight of FIG. 8 , wherein the exemplary shade of FIG. 9 a is used as a shade;
[0037] FIG. 12 is a schematic side cross-section view depicting a structure for a conventional projector headlight in which an LED is used as a light source; and
[0038] FIG. 13 is a schematic side cross-section view depicting a projector lens for another conventional projector headlight.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0039] The disclosed subject matter will now be described in detail with reference to FIG. 1 to FIG. 11 . FIG. 1 is a schematic side cross-section view showing an exemplary vehicle headlight of a projector type for a low beam made in accordance with principles of the disclosed subject matter. The projector headlight 10 for a low beam can include: a semiconductor light source 12 , a reflector 14 , a projector lens 16 and a shade 18 .
[0040] The semiconductor light source 12 can be, for example, a white LED which is attached to a base board 19 so that an optical axis of the semiconductor light source 12 can slant in the opposite direction of the projector lens 16 . Other semiconductor devices such as a laser can also be used as the semiconductor light source 12 .
[0041] The reflector 14 can be located so as to cover the semiconductor light source 12 . An inner surface of the reflector 14 can be configured with a reflex surface 14 a in a free surface shape based on a plurality of ellipsoidal reflex surfaces. Therefore, the reflex surface 14 a can be basically ellipsoidal having a first focus and a second focus, and the first focus can be located at substantially the semiconductor light source 12 so that light emitted from the semiconductor light source 12 can concentrate at the second focus through the reflex surface 14 a.
[0042] The second focus of the reflex surface 14 a can be located near a focus F of the projector lens 16 . Thus, an optical axis of the projector headlight 10 can substantially correspond to an optical axis of the projector lens 16 including the focus F, the semiconductor light source 12 , and the first and second focus of the reflex surface 14 a . Light emitted from the semiconductor light source 12 can be illuminated as an inverted light in a forward direction of the projector headlight 10 via the projector lens 16 .
[0043] When the projector headlight 10 is used in low beam mode using the above-described structure, the projector headlight 10 can include the shade 18 in order to shield an upward light that may give a glaring type light to an oncoming car and the like. The shade 18 can include a horizontal plate 18 a , a vertical plate 18 b and a top edge 18 c . A surface treatment for reflecting light such as an aluminum deposition, a silver coating and the like can be formed on the horizontal plate 18 a so that light arriving at the horizontal plate 18 a can be reflected towards the projector lens 16 .
[0044] The top edge 18 c can be located between the horizontal plate 18 a and the vertical plate 18 b , and can be configured to form a horizontal cut-off line for an oncoming lane and for a driving lane. The shade 18 can be located so that the focus F of the projector lens 16 can be located at or near (i.e., substantially at) the top edge 18 c thereof. Therefore, the projector headlight 10 can form a light distribution pattern for a low beam with light emitted from the semiconductor light source 12 through the shade 18 and the projector lens 16 .
[0045] The shade 18 will now be described in detail. FIG. 2 is a partial perspective close-up view showing the shade 18 for the projector headlight 10 shown in FIG. 1 and is a perspective view from a front top of the shade 18 . The horizontal plate 18 a of the shade 18 can include a top surface 18 a 1 , and the vertical plate 18 b can include a front surface 18 b 1 . An end of the top surface 18 a 1 towards the front surface 18 b 1 can include or constitute the top edge 18 c.
[0046] The top edge 18 c can be formed in a substantially circular arc shape as viewed from a top view of the shade 18 , and can be configured to form a top line of the horizontal cut-off line. The top edge 18 c can include: a first top edge line 18 c 1 for forming the top line of the horizontal cut-off line for an oncoming lane, a second top edge line 18 c 2 for forming the top line of the horizontal cut-off line for a driving lane, and a third top edge line 18 c 3 that is located between the first top edge line 18 c 1 and the second top edge line 18 c 2 for forming the top line of an elbow line on the cut-off line near a vertical line.
[0047] In addition, an R surface 20 , for example a radiused surface, can be formed between the top edge 18 c and an edge of the front surface 18 b 1 that includes a first front edge line, a second front edge line and a third front edge line so as to face the first top edge line 18 c 1 , the second top edge line 18 c 2 and the third top edge line 18 c 3 , respectively. Moreover, a height of the first top edge line 18 c 1 of the top edge 18 c can be higher than that of the second top edge line 18 c 2 in a side view from the projector lens 16 . Therefore, the third top edge line 18 c 3 can slant between the first top edge 18 c 1 and the second top edge 18 c 2 .
[0048] FIG. 3 a is a schematic diagram showing a fundamental light distribution pattern formed on a virtual screen that is vertically located at 25 meters away from the projector headlight, which includes a conventional shade without the R-surface 20 shown in FIG. 2 . The fundamental light distribution pattern PL can include a horizontal cut-off line CL 1 on the oncoming lane that is formed by the first top edge line 18 c 1 of the shade 18 . The horizontal cut-off line CL 1 can be formed downward than a horizontal line H due to the oncoming lane.
[0049] The fundamental light distribution pattern PL can include a horizontal cut-off line CL 2 on the driving lane that is formed by the second top edge line 18 c 2 . The horizontal cut-off line CL 2 can be formed substantially on the horizontal line H because of the driving lane. In addition, the fundamental light distribution pattern PL can include an elbow line CL 3 between the horizontal line CL 1 for the oncoming lane and the horizontal line CL 2 for the driving lane, which is formed by the third top edge line 18 c 3 .
[0050] In this case, the shade 18 can include a neutral point that is an intersection of a virtual extending line of the second top edge line 18 c 2 and another virtual line that passes at a intersection of the first top edge line 18 c 1 and the third top edge line 18 c 3 and intersects with the virtual extending line of the second top edge line 18 c 2 at a right angle. The neutral point can be located substantially at the focus F of the projector lens 16 so that the first and second top edge liens 18 c 1 , 18 c 2 can be configured to form the horizontal cut-off line for both a driving lane and an oncoming lane with the light emitted from the semiconductor light source 12 .
[0051] FIG. 3 b is a schematic diagram showing a fundamental light distribution pattern formed on the virtual screen that is vertically located at 25 meters away from the projector headlight, which includes the shade 18 . In this case, a continuous blur portion P can be formed on the horizontal cut-off line CL 1 -CL 3 by the R surface. A principle of the continuous blur portion P will now be described in detail with reference to FIG. 4 a and FIG. 4 b . FIG. 4 a and FIG. 4 b are partial close-up side cross-section views showing the shade 18 and a conventional shade, respectively.
[0052] The conventional shade 24 shown in FIG. 4 b includes: a horizontal plate 24 a ; a top surface 24 a 1 located on the horizontal plate 24 a ; a top edge line being an end of the top surface 24 a 1 ; a vertical plate 24 b ; and a front surface 24 b 1 located on the vertical plate 24 b that is substantially perpendicular to the horizontal plate 24 a . A mark 24 C(F) shows a point on the top edge line of the end of the top surface 24 a 1 , and the top edge line of the end of the top surface 24 a 1 can form the horizontal cut-off line CL 1 -CL 3 in the light distribution pattern PL as shown in FIG. 3 a.
[0053] The shade 18 shown in FIG. 4 a can include a point 18 C (F) on the top edge 18 c corresponding to the point 24 C (F) shown in FIG. 4 a . The horizontal plate 18 a can extend toward the projector lens 16 from the top edge 18 c including the point 18 C(F), and the R surface 20 can be located in a circular arc shape between the top edge 18 c and the front surface 18 b 1 so as to extend along the top edge 18 c and the front surface 18 b 1 . A surface treatment for reflecting light can be formed on the R surface 20 as well as the top surface 18 a 1 . The R surface 20 can result in the continuous blur portion P as shown in FIG. 3 b.
[0054] More specifically, light rays A, B and C can be caused to intersect at a point M shown in FIG. 4 a . With regard to FIG. 4 b , the point M is located at a distances d away from the point 24 C (F) in an upwards direction of the point 24 C (F). The ray A emitted from the semiconductor light source 12 intersects with the point M and passes over the point 24 C (F). The ray B intersects with the point M at an angle that is nearly equal to 0 degree with respect to the top surface 24 a 1 , and passes over the point 24 C(F). The ray C is reflected on the top surface 24 a 1 and passes at the point M.
[0055] In this case, when each of the projector headlights include the shade 18 shown in FIG. 4 a or the shade 24 shown in FIG. 4 b , each of the rays B passes at the point M without a contact with the shades 18 and 24 , respectively, and enters into the projector lens 16 . Then, each of the rays B that passes over the shades 18 and 24 may be emitted toward the substantially same position under the horizontal cut-off line through the projector lens 16 , respectively.
[0056] Each of the rays C passes at the point M after reflecting on the shades 18 and 24 , and enters into the projector lens 16 , respectively. Then, each of the rays C that reflect on the shades 18 and 24 may be emitted slightly upwards through the projector lens 16 , respectively. The ray A shown in FIG. 4 b that passes at the point M over the shade 24 can be emitted under the horizontal cut-off line through the projector lens 16 .
[0057] On the other hand, the ray A shown in FIG. 4 a that passes at the point M gets to the R surface 20 , and may be reflected on the R surface. The ray A can be emitted from the projector lens 16 as a ray emitted under the top edge 18 c , and therefore can be emitted on or slightly over the horizontal cut-off line through the projector lens 16 . Thus, the light that is reflected on the R surface 20 can basically form the continuous blur portion P on the horizontal cut-off line CL 1 -CL 3 . In this case, the nearer (smaller) the distance d is, the larger the ray forming the blur portion P is.
[0058] FIG. 5 is a graph showing a relation between an angle in a horizontal direction and a light intensity of a light distribution near the cut-off line with respect to projector headlights using the shade 18 as compared with the conventional shade 24 . When the conventional shade 24 is used, a slant of the light intensity becomes sharp near the cut-off line. When the shade 18 of the disclosed subject matter is used in the projector headlight 10 , the slant of the light intensity can become moderate near the horizontal cut-off line.
[0059] That is to say, the intensity of the light distribution pattern in accordance with the disclosed subject matter can be slightly decreased underneath the horizontal cut-off line as compared to that of the conventional light distribution pattern. In addition, the intensity of the light distribution pattern in accordance with the disclosed subject matter can be slightly increased on the horizontal cut-off line. Thus, the shade 18 of the disclosed subject matter can result in the continuous blur portion P near the horizontal cut-off line of the light distribution pattern.
[0060] The above-description assumes that both the top edge 18 c of the shade 18 and the top edge 24 c of the conventional shade 24 correspond to (are located substantially at) the focus F of the projector lens 16 . However, even when both top edges 18 c and 24 c do not correspond to the focus F of the projector lens 16 , the continuous blur portion P near the horizontal cut-off line can be formed by the R surface 20 that is provided underneath the top edge 18 c . Thus, the project headlight 10 of the disclosed subject matter can form the continuous blur portion P on the horizontal cut-off line CL 1 -CL 3 as shown in FIG. 3 b with the diffusing light that is reflected on the R surface 20 .
[0061] According to a vehicle headlight standard (for example, ECE Regulation), a maximum light intensity of H-V point (an intersection of the horizontal line H and the vertical line V shown in FIG. 3 a ) in front of a headlight is established so that the headlight is prevented from producing glare towards an oncoming car and/or pedestrian. When a central portion of the cut-off line in the light distribution pattern shown in FIG. 3 a is provided with the blur effect by the above-described R surface, the diffusing light reflected from the R surface may exceed the reference of the maximum light intensity due to an increase of the light intensity.
[0062] Therefore, the shade 18 can be made so as not to cause such a problem. For example, the R surface 20 can be designed so that the R surface is not formed near a part of the top edge 18 c that corresponds to such a region of the cut-off line, or so that the R surface having a small radius is formed near the part of the top edge 18 c . In addition, the R surface can be formed only within a prescribed range in order to be able to conform to a standard with regard to a light intensity of a cut-off line for a headlight.
[0063] FIG. 6 is a partial schematic enlarged view depicting another exemplary shade and is a perspective view from a front top of the shade 18 , which blurs the light intensity within the prescribed range of the cut-off line. The R surface 20 can be formed from 1 millimeter away from a point between the second and third top edge lines 18 c 2 and 18 c 3 , to 4 millimeters away from that point. Another R surface 22 that has a smaller radius than that of the R surface 20 can be formed out of the range of the above R surface 20 .
[0064] FIG. 7 is an explanatory schematic diagram showing a fundamental light distribution pattern formed by the shade 18 shown in FIG. 6 . A blur portion A corresponding to the above-described R surface 20 can be formed near a part of the cut-off line CL 1 . A radius of other R surface between the R surfaces 20 and 22 shown in FIG. 6 changes from the large radius of the R surface 20 to the small radius of the R surface 22 by certain degrees. A degree of the blur portion can be adjusted by the above-described structure carefully in accordance with a headlight standard.
[0065] FIG. 8 is a schematic cross-section view depicting another exemplary vehicle headlight of a projector type for a low beam made in accordance with principles of the disclosed subject matter. A projector headlight 30 for a low beam can include: a light source unit 33 including a light source 32 , a reflector 34 , a projector 36 and a shade 38 .
[0066] The light source 32 can be a high intensity discharge lamp (HID) lamp, a halogen bulb, etc. The reflector 34 can be located so as to cover the light source 32 . An inner surface of the reflector 34 can be configured with a reflex surface 34 a configured in a free surface shape based on a plurality of ellipsoidal reflex surfaces. Therefore, the reflex surface 34 a can be basically ellipsoidal having a first focus and a second focus, and the first focus can be located at substantially the light source 32 so that light emitted from the light source 32 can concentrate at the second focus through the reflex surface 34 a.
[0067] The second focus of the reflex surface 34 a can be located near a focus F of the projector lens 36 . Thus, an optical axis of the projector headlight 30 can substantially correspond to an optical axis of the projector lens 36 including the focus F, the light source 32 , and the first and second focus of the reflex surface 34 a . Light emitted from the light source 32 can be illuminated as an inverted light in a forward direction of the projector headlight 30 via the projector lens 36 .
[0068] The projector headlight 30 can include the shade 38 in order to shield an upward light that may give a glaring type light to an oncoming car and the like, and therefore can form the light distribution pattern PL for a low beam as shown in FIG. 3 a . The shade 38 can include a top surface 38 a , a front surface 38 b and a top edge 38 c that can be configured to form a cut-off line CL 1 -CL 3 on the light distribution pattern PL.
[0069] The shade 38 of the projector headlight 30 can be made of an aluminum material such as an aluminum die cast material, steel plate cold (SPC), etc. However, a surface treatment may not be carried out, unlike with the shade 18 in which surface treatment can be carried out. FIG. 9 a and FIG. 9 b are partial close-up side cross-section views showing another exemplary shade made in accordance with the disclosed subject matter and another conventional shade, respectively.
[0070] The conventional shade 44 shown in FIG. 9 b includes: a top surface 44 a ; a top edge being an end of the top surface 44 a ; and a front surface 44 b located substantially perpendicular to the top surface 44 a . A mark 44 C(F) shows a point on the top edge of the end of the top surface 44 a , and the top edge of the end of the top surface 44 a can form the horizontal cut-off line CL 1 -CL 3 in the light distribution pattern PL as shown in FIG. 3 a.
[0071] The shade 38 shown in FIG. 9 a can include a point 38 C (F) on the top edge corresponding to the point 44 C (F) shown in FIG. 9 b . The horizontal plate 38 b can extend toward the projector lens 16 from the top edge including the point 38 C(F), and R surface 40 can be configured in a circular arc shape and located between the top edge line and the front surface 38 b so as to extend along the top edge and the front surface 38 b 1 . A surface treatment for reflecting light may not be formed on the R surface 40 but rather a surface treatment for absorbing light can be formed on the R surface 40 . The R surface 40 can result in the continuous blur portion P as shown in FIG. 3 b.
[0072] More specifically, rays A, B and C may intersect with a point M shown in FIG. 9 b . The point M is located at a distances d away from the point 44 C (F) in an upwards direction of the point 44 C (F). The ray A emitted from the light source 32 intersects with the point M and passes over the point 44 C (F). The ray B intersects with the point M at an angle that is nearly equal to 0 degree with respect to the top surface 44 a , and passes over the point 44 C(F). If the top surface 44 a is formed with a reflex surface, the ray C may be reflected on the top surface 44 a and may pass at the point M.
[0073] In this case, when each of the shade 38 shown in FIG. 9 a and the shade 44 shown in FIG. 9 b is used as a shade, each of the rays B passes at the point M without contact with the shades 38 and 44 , respectively, and enters into the projector lens 36 . In this case, each of the rays B that passes over the shades 38 and 44 may be emitted toward the substantially same position under the horizontal cut-off line through the projector lens 36 , respectively.
[0074] However, each of the rays C gets to the shades 38 and 44 , and may be absorbed in the shades 38 and 44 without entering into the projector lens 36 , respectively. On the other hand, the ray A shown in FIG. 9 b that passes at the point M over the shade 44 can be emitted under the horizontal cut-off line through the projector lens 36 . However, the ray A shown in FIG. 9 a gets to the R surface 40 and may be absorbed in the shade 38 . Therefore, the shade 38 of the disclosed subject matter can decrease light emitted near the horizontal cut-off line by using the R surface 40 that is a non-reflex surface as compared with the other conventional shade 44 .
[0075] FIG. 10 is a graph showing a relation between an angle in a horizontal direction and a light intensity of a light distribution near a horizontal cut-off line with respect to projector headlights using the exemplary shade of FIG. 9 a and the conventional shade of FIG. 9 b . When the conventional shade 44 is used, a slant of the light intensity becomes sharp near the cut-off line. However, when the shade 38 of the exemplary embodiment is used in the projector headlight 10 , the slant of the light intensity can become moderate near the horizontal cut-off line.
[0076] That is to say, the intensity of the light distribution pattern in accordance with the disclosed subject matter can be slightly decreased underneath the horizontal cut-off line as compared to that of the conventional light distribution pattern. In addition, the intensity of the light distribution pattern can also be slightly increased on the horizontal cut-off line. Thus, the shade 38 of the disclosed subject matter can also allow forming of the continuous blur portion P near the horizontal cut-off line of the light distribution pattern because of the action in which light is absorbed on the R surface 40 .
[0077] The above description is set forth so that both the top edge point 38 C (F) of the shade 38 and the top edge point 44 C (F) of the conventional shade 44 correspond to the focus F of the projector lens 36 . However, even when both top edge points 38 C (F) and 44 C (F) do not correspond to the focus F of the projector lens 36 , the continuous blur portion P near the horizontal cut-off line can be formed by the R surface 40 that is provided underneath the top edge 38 c.
[0078] Thus, the projector headlight 10 of the disclosed subject matter can form the continuous blur portion P′ underneath a horizontal cut-off line CL 1 -CL 3 of a light distribution pattern PL as shown in FIG. 11 when the R surface 40 , which is a non-reflex surface, is used to absorb light. Furthermore, in the above-described exemplary embodiment, the R surface 40 can also be formed within a prescribed range as shown and described with respect to FIG. 6 .
[0079] A projector headlight using the LED light source and the shade 18 will now be given. The projector lens 16 and the shade 18 can be attached to a housing so that the neutral point of the shade 18 can be located substantially at the focus F of the projector lens 16 , and so that the top edge 18 c can be substantially bilaterally symmetric with respect to the optical axis of the projector lens 16 in the top view of the shade 18 .
[0080] At least one ellipsoidal reflector having the first focus and the second focus can be attached to the base board 19 so that the first focus thereof can be located substantially at the LED light source, which is mounted on the base board 19 . The at least one ellipsoidal reflector can be attached to the housing along with the base board 19 and projector lens 16 so that the optical axis of the LED light source can intersect with an imaginary line of the projector lens 16 that connects the first and second focuses of the ellipsoidal reflector to the optical axis of the projector lens 16 , substantially at the first focus of at least the ellipsoidal reflector so as to correspond to each other in a vertical direction.
[0081] In this case, when an intersecting angle of the optical axis of the LED light source and the imaginary line of the projector lens 16 towards the at least one ellipsoidal reflector is smaller than the intersecting angle towards the projector lens 16 , because a strong light near the optical axis of the LED light source can be reflected on a rearward part of the reflex surface 14 a that is located on the opposite side of the projector lens 16 , the projector headlight 10 can improve faraway or distance visibility.
[0082] In addition, second focuses of other ellipsoidal reflectors (other than the at least one ellipsoidal reflector) can be located substantially on the second top edge line 18 c 2 of the shade 18 and a virtual extending line of the second top edge line 18 c 2 . Thereby, the projector headlight 10 may not concentrate light emitted from the LED light source at a central portion of the horizontal cut-off line, and can form a favorable light distribution pattern with a wide range.
[0083] However, the above-described structure may make it difficult to control light between the first top edge line 18 c 1 and the virtual extending line of the second top edge line 18 c 2 , although such an ellipsoidal reflector may be easy to design and make. In addition, the structure may waste light in some cases because the second focuses of the ellipsoidal reflectors are located on the virtual extending line of the second top edge line 18 c 2 , which is located under the first top edge line 18 c 1 .
[0084] Consequently, the second focuses of the other ellipsoidal reflectors other than the at least one ellipsoidal reflector can be located substantially on the first top edge line 18 c 1 of the shade 18 and the second top edge line 18 c 2 . In this case, the projector headlight 10 can provide a favorable light distribution pattern having a wide range and a high efficiency. Thus, the disclosed subject matter can provide a small projector headlight using the LED light source having low power consumption and a high efficiency, which can be employed for vehicles such as an electric car and the like.
[0085] Various modifications of the above disclosed embodiments can be made without departing from the spirit and scope of the presently disclosed subject matter. For example, the above-described R surface of the shade may not be limited to the circular arc shape. Instead, various shapes such as a slanted planar surface, an ellipsoidal surface, a parabolic surface and the like can be used as the R surface.
[0086] While there has been described what are at present considered to be exemplary embodiments of the invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover such modifications as fall within the true spirit and scope of the invention. All conventional art references described above are herein incorporated in their entirety by reference. | A projector headlight for a low beam can include a light source, an ellipsoidal reflector, a projector lens and a shade. Light emitted from the light source can form a fundamental light distribution pattern from the projector lens via the ellipsoidal reflector by shielding an upward portion of the light with the shade. The shade can form a blurred part on a horizontal cut-off line using a radiused R surface between a top and front edge lines of the shade. Therefore, a contrasting difference between the upper and lower sides of the horizontal cut-off line can be reduced so as to be able to conform to a light distribution standard for a headlight. The R surface can be configured with a reflex surface or a non-reflex surface to match the light source. Thus, the projector headlight can perform a favorable light distribution pattern utilizing a simple structure. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 708,180 filed July 23, 1976 now U.S. Pat. No. 4,025,555.
BACKGROUND OF THE INVENTION
Virus infections which attack animals, including man, are normally contagious afflictions which are capable of causing great human suffering and economic loss. Unfortunately, the discovery of antiviral compounds is far more complicated and difficult than the discovery of antibacterial and antifungal agents. This is due, in part, to the close structural similarity of viruses and the structure of certain essential cellular components such as ribonucleic and deoxyribonucleic acids. Nevertheless, numerous non-viral "antiviral agents", i.e. substances "which can produce either a protective or therapeutic effect to the clear detectable advantage of the virus infected host, or any material that can significantly enhance antibody formation, improve antibody activity, improve non-specific resistance, speed convalescence or depress symptoms" [Herrman et al., Proc. Soc. Exptl. Biol. Med., 103, 625 (1960)], have been described in the literature. The list of reported antiviral agents includes, to name a few, interferon and synthetic materials such as amantadine hydrochloride, pyrimidines, biguanides, guanidine, pteridines and methisazone. Because of the rather narrow range of viral infections that can be treated by each of the antiviral agents commercially available at the present time, new synthetic antiviral agents are always welcomed as potentially valuable additions to the armamentarium of medical technology.
U.S. Pat. No. 3,906,044 discloses the antiviral activity of certain adamantyl amidine compounds of the formula: ##STR1## wherein n is 0 or 1, and Ad is adamantyl or bridgehead carbon atom-substituted alkyladamantyl. The antiviral activity of the compound N-[bis-phenyl-(2-methoxy-5-chloro-phenyl)-methyl]acetamidine is disclosed in British Patent No. 1,426,603.
SUMMARY OF THE INVENTION
It has now been found that certain novel benzamidine and N-substituted benzamidine compounds are capable of combating viral infections in vertebrate animals. The novel compounds of this invention have the formula ##STR2## and the non-toxic acid addition salts thereof wherein R 1 and R 2 are each alkyl of from twelve to twenty-four carbon atoms; and
R 3 is selected from the group consisting of hydrogen; alkyl of from one to six carbon atoms; alkenyl of from three to six carbon atoms; cycloalkyl of from three to eight carbon atoms; phenyl; phenylalkyl of from seven to nine carbon atoms; pyridyl; pyrimidyl; dimethlamino; ##STR3## --(CH 2 ) n CH 2 OH, --(CH 2 ) n SO 3 H, and --(CH 2 ) n CF 3 , wherein n is an integer of from one to six; and mono- and di-substituted phenyl wherein said substituents are selected from the group consisting of fluoro, chloro, bromo, hydroxyl, nitro, trifluoromethyl, alkyl and alkoxy of from one to three carbon atoms, dimethylamino, --N(CH 3 ) 3 + Cl - , --SO 2 NH 2 , ##STR4## wherein R 4 is alkyl of from one to three carbon atoms, provided that when said phenyl ring is di-substituted at least one of said substituents is selected from the group consisting of hydroxyl, alkyl and alkoxy of from one to three carbon atoms, and dimethylamino.
The invention disclosed herein comprises the novel antiviral compounds of formula I and the novel method of treating viral infections in vertebrate animals characterized by administration of a pharmaceutical composition containing an antivirally effective amount of a compound of formula I as the essential active ingredient.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of formula I exhibit prophylactic antiviral activity in vivo in vertebrate animals. It is probable that these compounds function as antiviral agents by virtue of their ability to induce the production of endogenous interferon, although the present invention is not to be construed as limited by such a theory.
By "non-toxic" acid addition salts is meant those salts which are non-toxic at the dosages administered. The non-toxic acid addition salts which may be employed include such water-soluble and water-insoluble salts as the hydrochloride, dihydrochloride, hydrobromide, phosphate, diphosphate, nitrate, sulfate, acetate, hexafluorophosphate, citrate, gluconate, benzoate, propionate, butyrate, sulfosalicylate, maleate, laurate, malate, fumarate, succinate, oxalate, tartrate, amsonate (4,4'-diaminostilbene-2,2'-disulfonate), pamoate (1,1'-methylene-bis-2-hydroxy-3-naphthoate), stearate, 3-hydroxy-2-naphthoate, p-toluenesulfonate, methanesulfonate, lactate, dilactate, and suramin salts.
One preferred group of the compounds of formula I consists of the hydrochloride, dihydrochloride, hydrobromide, dihydrobromide, phosphate, diphosphate, lactate, methanesulfonate and succinate salts of the bases of formula I.
Another preferred group of the compounds of formula I consists of those wherein R 1 and R 2 are both normal alkyl.
Another preferred group of the compounds of formula I consists of those wherein R 1 and R 2 are both normal alkyl and contain the same number of carbon atoms.
Another preferred group of the compounds of formula I consists of those wherein R 1 and R 2 are both n-hexadecyl.
Another preferred group of the compounds of formula I consists of those wherein R 1 and R 2 are both n-octadecyl.
Another preferred group of the compounds of formula I consists of those wherein the benzene ring of said formula is meta-substituted.
The preferred substituents for R 3 are hydrogen; alkyl of from one to three carbon atoms; allyl; phenylalkyl of from seven to nine carbon atoms; dimethylamino; ##STR5## --(CH 2 ) n --SO 3 H and --(CH 2 ) n CF 3 , wherein n is an integer of from one to three; and para-mono-substituted phenyl, wherein said substituent is selected from the group consisting of hydroxyl, methyl, methoxy, dimethylamino, --N(CH 3 ) 3 + Cl - and --SO 2 NH 2 .
Particularly valuable are the following compounds:
m-[N,N-di(n-hexadecyl)aminomethyl]-benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-(2-propyl)benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-(2,2,2-trifluoroethyl) -benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-allyl-benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-dimethylamino-benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-(p-hydroxyphenyl)-benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-(p-methoxyphenyl)-benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-methyl-benzamidine,
m-[N,N-di(n-hexadecyl)aminomethyl]-N-(p-dimethylaminophenyl)-benzamidine, and their non-toxic acid addition salts.
The compounds of this invention are prepared by methods familiar to those skilled in the art. The first step is generally the condensation of the appropriate α-[N,N-di(higher alkyl)amino]-toluonitrile with ethanthiol or ethanol in a hydrogen chloride saturated inert solvent such as chloroform to form the corresponding ethylthio-benzimidate or ethylbenzimidate dihydrochloride, as for example: ##STR6##
The second step is the reaction of H 2 NR 3 with the imidate. When R 3 is not hydrogen and H 2 NR 3 is not strongly basic, the second step of the preparation is the standard Pinner synthesis of amidines from imidates (Patai, S., ed., "The Chemistry of Amidines and Imidates", John Wiley and Sons, Inc., New York, 1975, pp. 283-341), i.e., the nucleophilic substitution of --NHR 3 for ethanthiol or ethanol in an inert solvent, e.g. chloroform, as for example: ##STR7## The reaction product is the desired N-substituted benzamidine.
When R 3 is not hydrogen and H 2 NR 3 is strongly basic, use of the standard synthesis described above yields the nitrile rather than the amidine. Efficient production of the amidine can be achieved, however, by pH control in the region 4-9 as e.g., with acetic acid or an acetic acid/sodium acetate buffer system as described in Examples 20-33.
Compounds of formula I wherein R 3 is hydrogen are prepared by condensation of the appropriate α-[N,N-di(higher alkyl)amino]toluonitrile with ethanol or ethanethiol in a hydrogen chloride saturated inert solvent such as dioxane to form the corresponding ethylbenzimidate or ethylthiobenzimidate dihydrochloride, followed by nucleophilic substitution with NH 3 and elimination of ethanol or ethanethiol, which is carried out in ammonia saturated ethanol. The reaction product is the desired [N,N-di(higher alkyl)aminomethyl]benzamidine.
The compounds wherein R 3 is --(CH 2 ) n SO 3 H, wherein n is an integer of from one to six, are prepared by condensation of the appropriate [N,N-di(higher alkyl)aminomethyl]benzamidine (i.e. R 3 ═ H) with the appropriate γ-sultone or the appropriate sulfonic acid in an inert solvent, e.g. 1,2-dichloroethane. The compounds wherein R 3 is ##STR8## are prepared in the same manner using oxalyl chloride and the appropriate benzamidine.
It is to be understood that any reaction-inert solvent may be used in place of chloroform, dioxane or 1,2-dichloroethane in any of the methods of preparation described above. The list of acceptable reaction solvents includes, but is not limited to, chloroform, dioxane, 1,2-dichloroethane, ethyl acetate and methylene chloride. Each of the reactions described above is typically performed at or near room temperature.
It is to be understood that any of the common procedures for amidine synthesis referred to in the literature reviews, such as Patai, S., ed., op. cit., arising from the appropriate intermediates such as imidates, thioimidates, iminoyl chlorides, thioamides, nitriles, amides or amidines, may be used to produce the compounds of this invention.
Acid addition salts of the bases of formula I may be prepared by conventional procedures such as by mixing the amidine compound in a suitable solvent with the required acid and recovering the salt by evaporation or by precipitation upon adding a non-solvent for the salt. Hydrochloride salts may readily be prepared by passing dry hydrogen chloride through a solution of the amidine compound in an organic solvent.
The α-[N,N-di(higher alkyl)amino]-toluonitriles used as starting materials may be prepared by contacting α-bromo-toluonitrile with an appropriate N,N-di(higher alkyl)amine in dimethylacetamide in the presence of potassium carbonate. α-Bromotoluonitrile is an article of commerce obtainable, for example, from Shawnee Chemicals. The N,N-di(higher alkyl)amine is obtained by refluxing a (higher alkyl)amine with the appropriate carboxylic acid in a suitable solvent such as xylene and then contacting the N-(higher alkyl)amine which is formed with sodium bis-(2-methoxyethoxy)-aluminum hydride in a suitable solvent such as benzene to produce the desired N,N-di(higher alkyl)amine. Sodium bis-(2-methoxy-ethoxy)aluminum hydride is an article of commerce obtainable, for example from Eastman Kodak Corporation as a 70% solution in benzene under the trade name of Vitride. As will easily be recognized by those skilled in the art, this procedure may be employed to prepare N,N-di(higher alkyl)amines in which the alkyl groups are either identical or different. If an N,N-di(higher alkyl)amine with identical alkyl groups is desired, a process comprising refluxing the mono-(higher alkyl)-amine in a suitable solvent such as toluene in the presence of Raney nickel catalyst to produce the desired N,N-di(higher alkyl)-amine may also be employed. This latter process is not in common use because tertiary amines, which are typically difficult to separate from the desired secondary amine product, are frequently formed. This problem is not serious, however, when the alkyl groups are higher alkyl (i.e., twelve to twenty-four carbon atoms), because of the apparent steric hindrance to tertiary amine formation afforded by the great bulk of the alkyl moieties and the ease of separating tertiary from secondary (higher alkyl)amines.
The antiviral activity of the compounds of formula I is determined by the following procedure. The test compound is administered to mice by the intraperitoneal route eighteen to twenty-four hours prior to challenging them with a lethal dose of encephalomyocarditis (EMC) virus. The survival rate is determined ten days after challenge and an ED 50 [dosage level (mg of compound/kg body weight) required to obtain a fifty percent survival rate] calculated. The procedure in which the drug is given eighteen to twenty-four hours before, and at a distinctly different site from, virus injection is designed to eliminate local effects between drug and virus and identify only those compounds which produce a systemic antiviral response.
Certain of the compounds of formula I were also tested for their ability to induce circulating interferon in mice after parenteral administration, using the procedure described by Hoffman, W. W. et al., Antimicrobial Agents and Chemotherapy, 3, 498-501 (1973).
Parenteral, topical and intranasal administration of the above-described amidines to an animal before exposure of the animal to an infectious virus provide rapid resistance to the virus. Such administration is effective when given as much as five days prior to exposure to the virus. Preferably, however, administration should take place from about three days to about one day before exposure to the virus, although this will vary somewhat with the particular animal species and the particular infectious virus.
When administered parenterally (subcutaneously, intramuscularly, intraperitoneally) the materials of this invention are used at a level of from about 1 mg./kg. of body weight to about 250 mg./kg. body weight. The favored range is from about 5 mg./kg. to about 100 mg./kg. of body weight, and the preferred range from about 5 mg. to about 50 mg./kg. of body weight. The dosage, of course, is dependent upon the animal being treated and the particular amidine compound involved and is to be determined by the individual responsible for its administration. Generally, small doses will be administered initially with gradual increase in dosage until the optimal dosage level is determined for the particular subject under treatment.
Vehicles suitable for parenteral injection may be either aqueous such as water, isotonic saline, isotonic dextrose, Ringer's solution, or non-aqueous such as fatty oils of vegetable origin (cottonseed, peanut oil, corn, sesame) and other non-aqueous vehicles which will not interfere with the efficacy of the preparation and are non-toxic in the volume or proportion used (glycerol, ethanol, propylene glycol, sorbitol). Additionally, compositions suitable for extemporaneous preparation of solutions prior to administration may advantageously be made. Such compositions may include liquid diluents, for example, propylene glycol, diethyl carbonate, glycerol, sorbitol.
When the materials of this invention are administered, they are most easily and economically used in a dispersed form in an acceptable carrier. When it is said that this material is dispersed, it means that the particles may be molecular in size and held in true solution in a suitable solvent or that the particles may be colloidal in size and dispersed through a liquid phase in the form of a suspension or an emulsion. The term "dispersed" also means that the particles may be mixed with and spread throughout a solid carrier so that the mixture is in the form of a powder or dust. This term is also meant to encompass mixtures which are suitable for use as sprays, including solutions, suspensions or emulsions of the agents of this invention.
In practicing the intranasal route of administration of this invention any practical method can be used to contact the antiviral agent with the respiratory tract of the animal. Effective methods include administration of the agent by intranasal or nasopharyngeal drops and by inhalation as delivered by a nebulizer or an aerosol. Such methods of administration are of practical importance because they provide an easy, safe and efficient method of practicing this invention. For intranasal administration of the agent, usually in an acceptable carrier, a concentration of agent between 1.0 mg./ml. and 100 mg./ml. is satisfactory. Concentrations in the range of about 30 to 50 mg./ml. allow administration of a convenient volume of material.
For topical application the antiviral agents are most conveniently used in an acceptable carrier to permit ease and control of application and better absorption. Here also concentrations in the range of from about 1.0 mg./ml. to about 250 mg./ml. are satisfactory. In general, in the above two methods of administration a dose within the range of about 1.0 mg./kg. to about 250 mg./kg. of body weight and, preferably, from about 5.0 mg./kg. to about 50 mg./kg. of body weight will be administered.
The compounds employed in this invention may be employed alone, i.e., without other medicinals, as mixtures of more than one of the herein-described compounds, or in combination with other medicinal agents, such as analgesics, anesthetics, antiseptics, decongestants, antibiotics, vaccines, buffering agents and inorganic salts, to afford desirable pharmacological properties. Further, they may be administered in combination with hyaluronidase to avoid or, at least, to minimize local irritation and to increase the rate of absorption of the compound. Hyaluronidase levels of at least about 150 (U.S.P.) units are effective in this respect although higher or lower levels can, of course, be used.
Those materials of this invention which are water-insoluble, including those which are of low and/or difficult solubility in water, are, for optimum results, administered in formulations, e.g., suspensions, emulsions, which permit formation of particle sizes of less than about 20μ. The particle sizes of the formulations influence their biological activity apparently through better absorption of the active materials. In formulating these materials various surface active agents and protective colloids are used. Suitable surface active agents are the partial esters of common fatty acids, such as lauric, oleic, stearic, with hexitol anhydrides derived from sorbitol, and the polyoxyethylene derivatives of such ester products. Such products are sold under the trademarks "Spans" and "Tweens," respectively, and are available from ICI United States Inc., Wilmington Del. Cellulose ethers, especially cellulose methyl ether (Methocel, available from the Dow Chemical Co., Midland, Mich.) are highly efficient as protective colloids for use in emulsions containing the materials of this invention.
The water-soluble materials described herein are administered for optimum results in aqueous solution. Typically they are administered in phosphate buffered saline. The water-insoluble compounds are administered in formulations of the type described above or in various other formulations as previously noted. Dimethylsulfoxide serves as a suitable vehicle for water-insoluble compounds. A representative formulation for such compounds comprises formulating 25 to 100 mg. of the chosen drug as an emulsion by melting and mixing with equal parts of polysorbate 80 and glycerin to which hot (80° C.) water is added under vigorous mixing. Sodium chloride is added in a concentrated solution to a final concentration of 0.14 M and sodium phosphate, pH 7, is added to a final concentration of 0.01 M to give, for example, the following representative composition.
______________________________________ mg./ml.______________________________________Drug 50.0Polysorbate 80 50.0Glycerin 50.0Sodium Phosphate Monobasic Hydrous 1.4Sodium Chloride 7.9Water 842.0 1001.3______________________________________
In certain instances, as where clumping of the drug particles occurs, sonication is employed to provide a homogeneous system.
The following examples illustrate the invention but are not to be construed as limiting the same.
EXAMPLE 1
Ethyl-m-[N,N-di(n-hexadecyl)aminomethyl]-benzimidate Dihydrochloride
A mixture of α-[N,N-di(n-hexadecyl)amino]-m-toluonitrile (29.0 g., 0.05 mole), ethanol (40 ml., 0.67 mole) and dioxane (100 ml.) was saturated with dry hydrogen chloride gas for 40 minutes at 15°-25° C. It was then stoppered and held overnight at room temperature. Thin layer chromatography analysis (4:1, benzene:ethanol on silica gel) indicated complete reaction of the nitrile. The mixture was evaporated in vacuo yielding the named product quantitatively as a foam [35.0 g., ˜ 100% yield, R f .87 (4:1, benzene: ethanol on silica gel)].
EXAMPLE 2
m-[N,N-Di-(n-hexadecyl)aminomethyl]-benzamidine
Ethyl-m-[N,N-di(n-hexadecyl)aminomethyl]-benzimidate dihydrochloride (35.0 g., 0.05 mole) was dissolved in ethanol (150 ml.) and the mixture saturated with ammonia gas at 20° C. The mixture was held for three hours at 20° C., resaturated with ammonia gas at 20° C., and then stoppered and held overnight at room temperature. The mixture was evaporated in vacuo to a solid which was triturated with acetone (200 ml.), filtered, washed with water (4 × 100 ml.), triturated again with acetone (2 × 100 ml.), filtered and dried in vacuo overnight [22.0 g., 74% yield, R f 0.42 (4:1, benzene:ethanol on silicic acid)]. The crude product was recrystallized from hot acetone (20.9 g., 70% yield, m.p.-forms a gel at 84° C.).
EXAMPLE 3
m-[N,N-Di(n-hexadecyl)aminomethyl]-N-(n-propane)sulfonic acid-benzamidine
m-[N,N-Di(n-hexadecyl)aminomethyl]-benzamidine (1.196 g., 2.0 mmoles) was added to a solution of 3-hydroxy-1-propanesulfonic acid-γ-sultone (244 mg., 2.0 mmoles) dissolved in 1,2-dichloroethane (15 ml.). The mixture was held for 18 hours at room temperature. It was then diluted to 300 ml. with ethyl acetate-ether (2:1), washed with 1N HCl (3 × 50 ml.), washed with saturated aqueous sodium chloride solution (3 × 50 ml.), dried (Na 2 SO 4 ) and evaporated in vacuo to an oil. The oil was crystallized from 1,2-dimethoxyethane/acetonitrile [531 mg., 35% yield, R f 0.35 (4:1, benzene:ethanol on silicic acid), m.p.-forms a gel at 87°-95° C.].
EXAMPLE 4
m-[N,N-Di(n-hexadecyl)aminomethyl]-N-oxoacetic acid-benzamidine
In like manner to that described in Example 3 the compound m-]N,N-di-(n-hexadecyl)aminomethyl]-N-oxoacetic acid-benzamidine was prepared by using oxalyl chloride as starting material and a reaction time of 1.5 hours. The oil was crystallized from 1,2-dimethoxyethane [34% yield, R f 0.31 (4:1, benzene:ethanol on silicic acid), m.p.-forms a gel at 97°-105° C.].
EXAMPLE 5
Ethyl-m-[N,N-di(n-hexadecyl)aminomethyl]-thiobenzimidate Dihydrochloride
A mixture of α-[N,N-di(n-hexadecyl)amino]-m-toluonitrile (23.2 g., 0.04 mole), ethanthiol (6.0 ml., 0.08 mole) and chloroform (100 ml.) was saturated with dry hydrogen chloride for 30 minutes at 20°-25° C. It was then stoppered and held for six days at 5° C. The mixture was evaporated in vacuo to a foam which was crystallized by trituration with 1,2-dimethoxyethane. The crude product was recrystallized from hot 1,2-dimethoxyethane/chloroform [24.9 g., 88% yield, R f 0.79 (4:1, benzene:ethanol on silicic acid), m.p. 109°-111° C.].
EXAMPLE 6
m-[N,N-Di(n-hexadecyl)aminomethyl]-N-(p-methoxyphenyl)-benzamidine
A mixture of ethyl-m-[N,N-di(n-hexadecyl)aminomethyl]-thiobenzimidate dihydrochloride (1.074 g., 1.5 mmoles), p-anisidine (369 mg., 3.0 mmoles) and chloroform (10 ml.) was held at room temperature for sixteen hours. It was then diluted to 400 ml. with chloroform, washed with 1N HCl (2 × 50 ml.), dried (Na 2 SO 4 ) and evaporated in vacuo to a foam. The foam was crystallized from 1,2-dimethoxyethane [868 mg., 73% yield, R f 0.64 (4:1, benzene:ethanol on silicic acid), m.p.-forms a gel at 84°-86° C.].
EXAMPLES 7-19
In like manner to that described in Example 6 the following compounds were prepared by using appropriate reactants (H 2 N-R 3 ) in place of p-anisidine: ##STR9##
__________________________________________________________________________Example Reaction CrystallizationNumberR.sub.3 Time (hrs.) Yield (%) Solvent System.sup.a M.P. (°C) R.sub.f.sup.b__________________________________________________________________________ 16 88 DME 86-88.sup.d .508 ##STR10## 16 88 DME 135-137 .479 ##STR11## 16 73 DME 164-167 .6910 ##STR12## 16 67 DME 156-157 .7311 ##STR13## 48 19 DME/CH.sub.3 CN 85-87.sup.d .8312 ##STR14## 48 59 DME/CHCl.sub.3 125.sup.d .2413 ##STR15## 48 62 DME 152-154 .7614 ##STR16## 3 83 DME 167 .3715 ##STR17## 48 68 DME 91-92.sup.d .6916 ##STR18## 48 89 DME/CHCl.sub.3 164.sup.d .7817 ##STR19## 36.sup.c 8 DME 128.sup.d .7018 ##STR20## 0.5 90 DME 167-169 .5519 ##STR21## 48 15 Acetone 75.sup.d .69__________________________________________________________________________ .sup.a DME.tbd.1,2-dimethoxyethane; CH.sub.3 CN.tbd.acetonitrile; CHCl.sub.3 .tbd.chloroform .sup.b 4:1, benzene:ethanol on silicic acid .sup.c reaction carried out at reflux .sup.d forms a gel
EXAMPLE 20
m-[N,N-Di(n-hexadecyl)aminomethyl]-N-cyclopentyl-benzamidine
Ethyl-m-[N,N-di(n-hexadecyl)aminomethyl]-thiobenzimidate dihydrochloride (1.074 g., 1.5 mmoles) was added to a solution of cyclopentylamine (255 mg., 3.0 mmoles), glacial acetic acid (0.3 ml., 5.3 mmoles) and chloroform (10 ml.). The mixture was held for 72 hours at room temperature. It was then diluted to 300 ml. with chloroform, washed with saturated aqueous sodium bicarbonate solution (3 × 50 ml.), washed with saturated aqueous sodium chloride solution (3 × 50 ml.), dried (Na 2 SO 4 ) and filtered. The filtrate was acidified with a 10% solution of anhydrous hydrogen chloride in dioxane (5 ml.) and then evaporated in vacuo to an oil. The oil was crystallized from warm 1,2-dimethoxyethane [850 mg., 77% yield, R f 0.30 (4:1, benzene:ethanol on silicic acid), m.p.-forms a gel at 78° C.].
EXAMPLES 21-27
In like manner to that described in Example 20 the following compounds were prepared by using appropriate reactants (H 2 N-R 3 ) in place of cyclopentylamine: ##STR22##
__________________________________________________________________________Example Reaction Yield CrystallizationNumberR.sub.3 Time (hrs.) (%) Solvent System.sup.a M.P. (° C) R.sub.f.sup.b__________________________________________________________________________21 48 28 DME 172-176 .7522 ##STR23## 1.5 88 DME 154-157 .3723 N(CH.sub.3).sub.2 16 23 DME/CH.sub.3 CN 82.sup.d .3824 CH.sub.2 CHCH.sub.2 16 77 DME/CH.sub.3 CN 70.sup.d .2925 CH(CH.sub.3).sub.2 48 55 DME 95.sup.d .3026 CH.sub.2 CH.sub.3.sup.c 72 84 DME 91.sup.d .2227 CH.sub.3.sup.c 72 90 DME 106.sup.d .18__________________________________________________________________________.sup.a - DME .tbd. 1,2-dimethoxyethane; CH.sub.3 CN .tbd. acetonitrile.sup.b - 4:1, benzene:ethanol on silicic acid.sup.c - ethylamine (methylamine)bubbled as a gas into acetic acid:chloroform solution.sup.d - forms a gel
EXAMPLE 28
m-[N,N-Di(n-hexadecyl)aminomethyl]-N-(2,2,2-trifluoroethyl)-benzamidine
Ethyl-m-[N,N-di(n-hexadecyl)aminomethyl]-thiobenzimidate dihydrochloride (1.074 g., 1.5 mmoles) was added to a slurry of 2,2,2-trifluoroethylamine hydrochloride (406 mg., 3.0 mmoles) and anhydrous sodium acetate (246 mg., 3.0 mmoles) in chloroform (10 ml.) and glacial acetic acid (0.3 ml., 5.3 mmoles). The mixture was held for 12 hours at room temperature. It was then diluted to 300 ml. with chloroform, washed with saturated aqueous sodium bicarbonate solution (2 × 50 ml.), washed with saturated aqueous sodium chloride solution (2 × 50 ml.), dried (Na 2 SO 4 ) and filtered. The filtrate was acidified with a 10% solution of anhydrous hydrogen chloride in dioxane (5 ml.) and then evaporated in vacuo to a foam. The foam was recrystallized from 1,2-dimethoxyethane [974 mg., 86% yield, R f 0.39 (4:1, benzene:ethanol on silicic acid), m.p.-forms a gel at 125°-127° C.].
EXAMPLES 29-33
In like manner to that described in Example 28 the following compounds were prepared by using appropriate reactants (H 2 N-R 3 ·HCl) in place of 2,2,2-trifluoroethylamine hydrochloride: ##STR24##
__________________________________________________________________________Example Reaction Yield CrystallizationNumberR.sub.3 Time (hrs.) (%) Solvent System.sup.a M.P. (° C) R.sub.f.sup.b__________________________________________________________________________29 24 57 DME 77-79.sup.c .4330 ##STR25## 48 60 DME/CH.sub.3 CN 115-118.sup.c .4631 ##STR26## 16 29 DME 238.sup.c .6032 ##STR27## 3 55 DME/CHCl.sub.3 163-166 .0033 ##STR28## 24 40 DME/water 140.sup.c .27__________________________________________________________________________.sup.a - DME .tbd. 1,2-dimethoxyethane; CH.sub.3 CN .tbd. acetonitrile;CHCl.sub.3 .tbd. chloroform.sup.b - 4:1, benzene:ethanol on silicic acid.sup.c - forms a gel
EXAMPLES 34-35
In like manner to that described in Examples 3-4 the following compounds may be prepared by using appropriate reactants in place of 3-hydroxy-1-propanesulfonic acid-γ-sultone:
______________________________________ ##STR29##ExampleNumber R.sub.3 Reactant______________________________________34 CH.sub.2 SO.sub.3 H iodosulfonic acid35 (CH.sub.2).sub.6 SO.sub.3 H 6-hydroxy-1-hexanesulfonic acid-ζ-sultone______________________________________
EXAMPLES 36-74
In like manner to that described in Examples 6-19 the following compounds may be prepared by using appropriate reactants (H 2 N-R 3 ) in place of p-anisidine: ##STR30##
______________________________________ExampleNumber R.sub.5______________________________________36 2-fluoro37 3-fluoro38 2-chloro39 3-chloro40 2-bromo41 3-bromo42 4-bromo43 2-hydroxyl44 3-hydroxyl45 2-nitro46 4-nitro47 2-trifluoromethyl48 3-trifluoromethyl49 4-trifluoromethyl50 2-methyl51 3-methyl52 2-n-propyl53 3-ethyl54 4-isopropyl55 2-methoxy56 3-methoxy57 2-n-propyloxy58 3-ethoxy59 4-isopropyloxy60 2-dimethylamino61 3-dimethylamino62 2-SO.sub.2 NH.sub.263 3-SO.sub.2 NH.sub.264 2-(CO)OCH.sub.365 3-(CO)OCH.sub.366 4-(CO)OCH.sub.367 2-(CO)O(CH.sub.2).sub.2 CH.sub.368 3-(CO)OCH.sub.2 CH.sub.369 4-(CO)OCH(CH.sub.3).sub.270 2-SO.sub.2 CH.sub.371 3-SO.sub.2 CH.sub.372 2-SO.sub.2 CH(CH.sub.3).sub.273 3-SO.sub.2 (CH.sub.2).sub.2 CH.sub.374 4-SO.sub.2 CH.sub.2 CH.sub.3______________________________________
EXAMPLES 75-92
In like manner to that described in Examples 6-19 the following compounds may be prepared by using appropriate reactants (H 2 N-R 3 ) in place of p-ansidine:
______________________________________ ##STR31##ExampleNumber R.sub.6 R.sub.7______________________________________75 chloro methyl76 trifluoromethyl methoxy77 bromo dimethylamino78 chloro dimethylamino79 methyl methyl80 methyl methoxy81 2-propyl dimethylamino82 methoxy dimethylamino83 1-propyloxy SO.sub.2 (CH.sub.2).sub.2 CH.sub.384 ethyl SO.sub.2 NH.sub.285 ethoxy (CO)OCH(CH.sub.3).sub.286 1-propyl (CO)OCH.sub.387 dimethylamino dimethylamino88 2-propyloxy dimethylamino89 dimethylamino SO.sub.2 NH.sub.290 dimethylamino SO.sub.2 CH.sub.391 dimethylamino (CO)OCH.sub.392 dimethylamino (CO)O(CH.sub.2).sub.2 CH.sub.3______________________________________
examples 93-98
in like manner to that described in Examples 20-27 the following compounds may be prepared by using appropriate reactants (H 2 N-R 3 ) in place of cyclopentylamine:
______________________________________ ##STR32##ExampleNumber R.sub.3______________________________________93 n-hexyl94 2-butenyl95 2-hexenyl96 cyclopropyl97 cyclooctyl98 phenyl (1-propyl)______________________________________
EXAMPLE 99-103
In like manner to that described in Examples 28-33 the following compounds may be prepared by using appropriate reactants (H 2 NR 3 .HCl) in place of 2,2,2-trifluoroethylamine hydrochloride:
______________________________________ ##STR33##ExampleNumber R.sub.3______________________________________ 99 (CH.sub.2).sub.2 OH100 (CH.sub.2).sub.7 OH101 (CH.sub.2).sub.6 CF.sub.3102 ##STR34##103 ##STR35##
EXAMPLES 104-112
In like manner to that described in Examples 28-33 the following compounds may be prepared by using appropriate reactants (H 2 NR 3 .HCl) in place of 2,2,2-trifluoroethylamine hydrochloride:
______________________________________ ##STR36##ExampleNumber R.sub.6 R.sub.7______________________________________104 hydroxyl chloro105 hydroxyl methoxy106 hydroxyl dimethylamino107 hydroxyl SO.sub.2 NH.sub.2108 hydroxyl (CO)OCH.sub.3109 hydroxyl N(CH.sub.3).sub.3.sup.+ Cl.sup.-110 N(CH.sub.3).sub.3.sup.+ Cl.sup.- methyl111 N(CH.sub.3).sub.3.sup.+ Cl.sup.- dimethylamino112 hydroxyl ethyl______________________________________
EXAMPLE 113
Antiviral Activity of m-[N,N-di(n-hexadecyl)aminomethyl]-N-allylbenzamidine Dihydrochloride
Three groups of ten female albino mice (20-25 g. body weight) were given single 0.5 ml. intraperitoneal injections containing dosage levels of 1.5, 5, and 15 mg. of the named compound/kg. body weight, respectively. A fourth control group was given no such injection. Eighteen to twenty-four hours later all four groups were challenged with a 0.2 ml. subcutaneous injection containing 20-30 times the LD 50 , the dosage level causing a 50% death rate in ten days, of encephalomyocarditis (EMC) virus. The following survival data were recorded for the following ten days:
______________________________________Dosage Levelof Named Number of Survivors on Day NumberCompound 0 1 2 3 4 5 6 8 9 10 S.sub.r______________________________________15 mg./kg. 10 10 10 10 9 8 8 8 8 8 8 80 5 10 10 10 10 10 6 6 6 5 5 5 53 1.5 10 10 10 10 9 5 4 2 2 2 1 19 0 (control) 10 10 10 9 3 1 1 0 0 0 0 --______________________________________ 3
Antiviral activity is expressed as the relative survival (S r ) in experimental groups compared to the controls on the tenth day after challenge. S r is defined by the formula ##EQU1## wherein S r = relative survival
S x = percent survival after ten days in experimental group
x i = number of survivors on the ith day in experimental group
e i = number of survivors on the ith day in control group The ED 50 [dosage level (mg. of compound/kg. body weight) required to obtain a fifty percent survival rate] is determined graphically by plotting S r (ordinate) vs. ln dosage level (abscissa) and then fitting the points with a line of predetermined slope by least squares. The dosage level at which this fitted line has an ordinate of 50 is equivalent to the ED 50 .
This graphical method was used to determine an ED 50 for the named compound of 4.7 mg. (as dihydrochloride salt)/kg.
EXAMPLES 114-143
In like manner to that described in Example 113 the antiviral activity was determined for the compounds listed below.
______________________________________Example Compound Prepared inNumber Example Number ED.sub.50 (mg./kg.).sup.a______________________________________114 2 4.7115 3 8.0116 4 9.9117 6 5.3118 7 12.3119 8 16.0120 9 7.7121 10 49.3122 11 35.7123 12 4.9124 13 21.6125 14 8.0126 15 38.0127 16 7.0128 17 12.9129 18 17.9130 19 8.9131 20 27.3132 21 47.5133 22 7.8134 23 5.0135 25 2.8136 26 7.6137 27 5.7138 28 3.8139 29 6.9140 30 7.7141 31 11.7142 32 7.4143 33 37.2______________________________________ .sup.a all as mg. dihydrochloride salt except for Example 115 (mg. free base)
EXAMPLE 144
Ability of m-[N,N-di(n-hexadecyl)aminomethyl]-N-(p-hydroxyphenyl)-benzamidine to Induce Circulating Interferon
A quantity of the named compound was fused with equal weights of polysorbate 80 and glycerol. The mixture was then homogenized in hot 0.14 M NaCl containing 0.01 sodium phosphate, pH 7 (PBS). The resulting oil-in-water emulsion was readily diluted with PBS.
Female Swiss mice (20-25 g. body weight) were injected (intraperitoneal) with an amount of the above diluted emulsion containing 25 mg. of the named compound/kg. body weight. Eight, twelve, sixteen and twenty hours after injection samples of plasma were withdrawn from the mice. These samples were then serially diluted. L-929 mouse fibroblasts were incubated on microtiter plates with aliquots of the various samples of serially diluted plasma for eighteen hours at 37° C. The fibroblast monolayers were then washed with protein-free medium and challenged with 10-40 times the TCID 50 , the dose in which 50% of the cultures are infected, of vesicular stomatitis virus (VSV). The virus was allowed to absorb for one hour at 37° C. before addition of 0.2 ml. of maintenance medium. The cultures were scored and analyzed about twenty-four to forty-eight hours later and the plasma interferon level, the reciprocal of the plasma dilution at which fifty percent of the cultures are protected, determined. The following data were obtained.
______________________________________Plasma Interferon Levels (units/ml.)Time (hrs.) after Injection8 12 16 20______________________________________102 276 143 76______________________________________
EXAMPLES 145-150
In like manner to that described in Example 144 the ability to induce circulating interferon was determined for the compounds listed below.
______________________________________ Plasma Interferon Levels (units/ml.)Example Compound Prepared Time (hrs.) after InjectionNumber in Example Number 8 12 16 20______________________________________145 2 76 116 56 48146 24 26 60 110 102147 25 <17 114 34 154148 27 37 95 100 71149 28 38 160 126 49150 30 66 87 61 64______________________________________
EXAMPLE 151
Compounds wherein R 1 and R 2 are not both n-(hexadecyl) and/or the phenyl ring of formula I is not meta-substituted may be prepared in like manner as described in Examples 1-33 for the corresponding m-[N,N-di(n-hexadecyl)] compounds by using the appropriate starting materials, and tested for antiviral activity in like manner as described in Example 113. | Novel [N,N-di(higher alkyl)aminomethyl]benzamidine and substituted compounds such as [N,N-di(higher alkyl)aminomethyl]-N-(2-propyl)-benzamidine and [N,N-di(higher alkyl)aminomethyl]-N-(p-hydroxyphenyphenyl)-benzamidine and their non-toxic acid addition salts are useful for combating viral infections in vertebrate animals. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention is related to the field of perpendicular magnetic recording (PMR) on magnetic recording hard disk drive systems and, in particular, to fabricating a stitched wrap around shield for a PMR write head.
[0003] 2. Statement of the Problem
[0004] Magnetic hard disk drive systems typically include a magnetic disk, a recording head having write and read elements, a suspension arm, and an actuator arm. As the magnetic disk is rotated, air adjacent to the disk surface moves with the disk. This allows the recording head (also referred to as a slider) to fly on an extremely thin cushion of air, generally referred to as an air bearing. When the recording head flies on the air bearing, the actuator arm swings the suspension arm to place the recording head over selected circular tracks on the rotating magnetic disk where signal fields are written to and read by the write and read elements, respectively. The write and read elements are connected to processing circuitry that operates according to a computer program to implement write and read functions.
[0005] In a disk drive utilizing perpendicular recording, data is recorded on a magnetic recording disk by magnetizing the recording medium in a direction perpendicular to the surface of the disk. In this type of recording, the magnetic easy axes of the magnetic grains which store the recorded data are arranged perpendicular to the disk surface, instead of parallel to the disk surface as is the case in longitudinal recording. Perpendicularly recorded data is more stable than longitudinal data, and the data can be recorded at a higher density than longitudinal data. The coercivity of the medium is higher, since the magnetic recording layer is in effect “inside the gap” between the head and a soft underlayer (SUL) that is located under the magnetic layer. In addition, for the same read head design, perpendicular data provides greater read back amplitude. The disk has a higher magnetic moment-thickness product (MrT). For the same physical width of the read head, the magnetic read width is narrower.
[0006] High track density heads use narrow write pole widths. A sufficiently short flare length (i.e., the distance between the ABS and the point where the write pole flares out) is used to maintain the write field strength of a narrow track width perpendicular write head. As a result, the widened portion of a write pole behind the flare point is close to the recording medium and can produce undesired fields to the extent that the data in adjacent tracks may be erased. A balance between writeability and adjacent track interference (ATI) is needed for high track density perpendicular write heads.
[0007] Wrap around shield designs are utilized for high track density recording to shield adjacent tracks from unintended recording. FIG. 1 illustrates an ABS view of a typical write head 100 with a wrap around shield 120 . As shown in FIG. 1 , wrap around shield 120 has a trailing shield 122 placed in the proximity of the trailing surface 112 of the write pole 110 , separated from write pole 110 by a gap 135 . The function of trailing shield 122 is to improve the write field gradient and transition curvature of write pole 110 . Wrap around shield 120 also has side shields 124 and 126 disposed on sides of write pole 110 . Side shields 124 and 126 are separated from write pole 110 by a gap 130 . Utilizing wrap around shield 120 , the fringe fields are mostly confined between write pole 110 and side shields 124 and 126 and therefore the fringe fields create much less interference with adjacent tracks. Gap 135 is smaller than gap 130 , and the thickness for both is important for proper write performance, and thus, there is a need for accurately controlling the thickness of trailing gap 135 and side gap 130 during manufacturing.
[0008] In prior art processes, trailing shield 122 and side shields 124 and 126 are fabricated at the same time. As a result, the manufacturing process focuses more on the alignment of trailing shield 122 with write pole 110 than the alignment of side shields 124 and 126 with write pole 110 . This is because the tolerance of aligning trailing shield 122 with write pole 110 is less than the tolerance of aligning side shields 124 and 126 with write pole 110 . Further, prior art processes lack flexibility and require very aggressive design points, such as flare point and shield throat height, which are challenging for processing control during manufacture. Further, fabrication is more difficult because of the topography caused by present fabrication methods.
SUMMARY OF THE SOLUTION
[0009] Embodiments of the invention solve the above and other related problems with improved methods for fabricating write heads. More specifically, a wrap around shield of a write head is fabricated in multiple processes, with side shields fabricated in one process, and a trailing shield formed in another process. These multiple processes form a stitched wrap around shield, with the side shields and trailing shield magnetically coupled. Advantageously, the gap between the side shields and the write pole may be accurately defined in one process, and the gap between the trailing shield and the write pole may be accurately defined in a separate process. As a result, the wrap around shield is more accurately aligned with the write pole.
[0010] Further, the shapes and sizes of the trailing shield and side shields can be independently made and controlled to balance writeability, saturation, and adjacent track interference (ATI) of the write head. The trailing shield and the corresponding gap may be accurately defined on a more relatively flat surface. The placement of the side shields is easier and more accurately controlled compared to prior art wrap around shield fabrication processes, which focus more on the placement of the trailing shield.
[0011] Further, a notch may be formed in the trailing shield gap and the trailing shield. A perpendicular head with a notched wrap around shield structure has less transition curvature and better writeability. The reduced transition curvature is due to the modification of the main pole field contour by the notched top write gap. The better writeability of the recording head is a result of less flux shunting to the shield.
[0012] An embodiment of the invention is a method for forming a stitched wrap around shield of a write head. The method comprises forming a write pole of the write head. The method further comprises forming side shield gap structures on side regions of the write pole. The side shield gap structures may be formed by depositing a first layer of non-magnetic material. The method further comprises forming side shields on side regions of the write pole above the side shield gap structures. The side shield gap structures define a first gap separating the write pole and the side shields. The method further comprises removing portions of the first layer of non-magnetic material above the write pole. The method further comprises forming a trailing shield gap structure above the write pole, and forming a trailing shield of the write head. The trailing shield gap structure defines a second gap separating the write pole and the trailing shield, and the second gap is less than the first gap. Advantageously, the method allows the side shields and trailing shield to be formed separately, resulting in more accurate alignment of the shields with respect to the write pole, and independent sizes and shapes of the side shields and trailing shield.
[0013] The invention may include other exemplary embodiments described below.
DESCRIPTION OF THE DRAWINGS
[0014] The same reference number represents the same element or same type of element on all drawings.
[0015] FIG. 1 illustrates an ABS view of a write head with a wrap around shield.
[0016] FIG. 2 illustrates a flow chart of a prior art method for fabricating the write head of FIG. 1 .
[0017] FIGS. 3-11 illustrate cross sectional views of a prior art write head of FIG. 1 during fabrication according to the method of FIG. 2 .
[0018] FIG. 12 illustrates a method for fabricating a write head with a stitched wrap around shield in an exemplary embodiment of the invention.
[0019] FIGS. 13-18 illustrate cross sectional views of a write head fabricated according to the method of FIG. 12 in an exemplary embodiment of the invention.
[0020] FIG. 19 illustrates a method for fabricating a write head with a stitched wrap around shield in another exemplary embodiment of the invention.
[0021] FIGS. 20-29 illustrate cross sectional views of a write head fabricated according to the method of FIG. 19 in an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 2 illustrates a flow chart of a prior art method 200 for fabricating the write head 100 of FIG. 1 . FIGS. 3-11 illustrate cross sectional views of a prior art write head 100 during fabrication according to method 200 of FIG. 2 . The steps of method 200 will be described in reference to write head 100 illustrated in FIGS. 3-11 .
[0023] In step 202 , laminated layers 304 of a write pole (e.g., write pole 110 of FIG. 1 ) are deposited on an insulator layer 302 (see FIG. 3 ). A hard masking layer 306 (such as Alumina) is deposited above laminated layers 304 . In step 204 , a photoresist mask structure 308 is formed (see FIG. 4 ) using a photolithographic process. In step 206 , a reactive ion etching (RIE), ion milling, or reactive ion milling process is then performed to remove exposed portions of masking layer 306 not protected by photo resistive layer 308 to form hard mask structure 306 (see FIG. 5 ). In step 208 , an ion milling process is performed to define write pole 110 (see FIG. 6 ). In step 210 , a stripping process removes photoresist layer 308 (see FIG. 7 ).
[0024] In step 212 , a gap thickness of a wrap around shield 120 (see FIG. 1 ) is defined around write pole 110 . First, a layer of non-magnetic material 802 (such as atomic layer deposition (ALD) Alumina) is deposited (see FIG. 8 ). Ion milling removes non-magnetic material 802 above hard mask 306 (see FIG. 9 ). Gaps are defined around write pole 110 , with the side shield gap 130 (see FIG. 1 ) being the thickness of the layers of ALD Alumina 802 , and the trailing shield gap 135 (see FIG. 1 ) being the thickness of the layer of Alumina mask 306 . In step 214 , an electroplating process is performed to fabricate wrap around shield 120 (see FIG. 10 ). CMP is performed to planarize a top surface of write head 100 .
[0025] FIG. 11 illustrates a top view of write head 100 after completion of step 212 . Trailing shield 122 is disposed on a trailing edge of write pole 110 . Below trailing shield 122 are side shields 124 and 126 on each side of write pole 110 . Side shields 124 and 126 drape from trailing shield 122 , and the dimensions of side shields 124 and 126 are determined by the dimensions of trailing shield 122 . Thus, write head 100 fabricated according to method 200 does not provide flexible control of independent sizes and shapes of trailing shield 122 and side shields 124 and 126 . As previously discussed, method 200 may not be adequately flexible to form gaps and shields of write head 100 to achieve desired writing performances. The processing control is also challenging during manufacture. The subsequently described methods of fabricating a stitched wrap around shield solves the previously described problems and other problems encountered in fabrication of write head 100 .
[0026] FIGS. 12-29 and the following description depict specific exemplary embodiments of the invention to teach those skilled in the art how to make and use the invention. For the purpose of teaching inventive principles, some conventional aspects of the invention have been simplified or omitted. Those skilled in the art will appreciate variations from these embodiments that fall within the scope of the invention. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific embodiments described below, but only by the claims and their equivalents.
[0027] FIG. 12 illustrates a method 1200 for fabricating a write head with a stitched wrap around shield in an exemplary embodiment of the invention. FIGS. 13-18 illustrate cross sectional views of a write head 1300 fabricated according to method 1200 of FIG. 12 in an exemplary embodiment of the invention. The steps of method 1200 will be described in reference to write head 1300 illustrated in FIGS. 13-18 . The steps of method 1200 may not be all-inclusive, and may include other steps not shown for the sake of brevity.
[0028] Step 1202 comprises forming a write pole 1304 (see FIG. 13 ) above insulator layer 1302 using hard mask 1306 (e.g., Alumina material) of write head 1300 . Step 1204 comprises forming side shield gap structure 1402 (see FIG. 14 ) of write head 1300 . Side shield gap structure 1402 may be formed by depositing one or more layers of non-magnetic material (such as ALD Alumina). The deposition thickness of the layers of non-magnetic material may correspond to the desired side shield gap thickness of write head 1300 . The resulting structure of write head 1300 is illustrated in FIG. 14 .
[0029] Step 1206 comprises ion milling to remove a top portion of the non-magnetic material (e.g. side shield gap structure 1402 ) to form a trailing shield gap 1306 , and to remove a bottom portion of the non-magnetic material to allow subsequently formed side shields to cover write pole 1304 (see FIG. 15 ).
[0030] Step 1208 comprises forming side shields 1602 (see FIG. 16 ) of write head 1300 . Side shields 1602 may be formed through an electroplating process, and a CMP process may be used to planarize side shields 1602 to mask structure 1306 . The resulting structure of write head 1300 is illustrated in FIG. 16 .
[0031] Step 1210 comprises forming a trailing shield 1702 (see FIG. 17 ). Trailing shield 1702 may be formed through an electroplating process. A CMP process may be used to planarize trailing shield 1702 to a desired height. The resulting structure of write head 1300 is illustrated in FIG. 17 .
[0032] FIG. 18 illustrates a top view of write head 1300 after completion of step 1210 . Trailing shield 1702 is disposed on a trailing edge of write pole 1304 . Below trailing shield 1702 is a side shield 1602 on each side of write pole 1304 . Side shields 1602 don't drape from trailing shield 1702 like the side shields of write head 100 in FIG. 11 . Advantageously, write head 1300 of FIGS. 17-18 has a side shield gap defined by side shield gap structure 1602 and a trailing shield gap defined by mask structure 1306 . These gaps are of different widths and more accurately aligned with write pole 1304 . Also, the dimensions of side shields 1602 are determined independently of the dimensions of trailing shield 1702 and are more flexibly controlled, as are the dimensions of trailing shield 1702 .
[0033] FIG. 19 illustrates a method 1900 for fabricating a write head with a stitched wrap around shield in another exemplary embodiment of the invention. FIGS. 20-29 illustrate cross sectional views of a write head 2000 fabricated according to method 1900 of FIG. 19 in an exemplary embodiment of the invention. The steps of method 1900 will be described in reference to write head 2000 illustrated in FIGS. 20-29 . The steps of method 1900 may not be all-inclusive, and may include other steps not shown for the sake of brevity.
[0034] Step 1902 comprises forming a write pole 2004 (see FIG. 20 ) of write head 2000 . Write pole 2004 may be formed over an insulator layer 2002 in a similar manner as described in steps 202 to 208 of method 200 of FIG. 2 . The laminated layers may be AFC CoFe/Cr/CoFe/CrNi. The stripping process may be performed in multiple steps, such as a Tetra-methyl ammonium hydroxide (TMAH) etching process, an N-methyl pyrrolidinone (NMP) stripping process, and an O 2 RIE process to remove the photoresist mask. As such, a hard mask Alumina structure 2006 may be present above write pole 2004 after the write pole definition process is completed. The resulting structure of write head 2000 is illustrated FIG. 20 .
[0035] Step 1904 comprises depositing one or more layers of non-magnetic material to define a side gap of write pole 2004 . First, a layer of non-magnetic material 2102 (see FIG. 21 ) may be deposited, such as ALD Alumina.
[0036] In step 1906 , an Ar ion milling process is performed to remove non-magnetic material 2102 above hard mask layer 2006 on top of write pole 2004 . The ion milling process may be performed at an angle between 45-60 degrees using SIMS end point detection, such as an angle of 55 degrees. The ion milling process end point may be controlled by detecting Ta, Ti, and Si if hard mask structure 2006 comprises a TaO 2 layer, a TiO 2 layer, or a SiO 2 layer above a hard mask Alumina layer. The ion mill process also removes the bottom regions of non-magnetic material 2102 on each side of write pole 2004 to allow subsequently formed side shields to cover write pole 2004 . The resulting structure of write head 2000 is illustrated in FIG. 22 .
[0037] In step 1908 , a layer of non-magnetic material 2302 (see FIG. 23 ) may be deposited, such as an Rh layer, which acts as a seed layer for electroplating the side shields as well as a stop layer during a subsequent CMP process. Multiple layers may form non-magnetic material 2102 , such as 5 nm of Ta, 15 nm of Rh and 5 nm of CoFe. The Ta acts as an adhesion layer, the Rh acts as an electroplating seed and a CMP stop layer, and the CoFe acts as a photo adhesion promotion layer for an electroplating process. The resulting structure of write head 2000 is illustrated in FIG. 23 .
[0038] Step 1910 comprises depositing side shield material 2402 (see FIG. 24 ). Side shield material 2402 may be deposited using an electroplating process with non-magnetic layer 2302 (e.g., an electroplating seed layer). CMP is performed on side shield material 2402 down to non-magnetic layer 2302 (e.g., the CMP stop layer) to planarize side shield material 2402 and form side shields 2402 . Non-magnetic material 2302 may act as both an electroplating seed layer and a CMP stop layer for the CMP process. For electroplating seed layer purposes, non-magnetic material 2302 may be Rh, Ru, or Au. For CMP stop layer purposes, Rh provides better properties than Ru, and Ru provides better properties than Au. Side shields 2402 are separated from write pole 2004 by a side gap defined by non-magnetic material 2102 and non-magnetic material 2302 . The side gap may be between about 20 nm and about 200 nm. The resulting structure of write head 2000 is illustrated in FIG. 24 .
[0039] Step 1912 comprises ion milling to remove non-magnetic material 2302 above hard mask layer 2006 on write pole 2004 . An Ar ion milling process controlled by SIMS end-point detection of mask structure 2006 may be used to remove non-magnetic material 2302 above hard mask layer 2006 . For example, the ion milling process may detect Ta, Ti, and Si if hard mask structure 2006 comprises a TaO 2 layer, a TiO 2 layer, or a SiO 2 layer on a hard mask Alumina layer. An RIE process may be performed, if necessary, to remove the TaO 2 layer, the TiO 2 layer, or the SiO 2 layer on a hard mask Alumina layer 2006 . The ion milling process may also form a notch in write head 2000 after removing non-magnetic material 2302 above hard mask Alumina layer 2006 . The resulting structure of write head 2000 is illustrated in FIG. 25 .
[0040] Step 1914 comprises depositing a layer of non-magnetic material 2602 (see FIG. 26 ), which acts as an electroplating seed layer. Step 1916 comprises milling to remove portions of non-magnetic material 2602 from each side region of write pole 2004 using a patterned photo mask to fabricate contacts in non-magnetic material 2602 on each side of write pole 2004 . The contacts allow contact between side shields 2402 and a trailing shield. The resulting structure of write head 2000 is illustrated in FIG. 27 .
[0041] Step 1918 comprises forming a trailing shield 2802 (see FIG. 28 ) above non-magnetic material 2602 (i.e., above a trailing surface of write pole 2004 ). Trailing shield 2802 may be formed by depositing trailing shield material using an electroplating process, and performing CMP to planarize the trailing shield material to a desired height to form trailing shield 2802 . Trailing shield 2802 is separated from write pole 2004 by a second gap defined by a thickness non-magnetic material 2602 and a thickness of hard mask Alumina layer 2006 . The trailing gap may be between about 10 nm and about 50 nm. The resulting structure of write head 2000 is illustrated in FIG. 28 . The notch which may be formed in trailing shield gap structure 2602 (see above write pole 2004 in FIG. 28 ) achieves better transition curvature and less flux shunting to the stitched wrap around shield for better writeability of write head 2000 .
[0042] FIG. 29 illustrates a top view of write head 2000 after completion of step 1914 . Trailing shield 2802 is disposed on a trailing edge of write pole 2004 . Below trailing shield 2802 is a side shield 2402 on each side of write pole 2004 . Side shields 2402 don't drape from trailing shield 2802 like the side shields of write head 100 in FIG. 11 . Thus, the dimensions of side shields 2402 advantageously are determined independently of the dimensions of trailing shield 2802 and are more flexibly controlled, as are the dimensions of trailing shield 2802 .
[0043] Although specific embodiments were described herein, the scope of the invention is not limited to those specific embodiments. The scope of the invention is defined by the following claims and any equivalents thereof. | A wrap around shield of a write head is fabricated in multiple processes, with side shields fabricated in one process, and a trailing shield formed in another process. These multiple processes form a stitched wrap around shield, resulting in more flexible and accurate placement of the trailing shield and side shields with respect to the write pole. These processes also independently form the dimensions (shapes and sizes) of the side shields and the trailing shield which allows better control of writeability, saturation, and adjacent track interference of the perpendicular recording write head. | 8 |
FIELD OF THE INVENTION
The present invention relates to sewing machines and, more particularly, to sewing machines adapted to sew binding material onto carpet edges.
BACKGROUND OF THE INVENTION
Carpet binding machines are used to sew binding material, or tape, to the top and bottom of a piece of carpet to bind the edge of the carpet. Oftentimes, in a wall-to-wall carpet installation, a four or six inch strip of contrasting carpet will be used as coving instead of wood or rubber cove molding. In such an installation, the upper edge of the carpet cove needs binding material sewn thereon to present a finished appearance and so that the edge does not unravel. The stitch utilized by most carpet binding machines is the federal stitch type 401 chain stitch because of its streamlined appearance and effective binding capability.
Carpet binding machines are generally classified as being portable or stationary. Stationary machines are heavy, often weighing between 55 and 65 pounds. The weight of such machines forces them to be used at a single location, for example, in a carpet installer's warehouse, to sew binding material onto a carpet edge. While such machines tend to be durable, their lack of portability limits their usefulness in situations where the carpeting cannot be precut into appropriate length pieces for the job and bound in the installer's warehouse. Also, such stationary machines tend to be costly compared to their portable counterparts.
Portable carpet binding machines have the advantage of being capable of being transported and used at installation sites by installers. They do not require the carpeting to be precut and prebound as with a stationary machine and are lower in cost than stationary machines. However, the durability and reliability of most prior art portable carpet binding machines has been unsatisfactory.
Portable carpet binding machines are manufactured by modifying a standard household sewing machine. While such sewing machines are suitable for sewing clothes and similar light fabrics, subjecting such machines to the rigors of sewing carpeting characterized by heavy backing material and a plush pile results in an undesirable rate of skipped or otherwise malformed stitches, carpet feed problems, or even sewing machine breakdowns.
A skipped or malformed stitch can be corrected at the installation site. However, because such problems recur with frequency, oftentimes taking the time to restitch a piece of carpet can result in substantial delays and inconvenience.
A skipped stitch may occur in a type 401 stitch sewing cycle, for example, if the needle loop is not properly formed and the looper misses the opening of the needle loop as a result. Because portable carpet binding machines typically use a plastic needle thread, there is a greater tendency for the needle thread to flex in an unpredictable manner and, therefore, create unpredictable sewing results. Oftentimes, a single skipped stitch will cause the succeeding stitch to be missed because the previously improperly formed needle loop generates additional slack in the needle thread making it difficult to form the next needle loop. A series of missed stitches can cause an unsightly gap in the stitching of the binding material and a risk of the carpet edge unraveling.
A malformed stitch may occur, for example, if there is too much slack in the needle thread or looper thread. A household sewing machine incorporates thread take-up mechanisms to remove slack in the threads. These thread take-up mechanisms, however, are not designed to be used in a portable carpet binding machine. Some prior art portable carpet binding machines that modify such household sewing machines fail to adequately modify the thread take-up mechanism, which, in turn, can cause such malformed stitches.
A malformed stitch can also occur when the piece of carpet is not fed properly through the sewing machine. Portable carpet binding machines that are made from a modified household sewing machine utilize what is known in the art as a presser foot and feed-dog to feed the carpet. It has been found that this single feed assembly is unsatisfactory for feeding a piece of carpet. Furthermore, the rigors of carpet binding may subject components of the machine to undue stress and cause excessive wear or failure in the components.
Since most carpet installers can only afford a single carpet binding machine, a breakdown of the machine requires the installer to quit working on the installation, take the machine to a repair shop, procure needed repairs and then return to the installation site to finish the job. The downtime of a portable carpet binding machine, whether due to restitching or repairing, results in downtime of the installer in addition to the expense of repair of the machine. Since most installers are paid by the job, downtime has a direct impact on the number of jobs completed by the installer and his or her net income.
Because of the thickness and stiffness of the carpet being bound, another problem with prior art carpet binding machines is their tendency to pull or angle away from the carpet edge while the machine moves along the carpet. This is typically caused by an insufficient carpet feeding assembly and results in poor appearance of the resulting bound carpet edge. When the binding machine angles away from the carpet edge as is moves along the carpet, the stitching and binding material are angled with respect to the edge of the carpet. Moreover, instead of the binding material being snugly pulled and stitched around the edge of the carpet, excess binding material gathers loosely around the carpet edge providing an unsightly appearance and poor durability.
One portable carpet binding machine that represented a significant advance in the art was the machine disclosed in U.S. Pat. No. 5,875,723 to Lobur. The '723 patent is incorporated herein in its entirety by reference. The '723 patent disclosed a portable carpet binding machine that included a novel carpet feeding assembly with a feed driver mechanism and coacting puller mechanism acting in synchronization to pull the carpet through the sewing mechanism.
While the carpet binding machine disclosed in the '723 patent proved to be a lightweight, yet rugged and durable machine, certain improvements were desirable to further improve the feed drive mechanism such that even the heaviest and thickest carpet would be pulled linearly through the sewing mechanism and the machine would not tend to pull away from the edge of the carpet.
What is needed is a portable carpet binding machine that is adapted to sewing light or heavy pile carpeting and that includes a carpet feeding assembly that feeds the carpet linearly through a sewing assembly and that moves the machine uniformly along an edge of the carpet. What is further desired is an upper direct drive mechanism within close proximity to the existing puller mechanism, wherein the upper direct drive mechanism is capable of vertical movement to compensate for varying thicknesses in the carpet material. It is desirable to accomplish such vertical movement of the upper drive mechanism through a direct connection with a minimal number of parts, such as universal joints, linkages, and bushings, which increase the cost of the machine and decrease efficiency. What is also needed is a portable carpet binding machine that is lightweight and that is more durable and reliable than prior art portable carpet binding machines. Such a machine must also be easy to manufacture and repair and be competitively priced with prior art portable carpet binding machines.
SUMMARY OF THE INVENTION
The present invention is directed to a portable carpet binding machine that is adapted to bind binding material, or tape, to the edge of light or heavy carpeting. The portable carpet binding machine is durable, lightweight (weighing about 18 pounds) and is easy to manufacture using known manufacturing techniques. Its design also facilitates easy repair of worn out or damaged working components of the machine.
The portable carpet binding machine includes a housing defining an interior region. The housing supports two rolls of thread and a coil of binding material. A distal end of the first roll of thread is threaded through a needle of the sewing assembly while a distal end of the second roll of thread is threaded through a looper of the sewing assembly. The binding material is sewn to the top and bottom to bind the edge of the piece of carpet using a chain stitch known as a federal stitch type 401 double locked chain stitch to those skilled in the art.
The housing is supported on rollers permitting the machine to move with respect to a stationary piece of carpet to be bound. Alternately, if the piece of carpet to be bound is relatively small, the carpet binding machine may be held stationary and the carpet fed through the machine.
Extending from the housing is also a handle to aid in positioning the machine as desired and carrying the machine between locations at an installation site. The housing supports a finger trigger switch for activating the drive mechanism. Advantageously, the trigger switch can be locked into an “on” position and a microswitch is provided for actuating the machine when carpet is fed into the sewing assembly.
A drive mechanism is supported by the housing and at least partially disposed in the interior region. A prime mover is operatively coupled to the drive mechanism for providing motive power to the drive mechanism. In the preferred embodiment, the prime mover comprises an AC 60 watt series motor. In the preferred embodiment, a potentiometer is operative to vary the speed of the prime mover and, consequently, the speed of the drive mechanism.
The drive mechanism drives a sewing assembly. The sewing assembly is operative to sew a strip of material to a piece of carpet. The sewing assembly includes a binder guide, a sewing needle and a looper. The binder guide operates to fold the strip of material around an edge portion of the piece of carpet. A first piece of thread is threaded through an aperture of the needle and a second piece of thread is threaded through an aperture of the looper. The sewing assembly, when driven by the drive mechanism, is operative to stitch the strip of material to opposite sides of the edge portion of the piece of carpet using the first and second pieces of thread.
The present invention also includes a carpet feeding assembly. The carpet feeding assembly includes a feed driver mechanism and a coacting puller mechanism that operate in substantially synchronous movement to linearly feed the piece of carpet relative to the sewing assembly. The feed driver mechanism includes a feed-dog that is driven by the drive mechanism and that intermittently engages the bottom of the piece of carpet, which, in turn, advances the piece of carpet forward.
The coacting puller mechanism includes a first feed roller disposed above the feed-dog so that the piece of carpet is engaged between the feed-dog and the first feed roller when the carpet is advanced. The first feed roller is biased by a spring to provide a downward force against the top of the piece of carpet. The second feed roller is driven by the drive mechanism to pull the piece of carpet forward substantially simultaneously with respect to advancement of the piece of carpet by the feed-dog.
The coacting puller mechanism further includes a second feed roller located downstream of the feed-dog. Like the first feed roller, the second feed roller is driven by the drive mechanism. The second feed roller engages the bottom of the piece of carpet and pulls the piece of carpet forward substantially simultaneously with respect to the advancement by the feed-dog and the first feed roller.
The coacting puller further includes a presser roller, which is disposed above the second driven roller. The presser roller provides a downward force opposite the second feed roller so that the piece of carpet is engaged therebetween. A spring biases the presser roller downwardly.
The first and second feed rollers also comprise a helical profile on their outer surface. The helical profile advantageously produces a force that pulls the carpet inward relative to the sewing assembly. The helical profile increases the quality of the stitch, as well reduces the effort required by the operator of the carpet binding machine in maintaining a linear feed of the carpet into the machine.
The first feed roller and feed-dog are driven by a single piece drive mechanism that comprises an integral first and second eccentric cams for advancing the carpet through the sewing assembly. Such integral configuration help reduce breakdowns in the equipment while increasing the quality of the stitching. The single piece drive mechanism further comprises a third eccentric cam that is removably attached to the shaft that is used to drive the second feed roller.
Additional features will become apparent and a fuller understanding obtained by reading the following detailed description made in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view with a cut-away portion of the portable carpet binding machine of the present invention shown sewing binding material to a strip of carpeting;
FIG. 2 is a front elevation view of the portable carpet binding machine of FIG. 1 showing upper and lower feed rollers;
FIG. 3 is a left side view, partly in section and partly in elevation, of the portable carpet binding machine of FIG. 1 showing a drive mechanism for an upper feed roller
FIG. 4 is a left side view, partly in section and partly in elevation, of the portable carpet binding machine of FIG. 1 showing a drive mechanism for a lower feed roller;
FIG. 5A is a front view, partly in section and partly in elevation, of the portable carpet binding machine of FIG. 1 showing a rocker arm that drives the lower feed roller;
FIG. 5B is a front view, partly in section and partly in elevation, of the portable carpet binding machine of FIG. 1 showing a unidirectional clutch and a rocker arm that drives the lower feed roller shaft;
FIG. 5C is a sectional view of the portable carpet binding machine of FIG. 1 showing the drive mechanism for the upper feed roller;
FIG. 6 is a perspective view of a single piece drive shaft of the portable carpet binding machine of FIG. 1 that drives a feed-dog and upper and lower feed rollers;
FIG. 7A is an elevation view of a looper drive mechanism of the portable carpet binding machine found in the prior art in a first position; and
FIG. 7B is an elevation view of the looper drive mechanism of the portable carpet binding machine of FIG. 1 in a second position.
DETAILED DESCRIPTION
A portable carpet-binding machine of the present invention is shown generally at 10 in FIG. 1 . To describe the features of the present invention the illustrated embodiment shows a Newlong Model NP-3II portable bag-closing machine with modifications thereto. However, it should be understood by those skilled in the art that the present invention is adaptable to any type of sewing machine.
The machine 10 is shown binding a cut edge 11 of a piece of carpet 12 . The binding process involves sewing a binding material 14 to the top 15 and bottom 16 of the piece of carpet 12 so that the binding material 14 overlies the cut edge 11 of the piece of carpet 12 . Typically, the binding material 14 is ⅞ inch wide but can vary from ¾ inch to 3 inches. The carpeting 12 is a strip four to six inches in width. Such a carpet strip 12 is used for coving in a wall-to-wall carpet installation, but it should be understood that the machine 10 will function to sew binding material to a peripheral edge of any size piece of carpet 12 .
The machine 10 includes a housing 20 and an AC motor 22 attached to and extending from the housing 20 . A drive belt 34 is driven by a pulley shaft 36 of the motor 22 . The housing 20 supports a driven pulley 38 and a handle 30 used to position the machine 10 and carry the machine 10 between job locations.
The housing 20 supports a drive mechanism 40 that includes the driven pulley 38 and a single piece drive shaft 46 affixed to the pulley 38 . As can be seen in FIGS. 3 and 4 , the drive shaft 46 is supported near its front 41 and rear 42 by bushings 51 , 52 . The single piece drive mechanism 40 is driven by the motor 22 (shown in FIG. 1 ) via drive belt 34 and pulley 38 and provides motive power to a sewing assembly generally designated as reference character 100 ( FIG. 1 ), and a carpet feeding assembly generally designated as reference character 200 ( FIGS. 3 and 4 ).
A detailed drawing of the single piece drive shaft 46 is shown in FIG. 6 . The drive shaft 46 preferably is turned from a single piece of bar stock and formed integrally on the shaft is a first eccentric cam 43 and second eccentric cam 44 . Because of the position of the first and second cams 43 , 44 being exterior to or outside of the region between the bushings 51 , 52 , the drive shaft 46 of the present invention advantageously is a one piece drive shaft. By contrast, in prior art drive shafts, at least one of the cams was in the region between the shaft bushings and, therefore, in order to remove the drive mechanism 40 from housing 20 , the cam between the bushings had to be capable of being disengaged from the shaft.
Because the design of the present invention locates first eccentric cam 43 to the outside of bushing 52 , that is, toward a front F of the machine 10 , a single piece shaft drive mechanism can be used. The single piece shaft drive mechanism is advantageous in several respects. First, single piece shaft drive mechanism avoids timing problems often seen in the prior art because the single piece design will not have cams held in place by set screws which are prone to becoming loosened over time with the vibration of the machine. Second, space saving resulting from the relocation of the first eccentric cam 43 outside of the bushings advantageously permits two motor driven puller mechanisms 201 , 221 to the feeding assembly 200 instead of a single puller mechanism utilized in the prior art. The addition of a second puller mechanism insures a linear feed of the carpet through the sewing assembly 100 regardless of the thickness of the carpet and mitigates the tendency of the carpet 12 to pull away from the machine 10 (or the machine to pull away from the carpet) as the machine 10 is progresses along the edge 11 of the carpet 12 to sew the binding material 14 to overlie the carpet edge 11 .
The sewing assembly 100 includes a sewing needle 102 for introducing a needle thread 103 , a binder guide 104 for introducing binding material 14 , and a looper 106 (shown in FIG. 1 and FIG. 7 ) for introducing a looper thread 107 . The threads 103 , 107 are supplied via a needle thread spool 122 and a looper thread spool 124 , respectively (see FIG. 1 ).
As can be seen in FIG. 1 , the sewing needle 102 is connected to a reciprocating rod 108 mounted in an extending arm portion 24 of the housing 20 . The rod 108 effects upward and downward movement of the needle 102 . Reciprocal motion of the rod 108 is driven and controlled by a lever and connecting rod assembly (not shown) driven by the drive mechanism 40 . In operation, one revolution of the drive mechanism 40 effects a full upward and downward stroke, or cycle, of the sewing needle 102 .
In operation, as the carpet 12 is advanced by the carpet feeding assembly 200 (partially shown in FIGS. 2 , 3 , and 4 ), the sewing assembly 100 operates to stitch the binding material 14 simultaneously to a top 15 and a bottom 16 of the piece of carpet 12 by what is known in the art as a type 401 double locked chain stitch.
The carpet feeding assembly 200 includes the two coacting puller mechanisms, generally indicated as reference characters 201 and 221 and a feed-dog 240 , which operate in synchronized movement to feed the piece of carpet 12 relative to the sewing assembly 100 .
The presence of two coacting puller mechanisms 201 and 221 provide significant advantages over the single puller mechanism of the prior art. Both puller mechanisms 201 and 221 act cooperatively with one another and the feed-dog 240 to pull the carpet 12 through the sewing assembly 100 . One of the advantages of having two puller mechanisms 201 and 221 is that the carpet can be more easily fed through the sewing assembly 100 , reducing the number of malformed stitches. The operator also expends less energy making said operator more productive during the sewing operation. Yet another benefit is the reduction in stress on the components of the feeding assembly, resulting in a decrease in breakdowns, loosening of detail connections, and a reduction in the number of service calls.
FIG. 4 shows the lower coacting puller mechanism 201 . The puller mechanism 201 includes a bottom-mounted or lower motor-driven feed roller 203 with a helical profile 214 , a rocker shaft 204 , and a rocker arm 211 comprising a cam follower path 213 . Mounted on the extending upper arm 24 of the housing 20 is a presser roller 202 . The presser roller 202 is biased downwardly, via a spring 205 , against the upper surface 15 of the carpet 12 . The carpet 12 is firmly gripped or engaged between the upper presser roller 202 and the bottom-mounted feed roller 203 . The lower feed roller 203 is downstream, that is, the direction D in FIG. 2 , of the feed-dog 240 and the upper puller mechanism 221 and it rotates in synchronization with movement of the feed-dog 240 and rotation of the upper puller mechanism 221 to feed the carpet 12 through the sewing assembly 100 , which is fed by rotation of the lower feed roller 203 .
As the lower feed roller 203 rotates, the presser roller 202 rotates in a direction opposite the lower feed roller 203 , and both rollers in a coacting fashion pull the carpet 12 through the sewing assembly 100 . A presser roller adjusting mechanism 206 maintains a predetermined amount of down force on the presser roller 202 .
The lower feed roller 203 is fixedly attached to a rocker shaft 204 and comprises a helical profile 214 . The rocker shaft is supported near its front 207 and rear 208 by bushings 209 and 210 respectively. The motor driven roller 203 is intermittently rotated by the rocker arm 211 . When viewed in FIG. 5B , the counterclockwise rotation of the first eccentric cam 43 generates both clockwise and counterclockwise rotation of the rocker arm 211 . The uni-directional clutch 212 is fixedly attached to the rocker arm 211 , which engages the rocker shaft 204 when rotated counterclockwise and disengages the rocker shaft when rotated clockwise, as depicted by the arrows in FIG. 5B .
Rocker arm 211 comprises a cam follower 213 that engages the first eccentric cam 43 . The clockwise and counterclockwise rotation of the rocker arm 211 is a result of the profile of the first eccentric cam 43 and the configuration of the cam follower 213 . Modification of the first eccentric cam 43 or the cam follower 213 will change the amount of rotation resulting in the rocker arm 211 . Because of the uni-directional clutch 212 , the rocker shaft 204 is intermittently rotated in a counterclockwise direction as described above. The bottom mounted roller 203 is fixedly attached to the rocker shaft 204 , which also rotates intermittently in a counterclockwise direction. The counterclockwise rotation of the lower feed roller 203 pulls the carpet 12 by engaging the carpet bottom 16 . Facilitation of the pulling process occurs through the synchronized rotation of the lower feed roller 203 and the clockwise rotation of the presser roller 202 , on the carpet 12 therebetween. The presser roller 202 engages the top portion 15 of the carpet 12 . The spring 205 asserts an axial force downward through the presser roller 202 onto the carpet 12 , thereby ensuring the engagement of both the presser roller and the lower feed roller 203 to the carpet as its pulled through the sewing assembly 100 . The amount of axial downward force can be varied through a presser roller adjusting mechanism 206 .
As can best be seen in FIG. 4 , the lower feed roller 203 and the top mounted presser roller 202 include a helical profile or outer surface 214 and 217 , respectively. The exemplarily embodiment shows the helical profile of 214 to resemble a left-handed thread configuration and helical profile 217 comprises a right-handed configuration. This forces the carpet 12 to be drawn inward, that is, in the direction I in FIGS. 3 and 4 , relative to the carpet feeding assembly 200 because of the axially-transverse thrust generated by the left-handed helical profile 214 , and the counterclockwise rotation of the bottom mounted motor driven roller 203 along with the axially-transverse thrust generated by the right-handed helical profile 217 , and the clockwise rotation of the top mounted presser roller 202 . The helical profiles then reduce the amount of effort required by the operators during the sewing process, since the carpet 12 has a tendency to pull away from the sewing assembly 100 during sewing as the machine 10 moves along the carpet edge 11 . The feed roller profiles used by the prior art resemble a spur or spline configuration, which exacerbates the carpet's tendency to pull away from the machine, because of such profiles inherent lack of resistance. In addition, the prior art lacks the axially transverse thrust generated by the described invention. The helical profiles 214 and 217 can also contain breaks in the threads resembling crenellated rows or teeth along a left-hand or right-handed thread path.
The coacting puller mechanisms 201 and 221 are not only designed to achieve proper kinematic motion, but also to operate harmoniously with other linkages, levers, cams, shafts, and followers within a limited amount of space defined by the housing 20 . The described invention makes best use of the limited space through the unique designs of the rocker arm 211 , uni-directional clutch 212 , cam follower 213 , and first eccentric cam 43 located between the internal housing flange 21 , as shown in FIG. 4 , and the feed-dog 240 and lifter 241 shown in FIG. 3 .
The design of the present invention advantageously provides a ⅜ inch cavity to accommodate the location of the rocker arm 211 and the first eccentric cam 43 . The design was accomplished without the need of any additional linkages or universal joints. The present invention maintains the configuration of the feed-dog 240 and feed-dog lifter 241 disclosed in the '723 patent. This reduces the cost of production by using standard components. Yet another advantage of the present invention is that it incorporates a direct drive between the second eccentric cam 44 and feed-dog lifter 241 , thus preventing any loss of motion that would occur through the use of additional linkages or universal joints.
Relocating coacting puller mechanism 201 toward the front F of the housing 20 not only permits a single piece drive mechanism 40 , but also enables the addition of the second upper coacting puller mechanism 221 to the mid-section 54 of the single piece drive mechanism 40 , as shown in FIGS. 3 and 4 . The upper coacting puller mechanism further reduces the amount of effort expended by the operator during a sewing operation, since the carpet 12 can now be more easily fed through the sewing assembly 100 . As well, there is a reduction in the opposing forces on the components of the puller mechanisms, thereby making the details less susceptible to breaking or working loose. In addition, the second motor driven puller mechanism 221 reduces carpet slippage and the malformed stitches, which would result from such slippage.
Referring more closely to FIGS. 3 , 5 A, and 5 C the upper coacting puller mechanism 221 comprises an eccentric cam 224 , a connecting rod 225 , rocker arm 226 , a housing 222 , and an upper motor-driven feed roller 223 with a helical profile 232 . The upper coacting puller mechanism 221 works in synchronization with the feed-dog 240 and the lower puller mechanism 201 . The eccentric cam 224 is fixedly attached to single piece shaft 46 between front bushing 51 and rear bushing 52 . As can be seen in FIG. 6A , a flat region 45 near a center of the shaft 46 is adapted to be engaged by a set screw which fixes the cam 224 in place with respect to the shaft. Driven by the profile of the eccentric cam 224 is the connecting rod 225 , which translates about the drive shaft 46 . The connecting rod 225 is rotatably connected to the rocker arm 226 via pin 231 . The translation in the connecting rod 225 forces the rocker arm 226 to rotate in both a clockwise and counterclockwise direction. The rotation of the rocker arm 226 creates a ratcheting effect on the upper rocker shaft 227 . This allows intermittent rotation of the rocker shaft in a clockwise direction as viewed from FIG. 5A , while remaining idle when the rocker arm 226 is rotated in a counterclockwise direction. The rocker shaft 227 is supported by bushings 229 and 230 press fit within the roller housing 222 . The ratcheting effect on the rocker shaft 227 is accomplished through a uni-directional clutch 228 fixedly attached to the rocker shaft 227 .
In order to accommodate varying thicknesses of the carpet material the upper motor driven roller 223 must be capable of vertical movement, while at the same time able to rotate pulling the carpet 12 through the sewing assembly 100 . As best can be seen in FIGS. 2 and 3 , relative vertical movement of the straight shaft 227 and the drive shaft 46 is provided by the pivotal connection between the connecting rod 225 and rocker arm 226 . As the straight shaft 227 moves vertical with respect to the drive shaft 46 and a throat plate 242 of the feed-dog 240 , the shaft 227 remains parallel to the drive shaft 46 . This eliminates the use of universal joints and linkages that are typically required to obtain this dual acting motion. The current invention allows for both rotation and translation through the use of only the straight shaft 227 and rocker arm 226 . Manual vertical movement of the upper feed roller 223 is also permitted by a manually activated lever that is coupled to a roller rod 233 and the roller housing 222 .
The rotation of the upper feed roller 223 occurs once per sewing cycle, where one revolution of the drive shaft 46 causes an oval-type movement the feed-dog 240 and a clockwise rotation of the top-mounted motor driven roller 223 to act in concert to engage and pull the carpet 12 through the sewing assembly 100 . The feed-dog 240 operates to engage the bottom 16 of the piece of carpet 12 through the lifter 241 , which is driven by the second eccentric cam 44 located on the drive shaft 46 . The second eccentric cam 44 and the lifter together control the rise and fall of the feed-dog 240 . The feed-dog 240 moves in both the horizontal and vertical directions in a generally oval path. When the feed-dog 240 rises above an upper surface of the feed-dog throat plate 242 ( FIGS. 1 & 5A ) and engages the bottom surface 16 of the carpet 12 , it then moves generally horizontally in the downstream direction D to move the carpet 12 in the downstream direction D. The length of the path of travel of the feed-dog 240 in the downstream direction D while above the throat plate 242 will determine the length of each stitch. At the same time the feed-dog 240 is moving above the throat plate 242 in the direction D, the upper feed roller 223 rotates in a clockwise direction CW (as seen in FIG. 2 ) and the lower feed roller 203 rotates in a counterclockwise direction CCW (again, as seen in FIG. 2 ) in appropriate rotational amounts to match the linear distance the feed-dog 240 moves the carpet 12 downstream D. To complete its oval path, the feed-dog 240 at the end of path of travel downstream D falls vertically below the throat plate 242 (out of contact with the carpet 12 ) and moves horizontally upstream (opposite the direction D) while remaining below the throat plate 242 .
The top mounted motor driven roller 223 also comprises a helical profile 232 that resembles a right-handed thread configuration. The carpet 12 is then drawn inward direction I (see FIGS. 3 and 4 ) relative to the carpet feeding assembly 200 because of the axially-transverse thrust generated by the right-handed helical profile and the clockwise rotation of the top mounted motor driven roller 223 .
The helical profile in the top mounted motor driven roller 223 like that in the bottom mounted motor driven roller 203 reduces the amount of effort expended by the operators during the sewing process, since the carpet 12 has a natural tendency to pull away from the sewing assembly 100 . There exists a natural tendency to pull away because, inter alia, the majority of the carpet's weight is outside of the feeding assembly 200 . The helical profile as discussed above can comprise any number of different configurations, including continuous threads, or crenellated rows or teeth along a left-hand or right-handed thread path.
A predetermined amount of downward force is applied to the carpet 12 through the top-mounted feed roller 223 by way of the housing 222 and the roller rod 233 . The amount of down force applied to the roller rod can be varied by changing the location of an adjustment mechanism 235 relative to a spring 234 . The amount of axial down force varies the force of engagement between the upper feed roller 223 and the feed-dog 240 with the carpet 12 when the feed-dog 240 is in an upward position, that is engaged and moving the carpet in the downstream direction D. When the feed-dog 240 is not in its upward position, that is, the feed-dog is recessed below openings in a feed-dog throat plate 242 , the carpet 12 is engaged between the throat plate 242 and the upper feed roller 223 . The axial down force also acts in conjunction with the helical profile 232 to force the carpet 12 down and inwardly (in the direction I) as it moves through the sewing assembly 100 , opposed to the natural tendency to pull up and away from the housing 20 . This again reduces the amount of energy required by the operator in using the carpet-binding machine 10 .
Another enhancement of the present invention is shown in FIGS. 1 and 7B , which is a retractable linkage in the looper assembly 250 . The looper 106 uses looper thread 107 in making among others, a type 401 double locked chain stitch as discussed above. One of the inherent problems in any sewing operation is rethreading the looper when the looper thread 107 runs-out or breaks during operation. Rethreading the looper requires significant time as the looper thread 107 must be hand fed through a first aperture 252 located at the heel 251 of the looper up through a second aperture 253 located in the front 254 portion of the looper 106 . The significant amount of time to rethread the looper is a result of the close proximity of the feed-dog 240 and the lifter 241 to the front portion 254 of the looper represented by distance D 1 in FIG. 7A . FIG. 7A also shows prior art's looper 106 in its most retracted position, since a connecting rod 255 in the prior art comprises a continuous link. Thus, the prior art shown in FIG. 7A is the looper's most retracted position hereinafter referred to as Position 1 , which limits the looper to a rotation of an angle ⊖ 1 about pin 257 on a rocker shaft 260 .
To significantly reduce the amount of time required to rethread the looper 106 , the described embodiment modifies the connecting rod 255 into a two-piece linkage assembly 259 , as shown in FIG. 7B . The two-piece linkage assembly 259 comprises a first link 256 rotatably connected to a second link 261 through connection pin 258 . The two-piece linkage assembly allows the looper 106 to rotate to an angle ⊖ 2 about pin 257 on the rocker shaft 260 , hereinafter referred to as Position 2 . The distance between the feed-dog 240 and lifter 241 to the front of the looper 254 is represented by distance D 2 in FIG. 7B .
The new design's increase in retraction shown by distance D 2 and angle ⊖ 2 in Position 2 is more than twice that of D 1 and ⊖ 1 respectively. This increase in retraction resulting from the linkage assembly's design is an important advantage over the prior art, which will reduce the amount of time and effort required in rethreading the looper after thread run-outs or breaks during operation.
Although the present invention has been described with a certain degree of particularity, it should be understood that those skilled in the art can make various changes to it without departing from the spirit or scope of the invention as hereinafter claimed. | A portable carpet binding machine comprising a housing defining an interior region, a drive mechanism supported by the housing and at least partially disposed in the interior region, a prime mover operatively coupled to the drive mechanism for providing motive power to the drive mechanism, a sewing assembly driven via the drive mechanism for sewing a strip of material to a piece of carpet. The portable carpet binding machine includes a carpet feeding assembly including a feed driver mechanism and a coacting puller mechanism operating in substantially synchronous movement to linearly feed the piece of carpet relative to the sewing assembly. The feed driver mechanism includes a feed-dog driven via the drive mechanism that intermittently engages the bottom of the piece of carpet to thereby advance the piece of carpet forward. The coacting puller mechanism includes first and second feed rollers driven via the drive mechanism. The first feed roller engages the top of the piece of carpet and the second feed roller engages the bottom of the piece of carpet. The first and second feed rollers pull the piece of carpet forward substantially simultaneously with respect to the advancement by the feed-dog of the feed driver mechanism. | 3 |
This is a continuation of patent application Ser. No. 08/337,260 filed Nov. 10, 1994, now U.S. Pat. No. 5,533,789, filed in the name of George C. McLarty, III, Anthony R. Waldrop and Kathryn T. Anderson, specific reference being made herein to obtain the benefit of such filing date.
FIELD OF THE INVENTION
This invention relates generally to seating structures and more particularly to seating structures having support surfaces formed from resilient fabric without the need for underlying springs or cushion support structures.
BACKGROUND
Traditional seating structures such as for use in a vehicle, office environment or residential setting are formed from relatively thick urethane foam buns mounted on semi-flexible spring wire constructions. These foam buns are, in turn, typically covered with an aesthetically pleasing fabric cover for contacting the user. As will be readily appreciated, the use of such a multiplicity of components (i.e. springs, cushions and covers) all of which are attached to a frame gives rise to a relatively complicated assembly practice.
In order to reduce the number of components in seating structures and to reduce the bulk thereof, it has been proposed to provide thin profile seats, including thin seats using elastomeric seat backing material. For example, in U.S. Pat. No. 2,251,318 to Blair et al, solid rubber tape or strips reinforced by fabric are stretched over a seat frame. In U.S. Pat. No. 4,545,614 to Abu-Isa et al., (incorporated by reference) a thin profile vehicle seat is disclosed in which a multiplicity of side by side elastomeric filaments made from a block copolymer of polytetramethylene terephthalate polyester and polytetramethylene ether are stretched across a vehicle seat frame. U.S. Pat. No. 4,869,554 to Abu-Isa et al., issued Sep. 26, 1989 (incorporated by reference) discloses a thin profile seat in which elastomeric filaments like that of the U.S. Pat. No. 4,545,614 patent are woven together to form a mat. The mat was prestretched to at least 5 percent elongation and attached to a seat frame. U.S. Pat. No. 5,013,089 to Abu-Isa et al., (incorporated by reference) discloses a seat assembly having an elastomeric filament suspension and a fabric cover. The filament suspension and the fabric cover are integrated by having the elastomeric filaments and the fabric knitted together to provide a low profile finished seat or backrest.
The present invention provides a seating structure wherein the support surfaces (i.e. the seat and backrest) comprise a weft insertion knitted fabric which fabric can be formed in a single operation on one knitting machine. The fabric has an aesthetic side suitable for contacting the user of the seating structure. The structure of the fabric is such that it also has a performance side to provide the user with resilient support during repeated use. The present invention therefore represents a useful advancement over the state of the art.
OBJECTS AND SUMMARY
In light of the foregoing, it is a general object of the present invention to provide a seating structure having webbed support surfaces formed from a single knitted fabric structure.
It is an object of the present invention to provide a seating support structure having a webbed support surface formed from warp knit fabric wherein the fabric undergoes easy initial elongation in the weft direction while having relatively limited elongation in the warp direction.
It is a further object of the present invention to provide a seating structure having a webbed support surface displaying sufficient vertical ride upon use to provide comfort to the user while avoiding overextension of the support surface.
It is yet a further object of the present invention to provide a seating structure having a webbed support surface formed from a warp knit fabric with weft insertion wherein one side of the fabric yields desired structural performance characteristics while the opposite side is aesthetically pleasing.
In that respect it is a feature of the present invention to provide a seating structure having a webbed support surface formed from a warp knit fabric with weft insertion of an elastomeric yarn, wherein the warp stretch is substantially linear over a full range of applied stress from zero pounds to breaking and elongation of the filling has two substantially linear components wherein a first substantially linear high elongation component operates over the range of zero to about 10 pounds applied force and a second linear component operates over the range of about 10 pounds applied force to breaking.
Other objects, advantages and features of the invention will, of course, become apparent upon reading the following detailed description and upon reference to the drawings below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a seating structure according to the present invention.
FIG. 2 is a needle bed point diagram illustrating a potentially preferred construction of the fabric used in the support surface of the seating structure of the present invention.
FIGS. 3-5 are needle bed point diagrams illustrating the components in the potentially preferred construction of the fabric as shown in FIG. 2.
FIG. 6 is a view of the aesthetic side of the potentially preferred fabric for use in the support surface of the seating structure of the present invention.
FIG. 7 is a view of the performance side of the potentially preferred fabric for use in the support surface of the seating structure of the present invention.
DESCRIPTION
While the invention will be described in connection with certain preferred embodiments and procedures, it is to be appreciated that we do not intend to limit the invention to such embodiments and procedures. On the contrary, we intend to include all alternatives, modifications and equivalents as may be included within the true spirit and scope of the invention as defined by the appended claims.
Turning now to the drawings, in FIG. 1 there is shown a seating structure 10 according to the present invention such as may be used in an automobile, an office chair or a home environment. While the actual design of the seating structure 10 may be varied depending on environment of use and aesthetic preferences, in general the seating structure will preferably include a seating frame 12, a seating support web 14, a back frame 16 and a back support web 18. In the illustrated and preferred embodiment, the seating support web 14 and the back support web 18 are disposed in tension over the seating frame 12 and back frame 16 respectively without the need for added cushions or other support structures, although it is contemplated that such support structures could be utilized if desired.
As will be appreciated by those of skill in the art, the seating support web 14 and back support web 18 should be constructed to provide a so called "vertical ride" when a load is applied in the form of an occupant so that a feeling of support and comfort is provided. This feature in seating structures has historically been provided by the use of springs and cushions which compress in known repeatable fashion when loads are applied.
While some degree of movement is important to the impartation of comfort, such movement should also not be so extreme as to negate the feeling of support. Accordingly, it is important that any seating support structure have a limited degree of movement when loads are applied. As will be understood, the use of spring structures has historically been used in this function since the spring compression effectively limits movement when loads are applied.
In order to provide a seating structure which has these desirable operational features while avoiding the need to use previously available complex support structures and still providing an aesthetically pleasing appearance, the present invention utilizes a weft-insertion fabric (FIG. 2) to form the seating support web 14 and back support web 18. As illustrated in the point diagrams FIGS. 3-5, this weft-insertion fabric preferably includes three components.
In the illustrated and preferred embodiment the components of the weft-insertion fabric are an elastomeric monofilament yarn 30 in the warp, a highly elastomeric filament yarn 32 wrapped for aesthetics and inserted in the weft and a knit filament yarn 34 which is used to tie the warp yarn and the weft-inserted yarn together at their intersections.
The face or aesthetic side of the resultant fabric is illustrated in FIG. 6, and the rear or performance side of the resultant fabric is illustrated in FIG. 7. In the illustrated and potentially preferred embodiment, the elastomeric monofilament yarns 30 are 2500 denier ELAS-TER™ monofilament yarn believed to be available from Hoechst Celanese Corporation whose business address is I-85 at Road 57, Spartanburg, S.C. 29303. The wrapped filament yarns 32 which are inserted in the weft preferably comprise a highly elastomeric core 40 formed from a material such as is available under the trade designation SPANDEX™ or the like. As shown, this elastomeric core 40 is preferably wrapped with an aesthetically pleasing yarn 42. One preferred composite of wrapped filament yarn 32 for weft insertion is available from World Elastic whose business address is believed to be 231 Pounds Avenue SW, Concord, N.C. 28025. The knit filament yarn 34 is preferably a solution dyed polyester of between about 100 and 250 denier and more preferably about 150 denier such as are well known to those of skill in the art although alternative materials may be utilized.
In the potentially preferred final fabric configuration, the elastomeric monofilament yarn 30 will be disposed at about 12 to about 32 ends per inch and more preferably 16 to 24 ends per inch and the weft-inserted wrapped filament yarns will be inserted at about 16 to about 40 picks per inch and more preferably 22 to 30 picks per inch.
In an important aspect of the present invention, it has been found that the use of a warp knit weft-insertion fabric as described above provides exceptional comfort and support in the support webs of the seating structure 10 without the need for any supplemental supports or resilient load carrying members. Tensile testing of this weft-insertion fabric according to ASTM D-5034 indicates that elongation in the warp direction is substantially linear up to failure. Specifically, such elongation has been measured to be in the range of between about 2 pounds force per percent elongation and about 4 pounds force per percent elongation.
In contrast to the linear stress strain relationship existing from initiation to failure in the warp direction, tensile tests in the weft direction indicate two separate linear regions. Specifically, the weft insertion configuration described above yields elongations of between about 25 and about 65 percent at a load of 10 pounds (i.e. 0.4 to 0.17 pounds force per percent elongation) followed by a relatively gradual linear region of elongation between about 10 pounds force and breaking with ratios of between about 2 and about 4 pounds force per percent elongation.
It can thus be appreciated that the use of weft-inserted fabrics as described above as the seating support web 14 and the back support web 18 in a seating structure 10, provides for initial limited displacement upon loading due to the elongation in the weft direction followed by steady support after such initial loading due to both the warp and the weft being in a region of linear elongation up to breaking. Moreover, the use of the weft-inserted fabric as described provides for an aesthetically pleasing surface by itself with no additional cover.
In accordance with the present invention, a useful seating structure can be formed by stretching a weft-inserted fabric as described over a seating frame and back frame without the need for any additional padding, springs or other support structures. Such seating structures thus represent an important and significant advancement over the present art. | A seating structure including fabric support webs is provided. The seating structure includes a webbed support surface formed from a warp knit fabric with weft insertion of an elastomeric yarn. The stretch in the warp is substantially linear over a full range of applied stress from zero pounds to failure. The stretch in the weft has two substantially linear components wherein the first linear component operates over the range of zero to about 10 pounds applied force and the second linear component operates over the range of 10 pounds applied force to failure. | 3 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/295,550, filed Jun. 4, 2014, now U.S. Pat. No. 9,743,955, which claims the benefit of U.S. Provisional Patent Application No. 61/830,696, filed Jun. 4, 2013, each of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] This invention relates to the field of devices fabricated for intracorporeal treatment of the human body. More specifically, the invention comprises a device which can illuminate certain tissue within a patient's body primarily by passing light through those tissues. The invention assists surgical operations in many ways, including clearly defining a location for an incision. The device, which can take many forms, uses embedded LED lights in order to illuminate the relevant tissue, organ or other structures.
BACKGROUND
[0003] The human body consists of a series of internal organs. Like the rest of the human body, internal organs are affected by disease, the inability to function properly, as well as other complications. In these instances, it may become important to investigate, or in the most extreme case, remove the problematic organ(s) or portions thereof. A doctor can investigate the state of a person's organs or tissue using endoscopy or laparoscopy. The term “endoscope” refers generally to a visualization tool—now typically a small digital camera—that may be inserted into a patient's body through an existing orifice or a small incision. Similar visualization devices have differing names depending upon their region of intended use. For example, a “laparoscope” is a visualization device that is intended for use in the patient's abdomen. Using an appropriate “scope” tissue that needs to be removed can be identified and excised using other surgical tools passed into the same area. Laparoscopy continues to become more popular as advancements are made in this field. If laparoscopy is an option for a patient's surgical procedure, then the benefits can be enormous compared to laparotomy. These advantages include reducing post-operative pain, shortening hospital stays, and reducing recovery times. Although laparoscopy is not always an option for surgery, these advantages have led to more surgical procedures that use laparoscopy or computer-aided laparoscopy.
[0004] In the case of laparoscopy and laparotomy, it is extremely important for the surgeon to have the clearest view possible. Of course, in the case of laparotomy this is less of a problem since the patient has a large incision that allows the surgeon to see into the patient's body using ambient light from the operating room and fixed lights shining onto the operation region. However, laparoscopic surgery is accomplished using only a few small incisions in the patient's body with all the structures having to be viewed through the small “scope.”
[0005] Although laparoscopic surgery is less invasive than laparotomy, one commonly cited drawback is a lack of visibility of the operating area as it relates to visualizing hidden critical structures and the limited tactile feedback or the lack thereof altogether in robotic surgery applications. In laparoscopic surgery, this lack of visibility and tactile feedback can potentially lead to injury of vital structures including the ureters, bladder, major vessels, nerves as well as any other structures or organs in the relevant region of surgery (this depends on location of surgery). It would appear, then, that increased visibility would reduce the risk of injury during laparoscopic surgery.
[0006] One of many procedures that benefit from the use of laparoscopic surgery is a hysterectomy. A hysterectomy is the procedure in which a patient's uterus is surgically removed. There are several types of hysterectomies that can be performed. For example, a radical hysterectomy is the complete removal of the uterus, cervix, upper vagina, and parametrium. This type of hysterectomy is commonly used for the treatment of cancer. A total hysterectomy is the complete removal of the uterus and cervix, with or without oophorectomy (removal of the ovaries). A subtotal hysterectomy is the removal of the uterus, leaving the cervix in situ.
[0007] A common device used in laparoscopic hysterectomy is a uterine manipulator. A uterine manipulator is used to delineate the proper plane of dissection for colpotomy at the cervicovaginal junction (which is equipped with a colpotomy cup). In the event of a radical hysterectomy or a procedure involving a patient having cancer, a sponge stick is the preferred tool due to the absence of a stem entering the uterus. While an intrauterine stem is helpful for retraction of the uterus, the risk of inadvertent uterine perforation transabdominally is increased, which can cause upstaging of the cancer due to cancer cells spilling into the abdomen. This must be avoided at all costs.
[0008] A hysterectomy is a procedure which is commonly performed using a laparoscopic or robotically assisted laparoscopic technique. Therefore, what is needed in this particular example is a device that increases the visibility of the location at which to cut and/or cauterize the tissue in order to remove the patient's uterus more safely and effectively. However, more generally, what is needed is a device that increases the visibility of the location within the body at which the surgical procedure is taking place. Oftentimes the objective is to cut or cauterize tissue, but the objective can include any number of procedures—such as drawing fluid, locating a structure, stapling tissue, or simply maneuvering an organ or other structure. The present invention achieves this objective, as well as others that are explained in the following description.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention comprises a device which illuminates internal tissue and organs of a patient. The device is available in many forms. The form of the device is dependent on the procedure for which the device is used. Each device includes an array of light-emitting diodes (“LEDs”). The arrangement of the array also depends on the configuration of the device and the procedure for which the device is being used. In the case of the example given in the preceding text, a hysterectomy, the LED array is positioned in the form of a ring embedded within a colpotomy cup. This allows the LED array to transilluminate the tissue surrounding the cervix (illuminate the critical area by actually passing light through a portion of the tissue). When performing a laparoscopic hysterectomy a surgeon inserts a laparoscope and a cutting or cauterization device through ports in a patient's abdomen. At the same time, a uterine manipulator is often passed through the vagina and into the uterus (often with a “cup” encircling the cervix). Thus, the tissue of the patient is being physically manipulated from one side of an enclosed volume (inside the vagina/uterus) while the actual incision is being performed on the opposite side of this volume (inside the abdomen but outside the uterus.
[0010] In the present invention, an array of powerful LED lights is provided on the end of a specially shaped distal end of an elongate member. As an example, in the case of a hysterectomy, the distal end may assume the form of a colpotomy ring with the LED array being disposed about the circumference of the ring. When the LED lights are illuminated the surgeon is able to easily and efficiently locate the colpotomy ring behind the relevant tissue by way of transillumination. The LED array is located inside the vagina/cervix and the surgeon can see the light from the LED's passing through the wall of the cervix. Thus, the LED array device allows the surgeon to make an incision at the proper location to best remove the uterus safely and effectively.
[0011] Although the example provided is that of a hysterectomy with an LED array in the shape of a ring, the LED array of the present invention may be applied to many procedures and devices. The LED array reduces the potential for inadvertent injury to internal structures for procedures located throughout the body. These procedures include those involving the reproductive organs of males and females, gastric and bariatrics, and other structures in the abdomen.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 is a perspective view, showing a preferred embodiment of the present invention for a generic surgical procedure.
[0013] FIG. 2 is a perspective view, showing a prior art uterine manipulator.
[0014] FIG. 3 is a schematic view, showing a prior art device in use.
[0015] FIG. 4 is a perspective view, showing a preferred embodiment of the present invention.
[0016] FIG. 5 is a schematic view, showing the embodiment of FIG. 4 in use during a hysterectomy procedure.
[0017] FIG. 6 is a perspective view, showing an alternate embodiment of the present invention.
[0018] FIG. 7 is a perspective view, showing another alternate embodiment of the present invention.
[0019] FIG. 8 is a schematic view, showing the embodiment of FIG. 7 in use.
[0020] FIG. 9 is a perspective view, showing another alternate embodiment of the present invention.
[0021] FIG. 10 is a schematic view showing the embodiment of FIG. 9 in use.
[0022] FIG. 11 is a perspective view, showing yet another alternate embodiment of the present invention.
[0023] FIG. 12 is a schematic view, showing the embodiment of FIG. 11 in use.
[0024] FIG. 13 is perspective view, showing an alternate embodiment of the present invention.
[0025]
[0000]
REFERENCE NUMERALS IN THE DRAWINGS
10
illumination member
12
member handle
13
LED mounting surface
14
elongate member
16
distal end
18
LED array
20
uterine manipulator
22
colpotomy ring
24
intrauterine balloon
26
control handle
28
elongate member
30
positioning member
32
cutting device
34
vaginal canal
36
cervix
38
body of patient
40
tissue
42
LED
44
LED power cord
46
balloon
48
LED adjustment knob
50
uterus
52
suction port
53
irrigation port
54
esophagus
56
stomach
58
antrum
59
suction port
60
bladder
62
penis
64
urethra
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention provides a device which illuminates a region of interest within a patient's body during surgery or other medical procedures. FIG. 1 shows a relatively simple embodiment that includes the preferred features. Illumination member 10 varies with each application for various procedures. Here, illumination member 10 includes member handle 12 , LED mounting surface 13 , elongate member 14 , distal end 16 , and light emitting diode (“LED”) array 18 .
[0027] In general, distal end 16 is inserted into the patient's body. Elongate member 14 creates distance between the operator and the cavity in which illumination member 10 is inserted. Although elongate member 14 is shown as a cylinder with a linear axis in space, it may have a curved axis in space. It may also include features allowing it to be bent in various ways to conform to the relevant anatomy. In addition, LED array 18 is shown as two linear arrays, but LED array 18 can take many forms such as a curved array, a circular array, or any other planar shape including a singular LED. Most of these embodiments will be demonstrated in the following examples of alternate embodiments of the present invention.
[0028] One of the primary applications for illumination member 10 is that of a hysterectomy, or the removal of a uterus and/or other reproductive organs. In order to aid the reader's understanding, it is helpful to consider some prior art instruments used in this procedure. FIG. 2 illustrates a prior art uterine manipulator 20 in conjunction with a colpotomy ring 22 and an intrauterine balloon 24 . This type of prior art device is typically used in a laparoscopic hysterectomy. As illustrated, uterine manipulator 20 includes a control handle 26 and elongate member 28 , which attaches to colpotomy ring 22 , positioning member 30 and pneumo-occluder balloon 24 . In use, the colpotomy ring 22 is inserted into the vaginal canal of the patient until the colpotomy ring 22 reaches the vaginal fornices and cervix. The intra-uterine balloon 24 is directed into the uterus of the patient and is expanded inside of the uterus in order to secure the device. A series of ports are inserted through the abdomen of the patient which allows accommodation of the laparoscope and other suture or specialized laparoscopic instruments such as cutting/cauterizing devices, specimen retrieval bag, Endo Stitch suture-assist device or a tissue morcellator.
[0029] The reader will appreciate that a variety of laparoscope instruments can be used to perform a hysterectomy. Thus, the application should not be limited by the use of any specific instruments. As illustrated in FIG. 3 , the cutting device 32 enters the patient's body such that the relevant tissue to be cut or cauterized is between the cutting device 32 and the colpotomy ring 22 . The viewing device is typically inserted next to cutting device 32 . Thus, the viewing device cannot directly see the location of the colpotomy ring other than by noting the bulge it creates in the cervical tissue. The surgeon may therefore have a difficult time identifying the exact location at which the tissue should be cut or cauterized.
[0030] As illustrated, uterine manipulator 20 is fully inserted into the vaginal canal 34 . Intrauterine balloon 24 is inflated in order to keep uterine manipulator 20 in position. Colpotomy ring 22 is positioned within the vaginal fornices at the opening of the cervix 36 . During the operation a cutting device 32 enters the patient's body 38 through a port (not shown). The surgeon must position cutting device 32 such that as the cut through the tissue 40 is made, the cuff of the colpotomy ring 22 is on the opposing side.
[0031] FIG. 4 shows an embodiment of the present invention used for this same hysterectomy procedure. Illumination member 10 replaces uterine manipulator 20 and its associated colpotomy ring. In a preferred embodiment, illumination member 10 includes member handle 12 , elongate member 14 , distal end 16 , and LED array 18 (as discussed in the preceding text). In addition to the primary elements, this embodiment of illumination member 10 includes colpotomy ring 22 , intrauterine balloon 24 , and positioning member 30 . The reader will note that an important difference between prior art uterine manipulator 20 and this embodiment of illumination member 10 is the addition of LED array 18 . Also, illumination member 10 preferably includes LED power cord 44 (which may run internally within elongate member 14 ). Preferably, LED power cord 44 leads to a power switch device (not shown). In a preferred embodiment, the switch has multiple functions, including the capability of switching the LEDs ON/OFF, dimming and brightening, flashing, etc.
[0032] FIG. 5 illustrates the embodiment of FIG. 4 being used in a laparoscopic surgery. As illustrated, illumination member 10 is fully inserted into the vaginal canal 34 . Colpotomy ring 22 is positioned within the vaginal fornices at the opening of the cervix 36 . LED array 18 is located at the upper cuff of the colpotomy ring 22 . During the operation a cutting device 32 enters the patient's body 38 through a port (not shown). The surgeon must position cutting device 32 such that as the cut through the tissue 40 is made, the cuff of the colpotomy ring 22 is on the opposing side.
[0033] The present illumination member 10 allows the surgeon to effectively see through the tissue to identify the exact location of colpotomy ring 22 . When the LED's are switched on, they shine through the tissue wall defining the cervix. The surgeon, who is looking through the laparoscope on the opposite side of the tissue wall, can actually see the LED's and thereby precisely visualize the location of the colpotomy ring. As discussed above, LED lights 42 can be brightened if tissue 40 is thick and difficult to see through or can be selectively dimmed as the tissue is cut so that the light is not too bright.
[0034] This procedure illustrates a general case of the invention's use. It is most effective in illuminating a tissue wall that separates a first volume within a patient's body from a second volume. In the case of laparoscopic surgery of FIG. 5 , the first volume is contained within the vagina/cervix/uterus. Access to this volume is obtained through a first opening in the patient's body (the vagina). Illumination member 10 is inserted through the vagina and thereby gains access to this first volume.
[0035] The second volume in this scenario is the volume within the abdominal cavity that lies outside the vagina/cervix/uterus. Access to this second volume is obtained via an incision. The LED array is then placed against the tissue wall and the LED's are illuminated. The light from the LED's shines through the tissue wall and becomes visible in the second volume.
[0036] Illumination of the relevant tissue in the first volume of the patient allows the surgeon to identify the location of that tissue via laparoscope inserted into the second volume of the patient. In the case of a hysterectomy, that tissue is to be cut in order to remove the patient's uterus. However, other surgical action can be taken. Surgical action can take many forms—some examples include cutting, grasping, cauterizing, scraping, stitching, puncturing, securing, strengthening, viewing, reshaping, stapling, or removing. The reader will note that this is not meant to be an exhaustive list of all the surgical actions that can be accomplished, but rather some examples given to demonstrate the large number of surgical actions. Thus, the scope of the present invention should not be limited to any single surgical action.
[0037] The reader will also note that tissue 40 creates a wall of tissue between the first and second volumes as described in the preceding text. In the case of the hysterectomy, that wall of tissue is the region where surgical action is required. Transillumination of the wall of tissue indicates to the surgeon which region to cut. In general, a wall of tissue may separate the first volume and the second volume. It should be noted, however, that surgical action does not necessarily occur at the wall of tissue. In fact, the wall of tissue may simply provide the barrier between the two volumes.
[0038] Oftentimes, especially in the case of cancer, it is dangerous to insert positioning member 30 and intra-uterine balloon 46 into the uterus. In the case of accidental perforation of the uterus, cancerous cells could spill into the abdomen. Typically, a doctor will use ring forceps grasping a sponge instead of uterine manipulator 20 in order to avoid entering the uterus. This technique allows for very limited manipulation of the tissue while limiting the risk of uterine perforation by entering the uterus. FIG. 6 shows an alternate embodiment of illumination member 10 that is intended to deal with this situation. The reader will notice that the embodiment illustrated is similar to uterine manipulator 20 . Illumination member 10 includes member handle 12 and colpotomy ring 22 located on distal end 16 . This particular embodiment of illumination member 10 allows the surgeon to transilluminate the relevant tissue surrounding the cervix (as discussed in the preceding text) without any pieces entering the uterus. Thus, even in the case of cancer in the uterus or other complications, LED array 18 can be utilized in order to more readily and effectively perform a hysterectomy.
[0039] Still another embodiment of the illumination member 10 is shown in FIG. 7 . The reader will note that the distal end 16 of illumination member 10 is enlarged compared to the previous embodiment. As illustrated, LED array 18 can take the form of a ring or LEDs 42 can span distal end 16 axially. The organization of LEDs 42 on distal end 16 is dependent on the application of illumination member 10 . Thus, the reader should not limit the scope of the present invention based on the form or placement of LED array 18 .
[0040] The embodiment of illumination member 10 in FIG. 7 is used as a vaginal plane delineation device. The device is used as a transvaginal retraction and positioning device for vaginal vault dissection during a sacrocolpopexy surgical procedure. FIG. 8 shows the device in use. LED array 18 allows for transillumination of the vaginal vault in order to better delineate the vesicovaginal plane and the rectovaginal plane.
[0041] FIG. 9 shows yet another alternate embodiment of illumination member 10 . FIG. 10 illustrates the application of this particular embodiment. Preferably, the embodiment of illumination member 10 in FIG. 9 is used in gastric and bariatric surgical procedures in order to provide visible and tactile delineation of the antrum of the stomach. Illumination of this region using LED array 18 allows a surgeon to easily identify the placement of the distal end 16 of the device 10 . In addition, illumination member 10 preferably includes components similar to those of a gastric calibration tube such as suction port 52 . In addition, illumination member preferably includes irrigation port 53 . Suction port 52 and irrigation port 53 allow the surgeon to add and remove liquid during a procedure in the gastric channel.
[0042] This particular embodiment of the present invention is inserted into the patient's esophagus 54 , through stomach 56 and into antrum 58 . The reader will note that this particular embodiment is preferably made flexible in order to navigate the gastric channel. It may also include guiding wires that a surgeon can employ to manipulate the curvature and deflection direction of the device. In a preferred embodiment, elongate member 14 is fabricated from a soft, hollow conduit such as silicone. LED array 18 is preferably located at the very tip of distal end 16 . Preferably, member handle 12 includes a check valve mated with a syringe (not shown) which is used to fill balloon 46 .
[0043] FIGS. 11 and 12 illustrate the application of illumination member 10 as a Foley catheter. This embodiment includes the all of the components of a typical prior art Foley catheter with the addition of LED array 18 . In addition to the management of urination, a catheter is also used to identify the bladder during surgical procedures. Preferably, elongate member 14 is fabricated from a flexible, hollow material. The preferred embodiment of the present invention includes two hollow conduits—one is used for the drainage of urine and the other is to inflate balloon 46 . LED array is preferably embedded into balloon 46 , but can also be attached at the tip of distal end 16 as illustrated.
[0044] As illustrated, illumination member 10 is inserted into the urethra 64 , spanning the length of penis 62 and into bladder 60 . By illuminating LED array 18 within bladder 60 , surgeons working in the abdominal cavity proximate the bladder can positively identify the location of the bladder, thereby avoiding accidental injury to the bladder and surrounding structures.
[0045] A circular stapler spike is used to perform anastomoses in a patient. The spike portion is coupled with an anvil in the alimentary canal for the creation of end-to-end, end-to-side, and side-to-side anastomoses. FIG. 13 shows illumination member 10 in the form of the spike used for anastomoses. LED array 18 allows illumination of the region of interest inside the patient during a surgical procedure. Preferably, illumination member 10 is a disposable spike which replaces the original spike on a circular stapler device. However, illumination member 10 can also take the form of a sheath that fits over the original spike on the stapler device. In either form, the spike increase visibility for the surgeon in order to perform anastomoses.
[0046] Returning to the embodiment of FIG. 7 , some preferred features of the invention will be discussed in more detail. The reader will note that the distal end of the illumination member assumes the form of a shaped surface (in this case a cylinder with a smoothly filleted leading edge). It is preferable to contour this surface so that it rests smoothly against the anatomy it is intended to contact. The portion of this surface that contains the LED array is known as an “array mounting surface.” This surface is shown generally in FIG. 1 , but it is preferably included with each embodiment. This surface is preferably shaped to place the LED's in position against the relevant tissue wall. Of course, in some cases a simple shape will suffice.
[0047] Each embodiment of the present invention preferably includes a power source and controller for the LED array. Preferably, the power source is a lithium-ion rechargeable battery. However, in the case where the illumination member is disposable, along with the circuitry, a less expensive power supply can be used such as AA batteries. The controller for the LED array can be as simple as a power ON/OFF switch. In the preferred embodiment of illumination member, the LED controller has dimming functionality. In some embodiments, the LED power source and controller are integral to the member handle. This is the preferred configuration, but may not be possible in all embodiments.
[0048] LED lights are particularly beneficial when applied to devices that enter the body or contact the tissue of a patient and in use during a laparoscopic surgery because of the natural properties of a LED light, namely, that LED lights are small in area and can achieve high brightness while remaining cool to the touch. Further, LED lights are powerful, have lower energy consumption and have a longer lifetime. Thus, it is important that the present ring device include light-emitting diodes lights.
[0049] The preceding description contains significant detail regarding novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by examples given. | A device which illuminates internal tissue and organs of a patient is described. The illumination member includes an array of light-emitting diodes (“LEDs”). The arrangement of the array depends on the configuration of the device and the procedure for which the device is being used. In all cases, the illumination member is used to illuminate relevant organs or structures in the body in order to increase visibility during surgical procedures. The LED array reduces the potential for inadvertent injury to internal structures for procedures located throughout the body. These procedures include those involving the reproductive organs of males and females, gastric and bariatrics, and other structures in the abdomen. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. patent applications Ser. No. 09/968,202 (filed Oct. 1, 2001), now U.S. Pat. No. 6,572,753, Ser. No. 10/115,539 (filed Apr. 3, 2002) and Ser. No. 10/266,006 (filed Oct. 7, 2002) to Chalyt et al., which are assigned to the same assignee. The teachings of these patent applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is concerned with analysis of halide ions in solutions, and in particular with determination of the chloride concentration in acid copper electroplating baths, as a means of providing control over the deposit properties.
2. Description of the Related Art
Electroplating baths typically contain organic additives whose concentrations must be closely controlled in the low parts per million range in order to attain the desired deposit properties and morphology. One of the key functions of such additives is to level the deposit by suppressing the electrodeposition rate at protruding areas in the substrate surface and/or by accelerating the electrodeposition rate in recessed areas. Accelerated deposition may result from mass-transport-limited depletion of a suppressor additive species that is rapidly consumed in the electrodeposition process, or from accumulation of an accelerating species that is consumed with low efficiency. The most sensitive methods available for detecting leveling additives in plating baths involve electrochemical measurement of the metal electrodeposition rate under controlled hydrodynamic conditions, for which the additive concentration in the vicinity of the electrode surface is well-defined.
Cyclic voltammetric stripping (CVS) analysis [D. Tench and C. Ogden, J. Electrochem. Soc. 125, 194 (1978)] is the most widely used bath additive control method and involves cycling the potential of an inert electrode (e.g., Pt) in the plating bath between fixed potential limits so that metal is alternately plated on and stripped from the electrode surface. Such potential cycling is designed to establish a steady-state condition for the electrode surface so that reproducible results are obtained. Accumulation of organic films or other contaminants on the electrode surface can be avoided by periodically cycling the potential of the electrode in the plating solution without organic additives and, if necessary, polishing the electrode using a fine abrasive. Cyclic pulse voltammetric stripping (CPVS), also called cyclic step voltammetric stripping (CSVS), is a variation of the CVS method that employs discrete changes in potential during the analysis to condition the electrode so as to improve the measurement precision [D. Tench and J. White, J. Electrochem. Soc. 132, 831 (1985)]. A rotating disk electrode configuration is typically employed for both CVS and CPVS analysis to provide controlled hydrodynamic conditions.
For CVS and CPVS analyses, the metal deposition rate may be determined from the current or charge passed during metal electrodeposition but it is usually advantageous to measure the charge associated with anodic stripping of the metal from the electrode. A typical CVS/CPVS rate parameter is the stripping peak area (A r ) for a predetermined electrode rotation rate. The CVS method was first applied to control copper pyrophosphate baths (U.S. Pat. No. 4,132,605 to Tench and Ogden) but has since been adapted for control of a variety of other plating systems, including the acid copper sulfate baths that are widely used by the electronics industry [e.g., R. Haak, C. Ogden and D. Tench, Plating Surf. Fin. 68(4), 52 (1981) and Plating Surf. Fin. 69(3), 62 (1982)].
Acid copper sulfate baths are employed in the “Damascene” process (e.g., P. C. Andricacos, Electrochem. Soc. Interface, Spring 1999, p.32; U.S. Pat. No. 4,789,648 to Chow et al.; U.S. Pat. No. 5,209,817 to Ahmad et al.) to electrodeposit copper within fine trenches and vias in dielectric material on semiconductor chips. In the Damascene process, as currently practiced, vias and trenches are etched in the chip's dielectric material, which is typically silicon dioxide, although materials with lower dielectric constants are under development. A barrier layer, e.g., titanium nitride (TiN), tantalum nitride (TaN) or tungsten nitride (WN x ), is deposited on the sidewalls and bottoms of the trenches and vias, typically by reactive sputtering, to prevent Cu migration into the dielectric material and degradation of the device performance. Over the barrier layer, a thin copper seed layer is deposited, typically by sputtering, to provide enhanced conductivity and good adhesion. Copper is then electrodeposited into the trenches and vias. Copper deposited on the outer surface, i.e., outside of the trenches and vias, is removed by chemical mechanical polishing (CMP). A capping or cladding layer (e.g., TiN, TaN or WN x ) is applied to the exposed copper circuitry to suppress oxidation and migration of the copper. Alternative barrier/capping layers based on electrolessly deposited cobalt and nickel are currently under investigation [e.g., A. Kohn, M. Eizenberg, Y. Shacham-Diamand and Y. Sverdlov, Mater. Sci. Eng. A302, 18 (2001)]. The “Dual Damascene” process involves deposition in both trenches and vias at the same time. In this document, the term “Damascene” also encompasses the “Dual Damascene” process.
Acid copper sulfate electroplating baths require a minimum of two types of organic additives to provide good leveling and satisfactory deposit properties. The “suppressor” additive (also called the “polymer”, “carrier”, or “wetter”, depending on the bath supplier) is typically a polymeric organic species, e.g., high-molecular-weight polyethylene or polypropylene glycol, which adsorbs strongly on the copper cathode surface, in the presence of chloride ion, to form a film that sharply increases the overpotential for copper deposition. The “anti-suppressor” additive (also called the “brightener”, “accelerator” or simply the “additive”, depending on the bath supplier) counters the suppressive effect of the suppressor to provide the accelerated deposition needed for good leveling and bottom up filling of Damascene features. From the prior art literature [e.g., J. D. Reid and A. P. David, Plating Surf. Fin. 74(1), 66 (1987); J. J. Kelly, C. Tian and A. C. West, J. Electrochem. Soc. 146(7), 2540 (1999); and R. D. Mikkola and L. Chen, Proc. IEEE 2000 Int. Interconnect Tech. Conf., p. 117 (2000)], the presence of chloride ion is known to be essential to the functioning of the suppressor and anti-suppressor additives in acid copper baths. In order to avoid overplating ultrafine Damascene trenches and vias, a third additive called the “leveler” (or “booster”, depending on the bath supplier) is used. The leveler is typically an organic compound containing nitrogen or oxygen that also tends to decrease the copper deposition rate. Plating bath suppliers generally provide additives in the form of solutions that may contain additives of more than one type, as well as other organic and inorganic addition agents. The suppressor additive may be comprised of more than one chemical species and generally involves a range of molecular weights.
In order to obtain satisfactory deposits, the concentrations of the organic additives used in acid copper plating baths must be accurately analyzed and controlled. The suppressor, anti-suppressor and leveler concentrations in acid copper sulfate baths can all be determined by CVS analysis methods based on the effects that these additives exert on the copper electrodeposition rate. At the additive concentrations typically employed, the effect of the suppressor in reducing the copper deposition rate is usually much stronger than that of the leveler so that the concentration of the suppressor can be determined by the usual CVS response curve or dilution titration analysis [W. O. Freitag, C. Ogden, D. Tench and J. White, Plating Surf. Fin. 70(10), 55 (1983)]. Likewise, the anti-suppressor concentration can be determined by the linear approximation technique (LAT) or modified linear approximation technique (MLAT) described by R. Gluzman [Proc. 70 th Am. Electroplaters Soc. Tech. Conf., Sur/Fin, Indianapolis, Ind. (June 1983)]. A method for measuring the leveler concentration in the presence of interference from both the suppressor and anti-suppressor is described in U.S. patent application Ser. No. 09/968,202 to Chalyt et al. (filed Oct. 1, 2001).
The concentration of chloride ion in acid copper plating baths must also be closely controlled (typically at a value in the 25 to 100 mg/L range) since chloride is essential to the functioning of the additive system. However, chloride ion specific electrodes are not suitable for use in acid copper plating baths because of the presence of interfering species (e.g., organic additives, copper ions and strong acid) that cause the electrode potential to drift with time. Another prior art method for chloride analysis involves titration with a solution of mercuric nitrate, which is a hazardous material that requires special handling and waste disposal. The calorimetric endpoint for this titration is also difficult to detect with sufficient accuracy, especially for an automated analysis system.
An alternative prior art method for chloride analysis of acid copper plating baths involves potentiometric titration with silver nitrate solution, for which the endpoint detection is readily automated and no hazardous waste is involved. However, the silver chloride precipitate produced during the titration is difficult to remove, and residues of the precipitate, or of a reducing agent (typically, sodium thiosulfate) used to dissolve it, can interfere with subsequent analyses performed in the same cell. The CVS methods used for analyses of organic additives in acid copper baths are particularly sensitive to interference from chloride and silver ions (derived from dissolution of the silver chloride precipitate) and reducing agents, which can affect the copper electrodeposition rate. Another disadvantage of this prior art method is that the silver nitrate solution is decomposed by ambient light and must be handled in darkened containers and tubing, which interfere with visual inspection of the reagent delivery system. In addition, this titration method is only moderately sensitive to chloride.
A sensitive and robust method for analysis of chloride in acid copper plating baths, without the use of contaminating or hazardous chemicals, would be useful for controlling industrial plating processes, particularly those employed by the electronics industry. Such a method would also be useful for other applications, for example, to monitor the quality of the feed water and effluents for industrial processes. A method for detecting other halides is also needed. Chloride ion is generally known to strongly affect the copper electrodeposition rate from acid copper plating baths containing organic additives [e.g., R. D. Mikkola and L. Chen, Proc. IEEE 2000 Int. Interconnect Tech. Conf., p. I1I7 (2000)] but the present inventors were the first to recognize that this effect might be used as a means of quantitative halide analysis.
SUMMARY OF THE INVENTION
This invention provides a method for determining the concentration of a halide ion (chloride, iodide or bromide) in an unknown solution from the effect that the halide ion exerts on the copper electrodeposition rate from a copper electrodeposition solution. In this method, a copper electrodeposition rate parameter is measured for the copper electrodeposition solution, a test solution, and a calibration solution. The copper electrodeposition solution includes copper ions, an anion (sulfate, for example), an acid (sulfuric acid, for example), and at least one organic additive at a predetermined concentration. Preferably, the copper electrodeposition solution contains substantially no halide ions, or contains a small predetermined concentration of a halide ion. The test solution comprises the copper electrodeposition solution and a known volume fraction of the unknown solution being analyzed. The calibration solution comprises the copper electrodeposition solution and a known concentration of the halide ion being analyzed, which may be added as a solution or a solid. The concentration of the halide in the unknown solution is determined by comparing the values of the electrodeposition rate parameter measured for the copper electrodeposition solution, the test solution, and the calibration solution. Preferably, a calibration curve is generated by measuring the electrodeposition rate parameter for a plurality of calibration solutions, and the halide concentration in the unknown solution is determined by interpolation of the rate parameter measured for the test solution with respect to the calibration curve. Alternatively, the halide concentration may be determined by the linear approximation method, for which the calibration solution comprises the test solution with a known concentration of the halide added.
The method of the present invention provides a sensitive measure of the halide concentration in the unknown solution since the effect of organic additives on the copper electrodeposition rate is generally small in the absence of halide ion but is large in the presence of halide ion. Consequently, halide derived from addition of the unknown solution to the copper electrodeposition solution (containing little or no halide ion) has a relatively large effect on the copper electrodeposition rate. Addition of halide to the copper electrodeposition solution may increase or decrease the copper electrodeposition rate, depending on the specific organic additives employed in the copper electrodeposition solution.
The method of the present invention is particularly useful for measuring the concentration of chloride ion in an acid copper sulfate electroplating bath. In a preferred embodiment, the copper electrodeposition solution contains the same organic additives as those used in the acid copper plating bath. In this case, addition of chloride ion to the copper electrodeposition solution typically produces a decrease in the copper electrodeposition rate, because of the dominant effect of the suppressor additive. The test solution comprises the copper electrodeposition solution and a known volume fraction of a sample of the copper plating bath. Organic additives present in the plating bath sample are diluted by addition of the plating bath sample to the copper electrodeposition solution so that their effect on the chloride analysis is generally small. A significantly different concentration (including zero concentration) of one or more of the additives may be utilized in the copper electrodeposition solution (compared to the copper plating bath) to improve the sensitivity, selectivity, and/or accuracy of the analysis.
The copper electrodeposition rate is preferably measured by the cyclic voltammetric stripping (CVS) method. A preferred electrodeposition rate parameter is the copper stripping peak area (A r ), which is preferably normalized by dividing the A r values for the test solution and the calibration solution by the A r (0) value for the copper electrodeposition solution. The normalized A r /A r (0) parameter inherently provides a measure of the difference in the copper electrodeposition rate for a given test or calibration solution relative and that for the copper electrodeposition solution. Use of a normalized rate parameter also minimizes errors resulting from fluctuations in the temperature of the copper electrodeposition solution, and variations in the working electrode surface state. The halide concentration in the test solution is preferably determined by comparison of the A r /A r (0) value for the test solution with a calibration plot of A r /A r (0) vs. halide concentration (for a plurality of calibration solutions). The halide concentration in the unknown solution may then be calculated from the volume fraction of the unknown solution in the test solution.
The present invention provides a sensitive method for determining the concentration of chloride ions in acid copper plating baths without the use of extraneous reagents. Thus, the cross-contamination and waste disposal issues associated with the reagents and reaction products utilized in prior art methods are avoided. In addition, the method may be practiced using CVS instrumentation, which is widely used for analysis of organic additives in acid copper plating baths. This invention is useful for providing the close control of the chloride concentration in acid copper baths needed for optimum additive functioning and acceptable deposit properties. The method may also be used to measure the concentrations of other halides or halide mixtures that could be used in acid copper electroplating baths. The invention also provides a sensitive measure of the halide concentration in a wide variety of solutions, including drinking water and industrial process feed and effluent solutions.
Further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a calibration plot of the CVS normalized copper stripping peak area, A r /A r (0), as a function of the concentration of chloride ion added to an acid copper electrodeposition solution.
FIG. 2 shows dilution titration plots of A r /A r (0) vs. Volume fractions of plating bath samples (containing 30, 50 or 70 mg/L chloride ion) added to 50 mL of the copper electrodeposition solution (of FIG. 1 ).
FIG. 3 shows a calibration plot of the CVS normalized copper stripping peak area, A r /A r (0), as a function of the concentration of bromide ion added to the acid copper electrodeposition solution (of FIG. 1 ).
FIG. 4 shows a calibration plot of the CVS normalized copper stripping peak area, A r /A r (0), as a function of the concentration of iodide ion added to the acid copper electrodeposition solution (of FIG. 1 ).
DETAILED DESCRIPTION OF THE INVENTION
Technical terms used in this document are generally known to those skilled in the art. The term “electrode potential”, or simply “potential”, refers to the voltage occurring across a single electrode-electrolyte interface. In practice, the electrode potential often includes an appreciable resistive voltage drop in the electrolyte, which typically remains constant and does not affect voltammetric analysis results.
Voltammetric data may be generated by scanning the electrode potential at a constant rate or by stepping the potential, or by a combination of potential scanning and stepping. A “cyclic voltammogram” is a plot of current or current density (on the y-axis) versus the working electrode potential (on the x-axis) typically obtained by cycling the working electrode potential with time between fixed negative and positive limits. A “potentiostat” is an electronic device for controlling the potential of a working electrode by passing current between the working electrode and a counter electrode so as to drive the working electrode to a desired potential relative to a reference electrode. Use of a potentiostat avoids passing appreciable current through the reference electrode, which might change its potential. Operation in the three-electrode mode may also reduce errors in the electrode potential associated with the resistive voltage drop in the electrolyte.
As used in this document, the term “unknown solution” denotes a solution having an unknown concentration of halide to be determined by the analysis of the invention. The unknown solution may be a sample of a plating bath or of another solution. The term “plating bath” encompasses both electroplating baths and electroless plating baths, used to plate any metal. The copper electrodeposition rate used for the analysis of the invention is measured in a “copper electrodeposition solution” having predetermined concentrations of copper ions, an anion, an acid, and at least one organic additive. The plural term “copper ions” is used since copper is typically present in solution as Cu 2+ and Cu + species in various complexes with anions. In acid copper plating solutions, the Cu 2+ species is typically dominant but the Cu + species is formed as an intermediate during copper electrodeposition. The copper electrodeposition solution may also contain a small predetermined concentration of a halide ion. The symbol “ M ” means molar concentration. The term “standard addition” generally means addition of a known volume of an unknown solution or of a standard halide solution to a known volume of a copper electrodeposition solution. The volume fraction is the volume of unknown solution or standard halide solution added to the copper electrodeposition solution divided by the total volume of the solution resulting from addition of the unknown solution or standard solution. The term “standard addition” also encompasses addition of a known weight of a solid halide salt to a known volume of a copper electrodeposition solution. Calibration data are typically handled as calibration curves or plots but such data may be tabulated and used directly, especially by a computer, and the terms “curve” or “plot” used in this document include tabulated data. As used in this document, the term “halide” encompasses chloride, bromide and iodide, but does not include fluoride, which is chemically atypical of the halides with respect to complexation and does not substantially enhance the effects of organic additives in acid copper plating baths.
The method of the present invention depends on the fact that organic additives used to brighten and level deposits from acid copper plating baths generally exert a strong effect on the copper electrodeposition rate only in the presence of halide ions. In a preferred embodiment, the copper electrodeposition rate is first measured in a copper electrodeposition solution containing predetermined concentrations of at least one organic additive and a small predetermined concentration of a halide ion (or no halide ion). The copper electrodeposition rate is then measured for a test solution comprised of the copper electrodeposition solution and a known volume fraction of an unknown solution. The change in the copper electrodeposition rate produced by such standard addition of the unknown solution to the copper electrodeposition solution provides a measure of the halide ion concentration in the unknown solution. A calibration curve is preferably generated by measuring the copper electrodeposition rate for the copper electrodeposition solution and for a plurality of calibration solutions comprised of the copper electrodeposition solution and known concentrations of the halide ion. In this case, the halide concentration in the unknown solution is determined by interpolation of the copper electrodeposition rate measured for the test solution with respect to the calibration curve. The analysis may be also be performed using only one calibration solution. For solutions containing more than one type of halide ion, the analysis yields the total concentration of halide ions.
Changes in the copper electrodeposition rate for the test and calibration solutions are preferably expressed as a normalized rate parameter. A preferred normalized rate parameter is the ratio of the copper electrodeposition rate for the test solution or calibration solution to that for the copper electrodeposition solution, which provides a measure of the copper deposition rate differential relative to the copper electrodeposition solution and minimizes errors associated with temperature fluctuations and changes in the working electrode surface state. Other normalized rate parameters may also be used, for example, the mathematical difference between the electrodeposition rate for the test solution or the calibration solution and that for the copper electrodeposition solution. The copper electrodeposition rate parameter may also be normalized as the ratio or difference of values measured under two well-defined hydrodynamic conditions, for example, at two electrode rotation rates (one of which may be zero).
A preferred copper electrodeposition solution for the analysis of the invention is an acid copper sulfate plating bath containing at least one organic additive and either a small predetermined concentration of halide ion or no added halide. Typical ranges for the major inorganic constituents of acid copper sulfate baths, which may be suitable ranges for the analysis of the present invention, are 40-240 g/L copper sulfate pentahydrate and 1-240 g/L sulfuric acid. The copper electrodeposition solution preferably contains a suppressor additive (polyethylene glycol or polypropylene glycol, for example), and may contain an anti-suppressor additive [bis-(3-sulfopropyl) disulfide or 3-mercapto-1-propanosulfonate, for example] and/or a leveler additive (benzotriazole, for example). The various additives are usually obtained from bath suppliers in the form of solutions for which the actual additive species and their concentrations may not be known. The concentrations of such additive solutions recommended by the bath supplier are generally suitable for use in the copper electrodeposition solution of the present invention. The copper electrodeposition solution may employ a variety of anions, including sulfate, alkylsulfonate, sulfamate, fluoroborate, citrate, and mixtures thereof.
The suppressor additive used in the copper electrodeposition solution typically comprises a polymeric species having a range of molecular weights. For the polyethylene glycol suppressor, the average molecular weight is preferably between 500 and 15,000, but higher or lower average molecular weights may be used. Polyethylene glycol concentrations from 0.1 to 1.0 g/L are preferred but other concentrations may be used.
For analysis of the chloride ion concentration in acid copper electroplating baths, a preferred copper electrodeposition solution contains either a predetermined small concentration of chloride (0.1 mg/L, for example) or substantially no chloride, but otherwise includes the same concentrations of inorganic constituents as the plating bath being analyzed. For acid copper sulfate plating baths, the inorganic constituents are typically copper ions, sulfate and sulfuric acid, but other metal ions (e.g., tin ions) and other anions (e.g., citrate) may also be included in the bath. The concentrations of the inorganic constituents of the copper electrodeposition solution are preferable the same as those of the plating bath, which minimizes the effects of these constituents on the analysis. However, a wide range of acid copper compositions may be used.
A preferred copper electrodeposition solution for analysis of chloride ion in copper plating baths also contains the same organic additive species as the plating bath being analyzed. These include a suppressor additive, an anti-suppressor additive, and, in some cases, a leveler additive, which are typically supplied as solutions that may contain more than one chemical species. The concentrations of the various additives in the copper electrodeposition solution may differ from those in the plating bath. For example, an excess of suppressor additive may be used in the copper electrodeposition solution to ensure that the effect of the suppressor additive, which depends strongly on the chloride concentration, is dominant. Since the effect of each of the additives generally depends on the chloride concentration, a copper electrodeposition solution containing only one additive species (a suppressor, for example) may be used for the analysis. For copper electrodeposition solutions in which the anti-suppressor effect is dominant, the copper electrodeposition rate increases with increased chloride concentration.
For the method of the present invention, the copper electrodeposition rate is preferably determined by cyclic voltammetric stripping (CVS) or cyclic pulse voltammetric stripping (CPVS). The latter is also called cyclic step voltammetric stripping (CSVS). As used in this document, the term “cyclic voltammetric stripping” or “CVS” implicitly includes the CPVS method, which is a variation of the CVS method. Likewise, the term “CVS rate parameter” includes the analogous CPVS rate parameters.
In the CVS method, the potential of an inert working electrode, typically platinum, is cycled in a copper electrodeposition solution at a constant rate between fixed potential limits so that copper is alternately electrodeposited on the electrode surface and anodically stripped back into the solution. Preferably, a rotating disk electrode configuration is used for the working electrode to control solution mass transport so as to improve the sensitivity and reproducibility of the analysis results. The copper deposition rate is preferably measured via the copper stripping peak area at a constant electrode rotation rate (A r ) but may also be determined from the stripping peak height, or from the electrode impedance, current (including average current), or integrated current (charge) measured for a predetermined cathodic potential or potential range (with or without electrode rotation). All of these rate parameters provide a relative measure of the copper electrodeposition rate that can readily be used for comparisons only when the measurement conditions are the same.
Preferably, the A r values measured for the test and calibration solutions are divided by the A r (0) value for the copper electrodeposition solution. The normalized A r /A r (0) parameter provides a measure of the difference in copper electrodeposition rate for the test and calibration solutions relative to that for the copper electrodeposition solution. Use of a normalized rate parameter also minimizes errors resulting from fluctuations in the solution temperature and variations in the working electrode surface state. In this case, the halide ion concentration in a test solution is preferably determined by comparison of the A r /A r (0) value for the test solution with a calibration plot of A r /A r (0) vs. halide ion concentration (for a plurality of calibration solutions). The halide concentration in the unknown solution may then be calculated from the volume fraction of unknown solution in the test solution. The electrodeposition rate parameter for the test and calibration solutions may also be normalized by other procedures, for example, via the mathematical difference with respect to the electrodeposition rate parameter measured for the copper electrodeposition solution, or via the ratio or difference for electrodeposition rates measured at two electrode rotation rates.
A preferred approach is to perform a CVS dilution titration by measuring A r (0) for the copper electrodeposition solution, and then measuring A, after each of a plurality of standard additions of the unknown solution to the copper electrodeposition solution. The halide concentration in the unknown solution is determined from the volume fraction of unknown solution added to the copper electrodeposition solution at the endpoint for the dilution titration, which is a predetermined A r /A r (0) value (0.30, for example). This approach ensures that the copper electrodeposition rate differentials inherent in the A r /A r (0) values is sufficiently large to provide reproducible results, and permits several data points to be averaged to further improve the precision of the analysis results.
For CVS electrodeposition rate measurements, a plurality of potential cycles is typically employed to condition the working electrode surface so as to provide reproducible results. Electrode conditioning may be performed for a predetermined number of cycles (3 cycles, for example), or until a steady-state electrode condition is indicated by substantially equivalent voltammograms or voltammetric features on successive cycles. Typically, steady state is indicated by successive A r values that differ by less than a predetermined percentage (0.5%, for example).
The inert working electrode for CVS measurements may be comprised of any suitable electrically conducting material that is stable in the background electrolyte under the conditions used for the voltammetric analysis but is preferably comprised of a noble metal, for example, platinum, iridium, gold, osmium, palladium, rhenium, rhodium, ruthenium, and alloys thereof. Other oxidation-resistant metals and alloys, stainless steel, for example, may also be used as working electrode materials. A typical CVS rotating disk electrode is comprised of a platinum metal disk (3-5 mm diameter), with an electrical contact wire on the backside, embedded flush with one end of an insulating plastic cylinder (10-20 mm diameter). The rotating disk electrode may be fabricated by press fitting the metal disk into a hole in the plastic but is preferably fabricated by hot pressing, which forms a seal between the metal and the plastic that prevents intrusion of the solution. A suitable plastic for mounting rotating disk electrodes by hot pressing is polytrifluorochloroethylene (Kel-F®). The rotating disk electrode is usually rotated at a constant rate (100-5000 rpm) but the electrode rotation may be modulated with time.
Precise control over the working electrode potential needed for CVS measurements is typically provided via an electronic potentiostat in conjunction with a counter electrode and a reference electrode, e.g., silver-silver chloride (SSCE), mercury-mercury sulfate, or saturated calomel electrode (SCE). A double junction may be used to extend the life of the reference electrode by inhibiting intrusion of plating bath species. The counter electrode may be comprised of an inert metal or copper. Depolarizers (sulfur or phosphorus, for example) may be included in a copper counter electrode to facilitate copper dissolution so as to avoid breakdown of the copper electrodeposition solution. Practically any electrical conductor that resists oxidation and reduction in the copper electrodeposition solution may be used as an inert counter electrode, including metals, alloys and conducting oxides (mixed titanium-ruthenium oxide, for example). A preferred inert counter electrode material is 316 stainless steel, which is highly oxidation-resistant and relatively inexpensive, but other types of stainless steel or other oxidation-resistant alloys (Inconel, for example) may also be used. Other suitable inert counter electrode materials include noble metals, for example, platinum, iridium, gold, osmium, palladium, rhenium, rhodium, ruthenium, and alloys thereof.
Metal electrodeposition rates according to the present invention may also be measured by methods other than CVS, including those based on measurements of the ac impedance of the cathode, for example. The same electrode materials and configurations may be used for such alternative methods. Although the precision and reproducibility of the analysis might be degraded, current measurements reflecting the metal electrodeposition rate could also be made at a stationary electrode and/or without potential cycling. If a stationary working electrode is used for the halide ion analysis of the present invention, the hydrodynamic conditions at the electrode is surface are preferably controlled, by stirring or pumping the solution, for example.
Improved results for the analysis of the present invention may be provided by optimizing the CVS measurement parameters. The key CVS measurement parameters and their typical ranges for acid copper systems include the electrode rotation rate (100-10,000 rpm), potential scan rate (10-1000 mV/s), negative potential limit (−0.05 to −0.5 V vs. SSCE) and positive potential limit (1.4 to 1.8 V vs. SSCE). A positive potential limit of relatively high voltage (in the oxygen evolution region) is typically used so that contaminants adsorbed on the electrode surface are removed by electrochemical oxidation on each cycle, which provides more reproducible results. Additional CPVS measurement parameters include the potentials and hold times for the pulses or steps used. The accuracy of the electrodeposition rate measurement may be improved by employing a slightly elevated solution temperature (typically, 3° or 4° C. above room temperature), which can be more consistently maintained.
Within the scope of the present invention, variations in the analysis procedures and data handling will be apparent to those skilled in the art. For example, the halide concentration may be determined by linear approximation analysis. In this case, a copper electrodeposition rate parameter (e.g., A r ) is measured for the copper electrodeposition solution before and after addition of a known volume fraction of an unknown solution. The electrodeposition rate parameter measurement is then repeated in this test solution after one or more standard additions of halide ion. The concentration of the halide in the unknown solution is calculated assuming that the electrodeposition rate parameter varies linearly with halide concentration, which is verified if the changes in the rate parameter produced by standard additions of the same amount of halide ion are equivalent. In this case, standard addition of halide ion to the test solution yields a calibration solution so that a separate calibration curve is not needed. An analogous procedure may be used when the variation in the electrodeposition rate parameter with halide concentration is non-linear but is nonetheless mathematically predictable.
The invention is particularly useful for analysis of chloride ion in acid copper sulfate electroplating baths. However, the method of the invention may also be applied to analysis of other halide ions (bromide and iodide), which are chemically similar and might be used instead of chloride, or in combination with chloride, in acid copper plating baths. For baths employing mixed halides, the analysis would yield a total halide concentration or an effective halide concentration. The invention may also be applied to analysis of halides in acid copper sulfate baths containing additional anions (citrate, for example), or acid copper baths based on alternative anions (alkylsulfonate, sulfamate, fluoroborate and citrate, for example). The invention may also be applied to analysis of halides in baths used to electrodeposit copper alloys (copper-tin alloys, for example) or other metals (nickel, gold, tin and lead, for example).
In addition, the method of the present invention may be applied to measure the halide concentration in a wide variety of unknown solutions, including drinking water and industrial process feed and effluent solutions. It is often necessary to monitor halides in process feed solutions to avoid unwanted side reactions, such as corrosion reactions. Halide in effluent solutions are often monitored for compliance with environmental regulations.
DESCRIPTION OF A PREFERRED EMBODIMENT
In a preferred embodiment of the present invention, the concentration of halide ion in an unknown solution is determined from the effect of standard addition of the unknown solution on the CVS stripping peak area (A r ) measured at a rotating Pt disk electrode in a copper electrodeposition solution. Preferably, the copper electrodeposition solution contains a small predetermined concentration of halide (0.1 mg/L chloride, for example) or substantially no halide. For analysis of halide in an acid copper plating bath, the concentrations of other bath constituents are preferably maintained within the ranges recommended by the bath supplier. After each standard addition, sufficient time should be allowed for stirring via the rotating disk electrode (or other means) to provide a homogeneous solution. During measurements, the solution temperature should be maintained at a constant value (within ±0.5° C.) around room temperature.
For A r measurements, the electrode potential is preferably cycled at a constant rate between fixed positive and negative limits. Typical ranges for the other CVS measurement parameters are 100-5000 rpm for the electrode rotation rate, 50-500 mV/s for the potential scan rate, and 1.4 to 1.8 V vs. SSCE for the positive potential limit. The potential of the rotating disk electrode is preferably controlled relative to a reference electrode via a potentiostat and a counter electrode.
Prior to the halide analysis, the potential of the working electrode is preferably cycled (over the potential range used for the analysis) in the copper electrodeposition solution to condition the electrode surface. For both the electrode conditioning and the halide analysis, the potential of the working electrode is preferably cycled for a predetermined number of cycles, typically three. Alternatively, the potential of the working electrode is cycled until successive A r values differ by less than a predetermined percentage (typically 0.5%).
The efficacy of the present invention was demonstrated via CVS measurements of A r at a platinum disk electrode (4 mm diameter) rotating at 2500 rpm in a copper electrodeposition solution (without halide added), calibration solutions (containing chloride, bromide or iodide), and various test solutions. Solutions were prepared using de-ionized water. The copper electrodeposition solution contained 75 g/L copper sulfate pentahydrate, 100 mL/L concentrated sulfuric acid, 1.0 mL/L Viaform Accelerator additive, 5.0 mL/L Viaform Suppressor additive, and 10 mL/L Viaform Leveler additive. Calibration solutions were prepared by standard addition of 50 mg/L halide solutions to 100 mL of the copper electrodeposition solution. For chloride dilution titration tests, copper plating bath samples containing known chloride concentrations (30-70 mg/L) were added to 50 mL of the copper electrodeposition solution. Measurements were also made for both the low acid and high acid formulations of the Viaform acid copper sulfate plating bath (Enthone OMI Corp.), and for a proprietary acid copper sulfate plating bath (not sold commercially).
CVS measurements were made under potentiostatic control using a Qualilab QL-10 plating bath analyzer or QLCA-320 Online Chemical Measurement System (ECI Technology, Inc.). The counter electrode was a stainless steel rod and the reference electrode was a modified silver-silver chloride electrode (SSCE-M) for which the solution in a standard SSCE electrode was replaced with a saturated AgCl solution also containing 0.1 M KCl and 10 volume % sulfuric acid. The working electrode potential was scanned at 200 mV/s between a positive limit of ±1.575 V and a negative limit of −0.225 V vs. SSCE-M. For A r and A r (0) measurements, the anodic current was integrated from the zero-current potential (at the cathodic-anodic crossover) to 0.30 V vs. SSCE-M. The electrode was conditioned for two potential cycles; A r or A,(0) was recorded for the third cycle. During CVS measurements, the solution temperature was controlled at 25° C. within ±0.5° C.
FIG. 1 shows a calibration plot of the CVS normalized rate parameter A r /A r (0) as a function of the chloride ion concentration in the copper electrodeposition solution. The value of A r /A r (0) is seen to decrease linearly with chloride concentration above about 0.05 mg/L (ppm). High sensitivity of A r /A r (0) to the chloride concentration in the linear region is evident. A linear response to chloride ion may be provided in practice via addition of about 0.05 mg/L chloride to the copper electrodeposition solution.
FIG. 2 shows dilution titration plots of A r /A r (0) vs. volume fraction of plating bath samples (containing various concentrations of chloride ion) added to 50 mL of the copper electrodeposition solution. The plating bath was the Viaform high acid formulation and contained 75 g/L copper sulfate pentahydrate, 100 mL/L concentrated sulfuric acid, 2.0 mL/L Viaform Accelerator, 8.0 mL/L Viaform Suppressor, 1.5 mL/L Viaform Leveler, and 30, 50 or 70 mg/L chloride ion. These chloride concentrations are representative of those typically found in acid copper plating baths. In all cases, the value of A r /A r (0) decreased linearly with the volume fraction of the plating bath sample added, and the volume fraction for a given A r /A r (0) value exhibited a strong dependence on the chloride concentration in the plating bath sample.
FIG. 3 shows a calibration plot of the CVS normalized rate parameter A r /A r (0) as a function of the bromide ion concentration in the copper electrodeposition solution. The value of A r /A r (0) is seen to decrease linearly with bromide concentration above about 0.2 mg/L (ppm). High sensitivity of A r /A r (0) to the bromide concentration in the linear region is evident. A linear response to bromide ion may be provided in practice via addition of about 0.2 mg/L bromide to the copper electrodeposition solution.
FIG. 4 shows a calibration plot of the CVS normalized rate parameter A r /A r (0) as a function of the iodide ion concentration in the copper electrodeposition solution. The value of A r /A r (0) is seen to decrease linearly with iodide concentration above about 0.5 mg/L (ppm). High sensitivity of A r /A r (0) to the iodide concentration in the linear region is evident. A linear response to iodide ion may be provided in practice via addition of about 0.5 mg/L iodide to the copper electrodeposition solution.
EXAMPLE 1
The method of the present invention was used to analyze the chloride concentration in high-acid Viaform acid copper plating baths having concentrations of the various constituents that corresponded to the target values, and the high and low supplier specification limits. The low-specification bath contained 58 g/L copper sulfate pentahydrate, 100 mL/L concentrated sulfuric acid, 30 mg/L chloride ion, 1.0 mL/L Viaform Accelerator, 4.0 mL/L Viaform Suppressor, and 1.0 mL/L Viaform Leveler. The target-specification bath contained 75 g/L copper sulfate pentahydrate, 100 mL/L concentrated sulfuric acid, 50 mg/L chloride ion, 2.0 mL/L Viaform Accelerator, 8.0 mL/L Viaform Suppressor, and 1.5 mL/L Viaform Leveler. The high-specification bath contained 90 g/L copper sulfate pentahydrate, 100 mL/L concentrated sulfuric acid, 70 mg/L chloride ion, 3.0 mL/L Viaform Accelerator, 12.0 mL/L Viaform Suppressor, and 2.0 mL/L Viaform Leveler. Chloride analyses were performed via dilution titration to 0.75 for the A r /A r (0) value. Table 1 shows that the chloride analysis values agreed well with those expected from the make-up solution composition.
TABLE 1
Chloride Analysis Results for
Viaform Acid Copper Plating Baths
Bath Composition
Expected (mg/L)
Analysis (mg/L)
Error (%)
Low-Specification
30
31.1
3.5
Low-Specification
30
30.5
1.6
Target
50
51.6
3.3
Target
50
50.3
0.6
High-Specification
70
71.2
1.8
EXAMPLE 2
The method of the present invention was used to analyze the chloride concentration in low-acid Viaform acid copper plating baths having concentrations of the various constituents that corresponded to the target values, and the high and low supplier specification limits. Eighteen chloride measurements were made over a one week period. The low-specification bath contained 140 g/L copper sulfate pentahydrate, 8.0 g/L sulfuric acid, 40 mg/L chloride ion, 4.0 mL/L Viaform Accelerator, 1.5 mL/L Viaform Suppressor, and 0.5 mL/L Viaform Leveler. The target-specification bath contained 160 g/L copper sulfate pentahydrate, 10.0 g/L sulfuric acid, 50 mg/L chloride ion, 6.0 mL/L Viaform Accelerator, 2.0 mL/L Viaform Suppressor, and 1.0 mL/L Viaform Leveler. The high-specification bath contained 180 g/L copper sulfate pentahydrate, 12.0 g/L sulfuric acid, 60 mg/L chloride ion, 8.0 mL/L Viaform Accelerator, 2.5 mL/L Viaform Suppressor, and 1.5 mL/L Viaform Leveler. Chloride analyses were performed via dilution titration to 0.75 for the A r /A r (0) value. For the low-specification (40 mg/l chloride), target (50 mg/L chloride), and high-specification (60 mg/L chloride) baths, respectively, the average chloride analysis results and the relative standard deviation (in parentheses) for 18 measurements were 40.17 mg/L (1.50%), 50.17 mg/L (1.41%) and 60.04 mg/L (1.37%).
The preferred embodiments of the present invention have been illustrated and described above. Modifications and additional embodiments, however, will undoubtedly be apparent to those skilled in the art. Furthermore, equivalent elements may be substituted for those illustrated and described herein, parts or connections might be reversed or otherwise interchanged, and certain features of the invention may be utilized independently of other features. Consequently, the exemplary embodiments should be considered illustrative, rather than inclusive, while the appended claims are more indicative of the full scope of the invention. | The concentration of chloride ion in an acid copper electroplating bath is determined from the effect that chloride exerts on the copper electrodeposition rate in the presence of organic additives. A cyclic voltammetric stripping (CVS) rate parameter is measured, before and after standard addition of a plating bath sample, in an acid copper electrodeposition solution containing little or no chloride and at least one organic additive. Cross contamination and waste disposal issues associated with the reagents and reaction products involved in chloride titration analyses are avoided. The method may also be applied to analysis of other halides (bromide and iodide) and other solutions. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit of U.S. Provisional Patent Application No. 61/427,726, filed Dec. 28, 2010, entitled GAS TURBINE ENGINE AND FUEL INJECTION SYSTEM, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to gas turbine engines, and more particularly, to fuel injection systems for gas turbine engines.
BACKGROUND
[0003] Gas turbine engines and fuel injection systems for gas turbine engines remain an area of interest. Some existing systems have various shortcomings, drawbacks, and disadvantages relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
SUMMARY
[0004] One embodiment of the present invention is a unique gas turbine engine. Another embodiment is a unique fuel injection system for a gas turbine engine. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for gas turbine engines and fuel injection systems for gas turbine engines. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
[0006] FIG. 1 schematically illustrates some aspects of a non-limiting example of a gas turbine engine in accordance with an embodiment of the present invention.
[0007] FIG. 2 depicts some aspects of a non-limiting example of combustion system in accordance with an embodiment of the present invention.
[0008] FIG. 3 depicts some aspects of a non-limiting example of a fuel injection system in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0009] For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nonetheless be understood that no limitation of the scope of the invention is intended by the illustration and description of certain embodiments of the invention. In addition, any alterations and/or modifications of the illustrated and/or described embodiment(s) are contemplated as being within the scope of the present invention. Further, any other applications of the principles of the invention, as illustrated and/or described herein, as would normally occur to one skilled in the art to which the invention pertains, are contemplated as being within the scope of the present invention.
[0010] Referring to the drawings, and in particular FIG. 1 , a non-limiting example of a gas turbine engine 10 in accordance with an embodiment of the present invention is depicted. In one form, engine 10 is an aircraft propulsion power plant. In other embodiments, engine 10 may be a land-based or marine engine. In one form, engine 10 is a multi-spool turbofan engine. In other embodiments, engine 10 may be a single or multi-spool turbofan, turboshaft, turbojet, turboprop gas turbine or combined cycle engine.
[0011] Gas turbine engine 10 includes a fan system 12 , a compressor system 14 , a diffuser 16 , a combustion system 18 and a turbine system 20 . Compressor system 14 is in fluid communication with fan system 12 . Diffuser 16 is in fluid communication with compressor system 14 . Combustion system 18 is fluidly disposed between compressor system 14 and turbine system 20 . Fan system 12 includes a fan rotor system 22 . In various embodiments, fan rotor system 22 includes one or more rotors (not shown) that are powered by turbine system 20 and operative to pressurize air. Compressor system 14 includes a compressor rotor system 24 . In various embodiments, compressor rotor system 24 includes one or more rotors (not shown) that are powered by turbine system 20 and operative to further pressurize air received from fan system 12 . Turbine system 20 includes a turbine rotor system 26 . In various embodiments, turbine rotor system 26 includes one or more rotors (not shown) operative to drive fan rotor system 22 and compressor rotor system 24 . Turbine rotor system 26 is driving coupled to compressor rotor system 24 and fan rotor system 22 via a shafting system 28 . In various embodiments, shafting system 28 includes a plurality of shafts that may rotate at the same or different speeds and in the same or different directions. In some embodiments, only a single shaft may be employed.
[0012] During the operation of gas turbine engine 10 , air is drawn into the inlet of fan system 12 and pressurized by fan system 12 . Some of the air pressurized by fan system 12 is directed into compressor system 14 , and the balance is directed into a bypass duct (not shown) for providing a component of the thrust output by gas turbine engine 10 . Compressor system 14 further pressurizes the air received from fan system 12 , which is then discharged in to diffuser 16 . Diffuser 16 reduces the velocity of the pressurized air, and directs the diffused airflow into combustion system 18 . Fuel is mixed with the pressurized air in combustion system 18 , which is then combusted. In one form, combustion system 18 includes a combustion liner (not shown) that contains a continuous combustion process. In other embodiments, combustion system 18 may take other forms, and may be, for example, a wave rotor combustion system, a rotary valve combustion system, or a slinger combustion system, and may employ deflagration and/or detonation combustion processes. The hot gases exiting combustion system 18 are directed into turbine system 20 , which extracts energy in the form of mechanical shaft power to drive fan system 12 and compressor system 14 via shafting system 28 . The hot gases exiting turbine system 20 are directed into a nozzle (not shown), and provide a component of the thrust output by gas turbine engine 10 .
[0013] Referring to FIG. 2 , combustion system 18 includes a combustion liner 30 and a fuel injection system 32 . Combustion liner 30 is disposed in a combustor case 34 . Combustion liner 30 is operative to contain combustion processes during the operation of engine 10 . Fuel injection system 32 is operative to inject fuel into combustion liner 30 . In particular, fuel injection system 32 is operative to inject a fuel/air mixture into combustion liner 30 , which is ignited by an igniter (not shown) to form a combustion process 36 that adds heat to the air discharged by compressor system 14 . The heated air is then discharged by combustion system 18 into turbine system 20 .
[0014] Referring to FIG. 3 in conjunction with FIG. 2 , fuel injection system 32 includes a pilot injection module 38 and a main injection module 40 . Main injection module 40 is disposed concentrically around pilot injection module 38 , i.e., radially outward of pilot injection module 38 . Pilot injection module 38 , disposed radially inward of main injection module 40 , is configured inject a pilot fuel flow 42 to generate a pilot combustion process 44 . Main injection module 40 is configured to inject a main fuel flow 46 to generate a main combustion process 48 disposed around pilot combustion process 44 . In one form, pilot injection module 38 and main injection module 40 are independently operable. During low power operation of engine 10 , e.g., including ground idle and flight idle conditions, pilot injection module 38 is employed. Main injection module 40 is employed during high power engine 10 operation, e.g., including take-off and cruise thrust. Some operating regimes include the use of both pilot injection module 38 and main injection module 40 , e.g., during transition from idle or other low power conditions to higher power conditions. In some embodiments, both main injection module 40 and pilot injection module 38 may be employed to inject fuel into combustion liner 30 during high power engine 10 operation. In other embodiments, only main injection module 40 is employed during high power engine 10 operation.
[0015] Pilot injection module 38 is fluidly coupled to a fuel supply line 50 . Main injection module 40 is fluidly coupled to a fuel supply line 52 . Fuel supply lines 50 and 52 are fluidly independent of each other, that is, one supply line may be pressurized to supply fuel to the corresponding injection module independent of the other fuel supply line. In one form, fuel injection system 32 is configured to selectively control fuel delivery (including fuel pressure) to fuel supply lines 50 and 52 , providing independent control of pilot injection module 38 and main injection module 40 to selectively supply fuel to one or both of pilot injection module 38 and main injection module 40 . In other embodiments, pilot injection module 38 and main injection module 40 may be fluidly coupled to a common fuel supply line, and may be selectively and independently operable via other means. In still other embodiments, pilot injection module 38 and main injection module 40 may not be independently operable as such. In one form, pilot injection module 38 is optimized for operation in low engine 10 power conditions, and main injection module 40 is optimized for operation in high engine 10 power conditions. In other embodiments, pilot injection module 38 and main injection module 40 may be optimized for operation at other engine 10 power conditions.
[0016] Pilot injection module 38 includes a pilot nozzle 54 , a pilot swirler 56 and a discharge nozzle 58 . Pilot nozzle 54 is in fluid communication with fuel supply line 50 . Pilot nozzle 54 is operative to inject fuel into combustion liner 30 . In one form, pilot nozzle 54 is a pressure swirl atomizer. In other embodiments, pilot nozzle 54 may take other forms. In one form, pilot swirler 56 surrounds pilot nozzle 54 . In other embodiments, pilot swirler 56 may be arranged in other locations and orientations. In one form, pilot swirler 56 includes a plurality of turning vanes 60 configured to induce swirl into airflow passing through pilot swirler 56 . In other embodiments, other means for inducing swirl may be employed, e.g., air injection and/or fuel injection ports configured to induce swirl.
[0017] The swirling pilot airflow from pilot swirler 56 mixes with the fuel sprayed by pilot nozzle 54 . In one form, pilot injection module 38 is configured to mix pilot fuel spray and air before injection into the combustion zone. The swirl induced by pilot swirler 56 enhances the mixing of fuel and air for pilot injection module 38 , e.g., relative to systems that do not employ swirlers. The amount of swirl may vary with the application. The fuel discharged from pilot nozzle 54 and the air passing through pilot swirler 56 are discharged into combustion liner 30 via discharge nozzle 58 . In one form, discharge nozzle 58 is circular in shape. In other embodiments, discharge nozzle 58 may be shaped differently.
[0018] Main injection module 40 includes a main fuel injector 62 , a main swirler 64 , a deswirler 66 and a discharge nozzle 68 . Main fuel injector 62 is in fluid communication with fuel supply line 52 . Main fuel injector 62 is operative to inject fuel for mixing with air and combustion in combustion liner 30 . In one form, main fuel injector 62 is configured to indirectly inject fuel into combustion liner 30 , via swirler 64 . In other embodiments, main fuel injector 62 may be configured to directly inject fuel into combustion liner 30 , e.g., similar to pilot nozzle 54 .
[0019] Main fuel injector 62 includes a fuel manifold 70 and plurality of main fuel nozzles 72 . In one form, manifold 70 is a distribution annulus formed in main fuel injector 62 and disposed radially outward of and circumferentially around pilot injection module 38 . In other embodiments, fuel manifold 70 may take other forms. Fuel manifold 70 is in fluid communication with fuel supply line 52 . Fuel nozzles 72 are in fluid communication fuel manifold 70 . In one form, fuel nozzles 72 are plain-jet nozzles. In other embodiments, other nozzle types may be employed in addition to or in place of plain-jet nozzles. In one form, nozzles 72 extend outward in a radial direction from manifold 70 . In the example depicted in FIG. 3 , nozzles 72 extend both radially outward and aft. In other embodiments, nozzles 72 may extend in other directions in addition to or in place of radial and/or aft directions. In one form, nozzles 72 are configured to discharge fuel radially outward, that is, having a radially outward flow direction component. In the example depicted in FIG. 3 , nozzles 72 are configured to discharge fuel both radially outward and aft. In other embodiments, nozzles 72 may be configured to discharge fuel in other directions in addition to or in place of radial and/or aft directions. In some embodiments, some nozzles 72 may be configured to discharge fuel in one direction, whereas others may be configured to discharge fuel in one or more other directions.
[0020] Main swirler 64 is configured to induce swirl in order to enhance the mixing of fuel and air for main fuel injector 62 . In one form, main swirler 64 is an axial swirler. In other embodiments, main swirler 64 may take one or more other forms. In one form, main swirler 64 includes a plurality of turning vanes 74 configured to induce swirl into airflow passing through main swirler 64 . In other embodiments, other means for inducing swirl may be employed, e.g., air injection and/or fuel injection ports configured to induce swirl. In one form, nozzles 72 include discharge openings 76 disposed in main swirler 64 , and are operative to inject fuel directly into main swirler 64 . In other embodiments, some or all of discharge openings 76 may be disposed elsewhere.
[0021] Deswirler 66 is configured to reduce swirl induced by main swirler 64 . In one form, deswirler 66 is disposed radially outward of main swirler 64 . In other embodiments, deswirler 66 may be positioned in other locations and orientations. In one form, deswirler 66 includes a non-swirling air passage. In a particular form, deswirler 66 is configured to form an annular non-swirling air stream disposed around the swirling fuel and air discharged by main swirler 64 , to reduce the exit swirl angle of the fuel and air discharged through discharge nozzle 68 . In other embodiments, other means for reducing swirl may be employed.
[0022] Discharge nozzle 68 is operative to discharge the air fuel mixture, generated by main injection module 40 , into combustion liner 30 . In one form, discharge nozzle 68 is a converging nozzle. In other embodiments, discharge nozzle 68 may take other forms. In one form, discharge nozzle 68 includes contraction ramps 80 and 82 extending to and forming a throat 84 . In one form, ramps 80 and 82 are conical. In other embodiments, ramps 80 and 82 may take other forms. In some embodiments, only a single contraction ramp may be employed. The air fuel mixture generated by main injection module 40 is injected into combustion liner 30 via discharge nozzle 68 . In one form, discharge nozzle 68 is annular in shape, extending concentrically around pilot injection module 38 and discharge nozzle 58 . In other embodiments, discharge nozzle 68 may take other forms. In one form, ramps 80 and 82 are configured to direct the air fuel mixture from main injection module 40 in a radially outward direction, that is, in a direction having a radially outward component from pilot injection module 38 . In one form, discharge nozzle 68 includes a plurality of air injection openings 86 spaced apart circumferentially around the periphery of discharge nozzle 68 , located aft of deswirler 66 and forward of contraction ramp 80 . Air injection openings 86 are positioned to injection air into main injection module 40 upstream of discharge nozzle 68 . In other embodiments, air injection openings may be disposed in other locations. Air injection openings 86 may take any convenient shape. Some embodiments may not include air injection openings 86 .
[0023] Disposed between pilot nozzle 54 and main injection module 40 is a separating member 88 . In one form, separating member 88 is configured as a heat shield to shield pilot nozzle 54 from heat generated during the combustion of fuel.
[0024] Embodiments of the present invention include a gas turbine engine, comprising: a compressor system; a turbine system; and a combustion system fluidly disposed between the compressor system and the turbine system, the combustion system including a combustion liner and a fuel injection system operative to inject fuel into the combustion liner, wherein the fuel injection system includes: a pilot injection module having a pilot nozzle and a pilot swirler for the pilot nozzle, wherein the pilot swirler is operative to induce swirl to enhance mixing of fuel and air for the pilot injection module; and a main injection module disposed radially outward of the pilot injection module, wherein the main injection module includes a main fuel injector; a main swirler; and a deswirler, wherein the main fuel injector includes a plurality of nozzles operative to discharge fuel radially outward; wherein the main swirler is operative to induce swirl to enhance mixing of fuel and air for the main fuel injector; and wherein the deswirler is operative to reduce swirl induced by the main swirler.
[0025] In a refinement, the deswirler is located radially outward of the main swirler.
[0026] In another refinement, the main fuel injector includes a plurality of plain-jet nozzles.
[0027] In yet another refinement, the engine further comprises a main fuel manifold, wherein at least one of the plain-jet nozzles extends outward in a radial direction from the main fuel manifold.
[0028] In still another refinement, at least one of the plain-jet nozzles has a discharge opening disposed in the main swirler.
[0029] In yet still another refinement, the engine further comprises a first fuel supply line; and a second fuel supply line that is fluidly independent of the first fuel supply line, wherein the pilot nozzle is fluidly coupled to the first fuel supply line; and wherein the main fuel injector is fluidly coupled to the second fuel supply line.
[0030] In a further refinement, the fuel injection system is configured to selectively supply fuel to one or both of the pilot injection module and the main injection module.
[0031] Embodiments of the present invention include a fuel injection system for a gas turbine engine, comprising: a main injection module including a plurality of plain-jet nozzles; a main swirler; and a deswirler; wherein at least one of the plain-jet nozzles is operative to discharge fuel radially outward; wherein the main swirler is operative to induce swirl to enhance mixing of fuel and air for the main injection module; and wherein the deswirler is operative to reduce swirl induced by the main swirler; and a pilot injection module disposed radially inward of the main injection module, wherein the pilot injection module includes a pilot nozzle and a pilot swirler for the pilot nozzle, wherein the pilot swirler is operative to induce swirl to enhance mixing of fuel and air for the pilot injection module.
[0032] In a refinement, the deswirler includes a non-swirling air passage.
[0033] In another refinement, the main injection module includes an annular discharge nozzle for discharging a fuel air mixture.
[0034] In yet another refinement, the main injection module includes a discharge nozzle for discharging a fuel air mixture, further comprising a plurality of air injection openings positioned to inject air into the main injection module upstream of the discharge nozzle.
[0035] In still another refinement, the system further comprises a ramp configured to direct an air fuel mixture from the main injection module in a radially outward direction.
[0036] In yet still another refinement, the ramp is conical.
[0037] In a further refinement, the system further comprises a separating member disposed around the pilot nozzle and positioned between the pilot nozzle and the main injection module.
[0038] In a yet further refinement, the separating member is configured to shield the pilot nozzle from combustion heat.
[0039] In a still further refinement, the at least one of the plain-jet nozzles is configured to inject fuel directly into the main swirler.
[0040] Embodiments of the present invention include a fuel injection system for a gas turbine engine, comprising: a pilot injection module having a pilot nozzle operative to produce a pilot combustion zone; and a main injection module having a fuel distribution manifold; a plurality of main nozzles extending from the fuel distribution manifold for injecting fuel; a main swirler; and a deswirler, wherein the main swirler is operative to induce swirl into fuel and air in the main injection module; and wherein the deswirler is operative to reduce swirl induced by the main swirler.
[0041] In a refinement, the system further comprises a heat shield disposed around the pilot injection module and positioned between the pilot injection module and the main injection module.
[0042] In another refinement, the main nozzles are plain-jet nozzles oriented with a directional component extending radially outward of the pilot nozzle.
[0043] In still another refinement, the main injection module is configured to produce a main combustion zone disposed radially outward of the pilot combustion zone.
[0044] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary. | One embodiment of the present invention is a unique gas turbine engine. Another embodiment is a unique fuel injection system for a gas turbine engine. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for gas turbine engines and fuel injection systems for gas turbine engines. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
Drill rods or pipes come in sections that are joined by male threads, tapered convergently, and female sockets, threaded and tapered internally complementarily to the male threads. The drill strings are rotated in a direction that tends to tighten the joints. That, plus the fact that the joints are liable to get gritty material between the threads, makes breaking the joints difficult. Various power mechanisms have been proposed and used (e.g., U.S. Pat. Nos. 4,345,493, 5,727,432). Where non-rotating vises have been employed, they have held the rod while a pipe wrench or the like has been used to turn the section that is not gripped by the vise. The wrench has been turned either manually or by some power mechanism. The pipe wrench type joint breakers have the disadvantage that the gripping surface is limited, putting extreme pressure in a limited area, and may not provide sufficient gripping force. Another approach to turning the free section has been to provide jaws sliding in a cradle rotated on a radius concentric with the radius of a pipe or rod clamped between the jaws. However, this construction has heretofore been subject to wear, with metal-to-metal contact, and a tendency to distortion, which leads to misalignment between the sections of the string.
One of the objects of this invention is to provide an improved open top rotating vise, in which there is substantially no wear or distortion, and in which the rotation of the rotating vice is facilitated.
Other objects will become apparent to those skilled in the art in the light of the following description and accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention, generally stated, an open top rotating vise for use in breaking joints in a drill string is provided which comprises a cradle having side plates and end plates, and semi-circular bearing surfaces carried by and extending outboard from the side plates. A stand comprises side frame members extending parallel to the cradle side plates, and carrying anti-friction rollers extending inboardly from the side frame members. The rollers are arranged on a radius concentric with the radius of the semi-circular bearing surfaces in position to engage the bearing surface. Jaws carried by the cradle slide intermediate the side plates. Preferably, two sets of jaws, facing one another, are powered toward and away from one another. The rollers are of the nature of cam followers, with needle or roller bearings, each with an inside race mounted on a heavy stub shaft threaded at its outer end to receive a nut to hold the assembled rollers in place. Power means, such as a hydraulic cylinder, rock the cradle about the center axis of the bearing surface and rollers, which is coincident with the axial center line of the drill string.
In operation, one end of a drill string section is clamped between jaws of a stationary vise adjacent the rotating vise. The section to be disengaged is clamped between the jaws of the rotating vise, and the rotating vise is given a turn in the uncoupling direction, through a short angle, just enough to break the joint. Because the threaded sections are tapered, rotation of one segment with respect to its connected segment through a small angle, generally less than 30 degrees, is enough to free the two sections.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the drawings,
FIG. 1 is a view in side elevation of one embodiment of vise of this invention; with jaws in one angular position with respect to a heavy fixed frame of a platform or vehicle, shown in phantom lines, to which the device is secured;
FIG. 2 is a view in side elevation, corresponding to the view in FIG. 1, but with the jaws in a second angular position;
FIG. 3 is a top plan view of the device, without the jaw mechanism, and with a fixed vise frame in place;
FIG. 3A is top plan view, partly fragmentary, showing the rotating vise with the jaws in place;
FIG. 4 is view in side elevation corresponding to the assembly of FIG. 3A;
FIG. 5 is a view in side elevation, partly in section, showing the jaw operating mechanism, but without the jaws in place;
FIG. 6 is a view in side elevation of a jaw assembly;
FIG. 6B is a view in front elevation of the jaw assembly of FIG. 6;
FIG. 6A is a top plan view of the jaw assembly;
FIG. 7 is a view in end elevation of a support stand portion of the device;
FIG. 7A is a view in side elevation of the support stand shown in FIG. 7;
FIG. 8 is a view in end elevation of a support stand of a fixed vise;
FIG. 8A is a view in side elevation of the stand shown in FIG. 8;
FIG. 8B is a view in side elevation, partly fragmentary, of the fixed vise;
FIG. 8C is a top plan view of the fixed vise shown in FIG. 8B;
FIG. 9 is a view in side elevation of a side plate of the cradle;
FIG. 9A is a view in end elevation of the side plates shown in FIGS. 9 and 9B, showing a bearing surface welded to the side plate; and
FIG. 9B is a view in side elevation of a side plate of the cradle opposite the side plate shown in FIG. 9 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings for one illustrative embodiment of rotating vise assembly of this invention, reference numeral 1 indicates the assembled device, mounted on a frame 2 , in this embodiment, of a platform carried by a tracked or wheeled vehicle. The assembly includes a fixed support stand 3 with support stand mirror image side plates 4 bolted to the frame 2 . The side plates have a U-shaped opening 5 as shown in FIG. 5, to receive a drill string section. Anti-friction rollers, which can be cam followers 7 , are mounted on the side plates 4 . The cam followers 7 extend inboardly of the side plates, with stub shafts extending through openings in the side plates and being bolted in place with heavy nuts 9 . As is common with such cam followers, the stub shaft has an annular shoulder to space it from the side plate sufficiently to permit the roller to roll smoothly.
As shown in FIGS. 3, 3 A and 4 , the cam followers are provided with grease fittings 8 at their outer ends, to permit the bearings to be lubricated.
A cradle 10 has cradle side plates 11 . In this embodiment, lever extensions 12 , integral with the side plates 11 , are provided, between which a gudgeon 13 extends, to which a piston rod 14 is connected. The piston rod 14 is connected to a piston in a cylinder 15 that is pivotally mounted at its lower end on and between a pair of plates 29 fixedly mounted on the frame to which the rest of the device is mounted, on a sleeve 16 surrounding a pintle 17 , as shown in FIGS. 4 and 5. The support side plates are welded to crossbars 6 which are, in turn, bolted to the platform carried by the vehicle, as shown in FIGS. 3 and 5.
The sides plates 11 of the cradle are bolted to end plates 23 , as shown particularly in FIGS. 3A and 8C; the end plates serve both as supports and as spacers.
Hydraulic cylinders 32 are mounted on an outboard face of the endplates 23 . The endplates 23 have an opening to permit the passage of a piston rod 30 from each of the hydraulic cylinders 32 . The piston rod 30 is connected to move a jaw assembly 25 , supported below by slide channels 21 , as illustrated in FIGS. 9, 9 A and 9 B. A somewhat modified slide channel 54 , as applied to the fixed vise 40 , is shown in FIGS. 8, 8 A and 8 B. The two jaw assemblies 25 , face one another, as shown in FIGS. 1, 2 and 3 A, and are moved toward and away from one another by the action of the hydraulic cylinders 32 and pistons 30 . To that end, the hydraulic cylinders 32 , like the hydraulic cylinder 15 , are provided with the usual hydraulic fittings, and connected to a source of hydraulic fluid under pressure, not here shown.
As shown particularly in FIG. 9A, bearing surfaces 18 are provided, in this embodiment, in the form of the circumferential wall of heavy semi-circular plates 18 welded to the outboard surface of the cradle side plates. The outer surface 18 of the bearing surface plate is interruptedly circular, interrupted at the edges of a mouth of the U-shaped opening 20 . The inner surface of the plate is shaped complementarily to the U-shaped opening. Although the pattern in which the cam followers are arranged and the arc of the bearing surfaces are sometimes referred to as semi-circular, the term is used to describe an interrupted circle, and not merely a half circle.
Referring now to FIGS. 3, 8 , 8 A, 8 B and 8 C, a fixed vise 40 has a pair of oppositely disposed side plates 44 with U-shaped openings 45 , aligned with the U-shaped openings in the rotating vise side plates, and end plates 46 , to which cylinders 32 are mounted, from which piston rods 50 extend, connected at their outer ends to jaw assemblies 52 . The operation of the fixed vise is conventional. It serves to hold one end of a drill section tightly against rotation, while the end of the second section is gripped by the jaws 25 of the rotating vise and the cradle of the rotating vise is rotated around the axial center line of the drill sections.
It can be seen that the forces exerted by the jaws, both in their movement toward the string, and in the rotating movement, are transmitted to heavy sections of plate, backed by the rollers, which not only provide support, but provide smooth and easy movement of the cradle. Merely by way of example, the cradle and stand side walls can be 1-inch thick steel, with the bearing plate 19 projecting 1½ inch from the two side walls of the cradle, and the end plates of the cradle, 2 inches thick, in a cradle 30 inches long from the end of the lever arm 12 to the side of the end plate 23 most remote from the lever. The cam followers can be 2 inches in diameter, and spaced angularly 45 degrees from one another. In the embodiment shown, there are 7 cam followers, describing an arc of 315 degrees, on a radius of 5½ inches, and extending axially inboard of the side plates 1½ inches. The effective radius of the bearing surface 18 of the bearing plate 19 is, therefore, 4½ inches, because it touches each roller at a tangent 1 inch from the roller centerline. The rest of the elements of the device are sized proportionately.
Numerous variations in the construction of the device of this invention, within the scope of the appended claims, will occur to those skilled in the art in the light of the foregoing disclosure. Merely by way of example, one of the jaws of the vise can be made fixed, provided the diameter of the drill string section is known, and does not vary from one section or drill string to another. The advantage of the dual moveable jaws is that they will accommodate and center different sizes of pipe or rod. Sealed rollers, which do not need grease fittings, can be used, as suggested by the drawing figures in which no such fittings are shown. Although the rollers could be mounted on the outboard side of the cradle side plates, and a bearing surface provided on a radially inner side of a semi-circular plate, such an arrangement would be difficult, because the nuts on the stub shafts of the rollers would tend to be in the way of the jaws, and if grease fittings are provided, it would complicate matters even more. Other means for biasing the jaws toward one another can be used, including manually operated toggles (cf. U.S. Pat. No. 5,727,432) or motor-driven screws, but the hydraulic cylinders have the advantage of simplicity and versatility. The numbers and sizes of the rollers, and the sizes of the various other elements can be varied. The U-shaped openings are shown as slanted from the vertical. This is for convenience in loading and unloading, but the angle can be varied from vertical to a lesser angle than the one shown. The vise can be mounted on the vehicle frame itself, or on a separate frame or platform. The usual vehicle-mounted platform is capable of being swung to various angles with respect to the ground. The vise of this invention will operate in any angular position of the platform. The cradle of the vise of the present invention operates so smoothly and easily, that, given a suitable handle, the vise can be rotated manually to break a joint, but as a practical matter, because most of the operation of drilling rigs these days is mechanical or hydraulic, manual operation will seldom be used. These variations are merely illustrative. | An open top rotating vise for use in breaking joints in a drillstring has a cradle with two side plates and two end plates secured to one another and semi-circular bearing surfaces carried by and extending outboard from the side plates. A stand with side frame members extending parallel to the cradle side plates has anti-friction rollers carried by and extending inboardly from the side frame members. The rollers are arranged on a radius concentric with the radius of the cradle semi-circular bearing surface and positioned to engage the cradle bearing surface. Oppositely facing jaw members are carried by the cradle intermediate the cradle side plates. | 4 |
DEDICATORY CLAUSE
The invention described herein may be manufactured, used, and licensed by or for the Government for governmental purposes without the payment to us of any royalties thereon.
BACKGROUND OF THE INVENTION
In the past, deploying a fiber from the side of a missile during launch applied a direct pull to the fiber. The fiber then pulled tearing through a cover on the side of the missile as the missile moved forward. The fiber had to be strong enough to withstand resultant loads and this was not desirable or good.
Therefore, it is an object of this invention to eliminate direct pull on the fiber during deployment and thereby greatly reduce stress imparted to the fiber.
Another object of this invention is to employ a stronger fiber or band of fibers or other material that can be used to tear through a covering that can be used to hold the fiber in place until deployment.
Still another object of this invention is to use a deployment arrangement that is especially adapted for deploying an optical fiber.
Other objects and advantages of this invention will be obvious to those skilled in this art.
SUMMARY OF THE INVENTION
In accordance with this invention, a fiber deployment mechanism is provided on the side of the missile and mounts the fiber in a particular position from the bobbin on the missile to the launcher from which the missile is to be launched. This fiber deployment mechanism includes a cover of a material that can be easily torn with the cover being secured in a spaced position by spacers at the edge of the cover. Between an under surface of the cover and the outer surface of the missile, a tape, group of fibers or other substantial structure is secured to the under side of the cover with the fiber positioned under the tape and at the surface of the missile. The tape is also secured to the fixed launcher with the fiber including a loose loop at the inner connection of the fiber to the launcher and down the deployment mechanism to the spool on the missile. This mounting allows the tape to tear the cover and allows the fiber to be deployed through the torn portion of the cover as the missile is launched. By this mounting, the tape absorbs the load imparted by launching as the cover is torn away and as the missile moves forward the tape completely parts the cover and frees the fiber to pay out from its bobbin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic and pictural view of the missile with the fiber deployment mechanism mounted on the side of the missile and innerconnected to a fixed launcher means, and
FIG. 2 is an enlarged sectional view along line 2--2 of FIG. 1 with portions of the missile cutaway.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, a missile 10 has a bobbin 12 mounted thereon in a conventional manner for dispensing a fiber 14 wound on bobbin 12. Fiber 14 can be an optical fiber or a wire fiber and fiber 14 has one end secured at 16 to a fixed structure such as the launcher for the missile and fiber 14 serves as the data link between missile 10 and the ground station at launcher 18. Fiber 14 is held in place prior to launch and during launch by a cover 20 that is made of paper or other material that will tear relatively easily and cover 20 is secured to missile 10 through spacers 22. Cover 20 is secured to the missile in a conventional manner such as by bonding, screws, or other mechanical fastener for securing devices of this nature. A tear strip 24 is secured, such as by bonding, to the under surface of cover 20 and is made of a material that is stronger than cover 20 and mounted to the under surface of cover 20 with fiber 14 on an opposite side of tear strip 24. Tear strip 24 holds fiber 14 between its under surface and the outer surface of missile 10 until the missile is being deployed. Tear strip 24 can be made of most any material that is stronger than cover 20 and can be fiber material, a group of fibers, tape or any other material which can tear cover 20 over its full length as missile 10 is being launched. Tear strip 24 is secured to launcher 18 as illustrated at end 260 to form a tighter connection of tear strip 24 relative to the launcher then the innerconnection of fiber 14 to launcher 18. That is, loop 26 of fiber 14 is provided so that no appreciable load or stress forces will be initially applied to fiber 14 during launch until missile 10 is moving away from the launcher and fiber 14 can be easily dispensed or paid-out from bobbin 12 without imparting undue stress and loads to fiber 14. Fiber 14 is held in position along the length of missile 10 by cover 20 and tear strip 24 with the end of the fiber at 16 attached to the launcher and connected to the ground support equipment (not shown). The other end of fiber 14 is wound on bobbin 12 in a conventional manner and with the ultimate end of fiber 14 attached to the missile guidance and control electronics for guiding and controlling the missile.
In operation, with the missile and launcher positioned generally as illustrated and with fiber 14 and tear strip and cover 20 secured in place as illustrated, as missile 10 moves forward in relation to launcher 18, tear strip 24 tightens and then tears through cover 20. When missile 10 moves forward a sufficient distance, tear strip 24 completely parts cover 20 and frees fiber 14 without appreciable load being applied thereto and fiber 14 is paid-out from bobbin 12 in a free and conventional manner. By the arrangement specifically provided, fiber 14 does not have to be capable of withstanding loads and stresses as have been required of fibers utilized in fiber systems of this type in the past. | A fiber deployment mechanism for deploying a fiber at the launching of a sile to allow the fiber to be deployed without having to take the load as the missile is deployed and before the fiber is actually being paid-out from its bobbin. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/032,534 filed on Feb. 29, 2008, which is incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a game of chance. In particular, the invention relates to a game of chance implemented as a video slot game.
BACKGROUND
[0003] Playing video games is a very popular and well-known entertainment activity. There is a large variety of video games available to consumers. One category of video games is the games of chance category. Some examples of video games of chance include video poker and video slot games.
[0004] Slot machine games were originally designed for mechanical machines that used a number of physically rotating wheels actuated by a user inserting a coin or token and pulling down a lever.
[0005] The advent of video slot games permitted game designers to be more creative by eliminating the limitations associated with physical reels and mechanical machines. The designers were no longer limited to physical reels having a fixed number of symbols per reel. Video slot games permitted game designers to easily create any number of virtual reels with any number of symbols on each reel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] For a better understanding of embodiments of the systems and methods described herein, and to show more clearly how they may be carried into effect, reference will be made, by way of example, to the accompanying drawings in which:
[0007] FIG. 1 is a block diagram of a system for conducting a video game of chance according to an embodiment of the present invention;
[0008] FIG. 2 is a perspective view of a standalone gaming machine for conducting a video game of chance according to an embodiment of the present invention;
[0009] FIG. 3 is a screen shot of the video game according to an embodiment of the present invention; and
[0010] FIG. 4 is a flowchart of the steps of a method of conducting a video game of chance according to an embodiment of the present invention.
[0011] It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.
SUMMARY
[0012] According to a first aspect of the invention, a method of conducting a video game of chance is provided. The method comprises:
a) receiving a first wager from a first player and a second wager from a second player; b) populating a first plurality of cells with a first plurality of symbols, wherein the first plurality of cells is associated with the first player; c) populating a second plurality of cells with a second plurality of symbols, wherein the second plurality of cells is associated with the second player; d) determining whether the first plurality of symbols comprise at least one first winning combination; e) if the first plurality of cells comprises the at least one first winning combination, determining a first award for the at least one first winning combination; f) determining whether the second plurality of symbols comprises at least one second winning combination; g) if the second plurality of cells comprises the at least one second winning combination, determining a second award for the at least one second winning combination; and h) selecting a round winner based on a comparison of the first and second award, wherein the first player is selected as the round winner if the first award exceeds the second award, wherein the second player is selected as the round winner if the second award exceeds the first award.
[0021] According to a second aspect of the invention, a method of playing a video game of chance is provided. The method comprises:
a) communicating a first wager from a first player and a second wager from a second player; b) displaying a first plurality of cells populated with a first plurality of symbols, wherein the second plurality of cells is associated with the second player; c) displaying a second plurality of cells populated with a second plurality of symbols, wherein the first plurality of cells is associated with the first player; d) if the first plurality of symbols comprises at least one first winning combination, displaying a first award to the first player, wherein the first award is determined from the at least one first winning combination; e) if the second plurality of symbols comprises at least one second winning combination, displaying the second award to the second player, wherein the second award is determined from the at least one second combination; and f) displaying a round winner based on a comparison of the first and second award, wherein the first player is selected as the round winner if the first award exceeds the second award, wherein the second player is selected as the round winner if the second award exceeds the first award.
[0028] According to a third aspect of the invention, a system for conducting a video game of chance between a first player and a second player is provided. The system comprises a server and a client device adapted for communication with the server. The client device includes a display. The client device is adapted to receive a first wager and communicate the first wager to the server. The display is adapted to display a first plurality of cells populated with a first plurality of symbols and a second plurality of cells populated with a second plurality of symbols. The first wager is associated with a first plurality of cells, and the second plurality of cells is associated with a second wager. The server is adapted to: (i) determine whether the first plurality of symbols comprise at least one first winning combination, and if the first plurality of symbols comprise at least one first winning combination, determine a first award for the at least one first winning combination; and (ii) determine whether the second plurality of symbols comprise at least one second winning combination, and if the second plurality of symbols comprise at least one second winning combination, determine a second award for the at least one second winning combination. The server is adapted to select a round winner based on a comparison of the first and second award. The first player is selected as the round winner if the first award exceeds the second award. The second player is selected as the round winner if the second award exceeds the first award.
[0029] According to a fourth aspect of the invention, a gaming machine for conducting a video game of chance between a first player and a second player is provided. The machine comprises: (a) a processor, (b) a memory, (c) an input interface; and (d) a display. The input interface is adapted to receive a first wager and store the first wager in the memory. The display is adapted to display a first plurality of cells populated with a first plurality of symbols and a second plurality of cells populated with a second plurality of symbols. The first wager is associated with a first plurality of cells, and the second plurality of cells is associated with a second wager. The processor is adapted to: (i) determine whether the first plurality of symbols comprise at least one first winning combination, and if the first plurality of symbols comprise at least one first winning combination, determine a first award for the at least one first winning combination; and (ii) determine whether the second plurality of symbols comprise at least one second winning combination, and if the second plurality of symbols comprise at least one second winning combination, determine a second award for the at least one second winning combination. The processor is adapted to select a round winner based on a comparison of the first and second award. The first player is selected as the round winner if the first award exceeds the second award. The second player is selected as the round winner if the second award exceeds the first award.
DETAILED DESCRIPTION
[0030] It will be appreciated that numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Furthermore, this description is not to be considered as limiting the scope of the embodiments described herein in any way, but rather as merely describing the implementation of the various embodiments described herein.
[0031] Reference is now made to FIG. 1 , in which a system 100 for conducting a video game of chance is illustrated. The system 100 includes a client device 14 that is connected to a host server 10 via a network 12 . A first player uses the client device 14 to access the game, which is hosted on the host server 10 . The game is implemented electronically by software that is installed on the host server 10 .
[0032] The host server 10 is preferably implemented by the use of one or more general purpose computers, such as, for example, a Sun Microsystems™ F15K server. The client device 14 is also preferably implemented by the use of one or more general purpose computers, such as, for example, a typical personal computer manufactured by Dell™, Gateway™, or Hewlett-Packard™. Those skilled in the art will understand that the client device 14 may be any other suitable device, such as a game console, a portable gaming device, a laptop computer, a personal digital assistant (PDA), a mobile phone, a set top box, or an interactive television.
[0033] Each of the host server 10 and the client device 14 may include a microprocessor. The microprocessor can be any type of processor, such as, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC), a programmable read-only memory (PROM), or any combination thereof. The host server 10 may use its microprocessor to read a computer-readable medium containing the software that includes instructions for carrying out one or more of the functions of the host server 10 , as further described below.
[0034] Each of the host server 10 and the client device 14 can also include computer memory, such as, for example, random-access memory (RAM). However, the computer memory of each of the host server 10 and the client device 14 can be any type of computer memory or any other type of electronic storage medium that is located either internally or externally to the host server 10 or the client device 14 , such as, for example, read-only memory (ROM), compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, erasable programmable read-only memory (EPROM), and electrically-erasable programmable read-only memory (EEPROM), or the like.
[0035] According to exemplary embodiments, the respective RAM can contain, for example, the operating program for either the host server 10 or the client device 14 . As will be appreciated based on the following description, the RAM, can, for example, be programmed using conventional techniques known to those having ordinary skill in the art of computer programming. The actual source code or object code for carrying out the steps of, for example, a computer program can be stored in the RAM.
[0036] Each of the host server 10 and the client device 14 can also include a database. The database can be any type of computer database for storing, maintaining, and allowing access to electronic information stored therein.
[0037] The host server 10 preferably resides on a network 12 , such as a local area network (LAN), a wide area network (WAN), or the Internet. The client device 14 preferably is connected to the network 12 on which the host server 10 resides, thus enabling electronic communications between the host server 10 and the client device 14 over a communications connection, whether locally or remotely, such as, for example, an Ethernet connection, an RS-232 connection, or the like.
[0038] The client device typically includes a monitor or other display for displaying the actions and status of the video game. The client device 14 may be configured to accept player inputs provided via, for example, a keyboard, mouse, a joystick or a touchscreen.
[0039] The video game may be played in one of two modes: peer-to-computer mode or peer-to-peer mode. In peer-to-computer mode, a live player plays the game against a computer (also referred to as the House). In peer-to-peer mode, one live player plays the game against another live player. Where the game is being played in peer-to-peer mode, system 100 shown in FIG. 1 will further comprise a second client device 14 (only one is shown in FIG. 1 ) connected to the network 12 and in communication with the host server 10 .
[0040] Reference is now made to FIG. 2 , in which a standalone gaming machine for conducting the game of chance is illustrated. The standalone gaming machine may be a video slot machine 20 . The slot machine 20 is housed in a cabinet 22 . The slot machine includes a reference plate 24 that identifies the type of game played on the slot machine 20 , a name plate 26 , speakers 28 , a bill acceptor 30 , a coin slot 32 , a ticket slot 34 for coinless play, belly art plate 36 , and a coin try 38 . The slot machine also includes a video display 40 , a game playing instructions plate 42 , and an input interface, such as game function buttons 44 for one or more players. In the peer-to-peer mode, the game may be played by two players on a single gaming machine 20 , or the game may be implemented using two or more gaming machines 20 which communicate with each other using any suitable network.
[0041] Those skilled in the art will understand that the video game of chance may be implemented on a wide variety of other standalone gaming devices, such as game consoles, portable gaming devices, personal computers, laptop computers, personal digital assistants (PDAs), mobile phones, set top boxes, and interactive televisions.
[0042] Preferably the gaming machine 20 , includes a microprocessor (not shown). The microprocessor can be any type of processor, such as, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC), a programmable read-only memory (PROM), or any combination thereof. The video slot machine 20 may use its microprocessor to read a computer-readable medium containing the software that includes instructions for carrying out one or more of the functions of the game described below.
[0043] Preferably, the video slot machine 20 also includes computer memory, such as, for example, random-access memory (RAM). However, the computer memory of video slot machine 20 may be any other type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, erasable programmable read-only memory (EPROM), and electrically-erasable programmable read-only memory (EEPROM), or the like.
[0044] According to exemplary embodiments, the memory of the video slot machine 20 may contain, for example, the operating instructions to implement the functionality of the game described below. As will be appreciated based on the following description, the memory, can, for example, be programmed using conventional techniques known to those having ordinary skill in the art of computer programming. The actual source code or object code for carrying out the steps of, for example, a computer program can be stored in the memory.
[0045] The video slot machine 20 can also include a data storage, such as a database. The database may be any suitable type of computer database for storing, maintaining, and allowing access to electronic information stored therein.
[0046] The display 40 of the video slot machine 20 or the display of the client device (depending on the embodiment) is configured to display the game board.
[0047] Reference is now made to FIG. 3 , in which the layout of a game board 300 in accordance with an embodiment is illustrated. The game board 300 includes a first plurality of cells, such as first group of cells 302 and a second plurality of cells, such as second group of cells 304 where the first group of cells 302 is associated with a first player and the second group of cells 304 is associated with a second player. Where the game is being played in peer-to-computer mode, the live player will be referred to as the first player and the computer (or the “House”) will be referred to as the second player. Where the game is being played in peer-to-peer mode, both the first and second player are live players.
[0048] The cells in the first and second groups 302 and 304 may be arranged in an N×M matrix where N represents the number of rows in the matrix and M represents the number of columns in the matrix. N and M may be any whole number greater than one and may be the same or different. In the embodiment shown in FIG. 3 , N and M are equal to three, forming 3×3 matrices.
[0049] The first and second groups of cells 302 and 304 are configured to form a number of lines, herein after referred to as betting lines. For example, the first and second groups of cells 302 and 304 shown in FIG. 3 are configured so that eight betting lines 306 , 308 , 310 , 312 , 314 , 316 , 318 , and 320 are formed, each having three cells. The betting lines may be vertical lines, horizontal lines, or diagonal lines, as shown in FIG. 3 , or any other free geometry lines (e.g. broken lines).
[0050] During game play, each cell is preferably populated by a symbol, which may be randomly generated by video slot machine 20 or by server 10 . In one embodiment, the game has a board game theme and the symbols used to populate the cells are associated with a particular board game. Suitable board games include, but are not limited to, Risk™, Dungeons and Dragons™, Clue™ and Transformers™. In the embodiment shown in FIG. 3 , the game has a Risk™ theme. Accordingly, the symbols may comprise various war symbols, such as canons, swords, guns, infantry soldiers, and cavalry soldiers.
[0051] In one embodiment, the symbols displayed in the first and second groups of cells 302 and 304 are arranged to face the centre of the game board 300 such that the symbols in the two group of cells can be said to be facing each other. For example, as shown in FIG. 3 , the cannon symbols in the first group of cells 302 are pointing toward the right and the cannon symbols in the second group of cells 304 are pointing toward the left. Arranging the symbols in this manner creates the entertaining impression, that the two groups of symbols are opposing armies fighting each other.
[0052] It is the configuration of the symbols in the first and second groups of cells 302 and 304 that are used to determine the outcome of a primary game. In one embodiment the first player is provided a first award if the symbols in the first group of cells 302 comprise at least one winning combination. Where the game is played in peer-to-peer mode, the second player is similarly provided a second award if the symbols in the second group of cells 304 comprise at least one winning combination. Preferably, a winning combination occurs when all of the cells in a particular betting line are populated with the identical symbol. In the example, shown in FIG. 3 , betting line 308 for Player Bill and betting line 320 for Player Alex have winning combinations. Specifically, betting line 308 for Player Bill is made up of three horsemen and betting line 320 for Player Alex is made up of three cannons.
[0053] The first and second player awards may be displayed in an award section 336 of the game board 300 . For example, it is shown in FIG. 3 that the first player, Alex, was provided the first award of $20 based on the first winning combination in the betting line 320 and the second player, Bill, was provided the second award of $140 based on second winning combination in the betting line 308 . Awards for the first and second winning combinations comprised of various symbols may be awarded in accordance with a payout table. Payout tables are well known in the art and will not be further described.
[0054] The game board 300 may further include a player interface 322 that allows a live player to interact with the game. For example, the input interface 322 may include a paytable button 324 , a betting lines selector 326 , a wager selector 328 , a spin button 330 , and a bet max button 332 . The method for the player to activate the input interface 322 buttons and selectors will depend on the configuration of the client 14 or slot machine 20 . For example, where the display 10 of the slot machine 20 or the display of the client 14 is touch screen enabled then the player may simply touch the buttons and selectors to activate them. Alternatively, the player may be provided with a pointing device, such as a mouse or the like, that allows them to “click” on the button or selection.
[0055] The paytable button 324 , when activated, displays the payout table to the player. The pay table may list, for example, payout odds for winning combinations comprised of various symbols. This is a particularly beneficial feature for a new player who is unfamiliar with the game and the symbols used in the game.
[0056] The betting lines selector 326 , and the wager selector 328 allow the player to adjust his/her wager for a particular round of the primary game. In one embodiment, the betting lines selector 326 allows the player to select the number of betting lines they wish to bet on. For example, if the player selects two betting lines then the first and second betting lines 306 and 308 are used to determine whether the player receives a payout. This means that if a winning combination occurs in one of the other six betting lines 310 , 312 , 314 , 316 , 318 , and 320 the player does not receive a payout.
[0057] The wager selector 328 allows the player to select the wager amount per betting line. For example, if the wager is $1 and eight betting lines are selected then the total wager is $8.
[0058] In another embodiment, the betting lines selector 326 and the wager selector 328 may allow the player to strategically select a different wager for each betting line selected. For example, if the betting line selector 326 is set to betting line 1 then the wager selector 328 can be used to set the wager for betting line 1.
[0059] Both the betting lines selector 326 and the wager selector 328 may have a default setting. For example, the betting lines selector 326 may have a default setting equal to the maximum number of betting lines (e.g. eight) and the wager selector 328 may have a default setting equal to the minimum bet (e.g. $1). In the peer-to-computer embodiment, the wager may be automatically set to a particular amount. Alternatively, the second player (i.e. computer or House) wager is automatically matched to the first player's wager.
[0060] The spin button 330 and the bet max button 332 are used to activate play of the primary game. The spin button 330 activates the primary game using the settings of the betting lines selector 326 and the wager selector 328 . The bet max button 332 activates the primary game using the maximum betting lines and the maximum wager amount. Accordingly, the bet max button 332 effectively ignores the status of the betting lines selector 326 and the wager selector 328 .
[0061] The player interface 322 may also be used to display other player-specific information such as the player's balance, the total amount paid out to the player and the amount of the current bet. Those skilled in the art will understand that there are many other elements that may be included in the player interface 322 .
[0062] The game board 300 may further include a bonus game section 334 to display the status of a bonus game. Typically the bonus game is designed to encourage the player to play multiple rounds of the primary game. For example, the bonus game may track the number of rounds of the primary game won and award a bonus to player if he/she wins a predetermined number of rounds. A method for determining the winner of a particular round will be described below in relation to FIG. 4 .
[0063] The bonus game section 334 may display items such as the current number of rounds won for each player and a visual image of the current position of the players with respect to each other.
[0064] Where the game of chance has a board game theme, then the bonus game may relate to a plot of the board game. For example, where the game of chance has a Risk™ theme, the bonus game may simulate war between two armies. In particular, say the first player is associated with the British Army and the second player is associated with the French Army, then the bonus game may simulate a war between these two countries so that when the first player wins a round of the primary game the British Army advances its position (e.g. gains control of additional territory) and when the second player wins a round of the primary game the French Army advances its position. In one embodiment, the greater the margin of victory in a round, the greater the territorial advance of the associated Army.
[0065] The method according to an embodiment of the present invention will now be described with reference to FIGS. 3 and 4 . The method 400 begins at step 402 where a first wager is input by the first player into the video slot machine 20 or by client 14 , as the case may be. In the client-server embodiment, the first wager is communicated to the server 10 .
[0066] Preferably, the first wager amount is fixed and cannot be changed by the first player (e.g. fixed at $1). Preferably, all betting lines are automatically selected and also cannot be changed by the first player. A second wager and betting line selection is made by the second player in preferably the same manner as for the first player (i.e. automatically). In this embodiment, the betting line selector button 326 , wager selector button 328 , and bet max button 332 shown in FIG. 3 would not be necessary.
[0067] In an alternative embodiment applicable to the peer-to-computer mode, the first player (i.e. live player) may be given the option of selecting the amount of the wager and the betting lines to be played using the betting line selector button 326 , wager selector button 328 , and bet max button 332 . In such an embodiment, the second wager amount and pay lines of second player (i.e. House) would automatically be selected to match the first wager and betting line selection of the first player.
[0068] In another alternative embodiment applicable to the peer-to-peer mode, each player may be given the option to select the amount of his/her wager (up to a maximum bet) and select one or more betting lines. Each player would select his/her wager and betting line selection in turn using the betting line selector button 326 , wager selector button 328 , and bet max button 332 . Such an embodiment may add an additional strategy and risk element to the game.
[0069] At step 404 , the first player (in the peer-to-computer mode) or either of the players (in the peer-to-peer mode) press the spin button 330 . Each cell in the first and second groups of cells 302 , 304 is then populated with a symbol. As described above in relation to FIG. 3 , the symbols may be randomly generated by video slot machine 20 or by server 10 . In addition, to increase the user's enjoyment of the game, the symbols may relate to a particular board game (e.g. Risk™).
[0070] At decision diamond 406 , the video slot machine 20 or server 10 determines whether any combinations of the symbols in the first group of cells 302 constitute winning combinations. Where the wager is associated with a specified number of betting lines, only the betting lines associated with the wager can qualify as winning combinations. For example, where the first and second group of cells 302 and 304 are configured for eight betting lines as shown in FIG. 3 , and the player only associated the wager with one betting line, then only the selected betting line is used to determine if there is a winning combination. Similarly, where the wager is only associated with two betting lines, only the two selected betting lines are used to determine if there is a winning combination. If no winning combinations are present in the first group of cells 302 , the method proceeds to decision diamond 410 .
[0071] If at least one winning combination is present in the first group of cells, the method proceeds to step 408 where the first award for first player is determined based on the payout odds which depend on the probability of various winning combinations arising, as is known in the art. The first award may be displayed on the display 40 of the slot machine 20 or the display of the client device(s) 14 . For example, the first award may be displayed in the award section 336 of the board game 300 . The first award may be a monetary award or any other type of award, such as additional credits to play the game. Preferably, the first award is provided to the first player at this step, but may also be awarded at a later stage. The method then proceeds to decision diamond 410 .
[0072] At decision diamond 410 the video slot machine 20 or server 10 determines whether any combinations of the symbols in the second group of cells 304 constitute winning combinations. Winning combinations are determined in the same manner as described with respect to decision diamond 406 .
[0073] At step 412 , the second award is determined and displayed in the same manner as described with respect to step 408 . After the second award is determined, the method proceeds to decision diamond 414 . In the peer-to-peer mode, the second award is preferably awarded to the second player at this step, but may be awarded at a later stage. In the peer-to-computer mode, the second award is determined only for the purpose of identifying the round winner, as discussed below.
[0074] At decision diamond 414 , a round winner is selected by comparing the first award to the second award, with the player having the highest award being selected as the round winner. If the value of the first and second awards is equal, neither player is selected as the round winner. In one embodiment, a bonus award may be awarded to the player who is the round winner. In the peer-to-computer mode, if the second player (i.e. House) is the round winner, this simply means that the first player does not receive the bonus award.
[0075] In some embodiments this is the end of the game.
[0076] In other embodiments, this only constitutes one round of the game and the method proceeds to either step 416 or 418 . If the first player is the round winner, then the method proceeds to step 416 where a counter that keeps track of how many rounds the first player has won is incremented. The method then proceeds to decision diamond 420 . If there is a tie, neither counter is incremented and the method returns to step 402 from decision diamond 414 .
[0077] In the peer-to-peer mode, if the second player is the round winner, then the method proceeds to step 418 where a counter that keeps track of how many rounds the second player has won is incremented. The method then proceeds to decision diamond 420 . In the peer-to-computer mode where the second player is the House, a counter for the second player is not required.
[0078] In the peer-to-peer mode, at decision diamond 420 , the video slot machine 20 or server 10 determines whether either of the players has won a predetermined number of rounds. The predetermined number of rounds may be based on the level of the game. For example, the higher the level of the game, the higher number of games must be won. If none of the players have won the predetermined number of rounds then the method proceeds back to step 402 . In the peer-to-computer mode, a check is made only to determine whether the first player has won the predetermined number of rounds. The second player (i.e. House) wins are ignored. Consequently, the first player is preferably always able to win a bonus award provided he/she plays enough rounds. This provides the added advantage of motivating the player to play more rounds.
[0079] In the peer-to-peer embodiment, if one of the players has won the predetermined number of rounds, then a bonus award is preferably awarded to the winning player in step 422 . In the peer-to-computer embodiment, if the first player has won the predetermined number of rounds then the first player is awarded a bonus award. The bonus award may be a monetary award or any other type of award such as additional credits to play the game.
[0080] In one embodiment, the bonus award is based on the total amount wagered in all rounds played. For example, if the first player plays two rounds before they are awarded the bonus, and they wagered $10 in the first round and $5 in the second round, then the amount of the bonus will be based on the total wager in both rounds (i.e. $15).
[0081] If the first player exits the game before either of the players has won the predetermined number of rounds, the player's number of rounds won may be saved by the client 14 , server 10 or the slot machine 20 for subsequent retrieval. This encourages the player to return at a later time to play this particular game since they do not forfeit credit for any of the winning rounds that they have accumulated.
[0082] While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the invention and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto. | Systems and methods of conducting a video game of chance are disclosed. The method includes the following steps:
a) receiving a first wager from a first player and a second wager from a second player; b) populating a first group of cells with symbols, where the first group of cells is associated with the first player; c) populating a second group of cells with symbols, where the second group of cells is associated with the second player; d) determining whether the first group of symbols includes a winning combination; e) if the first group of cells includes a winning combination, determining a first award for the winning combination; f) determining whether the second group of symbols includes a winning combination; g) if the second group of cells includes a winning combination, determining a second award for the winning combination; and h) selecting a round winner based on a comparison of the first and second award, such that the first player is selected as the round winner if the first award exceeds the second award, and the second player is selected as the round winner if the second award exceeds the first award. | 6 |
BACKGROUND
[0001] Food service companies use hot liquids in food preparation and cooking processes, and often for cleaning. Thousands of injuries occur every year in commercial food service operations due to scalding from hot liquid. Scalding injuries are severe. Third degree burns occur from liquid contact above 150 degrees Fahrenheit for only two seconds. Similar burn can be caused by a six-second exposure to 140 degree liquid, or from a thirty second exposure to liquid at 130 degrees. Notably, commercial hot water dispensers in the food service industry commonly dispense water at temperatures approaching 200 degrees. Scalding injuries are primarily caused by employees spilling vessels, such as pitchers, while transporting hot liquid from a dispenser to another location.
[0002] Currently, transporting a hot liquid in a commercial setting, such as a restaurant kitchen or commissary, involves filling a vessel and walking with it to a desired location. Although covered vessels are typically indicated for such uses, open containers are frequently used. Hot liquid in an uncovered vessel is prone to slosh up and out of the vessel when agitated by an employee's walking and turning movements. If some portion of the hot liquid leaving the vessel contacts the employee's hand, face or body, the typical reaction is to release the entire vessel, which falls to the floor, ejecting the remaining hot liquid in uncontrolled directions and creating a high risk of injury to the employee and other persons in the vicinity. Bums resulting from such a spill come at great expense to the employer due to employee injury, lost work time, and worker compensation and medical claims.
[0003] Covered vessels usually have a secured lid to prevent hot liquid from sloshing out when moved. Although this lowers the likelihood of scalding from spilled hot liquid, vessel lids typically have a tenuous connection to the vessel, or are removable. If a lidded vessel is inadvertently dropped, or even tilted over in many instances, the lid may disengage, allowing hot liquid inside to splash out and cause injury. Other problems with lidded vessels is the tendency for removable lids to become lost, or many times simply thrown away by employees, thus encouraging use of the vessel without a lid. The very nature of removable lids encourages employees to not use, or discard lids, deeming them an inconvenient nuisance.
[0004] For these reasons it is an object of the present invention to provide a vessel for safely containing, transporting, and decanting hot liquids. Another object is to provide a vessel capable of safely accepting hot liquid from a dispenser and securely holding the hot liquid, preventing it from sloshing or splashing during filling, during transport when full, and during decanting. Another object is to provide a vessel with a lid incapable of dislodging, if the vessel is inadvertently dropped, or removed by a user. Another object is to provide a vessel allowing only a controlled release of hot liquid when poured or inadvertently dropped. Another object is to provide a vessel easy to disassemble, clean, and dry. Another object is to provide a locking mechanism incapable of allowing the pitcher to inadvertently disassemble. These and other objects are more fully discussed herein.
SUMMARY
[0005] A pitcher for safely receiving, transporting and decanting a hot liquid includes a body having a first opening and a second opening, a bottom cover attached to the body but able to he removed, an opening baffle in fluid communication with the first opening, the opening baffle near the first opening to reduce the hot liquid flow rate through the first opening during decanting of the hot liquid, and a funnel near the second opening to direct the hot liquid through the second opening during receiving the hot liquid. The funnel directs the hot liquid from the second opening to the first opening opening during decanting of the hot liquid.
[0006] Preferably, the bottom cover is larger in diameter than the funnel at the top of the pitcher to reduce tipping, and the pitcher includes an elongated handle extending from near the funnel to near the bottom cover for ease of the user grasping the pitcher during decanting. A fin near the first opening divides the hot liquid's flow during decanting of the hot liquid. The body includes an outer sidewall with a scalloped surface for less surface area for contacting the user's hand. The body also has a chamber baffle inside the pitcher for settling the hot liquid during transporting of the hot liquid, and a lower flange in peripheral contour with the bottom cover. The bottom cover has an inner wall extending into the body of the pitcher.
[0007] The pitcher for safely receiving, transporting and decanting a hot liquid, may also be described as having a body with a funnel and a sidewall extending downward from the funnel. The funnel includes a first opening next to the sidewall and a second opening below the first opening. The handle is preferably opposite the first opening. An opening baffle in the body next to the first opening hinders the hot liquid when decanting, and a bottom cover is attached, but removable, to the body. The pitcher is configured such that the funnel directs the hot liquid from the second opening toward the first opening when decanting.
[0008] A third characterization of the pitcher for safely receiving, transporting, and decanting a hot liquid, is the pitcher having a body with a baffle to settle the hot liquid in the body. A funnel is formed in the body, and the funnel has a first opening for dispensing the hot liquid and a second opening for receiving the hot liquid. A bottom cover is removably attached to the body, wherein the funnel directs the hot liquid from the second opening to the first opening when decanting the hot liquid. A hole in the body fully drains the hot liquid from the body when the pitcher is inverted. And the body has a flange in peripheral contour with the bottom cover, the bottom cover having an inner wall extending into the body of the pitcher.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 illustrates a perspective view of a hot liquid safety pitcher.
[0010] FIG. 2 illustrates a side view of the pitcher.
[0011] FIG. 3 illustrates a top plan view of the pitcher.
[0012] FIG. 4 illustrates a bottom view of the pitcher.
[0013] FIG. 5 illustrates a perspective view of the pitcher with a bottom cover removed.
[0014] FIG. 6 illustrates a bottom view of the pitcher with the bottom cover removed.
[0015] FIG. 7 illustrates a section view of the pitcher filled with hot liquid.
[0016] FIG. 8 illustrates a section view of the pitcher tipped to a normal angle decanting the hot liquid.
[0017] FIG. 9 illustrates a section view of the pitcher tipped to an extreme angle safely decanting the hot liquid.
DESCRIPTION
[0018] Referring to FIGS. 1 and 2 , a pitcher 10 for transporting a scalding hot liquid 100 ( FIGS. 7 and 8 ) includes a body 12 and a locking bottom cover 14 . The body 12 is characterized by a handle 16 , a flange 18 , a sidewall 20 , and a splash guard 22 . In addition to having a smaller diameter than the flange 18 , the sidewall 20 may also decrease in diameter from the flange 18 toward the splash guard 22 , thereby enhancing the pitcher's 10 low center of gravity. The sidewall 20 is characterized by a circumferential series of vertically oriented scallops 24 . The scallops 24 , recessed in the sidewall 20 , create ridges 26 to reduce surface area contact when touching the hot pitcher 10 .
[0019] The sidewall 20 also includes grading 28 for accurate measuring. The pitcher 10 may be clear or partially opaque to allow viewing the hot liquid 100 level, or alternatively, only the grading 28 may be transparent, thereby showing the hot liquid 100 level. Multiple grading 28 indicia on the sidewall 20 are contemplated to allow measuring in different units, such as metric versus U.S. customary. Preferably, all components of the pitcher 10 , including the body 12 and bottom cover 14 , comprise food grade BPA-free and FDA approved materials.
[0020] The splash guard 22 extends upward from the sidewall 20 to prevent the hot liquid 100 from splashing out of the pitcher 10 , and preferably includes a lip 30 to help prevent adhesion to the pitcher 10 during decanting. That is, the hot liquid 100 running down the sidewall 20 of the pitcher 10 . The splash guard 22 surrounds a funnel 32 integrally formed as part of the body 12 which functions as a non-removable lid. Although molding the funnel 32 with the body 12 is preferred, alternative embodiments may include a separately constructed Runnel 32 affixed to the body 12 , preferably requiring a special tool for removing the funnel 32 from the body 12 .
[0021] The funnel 32 includes first openings 34 through which hot liquid 100 is decanted. The first openings 34 preferably include an opening guard 36 to prevent hot liquid 100 from gushing out of the pitcher 10 , and a fin 38 , preferably bisecting the first openings 34 and opening guard 36 , for added directional pouring control and to reduce splashing. The funnel 32 also incorporates small holes 40 to aid in equalizing displaced air as hot liquid 100 enters or exits the pitcher 10 . The small holes 40 also allow drainage and drying after use when the pitcher 10 is inverted and resting on a flat surface.
[0022] The handle 16 is preferably shaped in a broad arc, extending from the splash guard 22 to the flange 18 , to more easily control the pitcher 10 , particularly when full. An elevated thumb guard 42 where the handle 16 joins the splash guard 22 extends higher than the splash guard 22 for both added protection, and to allows drainage and drying when the pitcher 10 is inverted on a flat surface (not shown) by allowing air flow under the splash guard 22 .
[0023] At the top of the handle 16 adjacent the thumb guard 42 is a groove 44 to accommodate a user's finger or thumb (not shown). The groove 44 is enlarged and lengthened to accommodate a variety of sizes. Below the groove 44 , the handle 16 includes a channeled section 46 . The groove 44 and channeled section 46 provide dual purposes of providing for effective gripping while also reducing the quantity of material needed to construct the pitcher 10 .
[0024] The bottom cover 14 is positioned just below the flange 18 when installed on the pitcher 10 . The bottom cover 14 is preferably at least the same diameter as the flange 18 and includes a locking mechanism 48 , discussed in more detail below, for preventing the bottom cover 14 from inadvertently disengaging from the pitcher 10 . To assist affixing the bottom cover 14 to the pitcher 10 , an upper indicator 50 and a lower indicator 52 are used. The upper indicator 50 is preferably disposed on the flange 18 , adjacent the handle 16 , and the lower indicator 52 is disposed on the bottom cover 14 . A release 54 allows the locking mechanism 48 to be unlocked.
[0025] Referring to FIG. 3 , the funnel 32 extends to the splash guard 22 and thumb guard 42 . The opening guard 36 and fin 38 are also preferably incorporated into the funnel 32 opposite the handle 16 . Also shown in this view, the flange 18 extends beyond the scallops 24 and ridges 26 of the sidewall 20 . The funnel 32 also includes one or more second openings 56 and a domed section 58 . The second openings 56 accept hot liquid 100 ( FIGS. 7 and 8 ) poured into the funnel 32 , and the domed section 58 helps direct hot liquid 100 from the funnel 32 toward the second. openings 56 to prevent splashing. Providing multiple second openings 56 also facilitates venting of displaced air as hot liquid 100 enters the pitcher 10 .
[0026] Referring to FIG. 4 , the bottom cover 14 preferably includes a rotating grip 60 to facilitate grasping and rotating the bottom cover 14 relative to the body 12 . Aligning the upper indicator 50 ( FIGS. 1 and 2 ) with the lower indicator 52 and turning the bottom cover 14 with the rotating grip 60 to align the release 54 with the upper indicator 50 locks the bottom cover 14 onto the body 12 . Depressing the release 54 allows the bottom cover 14 to rotate in the opposite direction and eventually disengage from the body 12 . In the illustrated embodiment the rotating grip 60 is a single cross piece bisecting two semi-circular indentations 62 , although any configuration effective for turning the bottom cover 14 is contemplated.
[0027] Referring to FIG. 5 , the pitcher 10 is shown with the bottom cover 14 separated from the body 12 . To assemble the pitcher 10 , the bottom cover 14 is aligned with the body 12 and rotated against it. To ensure fast and easy alignment, an inner wall 64 is provided on the bottom cover 14 , sized to fit just inside the body 12 . A first thread 66 on the body 12 aligns with a second thread 68 surrounding the inner wall 64 . When the inner wall 64 is inserted into the body 12 and the bottom cover 14 rotated, the first thread 66 engages the second thread 68 , bringing the bottom cover 14 up against the flange 18 , and in a corresponding movement, drive the inner wall 64 further into the body 12 .
[0028] As the first and second threads 66 , 68 rotate against each other, driving the bottom cover 14 onto the body 12 , the release 54 eventually encounters a wedge member 70 projecting from the flange 18 . The wedge member 70 passes between the release 54 , and a release tab 72 , thereby impinging on the release tab 72 to deflect a resiliently deformable arm 74 holding the release 54 and release tab 72 .
[0029] When the bottom cover 14 reaches a fully engaged position, the release tab 72 clears the wedge member 70 , allowing the resiliently deformable arm 74 to return the release tab 72 to an obstructed position behind the wedge member 70 with an audible “click.” At the same time, the upper indicator 50 and lower indicator 52 come into alignment, providing visual confirmation that the bottom cover 14 is locked onto the body 12 . In the locked position, a gasket 76 ( FIGS. 7 and 8 ), for example an o-ring as shown in the illustrated embodiment, is pressed between the body 12 and the bottom cover 14 , rendering the pitcher 10 leak proof.
[0030] To uninstall the bottom cover 14 , the release 54 is depressed, bending the deformable arm 74 and causing the release tab 72 to clear the wedge member 70 , thereby allowing the bottom cover 14 to rotate in the opposite direction. When the first thread 66 clears the second thread 68 , the bottom cover 14 may be pulled away from the body 12 .
[0031] Referring FIG. 6 , the body 12 is shown with the bottom cover 14 (not shown) removed. In this view the first thread 66 and wedge member 70 of the flange 18 are shown, along with additional structures of the body 12 interior, including the sloping nature of the sidewall 20 , a chamber baffle 78 and two opening baffles 80 that reduce turbulence under the funnel 32 . The chamber baffle 78 extends downward from the funnel 32 to help settle agitated hot liquid 100 ( FIGS. 7 and 8 ) in the body 12 . The opening baffles 80 serve that purpose as well, but also prevent hot liquid 100 from pouring freely through the first openings 34 .
[0032] Referring to FIG. 7 , a bilateral section view of the pitcher 10 shows the bottom cover 14 installed on the body 12 , the first and second threads 66 , 68 , the release 54 and release tab 72 in a locked position, and the gasket 76 preventing the hot liquid 100 ( FIGS. 7 and 8 ) from escaping. Also shown is the chamber baffle 78 , which settles the hot liquid 100 and the fin 38 , which directs and guides the hot liquid 100 as it leaves the pitcher 10 .
[0033] Referring to FIG. 8 , a non-bilateral section view of the pitcher 10 is shown, tipped to a normal angle for decanting the hot liquid 100 . The pitcher 10 is tipped sufficiently to cause the hot liquid 100 to flow through the first openings 34 . Hot liquid 100 flowing toward the first openings 34 encounters the opening baffles 80 ( FIG. 6 ). As the hot liquid 100 flows against and around the opening baffles 80 , changes in flow direction increase turbulence in the hot liquid 100 , slowing it down. After travelling around the opening baffles 80 , the hot liquid 100 passes through the first openings 34 and encounters the fin 38 , which introduces more turbulence, slowing the hot liquid 100 down further. The position of the fin 38 causes hot water 100 glancing off the fin 38 to leave the pitcher 10 at the lip 30 . Hot liquid 100 in the pitcher 10 may be decanted in this manner until the pitcher 10 is empty.
[0034] Referring to FIG. 9 , a non-bilateral section view of the pitcher 10 is shown, tipped to an extreme angle when decanting the hot liquid 100 . Occasionally, the pitcher 10 may be inadvertently tipped too far over during decanting, such that the hot liquid 100 reaches the level of the second openings 56 . When this happens, the hot liquid 100 exits the second openings 56 in addition to exiting the first openings 34 in the manner shown in FIG. 8 . When the hot liquid 100 reaches the second openings 56 and passes through them, the funnel 32 directs the hot liquid 100 toward the fin 38 , where it joins the hot liquid 100 exiting the first openings 34 and leaves the pitcher 10 at the the lip 30 .
[0035] While there are no structures immediately adjacent the second openings 56 to slow down the hot liquid 100 , the second openings 56 are sized so that only a small volume of the hot liquid 100 can exit through the second openings 56 . Some additional turbulence is introduced in embodiments having numerous second openings 56 as shown due to the hot liquid 100 encountering and traveling around the domed section 58 . With the funnel 32 holding back most of the hot liquid 100 (except the hot liquid 100 exiting the first openings 34 and second openings 56 ) when the pitcher 10 is tipped severely, a person operating the pitcher 10 has time to notice or to be alerted to the incorrect pour angle and correct it before the hot liquid 100 can spill and cause injury.
[0036] Once all of the hot liquid 100 is decanted, the pitcher 10 can be taken away for cleaning, or refilled. To refill the pitcher 10 , the hot liquid 100 is introduced into the funnel 32 , where it travels over the domed section 58 and through the second openings 56 until the pitcher 10 is full. As is the case with decanting, when filling the pitcher 10 , the first openings 34 and second openings 56 work together for safety. Namely, if the hot liquid 100 is introduced into the funnel 32 at too great a rate so that it builds up behind the second openings 56 , the first openings 34 provide a relief point of entry, thereby preventing the hot liquid 100 from rising up and over the splash guard 22 and causing injury.
[0037] The structure of the pitcher 10 having been shown and described, its method of use will now be discussed.
[0038] When retrieving, transporting, and decanting hot liquid 100 , a user Obtains an empty pitcher 10 . If the bottom cover 14 is separated due to prior use, cleaning or storage, the user brings the body 12 against the bottom cover 14 and inserts the inner wall 64 into the body 12 . The user then rotates the bottom cover 14 , causing the first and second threads 66 , 68 to bring the upper indicator 50 and the lower indicator 52 into alignment, whereupon the release tab 72 “clicks” behind the wedge member 70 , urged into position by the deformable arm 74 , and locking the bottom cover 14 against the body 12 with the body 12 held tightly against the gasket 76 to prevent leakage.
[0039] The pitcher 10 may then be filled with hot liquid 100 , which is introduced into the funnel 32 . Splashing hot liquid 100 entering the funnel 32 is retained by the splash guard 22 , and travels downward where it encounters the domed section 58 which directs it through the second openings 56 and into the pitcher 10 . If the hot liquid 100 builds up behind the second openings 56 , it will reach the first openings 34 and enter the pitcher 10 that way. If the hot liquid 100 is introduced at a flow rate exceeding what the second openings 56 and first openings 34 can accommodate, the splash guard 22 above the funnel 32 confines the hot liquid 100 , giving a user time to adjust the hot liquid 100 flow rate.
[0040] As the hot liquid 100 fills the pitcher 10 , the user may also observe grading 28 on the sidewall 20 to accurately measure a particular desired volume of hot liquid 100 . Once the pitcher 10 is full or a predetermined volume of the hot liquid 100 received therein, the hot liquid 100 supply (not shown) is turned off. The pitcher 10 may then be transported to a desired location for decanting the hot liquid 100 . After the hot liquid 100 is decanted, the pitcher 10 may be refilled or cleaned for storage.
[0041] When a user needs to clean and dry the pitcher 10 , or remove the bottom cover 14 for any reason, the release 54 is depressed, the bottom cover 14 rotated in a releasing direction until the first thread 66 clears the second thread 68 , allowing the bottom cover 14 to disengage from the body 12 . With the bottom cover 14 removed, the user can access all surfaces of the body 12 and the bottom cover 14 . To dry the pitcher, the bottom cover 14 is preferably kept separate from the body 12 and the body inverted over a drying rack (not shown) or similar drying structure. Any remaining moisture (not shown) will drain through the small holes 40 where the funnel 32 meets the splash guard 22 , which is the lowest point of the body 12 when inverted, thereby allowing the body to dry completely and avoid moisture-related contamination such as mold buildup.
[0042] The foregoing description of the preferred embodiment of the Invention is sufficient in detail to enable one skilled in the art to make and use the invention. It is understood, however, that the detail of the preferred embodiment presented is not intended to limit the scope of the invention, in as much as equivalents thereof and other modifications which come within the scope of the invention as defined by the claims will become apparent to those skilled in the art upon reading this specification. | A pitcher for safely receiving, transporting and decanting a hot liquid includes a body with first and second openings, and a bottom cover removably attached to the body. An opening baffle near the first opening reduces the hot liquid flow rate through the first opening during decanting, and a funnel near the second opening directs the hot liquid through the second opening when receiving the hot liquid. The funnel directs the hot liquid from the second opening to the first opening opening if the hot liquid exits the second opening during decanting. The pitcher includes an elongated handle, a fin for dividing the hot liquid during decanting, and a scalloped outer sidewall for limiting contact with a user's hand. | 0 |
BACKGROUND OF THE INVENTION
The invention relates generally to a wall structure resembling natural stone. More specifically, the invention relates to a facade or veneer suitable for placement on structures such as buildings, fences or walls in which individual sections fit closely together resembling natural stone.
Many consumers and building owners prefer wall structures resembling natural stone such as ledgestone, field stone and quarried rock. The use of natural stone is limited by factors such as expense, availability, and difficulty of handling and transport due to heavy weight. Additionally, some geographic areas are subject to earthquake activity. This geological phenomenon can render traditional stone structures impractical or dangerous. The present invention provides a decorative or aesthetically pleasing facade which is lightweight and low cost as compared to a natural product.
SUMMARY OF THE INVENTION
The invention provides a block, section or component for use as a wall structure such as a facing layer or facade of a wall. The invention could be used wherever one wishes to display an appearance resembling natural stone. For example, the invention could be used not only to cover a wall but also to incorporate into a fireplace, a pillar, a ledge or some other construct which may be either structural or decorative. The section is typically substantially quadrilateral in outline, but it may take other shapes such as a triangular one.
The invention provides an interlocking modular system of precast fitted stone sections, blocks or components which fit together easily and quickly. The system reduces the labor, time and cost required for stone cutting, fitting, grouting and jointing when using natural stone. The final appearance of the installed invention resembles natural dry stacked stone such as ledgestone or cut or quarried stone having ashlar dimensions.
The sections duplicate crevices, lines, shadows, colorations and weathered edges found in naturally occurring stone or precut chiseled or rock faced surfaces or edges of hand treated natural stone. The sections are lightweight and are provided in a variety of shapes which are prefitted to help the user or consumer to quickly achieve a finished look of natural stone. The invention can be used in many applications. For instance, it can be used as an interior facing or an exterior veneer to a home or other building.
The back surface of the section is intended to contact an adhesive which holds the section to a structure such as a wall or a lathing. The adhesive may be any of a number of bonding means known in the art such as mortar, concrete, mastic, epoxy, adhesive and grout.
The top and bottom surfaces of the section have longitudinally oriented grooves. These grooves accept adhesive which overflows onto the upper or lower section surface when the section is compressed or embedded against the surface to which it is to be permanently bound. This feature permits the sections to be placed very closely together. Thus, the invention may avoid the obvious external appearance of a layer of grout or mortar between sections and enhance the natural stone appearance.
The grooves have the additional feature of forming a key with the overflowed mortar, mastic or adhesive. Thus, the key formed by one section fits together with a co-operating key formed by an overlying or underlying section. This additionally facilitates bonding of the section members.
In a preferred embodiment, the ledgestone pattern, the lateral surfaces of the section are not necessarily perpendicular to the upper and lower surfaces. Preferably, the lateral surface or a portion thereof forms an angle of approximately 30° with either an upper or a lower surface. When forming a joint between two cooperating angled lateral surfaces, the finished product resembles natural ledgestone more closely than a conventional manufactured brick product.
The grooves may be formed by any of a number of means such as, for example, drilling, cutting, casting or molding. Preferably, the sections are formed of concrete. The sections may be applied to any of a number of surfaces. For example, the sections could be applied to a lathing which is typically formed of metal, plywood or concrete. Additionally, the sections could be directly applied to a wall or any structurally sound substrate, such as drywall masonry.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows side plan views including preferred dimensions of sections constructed in accordance with the invention.
FIG. 2 is a plan view closeup of the circled portion of FIG. 1 showing the preferred lateral surface configuration.
FIG. 3 shows corner sections constructed in accordance with the invention.
FIG. 4 is a cross-sectional view of a section indicating a preferred dimension and location of the groove as well as an impression of the irregular front face.
FIGS. 5A, B and C show cross sections of the invention when installed on structures of wood frame, concrete section and metal respectively.
FIG. 6 shows additional component pieces which fit together in a repeating interlocking modular, ashlar pattern.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, FIG. 1 shows a section member 2 of the present invention which is in the preferred substantially quadrilateral configuration. The term "quadrilateral" is meant to include sections having an irregular lateral surface as depicted in FIG. 1. Section 2 has at least five surfaces including an upper surface 4, a lower surface 8, a lateral surface 6, a face surface 10 and a back surface 12. Upper and lower surfaces 4/8 are essentially parallel. In a preferred embodiment, section 2 has two lateral surfaces 6. Back surface 12 is substantially flat, as this is the portion of the section which will contact the adhesive on the structure to which the sections are to be mounted. Alternatively, back surface 12 can have a grooved surface to assist in providing an improved bonding surface between the mortar, grout or adhesive and the surface area to which it is adhered.
The lateral surface may have any of a number of configurations. It may be in a plane perpendicular to the upper and lower surfaces, or it may take an angled or irregular configuration. In an embodiment resembling ledgestone, each section member has at least one lateral surface 6 which is irregular or angled. In the ledgestone embodiment, the lateral surface 6 preferably has dimensions as specified in FIG. 2. That is, about a one inch long region of lateral surface 6 adjoining each of upper surface 4 and lower surface 8 is substantially perpendicular to surfaces 4 and 8, respectively. An intermediate region of lateral surface 6 is angled about 30° with respect to surfaces 4/8.
When multiple sections are joined together with sections having cooperating and co-adapting lateral surfaces 6, the result provides a finished facade more closely resembling natural ledgestone or other stone texture because the joints are not all at precise right angles. Most preferably, the sections possess two lateral sides 6 having the irregular 30° angled configuration. See the section labeled 2a in FIG. 1.
The dimensions of the sections may vary considerably, but most preferably the sections have a height of about four inches. The height is the distance measured from the plane of the upper surface 4 to the lower surface 8. The thickness of the section, measured from the back surface to the front surface, may vary because the shape of the face surface 10 varies considerably to mimic natural stone. Typically, the thickness ranges from about one inch to about three and one-half or four inches. The length of the stone as measured from lateral surface to lateral surface varies from about four inches to about 20 inches.
Alternatively, the sections can have lateral surfaces substantially perpendicular to the upper and lower surfaces. This ashlar embodiment is shown schematically in FIG. 6. The sections can be made in any of a number of dimensions. Preferably the dimensions of height and length are selected from an array including 4×4, 4×8, 4×12, 8×8, 8×12, and 12×12 inches. The thickness or depth is preferably from about 1 to about 4 inches. A thickness of about 1 to 2 inches is more preferred.
Longitudinal grooves 14 are provided in each of the upper surface 4 and lower surface 8. In a preferred embodiment, these grooves are about one-quarter inch wide and about one-quarter inch deep. The longitudinal orientation means that the grooves extend along the length of the sections in a plane substantially parallel to the back surface of the section. The grooves may be formed by casting in a mold, or alternatively they may be formed by cutting or drilling. Such cutting or drilling is preferably accomplished while the concrete is green or not yet completely cured.
Corner sections may be formed in accordance with the present invention. See FIG. 3. The corner sections have a face surface texture similar to the sections as previously described below. The L-shaped configuration of the corner sections further enhances the natural appearance of the finished facade because a conventional grouted corner joint is avoided. Instead, the corner appears more like natural stone.
The front or face surface 10 of section 2 is cast to resemble natural stone such as ledgestone. Alternatively, a surface resembling a rock face or quarry face is used. That is, the section is formed, shaped, molded or casted to have a face surface texture including projections, depressions, crevices, cracks and a rough weathered look to mimic the appearance of natural stone.
Each section of the invention is individually installed. The sections are permanently attached to the wall surface to which they are applied. At about 8 to 10 pounds per square foot, the sections are relatively lightweight compared to natural stone. These features allow multi-story use where natural stone might be economically or structurally impossible to use.
Because the method of adhesive is accomplished by adhering instead of stacking or mechanical fastening, installation is fast and easy without requiring footings or wall ties. On clean, untreated masonry, brick or concrete, the sections are directly applied to the wall surface using a mortar or adhesive. On other surfaces, such as wood, wallboard and sheetrock, an expanded metal lath or other suitable mesh is first applied. A weather-resistant barrier such as waterproof building paper is typically used on all applications other than to masonry or concrete surfaces.
Preferably, the corner pieces 20 are installed first. Installation of other sections may be started at either the top or bottom. When applying the sections to a wood frame or to open studs 26, a weather-resistant barrier 28 is first applied to the frame or studs. See FIG. 5A. Next, metal lath 30 is applied over the weather-resistant barrier 28. If open studs 26 are being used, a scratch coat 32 is next applied. A scratch coat refers to a rough-textured cementitous layer to which an adhesive or mortar is applied. Usually the scratch coat is comprised of Portland Cement and/or lime mortar. An application coat of adhesive (not shown) is applied and to this adhesive coating the sections are applied.
The sections are fitted closely together resulting in a minimal mortar joint 34. Compression of the section 2 against the coating of mortar or adhesive usually causes some flow of the semi-fluid mortar or adhesive onto the section. This flow is accepted by grooves 14, thus permitting close approximation of the sections upper and lower surfaces 4/8 without a visibly obvious grout joint. Additionally, the adhesive lodged in grooves 14 acts as a key or further bonding means between adjacent sections. Adhesive in groove 14 of upper surface 4 of a first section 2 contacts adhesive in groove 14 in lower surface 8 of a second section 2 where the second section is installed above the first section.
When applying the sections of the invention to a concrete block 36 or other masonry material, a masonry or concrete cap 38 is recommended. See FIG. 5B. Mortar 40 is applied directly to the masonry support surface 36 except when that surface is treated or painted. If treated or painted, application of a metal lath or sand blasting is recommended prior to application of mortar. The sections 2 are applied to the mortar coating.
When applying the sections of the invention to a metal building or structural frame 42, a horizontal fastening girth 44 is first applied to the structural frame 42. See FIG. 5C. Next, a metal panel 46 is applied and then metal lath 48 with weather-resistant barrier is affixed to the metal panel 46. A scratch coat 50 is next applied, followed by an application coat of the adhesive or mortar (not shown). The sections 2 are applied to the adhesive coat as previously described.
A material preferred for forming the sections is concrete such as a mixture of Portland cement, lightweight aggregates, and iron oxide colors. The sections are preferably engineered to meet or exceed specifications set by building code officials. For example, the sections preferably conform to or exceed test requirements as specified in the International Conference of Building Officials Evaluation Service, Inc., Acceptance Criteria for Precast Stone Veneer. Some of the tests include shear bond test (adhesion), water absorption, freeze/thaw characteristics, compressive strength, unit weight, tensile strength, flexural strength, and transverse load strength. Additional tests include efflorescence tests, thermal properties, non-combustibility, and color fastness.
The artisan will appreciate that modifications or variations of the above-described embodiment are evident. For example, the dimensions of the sections and the angles of the side or lateral surfaces could be varied. Additionally, the use of material other than concrete may be practical or desirable. For instance, a clay or ceramic section could be employed. Also, the face surface of the section could be made to resemble something other than the preferred ledgestone, ashlar and rock face. For example, the facing could be formed to resemble sandstone or limestone having fossilized deposits or depressions therein. Thus, the invention is not limited by the above description of a preferred embodiment, but rather by the claims which follow. | The invention provides a wall structure of precast concrete sections (2) having face surfaces (10) which resemble natural ledgestone, ashlar, rock face, or other stone textures surfaces and shapes. The sections are provided with grooves (14) at the upper (4) and lower (8) surfaces. The grooves accept overflow of mortar or adhesive which coats the surface to which the sections are to be bonded. Thus, the excess mortar is substantially hidden within the grooves where it acts as additional bonding between the layers of sections. At their lateral surfaces (6), the sections are angled to further resemble the appearance of natural stone upon installation. Methods of installation are also provided. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to methods and apparatuses for heat transfer. More particularly, the invention relates to optimized extended surfaces used for cooling electronic components and other objects whereas such methods and apparatuses involve heat transfer, such as the removal, absorption and/or dissipation of heat.
[0003] 2. Description of the Related Art
[0004] A “heat sink” (alternatively spelled “heatsink”) is a device used for removing, absorbing and/or dissipating heat from a thermal system. Generally speaking, conventional heat sinks are founded on well known physical principles pertaining to heat transference. Heat transference concerns the transfer of heat (thermal energy) via conduction, convection, radiation or some combination thereof. In general, heat transfer involves the movement of heat from one body (solid, liquid, gas or some combination thereof to another body (solid, liquid, gas or some combination thereof). In the present invention the term “heatsink” may also apply to heat exchangers, radiators, air and liquid-cooled coldplates, and other devices through which heat is transferred.
[0005] The term “conduction” (or “heat conduction” or “thermal conduction”) refers to the transmission of heat via (through) a medium, without movement of the medium itself, and normally from a region of higher temperature to a region of lower temperature. “Convection” (or “heat convection” or “thermal convection”) is distinguishable from conduction and refers to the transport of heat by a moving fluid which is in contact with a heated body. According to convection, heat is transferred, by movement of the fluid itself, from one part of a fluid to another part of the fluid. “Radiation” (or “heat radiation” or “thermal radiation”) refers to the emission and propagation of waves or particles of heat. The three heat transference mechanisms (conduction, convection and radiation) can be described by the relationships briefly discussed immediately hereinbelow.
[0006] Conductive heat transfer, which is based upon the ability of a solid material to conduct heat therethrough, is expressed by the equation q=kA c ΔT/L, wherein: q=rate of heat transfer (typically expressed in Watts) from a higher temperature region to a lower temperature region; k=thermal conductivity (W/m K), which is a characteristic of the material composition; Ac=cross-sectional area (m 2 ) of the material (perpendicular to the direction of heat flow; ΔT=temperature difference (° C.), which is the amount of temperature drop between the higher temperature region and the lower temperature region; and L=length (m) of the thermal path through which the heat is to flow.
[0007] Convective heat transfer, which is based upon the ability of a fluid to transfer heat energy through intimate contact with a solid surface, is expressed by the equation q=h c A s ΔT, wherein: h c =fluid convection coefficient (W/m 2 K), wherein h c is determined by factors including the fluid's composition, temperature, velocity, and turbulence; and, A s =surface area (m 2 ) which is in contact with the fluid.
[0008] Radiative heat transfer, which is based upon the ability of a solid material to emit or absorb energy waves or particles from a solid surface to fluid molecules or to different temperature solid surfaces, is expressed by the equation q=A s ∈σ(T s 4 −T a 4 ), wherein: ∈=dimensionless emissivity coefficient of a solid surface, which is a characteristic of the material surface; σ=Stefan−Boltzmann constant; A s =surface area (m 2 ) which radiates heat; T s =absolute temperature of the surface (K); and, T a absolute temperature of the surrounding environment (K).
[0009] It is theoretically understood that, regardless of the heat transfer mechanism, heat transfer rate q can be increased by increasing one or more of the numerator factors on the right side of the equation.
[0010] In current practical contexts, heat sinks, coldplates and heat exchangers are generally designed with a view toward furthering the conductive properties of the heat sink by augmenting the thermal conductivity k, for conduction; the surface area, A s , and heat transfer coefficient hc, for convection. In this regard, according to conventional practice, a heat sink structure is made of a highly thermally conductive solid material, thereby maximizing the conductivity k characteristic of the heat sink; an extended surface comprising a plurality of manufacturable fins or pins, thereby maximizing the surface area A s ; and a geometric shape in contact with the fluid medium, thereby maximizing the heat transfer coefficient h c .
[0011] Following conventional design practice, the heat sink structure tends to be rendered large (e.g., bulky or voluminous), therefore heat sinks are often rated by a heat transfer efficiency, or thermal resistance θ, found by dividing the ΔT, temperature rise of the heat source by the power input, i.e., ° C./W, whereby a lower value for thermal resistance θ, equates to a more efficient design.
[0012] As surface area and volume is increased, ancillary issues such as flow resistance and mass must be minimized. In order to gauge these ancillary effects on the efficiency of a heat sink, pumping power P p , (measured in W), and mass M, (in kg) can be weighted and added to the efficiency equation resulting in η=ΔTP p M/W. Flow resistance can be particularly important because this resistance increases at the square power of coolant velocity. High flow resistance may require larger pumps or fans to generate additional pumping power, which may also require additional cooling capability.
[0013] Due to manufacturing costs, optimized heat sinks are usually limited to a linear array of identical fins having fixed spacing, which are intended to increase the surface area available for heat transfer and increase the heat transfer coefficient. These heat sinks are further compromised by containing simple fin shapes such as squares or rectangles, and occasionally round pins.
[0014] Several factors combine to reduce the effectiveness of these conventional heat sinks. One of the most common problems is that the heat absorbed by a coolant media results in a higher temperature media. Due to the temperature rise of the coolant and because a passive heat sink can not cool a heat source below the temperature of the coolant, the temperature of the last device in a row of equally powered components will be hotter than the upstream components. The temperature rise of the coolant is found by ΔT=q/{dot over (m)}c p , where {dot over (m)}=mass flow rate (kg/s) and c p =specific heat (J/kg K) of the coolant media. This effect can also greatly change the coolant properties. Therefore, a linear fin array which is optimized for a specific inlet coolant temperature will not provide optimum heat transfer for the coolant after heat is absorbed. An extreme aspect of coolant media property change is in high heat flux applications whereby a saturated liquid enters a heat exchanger, becomes a two-phase flow through nucleate boiling, and subsequent vapor flow.
[0015] In addition, heat is not usually spread evenly across the heat input surface of the heat sink. Common practice is to have a plurality of small heat sources share a common heat sink. In such cases, a linear array of fin protrusions will require the same amount of pumping power to flow through the unheated regions as the heated regions.
[0016] Thus, there are potential problems associated with conventional approaches to effectuating heat sink cooling of an entity behaving at a high power density. Firstly, prior art manufacturing approaches result in an array of fin protrusions that are more optimized for cost and not for heat transfer. Secondly, a low-cost prior art fin array, consisting of identical fins with identical spacing, will waste pumping power on unheated regions, usually resulting in the need for larger fans or pumps. Thirdly, prior art fin arrays have no provision to account for the temperature rise of a coolant media or the changes in physical properties of the coolant, resulting in decreased efficiency. Fourthly, prior art heat sinks are often grossly overweight, due to the limitations of the manufacturing approach.
[0017] Of interest in the art are several United States patents, each of which is hereby incorporated herein by reference Klein et al. U.S. Pat. No. 4,151,548 issued Apr. 24, 1979 teaches the use of square or diagonal cross-section pegs in a fluid flow whereby turbulence is created to enhance cooling. Klein also teaches that opposing inlet and outlet ports cause a higher velocity between the ports. Klein does not teach the use of efficient structures or the role of flow resistance.
[0018] Pellant et al. U.S. Pat. No. 4,188,996 issued Feb. 19, 1980 describes a device that contains a plurality of spaced parallel channels. The channels being divided by studs spaced longitudinally in an effort to promote more fluid turbulence. Pellant does not teach the use of efficient structures or the role of flow resistance.
[0019] Iversen U.S. Pat. No. 4,712,609 issued Dec. 18, 1987 discloses a roughened heat exchanger surface with a coolant flow heated to boiling and producing pressure gradients to remove nucleate bubbles. Although Iversen teaches that low flow resistance is important, Iversen does not teach, and makes no provision for the fact that the optimum heat transfer surface for liquid flow is very different than the optimum for two-phase and gaseous flow.
[0020] Steffen et al. U.S. Pat. No. 4,997,034 issued Mar. 5, 1991 teaches a heat transfer surface consisting of diamond-shaped protrusions on a pie-shaped plate and recognition of manufacturing ease and flow resistance. Steffen does not teach that different aspect ratios will produce different heat transfer and flow resistance results, nor does Steffen teach the use of mixed shapes and heights of protrusions.
[0021] Wolgemuth et al. U.S. Pat. No. 5,453,911 issued Sep. 26, 1995 discloses the use of nozzles to cause impingement of a coolant onto the baseplate of an insulated gate bipolar transistor (IGBT) or silicon-controlled rectifier (SCR), and deflectors to cause greater a greater heat transfer coefficient at hot spots. Wolgemuth does not teach the importance of flow resistance, or that gross changes in flow direction and velocity can have a very negative impact on flow resistance, nor does Wolgemuth disclose the use of shaped protrusions to efficiently cool hot spots.
[0022] Romero et al. U.S. Pat. No. 5,915,463 issued Jun. 29, 1999 instructs the use of an optimized fin array to cool discrete components and a method of manufacture. Romero asserts that the fin surfaces perpendicular to coolant flow do not significantly contribute to heat transfer, directly contradicting a large body of published literature.
[0023] Frey et al. U.S. Pat. No. 5,978,220 issued Nov. 2, 1999 discloses the use of fusion bonded heat sinks to cool IGBT modules, whereby the heat sink pins are circular, perpendicular to coolant flow, and in a hexagonal pattern. Although Frey teaches that thermal resistance can be optimized by varying pin diameter and spacing, Frey does not disclose the detrimental effect of flow resistance in that optimization or a method to counter heat absorption by the coolant.
[0024] Becker et al. U.S. Pat. No. 6,039,114 issued Mar. 21, 2000 instructs the use of a cooling body consisting of protruding lugs. Becker teaches that the volume of the lugs is greater than the volume of the flow channels thereby producing homogeneous flow resistance. Becker does not disclose how the shape or pattern of said lugs can be optimized to reduce said flow resistance, or how the geometric shape of the cooling body may be changed to cool local regions of greater heat flux.
[0025] Cannell et al. U.S. Pat. No. 6,729,383 issued May. 4, 2004 teaches a heat sink with non-thermally conductive fins, heat transfer occurring on the heat sink plate. The pins serve to promote fluid turbulence. Cannell teaches that a disparity among pins is acceptable, but that configurational regularity promotes uniformity of heat transfer. Cannell does not teach that flow resistance is an important variable or that certain shapes are more efficient than other shapes. Although Cannell discloses a large number of embodiments there is no rational for using one embodiment over another.
[0026] Rinehart et al. U.S. Pat. No. 7,173,823 issued Feb. 6, 2007 discloses a fluid-cooled assembly wherein lies a heat sink. Rinehart teaches that the cooling pins at the fluid inlet may be of a smaller diameter than at the fluid outlet because of heat absorption by the fluid, but does not disclose that other shapes and spacing of fins are more effective, or that shortening the pins can offer less flow resistance while simultaneously increasing fin efficiency.
[0027] Referring to FIG. 1 a thru 1 d , of a prior art configuration, a round pin heat sink 10 is shown. Prior art pins 11 are round and attached to a prior art base 12 . Referring now to FIG. 1 b , prior art round pins 11 are arranged as such in prior art longitudinal rows 13 , parallel to the flow. Prior art longitudinal rows 13 are in staggered relationship with each other so that pins 11 in alternating longitudinal rows 13 are transversely (columnarly) 14 aligned as show. Referring now to FIG. 1 c , prior art round pin 11 pattern shown in FIG. 1 b can also be conceived to reveal a prior art heat sink 10 having prior art round pins 11 arranged in transverse columns 14 situated perpendicular to the flow so that alternating transverse are longitudinally (row-wise) aligned.
[0028] Referring to FIG. 1 b and FIG. 1 c of the prior art configuration, it is shown that prior art round pins 11 have equal prior art pin diameter 15 , equal longitudinal pin spacing 16 , and equal prior art transverse pin spacing 17 , whereas the terms “longitudinal” and “transverse” are in relation to the primary flow direction.
[0029] Referring now to FIG. 1 d of the prior art round pin heat sink 10 , prior art upper flow boundary surface 18 can be added, therefore prior art upper flow boundary surface 18 and prior art base 12 act as boundary layers for flow. Prior art upper flow boundary surface 18 and prior art base 12 are both planar. The prior art round pins 11 uniformly extend an overall prior art pin height 19 from prior art base surface 12 . Every prior art round pin 11 has the same prior art pin height 19 . Depending on the specific requirements of prior art round pin heat sink 10 , pins 11 may simply support, touch, or not touch prior art upper flow boundary surface 18 . Since prior art upper flow boundary surface 18 and prior art base surface 19 are both planar, the distance therebetween is constant.
[0030] Referring to FIG. 2 a thru 2 c , a prior art square pin heat sink 20 is shown. Prior art square pins 21 have an equal or near-equal prior art square pin longitudinal dimension 25 and prior art square pin transverse dimension 26 . Prior art square pins 21 are attached to prior art base 12 . Referring now to FIG. 2 b , prior art square pins 21 are arranged as such in longitudinal rows 13 , parallel to the flow. Rows 13 are in staggered relationship with each other so that pins 21 in alternating rows 13 are transversely (columnarly) 14 aligned. Prior art square pins pattern shown in FIG. 2 b can also be conceived to reveal a prior art heat sink having prior art square pins 21 arranged in transverse columns 14 situated perpendicular to the flow so that alternating columns are longitudinally (row-wise) aligned (not shown).
[0031] Referring to FIG. 2 b of the prior art configuration, it is shown that prior art square pins 21 have equal prior art longitudinal pin spacing 16 , and equal prior art transverse pin spacing 17 .
[0032] Referring now to FIG. 2 c of the prior art square pin heat sink 10 , prior art square pin 11 is seen to cause a prior art discontinuity in the flow velocity 27 . Prior art flow discontinuity 27 has elements of recirculation and velocity stagnation resulting in diminished heat transfer efficiency and greater pressure drop. Prior art flow discontinuity 27 is common among most prior art heat sinks having in-line or staggered patterns of shapes. Prior art flow discontinuity 27 is most pronounced when the ratio of transverse pin dimension to longitudinal pin dimension is greater than or equal to unity. Consequently, prior art flow discontinuity 27 diminishes as the ratio of transverse pin dimension to longitudinal pin dimension diminishes, but pressure drop caused by pin surface skin friction increases. The size of prior art flow discontinuity 27 grows with increased flow turbulence, indicated by the Reynolds number, Re. Where Re=ρUD/μ, and ρ is the fluid density (kg/m 3 ), U is the fluid velocity (m/s), D is a characteristic dimension (m), and μ is the absolute viscosity (N s/m 2 ).
[0033] Referring to FIGS. 3 a and 3 b , a prior art plate fin heat sink 30 is shown. Prior art plate fins 31 are usually characterized by having a prior art longitudinal dimension 35 much larger than prior art transverse dimension 36 . Prior art plate fins 31 are attached to prior art base 12 . Referring now to FIG. 3 b , prior art square pins 31 are arranged as such in longitudinal rows 13 , parallel to the flow. Rows 13 are in staggered relationship with each other so that fins 31 in alternating rows 13 are transversely (columnarly) 14 aligned. Prior art plate fin pattern shown in FIG. 3 b can also be conceived to reveal a prior art heat sink having prior art plate fins 31 arranged in transverse columns 14 situated perpendicular to the flow so that alternating columns are longitudinally (row-wise) aligned (not shown).
[0034] Referring to FIG. 3 b of the prior art configuration, it is shown that prior art plate fins 31 have equal prior art longitudinal fin spacing 16 , and equal prior art transverse fin spacing 17 .
[0035] Referring now to FIG. 3 c of the prior art square pin heat sink 30 , prior art plate fin 31 is seen to cause a prior art discontinuity 38 in the flow velocity. Prior art flow discontinuity 38 has a velocity boundary layer height 39 , measured perpendicular to the primary flow direction, found by the equation δ=5x/√{square root over (Re)}, where δ is the velocity boundary layer height 39 at dimension x (m), x is the distance parallel to flow (m) from the initial point of the object, and Re x is the Reynolds number at dimension x. It is understood that the height of velocity boundary layer 39 represents a near-stagnation zone along the surface of prior art plate fin 31 that causes the heat transfer coefficient to decrease as prior art longitudinal pin dimension 35 increases. The increasing thickness of the velocity boundary layer along the flow path acts to shroud downstream fins or pins in a “shadow” of lower velocity fluid thereby decreasing the heat transfer coefficient as the number of transverse columns 14 increases.
[0036] Referring to FIG. 4 a thru 4 c , a prior art two-diameter pin heat sink 40 is shown. Prior art round pins 11 are attached to a prior art base 12 . Prior art round pins 11 are grouped into two distinct regions, an inlet region 43 and an outlet region 44 , that are non-continuous and therefore non-interactive. Prior art inlet pins 41 within inlet region 43 have a smaller diameter than prior art outlet pins 42 within prior art outlet region 44 .
[0037] Referring now to FIG. 4 b , prior art round pins 11 are arranged as such in longitudinal rows 13 , parallel to the flow. Rows 13 are in staggered relationship with each other so that pins 11 in alternating longitudinal rows 13 are transversely (columnarly) 14 aligned. Prior art inlet pins 41 have equal longitudinal spacing 45 within inlet region 43 and prior art outlet pins 42 have equal longitudinal pin spacing 46 within outlet region 44 . Prior art inlet pins 41 have equal transverse spacing 47 within inlet region 43 and prior art outlet pins 42 have equal transverse pin spacing 48 within outlet region 43 .
[0038] Referring now to FIG. 4 c of the prior art two-diameter pin heat sink 40 , prior art upper surface 18 and prior art base 12 act as boundary layers for flow. Prior art upper surface 18 and prior art base 12 are both planar. The prior art round pins 11 uniformly extend an overall prior art pin height 19 from prior art base surface 12 . Every prior art round pin 11 has the same prior art pin height 19 . Depending on the specific requirements of prior art round pin heat sink 40 , pins 11 may simply support, touch, or not touch prior art upper surface 18 . Since prior art upper surface 18 and prior art base surface 19 are both planar, the distance therebetween is constant.
SUMMARY OF THE INVENTION
[0039] In view of the foregoing, it is an object of the present invention to provide heat sink method and apparatus which are capable of dissipating/removing heat from a device or other to-be-cooled object which is characterized by a high power density.
[0040] It is another object of this invention is to provide heat sink method and apparatus which provides cooling, for a to-be-cooled object (such as a module) having a baseplate, wherein the cooling is non-uniform over the surface area of the baseplate.
[0041] Another object of the present invention is to provide heat sink method and apparatus which are not large, cumbersome or heavy.
[0042] A further object of this invention is to provide heat sink method and apparatus in which extended surface protrusions are optimally shaped in recognition of convective heat transfer, conductive heat transfer, and flow resistance.
[0043] Another object of the present invention is to provide heat sink method and apparatus which offsets the temperature rise of a coolant media and provide enhanced cooling for the local coolant temperature.
[0044] A further object of this invention is to provide heat sink method and apparatus which delivers optimized cooling efficiency per the local physical properties of the coolant media.
[0045] The present invention provides a heat sink for cooling an object, and a methodology for accomplishing same. The inventive heat sink is capable of being used in association with a fluid (liquid or gas) for effectuating cooling. Either liquid coolant, gas coolant or a combination two-phase flow can be used in inventive practice.
[0046] The present invention further features turbulence enhancement of the coolant stream by a pin array through which the coolant stream passes. According to many embodiments, this invention additionally features a non-linear shape, spacing, and height pattern to provide optimal cooling while simultaneously reducing volume and flow resistance.
[0047] In accordance with many embodiments of the present invention, a heat sink device for utilization in association with fluid for cooling an object comprises a heat transfer structure which includes a foundation section, plural protrusions, side surfaces, and a lid surface. The foundation section has an upper surface. The protrusions are situated on the upper surface. The foundation bottom surface is adaptable to engagement with a heat source. The fluid streams approximately longitudinally with respect to the upper surface and with respect to the object. According to typical inventive practice, the structure is adaptable to such engagement and association wherein at least one protrusion affects the streaming of the fluid—more typically, wherein plural protrusions, which are some or all of the protrusions, affect the streaming of the fluid.
[0048] In another embodiment of the present invention a heat sink device for utilization in association with fluid for cooling an object comprises a structure which includes a foundation section, plural protrusions, side surfaces, and a lid surface. Wherein protrusions are situated on both the upper surface of the foundation and the lower surface of the lid. The foundation bottom surface is adaptable to engagement with a heat source. The fluid streams approximately longitudinally with respect to the foundation upper surface, the lid lower surface, and the object. Accordingly, the pins on the upper surface and the lower surface may have different shapes spacing, and heights, that when assembled, produce multiple local flowfields within the heat transfer structure.
[0049] The inventive cooling apparatus is for application to any body—for example, an electronic circuitry device or other electronic component.
[0050] The inventive fluid-cooling heat sink apparatus typically comprises fluidity means (e.g., a fluid generation system) and a member. The subject body has a body surface portion. The member has a member surface portion and a plurality of pins projecting therefrom. According to frequent inventive practice the pins are approximately parallel; however, such parallelness is not required in accordance with the present invention. Each pin has a pin end surface portion opposite the member surface portion. The fluidity means includes means emissive of a fluid which is flowable along at least a part of the member surface portion so as to be contiguous at least a part of the body surface portion when at least a part of the body surface portion communicates with at least some of the pin end surface portions. Typically, the pins are arranged and configured in such manner as to be capable of increasing the turbulence of the fluid which passes between the member surface portion and the body surface portion.
[0051] Many inventive embodiments provide a method for cooling an entity such as an electronic component. The inventive method comprises the following steps: (a) providing a device having a device surface area and plural members which jut from the device surface area, the members having corresponding extremities opposite the device surface area; (b) associating the entity with the device, the entity having an entity surface area, the associating including placing the entity surface area in contact with at least some of the extremities; and (c) discharging fluid between the device surface area and the entity surface area so as to be disturbed by at least some of the members.
[0052] This invention meets most military and commercial requirements for dissipating/removing heat. The inventive heat sink: is capable of dissipating heat from a single or multiple high power density devices; can provide uniform or localized cooling over a baseplate surface area; is highly efficient in terms of mass, total volume, pumping power, and thermal resistance; and, carries relatively low manufacture and assembly costs.
[0053] The terms “pin” and “fin,” in relation to the present invention, are used somewhat interchangeably. The term “pin” is usually applied to an extended surface protrusion of any height having roughly equivalent dimensions parallel and perpendicular to the general coolant flow direction. The term “fin” usually refers to an extended surface protrusion of any height having a greater dimension parallel to the general flow than perpendicular to the general flow. Hereinafter, “fin” is used to present the structure inside the heat sink.
[0054] In accordance with many embodiments of the present invention, the protrusions may be made of a thermally conductive material such as metal, thereby adding surface area and complementing heat convection by the working fluid with heat conduction by the fins.
[0055] According to inventive embodiments which thus implement thermally nonconductive fins, there is no significant or appreciable thermal conductivity; all or practically all of the heat which is removed from the heat source is removed via convection, wherein the cooling fluid comes into direct contact with a surface or surface portion of the heat source object. A thermally nonconductive material will generally be a nonmetallic material.
[0056] For instance, in inventive applications involving a module having a dielectric (e.g., ceramic) baseplate, the entirety of the heat is removed through the baseplate by the working fluid (e.g., water or air). The invention's fins serve as mechanical support for the ceramic baseplate and to enhance the turbulent flow of the working fluid; the turbulent flow increases the heat-removal effectiveness of the working fluid. The present invention not only provides support for the baseplate to prevent breakage, but also cools the baseplate.
[0057] It should be understood that, according to this invention, the fins do not necessarily project from the heat sink's base section. An inventive feature is that the fins may be interposed between the heat source and the heat sink surface. The heat sink surface bounds the working fluid flow on one side, and a heat source object surface bounds the working fluid flow on the opposite side. In inventive practice, the fins can project from either (i) a base which is part of a module for holding an electronic component, or (ii) a base section which is part of the heat sink device, this base section itself representing a sort of “base plate.”
[0058] In accordance with many embodiments of the present invention, the terms “heat source” and “coolant media” can be replaced with the terms “cold source” and heated media”. The invention can thus operate in either direction of heat flow, i.e. heat source to coolant media or heated media to cold source.
[0059] It should be understood that, according to this invention, the protrusions may be made of a thermally conductive material such as metal, thereby adding surface area and complementing heat convection by the working fluid with heat conduction by the fins.
[0060] The invention can thus operate regardless of which of two opposing substrates the fins project from, viz., an object surface (e.g., a “modular baseplate surface”) or a heat sink surface (e.g., a “heatsink baseplate surface”). Therefore, according to many embodiments, a cooling assembly may comprise a modular baseplate, a heatsink base, plural fins and a fluid. The fins located between the two surfaces. The fluid is disposed between the modular baseplate and the heatsink base so as to be disrupted by at least some of the fins. Such inventive arrangements can prove especially propitious for applications involving high heat fluxes, wherein the modular baseplate (and perhaps the rest of the module, as well) is made of a dielectric material, e.g., a nonmetallic material such as ceramic, and thereby affords electrical isolation to the electronic component which is housed by the module.
[0061] Further is should be understood that the invention structure applies to different physical geometries. For example, a multi-sided heat transfer structure wherein some sides transfer heat into the structure and other sides transfer heat out of the structure.
[0062] Other objects, advantages and features of this invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed. Other advantages and features of the invention will be apparent from the following description, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] The various objects and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawings, in which:
[0064] FIG. 1 a is an isometric view of a prior art heat sink device, wherein the extended surface is in the form of a linear array of identical round fins, having identical spacing, in a staggered pattern.
[0065] FIG. 1 b is a top plan view of the prior art configuration shown in FIG. 1 a , wherein the extended surface is in the form of a linear array of identical round fins, having identical spacing, in a staggered pattern.
[0066] FIG. 1 c is a top plan view of a prior art configuration wherein the extended surface is in the form of a linear array of identical round fins, having identical spacing, in an in-line pattern.
[0067] FIG. 1 d is a side elevation view of the prior art configuration shown in FIG. 1 c.
[0068] FIG. 2 a is an isometric view of a prior art heat sink device, wherein the extended surface is in the form of a linear array of identical square fins, having identical spacing, in a staggered pattern.
[0069] FIG. 2 b is a top plan view of the prior art configuration shown in FIG. 2 a , wherein the extended surface is in the form of a linear array of identical square fins, having identical spacing, in a staggered pattern.
[0070] FIG. 2 c is a top plan close-up view of the prior art configuration shown in FIG. 2 b , wherein the extended surface is in the form of a linear array of identical square fins, having identical spacing, in a staggered pattern. Vortex flow discontinuities that are characteristic of this fin pattern are shown.
[0071] FIG. 3 a is an isometric view of a prior art heat sink device, wherein the extended surface is in the form of a linear array of plate-shaped fins, having identical spacing.
[0072] FIG. 3 b is a top plan view of the prior art configuration shown in FIG. 3 a , wherein the extended surface is in the form of a linear array of plate-shaped fins, having identical spacing.
[0073] FIG. 3 c is a top plan close-up view of the prior art configuration shown in FIG. 3 b , wherein the extended surface is in the form of a linear array of plate-shaped fins, having identical spacing. Boundary layer flow discontinuities that are characteristic of this fin pattern are shown
[0074] FIG. 4 a is an isometric view of a prior art heat sink device, wherein the extended surface is in the form of a linear array of thin round fins at the coolant inlet, and thick round fins at the coolant outlet, all having identical spacing.
[0075] FIG. 4 b is a top plan view of the prior art configuration shown in FIG. 4 a , wherein the extended surface is in the form of a linear array of thin round fins at the coolant inlet, and thick round fins at the coolant outlet, all having identical spacing.
[0076] FIG. 4 c is a side elevation view of the prior art configuration shown in FIG. 4 a.
[0077] FIG. 5 is an isometric view of the preferred embodiment of the present heat sink invention, illustrating the novel non-linear fin shapes, fin heights, and fin spacings.
[0078] FIG. 6 is a top plan close-up view of the preferred embodiment of the present heat sink invention shown in FIG. 5 .
[0079] FIG. 7 is a side elevation view of the heat sink preferred embodiment shown in FIG. 6 .
[0080] FIG. 8 is a top plan view of the present invention showing the present heat sink invention.
[0081] FIG. 9 is an isometric view of the fins of the heat sink of the present invention.
[0082] FIG. 10 is a top plan close-up view of an alternate embodiment of the leading edge of the present invention showing an entrance channel optimized for laminar flow.
[0083] FIG. 11 is a top plan close-up view of an alternate embodiment of the trailing edge of the present invention showing an entrance channel optimized for turbulent flow.
[0084] FIG. 12 is a top plan view of an alternate embodiment of the present invention showing a nonlinear fin structure extending the length of the heat sink.
[0085] FIG. 13 is a top plan close-up view of an alternate embodiment of the present invention showing a nonlinear fin structure extending at the trailing edge of the heat sink.
[0086] FIG. 14 is a top plan view of an alternate embodiment of the present invention showing flow diverters and a plurality of heat sources and discrete fin arrays.
[0087] FIG. 15 is a side view of the alternate embodiment of FIG. 15 showing placement of heat sources.
[0088] FIG. 16 a is a top view of the present invention showing locations of cross sectional views a-a, b-b, c-c, and d-d.
[0089] FIG. 16 b is a cross sectional front view of the present invention along plane a-a of FIG. 18 a at a distance of roughly ⅛ along the flow length showing fins having a conical profile.
[0090] FIG. 16 c is a cross sectional front view of the present invention along plane b-b of FIG. 18 a at a distance of roughly ½ along the flow length showing fins having a truncated concave hyperbolic profile.
[0091] FIG. 16 d is a cross sectional front view of the present invention along plane c-c of FIG. 18 a at a distance of roughly ¾ along the flow length showing fins having a truncated concave parabolic profile.
[0092] FIG. 16 e is a cross sectional front view of the present invention along plane d-d of FIG. 18 a at a distance of roughly ⅞ along the flow length showing fins having a cylindrical profile.
[0093] FIG. 16 f is a cross sectional front view of the present invention along plane e-e of FIG. 18 a at a distance of roughly 15/16 along the flow length showing fins having a conical profile.
[0094] FIG. 17 is a top plan view showing a varying configuration of curved airfoil-shaped fins.
[0095] FIG. 18 a is a top plan view of a semi-staggered fin array showing an undulating flow path.
[0096] FIG. 18 b is a top plan view of the semi-staggered fin array of FIG. 20 a rotated 90o showing an orderly flow path.
[0097] FIG. 19 is a top plan view of a fin configuration having a pattern that varies along the longitudinal and transverse directions of the fin array from large round fins to highly elliptical fins.
[0098] FIG. 20 a shows a front view of two surfaces with varying fin thickness and varying spaces between adjacent fins.
[0099] FIG. 20 b shows a front view of the two surfaces of FIG. 22 a attached to form a flow channel depicting the resulting interspaced fins producing varying spaces between fins.
[0100] FIG. 21 is an isometric cutaway view of an embodiment of the present invention configured as a shell-tube heat exchanger.
[0101] FIG. 22 is a top plan view of an embodiment of the present invention showing fins used to simultaneously channel fluid and affect heat transfer.
[0102] FIG. 23 is an isometric exploded view of an embodiment of the current invention used in a power conversion module assembly.
[0103] FIG. 24 is an isometric view of an embodiment of the present invention using a central imfinging jet and four outlet ports.
[0104] FIG. 25 is a top plan view of the embodiment of the invention shown in FIG. 26 having a central imfinging jet and four outlet ports.
[0105] FIG. 26 is a top plan view of an embodiment of the present invention showing multiple inlet and outlet ports.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0106] Referring to FIG. 5 , a non-linear fin heat sink 50 is shown. The fins 51 are cross-sectionally shaped as ellipses and attached to a heat sink base 52 .
[0107] Referring now to FIG. 6 , each elliptical fin 51 has a cross-sectional fin longitudinal dimension 53 and a cross-sectional fin transverse dimension 54 . Longitudinal fin spacing (distance between two consecutive fins in the longitudinal direction, i.e., within a given row 55 ) is represented as 56 , and the transverse fin spacing (distance between two consecutive rows 55 or fins 51 in the transverse direction) is represented as 57 . Longitudinal rows 55 are in staggered relationship with each other so that fins 51 in alternating longitudinal rows 55 are transversely (columnarly) 58 aligned.
[0108] Referring now to FIG. 7 of the present invention 50 , upper lid 59 and base 52 act as boundary layers for flow. Upper lid 59 and base 52 are both planar. Elliptical fins 51 extend an overall fin height 60 from upper surface of the base 52 . Depending on the specific requirements of the present invention 50 , fins 51 may simply support, touch, or not touch or be fixedly joined to foundation surface of the upper lid 59 . Since upper lid 59 and base 52 are both planar, the distance therebetween is constant.
[0109] A novel feature of the invention is that for each fin 51 , longitudinal fin dimension 53 , transverse fin dimension 54 , and fin height 60 , are optimized for the local flow field. FIG. 7 shows that the entrance fin height 61 at the leading edge 62 of the non-linear heat sink is less than at the exit fin height 63 at the trailing edge 64 of the heat sink, even though the distance between upper lid surface 59 and base surface 52 is constant. The initial height of fins 61 at leading edge 62 is intended to cause a displacement trip, whereby the transition from laminar flow to turbulent flow is hastened, causing a higher heat transfer coefficient than would otherwise occur. Initial height of fins 61 must meet two requirements to initiate a displacement trip: ∈>820 ν/U and ∈>0.308δ d . Where ∈ is the height of the fin (m), ν is the kinematical viscosity (m 2 /s), U is fluid velocity (m/s) and δ d is the height of the displacement boundary layer (m) where 1.7208 Re x −0.5 . After the initial fin height causes the displacement trip, the height of the downstream fins is based on the increase in the velocity boundary layer thickness when turbulent.
[0110] Referring now to FIG. 8 , a novel feature of the present invention is that fin transverse dimension 54 increases in relation to δ, the thickness of the boundary layer. In this manner, each subsequent fin will protrude through the velocity boundary layer, thereby achieving a greater exposure to high turbulence flow, resulting in higher heat transfer from each fin 51 .
[0111] Another novel feature is that fin aspect ratio, described as fin longitudinal dimension 53 divided by fin transverse dimension 54 , progresses along a log curve from high aspect ratio ellipses at the leading edge of the heat sink 62 to low aspect ratio ellipses terminating at a distance approximately ⅞ of the total heat sink length 65 . For the remaining roughly ⅛ of the heat sink length 66 , fins 51 progress linearly back to high aspect ratio ellipses.
[0112] It is know in the art that for fins having a specific volume and height, greater cross-sectional ellipse aspect ratios will yield greater surface area, a lower coefficient of drag, and a lower heat transfer coefficient. Therefore, since one of the objects of the invention is to minimize flow resistance and volume while simultaneously increasing the heat transfer coefficient, fins 51 change aspect ratio as the distance from the leading edge of the heat sink increases. Fins 51 toward the leading edge have higher aspect ratios because at this longitudinal dimension the fluid has not absorbed enough heat to require a high heat transfer coefficient at the expense of volume and flow resistance. As shown in FIG. 8 and FIG. 9 , the first six transverse rows of fins 67 have an aspect ratio of 6.0:1; the next six transverse columns of fins 68 have an aspect ratio of 5.5:1; the next five transverse columns of fins 69 have an aspect ratio of 5.0:1; the next four transverse columns of fins 70 have an aspect ratio of 4.5:1; the next four transverse columns of fins 71 have an aspect ratio of 4.0:1; the next three transverse columns of fins 72 have an aspect ratio of 3.5:1; the next three transverse columns of fins 73 have an aspect ratio of 3.0:1; the next two transverse columns of fins 74 have an aspect ratio of 2.5:1; the remaining two transverse columns of fins 75 in the first ⅞ of flow length 65 have an aspect ratio of 2.0:1.
[0113] Referring now to FIG. 8 and FIG. 9 , as the fluid absorbs heat and the temperature of the fluid rises, lower aspect ratio fins increase the heat transfer coefficient to achieve uniform cooling. Although a log progression to lower aspect ratios is beneficial, the last roughly ⅛ of the heat sink 66 may contribute a majority of the flow resistance. For this reason, at about ⅞ distance along the flow axis, the fins progress linearly to high aspect ratios again. Again referring to FIG. 8 , starting at the leading edge of the last ⅛ of heat sink length 66 , the first transverse rows of fins 76 has an aspect ratio of 3.0:1; the next transverse columns of fins 77 has an aspect ratio of 4.0:1; the next transverse columns of fins 78 has an aspect ratio of 5.0:1; and the last transverse columns of fins 79 has an aspect ratio of 6.0:1. Alternately, fins at the trailing edge may have a reduced height to achieve the same effect.
[0114] FIG. 10 and FIG. 11 depict another embodiment of the present invention which makes greater use of fin configuration variations. For this embodiment, the number of fins along the leading edge is diminished, lending a “U” shape to the heat sink entrance 80 . The exact distance along the flow axis that the diminished fin zone extends is a function of the flow profile. Flow in an enclosed channel in the laminar flow region, wherein Reynolds number is roughly <2,000 will benefit from a parabolic entrance region 81 . Flow in an enclosed channel in the turbulent flow region, wherein Reynolds number is roughly >2,000 will benefit from a hyperbolic entrance region 82 . It appears that the benefit and effect of entrance regions is more applicable to fluids having a greater ratio of kinematical viscosity to thermal diffusivity. This ratio, the Prandtl number is described as Pr=c p μ/k.
[0115] The methodology of the present invention is not limited to fin heat sinks. As shown in FIG. 12 , a plate fin heat sink has a number of fins 83 parallel to the flow axis and mounted to base 52 . The fin transverse dimension 84 increases in relation to δ, the thickness of the boundary layer as the flow distance 86 from the leading edge 85 increases. In this manner, as flow distance 86 from leading edge 85 increases, the fin surface will protrude through the velocity boundary layer, thereby achieving a greater exposure to high turbulence flow, resulting in higher heat transfer from each fin 83 .
[0116] Again, as shown in FIG. 13 the greatest transverse fin dimension 87 of fin 83 is achieved at roughly ⅞ the length 88 of the heat sink. As longitudinal dimension 88 increases past this point, during the last roughly ⅛ of flow length 90 transverse fin dimension 84 again decreases to the trailing edge 89 of the heat sink. Fins having this profile will achieve greater heat transfer coefficients than simple fixed-thickness plate fins.
[0117] FIG. 14 depicts base 52 showing a plurality of discrete fin patterns 91 . Using the teachings herein it is apparent that the invention can be scaled up or down, or replicated to produce equal improvement at discrete heat sources. Flow enters at leading edge 62 and is diverted by flow diverters 92 toward fin patterns 91 . Flow diverters 92 are shaped to provide minimal flow resistance, while allowing high velocity at fin patterns 91 . By utilizing optimized fin patterns 91 each of a plurality of heat sources, having a multitude of discrete power levels could be cooled equally if so required by the design application.
[0118] FIG. 15 shows a side view of the object of FIG. 14 through section A-A. Protruding from base 52 are fin patterns 91 . Fluid flow is contained by upper lid 59 . As fluid enters at leading edge 62 the fluid velocity is increased by base flow diverters 93 protruding from base 52 and lid flow diverters 95 protruding from upper lid 59 . Attached directly to base 52 and upper lid 59 are a plurality of heat sources 94 which are aligned with areas of higher velocity present within fin patterns 91 .
[0119] Upper lid 59 and base 52 are depicted to be non-planar, as shown in FIG. 16 . Upper lid 59 and base 52 can be inventively practiced so as to have any of a diversity of “topographies.” The geometric configuration of an upper lid surface 59 can be entirely planar, entirely non-planar, or some combination thereof. Assuming a planar (flat) base 52 : If upper lid 59 is planar, then fin height 60 is constant; if the upper lid 59 is non-planar, and the base 52 thickness is variable, fin height 60 is not constant.
[0120] The geometry of upper lid 59 and base 52 can be characterized entirely by rectilinearity, entirely by curvilinearity, or by some combination thereof. FIG. 14 and FIG. 15 show both upper lid 59 and base 52 to be displaced from planar by lid flow diverter 95 and base flow diverter 93 and by flow diverters 92 . In inventive practice, any random or rigid geometry may be used for the foundation surface of upper lid 59 and the upper surface of the base 52 , such as, but not limited to, triangular, oval and sinusoidal.
[0121] Table. 1 shows the results of applying the teachings of the present invention when compared to a heat sink using the prior art teachings. Table. 1 lists the physical characteristics of a prior art fin heat sink and a heat sink of the current invention. Most notable are the decrease in thermal resistance, decrease in pumping power required, and decrease in mass and volume, embodied by the invention.
[0000]
TABLE 1
Heat Sink Material
Copper
Fluid Volumetric Flow Rate, q
11
(l/min)
Fluid Density, ρ (kg/m 3 )
840
Fluid Absolute Viscosity, μ (Ns/m 2 )
0.01
Fluid Thermal Conductivity, k
0.13
(W/mK)
Fluid Specific Heat, c P (J/kgK)
2450
Fluid Inlet Temperature, T F (° C.)
75
Ambient Air Environment, T A (° C.)
75
Baseplate L × W × D (cm)
17.6 × 6.5 × 0.3
Power, Q (W)
3,600
Prior Art
Invention
Maximum Temperature, T MAX (° C.)
161
140
Mean Baseplate Temperature, T MEAN (° C.)
154
135
Pressure Drop, ΔP (kPa)
37
14
Heat Sink Volume, V (cm 3 )
119
108
Heat Sink Mass, M (kg)
0.54
0.45
Thermal Resistance, θ (° C./W)
0.024
0.018
Pumping Power, P P (W)
6.69
2.6
Efficiency, η (1/(θP P M))
11.5
47.5
[0122] It is emphasized that inventive practice is not limited to the specific geometric ratios represented herein in the drawings. The geometric modalities shown in these figures are intended herein to be “generic” in nature because dissimilar geometric motifs can manifest similar principles and concepts; in particular, different aspect ratio geometries and forms of the fins and/or the base section can be used to generate attributes of thermal performance. It will be apparent to the ordinarily skilled artisan who reads this disclosure that there are thematic commonalities among the geometric modalities specifically disclosed herein, and that many geometric modalities and ratios not specifically disclosed herein can be inventively practiced in accordance with such thematic commonalities and in accordance with other inventive principles disclosed herein.
[0123] The present invention admits of a diversity of embodiments. As elaborated upon hereinbelow, the inventive practitioner can vary one or more dimensional, configurational and/or geometric parameters, including but not limited to the following: (i) fin length and/or height; (ii) fin cross-sectional shape (e.g., elliptical versus circular versus square, etc.); (iii) fin distribution (e.g., non-staggered rows versus staggered rows, angularity of row staggering, even or parallel row orientations versus offset row orientations, angularity of row orientation offset, etc.); (iv) fin spacing (e.g., distances between various fins in various directions); (v) passage depth (e.g., distance between baseplate and upper lid); (vi) passage shape (e.g., relative dispositions of baseplate and upper lid surface, contour (three-dimensional shape) of baseplate, contour (three-dimensional shape) of heat sink base section, etc.); (vii) heat sink base section's outline (two-dimensional) shape; (viii) heat sink base section's transverse dimensions; (ix) fluid inlet configuration; and, (x) fluid outlet configuration.
[0124] Although elliptically-shaped fin 51 cross-sections (having longitudinal fin dimension 53 and transverse fin dimension 54 ) are portrayed in the embodiment, it is readily appreciated by the ordinarily skilled reader of this disclosure that fin 51 cross-sections of any shape can be disposed either in angularly offset fashion (e.g., oblique with respect to a selected longitudinal line, such as an edge of the upper lid surface 59 ) or in angularly non-offset fashion (e.g., parallel with respect to a selected longitudinal line, such as an edge of the upper lid surface 59 ). The figures disclosed herein are merely exemplary insofar as generically demonstrating that inventive practice can use any combination of geometrical cross-sectional shapes, geometrical arrangements and angularities with respect to a longitude (e.g., angle theta can be any value greater than or equal to zero). In fact, the present invention encompasses a potentially infinite number of variations of cross-sectional shapes and locations of fins 51 .
[0125] It is again emphasized that any number or geometric arrangement of fins 51 can be used in inventive practice. With regard to the properties of staggeredness and uniformity (homogeneity), an inventive fin 51 array can be characterized by staggered uniformity, non-staggered uniformity, staggered nonuniformity or non-staggered non-uniformity. Further, any combination of two or more geometric fin 51 shapes can be used for a given fin 51 array.
[0126] Furthermore, the surface roughness of the flow cavity can be varied in accordance with the present invention. Irrespective of the essential geometry defined by upper lid 59 and base 52 , the detailed geometry defined by the surfaces can vary in terms of smoothness versus roughness. Not only the essential geometry of fins 51 , but also the detailed geometry of the boundary surfaces, can be selected so as to affect the flow of fluid in a desired fashion.
[0127] Surface roughness and porosity of fins 51 is an important factor in specific flows. In low viscosity fluids with a relatively high thermal conductivity, fin porosity can add greater surface area and serve to reduce pressure drop. In fluids having a boiling point near the expected operating conditions within non-linear heat sink 50 surface roughness will have a great effect on boiling incipience and wall superheat. In fact, it is a further object of the present invention to affect means for allowing a continuous control of boiling incipience and affectivity as a function of flow length.
[0128] It should be now obvious to those skilled in the art than in addition to local longitudinal and transverse dimensional and geometric alterations; fins may be similarly optimized along an axis measured parallel to the height of the fin. The effect of physical changes in fin cross section vs. distance measured from the fin base are well know in the art, but these characteristics can also be altered on an individual fin or fin region basis to affect local optimized flowfields and solid/fluid interaction. Referring now to FIG. 16 a a top plan view of the present invention is shown. FIG. 16 b shows a frontal cross section view of the fins at a distance of roughly ⅛ of the longitudinal distance of the heat sink base 52 . At this location along the longitudinal axis, the fins are of a conical shape 123 . The side walls of the fin progress from the large fin base 124 attached to base 52 to the fin tip 125 . This shape allows a low flow resistance and does not transfer heat very well, that is, the temperature of fin tip 125 is about the same temperature as the local flowable media. FIG. 16 c shows a frontal cross section view of the fins at a distance of roughly ½ of the longitudinal distance of the heat sink base 52 . At this location along the longitudinal axis, the fins are of a concave hyperbolic shape 126 . The side walls of the fin progress along a concave hyperbolic curve from the fin base 124 attached to base 52 to the truncated fin tip 127 . This shape allows a low flow resistance but transfer heat better than the conical profile 123 of FIG. 16 b . Truncated fin tip 127 allows a savings of material since the fin tip does not transfer much heat, and also allows the user the option of attaching truncated fin tip 127 to an upper lid wall 59 (not shown) and transferring some heat therethrough. FIG. 16 d shows a frontal cross section view of the fins at a distance of roughly ¾ of the longitudinal distance of the heat sink base 52 . At this location along the longitudinal axis, the fins are of a concave parabolic shape 128 . The side walls of the fin progress along a concave parabolic curve from the fin base 124 attached to baseplate 52 to the truncated fin tip 127 . This shape allows a maximum heat transfer at a minimum of material usage and shows a high fin efficiency when 100% fin efficiency is described as a fin of the same surface area having infinite thermal conductance. The truncated fin tip 127 allows a savings of material since the fin tip does not transfer much heat, and also allows the user the option of attaching truncated fin tip 127 to an upper lid wall 59 (not shown) and transferring heat therethrough. FIG. 16 e shows a frontal cross section view of the fins at a distance of roughly ⅞ of the longitudinal distance of the heat sink base 52 . At this location along the longitudinal axis, the fins are of a cylindrical profile 129 . The side walls of the fin progress along a straight line perpendicular from base 52 . This shape allows a maximum heat transfer. While fin efficiency is not as high as the concave parabolic profile of FIG. 16 d heat transfer to the fin tip is maximized which allows the use of the fin tip to transfer heat to the coolant or to transfer heat to an upper lid wall 59 (not shown). FIG. 16 f shows a frontal cross section view of the fins at a distance of roughly 15/16 of the longitudinal distance of the heat sink base 52 . At this location along the longitudinal axis, the fins are again of conical profile 123 which allows some heat transfer but is used primarily to transition the fluid coolant to the slower flow velocity downstream of the fin array and to minimize the turbulent velocity wake.
[0129] Referring now to FIG. 17 , airfoil-shaped fins 111 are know in the art to have exceptionally low skin flow resistance because of the termination of the laminar boundary layer, but these shapes are usually hindered by a low heat transfer coefficient. As taught herein and shown in FIG. 18 , these shapes can be formed into sections of varying curvature whereby flow is directed to the downstream fin in such a manner as to increase imfingement on one side of the fin surface 112 thereby increasing the heat transfer coefficient. The radius of curvature of the fins 113 can be reduced using an exponential function, just as the aspect ratio of the elliptical fins of the preferred embodiment are adjusted, as a function of the distance from the leading edge of the heat sink. Such improvements are particularly advantageous at very low Reynolds numbers. For high values of Reynolds number, the optimized airfoil shape will share geometric characteristics with a Sears-Haack body.
[0130] Again referring to FIG. 7 , FIG. 8 , and FIG. 17 , it will be seen to those knowledgeable in the art that the curvature of the fins and other characteristics of the geometries of individual fins can be altered to increase or reduce the local turbulence of the flowable media. Specifically, fin configurations having high longitudinal dimension to transverse dimension aspect ratios will have lower turbulence. Also, fin patterns that produce greater cross sectional flow area between fins will have higher turbulence. By varying the placement of these laminator and turbulator fins, a desired level of local heat transfer and local fluid mixing can be achieved.
[0131] In another embodiment of the invention, utilizing the fin pattern of the preferred embodiment, individual fins can be manufactured from different materials and combined with the geometric effects on coolant flow to control heat transfer or conversely individual fins may be made from more than one material. For example, in order to provide a more uniform base temperature, fins near the leading edge may be constructed of a material having a lower thermal conductivity such as aluminum while fins closer to the trailing edge may be constructed of a material having a higher thermal conductivity such as copper. Fins having different material characteristics may also be combined to produce other thermal effects. For example, the fins closer to a heat source may be manufactured from different materials to more closely match the coefficient of thermal expansion of the heat source. In one region of the heat sink, fins may be constructed of platinum while in another region of the heat sink, fins are constructed of beryllium. Although both materials have similar thermal conductivity, beryllium has almost 15 times the heat capacity, which may be useful in high power transient applications.
[0132] In FIGS. 18 a and 18 b , another embodiment of the invention is shown that has a specific arrangement of fins, learned from the teachings herein, that when rotated produce a different effect than the original orientation. A fluid flow enters semi-staggered fin array 114 on side A 115 and travels an undulating path 116 to side C 117 . When rotated 90 degrees, flow enters side D 118 of semi-staggered fin array 114 and the flow travels a more orderly path 119 toward side B 120 . Such an arrangement can yield a high heat transfer coefficient at higher flow resistance in the original orientation but will offer low flow resistance and low heat transfer when rotated. By way of example, the present invention may be rotated 180 degrees relative to fluid flow and impart a different set of characteristic flow patterns and effects. In the present invention, the specific novel fin pattern would produce an initial area of low flow resistance and heat transfer coefficient, followed by an area of higher flow resistance and higher heat transfer, followed by a very gradual transition to the original flowfield. Whereas the original orientation of the preferred embodiment produced a uniform base temperature, when rotated 180 degrees, the fin pattern will produce a much higher temperature at the trailing edge of the base than at the leading edge.
[0133] The effect of having a much higher temperature at the trailing edge can be used to benefit cooling applications that rely on a change in the coolant phase from liquid to gas. In this manner the base can be liquid cooled along the leading edge, and gas cooled at the trailing edge. One reason to impart this effect is for process control and assist chemical reactions. For example, the fins may be constructed of a porous material infused with a chemical, or simply coated with a chemical depending on the application. The application of liquid flow may produce an initial chemical reaction having a desired effect downstream of the leading edge. As the distance from the leading edge increases and the heat of the liquid increases exponentially (depending on the non-linear fin pattern), a secondary thermo-chemical reaction may occur. As the fluid changes phase, the incipience of gaseous nucleation may cause tertiary reactions to occur. One embodiment of the present invention may be used to facilitate vapor compression distillation of urine in a disposable canister. In addition to the specific thermo-chemical reactions caused by the example described, specific regions of a fin pattern may be coated with different chemicals which when combined produce an effect only in the presence of the flowable catalyst.
[0134] Depending on the chemical composition of a fin, the fin pattern may be varied to achieve a specific rate of chemical release into the flowable media which depends on the amount of turbulence and/or flow velocity. As shown in FIG. 19 , a base 52 has a region of large round fins that contain a higher core temperature and can be arranged to produce higher fluid velocity, which can be used to increase the rate of release of a chemical. Base 52 also transitions along the transverse axis to a region of highly elliptical fins 122 that produce lower core temperatures and lower velocities and therefore a lower heat transfer coefficient. Within a single disposable canister a number of chemical reactions can occur with or without the use of heat. Using the teachings of the present invention those knowledgeable in the art will therefore see a variety of applications in the fields of medicine, chemical processing, and military weaponry.
[0135] In another embodiment, shown as FIG. 20 a , fins 51 protrude not only from base 52 but also from upper lid 59 . As show, upper lid 59 has a plurality of protruding upper lid fins 130 as does base 52 have a plurality of base fins 51 . Base 52 and upper lid 59 both have a heat source 94 attached to the surface opposite base fins 51 and upper lid fins 130 respectively. As shown, upper lid fins 130 have a variable upper lid fin space 133 between adjacent upper lid fins 130 while base fins 51 have a variable base fin space 131 between adjacent base fins 51 . Also, base fin transverse dimension 54 and upper lid fin transverse dimension 132 may be varied to produce a desired effect. When base 52 and upper lid 59 are attached to form a fluid channel as shown in FIG. 20 b base fins 51 fit into upper lid space between fins 133 and upper lid fins 130 fit into base space between fins 131 . Because space 133 between upper lid fins 130 , space 131 between base fins 51 , upper lid fin transverse dimension 132 , and base transverse fin dimension 54 are varied, accordingly the effect is to provide a number of large spaces between adjacent fins 134 and a number of small spaces between adjacent fins 135 . It is important to note that although heat transfer can be increased by affecting higher fluid velocity, manufacturing considerations often do not allow base fin space 131 or upper lid fin space 133 to be reduced to a value that would cause higher fluid velocities. The technique disclosed herein and in FIG. 20 a and FIG. 20 b allows larger fin space for easier manufacturing, yet can still be used to produce higher fluid velocity leading to higher heat transfer coefficients. This technique can also be used whether or not all fins are used for heat transfer. For example, if only base 52 has a heat source 94 properly designed upper lid fins 130 will still produce the effect of higher velocity when used to produce smaller space between adjacent fins 134 and 135 . It can be seen to those knowledgeable in the art that the description of varying transverse dimensions 54 , 131 , 132 , and 133 are by way of example and that other dimension such as longitudinal fin length, thickness, spacing, angle, etc., can also be varied to produce similar effects. It is also seen that although the example of FIG. 20 a and FIG. 20 b show base fins 51 and upper lid fins 130 touching upper lid 59 and base 52 , respectively, the fins may be attached, not attached, have a variable space, or may even be designed so that base fin 51 and upper lid fin 130 are aligned. Some number of fins may not be attached while other fins are attached to impart structural strength, or provide a desired clearance. Furthermore, it is seen that although FIGS. 20 a and 20 b depict opposing faces containing fins, fins may be contained on other walls or objects at angles to the fluid flow.
[0136] FIG. 21 shows another embodiment of the present invention configured as a shell-tube heat exchanger 144 . Shell tube 139 forms a fluid conduit through which cooling fluid 141 flows. The interior surface of shell tube 139 contains a plurality of internal shell tube fins 142 having geometric shapes locations and sizes using the teachings of the present invention. Shell tube 139 contains a heat exchanger tube 136 which has a plurality of exterior fins 137 and interior fins 138 having geometric shapes locations and sizes using the teachings of the present invention. Hot fluid 140 flows through heat exchanger tube 136 . In the embodiment shown in FIG. 21 internal shell tube fins 142 and exterior fins 137 are interspaced according to the descriptive teachings of FIG. 20 a and FIG. 20 b . In use, heat contained in hot fluid 140 is convected and conducted by interior fins 138 to heat exchanger tube 136 . Heat is conducted through heat exchanger tube 136 to exterior fins 137 . Heat is then convected and conducted from the external surface of heat exchanger tube 136 and exterior fins 137 to cooling fluid 141 . In the embodiment shown, shell-tube heat exchanger 144 is in an environment having a higher temperature than cooling fluid 141 . Therefore, both shell tube 139 and internal shell tube fins 142 are constructed of a material having low thermal conductivity. In an alternate embodiment having an environment temperature lower than cooling fluid 141 shell tube 139 and internal shell tube fins 142 would be constructed of a material having high thermal conductivity and shell tube 139 would also contain a plurality of external fins (not shown) located on shell tube external surface 143 to enhance heat transfer to the environment. It is understood that FIG. 21 and the related descriptions are only one of a number of possible variations on the basic scheme of heat exchange.
[0137] Referring now to FIG. 22 , another embodiment of the present invention is shown. Fluid enters the first fin array 145 at entrance location 146 . Fluid flows through first fin array 145 and enters a plenum/manifold 147 . Plenum/manifold 147 contains a number of manifold fins 148 and fluid passages 149 . Plenum/manifold fins 148 and fluid passages 149 are so configured as to direct fluid flow from first fin array 145 to a second fin array 150 . Using the teachings herein, plenum/manifold fins 148 simultaneously route fluid through the 180 degrees turn of plenum/manifold 147 to enter second fin array 150 at an optimum angle, maximize heat transfer and fluid mixing, and minimize flow resistance. It is a novel aspect of this embodiment to affect a bulk fluid directional change within plenum/manifold 147 while applying the teachings herein. It is important to note that the bulk fluid properties may be quite different at fluid entrance 146 , first fin array exit 151 , second fin array entrance 152 , second fin array exit location 153 , and even within plenum/manifold 147 . Using the teachings herein therefore, the specific geometric shape of fins located in different regions of first fin array 145 , plenum/manifold 147 , and second fin array 150 are different. It is noted that although FIG. 22 shows fluid flowing in series through a first and a second fin array, fin arrays may be configured as series/parallel paths with fins using the teachings herein the fluid entrance, fluid exit, and at points between.
[0138] It is reemphasized that the present invention can be practiced in association with any among a multiplicity of geometries. Any of the fin 51 array patterns illustrated in the drawings (and many others not specifically shown) can be inventively practiced regardless of the geometric nature (e.g., planar or non-planar) of the bounding surfaces.
[0139] In the previous figures, fins 51 are shown to be made part of base 52 , protruding from the upper surface of base 52 , toward and contacting the bottom surface of upper lid 59 . Base 52 is part of heat source 94 . However, inventive practice can provide for the fabrication of fins 51 as part of another separate heat sink baseplate which is then attached to heat source base 52 . Again however, those leaned in the art will realize that fins 51 can extend from surface of upper lid 59 and attach to base 52 or any other part of the structure as described for the embodiment of FIG. 20 a and FIG. 20 b.
[0140] Referring now to FIG. 23 , of one possible assembly containing the present invention, manifold 96 is a housing fairly representative of that used in commercial practice. Manifold 96 has at least one receiving space to house the non-linear fin heat sink 50 . Non-linear fin heat sink 50 includes a rectangular plate-like foundation base 52 and a plurality of turbulence-enhancing and heat transferring fins 51 which project therefrom. Manifold 96 has upper lid 59 . Each fin 51 is based at its fin root in base 52 .
[0141] Manifold 96 further serves to channel the cooling fluid (liquid or gas) 97 through fins 51 , thereby enhancing turbulent flow. Manifold 96 provides an incoming coolant port 101 and an outgoing coolant port 100 to which incoming coolant barb 98 and outgoing coolant barb 99 are respectively attached. Manifold 96 has an upper mounting surface 103 and a lower mounting surface 104 and at least one opening 102 sized for attachment of non-linear fin heat sink 50 . Those skilled in the art will see that although FIG. 16 shows only upper mounting surface 103 being used for active mounting, lower mounting surface 104 can be used for the same function alone, or in addition to use of upper mounting surface 103 . Upper mounting surface 103 has provisions for mounting the object (e.g., device) to be cooled, such as power conversion module 105 which holds one or more heat sources 94 , shown in FIG. 15 .
[0142] Power conversion module 105 includes module housing 107 , which houses at least one heat source 94 . Power conversion module 105 has a module baseplate 106 to which heat sources 94 are thermally attached.
[0143] As illustrated in FIG. 23 , the edges of base 52 are attached to manifold 96 and power conversion module 105 is coupled with the manifold-heatsink assembly. A sealing element (e.g., gasket or O-ring, braze) 108 is provided to prevent coolant leakage. A layer of thermal interface material is provided between module baseplate 106 and heat sink base 52 to ensure effective thermal conductivity of heat from heat source 94 to heat sink base 52 .
[0144] Although shown as flat surfaces, module baseplate 106 , heat sink base 52 , and any other heat transfer interfaces may have specific geometric surface patterns to aid the conduction of heat. By way of example such patterns as hierarchical nested channels (T. Brunschwiler, U. Kloter, H. Rothuizen, and B. Michel, “Hierarchically nested channels for fast squeezing interfaces with reduced thermal resistance”, 21st IEEE SEMI-THERM Symposium, San Jose, Calif. 2000) can provide a marked reduction in interface resistance when used with flowable thermal interface materials.
[0145] When assembled, manifold 96 is contiguous with respect to non-linear fin heat sink 50 , whereby base 52 and the tips of fins 51 are mounted in a highly thermally conductive leak-proof manner. Likewise heat sources 94 within module housing 107 of power conversion module 105 are attached in a highly thermally conductive manner to module baseplate 106 , which is then mounted in a highly thermally conductive manner through thermal interface material 109 to upper mounting surface 103 of manifold 96 by attachment bolts 110 . Once power conversion module 105 and the manifold-heatsink unit are joined, fins 51 protrude into the path of coolant fluid 97 .
[0146] The fluid flow system will typically include fluid flow means (e.g., including fluid pumping means), fluid inlet means and fluid outlet means. In typical inventive practice, heat sink base 52 , upper lid inside the manifold 59 and sidewalls of manifold 96 will define an outline shape (e.g., a rectangular shape) which provides a flow cavity.
[0147] As shown in FIG. 23 , cooling fluid 97 is generated pursuant to a fluid system and is conveyed via incoming coolant fitting to incoming coolant port 101 to non-linear fin heat sink 50 to outgoing coolant port 100 to outgoing coolant fitting 99 .
[0148] Energy appearing as waste heat emanates from heat sources 94 and passes through several layers of material having various degrees of electrical and thermal conductivity to module baseplate 106 , through thermal interface material 109 , through heat sink base 52 , to fins 51 and convected and conducted to coolant fluid 97 .
[0149] In inventive practice, components can be made from a wide variety of materials. In reference to the preferred embodiment, nonlinear fin heat sink 50 and module baseplate 106 are made from copper.
[0150] Referring now to FIG. 24 , a non-linear impingement heat sink 160 is shown. Non-linear impingement heat sink 160 comprises a heat transferring baseplate 161 , a plurality of fins 162 , and four outlet ports 163 . Among the many novel features of this embodiment is the varying height of the fins based on the importance of heat transfer versus flow resistance within the immediate local flowfield. For clarity and because means for introducing a jet of impinging fluid and means to convey the outlet fluid are quite varied, they are not shown.
[0151] Referring now to FIG. 25 , an isometric view of a non-linear impingement heat sink 160 is shown. In the embodiment depicted, fluid enters at substantially a perpendicular angle to the surface 169 of baseplate 161 . Fluid enters as a high velocity, turbulent jet and contacts baseplate surface 169 at a central impingement point (also called a stagnation zone) 164 . The high velocity jet vector appearing perpendicular to baseplate surface 169 is converted to a laminar flow with a vector substantially parallel to baseplate surface 169 . The rapid change in vector and momentum causes a large reduction in the thickness of the velocity and boundary layers at impingement point 164 resulting in a local area of high heat transfer. Fluid travels in a radial direction away from impingement point 164 and towards four outlet ports 163 . Non-linear fins 162 of baseplate 161 are physically grouped into four local regions having specific fluidic and heat transfer function. Immediately surrounding impingement point 164 appears a region of inlet cylindrical fins 165 . The function of inlet cylindrical fins 165 is to capture the turbulent chaotic radial flow from the impingement point and provide a region of even laminar flow in all directions parallel to surface 169 . While doing this, inlet cylindrical fins 165 transfer heat on all surfaces while providing low pressure drop.
[0152] When the laminarized flow reaches the edge of inlet cylindrical fin region 165 a portion of the flow will progress through a region of elliptical fins 166 that are aligned parallel to the bulk flow and a region of elliptical fins 167 that are at a slight angle to the bulk flow. Moving radially from the impingement point, elliptical fins 166 aligned parallel to the flow are characterized by having high aspect ratios of longitudinal length to transverse width (measured according to the local flow direction. Past this entrance area at a distance roughly halfway between impingement point 164 and outlet port 163 elliptical fins 166 progress to lower aspect ratios having larger transverse dimensions. This change in aspect ratio and transverse size helps to maintain a constant velocity, disrupt the formation of a boundary layer, and allows elliptical fins 166 to have a higher core temperature providing a higher heat transfer coefficient. Flow resistance in this area is still low because of the elliptical shape of fins 166 .
[0153] The portion of fluid that did not travel through the region of fins 166 aligned parallel to the bulk flow, moves through a region of elliptical fins 167 that are at a slight angle to the bulk flow. Angled elliptical fins 167 have higher angles relative to the vector of the bulk flow as the distance from impingement point 164 increases. The increasing angle of the downstream fins helps to gradually change the fluid direction without a corresponding increase in flow resistance, prevents the occurrence of a thick boundary layer, and again results in a higher heat transfer coefficient than would normally occur. As the flow approaches the fluid boundary wall 170 of baseplate 161 the fluid is separated into two paths that each lead to an opposing outlet port 163 . Separation of the fluid and subsequent impingement at fluid boundary wall 170 provide a slight enhancement in heat transfer while effectively completing the change in fluid direction toward outlet ports 163 .
[0154] As the fluid leaving the region of elliptical fins 166 aligned parallel to the bulk flow and the region of elliptical fins 167 that are at an angle to the bulk flow combines from different directions, local mass flow, velocity and turbulence are increased and the fluid enters a region of outlet cylindrical fins 168 that are designed to transfer heat to the turbulent flow and allow fluid movement in a substantially perpendicular vector away from baseplate surface 169 and out through outlet ports 163 . The fins at this location are necessarily thin to avoid obstructing outlet fluid flow, and because at this radial distance from the central heat source, little heat is left to transfer to the fluid.
[0155] Although most of the embodiments of the present invention show a single inlet location and one or several fluid exit locations, the embodiment depicted in FIG. 26 shows the effect of an optimized non-linear fin structure, using the teachings herein, surrounding multiple fluid inlet and outlet locations to comprise a multiple inlet/outlet non-linear coldplate 180 . As shown a common baseplate 181 has a plurality of non-linear fins 182 used to affect heat transfer. Fins 182 are non-linear by way of having varying aspect ratios (longitudinal length to transverse width to vertical height), varying degrees of parallelness or perpendicularity to bulk fluid flow, varying material compositions and coatings, all based on the desired effect on fluid flow and heat transfer in the area of fluid flow directly adjacent to the individual fin. The present embodiment has four impingement points 183 and nine areas to manage outlet flow 184 . FIG. 26 shows inlet areas 183 and outlet areas 184 spaced evenly, but design practice may dictate more varied spacing based on the location of heat sources. FIG. 26 also shows identical groups of non-linear fins 182 surrounding each inlet location 183 . According to the application, these groups of fins, outlet port sizes, impingement jet diameter and flow rate may change significantly based on the desired amount of heat transfer in relation to the other heat sources.
[0156] There are numerous fluids (gaseous or liquid) which are conventionally used for cooling purposes in heat sink applications, any of which can be used in practicing the present invention with appropriate changes to fin geometries. Air is commonly used to dissipate low heat fluxes, such as in desktop computers.
[0157] Depending on the specific application, utilization of liquids for the cooling of electronic equipment is generally governed by certain requirements, principles and considerations. Among the many such requirements, principles and considerations which would possibly be applicable in inventive practice are the following: (i) a high thermal conductivity will yield a high heat transfer rate. (ii) High specific heat of the fluid will require a smaller mass flow rate of the fluid. (iii) Low viscosity fluids will cause a smaller pressure drop, and thus require a smaller pump. (iv) Fluids with a high surface tension will be less likely to cause leakage problems. (v) A fluid (e.g., liquid) with a high dielectric strength is not required in direct fluid (e.g., liquid) cooling. (vi) Chemical compatibility of the fluid and the heat sink material is required to avoid problems insofar as the fluid reacting to the material with which it comes in contact. (vii) Chemical stability of the fluid is required to assure that the fluid does not decompose under prolonged use. (viii) Nontoxic fluids are safe for personnel to handle and use. (ix) Fluids with a low freezing point and a high boiling point will extend the useful temperature ranges of the fluid; however, for most practical applications, a fluid should be selected to meet the operating conditions of the component to be cooled. (x) Low cost is desirable to maintain affordable systems.
[0158] Fluid-cooled heat sinks used in electronic enclosures and such contexts are usually water-cooled. The heat sink is cooled by the water which is passed therethrough. In many electronic applications, distilled or demineralized water is used to increase the dielectric strength of the water, thereby avoiding electrically coupling components. High heat removal rates can be achieved by circulating water systems. Anhydrous refrigerants are used in place of water or in mixtures with water to keep temperatures of heat sinks at subzero temperatures, thereby increasing the performance of the electronic components. Examples of refrigerants other than water include ammonia, carbon dioxide, CFC-based refrigerants such as R-12 (dichlorodifluoromethane or “freon”), HCFC-based refrigerants such as R134A, and non-CFC substitutes (e.g., for freon) such as R-406A.
[0159] Other embodiments of this invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. Various omissions, modifications and changes to the principles described may be made by one skilled in the art without departing from the true scope and spirit of the invention which is indicated by the following claims. | A non-linear fin heat sink is provided for dissipating/removing heat uniformly from a device, where the heat generation is non-uniform over that device, while also providing a small and relatively lightweight heat sink. The heat sink has extended surface protrusions that are optimally shaped in recognition of convective heat transfer, conductive heat transfer, and flow resistance allowing the heat sink to offset the temperature rise of a coolant media and provide enhanced cooling for the coolant temperature, deliver optimized cooling efficiency per the local physical properties of the coolant media, be used with a fluid for effectuating heat transfer; either liquid coolant, gas coolant or a combination thereof. Furthermore the heat sink features turbulence enhancement of the coolant stream by a pin array through which coolant stream passes, such fin array featuring a non-linear shape, spacing, and height pattern to provide optimal cooling while simultaneously reducing volume and flow resistance. | 7 |
BACKGROUND
[0001] The present disclosure relates to geophone devices for sensing vibrations in earth formations, and may be applicable to other types of vibration transducers, either in sensing or transmitting operation. More specifically, the present disclosure relates to a damping controlled geophone.
[0002] In seismic exploration, vibrations in the earth resulting from a source of seismic energy may be sensed at discrete locations by sensors and the output of the sensors used to image underground structures, or to locate seismic events. The source of seismic energy can be natural, such as earthquakes and other tectonic activity, subsidence, volcanic activity or the like, or man-made such as acoustic noise from surface or underground operations, or from deliberate operation of seismic sources at the surface or underground. Seismic sensors fall into two categories: hydrophones that sense the pressure field resulting from a seismic source, or geophones that sense vibration arising from a seismic source.
[0003] An oscillatory geophone is shown in FIG. 1-1 . The geophone 10 includes a housing 24 , a top cap 27 and a bottom cap 28 that are affixed to the housing 24 , a magnet 15 having a pair of pole pieces 16 , 18 that are respectively affixed to the top and bottom caps 27 , 28 , a moving coil that includes two coil windings 12 , 13 and a bobbin 14 with suspension springs 20 , 22 as shown in FIG. 1-1 . The magnet 15 , along with its two pole pieces 16 , 18 , can move with the housing 24 . Pole pieces 16 , 18 and housing 24 are made of magnetically permeable material and form a magnetic flux 25 in which the moving coil is suspended. The caps 27 , 28 are made of magnetically impermeable material. In this particular embodiment as shown, the coil windings 12 , 13 are connected in series to form a continuous coil. The windings 12 , 13 may be disposed about the bobbin 14 in opposite directions, so that the windings 12 , 13 can generate voltage in a common direction. The windings 12 , 13 of the moving coil are commonly mounted and move together. As illustrated, the magnetic flux 25 passes out one winding from inside to outside near the north of the magnet 15 , and then out the other winding from outside to inside near the south of the magnet 15 .
[0004] When the earth moves due to the seismic energy propagating either directly from the source or via an underground reflector, the geophone 10 , which can be located at the earth's surface or on the wall of a borehole penetrating the earth, moves in the direction of the particle motion resulting from propagation of the energy. If the axis of the geophone 10 is aligned with the direction of motion, however, the coil windings 12 , 13 mounted on the springs 20 , 22 inside the geophone 10 stay in the same position causing relative motion of the moving coil with respect to the magnetic flux 25 that moves with the housing 24 . When the moving coil moves in the magnetic field, a measurable voltage is induced in the moving coil, which is proportional to the velocity of the relative motion between the moving coil and the magnetic flux 25 .
[0005] Variations of geophones are described in U.S. Pat. No. 7,099,235 to Kamata, U.S. Publication 2011/0007608 to Woo, and U.S. Pat. No. 4,159,464 to Hall.
SUMMARY
[0006] In at least one aspect, the disclosure relates to a vibration transducer with controlled damping. The vibration transducer may include a magnet. The vibration transducer may include a bobbin disposed about the magnet. The vibration transducer may include a first coil disposed about the bobbin. The vibration transducer may include a controllable damping coil disposed about the bobbin. The first coil is movable relative to the magnet. The magnet is polarized with respect to the axis of the vibration transducer.
[0007] In at least one aspect, the disclosure relates to a seismic sensor. The seismic sensor includes controlled damping. The seismic sensor may include a magnet. The seismic sensor may include a bobbin disposed about the magnet. The seismic sensor may include a first coil disposed about the bobbin. The seismic sensor may include a controllable damping coil disposed about the bobbin. The first coil is movable relative to the magnet. The magnet is polarized with respect to the axis of the seismic sensor. The seismic sensor may also include a sensor housing. The seismic sensor may also include at least one signal output connectable to a data processing system.
[0008] In at least one aspect, the disclosure relates to a method of manufacturing a vibration transducer. The method may include providing a housing having a magnet structure disposed in the housing, and a bobbin and moving coil disposed about the magnet structure and resiliently mounted relative to the housing and the magnet structure. The method may also include providing a damping coil disposed concentrically about the bobbin adjacent to the moving coil.
[0009] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments of systems, apparatuses, and methods for a controlled damping geophone are described with reference to the following figures. Like numbers are used throughout the figures to reference like features and components.
[0011] FIG. 1-1 is a cross-sectional view of a geophone;
[0012] FIG. 1-2 shows a schematic of displacement of the geophone of FIG. 1-1 while sensing;
[0013] FIG. 2 shows a plot of an amplitude response for a unit velocity against frequency in Hertz for the geophone of FIG. 1-1 ;
[0014] FIG. 3 shows a plot of a phase response in degrees against frequency in Hertz for the geophone of FIG. 1-1 ;
[0015] FIG. 4 shows a plot of natural frequency f 0 , open circuit sensitivity S 0 , and open circuit damping D 0 , normalized at 20 degrees, versus temperature in degrees Celsius for the geophone of FIG. 1-1 ;
[0016] FIG. 5 shows a plot of geophone response over time for different temperatures for the geophone of FIG. 1-1 ;
[0017] FIG. 6 shows side view of a current flow in a metallic bobbin implemented in a geophone;
[0018] FIG. 7-1 shows a moving coil having an independent damping coil added to each end of a dual coil in an embodiment of the present disclosure;
[0019] FIG. 7-2 shows corresponding winding directions of the coils of the geophone of FIG. 7-1 ;
[0020] FIG. 8 shows an embodiment of a metallic slotted bobbin implemented in a geophone;
[0021] FIG. 9 shows an embodiment of a slotted bobbin reinforced with insulation rings;
[0022] FIG. 10 shows an embodiment of a slotted bobbin shorted with a chip resistor;
[0023] FIG. 11 shows a cross-section of a geophone having metal deposition on a plurality of independent insulation rings on a slotted metallic bobbin;
[0024] FIG. 12 shows a cross-section of a geophone having a damping coil embedded in a plastic bobbin;
[0025] FIG. 13 shows an embodiment for damping coil as a thin metallic foil around a slotted bobbin;
[0026] FIG. 14 shows an embodiment for damping coil as metal disposed on a plastic bobbin under a geophone coil;
[0027] FIG. 15 shows a geophone in accordance with the present disclosure disposed on a sea bed cable;
[0028] FIG. 16 shows a geophone in accordance with the present disclosure disposed on a land cable; and
[0029] FIG. 17 shows geophones in accordance with the present disclosure disposed on a borehole tool.
DETAILED DESCRIPTION
[0030] In the following description, numerous details are set forth to provide an understanding of the present disclosure. However, it will be understood by those skilled in the art that the present disclosure may be practiced without these details and that numerous variations or modifications from the described embodiments are possible.
[0031] Currents can be induced in a geophone bobbin to dampen oscillating motion of the bobbin relative to the remainder of the geophone as the coils move in a magnetic field. Damping caused in the bobbin may be accounted for, and controlled, by implementing a short circuit damping coil and temperature insensitive wire, such as Constantan. The damping coil can be controlled to produce effective damping (e.g., approximately 70%) without an external shunt resistor. In an embodiment, the damping coil may be manufactured of Constantan wire to limit temperature dependency.
[0032] Referring now to FIG. 1-1 , a cross-section of a geophone 10 is shown. The geophone 10 includes a moving coil with windings 12 , 13 mounted on a bobbin 14 , a magnet 15 , a pair of pole pieces 16 , 18 with suspension springs 20 , 22 and a housing 24 as shown in FIG. 1-1 . The pole pieces 16 , 18 and the housing 24 are made of magnetically permeable material and form a magnetic field in which the moving coil is suspended.
[0033] Referring now to FIG. 1-2 , a schematic of the displacement of the geophone of FIG. 1-1 while sensing is shown. R s represents an external shunt resistor, and r represents a DC resistance of the coil, as above. The moving coil has a moving mass m and its neutral position relative to the housing is x 0 . The displacement of the ground motion is u, which can be measured with reference to the neutral position x 0 . x is the displacement of the coil while sensing, which can also be measured with reference to the neutral position x 0 . The output is connected to the external shunt resistor R s to adjust the total damping factor D. The external shunt resistor R s may be varied to control the damping of the coil movement.
[0034] As the coil moves in the magnetic flux 25 , the coil generates signal e g , which can be defined by:
[0000] e g =Blv Equation 1
[0000] where B represents the magnetic flux density, l represents the length of the coil, v represents the velocity of the moving coil relative to the magnetic field, and u represents the displacement of the ground motion. The product, Bl, represents the conversion factor of a geophone from velocity of ground motion to the electric signal, e g , and can be defined as open circuit sensitivity, S 0 .
[0035] The current i flowing out of the coil and returned through the shunt resistor R s can be defined by:
[0000]
i
=
e
g
r
+
R
s
Equation
2
[0036] Current in the coil causes a force f to limit the motion of the coil, which can be defined by:
[0000] f=S 0 i Equation 3
[0037] A spring force acting on the moving mass m is proportional to the difference between the coil displacement x and the ground displacement u and can be defined by:
[0000] −k(x−u) Equation 4
[0000] where k is the spring constant.
[0038] A damping force is related to the velocity of the coil in the magnetic field and can be defined by:
[0000]
-
c
(
x
-
u
)
t
Equation
5
[0000] where c is the friction factor proportional to the velocity, t is time. One cause of damping may be the current flowing in the metallic bobbin, as friction of the moving mass in the air and the loss in the spring can be negligibly small.
[0039] Motion of the moving coil can be described in an equation of motion:
[0000]
m
2
x
t
2
=
-
c
(
x
-
u
)
t
-
k
(
x
-
u
)
-
S
0
i
Equation
6
[0040] From Equations 1 and 2, current can be defined as:
[0000]
i
=
e
g
r
+
R
s
=
S
0
r
+
R
s
ξ
t
Equation
7
[0041] A relative position of the moving coil to the ground motion in the housing can be defined as:
[0000] ξ= x−u Equation 8
[0042] A natural frequency ω 0 and a controlled damping D 0 can be defined as:
[0000]
ω
0
=
k
m
Equation
9
D
0
=
c
2
m
ω
0
Equation
10
[0043] Equation 6 can be rewritten as
[0000]
2
ξ
t
2
+
2
ω
0
D
0
ξ
t
+
ω
0
2
ξ
=
-
2
u
t
2
-
S
0
2
m
(
r
+
R
s
)
ξ
t
Equation
11
[0044] The total damping D can be defined as:
[0000]
D
=
D
0
+
S
0
2
2
m
ω
0
(
r
+
R
s
)
Equation
12
[0045] The equation of motion for the moving mass can be rewritten as:
[0000]
2
ξ
t
2
+
2
ω
0
D
ξ
t
+
ω
0
2
ξ
=
-
2
u
t
2
Equation
13
[0046] Assuming that ground motion u may be governed by:
[0000] u=a sin(ω t ) Equation 14
[0000] where a denotes the amplitude and ω is the angular frequency of the ground motion.
[0047] Then:
[0000]
ξ
=
a
(
ω
ω
0
)
2
(
1
-
ω
2
ω
0
2
)
2
+
(
2
D
ω
ω
0
)
2
sin
(
ω
t
-
ϕ
)
Equation
15
[0000] where the phase delay φ of the coil motion is
[0000]
tan
(
ϕ
)
=
2
D
ω
ω
0
1
-
ω
2
ω
0
2
Equation
16
[0048] The electric signals can be governed by:
[0000]
e
g
=
a
ω
S
0
(
ω
ω
0
)
2
(
1
-
ω
2
ω
0
2
)
2
+
(
2
D
ω
ω
0
)
2
cos
(
ω
t
-
ϕ
)
Equation
17
[0049] In a first example, a geophone has response parameters shown in Table 1.
[0000]
TABLE 1
f 0 [Hz]
10
S 0 [V/(m/s)]
40
D 0 [—]
0.2
r [ohm]
400
m [kg]
0.01
[0050] The total damping factor D is adjusted by shunt resistors R s to adjust Case 1 (D=0.3), Case 2 (D=0.7) and Case 3 (D=1.0) according to Equation 12 as shown in Table 2.
[0000]
TABLE 2
Case 1
Case 2
Case 3
R s [ohm]
12286
2145
1192
D [—]
0.30
0.70
1.00
S [V/(m/s)]
38.7
33.7
29.9
[0051] The output signal can be reduced by the shunt resistance and coil resistance, and the overall sensitivity S can be governed by:
[0000]
S
=
S
0
R
s
r
+
R
s
Equation
18
[0052] The amplitude response of the geophone with the response parameters shown in Table 1 for unit velocity against frequency in Hertz is calculated using Equation 17 for different cases of shunt resistor shown in Table 2. The plot 200 in FIG. 2 shows the geophone amplitude response (measured in V/(m/s)) over a plurality of frequencies (measured in Hz). The total damping factor is 0.3 for the frequency response line 202 , 0.7 for the frequency response line 204 , and 1.0 for the frequency response line 206 , showing a suppression of resonance at the natural frequency via the shunt resistor.
[0053] The phase response 300 resulting from Equation 16 is shown in FIG. 3 for Case 1, Case 2, and Case 3, plotting phase in degrees against frequency in Hertz. As in FIG. 2 , for the three responses plotted, the damping factor is 0.3 for the frequency response line 302 , 0.7 for the frequency response line 304 , and 1.0 for the frequency response line 306 .
[0054] In an example embodiment, the coil resistance r is a function of temperature. Typically the coil can be made of copper magnetic wire and the temperature dependency is found in an empirical relation as:
[0000] r=r 0 {1+0.00393( T−T 0 )}
[0000] where T is the operating temperature, T 0 is the room temperature, typically 20 degrees Celsius, and r 0 is the resistance at the room temperature.
[0055] The natural frequency f 0 , open circuit damping D 0 , and open circuit sensitivity S 0 may change with temperature. FIG. 4 is a plot 400 of natural frequency f 0 , open circuit sensitivity S 0 , and open circuit damping D 0 , versus temperature in degrees Celsius. The parameters are normalized by the values at 20 degrees Celsius. As can be seen in FIG. 4 , the natural frequency, f 0 changes slightly with temperature due to the change in the Young's modulus of the spring material. The open circuit sensitivity S 0 changes due to the change of the demagnetizing curve of the permanent magnet. The open circuit damping D 0 changes with temperature. The open circuit damping is reduced by about 30% at 175 degrees Celsius. This is due to the increase of resistance of the bobbing and the reduction of the open circuit sensitivity.
[0056] For an example geophone with response parameters: f 0 =15 Hz; S 0 =52; D 0 =0.57; r=2400 ohm; m=0.0078 kg; the total damping is about 70% with R s =11672 ohm. The controlled damping is reduced by about 30% while the reduction of the open circuit sensitivity is about 5%. The coil resistance increases by about 61% at 175 degrees Celsius. Assume that the shunt resistance does not change with temperature, then the total damping is reduced by about 28% at 175 degrees Celsius by using Equation 12 with the temperature dependencies shown in FIG. 4 . From Equation 18, the output sensitivity with the shunt resistor is reduced by about 14%. Table 3 summarizes the response of the geophone at 20 degrees Celsius and at 175 degrees Celsius.
[0000]
TABLE 3
T [degC.]
20
175
f 0 [Hz]
15
15
S 0 [V/(m/s)]
52
49.4
D 0 [—]
0.57
0.399
m [kg]
0.0078
0.0078
r [ohm]
2400
3862
R s [ohm]
11672
11672
D [—]
0.70
0.51
S [V/(m/s)]
43.1
37.1
[0057] FIG. 5 shows a plot 500 for simulated results of time responses of the geophone described above for temperature at 20 degrees Celsius and at 175 degrees Celsius. The input is an impulse that is band limited between 3 Hz and 60 Hz. Line 502 is the time response of the geophone at 20 degrees Celsius and line 504 is at 175 degrees Celsius. The amplitude of the response at 175 degrees Celsius is reduced and ringing is longer compared to the response at 20 degrees Celsius.
[0058] The resistance of the bobbin may be taken into account in order to control damping. The magnet wire is wound on a metallic bobbin 614 as shown in FIG. 6 , illustrating a coil wrapped bobbin 600 . As shown in FIG. 6 , the coil 612 is wound concentrically around the outer surface of the bobbin 614 , such that the coil 612 moves with the bobbin 614 in the magnetic flux field, relative to the housing (not shown). Current i b 650 is induced in the bobbin 614 , and in turn in the coil 612 , when the coil 612 moves in the magnetic flux field. The resistance of the bobbin 614 , r b , is
[0000]
r
b
=
ρ
2
π
d
b
H
τ
Equation
19
[0000] where ρ represents specific electrical resistance; H represents the height of the bobbin 614 ; τ represents the thickness of the bobbin 614 ; d b represents the diameter of the bobbin 614 .
[0059] The equation of motion (of the bobbin 614 and the moving coil 612 ) can be rewritten to include the damping caused in the bobbin 614 , accordingly:
[0000]
2
ξ
t
2
+
2
ω
0
D
0
ξ
t
+
ω
0
2
ξ
=
-
2
u
t
2
-
S
0
2
mr
b
2
ξ
t
2
-
S
0
2
m
(
r
+
R
s
)
2
ξ
t
2
Equation
20
[0000] where D r is the damping unrelated to the current in the bobbin 614 , such as the friction in surrounding air and/or the friction in the spring material. The controlled damping in turn, can take the form:
[0000]
D
0
=
D
r
+
S
0
2
2
m
ω
0
r
b
Equation
21
[0000] Then the total damping can be governed by:
[0000]
D
=
D
r
+
S
0
2
2
m
ω
0
r
b
+
S
0
2
2
m
ω
0
(
r
+
R
s
)
Equation
22
[0060] In comparison, a controllable damping coil added to a geophone may provide controlled damping without using the bobbin as the element to cause the damping, and thus, without an external shunt resistor. In an embodiment, the damping coil may be made of Constantan wire to limit the temperature dependency.
[0061] FIG. 7-1 shows a side view schematic of a dual coil geophone 700 having a damping coil added to each end of the coils. Underlying the geophone components, a bobbin (shown in shadow) is provided, about which additional geophone materials are disposed. The bobbin 714 may be made of various materials, including conductive metal or insulating plastic. A pair of coil windings 712 , 713 is disposed concentrically about the bobbin 714 , spaced apart from one another by a spacer 733 . The spacer 733 may be made of, for example, an insulating material. At opposing ends of the geophone 700 , a damping coil 730 is added to the bobbin 714 on the upper and lower ends of the moving coils 712 , 713 , respectively, and insulation rings 732 cap either end of the geophone 700 adjacent to each damping coil 730 . FIG. 7-2 shows the relative winding directions of the moving coils 712 , 713 , and the damping coils 730 .
[0062] Various aspects of the bobbin and/or the damping coil may be designed to achieve particular results. For example, the thickness of the bobbin may be reduced by high precision machining, but there may be a limit to the effect of thickness. In an embodiment, the bobbin, when manufactured of a conductive metal, may be slotted as shown in FIG. 8 to stop current flowing in the slotted bobbin 814 , as described in U.S. Pat. No. 7,099,235, commonly assigned with the present disclosure.
[0063] In an embodiment, a sheet metal may be employed to manufacture the bobbin, as described in U.S. Pat. No. 7,099,235. In an embodiment, the bobbin is formed from a simple tube of suitable thickness and material. For example, a plastic tube might be 0.15 mm thick and have a mass of about 2 g, which can be extruded or formed in any suitable manner. Optionally, the bobbin 814 may be formed from a flat sheet into a tubular shape with a slot 826 down one side ( FIG. 8 ), in which case aluminum having a thickness of 0.1 mm might be used. When the bobbin 814 is a continuous metal tube, currents can be set up which damp the motion of the moving coil. If the tube is incomplete (as shown in FIG. 8 ), currents may be prevented.
[0064] In FIG. 9 , an embodiment of the geophone 900 includes the moving coil 912 shown disposed and wrapped concentrically about the bobbin 914 . An insulation ring 932 is additionally wrapped or placed over the end of the bobbin 914 so as to be positioned concentrically about the bobbin 914 at either end such that the moving coil 912 is layered between rings of insulation 932 at either end.
[0065] In an embodiment, insulation material may be cladded to the bobbin as shown in FIG. 10 . In FIG. 10 , an embodiment of the geophone 1000 includes the moving coils 1012 , 1013 shown disposed and wrapped concentrically about the bobbin 1014 (shown in shadow). Insulation 1032 is cladded in a layer directly onto the outer surface of the bobbin 1014 at either end such that the moving coils 1012 , 1013 are layered between insulation 1032 at either end.
[0066] In the case that optimal damping resistance is high relative to the resistance of the bobbin, the damping resistance may dominate the total resistance, so the temperature dependency can be controlled by a chip resistor. As seen in FIG. 10 , a slotted bobbin 1014 may underlay additional geophone components. A pair of moving coils 1012 , 1013 is disposed and wrapped concentrically about the slotted bobbin 1014 , spaced apart by an open space lacking insulation or slot. In the open space separating the pair of moving coils 1012 , 1013 , a damping resistance 1035 , such as a chip resistor, may be employed. Capping either end of the bobbin 1014 , insulation 1032 (disposed as a ring or cladded directly to the bobbin 1014 ) is provided.
[0067] In still another embodiment, an embodiment of the geophone 1100 includes one or more independent damping coil(s), as shown in FIG. 11 . In an embodiment, each independent damping coil 1130 can be a one-turn coil of metal deposited onto the insulation ring 1132 , at either end of the moving coil 1112 . In the embodiment of FIG. 11 , a temperature insensitive wire material may be used for the one-turn damping coil 1130 , such as Constantan whose resistance is constant across a wide range of temperatures to reduce temperature dependence. The damping coil 1130 may be formed of a metal added to the outside of insulation 1132 (in ring form, or cladded directly to the bobbin as described above), forming a one-turn coil disposed on top of insulation 1032 at either end of the bobbin.
[0068] The resistance of the bobbin r b may be calculated as:
[0000]
r
b
=
ρ
2
π
d
b
n
π
d
w
2
/
4
=
ρ
8
π
d
b
n
π
d
w
2
Equation
23
[0000] where d w is the wire diameter of the damping coil, d b is the diameter of the bobbin, ρ is the resistivity of the bobbin, and n is the number of turns of the damping coil.
[0069] By implementing a damping coil with an open circuit response when output terminals are open, the amount of damping and temperature coefficient can be controlled. In turn, the controlled damping may be optimized to a particular degree of damping, for example, to about 70%, as would be achieved in a conventional geophone using external shunt resistor. By using temperature insensitive wire, such as Constantan, the temperature effects on the controlled damping can be reduced at high temperatures (for example, about 175 degrees Celsius and higher). Demagnetization of the magnet may affect the efficacy of damping, but to a lesser degree than in conventional geophones.
[0070] Alternatively, in an embodiment of geophone 1200 , a damping coil 1236 can also be embedded in the material of a plastic bobbin 1214 as shown in FIG. 12 . In the embodiment of FIG. 12 , the bobbin 1214 is made of an insulating plastic material, with a recess into which the moving coil 1212 is wound concentrically about the bobbin 1214 . In a groove (or second recess) disposed about the bobbin 1214 in the insulating plastic both above and below the recess in which the moving coil 1212 is disposed, a metal material may be disposed, thereby forming the damping coil 1236 embedded in the plastic bobbin 1214 material.
[0071] Alternatively, in an embodiment of geophone 1300 , an equivalent effect may be achieved by wrapping thin metallic foil as the damping coil 1338 around a slotted bobbin 1314 after providing insulation 1340 on the bobbin 1314 , such as insulation sheet or an anodic oxidation coating on the bobbin 1314 as shown in FIG. 13 . The insulation 1340 and the conductive foil damping coil 1338 can be sufficiently thin as to not reduce the space allowed for the sensing moving coil 1312 . As shown in FIG. 13 , a slotted bobbin (as shown in FIG. 8 ) may have a thin layer of insulation 1341 , added by cladding, layering, or sputtering onto the bobbin 1314 . On top of the conductive thin layer, the moving coil(s) 1312 may be concentrically wound about the bobbin as described previously. Insulation 1332 in the form of material disposed to the bobbin 1314 by cladding, or slipped over the ends of the bobbin in ring-form, spans the outer ends of the bobbin around the moving coil(s). The same effect can be obtained by depositing metal as the damping coil 1452 on to a non-conductive plastic bobbin 1414 underneath the sensing moving coil 1412 , as shown in the geophone 1400 of FIG. 14 .
[0072] Geophones of the present disclosure find particular applications in seismic surveying equipment. FIG. 15 shows a marine seismic survey 1500 having a sea bed cable 200 which includes a number of geophone packages 202 spaced at regular intervals and connected through the cable 200 to processing equipment 204 . FIG. 16 shows a land seismic survey 1600 having a land cable 200 ′ which has a similar configuration as the sea bed cable with geophones 202 ′ spaced apart and connected to processing equipment 204 ′.
[0073] FIG. 17 shows a borehole seismic survey 1700 having a downhole tool comprising a tool body 220 which can be lowered into a borehole 222 on a wireline cable 224 connected to surface processing equipment 226 . The tool body 220 includes an operable arm 228 which can be caused to bear against the borehole wall 230 , and a sensor package 232 which is forced against the borehole wall 230 due to the action of the arm 228 . The sensor package 232 contains three orthogonally oriented geophones 234 x, 234 y, 234 z (x,y,z directions) which can receive seismic signals and pass data back to the surface via the wireline cable 224 .
[0074] Although a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not simply structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | Vibration transducers, sensors including the vibration transducers, and methods for manufacturing the same. The vibration transducer may include a magnet. The vibration transducer may include a bobbin disposed about the magnet. The vibration transducer may include a first coil disposed about the bobbin. The vibration transducer may include a controllable damping coil disposed about the bobbin. The first coil is movable relative to the magnet. The magnet is polarized with respect to the axis of the vibration transducer. | 8 |
[0001] The present application is a continuation application of PCT/AT02/00356, filed on Dec. 19, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to a microorganism for the biological detoxification of mycotoxins, namely ochratoxins and/or zearalenons, as well as a method for biologically detoxifying mycotoxins, namely ochratoxins and/or zearalenons, in food products and animal feeds by the aid of at least one microorganism, as well as the use of bacteria and/or yeasts to detoxify ochratoxins and/or zearalenons, in food products and animal feeds.
DESCRIPTION OF THE PRIOR ART
[0003] Mycotoxins are naturally occurring secondary metabolites of mould fungi affecting agricultural products all over the world and causing toxic effects already in small quantities. The infestation of agricultural products with mycotoxins involves extremely high damage and also induces mycotoxicoses in men and animals, which partially exhibit dramatic effects. Due to the high economic losses and the strain on men and animals caused by mycotoxins and the thus induced mycotoxicoses, attempts have been made for long to find measures to combat mycotoxin contaminations, with basically two methods having been known from the literature. The first approach aims to prevent the growth of mould fungi on food products and animal feeds, thus simultaneously preventing the production of mycotoxins. The second approach is directed at subsequently destroying mycotoxins, or decontaminating food products and/or animal feeds.
[0004] Thus, WO 91/13555, for instance, describes a feed supplement as well as a method for inactivating mycotoxins, wherein particles of a phyllosilicate mineral are added to the feed in order to inactivate said mycotoxins. To enhance the effect of these phyllosilicates, the particles are coated with a sequestrant intended to accelerate their actions. Furthermore, an animal feed became known, for instance, from WO 92/05706, which animal feed contains montmorillonit clay as a feed supplement. These natural clay minerals having large internal surface areas are supposed to bind mycotoxins superficially due to their porosity, thus immobilizing the same.
[0005] Moreover, a feed supplement is known from Austrian Utility Model AT-U 504, which feed supplement uses an enzyme preparation capable of forming epoxidases and lactonases and chemically degrading mycotoxins both in animal feeds and in the gastrointestinal tract of animals. According to AT-U 504, the activity of this enzyme preparation can be enhanced by the addition of zeolithes and the like.
[0006] The addition of mycotoxin binders to animal feeds, which bind to mycotoxins immediately in the digestive tract during digestion, are able to minimize the effects of toxins in livestock. Beside the above-mentioned options, applied substances include alfalfa, bentonite, zeolithe, clays, active carbon, hydrogenated sodium calcium aluminum silicates, phyllosilicates and yeast or bacterium cell walls (U.S. Pat. No. 5,165,946; WO 99/57994; U.S. Pat. No. 6,045,834; EP 9721741; U.S. Pat. No. 5,165,946; U.S. Pat. No. 5,935,623; WO 98/34503; WO 00/41806). The binding of toxins to such materials is a function of the structural characteristics of the toxins. Thus, no effective mycotoxin binder has so far been found for trichothecenes. A further disadvantage of mycotoxin binders is that they are able to adsorb from the feeds in addition to said toxins also important nutrients like vitamins or antibiotics.
[0007] It has been recently found that mycotoxins can be degraded and hence partially detoxified, by microorganisms. An example of the detoxification of mycotoxins and, in particular, trichothecenes is contained in AT-B 406 166, in which a special pure culture of a microorganism belonging to the genus Eubacterium and deposited under number DSM 11798 as well as a mixed culture of the genus Eubacterium with an Enterococcus , which was deposited under number 11799, detoxify trichothecenes by cleaving the epoxy ring present on trichothecenes.
[0008] The detoxification of ochratoxins by enzymatic hydrolysis has already been described by M. J. Pitout: The hydrolysis of ochratoxin A by some proteolytic enzymes, Biochem. Pharmacol. 18, 485-491 (1969).
SUMMARY OF THE INVENTION
[0009] The present invention aims to provide special microorganisms as well as mixed or pure cultures and also combinations thereof, which are able to biochemically degrade mycotoxins, namely ochratoxins and/or zearalenons, in a selective manner and convert the same into physiologically safe substances and, in particular, safe substances for the feeds and food industries.
[0010] To solve these objects, the microorganism according to the invention, of the initially defined kind is essentially characterized in that a microorganism and, in particular, aerobic or anaerobic detoxifying bacteria or yeasts is/are used, which cleave(s) the phenylalanine group of the ochratoxins and degrade zearalenons, respectively, wherein the mycotoxin-detoxifying bacteria are selected from the species Sphingomonas, Stenotrophomonas, Ochrabactrum, Ralstonia and/or Eubacterium , and/or the detoxifying yeasts are selected from the species Trichosporon, Cryptococcus and/or Rhodotorula . By using a microorganism and, in particular, aerobic or anaerobic detoxifying bacteria or yeasts which cleave the phenylalanine group of the ochratoxins and degrade zearalenons, respectively, it is feasible to convert ochratoxins and, in particular, ochratoxin A or ochratoxin B into those metabolites which have no phenylalanine group and, therefore, do no longer exhibit the toxic effects of ochratoxins. This metabolization of ochratoxins is effected by an enzyme similar to carboxypeptidase A, which cleaves the amide bond of the ochratoxin directly or via a multi-enzyme complex by which the ring of the phenylalanine is hydroxylated and subsequently cleaved and degraded. Finally, the remaining aspartame is cleaved, thus yielding another nontoxic ochratoxin metabolite. This route can be demonstrated in a simple manner:
[0011] By using the microorganisms according to the invention, which are selected from bacteria and/or yeasts, it is feasible to detoxify not only ochratoxin A and ochratoxin B, but also the metabolites 4R-hyroxyochratoxin A, 4S-hydroxyochratoxin A, ochratoxin C, ochratoxin A methyl ester, ochratoxin B methyl ester and ochratoxin B ethyl ester. Furthermore, these microorganisms enable the degradation and hence detoxification of zearalenons.
[0012] The fact that, according to the present invention, both aerobic and anaerobic detoxifying bacteria, or yeasts can be used as microorganisms is of particular relevance, since, in the event of the intake of food products and/or animal feeds contaminated with the respective microorganisms, detoxification can be achieved even after the intake of such food products and/or animal feeds. This detoxification may occur at any stage, or in any phase, of the passage of the foodstuff or feed within the gastrointestinal tract, because the respective microorganisms or combinations thereof can be selectively caused to enter into effect in each case. The conditions within the gastrointestinal tract from the stomach to the colon are known to be increasingly anaerobic, which means that the redox potential is increasingly reduced such that, upon ingestion of a foodstuff and/or feeds contaminated with the respective mycotoxins or ochratoxins and/or zearalenons, detoxification at first can be started with aerobic bacteria and/or yeasts and continued with the respective anaerobic bacteria and/or yeasts at the end of a digestive process, or if the foodstuff or feed has already reached an intestinal segment where anaerobic conditions prevail.
[0013] A particularly complete detoxification of mycotoxins, namely ochratoxins and/or zearalenons, is feasible if detoxifying bacteria selected from the species Sphingomonas, Stenotrophomonas, Ochrobactrum, Ralstonia and/or Eubacterium , and/or detoxifying yeasts selected from the species Trichosporon, Cryptococcus and/or Rhodotorula are used as said microorganisms. Among these completely detoxifying bacteria and/or yeasts, the detoxifying bacteria selected from Sphingomonas sp. DSM 14170 and DSM 14167 , Stenotrophomonas nitritreducens DSM 14168 , Stenotrophomonas sp. DSM 14169 , Ralstonia eutropha DSM 14171 and Eubacterium sp. DSM 14197, as well as the detoxifying yeasts selected from Trichosporon spec. nov. DSM 14153 , Cryptococcus sp. DSM 14154 , Rhodotorula yarrowii DSM 14155 , Trichosporon mucoides DSM 14156 and Trichosporon dulcitum DSM 14162 have proved to be particularly efficient, since they not only ensure the complete degradation of mycotoxins, but can additionally be safely used in food products and animal feeds, which is not necessarily the case with a plurality of other mycotoxin-cleaving and/or degrading bacteria and yeasts.
[0014] Among said further bacteria or yeasts that are likewise capable of degrading microorganisms, those indicated below can be successfully applied, being usable either in a medium or in a buffer, or effective in both substances.
[0000]
Degradation in
Strain
Origin
medium
buffer
Pseudomonas cepacia
soil
60%
100%
Ochrobactrum
soil/water
100%
100%
Achromobacter
soil/water
50%
100%
Ralstonia
soil/water
100%
100%
Stenotrophomonas
soil/water
100%
100%
Rhodococcus erythropolis
DSM 1069
75%
90%
Agrobacterium sp.
DSM 30201
20-100%
60-100%
Agrobacterium tumefaciens
DSM 9674
25-40%
0-60%
Pseudomonas putida
ATCC 700007
10-50%
0%
Comomonas acidovorans
ATCC 11299a
20-57%
0-50%
Ascomyceten yeast
HA 168
95%
40%
Cryptococcus flavus
HB 402
90%
100%
Rhodotorula mucilaginosa
HB 403
20%
0%
Cryptococcus laurentii
HB 404
50%
0%
Unknown
HB 508
30%
30%
Trichosporon spec. nov .
HB 704
40%
40%
Unknown
HB 529
100%
95%
Asocomycetes yeast
HA 1265
90%
0%
Asocomycetes yeast
HA 1322
0%
95%
Trichosporon ovoides
HB 519
100%
90%
Triosporon dulcitum
HB 523
100%
100%
Rhodotorula fujisanensis
HB 711
30%
0%
Cryptococcus curvatus
HB 782
20%
95%
Trichosporon guehoae
HB 892
50%
20%
Trichosp. coremiiforme
HB 896
40%
20%
Trichosporon mucoides
HB 900
100%
100%
Trichosporon cutaneum
ATCC 46446
0%
70%
Trichosporon dulcitum
ATCC 90777
0%
100%
Trichosporon laibachii
ATCC 90778
0%
100%
Trichosporon moniliiforme
ATCC 90779
0%
60%
Cryptococcus humicolus
ATCC 90770
0%
30%
Eubacterium sp.
F6
30-70%
100%
Eubacterium callanderi
Di1_8
90%
100%
Streptococcus sp.
Dü2_20
40-70%
Lactobacillus vitulinus
Ru8
0-100%
Stenotrophomonas nitritreducens
DSM 17575
100%
100%
Stenotrophomonas nitritreducens
DSM 17576
50%
100%
Stenotrophomonas sp.
DSM 13117
50%
95%
[0015] It has proved particularly advantageous, as in correspondence with a preferred further development of this invention, that the bacteria and/or yeasts are stabilized particularly by lyophilization, spray-drying or microencapsulation. By stabilizing said microorganisms, their viability and life-time are improved or enhanced, and, in addition, they will be applicable on a more universal scale, and hence usable at any time in any desired application, in the stabilized state. Stabilization through lyophilization, spray-drying or micro-encapsulation is known per se, these being simple and rapidly realizable methods that yield stable, viable microorganisms.
[0016] According to a further development of the invention, the bacteria or yeasts are used as cell-free extracts or crude extracts. In doing so, a further development in using a cell-free extract contemplates that the latter is used in a solution and, in particular, an aqueous solution. Aqueous solutions of cell-free extracts offer the advantage that, being sprayed on the food or feed to be treated, they get into contact with the contaminating mycotoxins directly on the surfaces of the same, detoxification thus being achieved already immediately upon spraying of said extract. The use of a crude extract of bacteria and yeasts, which is obtained by applying ultrasound, enzymatic digestion, a combination of shock-freezing and thawing, a flow homogenizer, a French press, autolysis at a high NaCl concentration, and/or a bead mill, has the advantage that such a crude extract can be obtained in a particularly quick and unproblematic manner such that, in particular, in those cases where the rapid use of detoxifying or mycotoxin-degrading substances is required, the use of a crude extract yields rapid and reliable results. Moreover, crude extracts can be directly used in the production of animal feed such that the feed supplemented with microorganisms will be taken up by the animals, and the microorganisms and, in particular, yeasts or bacteria will enter into action only in the digestive tract of the animal. In this context, the invention also contemplates the use of a mixture containing the crude extracts of various detoxifying bacteria and/or yeasts.
[0017] The use of microorganisms in an unbuffered or buffered solution containing phosphate or trishydrochloride buffer at a pH value of between 1 and 12 and, in particular, 2 and 8, as in correspondence with a preferred embodiment, offers the advantage that the microorganisms can be administered directly with the foodstuff or feeds, thus entering into action in the gastrointestinal tract in those regions where the redox potential is suitable for the optimum action of the microorganisms employed. The use of a buffered solution renders feasible the immediate adaptation to the respective pH prevailing in the gastrointestinal tract such that the food or delicacy good supplemented with the buffered solution of microorganisms will not cause any shift or disturbance of the pH prevailing in the gastrointestinal tract, thus enhancing the easy digestibility of the supplemented food or feeds on the one hand and preventing any digestive disturbance in the gastrointestinal environment.
[0018] Another object of the present invention resides in providing substances or microorganisms which can be used to detoxify food products or delicacy goods without impairing or affecting the living beings ingesting the same and without impairing or affecting said food products or delicacy goods treated therewith, apart from detoxifying the mycotoxins present on said food products or delicacy goods.
[0019] To solve these objects, it was found according to the invention that the use of bacteria selected from Sphingomonas sp. DSM 14170 and DSM 14167 , Stenotrophomonas nitritreducens DSM 14168, Stenotrophomonas sp. DSM 14169 , Ralstonia eutropha DSM 14171 and Eubacterium sp. DSM 14197, and/or yeasts selected from Trichosporon spec. nov. DSM 14153, Cryptococcus sp. DSM 14154, Rhodotorula yarrowii DSM 14155 , Trichosporon mucoides DSM 14156 and Trichosporon dulcitum DSM 14162 enables the mycotoxins, namely ochratoxins, present on the surfaces of food products or animal feeds to be detoxified by cleaving the phenylalanine group and zearalenons to be cleaved, without affecting or influencing in any manner whatsoever the food products or animal feeds treated therewith.
[0020] The use of Trichosporon spec. nov. DSM 14153 , Eubacterium sp. DSM 14197 or Stenotrophomonas nitritreducens DSM 14168 has proved particularly suitable for this purpose, those microorganisms ensuring the, in particular, complete degradation of mycotoxins, namely ochratoxins and/or zearalenons, without entailing any risk.
[0021] In order to enable the, in particular, economical detoxification of mycotoxins, particularly in food products or animal feeds, mixed cultures or combinations of several bacteria and/or yeasts are used for the detoxification of ochratoxins and/or zearalenons in food products and/or animal feeds.
[0022] Another object of the present invention resides in providing a method for biologically detoxifying by a microorganism, mycotoxins, namely ochratoxins and/or zearalenons, in food products and animal feeds, which enables the contaminating toxins to be completely and rapidly decontaminated directly upon entering into contact with food products or animal feeds, or within the digestive tract of the living beings taking in said food products or animal feeds.
[0023] To solve these objects, the method according to the invention is essentially characterized in that a microorganism according to the invention and, in particular, bacteria and/or yeasts according to the invention are mixed with the food product or animal feeds in amounts ranging from 0.01% by weight to 1% by weight and, in particular, 0.05% by weight to 0.5% by weight. By mixing in solid form the food product or animal feed with the microorganism according to the invention and, in particular, with the bacteria or yeasts according to the invention, a food product or animal feed supplemented with the accordingly stabilized microorganism will be obtained in stable form. If such a food product or animal feed supplemented with the microorganism according to the invention is taken up, a suspension will form during insalivation, and the detoxification of the food product or animal feeds and, in particular, the degradation of ochratoxins will start immediately upon the intake of said food product or animal feeds by man or animal, respectively. In this manner, the complete degradation of noxious mycotoxins, namely ochratoxins and/or zearalenons, in the gastrointestinal tract of the intaking host animal is ensured such that the organism will not be strained by noxious mycotoxins in any manner whatsoever.
[0024] If already detoxified food products or animal feeds are intended to be ingested, a further development of the invention provides for the mixing of said food products or animal feeds by stirring in an aqueous suspension of said microorganism containing water at 20 to 99% by weight and, in particular, 35 to 85% by weight, at temperatures of from 10 to 60° C. and, in particular, 15 to 45° C., for 2 minutes to 12 hours and, in particular, 5 minutes to 2 hours. By treating the food product or animal feeds by stirring in an aqueous suspension of the respective microorganism, it is feasible, on the one hand, to provide an intimate contact with the detoxifying microorganisms, of the food product or animal feeds to be treated and, on the other hand, to provide careful treatment of the microorganisms, thus ensuring that the latter will not be deteriorated or killed when mixed with the food product or animal feed. During mixing it is, above all, important to take care that both that the mixing temperatures will not become too high or too low and the duration and composition of the slurry or suspension will fully comply with the present invention so as to safely prevent the destruction or killing of the microorganisms.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] In the following, the invention will be explained in more detail by way of examples relating to the isolation of the microorganisms and their mode of action.
[0000] 1. Cultivation, Production and Recovery of the Yeast Trichosporum Spec. Nov. (DSM 14153)
[0026] The following culture medium is used for growing the yeast:
10 g yeast extract 20 g malt extract 10 g glucose 5 g peptone 400 ppm ochratoxin A 1 l RO water pH 5.5
[0034] It is treated for 25 minutes at 121° C. in an autoclave. 30 ml of a pre-culture are prepared in a 100 ml Erlenmeyer flask (inoculation rate 0.33%). Incubation is effected for 72 hours at 25° C. on the shaker. The bacterial count obtained is about 5×10 7 /ml.
[0035] These 30 ml subsequently serve the pre-culture as an inoculum for fermentation in a 75 liter fermenter. The following cultivation medium is used for fermentation:
[0000]
Malt extract
4
g/l
Yeast extract
10
g/l
Peptone
5
g/l
Glucose
10
g/l
Antifoaming agent
0.1%
pH
5.5
[0036] A pO 2 of 40% and a maximum aeration rate of 3 m 3 /h are adjusted as additional parameters. The pH is 5.00 at the beginning, yet changes in the course of the growth process (rising up to 8.5). After about 40 to 44 hours, the contents can be used as an inoculum for the 3.6 m 3 production fermenter. The following medium is used for the latter:
[0000]
Malt extract
17
g/l
Yeast extract
5
g/l
Peptone
2
g/l
Antifoaming agent
0.1%
[0037] The aeration rate is 15 m 3 air per hour. After 40 to 48 hours, the cells are concentrated by means of a flow separator. The fermentation broth can be concentrated to about 1:10 by means of a separator with a bacterial count of about 3×10 9 /ml being obtained.
[0038] Subsequent stabilization is effected by freeze-drying or spray-drying. Whey powder serves as a cryoprotector in freeze-drying.
[0039] 10% is added, based on the concentrate volume. After this, the concentrate is frozen at −80° C. Freeze-drying is carried out at a pressure of 0.400 mbar, at a shelf area temperature of 20° C. The duration at a layer thickness of 1.5 cm is about 30 hours.
Spray-Drying Parameters:
[0000]
Entry temperature of drying medium (air): 160° C.
Exit temperature: 80° C.
Pressure: 3 bar
2. Cultivation, Production and Recovery of the Bacterium Stenotrophomonas nitritreducens (DSM 14168)
[0043] The cultivation of this bacterium takes place in a nutrient broth, once in Oxoid CM 001 B and once in CM 067 B with 400 ppb ochratoxin A. 30 ml of the medium are autoclaved in a 100-ml Erlenmeyer flask for 25 minutes at 121° C. 1.5 ml from a working cell bank tube serves as an inoculum. Incubation takes place at 30° C. for 72 hours on the shaker.
[0044] These 30 ml subsequently serve the pre-culture as an inoculum for fermentation in a 75-liter fermenter. The following cultivation medium is used for fermentation:
[0000]
Peptone from meat
5 g/l
Meat extract
3 g/l
Antifoaming agent
0.1%
[0045] A pO 2 of 40% and a maximum gassing rate of 3 m 3 /h are adjusted as additional parameters. The stirring rate is 200 rpm. The pH is about 6.8 to 6.9 at the beginning, yet changes in the course of the growth process, rising up to 8.3. After about 40 to 44 hours, the contents can be used as an inoculum for the 3.6 m 3 production fermenter. The following medium was used for the latter:
[0000]
Soybean flour
17
g/l
Yeast extract
5
g/l
Peptone
2
g/l
Antifoaming agent
0.1%
[0046] The aeration rate is adjusted to 15 m 3 air per hour. The stirring speed is 250 rpm.
[0047] After 40 to 48 hours, the cells can be concentrated by means of a flow separator. The concentration ratio is about 1:100.
[0048] Subsequent stabilization is effected by freeze-drying or spray-drying. Whey powder serves as a cryoprotector in freeze-drying.
[0049] 10% is added in most cases, based on the concentrate volume. After this, the concentrate is frozen at −80° C. (10 h) or by the aid of liquid nitrogen (2 h). Freeze-drying is effected at a pressure of 0.400 mbar, at a shelf area temperature of 20° C. The duration at a layer thickness of 1.5 cm is about 30 hours.
Spray-Drying Parameters:
[0050] Entry temperature of drying medium (air): 160° C.
Exit temperature: 80° C.— Pressure: 3 bar
3. Cultivation, Production and Recovery of the Bacterium Eubacterium sp. (DSM 14197)
[0053] The following medium is used to cultivate this anaerobic bacterium:
[0000]
D(+)-glucose
4
g/l
Peptone from casein
2
g/l
Yeast extract
2
g/l
Mineral solution I
75
ml/l
[KH 2 PO 4 6 g/l]
Mineral solution II
75
ml/l
[K 2 HPO 4 6 g/l; (NH 4 )SO 4 6 g/l;
NaCl 12 g/l; MgSO 4 × 7H 2 O 2.5 g/l;
CaCl 2 × 2 H 2 O 3 g/l]
Hemin
1
mg/l
Fatty acid mixture
3.1
ml/l
Cystein-HCl
0.5
g/l
Resazurin
1
mg/l
Ochratoxin A
400
ppb
pH
6.9
[0054] Cultivation takes place in a 100 ml Pyrex flask with a silicone septum. 80 ml of the autoclaved medium are decanted and mixed with KH 2 PO 4 /Na 2 HPO 4 buffer (pH 7). After the addition of the contents of a cryovial from the working cell bank, the headspace of the flask is gassed with N 2 (1 min). Upon closure of the vial, the latter is incubated at 37° C. for 72 hours.
[0055] After this, 4.5 liters of the above-mentioned culture solution are autoclaved in a 5-liter Schott flask. The latter comprises a bleeder connection and two tubes with sterile filters (for gassing the inoculum). After cooling of the medium to 37° C., the buffer solution (1% of the phosphate buffer) and subsequently 80 ml inoculum are added. After gassing of the headspace with nitrogen (for 5 min), the openings are closed by means of tube clamps and the inoculum is incubated at 37° C. for about 64 hours. After a purity test, it can be used as an inoculum for a 1 m 3 fermenter (700 liter capacity).
[0056] The following medium is used for production:
[0000]
Glucose
10
g/l
Yeast extract
5
g/l
Peptone
2
g/l
Cystein HCl
0.5
g/l
pH
7.00
[0057] The inoculum is added after the sterilization of the medium in a fermentation tank (40 min, 121° C., 1.21 bar) and recooling to 37° C. The headspace of the fermenter is flushed with N 2 . The stirring rate is 100 rpm, soda lye (8 mol/l) is used for pH adjustment. The redox potential is about −240 mV at the beginning, decreasing to more than −500 mV during growth. The fermentation time is about 48 hours. Concentration is effected by means of a flow separator.
[0058] Subsequent stabilization is effected by freeze-drying, micro-encapsulation or spray-drying. Whey powder serves as a cryoprotector in freeze-drying.
[0059] 10% is added, based on the concentrate volume. After this, the concentrate is frozen at −80° C. (10 h) or by the aid of liquid nitrogen (2 h). Freeze-drying is effected at a pressure of 0.400 mbar, at a shelf area temperature of 20° C. The duration at a layer thickness of 1.5 cm is about 30 hours.
[0060] The microorganism is protected from unfavorable living conditions during storage by fluidized-bed granulation using a vegetable fat (Holtmelt process, top spray).
[0000]
Spraying rate:
ca. 80-150
g/min
Temperature of incoming air:
50°
C.
Spraying pressure:
3
bar
Air amount:
750-1500
m 3 /h
Product temperature:
<47°
C.
Spray-Drying Parameters:
[0000]
Entry temperature of drying medium (inert gas): 160° C.
Exit temperature: 80° C.
Pressure: 3 bar
4. Detoxification of Ochratoxin A (OTA) by the Bacterial and Yeast Products According to Examples 1 to 3
[0064] A logarithmic dilution series to stage 10 −4 is prepared in physiological saline solution from the products obtained in Examples 1 to 3. Of stages 10 −1 to 10 −4 , 2 ml are each pipetted into 18 ml of the respective medium (minimal medium (Na 2 HPO 4 2.44 g/l; KH 2 PO 4 1.52 g/l; (NH 3 ) 2 SO 4 0.50 g/l; MgSO 4 ×7H 2 O 0.20 g/l, CaCl 2 ×2H 2 O 0.05 g/l), yeast medium or nutrient broth (Oxoid CM001B)), supplemented with 200 ppb OTA. The used flasks are incubated on a horizontal shaker under suitable conditions. After 2.5, 5 and 24 hours, samples are taken and examined for OTA cleavage by means of high-pressure liquid chromatography. At a dilution stage of 10 −3 (corresponding to product bacterial counts of 10 5 ), the yeasts in minimal medium have cleaved 90% of ochratoxin A after 5 hours and 100% after 24 hours.
[0065] If the complex yeast medium is used as a test matrix, the products exhibit a cleavage rate of 90% after 6 hours at a dilution stage of 10 −2 . After 24 hours, all of the OTA is detoxified.
[0066] The bacterial products in minimal medium at a dilution stage of 10 −3 (bacterial count from 10 6 -10 9 ) detoxified 40 to 100% of ochratoxin A after 2.5 hours, and 100% after 24 hours. In nutrient broth, detoxification proceeds somewhat slower—at stage 3, 40 to 50% is detoxified after 2.5 h and 80 to 100% after 24 hours. These tests demonstrate that the microorganisms can be converted into stable products exhibiting detoxification activities both in minimal and in complex media.
5. Ochratoxin Degradation (OTA) by Lyophilisates in Stimulated Intestinal Environment
Test Model A
[0067] This model serves to investigate lyophilisates of the yeast strains DSM 14153, DSM 14154, DSM 15155, DSM 14156 and DSM 14162 as well as the aerobic (DSM 14170, DSM 14167, DSM 14168 und DSM 14169) and anaerobic (DSM 14197) bacterial strains. The small bowel of a freshly slaughtered pig is cut into pieces of about 15 cm length, which are each added to 100 ml minimal medium containing OTA [200 ppb]. The batches were finally inoculated directly with 1 g lyophilisate and incubated at 35° C. After 0, 6, 24 and 48 hours, samples were drawn for a subsequent OTA analysis by means of HPLC and stored in a deep-frozen state (−20° C.) until said analysis.
[0068] Among the yeasts, germs DSM 14153, DSM 14156 and DSM 14162 proved to be the most active ones. Already after the first six hours of incubation, 70 to 90%, 50 to 90% and 80 to 90%, respectively, of the present toxin had been transformed (after 24 h: 90 to 95%). The two other tested yeasts (DSM 14154, DSM 14155) lagged behind the three above-mentioned strains in terms of activity (0 to 20% degradation after 6 h; 30 to 50% after 24 h; 80% after 48 h).
[0069] Among the aerobic bacteria, germ DSM 14168 was the best; after 6 hours, 50 to 100% of the present toxin had already been reacted, after 24 hours 80 to 100%. DSM 14169 too turned out to be absolutely “acceptable”: after 6 hours, 0 to 90% OTA had been detoxified, after 24 hours 70 to 95%. The two remaining germs clearly performed less well (0-40% after 6 h; 50 to 60% after 24 h; 60-80% after 48 h).
[0070] The anaerobic small-bowel isolate DSM 14197 degraded the present mycotoxin after 6 hours of incubation at a ratio of 0 to 60%; after 24 hours, between 50 and 100% OTA had been reacted.
[0071] Analogous tests were carried out with the following germs:
[0000]
Small bowel isolate F6:
90-95%
after 24 h
Colon isolate Di 1-8:
80-95%
after 24 h
Trichosporon ovoides :
40-50%
after 24 h
Triosporon dulcitum :
50-90%
after 24 h
Cryptococcus curvatus :
40-50%
after 24 h
Trichosporon laibachii :
50%
after 24 h
Stenotrophomonas nitritreducens :
60-95%
after 24 h
Stenotrophomonas sp.:
50-70%
after 24 h
[0072] This model demonstrated that OTA could be deactivated by the produced products in buffer medium containing an intestinal section with the appropriate environment (nutrients and intestinal flora).
Test Model B
[0073] This model served to examine lyophilisates of the yeast strains DSM 14153, DSM 14156 and DSM 14162 as well as the bacterial strains DSM 14168 (aerobic), DSM 14169 (aerobic) und DSM 14197 (anaerobic).
[0074] The small bowel of a freshly slaughtered pig was cut into pieces of about 25 cm length, which were closed on their ends by means of cords. 1 g of the product to be examined was weighed into a 50 ml centrifugal tube and resuspended in 20 ml test medium containing OTA [200 ppb] (aerobic germs and yeasts->minimal medium; anaerobic germs->anaerobic buffer). Departing from the thoroughly blended suspension, also tenfold dilutions were optionally prepared. The mixed suspension(s) were then each injected directly into a bowel piece. After having drawn a zero sample directly from the bowel piece, the latter was incubated at 35° C. suspended in a 250-ml Pyrex bottle (i.e. the cord of one end was fixed by the screw cap of the bottle). After 6, 24 and 48 hours, further samples were drawn for a subsequent OTA transformation analysis by means of HPLC.
[0075] In the case of yeasts (about 10 7 KBU/ml), a degradation of OTA up to 90% (DSM 14153) was recorded after 6 hours. After 24 hours at most, comparably high activities (80 to 100%) could be detected for all of the samples.
[0076] Comparable results were obtained also with tenfold and hundredfold dilutions of the lyophilisates. Similar results were obtained with the two aerobic bacteria DSM 14168 and DSM 14169. After 6 hours, 20 to 60% of OTA was transformed, after 24 hours 80 to 95%. The anaerobic germ DSM 14197 showed a degradation performance of between 40 and 50% after 6 hours, which was raised to 90% after 24 hours. Bowel sections incubated with OTA, yet without any products displayed no detoxification activities at all.
[0077] These tests showed that ochratoxin-detoxifying microorganisms were able to degrade this toxin also in a bowel-corresponding environment. Thus, the application of the microorganisms as food or feed supplements particularly for the detoxification of ochratoxins was clearly demonstrated.
6. Detoxification of Food Products and Animal Feeds
[0078] The ochratoxin-detoxifying microorganisms were cultivated for about 66 hours according to Examples 1 to 3 under the appropriate conditions. 25 ml of the suspension were each centrifuged for 15 min at 3210×g and taken up in an adequate volume of minimal medium supplemented with 200 ppb OTA. The suspension forming was used to inoculate 25 g or 25 ml foodstuff, coffee powder, hominy grits, semolina, beer and wine. After careful blending of the foodstuff with the microorganism suspension, a sample (=zero sample) was drawn. The incubation of the batches took place at 25° C. for 9 days. After this, 5 g of the sample were analyzed in comparison with the zero sample. In addition, blanks were co-incubated. The latter were provided with OTA, yet without microorganisms. To analyze the ochratoxin contained in the liquid foods, precisely 1 ml of each food freed of the microorganisms was acidified with 0.5 ml 1M phosphoric acid and extracted with 5 ml methylene chloride. 5 ml of the extract were dried under nitrogen. Each sample was processed twice, the residue after drying was taken up once in acetonitrile/water/acetic acid (45:54:1) and once in toluene/acetic acid (99:1). The analyses of the samples were carried out both by means of HPLC and by means of TLC. When analyzing the semolina, 5 g of the sample were weighed into a 100 ml Schott flask and shaken for one hour with 20 ml acetonitrile/water (60:40) at 170 rpm. After filtration, this extract was directly analyzed by means of HPLC. The processing of hominy grits and coffee for the OTA analyses was somewhat more cumbersome. In those cases, 5 g of the samples were each weighed into a 100 ml Schott flask and shaken with 20 ml acetonitrile:water (60:40) for one hour. After filtration, 4 ml of the extract were mixed with 44 ml PBS buffer (0.1% Tween 20) and packed on an immunoaffinity column. Subsequently, the HPLC analysis was made. Both the decrease of OTA and the emergence of the metabolite OTα were determined. No OTα could be detected in the coffee and corn samples due to the column purification applied. The following degradation rates could be obtained:
[0000]
OTA-Reduction in percent
Strain
Beer
Wine
Corn
Wheat
Coffee
DSM 14153
100
(+)
99
(+)
94
(+)
100
(+)
~67
(+)
DSM 14154
100
(+)
94
(+)
50
(+)
100
(+)
0
(−)
DSM 14155
30
(+)
0
(−)
99
(+)
100
(+)
0?
(−)
DSM 14156
100
(+)
95
(+)
96
(+)
100
(+)
30
(+)
DSM 14162
83
(+)
12
(+)
100
(+)
100
(+)
0
(−)
DSM 14170
75
(+)
0
(−)
0
(−)
89
(+)
0
(−)
DSM 14167
100
(+)
4
(+)
39
(+)
~90
(+)
0
(−)
DSM 14168
100
(+)
0
(−)
50
(+)
94
(+)
0
(−)
DSM 14169
100
(+)
0
(−)
0
(−)
91
(+)
0
(−)
DSM 14171
100
(+)
0
(−)
79
(+)
81
(+)
0
(−)
7. Degradation of Mycotoxins
[0079] The microorganisms were cultivated for about 66 hours. After this, they were centrifuged (3210×g, 15 min, room temperature) and the pellets obtained were resuspended in minimal medium. To the minimal medium were added 1 ppm desoxynivalenol, 1 ppm fumonisin B 1 , 1 ppm zearalenon, 200 ppb aflatoxin B 1 and 2 ppm citrinin. Before incubating the batches at 30° C., a sample was taken (“zero sample”). The incubation time was 96 hours. The batches were determined in duplicate by examining for the HPLC analysis once the supernatant (after centrifugation) and once the whole batch. For purification, 3 ml of the supernatants and 2 ml of the overall sample, respectively, were packed on 15 g Extrelut material. After 15 minutes, the samples were diluted with 40 ml ethyl acetate. 7 ml of the ethyl acetate were each dried and taken up in the appropriate solvent. The analysis of aflatoxin B 1 and fumonisin B 1 was carried out after a preceding derivatization.
[0080] The samples after 96 hours were examined for the degradation of the respective toxins in comparison with the samples at the beginning. To this end, both the supernatants (separation of the biomass by centrifugation) and the overall samples (with biomass) were analyzed for DON, ZON and AFB 1 . The results are illustrated in Table 2.
[0000]
TABLE 2
FB 1 -
CIT-
degra-
degra-
ZON-degradation
dation
AFB 1 -degradation
dation-
rate [%]
rate [%]
rate [%]
rate [%]
Super-
Super-
Super-
Super-
Strain
natant
total
natant
natant
total
natant
DSM 14170
0
24
0
0
0
100
DSM 14167
0
28
0
0
10
0
DSM 14168
0
32
0
0
10
0
DSM 14169
88
90
0
8
46
0
DSM 14171
0
43
0
0
24
0
DSM 14153
100
100
19
20
13
0
DSM 14154
19
67
22
64
63
0
DSM 14155
81
100
29
20
38
0
DSM 14156
100
100
6
0
61
0
DSM 14162
17
62
8
0
0
0
[0081] It is clearly apparent from the foregoing assays that some mycotoxins such as zearalenon (ZON), aflatoxin B 1 (AFB 1 ), fumonisin B 1 (FB 1 ) can partially be degraded extremely well with the microorganisms according to the invention. Citrinin (CIT) could be degraded 100% merely by the bacterium Sphingomonas sp. (DSM 14170).
[0082] To sum up, it is noted that the microorganisms according to the invention readily enable, in particular, the degradation of ochratoxins in food products and animal feeds and also in intestinal environment, with the degradation of zearalenon, citrinin and the like yet partially yielding good results.
Attachment to PCT Application PCT/AT02/00356
Applicant: Erber Aktiengesellschaft et al.
[0083] List according to rule 13bis, para 4 of the Regulations Under the Patent Cooperation Treaty
[0084] All microorganisms being cited in the present PCT application PCT/AT02/00356 have been deposited with DSMZ—Deutsche Sammlung von Mikroorganismen und Zellkulturen GmbH, Mascheroder Weg 1b, 38123 Braunschweig, Germany (DE).
[0000]
Filing No.
Filing date
DSM 14156
08 Mar. 2001
DSM 14155
08 Mar. 2001
DSM 14154
08 Mar. 2001
DSM 14153
08 Mar. 2001
DSM 14197
15 Mar. 2001
DSM 14171
08 Mar. 2001
DSM 14169
08 Mar. 2001
DSM 14168
08 Mar. 2001
DSM 14167
08 Mar. 2001
DSM 14170
08 Mar. 2001
DSM 14162
08 Mar. 2001 | A microorganism for the biological inactivation or detoxification of mycotoxins, in particular ochratoxins, which is selected from bacteria and/or yeasts, which cleaves the phenylalanine group of the mycotoxins, in particular ochratoxins, as well as a method for biologically inactivating or detoxifying mycotoxins, in particular ochratoxins, in food products and animal feeds by the aid of a microorganism, and the use of the microorganism(s). | 0 |
BACKGROUND—DESCRIPTION OF PRIOR ART
[0001] Arrows have long been used for war, hunting and competitive sports. A conventional arrow has a shaft, a nock at one end that receives the bow string, an arrowhead or point that attaches to the opposite end, and fletchings. The fletchings are glued to the shaft near the nock end, and help to stabilize the arrow in flight, as it rotates. Arrowheads generally have a pointed forward end, and an opposite threaded shaft end that attaches the arrowhead to the arrow shaft. Arrowheads are also attached to the forward end of arrow shafts by glueing and other methods.
[0002] Arrowheads come in a variety of different sizes and configurations depending on their intended use. For example, there are specifically designed arrowheads for competitive target shooting, shooting fish, hunting birds or small game animals, and for hunting big game animals.
[0003] The most common type of arrowhead used in hunting is the fixed-blade arrowhead, which has a pointed tip end used for penetrating, and blades that each have a razor sharp edge for cutting. Most conventional fixed-blade arrowheads have replaceable blades which are held in a fixed position on the arrowhead. The replaceable blades attach to the arrowhead body in longitudinal grooves called blade slots. The tip of the arrowhead may be separably attachable to the arrowhead body or may be integral with it. Arrowheads for hunting are generally known as broadheads.
[0004] Arrowheads used for hunting kill the game animal by cutting vital organs such as the lungs and vascular vessels such as arteries, which causes rapid hemorrhaging and/or suffocation. Quick and humane kills are dependent on accurate shot placement, and upon the amount or volume of the animal tissue that is cut. Hunting arrowheads that cut more tissue are more lethal, and therefore are better. The volume of tissue that is cut is determined by the cutting diameter of the arrowhead, the number of blades it contains, and by the distance the arrowhead penetrates into the animal. The cutting diameter of an arrowhead is determined by how far each cutting blade extends outward from the arrowhead body. The further the blades extend outward the larger the cutting diameter is, and therefore the more cutting potential the arrowhead has.
[0005] A problem with conventional fixed-blade arrowheads is that having the desirable, large cutting diameters generally cause unstable arrow flight or poor arrow aerodynamics, which affects accurate shot placement. This can lead to non-lethal wounding of the game animal or missing the animal altogether. Unstable arrow flight in hunting arrows is generally caused by arrowhead aligning and centering problems. Arrowhead aligning and centering problems are prevalent when the arrowhead is attached to the arrow shaft such that the longitudinal axis of the arrowhead is not in line with the longitudinal axis of the arrow shaft. Alignment and centering problems in arrowheads are generally created by low tolerances or sloppiness in the manufacturing of the arrowhead body. When a mis-aligned arrowhead is attached to an arrow and the arrow is shot, as the arrow spins or rotates in flight non-stabilizing forces are induced on the front end of the arrow and cause inconsistent or erratic flight, which steers the arrow from its intended path. Since the cutting blades of fixed-blade arrowheads extend out from the arrowhead body when the arrowhead is in flight, the blades greatly magnify any non-stabilizing forces induced on the arrow from misalignment, and therefore increase erratic arrow flight. This is the main reason why conventional fixed-blade arrowheads are limited in the maximum cutting diameter they can have, while retaining sufficiently stable aerodynamics.
[0006] To create a hunting arrowhead that has both a maximum cutting diameter and stable aerodynamics, despite moderate manufacturing tolerances, blade-opening arrowheads were designed. Blade-opening arrowheads differ from conventional fixed-blade arrowheads in that the cutting blades are folded up or held adjacent to the arrowhead body in a retracted position while the arrow is in flight, but at impact with the game animal rotate or pivot into an open position, therefore exposing the sharp blade edges and cutting the animal. Since the blades of blade-opening arrowheads are held adjacent to the arrowhead body and do not extend very far out from it, any aligning or centering problems of a blade-opening arrowhead attached to an arrow will not noticeably steer the arrow or undesirably affect its flight trajectory. In this manner blade-opening arrowheads can have both a desirable large cutting diameter, and the stable arrow flight characteristics necessary for accurate shot placement. Blade-opening arrowheads can therefore potentially be more lethal.
[0007] Blade-opening arrowheads like conventional fixed blade arrowheads generally have an elongated arrowhead body, a tip end, and a threaded opposite end. The blades of blade-opening arrowheads have an attachment end which attaches the blades to the arrowhead body by a pivot pin, so that the blades can pivot or rotate between the retracted position and the open position. Blade-opening arrowheads also come in a variety of different types and styles. The blades of the most common type of blade-opening arrowheads, when in the retracted position have a leading blade end positioned near the tip of the arrowhead that protrudes outward from the arrowhead body, and is some times shaped like a wing. The leading blade ends of the most common type of blade-opening arrowheads, rotate away from the arrowhead body in a rearward direction when penetrating an animal. Particularly, the leading blade ends catch on the animal's surface and serve to lever or rotate the blades into the open position. The blades of blade-opening arrowheads are also received in blade slots, which are machined or formed into the side of the arrowhead body.
[0008] Blade-opening arrowheads for hunting big game must be non-barbing, wherein the blades when in the open position must not inhibit or prevent arrow extraction from a game animal by barbing into the animal tissue. This makes it so non-fatally wounded animals can easily pull out an arrow still lodged in them. For an arrowhead to be non-barbing, the pivotal blades must rotate from the open position to an angle greater than ninety degrees, as measured between the rear edge of each blade and a location on the arrow shaft rearward of the blades.
[0009] Blade-opening arrowheads generally do not penetrate as deep as conventional fixed-blade arrowheads. Sometimes in hunting situations an arrow will not completely pass through the game animal and will not have sufficiently cut any vital organs or vascular vessels, and thus not having inflicted a lethal wound. Sometimes in these instances the arrowhead will have penetrated within the game animal near an artery or vital organ such that as the animal retreats, the arrowhead continues to cut as it moves within the animal, and the artery or vital organ is severed, and the animal is harvested. Conventional blade-opening arrowheads are generally not as lethal in these types of situations, as arrowheads having the cutting blades positioned near the tip of the arrowhead, such as conventional fixed-blade arrowheads. This is because the cutting blades of the most popular types of conventional blade-opening arrowheads when in the open position, are positioned approximately one and a half inches back from the arrowhead tip, and therefore cut a lesser volume of tissue despite equal arrowhead penetration depth.
[0010] To hold the blades of blade-opening arrowheads in the retracted position during flight until the arrowhead penetrates the animal, annular retention members such as O-rings are most commonly used. Other commonly known annular retention members are, rubber bands, tight fitting plastic sleeves, tape, heat-shrinkable fitting plastic sleeves, and other wrap materials. When the O-rings are stretched around the outside of the blades they exert a resistive force against the blades and hold the blades selectively in the retracted position.
[0011] O-ring use for blade retention is less than ideal. The elastomeric polymer materials are susceptible to drying-out and therefore cracking, which can lead to breaking of the O-ring during arrow acceleration when the arrow is shot. This will cause premature blade-opening and produce extremely erratic arrow flight and possible non-lethal wounding of the game animal. This may also cause severe lacerations to the archer. Also, bows shooting arrows at very high speeds can require as many as three O-rings to prevent premature blade-opening. The experience of learning this can be very undesirable for the archer. O-rings are a consumable item designed for one shot use, and the cost of constantly replacing them is a detrimental factor. Also, they are not user-friendly and are a general bother to worry about while out in the field.
[0012] Aside from consumer use considerations, humaneness to the hunted game animal is an important consideration as well. When the arrowhead penetrates the animal and the blades begin to rotate open, the more the O-ring is stretched the more resistive force it exerts back against the blades, thus impeding the rate of blade-opening. This can possibly prevent full blade-opening and a quick and humane kill. Also, extreme weather temperatures greatly affect the elasticity of O-rings; cold weather decreases elasticity which increases the likelihood of the blades not opening, and hot weather increases elasticity which increases the likelihood of premature blade opening.
[0013] Attempts in the prior art have been made to remedy the problems associated with O-ring use for blade retention of blade-opening arrowheads, but these attempts have their own problems as well. For example, the use of magnetism for blade retention is known to the art. The disadvantages of using magnets for blade retention are that magnets are heavy, relatively expensive, and can demagnetize. The use of a leaf spring for blade retention is also known to the art, where the leaf spring is positioned and held in the blade slot by a set-screw, which is usually also the pivot pin. One disadvantage of using a leaf spring for blade retention is the difficulty involved when replacing the blades; having to simultaneously line up a hole in the leaf spring, a hole in the blade, and a hole in the arrowhead body while inserting a set screw through all three members, for each blade. Another disadvantage of using a leaf spring for blade retention is limitations of the leaf spring, where a very small amount of dirt, debris or ice can prevent the leaf spring from deflecting, and also, the flexibility life span of the leaf spring can be short. This could possibly inhibit blade-opening altogether. Disadvantages of other blade retention methods known to the art are, reduced penetration of the arrowhead, structural weakening of various arrowhead elements, in-operability, and manufactural unfeasibleness.
[0014] It is apparent that there are much needed improvements in blade-opening arrowheads, both in consideration of the archery consumer and the hunted game animal.
[0015] It is apparent that there is a need for a blade-opening arrowhead that securely holds each blade selectively in a retracted or in-flight position, in a secure or locked manner, by methods other than O-rings or similar consumable elements, that is user-friendly, manufacturally feasible, and structurally strong.
[0016] It is also apparent that there is a need for a blade-opening arrowhead that securely holds each blade selectively in a retracted or in-flight position, in a secure or locked manner, that is operable and is not suspectable to malfunctioning by contamination of dirt, debris, or ice and/or by short life span of the blade retention method.
[0017] It is yet further apparent that there is a need for a blade-opening arrowhead that is capable of driving the razor cutting edges of the blades from the open position, forwardly into uncut or unpenetrated tissue of an arrowed game animal when the arrow is lodged in the animal, especially when the animal has not been fatally or lethally hit, thus to increase the lethality of the arrowhead, and to be more humane to the animal.
SUMMARY OF THE INVENTION
[0018] It is one object of the present invention to provide blade-opening arrowheads with blade retention methods that do not require the use of consumable annular members such as O-rings.
[0019] It is another object of the present invention to provide a blade-opening arrowhead that securely holds each blade selectively in a retracted in-flight position, in a secure or locked manner by methods other than O-rings or similar elements, that is user-friendly, manufacturally simple, and structurally strong.
[0020] It is another object of the present invention to provide a blade-opening arrowhead that securely holds each blade selectively in a retracted in-flight position, in a secure or locked manner that is operable and is not suspectable to malfunctioning, especially by contamination of dirt, debris, ice and/or by short life span of the blade retention method.
[0021] It is another object of the present invention to provide a blade-opening arrowhead that securely holds each blade selectively in a retracted or in-flight position, in a secure or locked manner by releasably latching the blade edge of each blade to the arrowhead body or equivalent. Specifically where an urging force urges the blades in a forward direction to securely hold the edge of each blade engaged against the arrowhead body, and therefore the blades are securely held adjacent to the arrowhead body when in a retracted position but freely rotate into an open position when the arrowhead penetrates an object.
[0022] It is still another object of the present invention to provide a blade-opening arrowhead that securely holds each blade selectively in a retracted or in-flight position, in a secure or locked manner by releasably latching the blade edge of each blade to a holding element. Specifically where an urging force urges the holding element to securely hold the edge of each blade engaged against the holding element, and therefore the blades are securely held adjacent to the arrowhead body when in a retracted position but freely rotate into an open position when the arrowhead penetrates an object.
[0023] It is yet further another object of the present invention to provide a blade-opening arrowhead that is capable of driving or continually urging the razor cutting edge of each blade from the open position, forwardly into uncut or unpenetrated tissue of an arrowed game animal.
[0024] The foregoing objects and advantages and other objects and advantages of the present invention are accomplished with a hunting arrowhead that attaches to the forward end of an arrow shaft, where a plurality of blades are pivotally connected to an arrowhead body. The blades freely rotate from an in-flight retracted position to an open position when the arrowhead penetrates an object, or when acted upon by a sufficient opening force. When the blades are in the in-flight retracted position they are securely held selectively adjacent to the arrowhead body by engagement of a blade edge of each blade to a holding element.
[0025] Such a blade-opening arrowhead according to one preferred embodiment of this invention has an arrowhead body with a tip end used for initial penetration and an opposing threaded shaft end that screws or threads the arrowhead to an arrow. The tip end may be removably attached to the arrowhead body, and may be made of material different than the rest of the arrowhead body. The arrowhead body has a plurality of blade slots, one for each respective blade. Each blade has a first end, an opposing second end and an edge extending about its periphery. One blade edge of each blade is sharpened for cutting. The first blade ends or the leading ends each have a protruding wing that is exposed out from the arrowhead body when the blades are in the retracted position. The wings serve to increase the moment-arm for levering or rotating the blades to the open position. The second end of each blade has an aperture or hinge pin receiving hole for receiving a pivot pin or a hinge pin. The arrowhead body also has a hinge pin receiving hole for each blade. The arrowhead body hinge pin receiving holes are recessed or drilled into the two opposing sidewalls of each blade slot, and are threaded to receive the threaded hinge pins. A single hinge pin is used for each blade, and when the blades are positioned in the blade slots, each hinge pin is extended through the aperture of a corresponding blade and is screwed into the arrowhead body. This pivotally connects the blades to the arrowhead body. The cross-sectional area or open area of each blade aperture is greater than the cross-sectional area of its corresponding hinge pin, such that a gap is created between each hinge pin and blade aperture of each blade, when the hinge pins are extended through the blade apertures. These gaps allow each blade to freely move in a forward and rearward direction independent of the arrowhead body and corresponding hinge pin. The blade edge of the first end of each blade has a catch lip or a bump protruding out from it near the cutting edge. The arrowhead body has one receiving notch or holding element formed in it for each blade. The notches are situated near the top of each blade slot and are recessed into the arrowhead body. An annular recess encircling the arrowhead body is situated below the blade slots, and is recessed into the arrowhead body. This annular recess communicates with each blade slot and leaves or defines a stem shaped portion on the arrowhead body. An annular compression spring or coil spring is positioned in the annular recess, with a separate annular ring positioned forward or above the annular spring. Both the annular ring and annular spring are slidably positioned around the stem portion of the arrowhead body, such that the annular ring contacts the second end of each blade. An annular blade-stop washer shaped like a doughnut, also having a recessed portion shaped to contain the annular spring, is slidably positioned around the arrowhead body stem below the annular spring, and contacts the rear end of the annular spring. The blade-stop washer has a sloped outer and upper side, that serves to abut against the blades when they are rotated to the fully open position, thus defining the cutting diameter of the arrowhead when the blades are in the fully open position.
[0026] When a blade-opening arrowhead according to the preferred embodiment of this invention as described above, is tightly fastened to the forward end of an arrow shaft, the blade-stop washer is tightened-up against both the arrow shaft and the arrowhead body. This tightening causes the annular spring to be compressed between the blade-stop washer and the annular ring. This compression or biasing of the spring causes an urging force to be exerted against the second ends of the blades in a generally axial direction. The annular ring serves to transfer the urging force equally to all blades. Since a gap exists between each hinge pin and each blade aperture, the urging force moves the blades forward relative to the arrowhead body, and engages or receives the catch lips on the blades into their corresponding receiving notches in the arrowhead body. The continual compression of the annular spring provides a continual urging force which maintains the engagement of the catch lips and notches, thus releasably latching and securely holding the blades selectively in the retracted position. The urging force is strong enough to maintain the blades in the retracted position when the arrow is exposed to incidental forces, such as those produced from transporting the bow, nocking an arrow to the bow string, and acceleration when the arrow is shot. The urging force is weak enough however, to be easily overcome when the arrow impacts or begins to penetrate a game animal.
[0027] When the arrowhead according to the above described preferred embodiment initially penetrates an animal, the first ends or leading ends of the blades catch on the animal's surface and the blades are driven rearwards which unlatches the blades. At initial penetration the annular spring is then compressed such that the catch lips are disengaged from the notches sufficiently that the blades lever-out and freely rotate towards the open position. With the blades in the open position, the urging force of the annular spring continually urges the cutting edges of each blade in a forward direction, providing the ability to further cut additional animal tissue, should the arrow still be lodged in the animal.
[0028] All that is required to securely lock the blades back in the retracted position, is to simply push each blade back into the retracted position, and the spring compresses as the catch lips are received back into the notches. Once the catch lips are received into the notches, the continual urging force of the spring simply maintains the blades in the retracted position again. Also, when the sharp edges of the blades become dull, all that is required to change the blades is to un-compress the spring by slightly unscrewing the arrowhead from the arrow shaft, and then remove the threaded hinge pin, insert a new blade, and re-insert the hinge pin. There is no requirement to spend additional time and effort lining up tiny holes in other tiny elements such as a leaf spring, with the blade aperture and arrowhead body pivot pin receiving hole, when changing blades or when replacing the spring element or elements.
[0029] Blade-opening arrowheads according to other preferred embodiments of this invention differ from the above described preferred embodiment in that they have an annular hinge pin, where the plurality of blades are all attached to the single annular hinge pin. The annular hinge pin is slidably positioned on the stem located near the rear end of the arrowhead body, and is received in the same annular recess as the annular spring and annular ring. According to one such annular hinge pin embodiment, there is substantially no gap between the hinge pin and each blade aperture, and the blades and hinge pin are both urged or moved forward together by the annular spring when the catch lips are received or engaged into the notches. In another annular hinge pin preferred embodiment according to this invention, a gap is formed between the hinge pin and each blade aperture, and the blades are urged or biased by the annular spring when the catch lips are received into the notches.
[0030] A blade-opening arrowhead according to another preferred embodiment of this invention, also has an annular recess encircling the arrowhead body, situated below the blade slots, which defines a stem shaped portion on the arrowhead body, and which houses an annular spring and an annular ring. The blade-opening arrowhead according to this preferred embodiment has a catch lip and an adjacent notch in the second end of each blade. Each notch is positioned medial to its corresponding catch lip when the blades are in the retracted position. Each notch is defined by its corresponding catch lip, wherein the notches were created by removal of blade material in fabricating the protruding catch lips. The annular spring urges the annular ring against each catch lip and into each notch, thus engaging the blade edges at the second end of each blade, and securely holding the blades selectively adjacent to the arrowhead body when in the retracted position. The blades are prevented from rotating outwards prematurely by the lateral or outside edge of each blade notch abutting against the lateral surface of the annular ring. When the blade-opening arrowhead according to this preferred embodiment impacts a game animal and the blades begin rotating outwards, the catch lips or lateral edges of the notches are driven into the annular ring, which compresses the annular spring such that the tip of each catch lip slips over the annular ring, thus disengaging the annular ring from the notches and thus allowing the blades to freely rotate towards the open position.
[0031] According to another preferred embodiment of this invention, an annular spring is positioned in an annular recess situated near the forward end of the arrowhead body within a separably attachable tip piece. The blade-opening arrowhead according to this preferred embodiment has a catch lip and an adjacent notch in the first end of each blade. Each notch is positioned lateral to its corresponding catch lip when the blades are in the retracted position. Also the notch and catch lip of each blade are situated near the cutting edges of the blades. Each notch is defined by its corresponding catch lip, wherein the notches were created by removal of blade material in fabricating the protruding catch lips. The annular spring urges the annular ring against each catch lip and into each notch in a rearward generally axial direction, thus latching the blade edges and securely holding the blades selectively adjacent to the arrowhead body in the retracted position. The blades are prevented from rotating outwards prematurely by the medial or inside edge of the blade notches abutting against the medial surface of the annular ring. When the arrowhead impacts an animal and the blades begin to rotate outwards, the catch lips are driven into the annular ring, which forces the annular spring to compress until the catch lips freely slip under the annular ring. In this manner the blades are unlatched and freely rotate towards the open position.
[0032] The blade-opening arrowheads according to this invention, use no consumable items such as O-rings, for blade retention. The blade retention methods of the blade-opening arrowheads according to this invention, are simple and user-friendly. The blade-opening arrowheads according to this invention provide blade retention methods that are not suspectable to malfunctioning when exposed to the harsh conditions commonly encountered in the field, and when subjected to prolonged use. Should ice, dirt or debris get intermingled with the annular spring of the type preferred for use according to this invention, the annular spring will still serve to produce an effective blade retention urging force, and to allow the timely opening of the blades at target impact. This is so because the spaces between the spring coil wires are large enough to handle a relatively large accumulation of foreign matter, yet have room to allow adequate spring compressing. Also, the length of spring flexibility life of the annular spring according to this invention, under normal use considerations, is indefinite. This is such because the diameter or gauge of the wire, and the general diameter of the spring are large enough that the annular spring is extremely rugged and durable in nature, especially when compared to the relatively light work load required of it.
[0033] The blade-opening arrowheads according to this invention are also more humane, and more lethal than prior art arrowheads. Should the arrow become lodged in the game animal, particularly when the animal has not been fatally hit, the blades will be driven or continually urged in a forward direction by the urging force of the annular spring, cutting additional tissue, which could possibly sever any nearby arteries or vital organs, and thus decrease the wounding loss. This trait of cutting additional tissue is a feature that no prior arrowhead performs. The blade-opening arrowheads, according to this invention are also structurally strong, simple and feasible to manufacture, and operable.
[0034] As has been shown in the above discussion, the blade-opening arrowheads according to this invention overcome deficiencies inherent in prior art arrowheads.
[0035] With the above objects and advantages in view, other objects and advantages of the invention will more readily appear as the nature of the invention is better understood, the invention is comprised in the novel construction, combination and assembly of parts hereinafter more fully described, illustrated, and claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] [0036]FIG. 1 is perspective view of an arrow with a blade-opening arrowhead according to one preferred embodiment of this invention attached to the forward end of the arrow shaft, with the blades in the retracted position;
[0037] [0037]FIG. 2 is a full length longitudinal cross-section of the preferred embodiment as illustrated in FIG. 1, but showing a plurality of two blades pivotally connected to the arrowhead body, with the blades in the retracted position. The annular ring and annular spring are shown in perspective view;
[0038] [0038]FIG. 3 is a full length longitudinal cross-section of a blade-opening arrowhead as illustrated in FIG. 2, showing initial rearward blade displacement occurring at initial penetration of an object;
[0039] [0039]FIG. 4 is a full length longitudinal cross-section of a blade-opening arrowhead as illustrated in FIG. 2, showing the blades rotating away from the arrowhead body after initial penetration of an object;
[0040] [0040]FIG. 5 is a full length longitudinal cross-section of a blade-opening arrowhead as illustrated in FIG. 2, showing the blades in the fully open position with the annular spring continually urging the blades forward;
[0041] [0041]FIG. 6 is an exploded full length longitudinal cross-section of a blade-opening arrowhead as illustrated in FIG. 2. The hinge pins, annular ring, annular spring and blades are shown in perspective;
[0042] [0042]FIG. 7 is a full length longitudinal cross-section of a blade-opening arrowhead according to another preferred embodiment of this invention, similar to the preferred embodiment shown in FIG. 2, but without an annular ring;
[0043] [0043]FIG. 8 is a full length longitudinal cross-section of a blade-opening arrowhead according to another preferred embodiment of this invention, showing the annular spring urging the annular ring into a notch in each blade. The hinge pins, annular ring, annular spring and blades are shown in perspective. An additional detached blade is shown also;
[0044] [0044]FIG. 9 is a full length longitudinal cross-section of a blade-opening arrowhead according to another preferred embodiment of this invention, showing an annular hinge pin slidably positioned on the arrowhead body, with substantially no gap between the blade apertures and annular hinge pin. The annular hinge pin is shown in a top view also;
[0045] [0045]FIG. 10 is a full length longitudinal cross-section of a blade-opening arrowhead similar to the blade-opening arrowhead illustrated in FIG. 9, but without an annular ring. The annular hinge pin is shown in a top view also;
[0046] [0046]FIG. 11 is a full length longitudinal cross-section of a blade-opening arrowhead according to another preferred embodiment of this invention, similar to the preferred embodiment illustrated in FIG. 9, except a gap is formed between the blade apertures and hinge pin. The annular hinge pin is shown in a top view also;
[0047] [0047]FIG. 12 is a full length longitudinal cross-section of a blade-opening arrowhead similar to the blade-opening arrowhead illustrated in FIG. 11, but without an annular ring. The annular hinge pin is shown in a top view also;
[0048] [0048]FIG. 13 is a full length longitudinal cross-section of a blade-opening arrowhead according to another preferred embodiment of this invention, showing a plurality of blades pivotally connected to the arrowhead body, with the blades in the retracted position. The annular ring and annular spring are shown in perspective;
[0049] [0049]FIG. 14 is a full length longitudinal cross-section of a blade-opening arrowhead according another preferred embodiment of this invention, similar to the preferred embodiment shown in FIG. 13, showing a plurality of blades pivotally connected to the arrowhead body, with the blades in the retracted position, but without an annular ring; and
[0050] [0050]FIG. 15 is an exploded full length longitudinal cross-section of a blade-opening arrowhead as illustrated in FIG. 13. The hinge pins, annular ring, annular spring and blades are shown in perspective.
REFERENCE NUMERALS IN DRAWINGS 16 arrow 17 nock 18 arrow shaft 19 fletching 20 blade-opening arrowhead 21 blade-opening arrowhead 22 blade-opening arrowhead 23 blade-opening arrowhead 24 blade-opening arrowhead 25 blade-opening arrowhead 26 blade-opening arrowhead 27 blade-opening arrowhead 28 blade-opening arrowhead 30 arrowhead body 32 tip 34 stem 36 blade-stop washer 38 hinge pin receiving hole, arrowhead body 40 notch, arrowhead body 42 sidewall of arrowhead body 44 notch, blade 46 second notch, blade 50 blade 52 aperture 54 inner edge, cutting edge 56 outer edge 58 distal edge 60 catch lip 62 proximal edge 64 wing 66 side of blade 68 blade slot 70 hinge pin 72 annular recess, arrowhead body 74 annular recess, blade-stop washer 76 annular recess, tip 78 abutting shoulder, arrowhead body 80 annular spring 82 annular ring 84 annular hinge pin 90 gap 100 opening force
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] FIGS. 1 - 6 illustrate a preferred embodiment according to this invention wherein FIG. 1 shows a conventional arrow 16 , having a nock 17 for receiving a bow string, an arrow shaft 18 , stabilizing fletchings 19 , and a blade-opening arrowhead 20 attached to the forward end of the arrow shaft 18 . The stabilizing fletchings 19 are helically mounted on the arrow shaft 18 , which causes the arrow 16 to spiral or rotate in flight, which greatly enhances accuracy. Blade-opening arrowhead 20 , in FIG. 1, shows a plurality of three blades 50 pivotally connected to an arrowhead body 30 , each by a hinge pin 70 that is threaded or screwed into a corresponding threaded hinge pin receiving hole 38 in arrowhead body 30 . Hinge pin receiving hole 38 passes through the opposing sidewalls of a corresponding blade slot 68 , for each blade 50 . An aperture 52 in one opposing end of each blade 50 has hinge pin 70 extending therethrough, when blades 50 are pivotally connected to arrowhead body 30 . Each blade 50 rotates between a retracted position where the edges of blades 50 are engaged and releasably latched to holding means, as shown in FIGS. 1 and 2, and an open position as shown in FIG. 5 where the other opposing blade end of each blade 50 is rotated away from arrowhead body 30 . A gap 90 is formed between each hinge pin 70 and aperture 52 , such that each blade 50 is free to move relative to corresponding hinge pin 70 and arrowhead body 30 . Hinge means connect each blade 50 to arrowhead body 30 .
[0052] Hinge means, according to this invention, are intended to comprise any suitable element or elements that serve to pivotally connect each blade 50 to arrowhead body 30 . As shown in FIGS. 1 - 8 and 13 - 15 according to some preferred embodiments of this invention, straight hinge pins 70 are received in apertures 52 located near a second blade end or a proximal blade edge 62 , of each corresponding blade 50 . As shown in FIGS. 9 - 12 according to other preferred embodiments of this invention, annular hinge pin 84 is received in apertures 52 of a corresponding plurality of blades 50 , near the second end of each blade or proximal blade edges 62 . Any shape of aperture 52 and any pin 70 , 84 , received therein will suffice for hinge means. Hinge means may comprise rod or bar stock, bearing members such as a ball bearing, and protrusions or bumps machined or formed into the arrowhead bodies 30 , and the like, and may be straight or curved such as annularly, and may accommodate, have connected thereto or have received thereon a plurality of blades 50 , or a single individual blade 50 . The hinge means according to this invention may attach to the arrowhead body 30 slidably, or be screwed or threaded on. It is apparent that apertures 52 may not communicate with the peripheral edges of blades 50 thereabout, thus creating a through hole, or that apertures 52 may communicate with the peripheral edges of blades 50 .
[0053] Referring to FIGS. 1 - 6 , wherein FIG. 2 shows a blade-opening arrowhead 20 , identical to blade-opening arrowhead 20 as illustrated in FIG. 1, but for reasons of clarity having only two blades 50 , which are superimposed upon a longitudinal cross-section or cutaway of arrowhead body 30 . Each blade 50 has a pair of blade sides 66 , and is positioned in a respective blade slot 68 that communicates with an outer sidewall 42 of arrowhead body 30 . An annular spring 80 and an annular ring 82 shown in perspective view in FIG. 2, are positioned slidably about a stem 34 of arrowhead body 30 . Annular spring 80 and annular ring 82 are positioned in an annular recess 74 of a blade-stop washer 36 and an annular recess 72 of arrowhead body 30 . Both annular recesses 72 , 74 encircle about the longitudinal axis of blade-opening arrowhead 20 . Each blade 50 when in the retracted position has an inner edge 54 extending generally longitudinally between opposing blade ends, and an outer edge 56 extending generally longitudinally between opposing blade ends. Also, a distal edge 58 extends between inner edge 54 and outer edge 56 at the first end or leading ends of blades 50 , and a proximal edge 62 extends between inner edge 54 and outer edge 56 , at the second end or hinge connecting ends of blades 50 .
[0054] Blade-stop means, such as blade-stop washer 36 , according to this invention, serve to abut outer edge 56 of each blade 50 when blades 50 are in the fully open position as illustrated in FIG. 5, thus defining the cutting diameter of arrowhead 20 . Blade-stop means according to this invention comprise any element that serves to abut against blades 50 , thus stopping their opening rotation. It is apparent that outer blade edges 56 may abut arrowhead body 30 or an equivalent, to lessen the impact forces transferred to the hinge means.
[0055] Selectively retaining blades 50 in a retracted or in-flight position according to this invention is intended to mean that the position blades 50 are placed in is selectable, or that blades 50 can be positioned in more than one position. Preferably selectable blade positions according to this invention are the retracted position and the open position. Blades 50 are securely held in the retracted position or in a first selectable position in a locked manner until acted upon by an opening force 100 , whereupon they freely rotate to the open position, or a second selectable position.
[0056] According to the preferred embodiment illustrated in FIGS. 1 - 6 , annular ring 82 is biased into or against proximal edges 62 of each blade 50 when annular spring 80 is compressed. When arrowhead 20 is tightly fastened to arrow shaft 18 , blade stop washer 36 is snugged up to both arrowhead body 30 and to arrow shaft 18 . This compresses annular spring 80 such that annular spring 80 biases annular ring 82 into blades 50 . The forward displacement of annular ring 82 and annular spring 80 is limited by an abutting shoulder 78 , as shown in FIG. 6. This biasing or compressing of annular spring 80 produces an urging force which urges blades 50 in a forward direction such that a catch lip 60 on distal blade edge 58 of each blade 50 is received or engaged in a corresponding receiving notch 40 . Notches 40 are recessed into arrowhead body 30 near the forward end of each corresponding blade slot 68 . When catch lips 60 are received into notches 40 the edges of blades 50 are releasably latched and engaged such that blades 50 are securely held selectively adjacent to arrowhead body 30 in the retracted position. When arrow 16 having blades 50 in the retracted position, as shown in FIG. 1, is shot and impacts an animal or an object, and begins initial penetration, as shown in FIG. 3, a wing 64 projecting out from blade edges 56 and 58 of each blade, catches on the animal's surface and opening force 100 drives blades 50 rearwardly. As is clearly shown in FIG. 3 at initial penetration or impact, annular spring 80 is compressed, such that gaps 90 are below hinge pins 70 , and catch lips 60 are effectively disengaged from notches 40 so that blades 50 are unlatched. As shown in FIG. 4, while penetrating the animal or object after initial impact, blades 50 begin to rotate away from arrowhead body 30 , towards the fully open position. As illustrated in FIG. 5, when blades 50 are in the open position the continual urging force produced by annular spring 80 drives or continually urges cutting edge 54 of each blade 50 in a forward direction, further slicing uncut or unpenetrated tissue. When arrowhead 20 is pulled-out from a target or a game animal blades 50 rotate from the fully open position to a non-barbing position as clearly shown in FIG. 4, wherein the angle between blade edges 56 of each blade and a point rearward of hinge pins 70 on arrow shaft 18 is greater than ninety degrees. It is apparent that wing 64 can be positioned at different locations along blade edge 56 of each blade 50 , specifically to create an open-after impact blade-opening arrowhead, as is known to the art.
[0057] Bias means according to this invention, comprise any element or elements that produce an urging force. Bias means according to this invention can comprise, but not be limited to, any resilient, compressible, deflectable, flexible, or stretchable mechanical member or members and the like, which have the ability to substantially return to their original state, such that an urging force is generated in a direction substantially opposite the direction the bias element or bias means is deformed. Bias means may include a single bias element urging a plurality of blades, or may be an individual bias element for each blade, or a combination thereof. Bias means for example, can include, cantilevers, rubber material, certain hydraulic systems and/or filled bladder systems, and springs such as compression, coil or leaf. The bias means can be fabricated of metal, plastics or composites. In the preferred embodiments according to this invention, bias means produce an urging force which is preferably strong enough to securely hold the pivotal blades 50 retained in the retracted position when exposed to incidental forces, but yet is weak enough to be quickly and immediately overcome when penetrating an object, such that razor cutting edges 54 are timely exposed, and the penetrated object is maximumly cut. According to this invention compressible annular spring 80 mounted on arrowhead body 30 to bias against the edges of blades 50 when blades 50 are in the retracted position, may include or mean that annular spring is biasing an element into the edges of blades 50 other than itself, such as annular ring 82 .
[0058] Means for continually urging cutting edges 54 of the blades 50 forward when in the open position may comprise the bias means according to this invention.
[0059] [0059]FIG. 7 illustrates blade-opening arrowhead 21 , another preferred embodiment according to this invention. Blade-opening arrowhead 21 is similar to blade opening arrowhead 20 except annular ring 82 is omitted. It is apparent that the operation of blade retention according to the scope of this invention is attainable without use of annular rings or equivalents, such as annular ring 82 .
[0060] [0060]FIG. 8 illustrates blade-opening arrowhead 22 , another preferred embodiment according to this invention which is similar to blade-opening arrowheads 20 and 21 , except blade-opening arrowhead 22 has no receiving notches in arrowhead body 30 , but rather has a notch 44 and adjacent catch lip 60 in proximal edges 62 of each blade 50 . As is clearly illustrated in FIG. 8, when blades 50 are in the retracted position catch lips 60 are positioned immediately lateral of notches 44 . To securely hold blades 50 of arrowhead 22 selectively adjacent to arrowhead body 30 in the retracted position, the urging force produced by annular spring 80 urges annular ring 82 into notches 44 and against catch lips 60 of each blade 50 . This engages each edge of blades 50 to annular ring 82 , which prevents blades 50 from rotating towards the open position prematurely or until acted upon by a sufficient opening force 100 . When arrowhead 22 is shot and impacts an animal, and begins initial penetration, wings 64 projecting out from blade edges 56 and 58 of each blade, catch on the animal's surface and opening force 100 drives blades 50 rearwardly, thus disengaging blade edges 62 and allowing blades 50 to freely rotate to the open position. It is apparent that another notch 46 can be situated in outer edge 56 of each blade near apertures 52 , such that when blades 50 are in the fully open position annular ring 82 is matingly received or engaged in such other notches. It is also apparent that annular ring 82 or annular spring 80 can contact blade edges 62 of each blade, medially of, in line with, or lateral of, the cross-sectional center of corresponding hinge pins 70 . According to this invention catch lips 60 of each blade 50 comprise a protruding point or tip and inclined sides, so that when annular spring 80 urges annular ring 82 against catch lips 60 of each blade 50 or when annular spring 80 is biased against catch lips 60 , the sides of catch lips 60 are contacting the bias means and/or holding means.
[0061] Holding means according to this invention comprise any surface or surfaces, whether integral with, or separably attachable from, arrowhead body 30 , which are capable of being in contact with a specific area or areas of the edge of each blade, to engage with such blade edge areas such that blades 50 are securely held selectively adjacent to arrowhead body 30 when blades 50 are in the retracted position. Holding means according to this invention may also comprise the blade edge or specific areas of the blade edge, in addition to the surfaces that contact the blade edges as discussed above. For example, holding means may comprise catch lips 60 and notches 40 .
[0062] According to the preferred embodiments of this invention retaining means comprise bias means and holding means, where an urging force produced from the bias means engages the holding means to the edge of each blade 50 , such that each blade 50 is securely held selectively adjacent to arrowhead body 30 when in the retracted position.
[0063] According to this invention engagement, or engaging and disengaging, of a blade edge to holding means has the intended meaning that when blades 50 are held in the retracted position the engaging areas of the blade edges are engaged with the holding means such that they are in contiguous or intimate contact with the holding means, and then when blades 50 are acted upon by a sufficient opening force 100 the specific engaging areas of the blade edges are disengaged such that they are no longer in contiguous or intimate contact with the holding means.
[0064] Releasably latching, or latching and unlatching, of a blade edge to holding means according to this invention, as used throughout this specification and in the claims, has the intended meaning that substantially no part of the blade edge of each blade is in contact with the holding means after disengagement of the holding means from the specific blade edge engaging area or areas. Contrastingly, O-rings and the like, remain in contact with the blade edges for a significant portion of the blade rotation while the blades are rotating towards the open position, wherein the more the blades rotate towards the open position the more the O-ring is stretched and further stretched, thus impeding the rate of blade opening, until the O-ring is sheared or rolls back.
[0065] According to the preferred embodiments of this invention the blade edges are engaged and disengaged to holding means. According to some preferred embodiments of this invention the blade edges are also releasably latched in addition to being engaged and disengaged, whereas in other preferred embodiments of this invention the blade edges are not releasably latched when the blades edges are engaged and disengaged. It is apparent that engaging and disengaging, and releasably latching according to this invention can be interchanged, and/or combined amongst the preferred embodiments of this invention in various different arrangements, without deterring from the scope of the invention.
[0066] In the preferred embodiment of this invention as illustrated in FIG. 8, retaining means comprise holding means and bias means, where bias means urge holding means into notches 44 and against catch lips 60 of edges 62 of each blade 50 , to securely hold edges 62 of blades 50 engaged against the holding means. Particularly, the holding means comprises annular ring 82 , and the bias means comprises annular spring 80 which urges annular ring 82 into notches 44 of each blade 50 .
[0067] Retaining means according to the preferred embodiments of this invention as illustrated in FIGS. 1 - 7 and 9 - 15 , releasably latch the edge of each blade 50 such that blades 50 are selectively held in a retracted position until penetrating an object or when subjected to opening force 100 , whereupon blades 50 are unlatched, and freely rotate towards the fully open position.
[0068] According to the preferred embodiments of this invention as illustrated in FIGS. 1 - 7 , and 9 - 12 , retaining means comprise holding means and bias means, where the bias means urge blades 50 into the holding means, to securely hold the edges of blades 50 engaged and latched against the holding means. Particularly, the holding means comprises receiving notches 40 and the bias means comprises annular spring 80 which urges catch lips 60 into notches 40 .
[0069] In the preferred embodiments of this invention as illustrated FIGS. 13 - 15 , retaining means comprise holding means and bias means, where bias means urge holding means into and against edges 58 of each blade 50 , to securely hold edges 58 of blades 50 engaged and latched against the holding means. Particularly, the holding means comprises annular ring 82 , and the bias means comprises annular spring 80 which urges annular ring 82 into notches 44 of each blade 50 .
[0070] [0070]FIGS. 13 and 15 illustrate a blade-opening arrowhead 27 according to another preferred embodiment of this invention, where annular spring 80 and annular ring 82 are housed in an annular recess 76 situated within removably attachable tip piece 32 , and annular recess 72 which is positioned near the forward end of arrowhead body 30 . Particularly, according to blade-opening arrowhead 27 bias means comprises compressible annular spring 80 biasing annular ring 82 against distal edge 58 of each blade 50 , and holding means comprises annular ring 82 . Blade-opening arrowhead 27 has substantially no gap between apertures 52 and hinge pins 70 .
[0071] [0071]FIG. 14 illustrates a blade-opening arrowhead 28 according to another preferred embodiment of this invention, similar to arrowhead 27 , except without an annular ring. Particularly, according to blade-opening arrowhead 28 as shown in FIG. 14, bias means comprises compressible annular spring 80 biased against distal edge 58 , of the first end of each blade 50 , and holding means also comprises annular spring 80 . Accordingly, holding means comprises bias means. When annular spring 80 is urged into notches 44 and against catch lips 60 of distal edge 58 of each blade 50 , blades 50 are engaged and latched in the retracted position.
[0072] FIGS. 9 - 12 illustrate blade-opening arrowheads 23 - 26 according to this invention, which are similar to blade-opening arrowheads 20 and 21 as illustrated in FIGS. 1 - 7 , except annular hinge pin 84 receives the plurality of blades 50 for each arrowhead 23 - 26 . Annular hinge pin 84 is slidably positioned in annular recess 72 around stem 34 of arrowhead body 30 .
[0073] [0073]FIGS. 9 and 10 illustrate blade-opening arrowheads 23 and 24 which have substantially no gap between apertures 52 of blades 50 and annular hinge pin 84 , wherein both the plurality of blades 50 and annular hinge pin 84 are urged together when engaging or receiving catch lips 60 into notches 40 . Particularly, blade-opening arrowhead 23 uses annular ring 82 to equally distribute the urging force to all blades 50 , whereas blade-opening arrowhead 24 does not.
[0074] [0074]FIGS. 11 and 12 illustrate blade-opening arrowheads 25 and 26 , having gaps 90 formed between apertures 52 of blades 50 and annular hinge pin 84 , wherein blades 50 are urged when engaging catch lips 60 into notches 40 . Particularly, blade-opening arrowhead 25 uses annular ring 82 to equally distribute the urging force to all blades 50 , whereas blade-opening arrowhead 26 does not. It is apparent that annular hinge pins 84 or hinge pins 70 , gaps 90 , apertures 52 , and blades 50 , can be altered or combined differently than suggested by the various disclosed embodiments of this invention, without deterring from the scope of this invention.
[0075] With reference to holding means, tip end 32 of the arrowhead bodies 30 according to this invention, may be removably attachable. For example, tip end 32 may be removably attachable to a substantially frustuconical arrowhead body 30 , as clearly shown in FIG. 2, or may be integral with arrowhead body 30 , as shown in FIG. 9. Holding means may be comprised of rigid or resilient materials or elements, and may be comprised of voids, notches, cavities, protrusions, lips, or any combination thereof that is suitable to be contiguously engaged with the engaging area or areas of the edge of each blade 50 . For example, holding means may comprise bias means. Accordingly, the engaging area of the blade edge will be configured in any sufficient shape such that when received in, or engaged to, the holding means, each respective blade 50 , is securely held in the retracted position until the arrowhead penetrates an object or the equivalent. The engaging surfaces of each blade edge and the holding means may comprise any combination of configurations of flat, convex, concave, and inclined, such as flat to flat, flat to concave, and concave to convex. For example, a rigid flat surface of the blade edge may be urged into a resilient flat rubber piece, or a flat rigid blade edge may be urged into a flat rigid area on arrowhead body 30 or the equivalent.
[0076] According to this invention, each blade is preferably housed in a respective blade slot or equivalent, configured to receive the blade or blades. The blade slot or slots, are in substantial alignment with the longitudinal axis of the arrowhead body, and may be radially or non-radially orientated. The amount each blade or a particular portion of each blade, is exposed outside the arrowhead body may vary, but will be such that the arrowhead exhibits the excellent arrow trajectory and aerodynamics, characteristic of blade-opening arrowheads, and will have a sufficient moment-arm to lever or rotate the blades quickly and freely to the open position. It is apparent that the blade-opening arrowheads according to this invention may have any number of blades, with two, three or four being preferred. It is apparent that the blade-opening arrowheads according to this invention may have stationary or fixed blades attached to the arrowhead body in combination with the pivotal blades. It is apparent that the different and various elements of this invention may be made of light weight and strong materials, such as composites, aluminum alloys, titanium alloys, stainless steels and other metals and materials. It is also apparent that the arrowhead body of the blade-opening arrowheads according to this invention may be fastened to the forward end of an arrow shaft by any method, such as threading into an insert, or glueing.
[0077] The user-friendly and durable nature of the blade retention methods according to this invention provide blade-opening arrowheads that are easy to use, failsafe and worry-free. While the arrowheads are exposed to hard use and harsh conditions in the field, the user will appreciate the simplicity and ease involved in their use. The non-consumable nature, of the blade retention methods of the present invention, allows the archer to simply push the blades back towards the retracted position to securely re-lock the blades in the retracted position, thus quickly and easily readying the arrowhead for repeated use. When compared to prior art spring elements in ruggedness, strength and durability, the annular spring of the present invention better retains its flexibility, and ability to produce an effective urging force. Also, the humanness and lethality of blade-opening arrowheads according to this invention are enhanced over conventional arrowheads, in that the razor sharp cutting edges are continually urged forward, thus providing the ability to cut more tissue.
[0078] It is apparent that different bias means, hinge means, holding means and other elements and their equivalents, as discussed above and according to other preferred embodiments of this invention, can be changed, or interchanged, or eliminated, or duplicated, or made of different materials, and connected to or associated with adjacent elements in different manners, other than suggested herein, without deterring from the desired results of the blade-opening arrowheads according to this invention.
[0079] It is to be understood that the present invention is not limited to the sole embodiments described above, as will be apparent to those skilled in the art, but encompasses the essence of all embodiments, and their legal equivalents, within the scope of the following claims. | Arrowheads, including blade-opening arrowheads as well as other non blade-opening arrowheads having a recessed collar or body that is slidably positionable about a stem portion thereof. The recess bounds and defines an internally contained void of the arrowheads. The collar is defined by having an internal centrally disposed bore extending therethrough so as to enable the collar or washer to be slidably positioned about an extending post or stem member of a corresponding arrowhead body. The collar and created internal void at least in part aid in attaching blades to the respective arrowhead bodies and serve to house various different annular elements that circumscribe the post member or equivalent. | 5 |
BACKGROUND OF THE APPLICATION
[0001] 1. Field of the Application The application relates to a method for testing an image capturing device, and, more particularly, to a method for testing whether the image capturing device is abnormal by using quality parameters.
[0002] 2. Background
[0003] Whatever kind of electronic devices, before being manufactured and sold or being installed in a system, need functional test to eliminate those under abnormal status, and along with popularization, miniaturization and versatility of image capturing device, fast and accurate functional test is increasingly important.
[0004] Most of the current test processes specialized on an image capturing device depend are tested manually. In an actual test, a test staff first uses related control devices to allow the image capturing device to be tested to capture and obtain a test image. The test image is tested for distortion or defocus, depending on the personal subjective experience and examination by naked eye to judge whether the function of image capturing device is abnormal.
[0005] However, method for testing a image capturing device depending on manual examination not only tends to misjudge and further affect yield rate, but also tends to be limited to limitation of speed of manual operation unable to test fast and further delay availability of goods and assembly process.
[0006] Furthermore, because personal subjective experience is unable to induct an uniform and objective judging standard. Thus, although abnormal image capturing device can be discovered correctly, maintenance staff, upstream firms and downstream firms can't realize where the problem is.
SUMMARY OF THE APPLICATION
[0007] In view of disadvantages of testing image capturing device by manual examination, one of the major purposes of this application lies in providing a test process solving the error of manual examination.
[0008] To achieve the purpose and other purposes, thus application provides a method for test an image capturing device, including the following steps: providing a standardized image corresponding to a specific target-object and a predetermined standard of a difference between quality parameters;
[0009] utilizing an image capturing device to capture a test image corresponding to identical specific target-object;
[0010] retrieving a plurality of standard image units and test image units at the same position from the standardized image and the test image, respectively; and comparing quality parameters of the standard image unit and test image unit at the same position, when the number of a difference between the standard image unit and test image unit exceeds the predetermined standard, judging the image capturing device as abnormality.
[0011] In an embodiment, the standard image unit and test image unit can be located at specific points or areas, and the specific points or areas can be located at the critical boundary of the standardized image and the test image. Besides, retrieving a single or a plurality of standard image unit(s) and test image unit(s) at the same position can be retrieving single or a plurality of standard image unit(s) and test image unit(s) at the same coordinates, and actual implementation of this application is able to be implemented by related automation equipment matched with test software.
[0012] Compared to current test technology of examining image capture device by manual examination, because thus application utilizes quality parameters to compare standard image unit of standardized image and test image unit of test image at same position and can be realized by automation equipment matched with test software. Thus, this application can not only solve the problem of error generated by manual examination, but also examine function of image capturing device with uniform judging standard, so the disadvantages in prior art can be avoided.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 is a flow chart of a method for testing an image capturing device of a first embodiment according to the present invention;
[0014] FIG. 2 is flow chart of a method for testing an image capturing device of a second embodiment according to the present invention;
[0015] FIG. 3 shows quality parameters analyzed from a standard image unit by capturing a standard image unit from a standardized image; and
[0016] FIG. 4 shows quality parameters analyzed from a test image unit by a capturing test image unit from a test image.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] The following explains this application by specific embodiments, whoever has ordinary knowledge in the technical field of this application can easily understand advantages and efficacy of the application from the specification.
[0018] FIG. 1 shows a flow chart of a method for test an image capturing device of a first embodiment according to the present invention. Notice that the method for test an image capturing device provided according to the present invention can be implemented by related automation equipment matched with test software.
[0019] Step S 11 provides a predetermined standard of a difference between a standardized image and quality parameters corresponding to a specific target-object, and then enters step S 12 . In an embodiment, the specific target-object can be an object or picture with an obvious color-level difference, and the standardized image is the comparison standard for testing image capturing device to be tested.
[0020] Step S 12 utilizes a testing image capturing device to be tested to capture a test image corresponding to identical specific target-object, and then enters step S 13 . In an embodiment, step S 11 and step S 12 can be optionally implemented at the same time for coping with different test environments.
[0021] Step S 13 retrieves a plurality of standard image units and test image units at the same position from the standardized image and the test image, respectively, and then enters step S 14 . In an embodiment, the standard image unit and test image unit are located at specific points or areas in the standardized image and the test image, respectively, and the specific points or areas can be located at a critical boundary of an image in the standardized image and the test image.
[0022] In detail, if a specific target-object is a picture with an obvious color-level difference, then pictures belong to a standardized image and test image have an obvious color-level difference likewise, and meanwhile the specific points or areas can be set on the critical boundary of an image in a different color-level. Retrieving a plurality of standard image units and test image units at the same position can be implemented by coordinates, that is, retrieving a plurality of standard image units and test image units with same coordinates.
[0023] Step S 14 compares quality parameters of a standard image unit and a test image unit at the same position, judging the image capturing device as abnormality when the difference of quality parameters between a standard image unit and a test image unit exceeds the predetermined standard. In an embodiment, the quality parameter can correspond to, but are not limited to, resolution, luminance or color.
[0024] In detail, if there are ten standard image units and test image units retrieved and the predetermined standard can be set as 50 %, under this standard, after comparing all quality parameters of standard image units and test image units at the same position. If there are over five standard image units and test image units has different quality parameters, then further judge the function of image capturing device as abnormality. Of course, the predetermined standard can be adjusted corresponding to different considerations of cost or requirements from manufacturers. Because the standard image unit and test image unit can be located on the critical boundary of an image, abnormality such as distortion and defocusing can be judged much faster.
[0025] FIG. 2 shows a flow chart of a method for testing an image capturing device in a second embodiment according to the present invention. Notice that step S 21 and step S 22 in FIG. 2 are the same as step S 11 and step S 12 in FIG. 2 , further description hereby omitted.
[0026] Step S 23 retrieves a single standard image unit and a test image unit from a standardized image and a test image, respectively, and then enters step S 24 . In short, step S 23 is not necessary to retrieve a plurality of standard image units and test image units at the same position like step S 13 .
[0027] Where step S 23 and step S 13 in common lies in standard image unit and test image unit can likewise and respectively be locate at specific points or areas, and the specific points or areas can likewise be located on the critical boundary of an image in the standardized image and the test image.
[0028] Step S 24 compares quality parameters of the standard image unit and test image unit, and judges the image capturing device as abnormality when the difference of quality parameters between the standard image unit and test image unit exceeds the predetermined standard.
[0029] For example, presume that predetermined standard is ten units of quality parameters, the image capturing device can be judged as abnormality when the difference of quality parameters between a standard image unit and a test image unit exceeds ten units of quality parameters. The quality parameter can likewise correspond to, but are not limited to, resolution, luminance or color.
[0030] For further understanding of the method for testing an image capturing device, please refer to FIG. 3 together with FIG. 4 . FIG. 3 shows quality parameters analyzed from a standard image unit by a capturing standard image unit from a standardized image. FIG. 4 shows quality parameters analyzed from a test image unit by capturing a test image unit from a test image.
[0031] In FIG. 3(A) , the image with a white area (W) and a black area (B) is a standard image, and a standard image unit A 1 is located within the white area (W). As illustrated in FIG. 3(B) , a standard image unit A 1 is analyzed as three primary colors “110,110,110,” that is, quality parameters corresponding to color are analyzed.
[0032] In FIG. 4(A) , the image with a white area (W), a black area (B) and a gray area (G) is a test image, and a test image unit A 2 is located on the critical boundary of an image between the white area (W) and the black area (B), wherein the position of test image unit A 2 is the same as that of the standard image unit A 1 . As illustrated in FIG. 4(B) , a test image unit A 2 is analyzed as three primary colors “148,148,148,” that is, quality parameters corresponding to color are analyzed.
[0033] For example, presume that a predetermined standard is set as ten units of quality parameters, meanwhile because quality parameters of a test image unit A 2 corresponding to color exceeds quality parameters of a standard image unit A 1 corresponding to color by ten units of quality parameters, such as 148+148+148−110−110−110>10, thus, an image capturing device is judged as abnormality. Of course, a plurality of standard image units A 1 and test image units A 2 by ten can be respectively captured, and a predetermined standard is set that an image capturing device is judged as abnormality when the difference of a number of parameters between a standard image unit A 1 and a test image unit A 2 exceeds five.
[0034] To sum up, because this application can utilize quality parameters to compare a single or a plurality of standard image unit(s) and test image unit(s) at the same position in the standardized image and test image, actually implementing operation by automation equipment matched with test software. Thus, this application can not only implement test process for image capturing device fast and correctly, but also examine the function of image capturing device with uniform and objective judging standard. Compared to current test technology for image capturing device by manual examination, this application avoid disadvantages of typically occurred misjudgment, tending to delay process and that no uniform and objective judging standard can be inducted.
[0035] However, method for testing image capturing device depending on manual examination, not only tends to misjudge and further affect yield rate, but also tends to be limited to limitation of speed of manual operation unable to test fast and further delay availability of goods and assembly process.
[0036] Furthermore, because personal subjective experience is unable to induct an uniform and objective judging standard. Thus, although abnormal image capturing device can be discovered correctly, maintenance staff, upstream firms and downstream firms cannot realize where the problem is.
[0037] The embodiments are only illustratively explain the theory and efficacy of this application rather than limiting this application. Whoever has ordinary knowledge in the technical field of this application can modify or alter the application without violation of the spirit and scope in the application. Thus, rights protection of the application should be listed as the following claims. | A method for testing an image capturing device with quality parameters includes providing a predetermined criteria for the variations in images and quality parameters corresponding to a specific target-object, capturing a test image corresponding to the same target object by an image capturing device to be tested, and retrieving a standardized image and a test image located at the same position by a standard image unit and a test image unit, respectively, thereby comparing quality parameters of the standard image unit and the test image unit on the same position to accurately detect and determine any abnormity in the image capturing device. | 7 |
This application is a continuation of application Ser. No. 07/347,889 filed May 23, 1989 now abandoned.
INTRODUCTION
This specification describes a modular, hollow floor panel which when laid over a structural sub-floor, allows reticulation of electrical and communications cabling, without significantly increasing the height of the finished floor level.
It has a major application in automated office buildings, where the extensive use of computing and communications equipment has created a need to locate cabling throughout open office areas, and it is an alternative to the raised "access flooring" used in computer areas which has a depth of several hundred millimeters.
PRIOR ART
In current building practice the problem of within-the-floor cable access to points on an open-plan floor Is solved by one of three methods:
1 in-floor ducted grids, which are typically cast into the floor slab, and consist of one-channel, two-channel or three-channel duct grids linked by cross-over boxes, and which have outlets provided at regular intervals. Australian patent no. 521,913 is an example of such a system. The ducts must be relatively widely spaced, and so the floor has limited cable-carrying capacity.
2 cellular floors, which utilise hollow cells built into the floor slab. The cells are fitted with outlet boxes at regular intervals and cables are fed along the cells (or "raceways") from a "header trench" which sits flush with the floor and is typically located along a wall or a corridor. Examples are Australian patent no. 410,965 and U.S. Pat. No. 2,445,197.
These systems have a greater flexibility in the location of outlets, but cable access between two adjacent points along the floor is only possible by routing the cable up one cell, along the header trench, and down the adjacent cell. Recent developments have included the system described in Australian specifications 48,697/85 and 32,227/85. (Specification 48,697/85 describes a header-trench module and specification 32,227/85 describes a cellular raceway module.) This is a low-height floor laid onto the structural slab, but is generically a cellular floor of the type described above, and suffers from the same disadvantages.
3 raised access floors, which conventionally consist of 600 mm ×600 mm deck panels supported at each corner on adjustable-height pedestals. An example is Australian patent 462,745. Such floors provide optimum accessibility and cable capacity, but are expensive, and create difficulties because of their height. They also require some form of cable guides to maintain order and to segregate power, telephone and data services.
DESCRIPTION OF THE INVENTION
The purpose of this invention is to provide a low-height access floor which will allow both lateral and longitudinal cable access to any point on the floor, and which has integral ducting which will provide continuous structural support to the deck, and a means of segregating services, and a means for creating orderly cable layouts.
Whereas the primary application of the invention is to floors in buildings (and the descriptions herein assume this), it should be understood that there are some situations where the system can be used on walls or cellings (for example in sound studios) and so the invention is not limited to floor applications.
The invention is now described with reference to the drawings, in which:
FIG. 1 is a plan view of one corner of a segmented panel which has a single-level cavity for the purpose of carrying services conduits;
FIG. 2 shows a section A--A through FIG. 1;
FIG. 3 is an isometric view of the panel shown in FIGS. 1 and 2;
FIGS. 4 and 5 show alternative cross-sections A--A in which the panel is of composite construction;
FIG. 6 is a plan view of one corner of a segmented panel which has a single-level cavity for the purpose of carrying services conduits, similar to the construction shown in FIG. 1, but assembled-from triangular segments;
FIG. 7 shows a section B--B through FIG. 6;
FIG. 8 shows an alternative cross-section B--B with a floor finish in place:
FIG. 9 is an isometric view of the panel shown in FIGS. 6, 7 and 8;
FIG. 10 is a plan view of one corner of a segmented panel which has triangular deck segments supported on a moulded base;
FIGS. 11, 12 and 13 show alternative cross-sections C--C through FIG. 10;
FIG. 14 shows a relocatable floor panel with a services outlet mounted on the deck;
FIG. 15 shows a method by which the floor panel system can be intergrated with in-floor outlet boxes;
FIG. 16 shows a plan view of the corner of a panel with interlocking keys on the sides and two levels of cable cavities;
FIG. 17 shows a cross-section D--D through FIG. 16;
FIG. 18 shows an isometric view of cover strips to protect the upwardly opening channels of the panel shown in FIGS. 16 and 17;
FIGS. 19 and 20 show plan views of panels which have diagonal cable channels in addition to orthogonal channels;
FIG. 21 shows a part section through a panel with a services outlet located beneath the deck surface;
FIG. 22 shows a plan-view of the panel shown in FIG. 21;
FIG. 23 shows an isometric view of a panel with two sets of ducts, each perpendicular, and located one above the other;
FIG. 24 shows a plan-view of the construction shown in FIG. 23;
FIG. 25 shows a cross-section through a levelling tray which can be used in conjunction with panels of the type shown in FIGS. 23 and 24;
FIG. 26 shows an isometric view of a panel based which has a series of upper ducts with continuous troughs, which interconnect with ducts on the underside of the panel base via vertical ducts located on each side of the upper ducts;
FIGS. 27 and 28 show details of two methods of connecting the deck to the base;
FIG. 29 shows a detail of one method of fixing the panel to the floor; and
FIG. 30 shows an isometric view of a transition piece to interconnect respective channels of adjacent but orthogonally arranged panels according to FIG. 26.
The panel can take a number of forms. The first type of construction is illustrated in FIGS. 1, 2 and 3, in which:
FIG. 1 is a top view of a corner of the panel,
FIG. 2 is a cross-section of the panel at line A--A, and
FIG. 3 is an isometric projection of the panel.
This panel has a flat upper surface, and the underside is criss-crossed with a series of "vaults" (1) which define channels through which the cabling may be laid. The channels occur in at least two directions: a first set of channels runs laterally from one side of the panel to the other, and a second set of channels runs longitudinally from one end of the panel to the other. Diagonal and vertical channels are also possible, and formations with these features will be described later. Between the said vaults, there are slits (2) which divide the panel into an array of rigid sub-elements in the form of pedestals, which are inter-connected by small cross-sections of material (3). This allows the panel to flex and to accommodate undulations in the surface of the structural sub-floor. The inter-connections are shown as occurring on the upper surface of the panel, but they may occur on the lower surface of the panel (see FIG. 5) or at any point on the sides of the pedestal sub-elements.
The vault size depends on the size of cable or conduit to be accommodated, but is limited by the rigidity of the bridge over the vault. In general a rigid construction material will allow wider vault spans and thinner bridge thickness (and hence thinner panel thickness) but an Inelastic construction material is more susceptible to brittle fracture, noise transfer, and rocking on an uneven sub-floor surface.
FIG. 4 illustrates a variation in which a rigid plate (4) is incorporated in the upper surface of each sub-element. The purpose of this is to increase the load-bearing capacity of the sub-element, and is applicable to panels formed from a semi-rigid base material such-as a rubber compound. The plate is illustrated as being flat, but it may be ribbed, folded or curved to increase its structural rigidity and to improve the key to the base material. It may also be provided with one or more holes to facilitate the passage of cables through the surface of the panel.
As an extension of the concept illustrated in FIG. 4, the upper body of the panel may be constructed from a strong and inelastic material, and the lower portion of the legs constructed from a flexible material, thus providing the panel with a flexible base. This is illustrated in FIG. 5. In this construction the panel may be divided into rigid sub-elements as before, but the inter-connections between the segments may be provided within the flexible base material.
The second type of construction is illustrated in FIGS. 6, 7, 8 and 9.
This second type of construction differs from the first in that additional slits (5) are provided which divide the panel into triangular sub-elements (6). Triangular sub-elements have the advantage of accommodating to an uneven sub-surface, and this type of construction is applicable to the use of rigid materials such as pressed steel, cast aluminium, or rigid plastics.
FIGS. 6 to 8 indicate construction from a cast or moulded material such as aluminium or rigid plastic, in which each triangular sub-element (6) has stiffening ribs (7) along its deck edges. As with other constructions the panel surface (or deck) may be provided with cable transit holes (9).
The panel construction illustrated in FIG. 8 has the floor finish (8) (in this case carpet) integral with the panel. As the floor finishing element is continuous, it can be utilised to inter-connect the panel sub-elements, and so in this case the previously described panel inter-connections (3) are not mandatory.
It is possible to form this type of panel in the manner shown in FIG. 4, in which the panel is constructed from a resilient material, and has rigid stiffening plates incorporated in the upper surface of each triangular sub-element. It is also possible to form the panel in the manner of FIG. 5 in which deck segments constructed from rigid material are provided with flexible feet.
A third type of construction is illustrated in FIGS. 10, 11, 12 and 13.
This panel construction comprises a lower section (10) with pillars (11) which locate and support a removable upper section (12). The lower section maybe constructed from a rigid or a semi-rigid material such as injection-moulded plastic, and it may be segmented to allow it to adapt to undulations in the structural floor surface. The deck, which must be rigid across the spans between the pillars, may be continuous, or divided with flexible connections along the joints between each pillar (into for example square or triangular shapes), or it may consist of discrete sub-elements which may be individually removed or replaced.
In the example shown in FIG. 11 the removable deck (12) is segmented into triangular sub-panels, each of which have clips which interlock with the pedestals (11). The deck segments are attached to a flexible membrane.
FIG. 12 illustrates a slightly different form of construction in which the upper surface (12) of the panel is pinned or screwed to the lower section of the panel.
FIG. 13 shows an arrangement in which the deck segments are formed with down-turns at each corner which engage into the pillars, which are hollow.
It should be noted that FIGS. 11, 12 and 13 merely illustrate three examples by which the upper and lower sections of the panel may be connected to one another. In all of the constructions described in this specification the deck may be attached to the base with other devices such as keys, clips, adhesive or "velcro" strip; or the upper section may be loose-laid onto the lower section with optional horizontally engaging keys to prevent shear between the upper and lower sections.
In use, the panels are laid on a structural sub-floor, and cabling is reticulated within the vaults of the panels from service points on the building structure to the required location of the service outlet. At the required location of the service a fixed service point may be provided, for instance by coring through the panel deck to allow cable access, and attaching the outlet over the panel and fixing it through to the structural sub-floor. Alternatively the service outlet may be incorporated into the panel itself. FIG. 14 illustrates a panel which incorporates a service outlet (13) and a length of cable (14), which connects to a permanent service outlet. Such a panel may be located at some distance from the permanent service outlet, and can be attached permanently to the floor or it can be made removable, and this will allow it to be easily relocated.
FIG. 15 illustrates a permanent services point which is located within the structural floor and which can be used in conjunction with the relocatable service panel illustrated in FIG. 14. In FIG. 15, the services connection points (15), (16) are located in a box (17) sunk into the structural floor. The box is provided with a rigid removable lid (17) which has cut-outs (18) at the edges to allow passage of the services cables from the panel vaults into the box itself.
In floor tiling systems of the type described previously it may be desirable to interlock the panels, in order to prevent vertical mis-alignment between adjacent panels, and to prevent incorrect orientation in the case of panels which have asymmetrical duct locations.
FIGS. 16 and 17 Illustrate one means of achieving interlocking between panels, in which the side faces of the panels (19) have incorporated on them convex dimples (20) alternated with concave dimples (21). The panels will interlock if on abutting faces each convex dimple aligns with a corresponding concave dimple.
Other forms of interlocking may be used to achieve this purpose, for example male-female connections of the form used to connect pieces in a jig-saw puzzle, or alternate snap-in plugs and sockets, or hooks which extend from alternate faces of each panel and engage In sockets formed in the body of the panel.
The interlocking devices can be designed so as to allow individual panels to be withdrawn from the body of the floor, for example by flexing of the panel to achieve a disengagement of the interlocking devices. Alternatively, in the case of panels with a detachable deck, the keys can be formed by offsetting the deck. The panel can in this case be removed by first disengaging the deck, and then extracting the base.
FIGS. 1 and 4 illustrated a panel which comprises rigid sub-elements joined by thin connections (3) which will allow the panel to flex along the lines of the slits (2). FIGS. 16 and 17 illustrate an arrangement in which in addition to the slits (24), small channels (25) may be formed in the upper surface of the panel, and this will create an alternative location for cabling. These channels should be narrow in cross-section to maximise the support to the overlying floor finish, but of sufficient size to allow the passage of small-diameter cable such as telephone wiring or optical fibre. This will allow these cables to be separated from cables underneath the panel by the body of the panel itself.
The upper channels (25) may also be provided with overhangs (25a) which will improve support to the floor finish and which will retain and protect any cabling in them.
Additionally the upper channels may be provided with cover strips to protect the cabling ana/or to support the overlying floor finish. FIG. 18 illustrates a segment of one possible cover-strip arrangement, which allows alternate cable troughs to carry different services, and which provides physical separation of each service.
In this arrangement, the lower cover (26)--which may for instance carry telephone cabling--has set-downs (27) to allow the separated passage of another cable network--for instance data--and which can be protected by an upper cover (28). Note that the set-downs (27) will require the channel (25) in the region of the channel intersections to be deeper than in the areas away from the intersection (in this case over the vaults).
Although FIG. 18 illustrates cover-stripping in a grid arrangement, it is of course possible to form the covers from simple extruded sections which can be cut to cover the cables as required. They may be "U" shaped in cross-section or they may for instance be flat (or slightly bowed) strips which engage in grooves or ledges on the sides of the channels.
The channels and the covers may be marked or coloured to distinguish the various cable networks that they are intended to contain.
Whilst FIG. 18 illustrates a two-channel cover system, the principle can be extended to create three or more separated channel networks. It is also possible to delete the vaults (1) and the slits (24), so that all the cable channels will be located on the upper side of the panel. Although this will require the use of larger channel widths and structurally rigid cover strips, the arrangement will remove the need for access to the underside of the panels, which may then be glued to the floor.
The panel may be provided with channels on the underside which are orthogonal to the sides of the panel, or diagonal to the sides of the panel, or both. FIG. 19 is a view of the underside of a panel with both orthogonal channels (28) and diagonal channels (29) which intersect in areas (30). Such a combination of channels allows cables to be reticulated in various directions, at 45° increments. It also permits cables to be turned about a larger radius of curvature than would be possible if there were no diagonal channels.
There is a trade-off involved in this arrangement however--as the span of the vaults is increased, the span over the intersection of the vaults (30) becomes quite large, and this necessitates the use of thicker cross-sections and more rigid materials in order to achieve the required rigidity of the flooring surface.
One means of reducing the arch spans is illustrated in FIG. 20, which is a plan view of a panel with an alternative vault configuration. In this arrangement the spacing between vaults has been increased, and both sets of vaults have been offset so that no more than two channels intersect at any one point. This decreases the maximum spans over the vault sections and thus allows the use of thinner panel cross-sections and softer material of manufacture. Note that in this arrangement the channels may be formed on either the underside of the panel or on the upper side.
A "service panel" was previously described (FIG. 12) which incorporates a services outlet and which can be located at any position on the floor. A variation to this should be noted in which the service outlets are located within the body of the panel. FIG. 21 is a section through part of such a panel, in which services outlets (31) are located in a cavity (32) which may be covered by a plate (33). With this and with the previously designed panel the extension leads may be permanently wired into the outlet,, or they may be detachable via plug connections. Considerations relating to these are described below.
A services panel may also be-designed to operate as a secondary terminal, to which services outlet panels can be connected. FIG. 22 is a plan view of such a secondary terminal panel, in which cabling (34) is brought into a junction box (35), and thence to a connector (36), for instance a female pin-connector. The junction box and connectors may be integral with the panel or separate from it, but it is preferable that they are contained within the thickness of the panel. Again with reference to FIG. 22, the secondary terminal panel may be provided with a cavity (37) in which plugs to the services outlet panel are located. A removable segment or a cover-plate may be used in or over this cavity when a services outlet panel is not connected.
In order to comply with wiring regulations it may be necessary to ensure that intermediate connections in the wiring such as the connection at the secondary terminal to the services outlet panel cannot be accidentally broken. Nevertheless it is desirable to use a removable plug as the means of connection, so that outlets may be relocated without requiring the assistance of an electrician.
One means of securing the plug against accidental disconnection is to make the connecting plug or plugs the same size as the plug cavity (37); thus the abutting panel (38) will prevent the plug from being withdrawn. Alternatively, the connecting plugs may be screwed to the junction box, or inserted in a vertical axis so that they will be restrained by the panel itself or by the flooring.
Both the secondary terminal panel and the services outlet panel may be provided with thermal detectors, overload detectors and/or circuit breakers.
A critical need of the various licencing authorities is that the various trunk cable networks within the floor-space are physically separated from each other. When the networks run only in one direction (for instance perpendicular to the walls) and are thus parallel to each other, separation can be achieved by physical spacing of the panels, or by providing solid barriers between vaults or groups of vaults, so that in effect the channels run in only one direction. Such a "tunnel-vault" panel could have a cross-section similar in principle to e.g. FIG. 2, but of extruded construction.
One means of allowing different cable networks to cross each other without passing through the same space is to provide the "tunnel-vault" panel described above with a second set of channels above the tunnel vaults, but at right-angles to them. FIGS. 23 (isometric projection) and 24 (plan view) show such a construction, which has lower channels (40) and perpendicular upper channels (41), which are connected by holes or knock-out panels (42). The holes or panels can be arranged so that each upper channel or group of channels can be uniquely linked to one or a group of lower channels.
In these illustrations there are shown two upper channels or ducts for every lower channel or duct. This arrangement has the advantage that the spans of the overlying deck are reduced, and it can be made thinner. A 2:1 ratio is not essential, however; a 1:1 or a 1:2 ratio may be equally satisfactory from the point of view of cable distribution.
This panel form can be constructed in a number of ways, for example by attaching two extrusions at right-angles, with permanent or removable connections. The panel shown in FIGS. 22 and 23 would be of injection-moulded construction, with a separate deck (43). This deck may be loose-laid or permanently attached or removably attached, and it may be attached over its full area or at the centre or for example along one edge. It may also incorporate the floor finish. In the case of a partially attached deck it may be provided with weakening grooves (44) over the supports or at right-angles to them which would enable it to flex upwards to provide access to the upper channels. The deck may also be fabricated with the upper channels (41) formed as vaults an its underside, so as to form two half-panels joined at the mid-line. This may allow the panels to be fabricated entirely from extruded sections.
The panel shown in FIG. 23 may be permanently or removably attached to the sub-floor. It is advantageous to glue it to the sub-floor around the centre of the panel, and in this case grooves (44), (45) may be provided through the walls of the lower vaults, to allow the panel to be curled upwards so as to allow access to the lower vaults from above.
Removable areas (46) may be provided In the walls of the channels in non-structural areas to permit the passage of cables from one channel to the adjacent channel, to improve flexibility and to permit larger radii of curvature from the upper channels to the lower channels.
In the case of a panel comprising a rigid deck and an injection-moulded base, it will be too rigid to adapt to undulations in the sub-floor. Small irregularities may be taken up by bedding the lower ribs in high-build adhesive (46), but in the case of a very uneven sub-floor it may be advantageous to seat the panels in levelling trays. Such an arrangement is shown in FIG. 25, which shows a panel (48) seated in a levelling tray (47). The ribs of the panel (49) are held between ribs (50) on the levelling tray, which provide support, and containment of levelling compound (51).
In all of the arrangements described In this document, the cabling may be introduced into the sub-flooring system in either of two ways--the cable may be laid along its intended route, in which case the cable route must be exposed by lifting the deck or lifting the panel itself so that the cable can be laid, or alternatively the cable may be fed along Its intended route, in which case the panel can remain undisturbed. The first method allows greater flexibility and the use of smaller and shallower cable channels, but the second method will minimise disruption to the room and the floor, and will allow the use of broadloom carpet rather than removable tiles.
The panel shown In FIG. 23 Is fairly simple in construction, but it is difficult to feed wires along the upper channels, because of the natural tendency of the wire to fall through the connecting hole into the lower channel.
An improvement on this basic principle is shown in FIG. 26, which shows a moulded panel base to be used in conjunction with a removable deck, and perhaps with a levelling tray as shown in FIG. 25.
In this arrangement, sets of ducts are provided along three axes at right-angles to each other. A lateral duct set 61, 62, 63 lies along the underside of the panel base, a longitudinal duct set 51, 52, 53 lies along the upper side of the panel base at right angles to the lower ducts, and the vertical duct set 71, 72, 73 extends from the lower duct set, on each side of the upper horizontal ducts. As shown in FIG. 26, each longitudinal duct 51, 52, 53 has an imperforate lower surface.
Each duct set is made up of a number of sub-sets; preferably three in number, to carry power, telephone and data services respectively.
Where a vertical duct abuts an upper horizontal duct of the same sub-set, an opening occurs between the two ducts (which may take the form of a knock-out panel); but where a vertical duct abuts an upper horizontal duct of a different sub-set, no opening occurs.
Thus each lower duct sub-set is connected to the corresponding upper duct sub-set via a vertical duct, and by such selective interconnections a series of physically separate duct networks are created.
In the example of FIG. 26 the upper duct (51) is dedicated to power cabling, and inter-connects with lower ducts of the same sub-set (61) via vertical ducts (71) to create a power conduit grid. Similarly, duct sub-sets 52, 62, 72 form a telephone conduit grid, and duct sub-sets 53, 63, 73 form a data conduit grid.
It will be seen that in addition to the major advantage of this arrangement that cables can be fed along the upper ducts with less risk of deflecting into the lower ducts, a number of further advantages accrue. Firstly, the arrangement provides regular access to each lower duct to enable control of cable feeding without the need to lift all or part of the panel. Secondly, the arrangement allows greater turning radii, of the order required for co-axial cables and optical fibre. Thirdly, the vertical ducts provide superior access to services outlets on the-deck above the panel.
Although FIG. 26 shows three sets of ducts (for power, telephone and data), this number may of course be varied.
In addition, there may b& several levels of horizontal ducts. Advantages can be gained by providing four layers of horizontal ducts, with the upper two layers having narrow and closely spaced ducts to reduce distances between possible services outlet points, and with the lower two layers having wide ducts to maximise cable carrying capacity and bending radii. Alternatively the panel may be constructed with a level dedicated to each service. This will remove the need for dividing ribs, and will permit cables to be run in any direction on their particular level, thus allowing shorter cable runs.
By utilising the sides of the panel base shown in FIG. 26, extending clips may be formed to attach the floor decking to the panel. FIG. 27 illustrates in detail the clips (80) which may be provided on the edges of the panel in FIG. 26. These clips can be disengaged from the decking panel to allow its temporary removal, and if they are asymmetrical on each side (e.g., of different heights or in different relative locations) the decking will be unable to be mis-oriented when it is replaced. This will allow the decking to have preformed outlets, or to be marked with the locations of the services ducts in the panel underneath, so that services can be accessed through drilled holes without the need to remove the panel.
FIG. 28 shows an alternative method of attaching the deck to the base, in which the base has formed on It, hollow upstands (84) which when a peg or screw (83) is Inserted into them, expand against the deck (82).
Other forms of attachment are also possible, such as screw-fixing into the base, or variations of FIG. 28 in which the peg (83) is formed integral with the upstand (84), to create a form of "snap-lock".
FIG. 29 shows a method of forming the base of the ribs so as to increase the surface area of the tile which bears onto the sub-floor, in which the rib has a foot (85). It should be noted that in constructions which have a foot or bearing pad, it is also possible to form thickened ribs, or double ribs which then connect to each side of the foot, rather than to the centre. These constructions have the advantage of creating column-like elements which are superior in transferring load from the deck to the sub-floor.
FIG. 30 shows a transition piece which enables one area of floor which is laid with upper ducts running In one direction to be connected with another section of floor in which the upper ducts run at right-angles. It is laid in a line along the junction of the two areas, and in the orientation shown in FIG. 30, the lower edge of the sloping trays (91) fits against the lower ducts (61), (62), (63) of the floor panel. It can, however, be mounted upside-down to create a joint-line along the adjacent face of the panels. | A modular panel, which in use is laid in a continuous two-dimensional array over a supporting sub-surface to form a hollow floor, wall or ceiling suitable for reticulating electrical, optic-fibre, hydraulic and other conduit. The panel having upper and lower duct zones each partitioned by lateral ribs and longitudinal ribs respectively. The upper duct zone being in communication with the lower duct zone by way of vertical duct sets. | 5 |
FIELD OF THE INVENTION
The present invention relates to a positioning hinge, particularly to a positioning hinge for pivoting between a main unit and an LCD display of a portable computer or electronic dictionary, which can adjust the pivot orientation of the LCD display.
BACKGROUND OF INVENTION
LCD displays of conventional portable computers are generally pivotally assembled on main units by a pair of hinges. U.S. Pat. No. 6,108,868 issued on Aug. 29, 2000 to Davys Lin discloses a positioning hinge having a cam block and a resilient friction member mounted on a pivotal base. The resilient friction member resiliently presses against the surface of the cam block to achieve the purpose of adjusting the orientation of the LCD display relative to the main unit. It is true that the '868 patent successfully achieves its predetermined purposes. However, because its resilient friction member is mounted on the pivotal member, the friction between the resilient friction member and the cam block has an undesirable, sudden change due to the complicated contour of the cam surface. That is, as the peripheral surface of the cam block diminishes in diameter, the friction force will be greatly reduced at the same time. This results in an unsmooth swinging of the LCD display. In details, the torsion spring constantly has a great torsion force during the swinging of the LCD display. When the LCD display suddenly stops due to the pivot positioning effect, the great torsion force in the torsion spring will shake the main unit and the LCD display due to the inertia in the display. In view of this defect, there is a need to provide an improved positioning hinge having a cushioning mechanism so as to obtain a relatively longer life.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an improved positioning hinge having the following advantages: (a) it provides a resilient swinging operation to the LCD display; (b) it allows a user to adjust the orientation of the LCD display when the display is resiliently swung to a predetermined viewing angle so as to adapt to ambient lighting; (c) it provides a smooth swinging operation to the LCD display so as to correct the positioning defects between the main unit and the display; and d) it provides a cushioning mechanism to the friction structure so as to reduce the wear between the hinge components.
To achieve the above intended purposes, the positioning hinge according to the present invention essentially comprises a pivotal member, a pivotal base, a first torsion spring and a friction device.
According to one embodiment of the present invention, the pivotal member is secured to a main unit and has a rotary shaft having a rotary axis. The pivotal base is secured to the LCD display and essentially includes a first support through which the rotary shaft passes so that the rotary shaft can pivot thereabout. The torsion spring has two ends which bias against the pivotal member and pivotal base, respectively, thereby providing a torsion force to allow the pivotal base to rotate with respect to the pivotal member so as to result in a relative pivotal movement between the display and the main unit. The positioning element formed with a friction surface is non-rotatably installed around the rotary shaft. The resilient compression member includes a slide-friction member and a resilient mechanism, wherein the resilient mechanism is provided between the pivotal base and the slide-friction member so that there is always a cushioning frictional contact between the slide-friction member and the positioning member.
The above and other features and advantages of the present invention may be realized from the accompanying drawings and the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a first embodiment of the present invention;
FIG. 2 is an assembled perspective view of the embodiment of FIG. 1;
FIGS. 3A-3D are schematic views illustrating the positioning hinge being assembled to a portable computer;
FIG. 4 is an exploded perspective view of a second embodiment of the present invention;
FIG. 5 is an exploded perspective view of a third embodiment of the present invention;
FIG. 6 is an assembled perspective view of the embodiment of FIG. 5;
FIG. 7 is an exploded perspective view of a forth embodiment of the present invention; and
FIG. 8 is an assembled perspective view of the embodiment of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate a positioning hinge 1 according to a first embodiment of the present invention. The positioning hinge 1 generally comprises a pivotal member 10 , a pivotal base 20 , a first torsion spring 30 , a friction device 40 and a fastening member R.
The pivotal member 10 comprises a mounting end 12 and a rotary shaft 14 . The mounting end 12 may further comprise holes H for mounting the pivotal member 14 to a main unit M (see FIGS. 3 A- 3 D). The rotary shaft 14 having a rotary axis preferably extends to a cylindrical shape.
The pivotal base 20 comprises one or one pair of mounting part(s) 22 and at least one first support 24 . The mounting part 22 mounts the pivotal base 20 to an LCD display D (see FIGS. 3 A- 3 D). The support 24 is formed with a pivotal opening 26 through which the rotary shaft 14 passes. The pivotal base 20 is assembled to the pivotal member 10 through the pivotal opening 26 which allows the pivotal base 20 to rotate about the rotary axis of the pivotal member 10 between a first position (i.e., the LCD display being at a closed state) illustrated in FIG. 3A and a second position (i.e., the LCD display being at an open state) illustrated in FIGS. 3B-3D.
The first torsion spring 30 provided around the rotary shaft 14 has a first end 32 and a second end 34 biasing against the pivotal member 10 and the pivotal base 20 , respectively, to provide a torsion force to allow the pivotal base 20 to rotate about the pivotal member 10 . The couplings between the first end 32 and pivotal member 10 and between the second end 34 and the pivotal base 20 may be achieved by various structures. For example, it is preferable to provide a notch-type mounting ring 16 having a notch 18 on the pivotal member 10 and a tab 28 on the pivotal base 20 .
The friction device 40 comprises a positioning element 50 and a resilient compression member 60 . The positioning element 50 comprises a friction surface 52 and a through hole 54 . The friction surface 52 generally shapes as a cam sidewall surrounding the rotary axis. The through hole 54 is configured to facilitate the positioning element 50 being non-rotatably assembled to the rotary shaft 14 .
The resilient compression member 60 comprises a slide-friction member 62 and a resilient mechanism 64 . The slide-friction member 62 has a longitudinal axis supported by the pivotal base 20 and a contact surface 62 a directly contacting the friction surface 52 of the positioning element 50 . The resilient mechanism 64 biases the slide-contact member 62 between the pivotal base 20 and the positioning element 50 . The resilient mechanism 64 preferably consists of at least one of disk springs 64 a and slit-type disk springs 64 b . Other appropriate resilient mechanism 64 includes arc-shaped resilient washers (not shown), wavy-shaped resilient washers (not shown), or a single spiral spring (not shown).
After the members ( 10 , 20 , 30 , 40 ) are assembled to the pivotal member 10 , a ring-type fastening member R may be provided to secure these members in place so as to constitute the positioning hinge 1 . The ring-type fastening member R may be replaced by a nut-type fastening member N (see FIG. 4) or a collar-type fastening member C (see FIG. 5 ).
FIGS. 3A-3D are schematic views illustrating the operational states among the LCD display D, main unit M, positioning element 50 and resilient compression member 60 after the positioning hinge 1 is assembled to the computer. Before the LCD display D is swung open, the LCD display D is maintained at a closed position (FIG. 3A) adjacent to the main unit M by means of fastening means (such as fasteners); the first torsion spring 30 (not illustrated in FIGS. 3A-3D) is under a torsion state, and the positioning element 50 has a smallest radius at this state in which the disk springs 64 a,b are in a relaxed condition. As a user opens the LCD display D by pushing a release switch or by other methods, the torsion energy in the torsion spring 30 will urge the LCD display D to swing up automatically such that the pivotal base 20 rotates about the pivotal axis until the swinging action slows at a position where the positioning element 50 slightly increases in radius (FIG. 3 B). At this state, the disk springs 64 a,b withstand a pressure from the positioning element 50 due to the increased radius and the resilience of the disk springs 62 a,b forces the contact surface 62 a to keep in a closer contact with the friction surface 52 . FIG. 3C illustrates an example operating viewing angle (which is larger than 90 degrees) where the swinging action stops and the positioning element 50 has a greater radius than the radius shown at the state of FIG. 3 B. Finally, the user may further adjust the LCD display D to attain an optimum viewing angle. In the illustrated examples of FIGS. 3A-3D, disk springs 64 a,b continue to resiliently pressure the slide-friction member 62 . It is preferable that the swinging operation from FIGS. 3A-3C results in a smoothly-increased friction urging by the disk springs 64 a,b , while the swinging operation form of FIGS. 3C-3D continues this resilient urging so as to maintain a greater friction force.
FIG. 4 illustrates a second embodiment of a positioning hinge 100 according to the present invention, which comprises a pivotal member 110 , a pivotal base 120 , a torsion spring 130 and a friction device 140 .
The pivotal member 110 comprises a mounting end 112 and a rotary shaft 114 . The pivotal base 120 comprises a mounting part 122 and a first support 124 . The first support 124 is formed with a pivotal opening 126 . The first torsion spring 130 is provided around the rotary shaft 114 and has a first end 132 and a second end 134 biasing against the pivotal member 110 and the pivotal base 120 , respectively. The friction device 140 comprises a positioning element 150 and a resilient compression member 160 . The resilient compression member 160 comprises a slide-friction member 162 and a resilient mechanism 164 . The slide-friction member 162 has a longitudinal axis supported by the pivotal base 120 . The resilient mechanism 164 biases the slide-contact member 162 between the pivotal base 120 and the positioning element 150 .
FIGS. 5 and 6 illustrate a third embodiment of a positioning hinge 200 according to the present invention. The positioning hinge 200 comprises a pivotal member 210 , a pivotal base 220 , a first torsion spring 230 , a friction device 240 including a positioning element 250 and resilient compression member 260 , and a fastening member C. The pivotal member 210 comprises a mounting end 212 , a rotary shaft 214 , and a notch-type mounting ring. The pivotal base 220 comprises at least one mounting part 222 and at least one first support 224 . The first torsion spring 230 has a first end 232 and a second end 234 biasing against a notch 218 of notch-type mounting ring 216 and the pivotal base 220 , respectively. A sleeve S may be fitted into the first torsion spring to avoid the leakage of the lubricant oil. The resilient compression member 260 comprises a slide-friction member 262 and a resilient mechanism 264 . The slide-friction member 262 has a longitudinal axis supported by the pivotal base 220 . The resilient mechanism 264 biases the slide-contact member 262 between the pivotal base 220 and the positioning element 250 . When the pivotal base 220 rotates, the slide-friction member 262 will slide on the friction surface 252 of the positioning element 250 , thereby traveling along its longitudinal axis depending on the ups or downs of the friction surface 252 under the biasing of the resilient mechanism 264 . The operation of positioning hinge 200 is identical to that shown in FIGS. 3A-3D.
The slide-friction member 262 preferably further comprises a tuning device ( 266 , 268 ) that couples with the pivotal base 220 to limit the axial movement of the slide-friction member 262 . The tuning device ( 266 , 268 ) allows a user to manually adjust the tightness degree of contact between the slide-friction member 262 and the positioning element 250 . The tuning device preferably consists of a threaded portion 266 formed on the slide-friction member 262 and a nut 268 mating with the threaded portion 266 .
As the invention has been particularly described with respect to preferred embodiments thereof, persons skilled in the art will understand that the above and other changes in form and detail may be made without departing from the scope and spirit of the invention. | A positioning hinge for providing pivotal positioning is disclosed.
The positioning hinge comprises a pivotal member, a pivotal base, a first torsion spring and a friction device. The friction device includes a positioning element and a slide-friction member, which are kept in a resilient friction contact with each other by means of a resilient mechanism. This enables the LCD display to be opened due to the pivoting action of the pivotal base under the results of resilience and frictional positioning. It is appreciated that the above features advantageously result in an appropriate reduction in the opening speed of the LCD display while at the same time obtaining a steady frictional pivotal positioning, thereby prolonging the working life of the positioning hinge. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to window coverings, and more particularly pertains to an insulating sheath which is of a flexible and reusable construction and which may be utilized to reduce air leakage through a window opening.
2. Description of the Prior Art
The use of flexible window coverings is known in the prior art. At the present time, flexible plastic may be purchased commercially for the purpose of covering window openings. This is especially desirable during periods of extreme temperature. More particularly, flexible plastic which is sealed over a window opening reduces the loss of air conditioning during hot summer months while retaining heat within a structure during the cold winter season. While these types of window coverings are known in the prior art, there are no commercially available connectors which facilitate an easy and efficient attachment of such plastic sheathing over a window opening. Usually, a user must nail, staple, glue, tape, or utilize some other known conventional means of attaching the plastic sheathing over a window and quite frequently, substantial air leakage still exists after the plastic is in place. Accordingly, it can be appreciated that there exists a continuing need for new and improved means for attaching such plastic sheathing over a window opening and in this regard, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of window coverings now present in the prior art, the present invention provides an improved insulative window covering construction wherein the same can be easily and efficiently attached over an existing window opening so as to provide added protection against air leakage both into and out of an enclosed structure. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved reusable insulating sheath for windows which has all the advantages of the prior art insulating sheaths and none of the disadvantages.
To attain this, the present invention essentially comprises a flexible and reusable plastic window covering which is designed to be selectively attached over an existing window opening to reduce or eliminate air leakage and drafts. Either hook and loop fasteners or locking strips can be used to attach the plastic sheath over a window opening and, if desired, the sheath can be provided with a zipper to allow air flow through the window. Special locking strips can be used to securely attach the flexible sheath over a window opening while facilitating an easy removal when required.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved reusable insulating sheath for windows which has all the advantages of the prior art reusable insulating sheaths for windows and none of the disadvantages.
It is another object of the present invention to provide a new and improved reusable insulating sheath for windows which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved reusable insulating sheath for windows which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved reusable insulating sheath for windows which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such reusable insulating sheaths for windows economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved reusable insulating sheath for windows which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a front elevation view of the reusable insulating sheath for windows comprising the present invention.
FIG. 2 is a cross-sectional view as viewed along the line 2--2 in FIG. 1.
FIG. 3 is a cross-sectional view as viewed along the line 3--3 in FIG. 1.
FIG. 4 is an isometric view of the invention.
FIG. 5 is an isometric view of a modified connecting structure utilizable with the invention.
FIG. 6 is an exploded end elevation view of the modified connecting structure.
FIG. 7 is an end elevation view of a modified locking insert used with the connecting structure shown in FIG. 5.
FIG. 8 is an isometric view of a rigid spring structure utilized in the modified locking insert shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1-4 thereof, a new and improved reusable insulating sheath for windows embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be seen that the reusable insulating sheath 10 essentially comprises a rectangularly-shaped sheet of transparent, flexible sheeting 12 positionable over an existing window opening as desired. Of course, the plastic sheath 12 may be manufactured in any desired shape and could be provided by special order to fit virtually any known type and shape of commercially available window structure. As such, the plastic sheath 12 shown in FIGS. 1 and 4 is for illustrative purposes only, and it is to be understood that any shape and size of such sheath could be provided to the consuming public.
With further reference to FIGS. 1-4, sheath 12 is illustrated as having a reinforced edge structure 14 to provide additional strength as required. This reinforced edge 14 could be achieved by a number of different means, to include thickening the edge to a greater extent than a central transparent portion of the sheet 12 or otherwise embedding a layer of mesh or independent fiber materials within the plastic. This embedded mesh or fiber 16 would reduce the transparency of the sheath 12; however, since the embedded mesh or fibers would be provided only around the edge 14 of the sheath, no loss of transparency through the viewing section thereof would be apparent. In the case of utilizing independent fibers 16, one embodiment envisions the use of metallic fibers of a ferrous construction, thereby to provide additional strength to the edge 14 as well as to be magnetizable or attracted to a magnetic structure as will be subsequently described in greater detail.
To attach the transparent sheet 12 over a window opening, a hook and loop fastening means is utilized. In this respect, strips of hook fasteners 18 provided with a tape attachment means 20 can be positioned around a peripheral edge of an existing window opening. The tape 20 is provided with a removable backing 22 so as to expose the adhesive surface of the hook material 18, thereby to facilitate a conventional attaching of the material around the window. Similarly, a loop fastener strip 24 is adhesively attached around the peripheral edge 14 of the sheet 12 in a manner which allows its precise alignment with the existing hook material 18. As is now apparent, the sheath 12 can be easily attached by the hook and loop fasteners 18, 24 over an existing window opening, and can just as easily be removed when desired. Recognizing that it is somewhat cumbersome to selectively remove and reattach the sheath 12 over an existing window opening through the use of the hook and loop fastening means 18, 24, the sheath may be provided with a zipper structure 26 which allows an occasional opening of the sheath without its removal from the window. This zipper structure 26 could extend around the entire peripheral edge of the sheath 12, whereby a section thereof could be completely removed or, as shown in FIG. 4, it may extend only partially around to allow a partial opening of the sheath.
Alternative means for attaching the sheath 12 over a window opening is shown in FIGS. 5 and 6. This alternative embodiment of connecting means which is generally designated by the reference numeral 28 includes a base member 30 having a strip of outdoor double backed tape 32 secured to a bottom surface thereof. A base member 30 is utilized to replace the hook fasteners 18 as shown in FIG. 4, whereby the base extends completely around the existing window opening, and the base includes an internal axially aligned slot 34 having first locking grooves 36 on one side of the slot and second locking grooves 38 on an opposed side of the slot. The locking grooves 36, 38 extend the entire length of the slot 34 and are designed to assist in the retention of the locking insert 40 which will be subsequently described in greater detail. Base 30 further includes an upstanding wall portion 42 which is integrally a part of the base and which includes a plurality of downwardly extending, integral teeth 44 designed to grip a sheath 12.
FIGS. 5 and 6 further illustrate the aforementioned locking insert 40 which is of an elongated construction and which is designed to engage the base 30 so as to retain a sheath 12 in position over a window opening. The locking insert 40 includes a downwardly extending leg portion 46 having continuous, axially aligned notches 48, 50 on opposed external surfaces thereof. Additionally, on a rear surface of the locking insert 40, downwardly extending teeth members 52 are integrally formed thereon and extend over the entire length of the locking insert.
In use, the base member 30 is attached around the periphery of a window opening by means of the outdoor double backed tape 32. When so positioned, a sheath 12 of transparent plastic is positioned against the upstanding wall member 42 and pressed into engagement with the downwardly extending teeth 44. A locking insert 40 is then slid into the slot 34 in the direction of the arrow 54 so as to effectively cause a gripping of the sheath 12 between the upstanding wall member 42 and the teeth 52 formed on the locking insert. As is now apparent, the locking notches 48, 50 are respectively engageable with and retained within the locking grooves 36, 38 whereby the locking insert 40 cannot be removed from the base 30. At the same time, the downwardly extending teeth 52 on the locking insert 40 and the downwardly extending teeth 44 on the upstanding wall member 42 effectively grip and retain the plastic sheath 12 in engagement within the slot 56 defined between the locking insert and the upstanding wall member. With this type of connection achieved around the entire peripheral edge 14 of a window covering sheath 12, a sealed and firm gripping thereof over a window opening is achieved.
FIGS. 7 and 8 illustrate a further modified embodiment of the invention which is essentially a modified embodiment of the locking insert 40 illustrated in FIGS. 5 and 6. This modified embodiment of locking insert is generally designated by the reference numeral 58. As shown, the locking insert 58 is identical in all respects to locking insert 40 shown in FIGS. 5 and 6 with the exception that a stiffening spring member 60 is molded within the structure of the locking insert. Recognizing that the locking insert 58 might be of a somewhat flexible construction in some cases, such as being manufactured from flexible rubber or plastic, it is desirable in those cases to provide some rigidity to the downwardly extending teeth 52. This is particularly important when substantial pressure differentials might be experienced over a window opening whereby the sheath 12 might be pulled out of the slot 56 as shown in FIG. 6. When the locking insert 58 is manufactured from a flexible rubber or plastic material, the teeth 52 could yield upwardly so as to release their grip on a sheath 12 and to prevent this, a metal spring tree 60 is integrally molded within the structure of the locking insert 58.
As best illustrated in FIG. 8, the locking spring tree 60 could have any number of downwardly extending leaves 62 wherein each of these leaves are integrally or otherwise attached to a flat plate member 64. With proper positioning within the insert 58, the leaves would limit upward flexing of the teeth 52 in a now apparent manner. Additionally, in those cases where the edge structure 14 of a sheath 12 is reinforced with metallic fibers comprising a ferrous material, a plurality of small magnets 66 could be attached or otherwise formed within each leaf member 62. These magnets 66 would provide an even further gripping and sealing of a sheath 12 over a window opening inasmuch as the metallic fibers 16 would be magnetically attracted to the magnets 66 to achieve this additional gripping function.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A flexible and reusable plastic window covering is designed to be selectively attached over an existing window opening to reduce or eliminate air leakage and drafts. Either hook and loop fasteners or locking strips can be used to attach the plastic sheath over a window opening and, if desired, the sheath can be provided with a zipper to allow air flow through the window. Special locking strips can be used to securely attach the flexible sheath over a window opening while facilitating an easy removal when required. | 4 |
This application claims benefit of provisional application 60/042360, filed Mar. 26, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electrical connectors and particularly to printed circuit board connectors.
2. Brief Description of Prior Developments
Electrical connectors for connecting small panel-like electrical devices, such as circuit boards or liquid crystal displays (LCD) to another circuit board are known. One such connector employs an insulative body having a slot for receiving an LCD module. A linear array of connector terminals are mounted on the body. The spring portions disposed at one end of the terminals are located along the slot to engage circuit contact pads on the LCD. The other ends of the terminals are wrapped about the connector body and extend in a fixed position along a bottom edge of the connector body to form bottom contacts. Because the bottom contacts have no compliance, it is necessary to utilize a sheet of elastomeric material between the bottom of the connector body and the circuit board. The elastomeric body is provided with appropriate conductive traces to electrically connect the bottom contacts with appropriate contacts on the printed circuit board. The connector is held compressed against the elastomeric material by a compressive force, typically generated by the portion of the housing in which the LCD is mounted. It is common to apply an adhesive to hold the connector secure onto the LCD. The use of conductive elastomers and adhesives adversely affects the ease and cost of manufacturing devices, such as portable hand held electronic devices that have visual displays, such as cellular telephones.
SUMMARY OF THE INVENTION
The electrical connector of the present invention includes an insulative body comprising a first portion and a second portion extending generally perpendicularly from the first second portion. The connector also includes a conductive means comprising a retention section and a resilient section. The conductive means is retained by the second portion of the insulative body and the resilient section extending adjacent the first portion of the insulative body. The connector may be interposed between a planar electrical device and a printed circuit board.
BRIEF DESCRIPTION OF THE DRAWINGS
The electrical connector of the present invention is further described with reference to the accompanying drawings in which:
FIG. 1 is a front elevational view of a connector embodying the invention;
FIG. 2 is a side elevational view of the connector shown in FIG. 1;
FIG. 3 is a back elevational view of the connector shown in FIG. 1;
FIG. 4 is a bottom view of the connector shown in FIG. 1;
FIG. 5 is a cross-sectional view taken along line AA of FIG. 3;
FIG. 6 is an enlarged view of area B of FIG. 1;
FIG. 7 is an enlarged view of area C of FIG. 4;
FIGS. 8a-8f are sequential illustrations of manufacturing and installation steps related to the connector of FIG. 1; and
FIGS. 9a and 9b show positions of the connector of FIG. 1 during application and use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be described in the context of a connector specifically adapted for electrically connecting planar electrical devices, such as LCD's, to another circuit board. However, the invention is believed to have applicability in other connectors.
FIG. 1 shows a connector 10 having a body 12 formed of a molded polymeric insulating material. The body 12 includes a vertically extending leg portion 14 and a generally horizontally extending top portion 16. The connector also includes a plurality of suitable conductive metal terminals 18, preferably formed by stamping.
Each terminal 18 includes a cantilevered spring contact portion 20 for engaging an electrical device, as will later be described. Terminals 18 further include a retention portion 22 (FIG. 5), where the terminal 18 is retained in the body 12. Each terminal further includes a downwardly extending resilient beam portion 24 extending along the rear of the body 12. At the bottom of each terminal 18 is a PCB contact portion 26 for engaging contact pads on a printed circuit board, as will later be explained. As can be seen in FIG. 5, the PCB contact section 26 is formed as a curved surface having an outside radius that contacts the printed circuit board. Adjacent the contact portion 26 is an opposed pair of retention ears 28 and 30 (FIG. 7), the upper portions 29 and 31 (FIG. 6) of which are bent inwardly to form radiused surfaces, such as surface 32 (FIG. 8d).
As shown in FIGS. 3, 4 and 8a-f, grooves 34 are formed in the back of the housing 12 for receiving the portions 24 of beams 18. Additionally, undercut portions 36 are formed in opposing relationship in each groove 34. The undercut portions 36 form shoulder surfaces 38 that are designed to engage the surfaces 32 of terminal 18, as will later be described.
In FIG. 8a, the connector 10 is shown in a intermediate stage of manufacture. In this stage, an array of terminals 18 in coplanar, side-by-side relationship may be formed by stamping from terminal sheet stock. As shown in the figure, the ends of the terminals 18 have been preliminarily bent to form the contact portion 21 of the cantilevered spring arm 20 and the printed circuit board contact portion 26. The connector body 12 is preferably formed by overmolding or insert molding the connector body 12 onto the array of terminals 18, so that the terminals are securely held in the body 12.
Referring to FIG. 8b, the cantilevered spring portion 20 has been formed by bending. Also, the beam portion 24 is formed by applying a force in the direction of arrow Fl at or near the tip of the section 24 to bend the section 24 about a bend radius formed generally in the area of region 39. Eventually, the beam portion 24 is bent toward the full line portion shown in FIG. 8c. At this time, force F1 is maintained on the end of the beam 24. At the same time, a force F2 is applied to the mid-section of the beam to extend the length of the beam to position the tip section 26 toward the dotted line position shown in FIGS. 8c and 8d. At this time, the surface 32 of each of the ears 28, 30 is positioned in general alignment with the shoulder surfaces 38. After the force F2 is removed, the beam retracts so that the surfaces 32 of the ears 28, 30 are retained against the shoulder surfaces 38. In this manner, the portion 26 is located and a desired amount of preload is imparted on it.
When a force the direction of arrow F2 is applied, the beam lengthens in the direction of arrow Ll. Conversely, when the force F2 is removed, the spring force in the beam returns the beam to its original shape, thereby shortening the length of the beam and raising the contact section 26 toward the connector body 12.
FIG. 8e shows the connector 10 substantially in a rest position, with the printed circuit board contact portion 26 extending beneath the housing. FIG. 8f shows the connector in mated condition, wherein a force in the direction of arrow F3 holds the connector 10 against the substrate 40 causing the beam 24 to be buckled. The resulting deflection generates a normal force pressing contact portion 26 against PCB 40. In addition, a force applied in the direction of arrow F4 to the LCD 42 causes the contact section 20 to deflect, thereby generating a normal force pressing contact portion 21 against LCD 42.
As shown in FIG. 9a, in a typical application, a frame 44 is provided to support the LCD 42 and the connector 10. In this arrangement, the LCD 42 is supported on portions (not shown) of the frame 44 and the connector 10 is inserted into the frame 44 by pushing the leg 14 of the connector through an aperture or recess in the frame 44. To accomplish this, a force in the direction of arrow F6 is placed on the connector 10 to insert the connector into the frame. In doing so, a retention tang 46 formed on the back of the connector body 12 is forced past the retention edge 48 of the opening. In this condition, the cantilevered beam contact 20 and the buckling beam 24 are deflected to a maximum extent, as the bottom edge of the connector is pressed against the surface of the printed circuit board 40. This figure also illustrates the action of the connector if, after assembly, a downward force is applied to the connector/LCD assembly, as by pressing downwardly on the LCD. An advantage of this construction is that the electrical connection at the level of contact portion 26 is maintained, even though a relatively high compressive force is repeatedly applied to connector 10. FIG. 9b shows the final mated position of the connector 10 wherein the retention tang 46 is retained against the surface 48 and the connector 10 has moved upward slightly away from the PCB 40, as a result of the spring force in beam 24.
It is to be further noted that the printed circuit board contact portion 26 undergoes a wiping and rolling action during this operation, to effect proper electrical connection with contact pads on PCB 40. This occurs as a result of the imposition of a vertical force on the beam section 24, which causes the section 26 to move along the surface of PCB 40 in the direction of arrow F5 (FIG. 9a). As this occurs, the contact portion 26 also rotates about a contact point between radius 32 and shoulder surface 38.
The connector disclosed has many advantages. The arrangement provides a relatively long spring travel using only a small area of the footprint of the connector. It also provides simplified locating and pre-loading of the contact portion 26. It further allows a contact wiping and cleaning action, thereby providing good contact. Further, this approach eliminates the need for conductive elastomeric members between the connector and the PCB.
While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims. | An electrical connector which includes an insulative body which has a leg portion and a top portion which extends generally perpendicularly from the leg second portion. A conductive contact which includes a retention section and a resilient section is also included in the electrical connector. The contact is fixed to the top section and the resilient section extends along the leg section. The connector may be interposed between a electrical device and a printed circuit board. | 8 |
FIELD OF THE INVENTION
The invention relates to metallized flexible laminate films, and bags made therefrom for packaging and protecting static sensitive devices, i.e. electronic components such as circuit boards. The bag is made of a thin metal layer and a layer of an antistatic polymeric film. More particularly, the instant invention provides for improved inter-layer adhesion between the metal film and the antistatic film. Moreover, the instant bags work surprisingly well even though the metal outside has a relatively high surface resistivity, which is contrary to the teachings of prior patents. The bags provide excellent protection from the discharge of electrical voltage, not allowing it to couple to an electronic component inside the bag.
BACKGROUND OF THE INVENTION
Some prior patents on metallized envelopes for protection of electronic components are U.S. Pat. No. 4,154,344 (Parent) and U.S. Pat. No. 4,156,751 (Divisional), both issued to Yenni et al, assignors to 3M. Both patents relate to envelopes having an inside antistatic surface with a surface resistivity of 10 8 to 10 14 ohms/square, a core insulative sheet with a volume resistivity of at least 10 10 ohm-centimeters, and an outside metal conductive surface with a surface resistivity not greater than 10 4 ohms/square. The 3M patents and the publicly available file histories thereof teach this outside surface has a surface resistivity of no greater than 10 4 even if there is a polymeric abrasion protection coating on the metal. For instance, 3M's commercially available 2100 bag has from bag outside to bag inside the structure: nickel/insulative polyester/adhesive/antistatic film of LDPE containing antistat. (The patents say the antistat is Ampacet No. 10069.) The nickel bag outside is coated with an ultrathin polymeric abrasion protection coating and still at ambient humidity and temperature the 2100 bag exhibits on the nickel outside a surface resistivity of 10 4 ohms/square. Such bags are referred to as "metal out".
Also of interest is U.S. Pat. No. 4,756,414 issued in 1988 to Mott, assignor to Dow Chemical. This patent relates to a bag or pouch having a first and second antistatic layer, which antistat layers are the electron beam radiation cured product as taught by British Published patent application 2,156,362 (which is the counterpart of U.S. Pat. No. 4,623,594 issued November 18, 1986 to Keough, assignor to Metallized Products). This electron beam radiation cured antistat film is sold by Metallized Products under the registered trademark Staticure. As per '414, these antistatic layers are bonded along their primary surfaces so that the secondary antistatic surface of one will form the bag outside and the secondary antistatic surface of the other will form the bag inside. At least one primary surface has on it a metal conductive layer, which then due to the sandwiching structure is an internal core of the bag layers. Commercial products like this are referred to as "metal in". For instance, a "metal in" structure is Dow's commercial Chiploc-ES bag, which from the bag outside to the bag inside is of the structure: Staticure/insulative polyester/metal/Staticure /LDPE. Another commercial "metal in" structure is what Fujimori sells as their NONSTAT-PC bag, which from the bag outside to the bag inside is of the structure: antistatic layer/insulative polyester/metal/antistatic layer.
Also of interest is U.S. Pat. No. 4,407,872 issued in 1983 to Horii, assignor to Reiko. This patent relates to an envelope for packaging electronic parts, the envelope having an outside layer of plastic and an inner metal film layer, the metal layer having electrical resistance less than 10 8 ohms/square centimeter. Optionally on the envelope inside is a heat-sealable resin film layer laminated onto the metal film layer. This also creates a "metal in" sandwich of the structure: plastic layer/metal layer/heat sealing layer.
OBJECTS
Accordingly, it is an object of the invention to provide flexible sheet material, said sheet material comprising a metal layer adhesively laminated to an antistatic polymeric layer, said antistatic layer being made of a film of carboxylic acid copolymer and quaternary amine, said antistatic film being permanently antistatic. It is another object to provide such a sheet material of improved metal layer to antistatic layer adhesion. The sheet material is adaptable for forming a package, bag, envelope, or the like, for receiving an electrostatically sensitive item. When the electrostatically sensitive item is packaged in the sheet material, the package will prevent the capacitive coupling of voltage through the package outside to the item, even though the metal outside of the package has a high, non-conductive surface resistivity of no less than about 10 8 ohms/square at ambient conditions of about room temperature and 40 to 60% relative humidity. At a "dry" RH of about 15% or less, the surface resistivity on the outside of the package will be no less than about 10 11 ohms/square.
It is also an object of the present invention to provide a method for improving interlayer adhesion between the metal layer and the antistatic polymeric layer of a flexible sheet material adaptable for forming a package, bag, envelope, or the like, for receiving an electrostatically sensitive item. The method involves adhesively laminating the antistatic layer to the metal. It is a feature of the present method that the antistatic layer is made of a film of carboxylic acid copolymer and quaternary amine, said antistatic film being permanently antistatic. The antistatic film defines the inner surface and the metal layer defines the outer surface of the package, bag, envelope or the like.
SUMMARY OF THE INVENTION
Therefore, the present invention provides a flexible sheet material adaptable for forming a package, bag, envelope, or the like, for receiving an electrostatically sensitive item, said sheet material having an outer surface and an inner surface, said sheet material comprising a metal layer adhesively bonded to an antistatic polymeric layer, (a) said antistatic layer defining the inner surface and said metal layer defining the outer surface of the package, bag, envelope or the like, (b) said outer surface providing a high non-conductive surface resistivity no less than about 10 8 ohms/square at ambient conditions of about room temperature and 40 to 60% relative humidity, whereby said metal layer and said antistatic layer in combination will provide static protection for the electrostatically sensitive item as determined by a capacitive probe test of discharging 1000 volts direct current onto the outer surface, by preventing the voltage from capacitively coupling to the electrostatically sensitive item; and (c) wherein the antistatic layer is made of a film of carboxylic acid copolymer and quaternary amine, said antistatic film being permanently antistatic, whereby said sheet material is of improved metal layer to antistatic layer adhesion.
The present invention also provides a method for improving interlayer adhesion in a flexible sheet material adaptable for forming a package, bag, envelope, or the like, having an outer surface and an inner surface, said sheet material having a metal layer adhesively bonded to an antistatic polymeric layer, said antistatic layer defining the inner surface and said metal layer defining the outer surface of the package, bag, envelope or the like, the method comprising adhesively laminating the antistatic layer to the metal layer, where the antistatic layer is made of a film of carboxylic acid copolymer and quaternary amine, said antistatic film being permanently antistatic, and said outer surface providing a high non-conductive surface resistivity no less than about 10 8 ohms/square at ambient conditions of about room temperature and 40 to 60% relative humidity, whereby said metal layer and said antistatic layer in combination will provide static protection for the electrostatically sensitive item as determined by a capacitive probe test of discharging 1000 volts direct current onto the outer surface, by preventing the voltage from capacitively coupling to the electrostatically sensitive item.
Also, the present invention provides a packaged electrostatically sensitive item protected from electrostatic charges comprising a static sensitive item having conformed thereabout a flexible sheet material, said sheet material having an outer surface and an inner surface, said sheet material having a metal layer bonded to an antistatic polymeric layer, said antistatic layer defining the inner surface and said metal layer defining the outer surface of the package, (a) said outside surface providing a high non-conductive surface resistivity no less than about 10 8 ohms/square at ambient conditions of about room temperature and 40 to 60% relative humidity, whereby said metal layer and said antistatic layer in combination will provide static protection for the electrostatically sensitive item as determined by a capacitive probe test of discharging 1000 volts direct current onto the outer surface, by preventing the voltage from capacitively coupling to the electrostatically sensitive item; (b) wherein the antistatic layer comprises a film made of carboxylic acid copolymer and quaternary amine, said antistatic film being permanently antistatic, whereby said sheet material is of improved metal layer to antistatic layer adhesion.
Also, the invention provides a flexible sheet material adaptable for forming a package, bag, envelope, or the like, for receiving an electrostatically sensitive item, said sheet material having an outer surface and an inner surface, said sheet material comprising a metal layer adhesively bonded to an antistatic polymeric layer, (a) said antistatic layer defining the inner surface and said metal layer defining the outer surface of the package, bag, envelope or the like, and (b) said antistatic layer being a multi-ply film having an antistat-free surface ply, the metal layer and antistat-free ply being in adhesive contact.
Also, the invention provides that in a metallized electronic packaging film having a metal layer and an antistatic layer, the antistatic layer is made of a film of carboxylic acid copolymer and quaternary amine, said antistatic film being permanently antistatic, whereby said sheet material is of improved metal layer to antistatic layer adhesion.
Preferably, the metal layer is first deposited on a polymeric insulative layer such as polyester, and this insulative layer is then adhesively bonded to the antistatic layer. The resultant is of the structure: metal/insulative layer/adhesive/antistatic layer.
DETAILED DESCRIPTION OF THE INVENTION
The laminate of the invention, which may be made into envelopes, bags, pouches, and the like for the packaging of static sensitive devices comprises a thin metal layer adhesively laminated to an antistatic polymeric layer.
Suitable metals include, but are not limited to, aluminum, stainless steel, copper, nickel, and mixtures thereof. Preferably the thickness of the metal should be not greater than about 300 angstroms (about 0.0012 mil), more preferably less than about 200 angstroms (about 0.00079 mil), most preferably less than about 125 angstroms (about 0.00049 mil). The thinner the metal layer, the more transparent is the finished bag of metal laminated to antistatic layer. Of course, it is more desirable that the bag be transparent enough so that code numbers printed on the circuit board packaged in the bag can be read.
Suitable thicknesses for the antistatic layer are from about 1 mil to 5 mils (25 microns to 125 microns), preferably about 2 to 4 mils {50 to 100 microns). The antistatic layer is made as per the permanent antistatic films of quaternary amine antistatic agent in a polymer containing carboxylic moieties, such as quaternary amine (QA) in ethylene acrylic acid copolymer (EAA) or in ethylene methacrylic acid copolymer (EMAA), as shown in U.S. patent application Ser. No. 143,885 (Parent) and Ser. No. 249,488 (continuation-in-part), both to Havens and Roberts, assignors to W. R. Grace & Co.-Conn., the disclosures of which are incorporated herein by reference. These two were combined for one foreign filing and their publicly available counterpart is European patent application Publication No. 0324494 published in European Patent Bulletin No. 1989/29, on Jul. 19, 1989. The U.S. Applications and EP Publication 0324494 disclose a film, which film has permanent, non-bleeding antistatic characteristics. By "permanent, non-bleeding" antistatic characteristics is meant the film exhibits a static decay time (hereinafter abbreviated as SDT) under about 3000 milliseconds (hereinafter abbreviated as ms) when the static decay test using 5000 volts direct current (hereinafter abbreviated as Vdc) is performed as per Federal Test Method 101c, Method 4046.1, after a 24-hour water shower, i.e. the antistat property is not washed out by the shower. In the preferred embodiments, the film will also still have this SDT of about 3000 ms or less even after 12 days in a hot (approximately 70° to 71° C.) oven. This antistatic film may be of 5 plies or layers, each ply containing the quaternary amine antistatic agent. Such a 5-ply film is commercially available as EPG-112 from the Cryovac Division of W. R. Grace & Co.-Conn. Optionally, an alternative version of EPG-112 having one or more antistat-free plies may be laminated to the metal. For instance, this version may have an antistat-free surface, wherein EPG-112 has been made with a surface ply free of antistat, this surface ply being a polyolefin. Suitable polyolefins for the one or more antistatfree plies include, but are not limited to, low density polyethylene (LDPE), linear low density polyethylene (LLDPE), ethylene-vinyl acetate copolymer (EVA), high density polyethlyene (HDPE), and the like, or mixtures thereof.
Also, these permanently antistatic films comprising carboxylic acid copolymer and quaternary amine adhesively laminated to aluminum/polyester are disclosed in commonly assigned copending U.S. Ser. No. 450,646 filed Dec. 13, 1989 to inventor Havens, the disclosure of which is incorporated herein by reference. Also, for clarity, pertinent portions of U.S. Ser. No. 450,646 are repeated here.
Between the metal layer and the antistatic layer, there may be a polymeric insulative layer. Preferably, this is a polyester such as a layer of polyethylene terephthalate (PET) or its glycol modified derivative (PETG), or of nylon. This insulative layer should be about 0.2 to 1 mil (about 5.08 to 25.4 microns) thick, preferably about 0.3 to 0.7 mil (about 7.62 to 17.78 microns) thick. Suitable laminates of aluminum metallized polyethylene terephthalate are commercially available from companies such as Scharr or National Metallizers, which aluminum metallized PET can then be laminated to EPG-112 (or laminated to an alternative version of EPG-112). The commercially available laminates of metallized PET are typically made by sputter deposition or vacuum deposition of the metal onto the PET.
As per U.S. Ser. Nos. 143,885 and 249,488 and their counterpart EP Publication 0324494, the polymer containing carboxylic acid moieties and the quaternary amine are combined by mixing with heat. Optionally, a polymer compatible therewith, such as a polyolefin, may be blended in the mixture. Any suitable mixing means may be employed such as a blender or a twin screw extruder. The heat should be from about 50° C. to 290° C., more preferably about 100° C. to 250° C., even more preferably about 100° C. to 200° C. Then the resultant may be formed into a film such as by extrusion methods. The film is permanently antistatic, which means it will dissipate an applied charge of ±5000 Vdc in less than about 3000 ms, more preferably less than 2000 ms, using the static decay time (SDT) method described in Federal Test Method Standard 101c, Method 4046.1, even after a 24 hour water shower. This is unlike prior polymeric films containing an antistatic agent to give them antistatic characteristics, which characteristics can be washed out after a 24 hour water shower because the agents operate by migrating to the surface and attracting moisture. Furthermore, in some embodiments, the films survive 1 day, more preferably 3 days, even more preferably 5 days, and most preferably 12 days in a hot oven at approximately 70° C. to 71° C. and still exhibit this static decay time (SDT) of less than about 3000 ms, more preferably less than about 2000 ms.
Measuring the Antistatic Property of the Antistatic Polymeric Film
The antistatic property is exhibited by the ability of a polymer containing an antistatic agent to promote static charge decay, i.e. to dissipate a static charge. The polymer alone will not dissipate a static charge, but the polymer containing the agent is able to dissipate 99% of an applied static charge of ±5000 volt potential in a short amount of time, i.e. less than 3 seconds, more preferably less than 2 seconds (2000 milliseconds). Federal Test Method Standard 101C, Method 4046.1, "Electrostatic Properties of Materials" states less than 2000 ms and thus it is preferred to have a material that complies with 101C. Decay meters for measuring the time for dissipation of the applied volts are commercially available, such as the 406C static decay meter supplied by Electrotech Systems, Inc. Unless otherwise indicated in the Examples below, the films, prior to testing, were equilibrated at less than about 15% relative humidity (RH), which is considered to be a "dry" atmosphere, at about room temperature (RT) for about 24 to 48 hours. For clarity, it is noted that for metallized films, the SDT test is not relevant. Due to the presence of the metal layer, the SDT will be less than 10 ms, which is statistically insignificant and can be considered as being 0 ms. The appropriate test for metallized films is measuring discharge to ground, as further discussed below.
Measuring Resistivity
Some of the films (both metallized and not metallized) were tested for surface resistivity and volume resistivity according to the method set out in ASTM D257, except that in the Examples, resistivity was measured at a "dry" relative humidity under about 15% RH, unless indicated that it was measured at an ambient 40 to 60% RH.
No Correlation between Resistivity and Static Decay Time
It is noted that there is not necessarily a correlation between the surface or volume resistivity of a polymeric film and the ability of a polymeric film to decay or dissipate charges as per the SDT test. Thus, the term "antistatic" as used herein describes a polymeric film which can dissipate 99% of an applied static charge of ±5000 Vdc in a short amount of time, preferably a static decay time less than about 3 seconds, more preferably less than about 2 seconds (Federal Test Method Standard 101c, Method 4046.1, "Electrostatic Properties of Materials"). If the polymeric film also happens to have an antistatic resistivity, i.e. a surface resistivity of about 10 5 to 10 12 ohms/square as per the DOD and EIA Standards explained below, then that material will be described using the term "antistatic surface resistivity".
DOD and EIA Standards
The Department of Defense and the Electronics Industry Association have standards on surface resistivity of a material in ohms/square as follows:
Surface Resistivity Ranges (ohms/square)
______________________________________ Antistatic orInsulative Static Dissipative Conductive______________________________________>10.sup.12 10.sup.12 to 10.sup.5 <10.sup.5______________________________________
It is noted that some of the 5-ply polymeric films as illustrated by U.S. Ser. Nos. 143,885 and 249,488 and their counterpart EP Pub. 0324494 have both a preferred static decay time of about 3000 milliseconds or less and a static dissipative (as opposed to insulative) surface resistivity of 10 12 to 10 5 ohms/square as per the DOD and EIA Standards, even after a 24-hour water shower or after 12 days in a hot oven. Thus these 5-layer films are permanently antistatic by the definition of static decay time and permanently antistatic by the definition of antistatic surface resistivity; neither the 24-hour water shower nor the 12-day hot oven takes out the "antistatic" characteristic.
Measuring Discharge to Ground; Old Capacitive Probe Test (Human Finger)
The old capacitive probe method (human finger) used to be employed for determining whether an electrical charge will pass through a sheet material and couple to an electronic component. The method of this old test employed a finger of a charged human and thus is less sensitive than the present test method which employs a discharge probe as described below. Although the same charge coupling is measured, use of a human is less sensitive than a discharge probe because interference will occur from such things a whether the human has eaten salty food, whether the human is wearing rubber soled shoes, whether the human is sweaty, and the like.
A printed circuit board having two conductive copper plates separated by a layer of insulated material would be placed inside a metallized bag. Wire leads were attached both to the plates of the circuit board and to the inputs of a dual trace oscilloscope through two matched 100 megaohm 3 picofarad one thousand to one high voltage probes so that the effective channel isolation from ground of the leads was on the order of 10 7 ohms. Then the scope would be adjusted so the voltage difference between the two plates on the printed circuit board was displayed and stored on the screen of the scope. The total capacitance of the double sided printed circuit board employed was measured. The source for the electrostatic charge used in the test was a person whose body capacitance was measured. The person was charged to a static electrical potential of about 3000 volts for each test. The bag with the circuit board inside was supported on a wooden bench as ground. The charged person discharged himself onto the test bag by placing one finger firmly onto the top of the bag adjacent the top plate of the enclosed circuit board. The scope showed any voltage pulse measurable by coupling to the printed circuit board inside the bag.
Measuring Discharge to Ground; Present Capacitive Probe Test (Test Fixture)
The present method for determining whether an electrical charge will pass through a metallized sheet material and couple to an electronic component is a variation of EIA-541 Appendix E. An Electro-Tech Systems, Inc. shielded bag test fixture Model 402 is fitted with a capacitor of about 25 picofarads which is placed inside a metallized bag. The capacitor simulates an electronic component such as a circuit board that would be stored inside the bag. The bag rests on an aluminum ground plate. Next, an Electro-Tech Systems Model 881 power supply is adjusted to 1000 volts. Then the 1.5 kilo-ohm discharge probe of the test fixture is lowered onto the bag. The capacitor is connected with leads through the test fixture which leads are connected to a 141A oscilloscope from Hewlett-Packard using a 1402 dual trace amplifier, DC 20 MHz. A reading of a few volts, say 10 or less, is statistically insignificant (as this new test is more sensitive than the old human finger method) and considered to be 0 volts and shows the bag performs well.
SUPPLIERS & TRADENAMES OF MATERIALS EXPLOYED IN THE EXAMPLES
__________________________________________________________________________ANTIBLOCK INGREDIENTS SUPPLIER__________________________________________________________________________EPE 8160 Polyethylene Teknor Apex Containing Micron Sized Silica__________________________________________________________________________LLDPE MI* DENSITY COMONOMER SUPPLIER__________________________________________________________________________DOWLEX 1.1 0.920 Octene Dow Chemical2045.03__________________________________________________________________________EVA MI %VA COMONOMER SUPPLIER__________________________________________________________________________LD318.92 2.0 9 Vinyl Acetate Exxon Rexene__________________________________________________________________________ % BY WEIGHT % BY WEIGHTEAA MI ACRYLIC ACID ETHYLENE SUPPLIER__________________________________________________________________________PRIMACOR 1.5 9 91 Dow Chemical1410__________________________________________________________________________QA FORMULA SUPPLIER__________________________________________________________________________Larostat Modified soyadimethyl Jordan/PPG/264A ethylammonium ethosulfate, MazerAnhydrous which is [H(CH.sub.2).sub.14-20 |(C.sub.2 H.sub.5)N(CH.sub.3).sub .2 +C.sub.2 H.sub.5 OSO.sub.3 -__________________________________________________________________________ *MI is an abbreviation for melt index.
The following Examples are intended to illustrate the invention and it is not intended to limit the invention thereby.
EXAMPLE I
Laminate of Aluminum Metallized PET to EPC-112
EPC-112 was coextruded, hot blown, 5-layer symmetric film of the structure: A/B/C/B/A made in thicknesses of 2.0, 3.0, and 4.0 mils, where the percentages recited below where in % by weight.
Layer A: Composed of EVA, EAA, antiblock, antistatic agent EVA: 30% of Layer A
______________________________________Density: 0.929 to 0.931 g/mlVA Content: 9.0 ± 0.5%Melt Index: 1.8 to 2.2 g/10 min., ASTM D-1238______________________________________
EAA: 52.5% of Layer A
______________________________________Density: 0.938 g/mlAcrylic Acid Content: 9.5%Vicat Softening Point: 180° F.Melt Index: 1.5 ± 0.5 g/10 min., ASTM D-1238______________________________________
Antiblock Masterbatch - Silica Dispersion in Polyethyelene: 10% of Layer A
______________________________________Density of Antiblock Masterbatch: 0.96 to 0.98 g/mlMelting Point of Masterbatch: UnknownSilica Content: 10%Melt Index of Masterbatch: 3.90 to 4.14 g/10 min., ASTM D-1238______________________________________
Antistat: Modified Soya Dimethylethlammonium Ethosulfate: 7.5% of Layer A
______________________________________Density of Antistat: 1.005 g/ml @25° C.pH 35% Solution in Water: 6.0-6.9 @25° C.Boiling Point: >300° F.Melting Point: 120° F.______________________________________
Layer B: Composed of EVA, EAA, and Antistatic Agent EVA: 67% of layer B
Same EVA as layer A
EAA: 24.7% of layer B
Same EAA as layer A
Antistatic Agent: 8.3% of layer B
Same antistatic agent as layer A
Layer C: Composed of LLDPE, EAA, Antistatic Agent LLDPE: 90% of layer C
______________________________________Density: 0.918 to 0.922 g/mlMelting Point: 123-126° C., DSC 2nd heatMelt Index: 1.1 ± 1 g/10 min.Octene Comonomer Content: 6.5 ± 0.5%______________________________________
EAA: 7.5% of layer C
Same EAA as layer A
Antistatic Agent: 2.5% of layer C
Same antistatic agent as layer A 4 mil EPG-112 was adhesively laminated to Scharr's commercial 48 gauge (0.48 mil) aluminum metallized polyester on the polyester side, using a polyurethane adhesive (commercially available under the tradename Korolam 880X301 or Korolam 880X388 from DeSoto Chemical, Chicago Heights, Ill.), to make a laminate of the structure:
aluminum/polyester/adhesive/antistatic film.
Bags were made by heat-sealing together on three edges two sections of the laminate; the antistatic film side was the sealing layer. Bags were sufficiently transparent to afford visual identification of an electrical component inside.
Results of electrical measurements at room temperature on the laminate of aluminum/polyester/antistatic EPG-112, as well as on EPG-112 and on the metallized polyester were as follows (NT means that measurement was not tested):
______________________________________ Aluminum Side Antistatic Film SideLaminate 60% RH 12% RH 60% RH 12% RH*______________________________________surface 1 × 10.sup.8 7.0 × 10.sup.11 7.8 × 10.sup.9 3.7 × 10.sup.11resistivityohms/sqvolume 4.7E11 NT 1.7 × 10.sup.13 5.6 × 10.sup.16resistivityohms-cmSDT ms NT NT NT less than 10______________________________________ Antistatic FilmEPG-112 60% RH 12% RH______________________________________surface NT 3 × 10.sup.11resistivityohms/sqSDT ms NT 450______________________________________Metallized Aluminum Side Polyester SidePolyester 60% RH 12% RH 60% RH 12% RH______________________________________surface 1 × 10.sup.8 NT off NTresistivity scale**ohms/sqvolume 3 × 10.sup.14 NT off NTresistivity scaleohms-cm______________________________________ ***As Reported in Modern PlasticsPET Encyclopedia______________________________________surface >10.sup.14resistivityohms/sqvolume >10.sup.16resistivityohms-cm______________________________________ *RH is an abbreviation for relative humidity. A moist humid atmosphere increases conductivity. Thus at a "humid" ambient 40 to 60% RH, resistivity should be lower than at a "dry" atmosphere of 12% RH. **The maximum meter scale reads to 10.sup.16. Thus, off scale means a resistivity of at least 10.sup.16. ***It is not possible to pull the polyester cleanly off the aluminum to obtain a reading on polyester alone; therefore, reported measurements on PET were taken from the Encyclopedia, 1985-86, page 563, vol. 62, Schulma (Supplier), Arnite (tradename for polyethylene glycol terephthalate).
This adhesive lamination of the EPG-112 to the aluminum metallized polyester was also repeated by adhesively laminating the aluminum side (as opposed to the PET side) of the PET/aluminum to EPG112. This was of the structure:
PET/aluminum/adh/antistatic film.
Surface resistivity on the PET side was 3.4×10 12 ohms/square.
EXAMPLE II
Another metallized laminate with 5-layer antistatic film was made as in Example I using 48 gauge (0.48 mil) aluminum metallized PET commercially available from Scharr, which was corona treated and then adhesively laminated with polyurethane adhesive to an antistatic film that was an alternative version of EPG-112. In the alternative, 1 of the 5 layers of EPG-112, a surface layer D, was instead made of ethylene-vinyl acetate copolymer free of any quaternary amine antistatic agent. Thus, the alternative antistatic film was of the structure: D/B/C/B/A, where D was the 100% EVA ply. The EVA was commercially available from Rexene. The 100% EVA side was laminated to the PET side of the PET/aluminum. This was of the structure:
aluminum/PET/adh/antistatic film.
Surface resistivity on the aluminum side was 4.1×10 11 .
This was also repeated by instead laminating the aluminum side of the PET/aluminum to the EVA surface of the 5-ply antistatic film. This was of the structure:
PET/aluminum/adh/antistatic film.
Surface resistivity on the PET side was off scale.
EXAMPLE III
Another metallized laminate with 5-layer antistatic film was made as in Example I using 48 gauge (0.48 mil) aluminum metallized PET commercially available from Scharr, which was corona treated and then adhesively laminated with polyurethane adhesive to an antistatic film that was an alternative version of EPG-112. In the alternative, 1 of the 5 layers of EPG-112, a surface layer D, was instead made of ethylene-vinyl acetate copolymer free of any quaternary amine antistatic agent. Thus, the alternative antistatic film was of the structure: D/B/C/B/A, where D was the 100% EVA ply. The EVA was commercially available from Exxon. The 100% EVA side was laminated to the PET side of the PET/aluminum. This was of the structure:
aluminum/PET/adh/antistatic film.
Surface resistivity on the aluminum side was 2.4×10 11 .
This was repeated by instead laminating the aluminum side of the PET/aluminum to the EVA surface of the 5-layer antistatic film. This was of the structure:
PET/aluminum/adh/antistatic film.
Surface resistivity on the PET side was 7.8×10 12 .
EXAMPLE IV
Another metallized laminate with 5-layer antistatic film was made as in Example I using 48 gauge (0.48 mil) aluminum metallized PET commercially available from National Metallizers, which was then adhesively laminated with polyurethane adhesive to an antistatic film that was an alternative version of EPG-112. In the alternative, the composition of ply B was not used and also 1 of the 5 layers of EPG-112, a surface layer D, was instead made of ethylene-vinyl acetate copolymer free of any quaternary amine antistatic agent. Thus, the alternative antistatic film was of the structure: D/A/C/A/A, where D was the 100% EVA ply. The EVA was commercially available from Exxon. The 100% EVA side was laminated to the PET side of the PET/aluminum. This was of the structure:
aluminum/PET/adh/antistatic film.
This was repeated by instead laminating the aluminum side of the PET/aluminum to the EVA surface of the 5-layer antistatic film. This was of the structure:
PET/aluminum/adh/antistatic film.
COMPARATIVE EXAMPLE A VERSUS EXAMPLE I
A bag of the structure from outside to inside: aluminum/PET/adhesive/EPG-112 as per Example I was compared to 3M's commercially available 2100 metalized bag of the structure: nickel/insulative polyester/adhesive/antistatic film of LDPE containing antistat. The 2100 bag has been advertised as having a thin polymeric abrasion protection coating on the nickel outside surface of the bag, and having on this outside surface a resistivity at ambient conditions of 10 4 ohms/square. Not greater than 10 4 ohms/square also is what is claimed in the above mentioned 3M U.S. Pat. Nos. 4,154,344 and 4,156,751. In contrast, as seen from Example I, the Al/PET/adhesive/EPG-112 had on its Al outside surface a resistivity of 1×10 8 ohms/sq at ambient RH, and about 7×10 11 ohms/sq at a "dry" 12% RH. Although it is not known why and not intended to be bound to any theory, it is theorized this occurred because aluminum, when exposed to air, quickly forms an insulator of Al 2 O 3 ; thus due to the presence of the Al 2 O 3 , the bag outside showed 1×10 8 .
Next, a capacitive probe test was performed on both the bag of the structure from outside to inside: aluminum/PET/adhesive/EPG-112 made as per Example I and the 3M 2100 bag with the new method of the Electro-Tech Systems shielded bag test fixture Model 402, not the old human finger method. The Example I bag provided readings ranging from 4 to 6 volts, whereas the commercially available 3M 2100 bag provided readings ranging from 2 volts to 4 volts. As mentioned above, this new method is more sensitive than the old human finger method. Thus, these small voltages are not statistically significant and can be considered as a 0 voltage reading when using the old human finger test method.
This data is summarized in the Table below as follows:
______________________________________COMPARATIVE TABLE A Surface Resistivity Ohms/Square Capacitive on Metal Probe Test Outside Surface Voltage ReadSample (Ambient RH) on Scope______________________________________Aluminum/PET/ADH/EPG-112 1 × 10.sup.8 4 to 63M's 2100 10.sup.4 2 to 4______________________________________
Accordingly, the material of the instant invention clearly protected a static sensitive device (the capacitive probe test was excellent) even though the material had a high surface resistivity of 10 8 , clearly beyond the not greater than 10 4 taught by the 3M patents.
COMPARATIVE EXAMPLE B VERSUS EXAMPLES I, III, & IV
The metal out structures of aluminum/PET/adhesive/antistatic film of Examples I, III, and IV were compared to various commercially available metal out bag materials for the test of inter layer adhesive lamination strength. All these commercial metal out bags were, from bag outside to bag inside, of the structure: metal/PET/adhesive/antistatic polymeric layer. One inch wide samples were cut. With the aid of solvents such as hexane, the metallized polyester was separated on its polyester side from its adhesive lamination to the antistatic film, for a distance of about 1 inch (about 2.54 cm) with the remainder of the separated portions forming grip tabs. After the solvent was dried and removed so that it would not affect the results, one tab was placed in one jaw of an Instron test fixture and the other tab in the other jaw. The jaws were then separated and the threshold force to pull the layers apart was recorded. This is summarized in the Table below as follows, where "TEAR OUT" indicates the material would not separate at the adhesive, but tore at some other ply.
______________________________________COMPARATIVE TABLE B FORCE (POUNDS) TRIAL 1 TRIAL 2 TRIAL 3 TRIAL 4SAMPLE DAY 1 DAY 7 DAY 15 DAY 28______________________________________EXAM I 0.7892EXAM III TEAR OUTEXAM IV TEAR TEAR TEAR TEAR OUT OUT OUT OUT3M 0.2777Richmond 4200 0.5923Richmond 4250 0.2837Simco 2854 1.0050______________________________________
Clearly the "metal out" material of the instant invention was better in adhesive lamination to the antistatic film than the commercially available metal out bags were.
While certain representative embodiments and details have been shown for the purpose of illustration, numerous modifications to the formulations described above can be made without departing from the invention disclosed. | A flexible sheet material and bags made therefrom for packaging electrostatically sensitive items such as electronic circuit boards. The sheet has a metal layer that is adhesively laminated to an antistatic polymeric layer, the instant bag being of improved metal layer to antistatic layer adhesion. The metal outer surface of the bag has a high non-conductive surface resistivity greater than or equal to 10 8 ohms/square, yet the bag protects the packaged item from static voltage by preventing the capacitive coupling of the voltage through the bag to the item packaged therein. | 8 |
BACKGROUND
When exploring spatial environments using virtual browsing tools, it can be difficult to determine a current position relative to the overall environment. For example, when looking at a map at a high zoom level, it can be difficult to know where you are looking. Or, when exploring outer space with a relatively narrow field of view, it can be difficult to know what portion of the sky is being explored.
SUMMARY
The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.
The present examples provide indicators operable to preview or show the position and relative zoom level of a field of view within a virtual space. Virtual space exploration tools typically make use of a field of view for limiting a user's view of the virtual space and zooming in on a portion of the virtual space. A spherical indicator is provided to show the current position of the field of view within the virtual space, as well as provide an indication of level of zoom. A local field of view indication is also provided to show the current position of the field of view, as well as provide an indication of level of zoom, with respect to a nearby object within the virtual space. Such indicators may be useful in exploring outer space as well as landscapes and any other spaces.
Many of the attendant features will be more readily appreciated as the same become better understood by reference to the following detailed description considered in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
The present description will be better understood from the following detailed description considered in connection with the accompanying drawings, wherein:
FIG. 1 is a block diagram showing a schematic diagram of an example spherical indicator.
FIG. 2 is a block diagram showing a schematic diagram of an example local field of view indicator.
FIG. 3 is a static image example of a virtual space presentation interface of a virtual space browsing tool including example spherical and local indicators.
FIG. 4 is a static image example of spherical and local indicators.
FIG. 5 is another static image example of spherical and local indicators.
FIG. 6 is a block diagram showing an example computing environment in which the technologies described herein may be implemented.
Like reference numerals are used to designate like elements in the accompanying drawings.
DETAILED DESCRIPTION
The detailed description provided below in connection with the accompanying drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present examples may be constructed or utilized. The description sets forth at least some of the functions of the examples and/or the sequence of steps for constructing and operating examples. However, the same or equivalent functions and sequences may be accomplished by different examples.
Although the present examples are described and illustrated herein as being implemented in a computing environment, the environment described is provided as an example and not a limitation. As those skilled in the art will appreciate, the present examples are suitable for application in a variety of different types of computing environments.
FIG. 1 is a block diagram showing a schematic diagram of an example spherical indicator 100 . Such an indicator may be used to provide a “you are here” view indicating the portion of some spatial environment being viewed when using a virtual space browsing tool or the like. In one example of indicator 100 , included is a translucent sphere 110 with ovals 111 and 112 to aid in providing a spherical appearance when displayed in two dimensions. Further included are lines 121 and 122 which provide for a visual center point 120 of sphere 110 . Sphere 110 typically represents an imaginary rotating sphere of gigantic radius, concentric and coaxial with the Earth, or some other body, located at center point 120 . Oval 111 is typically thought of as the celestial equator projected from the body at center point 120 . Line 122 is typically considered the celestial pole projected from the body at center point 120 . Symbol ‘N’ 113 indicates the north pole of sphere 110 and the body at center point 120 .
When browsing a virtual space all objects in the sky and/or surroundings may be thought of as lying on sphere 110 . When using a virtual space browsing tool to view such a sky and/or surroundings, indicator 100 typically indicates the position of the current field of view (“FOV”) of the browsing tool. In one example, indicator 100 shows the FOV as a projection 130 onto the surface of sphere 110 from center point 120 . The relative size of projection 130 is typically an indication of the relative zoom of the current FOV. For example, a larger projection generally indicates a lesser level of zoom and a smaller projection a greater level of zoom. Examples of zoom levels and corresponding projection sizes are provided in connection with FIGS. 4 and 5 .
Indicator 100 typically includes positional information for the current FOV. In one example of positional information, right ascension (“RA”) 160 is one of two conventional coordinates used, displayed using an hours, minutes, seconds format or the like. The second of the two conventional coordinates used is declination (“Dec”), displayed using a +/− degrees, minutes, seconds format or the like. These two conventional coordinates may be used to indicate the position of the current FOV on sphere 110 . Indicator 100 may thus be used to provide an indication of the position and relative zoom of a current FOV of a virtual space browsing tool or the like.
The term “virtual space” as used herein generally refers to a representation of some space, actual or imaginary, from a particular point of reference, such as outer space (the Earth, for example, being the point of reference) or some other space surrounding a particular point of reference (some point on the Earth, for example). The term “spatial environment” as used herein generally refers to a virtual space, real space, and/or imaginary space. Such spaces may, for example, be galactic, subatomic, or of any scope in-between.
FIG. 2 is a block diagram showing a schematic diagram of an example local field of view indicator 200 . Such an indicator may be used to provide a “you are here” view with respect to a nearby object 220 in a portion of the sky and/or surroundings being viewed when using a virtual space browsing tool or the like. In one example, indicator 200 includes area 210 typically showing an object 220 nearby the current FOV 211 position. Object 220 is typically centered in area 210 and the position of the current FOV 211 is typically shown relative to object 220 . Object 220 may be a representation of an object, an image of an object, or the like. The size of FOV 211 typically provides a relative indication of level of zoom. Symbol “L 4 ” 213 also typically provides a relative indication of the level of zoom, lower numbers typically indicating less zoom and higher number more zoom. Further, zoom indicator 230 may also provide a visual indication of the relative level of zoom with fill line 232 indicating less zoom when more toward the left and more zoom when more toward the right. Object Name field 212 typically presents the name or other information of object 220 . Indicator 200 may thus be used to indicate the position of the current FOV relative to a nearby object in the virtual space of a virtual space browsing tool or the like.
FIG. 3 is a static image example of a virtual space presentation interface 300 of a virtual space browsing tool including example spherical and local indicators 330 . Example 300 includes a current field of view (“FOV”) 310 of the virtual space which, in this example, is of outer space. A user may generally explore the virtual space by moving the FOV to a desired location in the virtual space via suitable user interface mechanisms. Further, the user may zoom in or out of the virtual space as desired, thus narrowing or widening FOV 310 respectively. Example spherical and local indicators 330 , such as described in connection with FIGS. 1 and 2 , may indicate the current FOV position within the virtual space.
FIG. 4 is a static image example of spherical and local indicators. In this example, local indicator 420 is centered on a representation of the Canes Venatici constellation with relatively little zoom and a relatively wide FOV, the FOV also centered on the representation of the Canes Venatici constellation. Further, spherical indicator 410 shows a projection of the current FOV including values for corresponding RA and Dec, again indicating a relatively wide FOV.
FIG. 5 is another static image example of spherical and local indicators. In this example, local indicator 520 is centered on a representation of the Canes Venatici constellation, this time with more zoom and a narrower FOV when compared with FIG. 4 . Further, spherical indicator 510 shows a projection of the current FOV including values for corresponding RA and Dec, again indicating a narrower wide FOV when compared with FIG. 4 .
FIG. 6 is a block diagram showing an example computing environment 600 in which the technologies described herein may be implemented. A suitable computing environment may be implemented with numerous general purpose or special purpose systems. Examples of well known systems may include, but are not limited to, cell phones, personal digital assistants (“PDA”), personal computers (“PC”), hand-held or laptop devices, microprocessor-based systems, multiprocessor systems, servers, workstations, consumer electronic devices, set-top boxes, and the like.
Computing environment 600 typically includes a general-purpose computing system in the form of a computing device 601 coupled to various components, such as peripheral devices 602 , 603 , 604 and the like. System 600 may couple to various other components, such as input devices 603 , including voice recognition, touch pads, buttons, keyboards and/or pointing devices, such as a mouse or trackball, via one or more input/output (“I/O”) interfaces 612 . The components of computing device 601 may include one or more processors (including central processing units (“CPU”), graphics processing units (“GPU”), microprocessors (“μP”), and the like) 607 , system memory 609 , and a system bus 608 that typically couples the various components. Processor 607 typically processes or executes various computer-executable instructions to control the operation of computing device 601 and to communicate with other electronic and/or computing devices, systems or environment (not shown) via various communications connections such as a network connection 614 or the like. System bus 608 represents any number of several types of bus structures, including a memory bus or memory controller, a peripheral bus, a serial bus, an accelerated graphics port, a processor or local bus using any of a variety of bus architectures, and the like.
System memory 609 may include computer readable media in the form of volatile memory, such as random access memory (“RAM”), and/or non-volatile memory, such as read only memory (“ROM”) or flash memory (“FLASH”). A basic input/output system (“BIOS”) may be stored in non-volatile or the like. System memory 609 typically stores data, computer-executable instructions and/or program modules comprising computer-executable instructions that are immediately accessible to and/or presently operated on by one or more of the processors 607 .
Mass storage devices 604 and 610 may be coupled to computing device 601 or incorporated into computing device 601 via coupling to the system bus. Such mass storage devices 604 and 610 may include non-volatile RAM, a magnetic disk drive which reads from and/or writes to a removable, non-volatile magnetic disk (e.g., a “floppy disk”) 605 , and/or an optical disk drive that reads from and/or writes to a non-volatile optical disk such as a CD ROM, DVD ROM 606 . Alternatively, a mass storage device, such as hard disk 610 , may include non-removable storage medium. Other mass storage devices may include memory cards, memory sticks, tape storage devices, and the like.
Any number of computer programs, files, data structures, and the like may be stored in mass storage 610 , other storage devices 604 , 605 , 606 and system memory 609 (typically limited by available space) including, by way of example and not limitation, operating systems, application programs, data files, directory structures, computer-executable instructions, and the like.
Output components or devices, such as display device 602 , may be coupled to computing device 601 , typically via an interface such as a display adapter 611 . Output device 602 may be a liquid crystal display (“LCD”). Other example output devices may include printers, audio outputs, voice outputs, cathode ray tube (“CRT”) displays, tactile devices or other sensory output mechanisms, or the like. Output devices may enable computing device 601 to interact with human operators or other machines, systems, computing environments, or the like. A user may interface with computing environment 600 via any number of different I/O devices 603 such as a touch pad, buttons, keyboard, mouse, joystick, game pad, data port, and the like. These and other I/O devices may be coupled to processor 607 via I/O interfaces 612 which may be coupled to system bus 608 , and/or may be coupled by other interfaces and bus structures, such as a parallel port, game port, universal serial bus (“USB”), fire wire, infrared (“IR”) port, and the like.
Computing device 601 may operate in a networked environment via communications connections to one or more remote computing devices through one or more cellular networks, wireless networks, local area networks (“LAN”), wide area networks (“WAN”), storage area networks (“SAN”), the Internet, radio links, optical links and the like. Computing device 601 may be coupled to a network via network adapter 613 or the like, or, alternatively, via a modem, digital subscriber line (“DSL”) link, integrated services digital network (“ISDN”) link, Internet link, wireless link, or the like.
Communications connection 614 , such as a network connection, typically provides a coupling to communications media, such as a network. Communications media typically provide computer-readable and computer-executable instructions, data structures, files, program modules and other data using a modulated data signal, such as a carrier wave or other transport mechanism. The term “modulated data signal” typically means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communications media may include wired media, such as a wired network or direct-wired connection or the like, and wireless media, such as acoustic, radio frequency, infrared, or other wireless communications mechanisms.
Power source 690 , such as a battery or a power supply, typically provides power for portions or all of computing environment 600 . In the case of the computing environment 600 being a mobile device or portable device or the like, power source 690 may be a battery. Alternatively, in the case computing environment 600 is a desktop computer or server or the like, power source 690 may be a power supply designed to connect to an alternating current (“AC”) source, such as via a wall outlet.
Some mobile devices may not include many of the components described in connection with FIG. 6 . For example, an electronic badge may be comprised of a coil of wire along with a simple processing unit 607 or the like, the coil configured to act as power source 690 when in proximity to a card reader device or the like. Such a coil may also be configure to act as an antenna coupled to the processing unit 607 or the like, the coil antenna capable of providing a form of communication between the electronic badge and the card reader device. Such communication may not involve networking, but may alternatively be general or special purpose communications via telemetry, point-to-point, RF, IR, audio, or other means. An electronic card may not include display 602 , I/O device 603 , or many of the other components described in connection with FIG. 6 . Other mobile devices that may not include many of the components described in connection with FIG. 6 , by way of example and not limitation, include electronic bracelets, electronic tags, implantable devices, and the like.
Those skilled in the art will realize that storage devices utilized to provide computer-readable and computer-executable instructions and data can be distributed over a network. For example, a remote computer or storage device may store computer-readable and computer-executable instructions in the form of software applications and data. A local computer may access the remote computer or storage device via the network and download part or all of a software application or data and may execute any computer-executable instructions. Alternatively, the local computer may download pieces of the software or data as needed, or distributively process the software by executing some of the instructions at the local computer and some at remote computers and/or devices.
Those skilled in the art will also realize that, by utilizing conventional techniques, all or portions of the software's computer-executable instructions may be carried out by a dedicated electronic circuit such as a digital signal processor (“DSP”), programmable logic array (“PLA”), discrete circuits, and the like. The term “electronic apparatus” may include computing devices or consumer electronic devices comprising any software, firmware or the like, or electronic devices or circuits comprising no software, firmware or the like.
The term “firmware” typically refers to executable instructions, code, data, applications, programs, or the like maintained in an electronic device such as a ROM. The term “software” generally refers to executable instructions, code, data, applications, programs, or the like maintained in or on any form of computer-readable media. The term “computer-readable media” typically refers to system memory, storage devices and their associated media, and the like.
In view of the many possible embodiments to which the principles of the present invention and the forgoing examples may be applied, it should be recognized that the examples described herein are meant to be illustrative only and should not be taken as limiting the scope of the present invention. Therefore, the invention as described herein contemplates all such embodiments as may come within the scope of the following claims and any equivalents thereto. | Indicators operable to preview or show the position and relative zoom level of a field of view within a virtual space. Virtual space exploration tools typically make use of a field of view for limiting a user's view of the virtual space and zooming in on a portion of the virtual space. A spherical indicator is provided to show the current position of the field of view within the virtual space, as well as provide an indication of level of zoom. A local field of view indication is also provided to show the current position of the field of view, as well as provide an indication of level of zoom, with respect to a nearby object within the virtual space. Such indicators may be useful in exploring outer space as well as landscapes and any other spaces. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of U.S. patent application Ser. No. 09/295,956 filed on Apr. 21, 1999.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This invention relates generally to fluid transfer devices and, more particularly, to panel assemblies for diverting fluids from one location to another.
[0004] 2. Description of the Related Art
[0005] Flow transfer panels are an important part of most processes and clean-in-place (CIP) systems in the food, beverage, dairy, pharmaceutical, and biopharmaceutical industries. The flow transfer panel provides the “physical break” required by most processing regulations and current Good Manufacturing Practices (cGMP's). In addition, flow transfer panels may be utilized for fluid diversion and delivery in industries where sanitary conditions and the inherent “physical break” are not process requirements.
[0006] As shown in FIG. 1, a typical transfer panel 10 generally includes a vertically oriented panel 12 and nozzles 14 that extend through the panel and are welded or otherwise attached thereto. Each nozzle includes a ferrule 16 formed at the end of a tube 18 and a mounting ring 19 formed on the tube and spaced from the ferrule 18 . A jumper conduit 20 has a ferrule 22 connected at the ends of a U-shaped tube 24 . The ferrules 22 of the jumper conduit 20 include faces 25 that mate with faces 26 of the ferrules 16 . The ferrules 22 are connected to the ferrules 16 through clamps or the like to thereby direct the flow of fluid from one pipe to another.
[0007] The flow transfer panel 10 may be mounted on a floor, wall, or ceiling through appropriate supports and/or brackets, and provides a basic support structure for several nozzles and jumper conduits that may extend between one or more pairs of nozzles. Generally, flow transfer panels provide a physical break required by some processing regulations and assure that products will not be cross contaminated with other products or with CIP solutions that are used for cleaning the interior of conduits or pipes associated with fluid processing.
[0008] Assembly of the nozzles to the transfer panel typically involves forming openings in the panel 12 then inserting the tube 18 of each nozzle in one of the openings such that the ferrule 16 is located on one side 24 of the panel with the tube 18 extending through the panel. The nozzle 14 is then affixed to the panel by welding the outer perimeter of the ring 19 to the panel 12 . With this arrangement, the distance between the panel and an outer face 26 of the ferrule 16 of each nozzle must be referenced from the side 24 of the panel, since the ring 19 is spaced at a fixed distance from the ferrule 16 . Ideally, the outer faces 26 of the ferrules 16 should lie in a common plane 28 . Although care is taken to provide a flat panel 12 , dips 30 and bows 32 in the panel may occur during formation of the panel itself, and may be further augmented by subsequent manufacturing processes, such as stamping, forming openings in the panel, welding of the nozzles to the panel, and the like. It has been observed that for a 0.25 inch thick plate, the dips and bows may vary by as much as 0.25 inch or more over the area of the plate, which in some applications may be quite large. Consequently, the outer faces 26 of the ferrules do not lie along a common plane 28 . When a jumper conduit 20 is connected to the ferrules under these circumstances, a gap “A” between a first pair of opposing faces 25 and 26 may be greater than a gap “B” between a second pair of opposing faces of ferrules 16 and 22 . When the jumper conduit is installed on the nozzles 14 , the gap “B” is closed, while the gap “A” may still be present. Consequently, leakage may occur at the junction of the ferrules 16 and 22 and contaminants may enter the processing line. In some cases, undue internal stresses may be created in the jumper conduit during an attempt to close gap “A” when assembling the jumper conduit to the nozzles. In many instances custom jumper conduits must be constructed, typically at the assembly sight away from the manufacturer, to accommodate the dips, bows and other deformities of the transfer panel, resulting in increased manufacturing and installation time, labor, and expense.
[0009] The above-described problems are further augmented by surface defects that may be present on the inner surface of the tube 18 during manufacture or during assembly to the panel 12 . In many cases, the surface defects are not readily observable or cannot be measured until after an electro-polishing operation wherein the inner surface of the nozzle 14 is given a smooth, mirror-like finish. Even when the surface contains no visible or discernible defects before electro-polishing, the electro-polishing operation itself may uncover pits in the surface. This is especially prevalent where the surface is mechanically finished before electro-polishing. Mechanical finishing often fills pits and other defects in the surface due to welding or other manufacturing operations. Since a layer of material is removed from the surface during electro-polishing, some of the pits and other defects may be uncovered. In many manufacturing environments, the electro-polishing operation itself is inherently non-repetitive, since factors such as electrolyte concentration, temperature, and immersion time of the surface in the electrolyte may vary. Discontinuities in the finish can encourage contamination and bacteria growth and therefore are unacceptable in sterile processing environments. When surface defects are detected after the nozzle is installed in the panel, the nozzle must either be ground out, which is a labor-intensive and time-consuming procedure, or the panel must be discarded.
[0010] In an attempt to overcome surface defects in the nozzle that may be caused from welding the nozzle directly to the panel assembly, U.S. Pat. No. 5,603,457 issued to Sidmore et al. on Feb. 18, 1997, proposes forming a ring on the nozzle and an enlarged opening in the panel for receiving the ring. The outer periphery of the ring is then welded to the panel and the welding bead is subsequently removed during a grinding operation. Although the ring effectively relocates the welding operation to a location spaced from the nozzle, the ring is the same thickness as the panel. The distance from the panel to a connection end of the nozzle must therefore be referenced from the panel itself. Consequently, the connection ends of nozzles on the panel may not lie in the same plane due to dips, bows and other imperfections in the panel.
SUMMARY OF THE INVENTION
[0011] According to the present invention, a method of constructing a panel assembly for transferring fluids from one location to another includes providing a panel with at least one opening, forming at least one nozzle with a tubular portion and at least one connection end, forming a sleeve on the tubular portion, the sleeve having an outer surface with an axial length that is greater than a combination of a thickness of the panel and any deformity on the panel, polishing an inner surface of the tubular portion, inspecting the inner surface for defects; and installing the at least one nozzle on the panel by a) inserting the tubular portion into the at least one opening in the panel until the sleeve is positioned within the at least one opening, and b) affixing the outer surface of the sleeve to the panel in the vicinity of the at least one opening. With this method, defects that may be present on the inner surface of the tubular portion can be discovered before installing the nozzle on the panel, and potential inner surface defects are precluded during installation of the nozzle on the panel. It is to be understood that the phrase “any deformity” refers to one or more typical deformities that may be present after manufacture of the panel itself. The length of the sleeve is preferably predetermined to accommodate these typical deformities, whether or not they are present on the panel.
[0012] According to a further embodiment of the invention, a method of constructing a panel assembly for transferring fluids from one location to another comprises providing a panel with a plurality of openings, forming a plurality of nozzles, with each nozzle including a tubular portion and at least one connection end, forming a sleeve on each tubular portion, polishing an inner surface of each tubular portion, inspecting the inner surface of each tubular portion for defects; and installing each of a plurality of nozzles that pass the inspection step on the panel by a) inserting the tubular portion into one of the openings in the panel, b) aligning the connection end of the tubular portion in a common reference plane while positioning the sleeve within the one opening, and c) affixing an outer surface of the sleeve to the panel in the vicinity of the one opening. Alignment of the connection ends with the common reference plane is thus independent of any deformity that may exist on the panel. With this arrangement, defects that may be present on the inner surface of the tubular portion can be discovered before installing the nozzles on the panel, and potential inner surface defects are precluded during installation of the nozzles on the panel.
[0013] A panel assembly according to the present invention for transferring fluids from one location to another comprises a panel structure having at least two openings, a nozzle projection through each opening and a sleeve affixed between each nozzle and its respective opening. Each nozzle includes a tubular portion with a connection end adapted for connection to a transfer conduit. The connection ends of the nozzles are preferably aligned with a common reference plane. Each sleeve has an outer surface with a length that is greater than a combination of a thickness of the panel and any deformity on the panel. With this arrangement, alignment of the connection ends with the common reference plane is independent of any deformity that may exist on the panel.
[0014] There are, of course, additional features of the invention that will be described hereinafter which will form the subject matter of the appended claims. Those skilled in the art will appreciate that the preferred embodiments may readily be used as a basis for designing other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions since they do not depart from the spirit and scope of the present invention. The foregoing and other features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0015] The preferred embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and:
[0016] [0016]FIG. 1 is a top plan view in partial cross section of a prior art transfer panel assembly;
[0017] [0017]FIG. 2 is an exploded front isometric view of a transfer panel assembly according to the present invention;
[0018] [0018]FIG. 3 is an isometric view of a nozzle and sleeve assembly according to the invention;
[0019] [0019]FIG. 4 is a cross sectional view of a sleeve according to one embodiment of the invention;
[0020] [0020]FIG. 5 is a cross sectional view of a sleeve according to a further embodiment of the invention; and
[0021] [0021]FIG. 6 is a top plan view in partial cross section of the transfer panel assembly according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring now to the drawings, and to FIG. 2 in particular, an exploded view of a transfer panel assembly 100 according to the present invention is illustrated. The transfer panel assembly 100 includes a generally vertically oriented panel 112 , nozzles 114 adapted for extending through openings 116 in the panel, and a collar or sleeve 118 that fits in the openings 116 between the panel 112 and the nozzles 114 . A jumper or transfer conduit 120 (FIG. 6) may be connected to the nozzles through well-known clamp assemblies (not shown). Where the transfer panel assembly is to be used in sterile processing environments, the panel 100 , nozzles 114 , sleeve 118 , and any jumper conduits 120 that may be used are preferably constructed of stainless steel material.
[0023] With additional reference to FIG. 3, each nozzle 114 includes a ferrule 122 formed at a forward end 124 of a tube or conduit 126 . The outer surface 125 of the ferrule 122 is larger in diameter than the tube 126 and includes an opening with an inner diameter that is substantially equal to the inner diameter of the tube 124 . The ferrule 122 is preferably formed in a separate operation and welded to the tube. The welding operation preferably involves butt welding the components together, wherein a rear surface 128 (FIG. 6) of the ferrule 122 and a forward edge 129 of the tube 126 are abutted together and aligned such that a center axis of the tube is coincident with a center axis of the ferrule. The ferrule 122 and tube 124 are then simultaneously heated in the vicinity of the rear surface 128 and forward edge 129 with a TIG welder, for example, until the material from each component flows together. Preferably, the butt welding is performed without filler material that typically accompanies other welding techniques. In some applications, it may be desirable to purge the tube 126 with an inert gas, such as Argon, while welding in order to prevent oxidation on an inner surface 132 of the tube. The temperature to which the material is heated during welding and the welding velocity are dependent on the type of material used and the thickness of the tube. Preferably, the temperature and welding velocity are chosen so that the weld fully penetrates the wall of the tube. The welding can be automated with the welding temperature and velocity set to assure a strong bond between the flange and tube. After welding, any welding bead that may have been produced is mechanically polished from the inner surface 132 and outer surface 130 of the tube 126 .
[0024] In an alternative construction, the ferrule 122 may be machined directly on the tube or may be formed on the tube through other known forming processes.
[0025] With further reference to FIG. 4, each sleeve 118 includes an annular body 136 with an outer surface 138 and a bore 146 with an inner surface 140 . A forward chamfered surface 142 and a rearward chamfered surface 144 extend between the inner and outer surfaces. The diameter of the bore 136 is substantially equal to the outer diameter of the tube 126 so that the sleeve 118 can be slipped over the tube and affixed thereon.
[0026] Preferably, the sleeve 118 is positioned a predetermined distance from the ferrule 122 and then seal-welded on the tube 126 at a forward edge 148 , which is the intersection of the forward chamfered surface 142 and inner surface 140 , and a rearward edge 150 , which is the intersection of the rearward chamfered surface 144 and the inner surface 140 . Seal welding is preferably accomplished with a TIG welder, and is performed without filler material that typically accompanies other welding techniques. In some applications, it may be desirable to again purge the tube 126 with an inert gas while welding in order to prevent oxidation on the inner surface 132 of the tube. The temperature to which the material is heated during welding and the welding velocity are again dependent on the type of material used and the thickness of the tube. Preferably, the temperature and welding velocity are chosen so that the weld does not fully penetrate the wall of the tube. The welding can be automated with the welding temperature and velocity set to assure a strong bond between the sleeve and tube. After welding, any welding bead that may have been produced is mechanically polished from the outer surface 130 of the tube 126 . However, since no filler material is used, the welding bead will be relatively small since the weld does not penetrate through the wall of the tube. In many instances, the welding bead will not require grinding. Since the weld does not fully penetrate the wall of the tube, the inner surface 132 of the tube will normally not be affected.
[0027] Although the sleeve 118 can be formed without chamfered surfaces, they serve to facilitate clean-up both during manufacture and in use since sharp comers between the tube and sleeve are eliminated, where dirt and other particles could otherwise become entrapped. In addition, the chamfered surfaces provide an aesthetically pleasing transition between the tube 126 and the sleeve 118 . The thickness “C” between the inner and outer surfaces of the sleeve is chosen so that when the sleeve is welded to the panel 112 , heat dissipation generated from the welding operation will not affect the inner surface 132 of the tube 126 . The length “D” of the outer surface 138 may vary greatly depending on the thickness of the panel 112 , but is preferably at least long enough to compensate for panel thickness and common panel deformities. For example, a panel thickness of 0.25 inch and a total deformation of 0.25 inch for dips and 0.25 inch for bows, the length “D” should be approximately 0.75 inches. This dimension, of course, is given only by way of example and can vary greatly.
[0028] Although the outer surface 138 of the sleeve 118 is shown as circular in cross section, the outer surface may have other cross sectional shapes including, but not limited to square, rectangular, hexagonal, oval, star, and so on, as long as the cross dimension of the outer surface, i.e. a distance between opposing sides of the sleeve 118 , is substantially constant throughout an axial length of the sleeve..
[0029] In an alternative construction, the sleeve 118 may be machined directly on the tube or may be formed on the tube through other known forming processes.
[0030] After the sleeve and ferrule are affixed to the tube, the inner surface 132 of the tube 126 is preferably electro-polished to provide a very smooth and uniform mirror-like surface that resists oxidation. If desired, the entire nozzle can be electro-polished to resist oxidation and provide a more aesthetic appearance. After electro-polishing, the nozzle is inspected for determining the quality of the inner surface 132 . If the inner surface is nonuniform, or if there are pits or other surface imperfections, the nozzle can be rejected before it is installed on the panel 112 . This offers a great advantage over the prior art, wherein electro-polishing occurs after the prior art nozzles are welded to the flow panel. Since surface imperfections are normally not noticed or cannot practically be measured until after electro-polishing, the nozzle must be ground out or the entire panel must be discarded if surface imperfections are found. In a large panel with several nozzles, this can be very disadvantageous in terms of manufacturing time and costs.
[0031] The present invention is particularly advantageous in that several nozzles with the same or various sizes of ferrules, tubes, and sleeves can be manufactured in advance and inspected before affixing the nozzles to transfer panels. In this manner, the prior art labor-intensive and time consuming task of grinding out one or more reject nozzles, and/or the cost of discarding the old transfer panel assembly and manufacturing a new transfer panel assembly with the same attendant risks are eliminated.
[0032] Referring now to FIG. 5, a cross section of a sleeve 160 according to a further embodiment of the invention is illustrated, wherein like parts in the previous embodiment are represented by like numerals. The sleeve 160 is similar in construction to the sleeve 118 with the exception of an annular groove 162 formed on the inner surface 140 of the sleeve. The sleeve 160 is installed on the tube 126 (shown in phantom line) in the same manner as sleeve 118 previously described. When installed, the groove 162 together with the outer surface 130 of the tube 126 form an annular pocket 164 that insulates the tube from dissipated heat during welding of the sleeve 160 to the panel 112 (also shown in phantom line). With this arrangement, it is contemplated that the thickness “C” of the nozzle may be reduced, as well as the size of the opening 116 in panel 112 .
[0033] As shown in FIG.'s 2 and 6 , the transfer panel assembly 100 is constructed by forming openings 116 in the panel 112 then inserting a nozzle 114 into each opening such that the sleeve 118 (or 160 ) is positioned in each opening and an outer face 170 of each ferrule 122 is positioned in a common plane 172 (shown in phantom line). The plane 172 is preferably a reference surface with an acceptable flatness and the outer faces 170 of the ferrules are positioned in abutting relationship with the reference surface. Subsequently, the sleeves 118 (or 160 ) are affixed to the panel 112 , preferably by seal welding the outer surface 138 of each sleeve to an outer circumferential edge 174 and an inner circumferential edge 176 of the opening 116 . In this manner, the nozzles are affixed to the panel 112 with the outer faces of each ferrule 122 lying in a common plane, even when the panel includes dips and bows and/or other deformities.
[0034] Although the reference surface 172 and panel are shown oriented vertically in FIG. 2, it is to be understood that the reference surface and panel can be oriented horizontally during assembly of the nozzles to the panel, or in any other orientation, as long as the outer faces of the ferrules are aligned in a common plane.
[0035] With particular reference now to FIG. 6, a jumper or transfer conduit 120 includes a ferrule 182 connected at the ends of a U-shaped tube 184 . The U-shaped tube 184 includes a pair of leg portions 180 and a curved portion 185 extending therebetween. Depending on the distance between nozzles to be connected, the curved portion 185 may include a straight section (not shown). The ferrules 182 include a face 186 that lie in a common plane. When the jumper conduit 120 is installed on the transfer panel assembly 100 , the faces 186 and 170 will be in abutting relationship, independent of any panel deformations or other imperfections. A clamp (not shown) can then be installed over the ferrules 182 and 122 in a well-known manner to thereby affix the jumper conduit to a pair of nozzles. Although a particular type of ferrule is shown for both the nozzles 114 and jumper conduit 120 , it is to be understood that ferrules with mutually engaging threads, or other means for connecting the jumper conduit to the nozzles are well within the scope of the present invention.
[0036] With the above-describe arrangement, a plurality of jumper conduits 120 can now be constructed at the manufacturer as a standard part. Thus, it is no longer necessary to custom form jumper conduits in the field during assembly as in the prior art due to changes in surface contour or other deformities in the transfer panel.
[0037] It is to be understood that the terms forward, rearward, inner, outer, and their respective derivatives as used herein denote relative, rather than absolute positions or locations.
[0038] While the invention has been taught with specific reference to the above-described embodiments, those skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and the scope of the invention. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A panel assembly for transferring fluids from one location to another comprises a panel structure with openings, a nozzle projecting through each opening and a sleeve affixed between the nozzle and its respective opening. Each nozzle includes a tubular portion with a connection end adapted for connection to a transfer conduit. The connection ends of the nozzles are preferably aligned with a common reference plane. Each sleeve has an outer surface with a length that is greater than a combination of a thickness of the panel and any deformity on the panel. With this arrangement, alignment of the connection ends with the common reference plane is independent of any deformity on the panel. A method of constructing a panel assembly includes determining if any defects are present on the inner surface of the tubular portion before installing the nozzle on the panel, and precluding potential inner surface defects during installation of the nozzle on the panel. | 5 |
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