description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
This application is a division of application Ser. No. 7,411, filed Jan. 29, 1979.
BACKGROUND OF THE INVENTION
This invention relates generally to pressure sensitive mates and in particular to semiconductor pressure sensing mats and circuits for detecting various pressure parameters and performing various functions.
The pressure sensitive treadles or mats of the prior art that were used to activate doors or intrusion detecting devices generally were of the switch type, that is, either the electrical current was switched "on" or "off" when pressure was applied to the mat. Some prior art mats utilized fibrous or porous materials that were impregnated with an electrical conducting material such as graphite or carbon. Such mats were designed to be rather thick and were readily compressible. They operated on the principle that compressing the graphite, carbon or other conductive material, caused a reduction in electrical resistance of the mat core material. In other words, there had to be substantial motion or deflection of the mat material to produce the resistance change. The problem with such mats was their instability under varying conditions of temperature and moisture content. For this reason, accurate measurement of pressures was not possible.
SUMMARY OF THE INVENTION
The pressure sensing mat of the present invention comprises, basically, a thin elastically deformable sheet of semiconductor material having an electrical conductivity generally invariable according to internal pressure applied to the semiconductor mat material itself. The mat material is sandwiched between two sheets of metal selected from the group consisting of aluminum, steel and copper and alloys thereof which are placed in mechanical contact with the semiconductor material. A circuit for measuring threshold voltage (which is also a function of pressure on the electrodes on the mat if connected to the electrode. Other circuits in which the mat is used include a learning circuit for establishing a threshold voltage and a circuit for measuring pressure-time functions such as for signature verification.
A further embodiment of the present invention utilizes a plurality of pressure sensing mats arranged in ordered array of rows and columns with scanning circuits to detect ordinate and abscissa coordinates of pressure locations.
It is, therefore, an object of the present invention to provide a pressure sensing mat having variable electrical conductivity in proportion to applied pressure.
It is a further object of the present invention to provide a pressure sensing mat and circuits therefore.
It is another object of the present invention to provide a pressure sensing mat and circuit which produces an output signal when a predetermined minimum pressure is applied to the mat.
It is still a further object of the present invention to provide a pressure sensing mat in which a learning circuit is employed to establish the predetermined pressure level to be detected.
It is still another object of the present invention to provide a pressure sensing mat and circuit therefore that produces an output signal when a pressure is applied to the mat which is between a predetermined maximum and minimum pressure.
It is yet another object of the present invention to provide a pressure sensing mat and circuit therefore in which a pressure-time function is measured and compared with a prior pressure-time function.
It is yet a further object of the present invention to provide a pressure sensing mat and circuit therefore adapted as a sectional unit of a matrix of pressure sensing mats.
It is a further object of the present invention to provide a matrix of pressure sensing mats and circuits therefore to act as an area monitor.
It is another object of the present invention to provide a matrix of pressure sensing mats and circuits therefore as a path determining device.
These and other objects of the present invention will be manifest upon study of the following detailed description when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional elevational view of the typical pressure sensing mat of the present invention.
FIG. 2 is a schematic circuit diagram of a threshold and learning circuit for use with the pressure sensing mat of the present invention.
FIG. 3 is a circuit diagram for the pressure sensing mat of the present invention adapted for use with an alternating current voltage supply.
FIG. 3A is a circuit diagram for the pressure sensing mat of the present invention adapted for use with a direct current voltage supply.
FIG. 4 is a circuit diagram for a pressure sensing mat of the present invention in which pressure-time variations are used to verify signatures or the like.
FIG. 4A is a graph showing a typical pressure-time curve for a signature.
FIG. 5 is a circuit diagram for the pressure sensing mat of the present invention in which two mats are utilized to actuate a device when a pressure level is detected between a predetermine maximum and minimum value.
FIG. 6 is a circuit diagram for a pressure sensing mat of the present invention adapted to count the number of vehicles entering and leaving an area and in which functions are performed when the area is empty and when it is full.
FIG. 7 is a top view of a pressure sensing mat of the present invention adapted to be joined with like mats to define a matrix of mats.
FIG. 7A is a bottom view of the pressure sensing mat of FIG. 7.
FIG. 7B is an elevational sectional view of the pressure sensing mat of FIG. 7 and 7A taken at line 7--7.
FIG. 8 is a schematic electrical diagram of a matrix of pressure sensing mats of FIG. 7 showing their method of electrical connection as a matrix.
FIG. 9 is an elevational sectional view of the matrix of pressure sensing mats of FIG. 8 taken at line 9--9.
FIG. 10 is a schematic electrical diagram illustrating the use of a matrix of pressure sensing mats adapted to create an X-Y coordinate display of pressure locations on a cathode ray tube.
FIG. 11 is a schematic electrical diagram of a matrix of pressure sensing mats of the present invention adapted to detect travel paths and learning paths.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, there is illustrated an elevational cross-sectional view of the pressure sensing mat 10 of the present invention which comprises, basically, a core 12 sandwiched between a first electrode 14 and a second electrode 16. Leads 18 and 20 are electrically connected, respectively, to electrodes 14 and 16, and are used to connect pressure sensing mat 10 to the other circuit members.
Specifically, core 12 comprises a thin elastically deformable sheet of semiconducting material having an irregular surface and an electrical conductivity generally invariable according to internal pressure of the material. Such a material having an irregular surface can be a thin sheet of fibrous material, such as cellulose fiber, impregnated with colloidal graphite. A typical core 12 would have a thickness approximately 0.003 cm. Core 12 also comprise a thin plastic sheet material having colloidal graphite suspended in the plastic in sufficient quantity to make it anti-static but retaining a relatively high resistivity. The surface of the plastic must be roughened to a degree as to cause microscopic irregularities or ridges and depressions to be created in the surface of the plastic. The thickness of the plastic sheet material can be approximately 0.001 cm.
First and second electrodes 14 and 16, respectively, are typically fabricated from aluminum, steel or copper foil when used with core 12 having a colloidal graphite filler.
Electrodes 14 and 16 are arranged to be in contact with the roughened surface of core 12 such that the surface of the metal foil and the surface of core 12 interact mechanically.
Where the variable resistance materials of the prior art utilize granular or loosely woven electrically conductive fibers to achieve their variable resistance with applied pressure, core 12 of the present invention does not rely on such phenomena.
As distinguished from other materials of the prior art, the variable resistance of mat 12 is achieved through the surface roughness or microscopic surface irregularities combined with the resilience or elastic deformability of the material. When no significant pressure is applied to the electrodes placed on the surface of core 12, the electrodes will "ride on " or be supported on the "peaks" or tips of the ridges of the surface. irregularities. When a pressure is applied to the electrodes, the surface irregularities are flattened or compressed and are caused to spread out over a larger area or surface of the electrode thus causing an increase in surface area through which electrons can pass and a resulting decrease in mat resistance. When the pressure on the electrode is released, since the core 12 material is elastically deformable, the electrodes will be forced away from the surface of core 12 to again "ride" on the tips of the surface irregularities.
Because of this, it has been found that the use of an electrically conductive paint or glue to hold the electrodes to the core material will destroy the ability of the combination to be sensitive to pressure. In a like manner, if a conductive fluid is placed between the electrode and the core material, the combination will again become insensitive to pressure. The operation of mat 10, therefore, does not depend upon the compression of the fibers within core 12 to increase conductivity, but rather, it depends upon the interaction of the surface of the aluminum, steel or copper, or any of their alloys, with the microscopic surface irregularities of the material of core 12.
With reference to FIG. 2, there is illustrated a schematic diagram of a typical circuit used to actuate a device 30 such as a relay which in turn could actuate any device such as a door, light, relay or other signal generating device, or the like.
In FIG. 2, electrode 14 is connected to one side of a voltage regulator 22 while electrode 16 is connected first, to a biasing resistor 24, then to a learning circuit 26, which in turn, is connected to a voltage (pressure) threshold detector circuit 28. The output of threshold detector 28 is, in turn, connected to device 30 to be actuated. The other side of voltage regulator 22 is connected to power supply 23.
Learning circuit 26 comprises a capacitor 32 connected in series with electrode 16 and voltage threshold circuit 28. Resistor 34 of learning circuit 26 is connected in parallel with threshold circuit 28.
Threshold circuit 28 comprises an operational or comparison amplifier 36 whose output is connected to device 30 to be actuated and whose one input side is connected to capacitor 32 while its other side is connected to potentiometer 38. Potentiometer 38 is connected in series with D.C. power supply 40.
To operate the circuit of FIG. 2, a weight is applied to mat 10, for example, a 150 pound man steps on electrode 14 to compress electrodes 14 and 16 against core 12. When this occurs, a current is caused to flow through biasing or sensitivity resistor 24 to create a voltage drop across resistor 24 and a voltage transient across capacitor 32 of learning circuit 26. Capacitor 32 and resistor 34 are selected to provide a relatively long time constant for learning circuit 26.
Depending upon the setting of potentiometer 38, the transient electrical signal or voltage across capacitor 32 is detected by comparison or operational amplifier 36, and, if the transient voltage is above the threshold voltage set for amplifier 36, a signal is transmitted to actuating circuit 30, for example, a door, causing it to open.
Since the voltage or electrical signal appearing on the amplifier 36 side of capacitor 32 will slowly decay if the weight is not removed from mat 20, the voltage will slowly decay to below the threshold value for the amplifier and the output signal to actuator 30 will stop and, for example, the door will close.
If, however, the 150 pound man proceeds to step off mat 10, and immediately therafter, say, a 100 pound man steps on mat 10, his weight will be insufficient to cause a high enough voltage drop across resistor 24 and no transient will appear at the input side of amplifier 36 through capacitor 32. Thus, amplifier 36 will not emit an output signal to cause circuit 30 to be actuated.
However, if a 200 pound man were to step on mat 10, a higher voltage drop would appear across resistor 24 resulting on a transient voltage equal to the difference between the voltage drop caused by the 150 pound man and the voltage drop caused by the 200 pound man to appear across capacitor 32 and the input of amplifier 36.
This would, of course, cause an output signal from amplifier 36 to actuate circuit 30.
A more detailed circuit diagram is shown in FIGS. 3 and 3A. The circuit of FIG. 3 is adapted for use with an alternating current source of supply, while the circuit of FIG. 3A is adapted for use with a direct current source of supply.
With reference to FIG. 3, voltage regulator circuit 22, voltage threshold circuit 28 and learning circuit 26 are shown in greater detail. In addition, a noise eliminator circuit 42 is also provided. Noise eliminator circuit 42 comprises a capacitor 43 connected across electrodes 14 and 16.
Also shown in FIG. 3, at the output end of the circuit, is rectifier circuit 44 used to convert the alternating current supplied to the circuit to a pulsating direct current.
In particular, rectifier circuit 44 comprises a set of four diodes 46 connected as a wheatstone bridge 48 in combination with noise eliminating capacitor 50 connected across output leads 52 and 54.
With respect to voltage regulator circuit 22, this circuit comprises a resistor 56 connected in series with plurality of serially connected zener diodes 58. The other end of serially connected diodes 58 is connected to one input side 60 of Wheatstone bridge circuit 48.
The junction point 62 at the other end of serially connected diodes 58 and resistor 56 is also connected to lead 18 of electrode 14. The other end of resistor 56 is connected to the other input side of Wheatstone bridge circuit 48.
Threshold circuit 28 of FIG. 3 comprises a silicon rectifier 66 having an anode 67, a cathode 69 and a gate 65. Cathode 69 is connected to input 60 of rectifier 44 while anode 67 is connected to the other side of rectifier 44. Gate 65, used to trigger silicon rectifier 66, is connected to junction point 72 of learning circuit 26.
Learning circuit 26 comprises a first resistor 70 having one end connected to junction point 62 of voltage regulator circuit 22 with its other end is connected to junction point 72, which in turn, as noted above, is connected to the gate 65 of silicon rectifier 66, as well as one side of capacitor 74 and one end of second resistor 76. Anode 67 of silicon rectifier 66 is connected to input side 64 of Wheatstone bridge 48 (rectifier circuit 44), while cathode 69 of silicon rectifier 66 (as noted above) is connected to input side 60 of Wheatstone bridge circuit 48.
The other side of capacitor 74 is connected to lead 20 and electrode 16 of mat 10. The other end of second resistor 76 is connected to the input side 60 of rectifier circuit 44.
With reference to FIG. 3A, there is illustrated a circuit similar in all respects to the circuit of FIG. 3 with the exception that rectifier circuit 44 is not used and silicon rectifier 66 is replaced by transistor 79 in threshold detector 28.
In the circuit of FIG. 3A, junction point 72 of learning circuit 26 is connected to the base of transistor 78 while its collector is connected to output lead 64 and its emitter is connected to output lead 60.
With respect to the operation of the circuit of FIG. 3, when, say, a 100 pound weight is applied to mat 10, a voltage drop will appear across sensitivity resistor 68 and a transient will appear across capacitor 74. Sensitivity resistor 68 is sized to a value that will give a signal for about a half loaded mat 10. Capacitor 74 and resistors 56, 70 and 76 are sized to give a generally long time constant.
The transient voltage across capacitor 74 will also appear at gate 65 of silicon rectifier 66 causing it to conduct, thus creating a signal across output leads 52 and 54.
The voltage to mat 10 is maintained at a generally constant value by voltage regulator 22 using resistor 56 in series with zener diodes 58. For this configuration, node or connection point 62 remains at a relatively constant voltage independent of any fluctuating voltage across input 60 and 64 of rectifier circuit 44.
With respect to the operation of the circuit of FIG. 3A, when a weight is applied to mat 10, a voltage drop will occur across resistor 68 and a transient voltage will appear across capacitor 74. The transient voltage will also appear at base 75 of transistor 78 which causes transistor 78 to conduct thus creating a signal across leads 60 and 64. In the case of the circuit of FIG. 3A, the resulting output current through leads 60 and 64 will be somewhat proportional to the weight applied to mat 10. It should be noted that all previous circuits, i.e., the circuit of FIGS. 2 and 3, can be made operational without the use of learning circuit 26. In this situation the circuit of FIG. 3A will trigger at a set weight determined by the parameters of the threshold device 28, mat 10, sensitivity resistor 68 and the voltage at junction 62.
With respect to FIGS. 4 and 4A, there is illustrated a block circuit diagram for a device for verifying signatures by means of a pressure-time diagram as illustrated in FIG. 4A.
Signature verifying circuit 80 comprises a pressure sensing mat 10 of the type previously described for FIG. 1, which is connected to a pressure-time recorder or temporary storage memory 82. A library of pressure-time recordings is stored in permanent storage memory 84. The two pressure-time recordings are then compared using time scale adjusting circuit 86 in conjuction with pressure matching circuit 88.
Scale adjusting circuit 86 comprises a clock 90 connected to a clock pulse counter 92. Clock 90 is also connected to scale timer 94 and finish time element 98.
Pressure matching circuit 88 comprises, basically, a maximum pressure detector 116 and a minimum pressure detector 118, connected in parallel, and connected to a scale force adjusting circuit 100. Force adjusting circuit 100 is connected through resistor 102 to one input side of comparison amplifier 104. The other input side of comparison amplifier 104 is connected through resistor 106 to permanent memory 84.
Signature verifier circuit 80 also comprises a start-stop detector 87 which connects pressure sensing mat 10 to clock 90, and scale timer 94. A master control circuit 83 is used as a central control means for signature verifier circuit 80 and is connected to start-stop detector 87, compare scaling control 94, one side of control-permanent memory transfer switch 81 and flip-flop circuit 85.
A control-permanent memory transfer switch or relay 81 is used to connect the output sie of force adjusting circuit 100 either to permanent memory 84 or master control unit 83, depending upon whether the signature is to be written for enty into the permanent memory 84 or comparison with a signature already stored in permanent memory 84.
The output side of comparison amplifier 104 is connected to one input side of first deviation amplifier 108 and one input side of second deviation amplifier 110. The output side of deviation amplifiers 108 and 110 are connected to an input side of OR-gate 112. The output of OR-gate 112 is connected to one input side of AND-gate 114. The other input side of AND-gate 114 is connected to scale timer 94 through inverter 115.
The output side of AND-gate 114 is connected to the input side of flip-flop circuit 85, the output of which is used to indicate a "no output signal" condition.
The sampled forces on sensing mat 10 are measured for maximum and minimum forces by maximum force or pressure scaling unit 116 and minimum force or pressure scaling unit 118.
Pressure sensing mat 10 is used with a normal pen or pencil 117 to measure the vertical force or pressure produced during writing of a signature to create a pressure (force) vs. time diagram 119, as shown in FIG. 4A. The maximum and minimum forces measured during the signature learning mode are retained by maximum force scaling unit 116 and minimum force scaling unit 118 and are used in conjunction with scale force adjusting circuit 100 during the comparison phase. The time period is normalized from the start of the signature to its end by scale adjusting circuit 86.
In particular, when a pen or writing implement 117 is applied to mat 10, start-stop detector 87 is activated upon detection of a predetermined minimum pressure to start clock 90 to begin counting in predetermined time increments while the pressure values are being recorded in temporary storage memory 82. Clock 90 continues to count as long as pen 117 is applying a pressure to mat 10 which is greater than the predetermined minimum detectable pressure. At the end of the signature when pen 117 is raised, clock 90 will stop its count. The last count value of clock pulse counter 92 is saved in finished time element 98.
Either automatically upon completion of the signature or by command from control unit 83, clock 90 will again operate to increment counter 92 and comparison scaling counter 94. Comparison scaling counter 94 divides the number of incoming clock pulses by the last value from counter 92 as saved in finished time element 98 and then multiplies this result by the number of memory cells of the signature that is pre-recorded in permanent memory 84. Each memory cell corresponds to a predetermined time period when the original signature was recorded.
This produces an index to the signature in permanent memory 84 which varies exactly from zero to the maximum size of space in memory 84. The size of each memory work space is arranged to be large enough to contain any signature of reasonable length.
During the comparison phase of the signature verifier, the count from counter 92 will vary from 0 to the end of the time of the signature just written (and stored in temporary memory 82) while comparison counter 94 will vary from 0 to the end of signature stored in permanent memory 84. The two signatures are then scanned in time increments for each signature corresponding to the signature writer's pen position along the signature.
The following tabulation illustrates the settings and conditions of the various modes of operation of the signature verifying circuit 80:
______________________________________Circuit or Unit Setting or Condition______________________________________LEARNING SIGNATURE MODEPHASE A: Signature being recorded preliminary to storage inpermanent memory 84 as master signature for comparison.Clock 90 Starts pulsing upon signal from start-stop circuit 87.Counter 92 Initially set to "0". Counts pulses from clock 90 during signature.Finish Time Element 98 Reset.Comparison Scale Counter 94 Reset.Permanent Memory 84 Off.Temporary Memory 82 On.Transfer Switch 81 Disconnect from memory 84.Master Control Unit 83 Programmed to reset circuit elements to Phase B at the end of signature.Max. Force Scaling Unit 116 Set to record maximum force observed.Min. Force Scaling Unit 118 Set to record minimum force observed.Flip-flop Circuit 85 No comparison.END OF SIGNATUREPHASE B: Transition phase between recording signature andtransferring signature to premanent storage memory 84.Clock 90 OffCounter 92 Stop count and hold last count.Finish Time Element 98 Save value of last count from counter 92.Comparison Scaling Unit 94 Off.Max. Force Scaling Unit 116 Save maximum force value.Min. Force Scaling Unit 118 Save minimum force value.Master Control Unit 83 Programmed to reset circuit elements to Phase C after Phase B.Transfer Switch 81 Disconnect from memory 84.Flip-flop Circuit 85 No Comparison.TRANSFER SIGNATURE TO MEMORYPHASE C: Signature stored in temporary memory 82 istransfered to permanent memory 84.Transfer Switch 81 Set to connect force scaling unit 100 to permanent memory 84.Permanent Memory 84 Record only condition.Finish Time Element 98 Hold value.Max. Force Scaling Unit 116 Hold value.Min. Force Scaling Unit 118 Hold value.Clock 90 Continue to count until count of counter 92 is equal to finish time element 98 count then stop.Comparison Scale Counter 94 Count and perform time scaling.Counter 92 Continue count.Force Scaling Unit 100 Perform force scaling function.COMPARE SIGNATURE MODEPHASE D: Input signature is compared to stored signature.In all prior phases, the output signal is ignored. In Phase D,the output signal from flip-flop circuit 85 indicates whethersignature is genuine.Transfer Switch 81 Disconnected from memory 84.Permanent Memory 84 Read only condition.Finish Time Element 98 Hold value.Max. Force Scaling Unit 116 Hold value.Min. Force Scaling Unit 118 Hold value.Clock 90 Continues to run until counter 92 count is equal to finish time element 98 count.Scale Timer 94 Count and perform time scaling function.Force Scaler 100 Perform force scaling function.Phase D ends when counter 92 equals the count from finishtime element 98.______________________________________
It should be noted that circuit elements 102, 106, 108, 109, 110, 111, 112, 114 and 115 continue to function during the setting and resetting of flip-flop circuit 85 by master control 83, however, the output of these circuits will be meaningful only during Phase D when circuit 80 is in the comparison mode.
Thus the pressure vs. time graph 119 (stored in temporary memory 82) is electronically compared using force or pressure matching circuit 88, with previous pressure vs. time graphs stored in premanent storage memory 84 using comparison amplifier 104. The deviation tolerance in force matching can be set by amplifiers 108 and 110 which have the other input sides connected, respectively, to deviation control units 109 and 111. If the output of deviation amplifiers 108 and 110 matches, a signal is transmitted through AND-gate 112 to indicate authentication of the signature on file.
With reference to FIG. 5, there is illustrated an adaptive maximum-minimum pressure actuator circuit 120 in which a circuit or device is activated only if the pressure applied to the mat comes within maximum and minimum pressure conditions.
The output side of first threshold detector circuit 122 is connected to one side of AND-gate 126 through inverter 128, while the output side of second threshold detector circuit 124 is connected to the other side of AND-gate 126.
In particular, circuit 120 comprises the same circuit elements as the circuit of FIG. 2 with the exception that two threshold detector circuits 122a and 122b are used in place of the single threshold detector 28 of FIG. 2.
Just as in FIG. 2, circuit 120 comprises electrode 14 which is connected to one side of voltage regulator 22 while electrode 16 is connected first to a biasing resistor 24, then to learning circuit 26. Learning circuit 26 can be an optional circuit in circuit 120.
Learning circuit 26, in turn, is connected to the input side of first and second threshold detectors 122a and 122b, respectively.
Similar to FIG. 2, learning circuit 26 of circuit 120 comprises a capacitor 32 connected in series with electrode 16 and first and second voltage threshold circuits 122a and 122b. Resistor 34 of learning circuit 26 is connected in parallel with first and second threshold circuits 122a and 122b.
First and second threshold circuits 122a and 122b are identical and comprise, referring to circuit 122a, operational or comparison amplifier 124a whose one input side (negative) is connected to electrode 16 through learning circuit 26, while its other side (positive) is connected to potentiometer 126a. Potentiometer 126a is connected in series to D.C. power supply 128a.
To operate the adaptive-minimum actuator circuit 120 of FIG. 5, first and second threshold circuits 122a and 122b are manually set to trigger at a particular weight. First threshold detector 122a is set to the maximum weight which will activate a signal while second threshold detector 122b is set to the predetermined minimum which will activate a signal. The next person stepping on mat 10 must come within those maximum and minimum pressure settings in order to cause a signal to be transmitted from AND-gate 130.
With reference to FIG. 6, there is illustrated a circuit using several mats 10 of the present invention in a circuit 140 in which a counting function is performed as, for example, in a garage where, if no cars are present, the lights are turned "off", and where one or more cars are present the lights are turned "on". In addition, when the garage is filled to capacity, a warning sign is activated to advise that no more parking spaces are available. The garage, in addition, can have any number of entrances and exits.
In FIG. 6, circuit 140 comprises two sets of in-out mats 142a-142b and 144a-144b, respectively, at each of the two exit-entrance 142 and 144. Mats 142a and 144a are both connected to threshold detector 146a, while mats 142b and 144b are both connected to threshold detector 146b.
The output of first threshold detector 146a is connected both to the input side of timer 148a and one input side of AND-gate 152, while second threshold detector 146b is connected both to the input side of timer 148b and one input side of AND-gate 150.
The output of timer 148a is connected to the other input side of AND-gate 150, while the output of timer 148b is connected to the other input side of AND-gate 152.
The output side of AND-gate 150 is connected to the "up" count terminal 154 of counter 158, while the output side of AND-gate 152 is connected to one input side of AND-gate 156, whose output side, in turn, is connected to "down" count terminal 160 of counter 158. The other input side of AND-gate 156 is connected, through inverter 162 to the "0" count terminal 164 of counter 158.
The maximum count terminal 166 of counter 158 is connected to relay 168 used to actuate "FULL" warning signs 172 while the "0" count terminal 164 of counter 158 is used to actuate relay 170 when counter 158 is on any count greater than "0". Relay 170 is used to turn light 174 "on" when the count on counter 158 is greater than "0", and "off" when the count is "0".
Thus, in operation, when no cars are in the garage, counter 158 is set to "0" at which condition light 174 is in the "off" condition. As a vehicle enters, for example, entrance 142, it first passes over mat 142a, and then a short time interval later, it passes over mat 142b. Thus two signals, spaced apart in time, are created first by threshold circuit 146a and then second by threshold circuit 146b. The signal transmitted by threshold circuit 146a will be delayed a corresponding interval of time by timer 148a such that the output signal from timer 148a will reach the input side of AND-gate 150 at the same time as the signal from threshold circuit 146b, thus producing an output signal from AND-gate 150 to the "up" count terminal 154 of counter 158 thus raising the count to "1". When this occurs, light 174 is turned "on" by relay 170 and remains on as long as the count is greater than "0".
When a vehicle leaves the garage, the reverse situation occurs whereby a signal is received at the "down" count terminal 160 of counter 158 to subtract a vehicle count from counter 158. The connection of the output side 164 of counter 158 to inverter 162 of AND-gate 156 is for the purpose of preventing a negative count.
After a sufficient number of vehicles have entered the garage area to reach a predetermined maximum count, "max" terminal 166 of counter 158 is activated which also actuates relay 168 to turn "FULL" warning signs 172 "on". As a vehicle leaves the garage, the warning lights 72 are turned "off" when the count is below the predetermined maximum.
With reference to FIGS. 7, 7A and 7B, there is illustrated a typical modular strip mat 180 for use with other light strip mats to form a matrix of mats defining rows and columns of modular mat units.
In particular, with reference to FIGS. 7 and 7B, there is shown a top view of a typical modular mat unit 180 comprising a core 182 of a sheet of semiconductor material. On top of core 182 are positioned squares 184a through 184f of aluminum, steel or copper foil with electrical conductors 186a through 186f connected, respectively, to squares 184a through 184f and running the length of mat 180 to one end of core 182 where they are adapted to be connected to a suitable plug or contactor (not shown) common in the art.
With reference to FIGS. 7A and 7B, the underside of mat 180 is shown with core 180 covered with a strip 188 of aluminum or copper foil approximately the same size as core 182. A conductor 190 connects strip 188 with a suitable plug connector (not shown) common in the art, for connection to the electrical circuit devices as described and shown elsewhere in the other figures of the drawings and described below.
With reference to FIG. 8, there is illustrated a schematic electrical diagram 200 of a matrix of mats 202 of the type illustrated in FIG. 7. The matrix is arranged in rows 204, namely, rows 204a through 204e, and columns 206, namely, columns 206a through 206f.
Conductors 208, namely 208a through 208e, connect the underside of one foil electrode for mat 202 as a row. Since mats 202 can be in the form of an elongated strip running the length of the core, as shown in FIG. 7, conductor 208 can correspond to strip electrode 188 of mat 180 of FIG. 7.
Conductors 210, namely, 210a through 210f connect the top squares or each mat 202 column 206 through connector lead 212 which also contains a diode 214 in series with the top electrode to prevent back flow of current by virtue of a circuit path from an activated mat through an inactivated mat.
Thus, a matrix of mats defining a cartesian coordinate system of X and Y coordinates of mats 202 is provided in which an objects weight can be detected and its position located.
For example, with reference to FIG. 10, such a mat matrix circuit 250 is shown using a circuit for graphically displaying the coordinate location of the object.
Circuit 250 of FIG. 10 utilizes a matrix 252 of mats 254 arranged in ordered array in rows 256 (256a through 256e) and columns 258 (258a through 258e). In all respects, mat matrix 252 is the same as mat matrix 200 of FIG. 8.
Circuit 250 further comprises a row scanner 260, which is connected to each row 256a through 256e, and a column scanner 262, which is connected to each column 258a through 258e.
Row scanner 260 is connected to and is controlled by row scanner control unit 264, while column scanner 262 is connected to and controlled by column scanner control unit 266.
Row scanner control unit 264 is also connected to vertical deflector plates 270 of cathode ray tube (CRT) 268 while column scanner control unit 266 is connected to horizontal deflection plates 272 of cathode ray tube (CRT) 268.
Also connected to row scanner 260 is voltage amplifier 274 whose suitably amplified output is connected to electron emitting cathode 276 of CRT 268. A load resistor 275 connects the input side of voltage amplifier 274 to ground. The purpose of load resistor 274 is the same as resistor 24 in FIG. 2, namely, when a matrix point is scanned, the current flowing through it is inversely proportional to the resistance of the point. This current then flows through resistor 276 generating a voltage that is inversely proportional to the resistance of the matrix point. An output signal from voltage amplifier 274 which is inversely proportional to the resistance at the matrix point being scanned, is arranged to cause an increase in electron beam brightness at the CRT 268 screen.
A clock or scanner control 278 is connected to both row scanning control unit 264 and column scanning control unit 266 to regulate the rate and sequence of scanning rows 256 and columns 258.
As an exmaple of the operation of circuit 250, weights 280, 282 and 284 are placed on mat matrix 252, respectively, at coordinates 256a-258b, 256b-258d and 256e-258e.
Using clock 278, column scan control unit 266 activates column scanner 262 to begin scanning at column 258a. At the same time, scan control unit 266 energizes horizontal deflection plates 272 of CRT 268 to deflect an electron beam 286 to an appropriate position on the left side of CRT 268 screen. While positioned at column 285a, clock 278 actuates row scanner control unit 264 to cause row scanner 260 to scan rows 256a through 256e in sequence. At the same time, row scanner control unit 264 energizes vertical deflection plates 270 of CRT 268 causing electron beam 286 to deflect vertically in steps corresponding to a row coordinate. Since no weight was placed on any mat in column 258a, no voltage is detected by threshold detector 274 to cause electron beam 286 to become brighter.
However, in the case of column 258b, when column 258b is scanned in the manner previously described for column 258a, when row 256d is reached, weight 280 is detected by threshold detector 274 and a voltage is generated at the output terminals of detector 274. This voltage causes cathode 276 to emit more electrons thus causing beam 286 to generate a bright spot 290 on CRT 268 screen at a coordinate position corresponding to the coordinate position that weight 280 occupies on mat matrix 252.
In a similar manner, spots 292 and 294 are generated corresponding to the coordinate positions of weights 282 and 284.
When a transistor and amplifier are used in threshold detector 274, the intensity of the spots or CRT 268 will vary corresponding to the magnitude of the weight detected by detector 274.
With reference to FIG. 11, there is illustrated a block schematic diagram 300 of a device for area surveillance and path learning.
The circuit comprises, basically, a matrix of mats 302 arranged in rows 304 and columns 306 of individual mats 308.
One side, or electrode, of mats 308 in rows 304 is connected to demultiplexer or "I" or row scanner 310, while the other side, or electrode, of mats 308 defining columns 306 is connected to electronic analog switch or "J" or columns scanner 312.
An "I-J" scan generator 314 is connected to demultiplexer 310 and analog switch 312 which function to cause all mats 308 to be sequentially scanned according to a predetermined row 304 and column 306 sequence. For example, columns 306a through 306d are scanned for row 304a, then columns 306a through 306d are scanned for row 304b, etc., until all columns have been scanned for all rows. A clock 316 is connected to "I-J" scan generator to regulate the timing of the scan.
A memory 318 is connected to the "I" and "J" outputs of scan generator 314.
The output side of electronic analog switch 312 is connected to analog-to-digital converter 320 either through learn-observe switch 322 or through maximum signal generator circuit 324.
The output or digital signal side of analog-to-digital converter 320 is connected both to the input side of memory 318 and one input side of digital comparator circuit 326. The output of memory 318 is connected to the other input side of digital comparator 326. The "high" output side of digital comparator 326 is connected to the input side of memory 318 through "learn" switch 328.
Maximum signal generator 324 can be an optional additional circuit to circuit 300. The input side of circuit 324 is connected to a load resistor 332, which is always required, having one end connected to the output side of electronic analog switch 312 with the same end also connected to one side of comparison amplifier 334 in circuit 324. The other side of load resistor 332 is connected both to ground and to one side of sensitivity adjusting potentiometer 336 whose other side is connected to ground through power supply 338. The sliding contactor 340 of potentiometer 336 is connected to the other side of comparison amplifier 334. The output side of comparison amplifier 334 is connected to analog multiplexer 342 which, in turn, is connected to the input side of analog-to-digital converter 320. Power is supplied to analog multiplexer 342 by power supply 344.
When operating circuit 300, two modes must be considered, namely, the (1) path or area learning mode, and the (2) path or area observing mode.
In the path learning mode, "I-J" scan generator 314 is used to actuate demultiplexer 310 to first hold on row 304a, that is, to apply a voltage to one side or electrode of mats 308 in row 304a while sequentially switching to each column 306a through d using electronic analog switch 312 which is connected through diode 350 first to column 306a, then column 306b etc., and finally to column 306d (or as many column as might be available). The process is repeated for rows 304b through 304c (or as many rows as might be available). Thus the condition of each mat is individually monitored or sampled.
The weight, pressure or output signal from the mats is switched through electronic analog switch 312 sequentially connecting mats 308 to maximum signal generator 324. Maximum signal generator 324 generates a maximum signal if the input value or pressure is above a predetermined value, otherwise it passes the signal from the mats directly to analog to digital converter 320.
After passing through maximum signal generator 324, the analog output signal from electronic analog switch 312 is converted to a digital signal by analog-to-digital converter 320. Thus any pressure on any of the mats 308 is represented by a digital value.
The purpose of maximum signal generator 324 is to set the memory weight or pressure data for the appropriate mats 308 to the maximum value so that during the observation mode, there will be no pressure or path mat that will cause a high signal when compared with the associated value in memory 318.
Concurrently, the scanning sequence is recorded in memory 318 so that each mat is addressed in memory 318 and concurrently provided with a corresponding digital pressure value as mat matrix 302 is sequentially scanned.
Thus, as a person walks over a path while the apparatus is in the learning mode, the values of weight in memory 318 associated with each mat walked upon will be those generated by the weight of the person, while the values for all other mats will be generated by the ambient weight conditions.
After the path learning is completed, switch 322 is connected to the "observe" condition and switch 328 is switched to "off".
The apparatus is now in the path observing mode. While in this mode "I-J" scan generator 314 continuously scans the rows and columns as it did in the learning mode. In the observing mode, maximum signal generator 324 is by-passed to provide only the output signal from mats 308 to analog to digital converter 320. The output side of digital comparator 326 is disconnected from memory 318, but its input side remains connected to the output of memory 318. Now, if any mat not in the learning path shows a pressure, memory 318 will read out the recorded pressure which is compared by digital comparator 326 with the input signal. If a difference exists, alarm 348 will sound. | A pressure sensing mat utilizes a thin sheet of semiconductor material that has an electrical conductivity generally invariable as to pressure applied to the mat material. The sheet of semiconductor material is sandwiched between sheets of copper, steel or aluminum foil which are in mechanical contact with the semiconductor sheet to define a pair of electrodes. The electrodes are connected to various circuits including a pressure (voltage) threshold detector, a learning circuit for establishing a learned threshold, a circuit for matching time-pressure patterns and a circuit for detecting pressures between a predetermined maximum and minimum level. A matrix of pressure sensing mats is utilized with various circuits to detect sequential pressure patterns. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a pollen sensor and method for detecting pollen particles and discriminating pollen particles floating in air from other particles on a real time basis. More specifically, the pollen sensor and method detects pollen particles floating in air which can be a cause for pollenosis.
BACKGROUND OF THE INVENTION
[0002] Conventionally, a microscope has been used to detect the number of pollen particles floating in air using a visual inspection process in which a glass plate is exposed to air for some time to collect pollen particles. The glass plate is stained, followed by a skilled technician's counting by visual inspection the stained particles through his or her microscope (hereinafter referred to as the “microscope method”).
[0003] The above microscope method is a lengthy time consuming process requiring advanced skills to count the stained pollen particles by visual inspection. In addition, the microscope method does not permit pollen particles to be detected on a real time basis which is a significant drawback. The place for taking measurements using a microscope is also very limited, which is another drawback.
[0004] It is also known to detect pollen particles on a real time basis utilizing polarized light. This alternate method is disclosed in Japanese Patent No. 3113720 and in Japanese Patent Publication No. 2001-83079. The pollen detector described in Japanese Patent No. 3113720 does not require the expertise that the microscope method requires, and the measurement result can be obtained anywhere on a real time basis. Nevertheless, the quantity of pollen particles floating in air is so small that to increase the available number of pollen particles, a large volume of air should be blown into the detection zone. However, this also increases the probability of other floating particles being simultaneously passed into the detection zone. Since the pollen detector described in Japanese Patent No. 3113720 cannot discriminate pollen particles from other floating particles, the pollen detector is prone to error. Moreover, either a decrease in luminous energy emitted from the light source over time or lens contamination will reduce the intensity of the scattered light beams, making it even more difficult to discriminate pollen particles from other particles.
[0005] A similar detection device is described in Japanese Patent Publication No. 2001-83079 which is capable of measuring floating particles in real time. This device cannot discriminate pollen particles from other particles passed through the detection zone when the volume of air blown into the detection zone is increased. Accordingly, this device has the same deficiencies as the pollen sensor described in Japanese Patent No. 3113720.
OBJECTS OF THE INVENTION
[0006] It is an object of the present invention to provide a pollen sensor and method of detection capable of accurately counting the number of pollen particles floating in the air in a detection zone on a real time basis. Another object of the present invention is to provide a pollen sensor and method for accurately discriminating pollen particles from other floating particles even if the luminous energy emitted by the illumination portion is weakened over time.
SUMMARY OF THE INVENTION
[0007] The present invention is based on the discovery that the degree of polarization of scattered light beams from pollen particles is smaller than the degree of polarization from other floating particles even of the same particle size as pollen particles. This principal is used in the pollen sensor of the present invention to discriminate pollen particles from other floating particles.
[0008] The pollen sensor of the present invention comprises: an illumination portion for illuminating particles floating in air using light beams polarized in a given direction; a first receiver for selectively measuring the intensity (Ip) of a light beam from a detection zone polarized parallel to the light beam polarized in a given direction from the illumination portion with the light beam selected from a group of light beams scattered by the floating particles; a second receiver for selectively measuring the intensity (Is) of light beam from a detection zone polarized perpendicular to the light beam polarized in a given direction from the illumination portion with the light beam selected from a group of light beams scattered by the floating particles and means for discriminating pollen particles from other floating particles including means for computing the degree of polarization of such particles as an arithmetic value from the intensity (Ip) of the polarized light beam detected by the first receiver and the intensity (Is) of the polarized light beam detected by the second receiver.
[0009] In accordance with another embodiment of the present invention, the pollen sensor comprises: an illumination portion for illuminating particles floating in air using a light beam polarized in a given direction; a first receiver for measuring the intensity (I) of a light beam corresponding to the dispersion of the light beam scattered by the floating particles; a second receiver for selectively measuring the intensity (Is) of light beams polarized perpendicular to light illuminated by the illumination portion from a group of light beams scattered by the floating particles; means for discriminating pollen particles from other floating particles from the degree of polarization of such particles computed from the intensity (I) of the scattered light beam detected by the first receiver and the intensity (Is) of the polarized light beam detected by the second receiver.
[0010] When the incident light is linearly polarized (hereinafter referred to as the “incident polarizing direction”), the degree of polarization can be computed either as an arithmetic value using (Ip), which is the intensity of light polarized parallel to the incident polarizing direction and (Is) which is the intensity of light polarized in a direction perpendicular to the incident polarization direction or as an arithmetic value using (I), which is the intensity for all polarized scattered light, and (Is) which is the intensity of light polarized in a direction perpendicular to the incident polarizing direction.
[0011] More specifically, for the first embodiment the degree of polarization may be expressed by the formula (Ip−Is)/(Ip+Is) wherein (Ip) is the intensity of the light beam polarized in the incident polarizing direction and (Is) is the intensity of the light beam polarized perpendicular to the incident polarizing direction. Alternatively, for the second embodiment the degree of polarization may be expressed by the formula (I−Is)/I wherein (I) is the intensity for all polarized scattered light and (Is) is the intensity of a light beam polarized perpendicular to the incident polarizing direction. A comparison of the degree of polarization of the pollen particles to that of other floating particles shows that the degree of polarization for pollen particles is smaller than that of other floating particles. This characteristic permits the pollen sensor to discriminate pollen particles from other floating particles.
ADVANTAGEOUS EFFECTS OF THE INVENTION
[0012] Utilizing the pollen sensor and method of the present invention, any person can readily discriminate pollen particles from other floating particles on a real time basis and can perform a real time analysis of the pollen count. Furthermore, the present invention can discriminate pollen particles form other particles notwithstanding the amount of air blown into the detection zone or the number of floating particles passed through the detection zone.
[0013] In addition, the present invention can accurately discriminate pollen particles from other particles even though the luminous energy from a light source in the illumination portion weakens over time and/or lens contamination occurs reducing the luminous energy that reaches the detection zone. Thus, the pollen sensor and method of the present invention permits simultaneous passage of two or more floating particles with a reliable output even if there is a reduction of light volume from light source due to its life problem, or a reduction of dispersion light volume due to the dirt of a lens.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a cross-sectional view of the pollen sensor of the present invention;
[0015] [0015]FIG. 2 is a plan view of the pollen sensor of FIG. 1, looking downwardly, part of the housing uncovered to show the arrangement of the first and second receiver to the illumination portion;
[0016] [0016]FIG. 3 is a diagrammatic view of the method of detecting the light intensity (Is) and light intensity (Ip) components of light scattered by the floating particles in accordance with the present invention;
[0017] [0017]FIG. 4 is a circuit schematic block diagram of the preferred means for discriminating pollen particles from other particles in the pollen sensor of FIGS. 1 and 2 respectively;
[0018] [0018]FIG. 5 is a histogram illustrating the degree of polarization of 20-micron polystyrene latex particles;
[0019] [0019]FIG. 6 is a histogram illustrating the degree of polarization of 30-micron latex particles;
[0020] [0020]FIG. 7 is a histogram illustrating the degree of polarization of 40-micron latex particles;
[0021] [0021]FIG. 8 is a histogram illustrating the degree of polarization of Japanese cedar pollen particles; and
[0022] [0022]FIG. 9 is a plan view of a pollen sensor similar to that of FIG. 2, showing another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention is described hereinafter with reference to FIGS. 1 - 9 of the drawings. As shown in FIGS. 1 and 2, the pollen sensor of the present invention comprises a shielding housing 14 which forms a confined area for housing an illuminating portion 1 containing a light beam generating source 4 , preferably a semiconductor laser diode. The light beam generating source generates a light beam 20 for illuminating one or more particles 25 (FIG. 3) floating in air within the detection zone F. The light beam 20 has a direction of polarization 22 perpendicular to the plane of the page of FIG. 2 as is diagrammatically illustrated in FIG. 3. The pollen sensor further comprises a first receiver 2 having a photodiode 7 aligned in the scattering polarizing direction of the light beam 20 , preferably at 60 degrees to the incident optical axis “OA” for measuring the intensity (Ip) of light beams polarized in a direction parallel to the incident polarizing direction of light selected from a group of light beams scattered by the floating particles; a second receiver 3 having a photodiode 10 provided in the scattering polarizing direction, preferably at 60 degrees to the incident optical axis “OA”, for measuring the intensity (Is) of light beams in a direction 23 which is polarized perpendicular to the light beam illuminated by the illumination portion selected from a group of light beams scattered by the floating particles and an electronic circuit 32 for discriminating pollen particles from other floating particles.
[0024] The pollen sensor also comprises an air blow port 13 located at the bottom of the shielding housing 14 to direct sampling air drawn from the atmosphere by a fan 26 through the air blow port 13 into the shielding housing 14 . The sampling air is introduced into the sensor in a direction from the bottom to the top of the plane containing FIG. 2.
[0025] Any semiconductor laser diode 4 may be used such as, e.g., an RLD 65 MZT 1 , manufactured by Rohm for generating the light beam 20 . The laser diode 4 is contained in an illuminating portion 1 supported in the housing 14 which, as shown in FIGS. 1 and 2, also includes a polarizing filter 5 and a plastic lens 6 . One example of a polarizing filter 5 is the HN 38 , manufactured by Polaroid. The polarizing filter 5 has a polarizing axis in a direction perpendicular to the plane containing FIG. 2 and is perpendicular to the plastic lens 6 . The plastic lens 6 has a focal length “f” of preferably 10 mm, i.e. f=10 mm. Lens 6 is arranged in the illuminating portion of the sensor in such a manner that the laser light transmitted through the polarizing filter 5 forms parallel beams of light energy upon reaching the detection zone (F). The detection zone F lies at the intersection of the light path through the filter 6 and the light path of the randomly polarized light 24 to the first and second receiver 2 and 3 respectively.
[0026] The first receiver 2 includes a polarizing filter 8 such as, e.g., HN 38 , manufactured by Polaroid, a plastic lens 9 (f=10 mm) and a photodiode 7 such as, e.g., S 2506-02 manufactured by Hamamatsu Photonics for measuring light transmitted through the polarizing filter 8 . The polarizing axis of the polarizing filter 8 is perpendicular to the plane containing FIG. 2 in the same manner as that of the polarizing filter 5 in the illuminating portion 1 of the pollen sensor.
[0027] The second receiver 3 includes a polarizing filter 11 such as e.g., HN 38 , manufactured by Polaroid, a plastic lens 12 (f=10 mm) and a photodiode 10 such as, e.g., S 2506 - 02 manufactured by Hamamatsu Photonics for measuring light transmitted through the polarizing filter 11 . The polarizing axis of the polarizing filter 11 is set perpendicular to the polarizing axis of polarizing filter 5 , which is in parallel to the plane containing FIG. 2.
[0028] As shown in FIG. 4, the photoelectric current conversion signal Ip and the photoelectric current conversion signal Is are fed to current voltage conversion circuits 35 and 36 respectively, to form voltage signals Vp and Vs respectively. The voltage signals Vp and Vs are amplified by the respective amplifiers 37 and 38 and converted into digital signals through the analog to digital converters 40 and 41 and fed into a microprocessor 39 for computing the degree of polarization as an arithmetic value utilizing (Ip), the intensity of polarized light detected by the receiver [2] and (Is), the intensity of polarized light detected by the second receiver [3] in accordance with the following formula:
degree of polarization=( Ip−Is )/( Ip+Is ).
[0029] The computation of the degree of polarization, as defined above, permits a determination to be readily made in accordance with the present invention as to whether the detected particles constitute pollen particles or other floating particles. It has been determined that when the computation of the degree of polarization (Ip−Is)/(Ip+Is) is in the range of 0.35-0.75 the detected particles constitute pollen particles. This range of 0.35-0.75 may vary with changes in the angle of alignment between the photodiode of the first and second receivers and the axis of the illuminating light beam generating portion (optical axis) which, for the preferred embodiment of the present invention, has been set at 60°. FIGS. 5 - 8 are histograms illustrating the comparative measurement of the degree of polarization for 20-micron polystyrene latex particles, 30-micron polystyrene latex particles, 40-micron polystyrene latex particles, and for Japanese cedar pollen particles respectively. The X-axis shows the degree of polarization (Ip Is)/(Ip+Is); and the Y-axis shows the frequency of particle detection. As is apparent from FIGS. 5 - 7 the range of measurement of the degree of polarization for the latex particles falls between 0.7-1.0 and for the Japanese cedar pollen particles as shown in FIG. 8 is between 0.35-0.75 permitting a possible overlap in measurement in the range between 0.70-0.75. Although some overlap in the measurement of the degree of polarization may exist between pollen particles and other floating particles, the degree of overlap consists of only about 5% of the total particle count and is therefore minimal. Thus, pollen particles are readily distinguishable from other floating particles using the pollen sensor and method of the present invention.
[0030] [0030]FIG. 9 is a plan view illustrating the configuration of another embodiment of the pollen sensor of the present invention. The pollen sensor in this embodiment excludes filter 8 from the first receiver 2 and is otherwise identical to the pollen sensor in FIG. 2. In FIG. 9, the components constituting the same elements as is shown in the sensor of FIG. 2 have the same reference symbols. In this embodiment, light beams scattered from floating particles directly reach photodiode 7 without passing through a polarizing filter. As a result, an output photoelectric conversion signal I will correspond to the intensity of the scattered light beams for all polarizing directions. Accordingly, the degree of polarization for this embodiment is computed in accordance with the formula: (I−Is)/I. When the degree of polarization falls within the range of 0.35-0.75, the particles constitute pollen particles as in the first embodiment and for the same reasons.
[0031] It should be understood that although the photodiode 7 in the first receiver 2 and the photodiode 10 in the second receiver 3 were each aligned in the scattering polarization direction at an angle of 60° to the incident optical axis OA, it is not essential to this invention for the angle to be limited to a 60° and, in fact, any angle within a range of 0°-90° may be used. Alternately, the scattered beams that enter a lens may be separated into a component that is in parallel to the plane containing FIG. 2 and into another component that is perpendicular to the plane containing FIG. 2, utilizing a polarized beam splitter, followed by analysis of each component using a photodiode. The degree of polarization can thus be obtained as well. | A pollen sensor and method for detecting pollen which discriminates pollen particles floating in air from other particles on a real time basis. The pollen sensor includes an illumination position for generating a light beam, a first receiver for measuring the intensity (I) or (Ip) of a light beam scattered by floating particles in a detection zone, a second receiver for measuring the intensity (Is) of a polarized light beam in a direction perpendicular to light illuminated by the light beam and means for measuring the degree of polarization of the particles for distinguishing pollen particles from other particles. | 6 |
This is an application filed under 35 USC §371 of PCT/EP2009/004121, claiming priority to DE 10 2008 029 305.9 filed on Jun. 20, 2008.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to screw elements for multiscrew extruders with pairs of co-rotating and fully wiping screws, to the use of these screw elements in multiscrew extruders and to a method of generating these screw elements.
(2) Description of Related Art
Co-rotating twin- or multiscrew extruders whose rotors fully wipe each other have been known for a long time (see, for example, German Patent No. 862,668). Screw extruders based on the principle of fully wiping profiles have been used for many diverse applications in the field of polymer production and processing. This is mainly due to the fact that polymer melts adhere to surfaces and are degraded over time at the processing temperatures commonly employed. This is prevented by the self-cleaning effect of fully wiping screws. Rules for generating fully wiping screw profiles are described for example in Klemens Kohlgrüber: Der gleichläufige Doppelschneckenextruder (“ The co - rotating twin - screw extruder ”), Publishers: Hanser Verlag, Munich, 2007, pp. 96 et seq,) (“Kohlgrüber”) (The abbreviations, symbols and indices written in normal script in the figures are written in italics in the description.). This reference describes the construction of one-, two- and three-flight profiles.
Those skilled in the art are aware of the fact that in the region of the screw tips a particularly large amount of energy is dissipated in the melt, thus leading to considerable local overheating in the product. This is described for example in Kohlgrüber on page 160 et seq. of Kohlgrüber. This local overheating can lead to damage to the product by, for example, producing changes in its smell, color, chemical composition or molecular weight or to the formation of inhomogeneities, such as gelled particles or specks. A large tip angle is particular damaging in this regard.
In twin-screw extruders energy is introduced in the form of highly valuable electrical energy and it is therefore desirable, for cost-related and environmental reasons, to reduce the energy input. In addition, a high input of energy leads to high product temperatures, which can in turn produce disadvantages with regard to quality. In addition, a high input of energy in many cases reduces the possible throughput and thus also the cost-effectiveness of twin-screw extruders.
The input of energy in twin-screw extruders is determined by the process parameters of throughput and speed of rotation, by the material properties of the product and by the geometry of the screws employed. Modern twin-screw extruders consist of a modular system in which various screw elements can be mounted onto a central shaft. Using such a system those skilled in the art can adapt a twin-screw extruder to suit the respective processing task. Today screw elements with two- and three-flight profiles are usually employed, since one-flight screw profiles have an excessively high energy input due to their large tip angle.
According to the prior art (see, for example, page 101 of Kohlgrüber), the geometry of fully wiping screw elements is determined by using the independent parameters of flight number Z, centre distance A and barrel diameter (i.e. which corresponds to the diameter DE of the fully wiping contour). The flight number is the number of arcs of each element which wipe the outer wall. The angle of such an arc in relation to the centre of rotation is referred to as the tip angle KW 0 . In the region of the tip angle, the outer radius of the profile is the same as the barrel radius. According to the prior art, KW 0 is not an adjustable parameter which can be modified to suit the problem at hand, but is given by the following equation 1:
KW 0 = π Z - 2 arccos ( A DE ) ( Eq . 1 )
wherein KW 0 is the tip angle of the fully wiping profile in terms of radian measurement and π is pi (π≈3.14159). The sum of the tip angles of both elements of a tightly intermeshing pair of elements SKW 0 is therefore as follows:
SKW
0
=
2
π
-
4
Z
arccos
(
A
DE
)
(
Eq
.
2
)
If regions of a twin-screw extruder are only partially filled with melt during operation, for example in a degassing zone or in the buffer region of a pressure build-up zone, the melt rotates downstream of the tips Kohlgrüber. Each screw profile has one flank which “pushes” the melt and one flank which “pulls” the melt. The screw rotates in such a manner that the “pushing” flank is arranged on the downstream side of the tip and the pulling flank on its upstream side. In the partially filled state the melt rotates downstream of the “pushing” flank. The dissipation of energy and processing efficiency, for example for degassing operations, in this rotating melt depends not only on the tip angle and the clearances but also on the geometry of the melt channel downstream of the “pushing” flank. The prior art does not provide any possibility of adapting this geometry to suit the problem to be solved.
During operation, the screws of multiscrew extruders are usually mounted in the gearbox at the drive end, which is at the same time the product feed end. At the product ejection end the screws are mounted in the molten product, since external mounting would be a hindrance in the product ejection zone. Before a multiscrew extruder is charged with product during a start-up process, the screws rotate without lubrication of their tips directly on the barrel material. This can lead to abrasion, damage to the screw and the barrel and contamination of the product. In order to avoid excessive wear of the tips, a certain minimum tip angle is required. It would therefore be desirable to be able to freely select this tip angle.
Twin-screw extruders can also be subject to wear, which can occur in the melting zone in the case of pure polymers. Products which are filled with solid filling and reinforcing materials such as for example talcum, calcium carbonate or in particular glass fibres, produce a particularly high degree of wear. Corrosive attack is, for example, also possible when the product contains acids or undergoes cleavage. Such abrasion and corrosive attacks have a particularly detrimental effect on the crests at the edges of a profile tip where it is, for example, possible for material to be worn away or for crumbling to occur. Such changes to the profile tip have a crucial effect on the efficiency of multiscrew extruders and this is undesirable. Rounded crests would be considerably less susceptible to such effects but cannot be used according to the prior art without losing the self-cleaning effect of the screws.
In the light of the prior art, the problem therefore arose of providing tightly intermeshing screw elements for multiscrew extruders which are not subject to the abovementioned restrictions of the screw elements according to the prior art. The problem was to provide screw elements in which the energy input is reduced. The problem was also to provide screw elements in which the geometry of the pushing and the pulling flanks can be designed in such a manner in relation to the problem to be solved that optimum processing of the product can be carried out in a multiscrew extruder.
Surprisingly, screw elements have been obtained which have a reduced tip angle compared to the prior art and which solve the abovementioned problems.
BRIEF SUMMARY OF THE INVENTION
The present invention therefore relates to screw elements for multiscrew extruders with pairs of co-rotating and fully wiping screws and two or more flights, characterized in that the sum SKW of all of the tip angles of a pair of elements can be freely selected and is greater than 0 and smaller than
2 π - 4 Z arccos ( A DE ) ,
wherein Z is the number of flights, A is the centre distance between two screw elements and DE is the external diameter of the screw elements. In screw elements according to the invention the geometries of the pushing and the pulling flanks can be designed individually according to requirements and the crests at the edges of the tips can, if required, be rounded.
The invention is not restricted to screw elements with a modular design of the type commonly used today, with a screw consisting of screw elements and central shafts, but can also be used for screws constructed in one piece. Screw elements therefore also refer to screws constructed as integrated wholes.
The number of flights Z of screw elements according to the invention is preferably 2, 3, 4, 5, 6, 7 or 8; preferably it is 2 to 4.
The outer radius of a screw profile is RE=DE/2, the inner diameter is DK and the inner radius is RK=DK/2. Thus the following always applies: A=RE+RK.
The generating and generated profiles of the screw elements according to the invention (the “screw profiles”) are composed of arcs which merge tangentially into each other. The generating and the generated profiles of the screw elements according to the invention each consist of at least 6*Z arcs.
The size of an arc is defined by its central angle and its radius. In the following, the “central angle of an arc” is abbreviated to the “angle of an arc”. The position of an arc is defined by the position of its centre point and that of its two end points.
The profile of screw elements according to the invention is characterized in that one or more of the arcs can have a radius of zero. In this case, the profile has one or more kinks.
A predefined screw profile of a first screw of a twin-screw extruder (the “generating” screw profile) specifically determines the screw profile of an adjacent second screw (the “generated”) screw profile. The screw profile of a first screw of the two-screw extruder is therefore referred to as the generating screw profile, whereas the screw profile of the adjacent second screw of the twin-screw extruder is referred to as the generated screw profile. In a multiscrew extruder, the generating screw profile and the generated screw profile are always arranged alternately.
The screw profiles according to the invention are always closed and convex. The sum of the angles of the individual arcs for each element is always 2π.
Screw elements according to the invention are characterized in that each arc of the generated screw profile “corresponds” to one of the arcs of the generating screw profile. “Correspond” is understood to mean that
the angles of corresponding arcs are identical in size, the sum of the radii of corresponding arcs equals the centre distance, each of the connecting lines between the centre point of an arc of the generating screw profile and its end points is parallel to one of the connecting lines between the centre point of the corresponding arc of the generated screw profile and its end points, those directions in which the end points of an arc of the generating screw profile lie in relation to the centre point of said arc are in each case opposite those directions in which the end points of the corresponding arc of the generated screw profile lie in relation to the centre point of said arc of the generated screw profile, the distance between the centre point of the arc of the generating screw profile and the centre point of the corresponding arc of the generated screw profile equals the centre distance, the connecting line between the centre point of the arc of the generating screw profile and the centre point of the corresponding arc of the generated screw profile is parallel to the connecting line between the point of rotation of the generating screw profile and the point of rotation of the generated screw profile, the direction in which the centre point of the arc of the generating screw profile would have to be shifted in order to coincide with the centre point of the corresponding arc of the generated screw profile is the same as that in which the point of rotation of the generating screw profile would have to be shifted in order to coincide with the point of rotation of the generated screw profile.
FIG. 1 depicts an example of two corresponding arcs. The centre of rotation of the generating screw is DR and the centre of rotation of the generated screw is DL. In this figure, arc 1 is the generating arc and arc 1 ′ the generated arc.
A generating screw profile of screw elements according to the invention has Z arcs whose radii are equal to RE and whose centre points coincide with the centre of rotation (=the “tip arcs”).
A generating screw profile of screw elements according to the invention has Z arcs whose radii are equal to RK and whose centre points coincide with the centre of rotation (=the “root arcs”). The corresponding generated screw profile also has Z tip arcs and Z root arcs.
The sum of the angles of the tip and root arcs of the generating screw profiles according to the invention can be freely selected and is greater than 0 and smaller than
2
π
-
4
Z
arccos
(
A
DE
)
.
The sum of the angles of all of the tip arcs of the generated and the generating screw profile is equal to the sum of the tip and root angles of the generating screw profile and is, according to the invention, greater than 0 and smaller than
2
π
-
4
Z
arccos
(
A
DE
)
.
In a preferred embodiment of screw elements according to the invention, the tip arcs and the root arcs are arranged in such a manner that they alternate with each other around the profile during the rotation of the screw, i.e. during rotation each tip arc is followed by a root arc and each root arc is followed by a tip arc. Thus, in the generated screw profile, the tip arcs and the root arcs are automatically arranged in such a manner that they alternate with each other around the profile during the rotation of the screw, i.e. during rotation each tip arc is followed by a root arc and each root arc is followed by a tip arc.
In a preferred embodiment of screw elements according to the invention a line “K 1 ” can be drawn for a generating screw element, which starts from the centre of rotation of the element and ends at a point on a tip arc, so that (Z−1) additional lines exist which intersect the first line at the centre of rotation of the generating screw element, where they are at an angle of 2*(i−1)*π/Z to the first line and in each case intersect an additional tip arc of the profile according to the invention, wherein i represents all numbers from 2 to Z. These lines are referred to hereinafter as K i .
An additional feature of this preferred embodiment is that each line which starts at the centre of rotation and is located at an angle (2*j−1)*π/Z to line “K 1 ” intersects a root arc, wherein j represents all numbers from 1 to Z. These lines are referred to hereinafter as N j .
Two lines K i and N j are referred to as “adjacent” if the angle between these two lines is exactly π/Z. This is the case for lines K 1 and N 1 , K 2 and N 2 , . . . and for lines N 1 and K 2 , N 2 and K 3 , . . . up to N Z and K 1 .
As far as the additional embodiments are concerned, the screw profile between two adjacent lines K i and N j is referred to as a “profile part”. An entire screw profile can be perceived as consisting of 2*Z profile parts.
Two profile parts are referred to as “adjacent” if they are separated by a shared line K i or N j .
The number of arcs in a profile part according to the invention is preferably at least four. If two adjacent arcs which directly merge into each other at one of the lines K i or N j have the same centre points and the same radii it is possible to combine these two arcs when numbering the arcs of the entire profile to form one single arc, with the result that the number of arcs can then be lower for the overall profile than the sum of the numbers of arcs for each individual profile part.
Two profile parts are referred to as corresponding if all of the component arcs of the two profile parts correspond to each other.
In a preferred embodiment of the screw elements according to the invention at least one arc of the generating screw profile which is adjacent to a tip angle is an arc with a radius of 0 (i.e. a sharp crest) and at least one arc of the generating screw profile which is adjacent to a root angle is an arc with a radius equal to the centre distance A. This automatically means that at least one arc which is adjacent to a tip arc of the generated screw profile is an arc with a radius of 0 and at least one arc which is adjacent to a root arc has a radius A=the centre distance.
In an additional preferred embodiment of the screw elements according to the invention, at least one arc of the generating screw profile which is adjacent to a tip arc is an arc with a radius of >0 and smaller than 0.1 times the screw diameter DE and at least one arc of the generating screw profile which is adjacent to a root arc is an arc with a radius of smaller than the centre distance A and greater than A−0.1*DE. This automatically means that at least one arc of the generated screw profile which is adjacent to a tip arc is an arc with a radius of >0 and smaller than 0.1 times the screw diameter DE and at least one arc which is adjacent to a root arc has a radius of smaller than A and greater than A−0.1*DE.
In a preferred embodiment, the screw profile of screw elements according to the invention is identical on the two screws—apart from possible rotation about π/Z for an even number Z—and dot-symmetrical to the point of rotation of the profile concerned. This profile is characterized in that it consists of two types of profile parts (hereinafter referred to as “X” and “Y”). Profile part X belongs to the generating profile and profile part Y belongs to the generated screw profile. By rotating profile part X about the centre of rotation of the generating screw profile by 2πk/Z , wherein k represents all integers from 1 to Z−1, the screw profile is completed in the profile sections concerned. By rotating the profile Y about the point of rotation of the generated screw profile by 2πk/Z, wherein k represents all integers from 1 to Z−1, the screw profile is completed in the profile sections concerned.
In addition, the generating screw profile is completed by profile parts Y in such a manner that profile parts Y of the generated screw profile are copied onto the generating screw profile by shifting them by the centre distance in a direction from the centre of rotation of the generated screw profile to the centre of rotation of the generating screw profile and, given an even number Z, additionally by rotation about π/Z. In addition, the generated screw profile is completed by profile parts X in such a manner that profile parts X of the generating screw profile are copied onto the generated screw profile by shifting them by the centre distance in a direction from the centre of rotation of the generating screw profile to the centre of rotation of the generated screw profile and, given an even number Z, additionally by rotation about π/Z. The number of arcs of a profile section is greater than or equal to four and preferably greater than or equal to six.
In an additional preferred embodiment of screw elements according to the invention the screw profile is identical on both screw shafts, apart from possible rotation about π/Z given an even number Z, dot-symmetrical about the point of rotation of the profile concerned and also characterized in that all lines K i and N j are lines of symmetry of the profile. In this case the profile is clearly determined by the profile part between lines K 1 and N 1 and, based on this profile part, is in each case obtained for an adjacent profile part by mirroring about the line of symmetry between the two profile parts. Line FP is introduced for defining both dot- and mirror-symmetrical screw profiles. FP is positioned at a minimum distance from the centre of rotation, which is A/2, intersects lines K 1 and N 1 and is vertical to the angle bisector between N 1 and K 1 .
The profile part between lines K 1 and N 1 of this preferred embodiment of screw elements according to the invention is characterized in that the arcs of the profile part merge tangentially into each other at a point located on FP. As a result, FP is a tangent on these arcs. At the point at which the arcs touch FP, the profile part X is subdivided into two additional profile parts, X 1 and X 2 . Profile part X 1 comprises those arcs from K 1 to the point of contact with FP and profile part X 2 comprises those arcs from the point of contact with FP to N 1 . Profile part Y 1 of the generated screw is that which corresponds to the arcs of X 1 . By mirroring about a straight line which runs vertically midway between the points of rotation of the two screw profiles and by subsequent rotation about the point of rotation of the generated profile by π/Z, profile part Y 1 is copied onto profile part X 2 . The profile part X thereby completed can be used for generating the complete generating screw profile by continuous mirroring about lines N 1 , K 2 , N 2 , . . . . The screw profile of the generated screw is obtained by shifting the screw profile of the generating screw and, if Z is an even number, by rotating the screw profile about the point of rotation of the generated profile by π/Z.
Those skilled in the art are aware of the fact that fully wiping screw profiles cannot be directly incorporated in twin-screw extruders and that clearances between the screws are actually required. Many different possible strategies are described for this purpose on pages 28 et seq. of Kohlgrüber. For the screw profiles of screw elements according to the invention clearances in the range from 0.001 to 0.1, preferably in the range from 0.002 to 0.05 and particular preferably in the range from 0.004 to 0.02, based on the diameter of the screw profile, can be used. As is well-known to those skilled in the art, these clearances can be different in size or identical between the screw and the barrel and between one screw and the other. They can be constant or variable within the specified limits. It is also possible to shift a screw profile within the clearances. Possible clearance strategies include those described on page 28 et seq. of Kohlgrüber of increasing the centre distance, of longitudinal equidistant clearance or of three-dimensional equidistant clearance. All of these strategies are known to those of ordinary skill in the art. In the case of increasing the centre distance a screw profile with a smaller diameter is constructed and pulled away by the size of the clearance between the screws. In the case of the method of longitudinal equidistant clearance the profile contour of the longitudinal section (parallel to the axis) is shifted inwards towards the axis by half the clearance between the screws. In the case of the method of three-dimensional equidistant clearance, which is based on the three-dimensional curved contour along which the screw elements wipe each other as they rotate, each screw element is reduced in size in the process of its production in a vertical direction to the surface of the fully wiping profile by half of the required clearance between the screws. Preferably longitudinal equidistant clearance and three-dimensional equidistant clearance are used. Particularly preferably three-dimensional equidistant clearance is used.
The ratio RE/A of the outer radius RE of the screw element to the centre distance A is preferably between 0.54 and 0.7, and particularly preferably between 0.58 and 0.63, for two-flight screws according to the invention, preferably between 0.53 and 0.57, and particularly preferably between 0.54 and 0.56, for three-flight screws, and preferably between 0.515 and 0.535 for four-flight screws.
The screw elements according to the invention can be designed as conveying elements or kneading elements or mixing elements.
As is known (see, for example pages 227-248 of Kohlgrüber), a conveying element is characterized by a screw profile which is continuously rotated and extends in an axial direction in the form of a screw. The conveying element can be right- or left-handed. The pitch of the conveying element, i.e. the axial length required for the complete rotation of the screw profile, is preferably in the range from 0.1 to 10 times the centre distance and the axial length of a conveying element is preferably in the range from 0.1 to 10 times the screw diameter.
As is known (see, for example pages 227-248 of Kohlgrüber), a kneading element is characterized by a screw profile which extends in an axial direction in steps in the form of kneading discs. These kneading discs can be arranged in a right-handed, left-handed or non-conveying fashion. The axial length of the kneading discs is preferably in the range from 0.05 to 10 times the centre distance. The axial distance between two adjacent kneading discs is preferably in the range from 0.002 to 0.1 times the screw diameter.
As is known (see, for example, pages 227-248 of Kohlgrüber), mixing elements are formed by designing conveying elements with openings in the screw tips. The mixing elements can be right-handed or left-handed. Their pitch is preferably in the range from 0.1 to 10 times the centre distance and the axial length of the elements is preferably in the range from 0.1 to 10 times the centre distance. The openings are preferably designed in the form of a u- or v-shaped groove and they are preferably arranged either in a backward-conveying manner or parallel to the axis. Preferably several openings are provided, which are arranged at a constant angle in relation to each other.
The present invention also relates to the use of the screw elements according to the invention in multi-screw extruders. Preferably the screw elements according to the invention are used in twin-screw extruders. The screw elements can be contained in the multi-screw extruders in the form of kneading, mixing or conveying elements. It is also possible to combine kneading, conveying and mixing elements with each other in one extruder. The screw elements according to the invention can also be combined with other screw elements which are, for example, known from the prior art.
The present invention also relates to a method of generating screw elements according to the invention. The method according to the invention allows the geometrical construction of corresponding profile parts merely by using a pair of compasses and an angle ruler and it is therefore simple to carry out. Advantageously it is executed by means of a computer program.
First of all the defining parameters Z, DE and A of the screw elements to be constructed are fixed. Then the points of rotation of the generating and the generated profile part are inserted at a distance A from each other. Line K 1 , which leads towards a point on the tip arc, is appropriately selected so that it starts from the point of rotation of the generating profile and proceeds in the direction of the point of rotation of the generated profile.
Line N 1 is drawn from the point of rotation of the generating profile part at an angle of π/Z to line K 1 . Parameters RE=DE/2 and RK=A−RE are calculated. Then the number of arcs n of the profile part is determined The number of arcs n is preferably 6, but can be smaller or larger.
Then the tip angle α is selected and an arc with an angle between 0 and α, preferably α/2, and a radius RE is formed, whose centre point is the centre point of the generating screw, one end of the arc being located on line K 1 and the arc being formed in the direction of N 1 . The angle selected for the root angle is angle β, which can, but must not necessarily, be the same as α. For this purpose, an arc β/2, which represents the root arc, is formed from line N 1 in the direction of K 1 .
Then the tangential arc 2 is drawn which follows on from the tip arc. The angle and the radius of this arc can be freely selected, although it is necessary for the radius of the arc to be smaller than or equal to the centre distance. When choosing the angle and the radius it may perhaps be no longer possible to close the profile part in subsequent steps since the requirements of a “closed profile” or a “convex profile” are not met. If this is the case, the angle or the radius must be reduced in size and a new attempt must be made. The arc can also have a radius of 0.
In order to construct a tangential arc, a perpendicular is always drawn from the end point of an already existing arc in the direction of the centre point of this existing arc of the generating screw profile. This perpendicular is referred to as the “boundary line” between two arcs. Each boundary line is allocated a direction which starts from the centre point of the arc and leads to the end point of the arc concerned. The centre points of both tangential arcs are always located on this boundary line. The centre point of the required arc is obtained by drawing a circle about the end point of the existing arc with a radius corresponding to that of the required arc. The intersecting point between this circle and the boundary line is the required centre point.
An arc with a radius of 0 is treated in the same way as an arc with a very small radius eps, which tends towards 0, so that the tangential transition can continue to be constructed. Alternatively an arc with a radius of 0 can be treated in such a manner that the screw profile has a kink at the position of this arc, the size of the kink being determined by the angle of this arc.
Then one or more additional tangential arcs 3 , 4 , . . . to n−4 can be formed. The radii r(n−3, r(n−2) and r(n−1) are fixed for arcs n−3, n−2 and n−1. The radius of arc n−1 is selected to be A, if the generated screw profile is required to have a sharp crest at its tip.
The profile is then closed in the following manner: A circle with a radius of r(n−3)-r(n−2) is drawn around the centre point of arc n−3. A circle with a radius of r(n−1)-r(n−2) is drawn around the centre point of arc n−1. Of the two points of intersection between these circles, the one located between N 1 and K 1 in their respective direction is the centre point of circle n−2. The boundary line of arc n−1 is then obtained by connecting the centre point of arc n−1 to the centre point of arc n−2, and the boundary line of arc n−3 and n−2 is obtained analogously. Arcs n−3, n−2 and n−1 are then drawn with the corresponding boundary lines between them.
The corresponding profile part of the generated screw is generated as follows: All the centre points of arcs M 1 and M 2 to Mn are shifted by the centre distance in the direction of the generated profile parallel to a line between the point of rotation of the generating profile and the point of rotation of the generated profile, thus producing corresponding points M 1 ′ and M 2 ′ to Mn′. The boundary lines which intersect points M 1 to Mn are initially also shifted by the centre distance in the direction of the generated profile parallel to a line between the point of rotation of the generating profile and the point of rotation of the generated profile. These shifted boundary lines intersect each other at the corresponding points M 1 ′ and M 2 ′ to Mn′. If they are each extended in an opposite direction through the respective points M 1 ′ and M 2 ′ to Mn′ and a corresponding radius r 1 ′, r 2 ′ to rn′ is marked off on the corresponding extended boundary lines starting from the respective centre points M 1 ′ and M 2 ′ to Mn′ so that the sum of the radii ri and ri′ is always equal to the centre distance for all of the corresponding arcs i and i′, the boundary lines of arcs 1 ′, 2 ′ to n′ and thus the corresponding arcs themselves are obtained.
It is recommendable to execute the method of generating the screw profiles by means of a computer. The measurements of the screw elements are then in a form in which they can be fed to a CNC (Computer Numerical Control) tool milling machine for producing the screw elements. The present invention therefore also relates to a computer program product with program code means for executing the method according to the invention for generating screw profiles according to the invention in a computer. In a preferred embodiment, the user of the computer program product preferably has a graphical user interface at his/her disposal, with the aid of which he/she can enter the parameters (the number of arcs of the generating and generated screw profile, the radii and the angles) to be selected. Preferably he/she is aided by instructions from the computer system if the selected parameter values would not produce pairs of screw profiles which wipe each other. On entering the parameter values he/she is preferably assisted by instructions concerning the permitted parameter value ranges. Permitted parameter values are understood to be such combinations of parameter values which produce pairs of wiping screw profiles.
In a preferred embodiment, not only the profiles but also entire screw elements are constructed virtually in a computer. The construction results are preferably fed to a computer screen or a printer in the form of construction drawings. It is also possible for the results to be supplied in the form of an electronic data file which, in a preferred embodiment, can be fed to a CAD milling machine for producing the corresponding screw elements.
After the profiles have been generated in the described manner the screw elements according to the invention can be produced using, for example, a milling machine, a lathe or a whirling machine. Preferred materials for producing the screw elements are steels, and in particular nitrated steels, chromium, tool and stainless steels, metallic composite materials produced by powder metallurgy and based on iron, nickel or cobalt and engineering ceramic materials such as for example zirconium oxide or silicon carbide.
The method according to the invention makes it possible to design the profile of a screw right from the beginning in such a manner that it is optimally suitable for a specified task. The screw elements known from the prior art are in most cases not optimally designed for a concrete task. On the contrary, manufacturers supply screw elements (conveying, kneading and mixing elements) from a set modular system independently of a concrete task. The present invention makes it possible for the first time to almost completely freely design the profiles of self-cleaning screw elements. It is thus possible to optimize the parameters of such profiles for the application concerned down to the most minute variation. In this connection it must be pointed out that there is no restriction on the number of arcs used for producing screw profiles. It is thus possible to approximate screw profiles which are not composed of arcs and are therefore not self-cleaning with the required precision by using a sufficiently high number of arcs. The profile approximated by means of arcs is of course self-cleaning.
It is also possible to calculate the longitudinal profile of a (generating or generated) screw profile. Preferably each arc of a screw profile is used for calculating that part of the longitudinal cross-section which belongs to this arc by means of an explicit function. In a first step the point of intersection (Sx, Sy) between a straight line g and an arc kb is determined. The straight line g is located in the plane of the screw profile and it leads through the point of rotation of the screw profile. The orientation of the straight line is given by the angle φ.
Arc kb is characterized by its radius r and the position of its centre point (Mx, My). In a second step the distance s of the point of intersection (Sx, Sy) from the point of rotation of the screw profile is calculated. The point of intersection of a straight line with an arc can be calculated by an explicit function. The same applies to the calculation of the distance. The distance is therefore s=s(φ, r, Mx, My). Given a known pitch t of a screw element angle φ can be converted into an axial position z_ax by means of φ/2π*t, so that the distance is s=s(z_ax, r, Mx, My)=s(φ/2π*t, r, Mx, My). The function s(z_ax, r, Mx, My) defines the longitudinal profile of an arc of the screw profile.
BRIEF SUMMARY OF THE INVENTION
The invention is illustrated in more detail hereinbelow by means of the figures, without however being limited thereto.
FIG. 1 depicts a diagrammatic cross-section of an example of two corresponding arcs,
FIG. 2 depicts the profiles of two-flight screw elements known according to the prior art,
FIG. 3 a , 3 b depict diagrammatic cross-sections of a profile part X of the generating screw profile and a corresponding profile part Y of the generated screw profile of two-flight screw elements,
FIG. 4 depicts diagrammatic cross-sections of screw elements
FIG. 5 depicts diagrammatic cross-sections of screw elements according to the invention with mirror- and dot-symmetrical screw profiles
FIG. 6 depicts diagrammatic cross-sections of profiles of two-flight screw elements known according to the prior art.
FIG. 7 a - 7 b depict two corresponding profile parts X (of a generating screw profile) and Y (of a generated screw profile) of screw elements.).
FIG. 7 c shows the x- and y-coordinates (Mx and My) of the centre points, the radii R and the angles α of the arcs for all of the arcs of FIG. 7 a.
FIG. 8 depicts diagrammatic cross-sections of screw elements according to the invention with a dot-symmetrical screw profile obtained by continuing to replicate FIG. 7 by the dot-symmetrical method.
FIG. 9 a - 9 b show two corresponding profile parts X (of the generating screw profile) and Y (of the generated screw profile) of screw elements.
FIG. 9 c depicts the x- and y-coordinates (Mx and My) of the centre points, the radii R and the angles α of the arcs for all of the arcs in FIG. 9 a.
FIG. 10 depicts cross-sectional diagrams of screw elements,
FIG. 11 a depicts two corresponding profile parts X 1 (of a generating screw profile) and Y 1 (of a generated screw profile) of dot- and mirror-symmetrical screw elements.
FIG. 11 b shows how the profile of FIG. 11 a can be continued to be replicated by mirroring about a vertical straight line midway between the points of rotation of the two screw.
FIG. 11 c shows the generating and generated screw profiles obtained by replicating the profile of profile 11 b by rotation and mirroring.
FIG. 12 a shows two corresponding profile parts X 1 (generating profile) and Y 1 (generated profile) of dot- and mirror-symmetrical screw elements.
FIG. 12 b shows the fully wiping profiles, which result from the profile parts depicted in FIG. 12 a by mirroring and rotating.
FIG. 12 c shows two profiles which were constructed from the profiles depicted in FIG. 12 b by using the method of three-dimensional equidistant clearance.
FIG. 12 d shows profiles being state of the art, having identical clearances and an identical inline according to the profiles depicted in FIG. 12 c.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts a diagrammatic cross-section of an example of two corresponding arcs of a generating and a generated screw profile. The centre of rotation of the generating screw profile is DR and the centre of rotation of the generated screw profile is DL. In this figure, arc 1 is a generating and arc 1 ′ a generated arc. Arc 1 has a centre point M 1 , a radius r 1 and an angle α 1 . Arc 1 ′ has a centre point M 1 ′=M 2 , a radius r 1 ′ and an angle α 1 ′, which is the same as α 1 according to the invention. According to the invention, the sum of radii r 1 and r 1 ′ equals the centre distance A. The connecting broken lines between the centre point M 1 of arc 1 and its end points form the boundary lines of arc 1 . They run parallel to the boundary lines of the corresponding arc 1 ′, i.e. parallel to the connecting lines depicted in the form of broken lines between the centre point M 1 ′ of arc 1 ′ and its end points.
The directions in which the end points of arc 1 lie in relation to the centre point M 1 of arc 1 are in each case opposite the directions in which the end points of the corresponding arc 1 ′ lie in relation to the centre point of arc 1 ′.
The distance between the centre point M 1 of arc 1 and the centre point M 1 ′ of the corresponding arc 1 ′ equals the centre distance.
The connecting line between the centre point M 1 of arc 1 and the centre point M 1 ′ of the corresponding arc 1 ′ runs parallel to the connecting line between the point of rotation DR and the point of rotation DL.
The direction in which the centre point M 1 of arc 1 would have to be shifted in order to coincide with the centre point M 1 ′ of the corresponding arc 1 ′ is the same as that in which the point of rotation DR would have to be shifted in order to coincide with the point of rotation DL.
FIG. 2 depicts the profiles of two-flight screw elements known according to the prior art. The centre distance is 48 mm, the outer diameter of a screw profile is 58 mm, the inner diameter is 38 mm and the tip angle KW 0 , in terms of radian measurement, is 0.3788 (=21.7°). The sum of all of the tip angles SKW 0 , in terms of radian measurement, is 1.5152.
FIGS. 3 a and 3 b depict, by way of example, diagrammatic cross-sections of a profile part X of the generating screw profile and a corresponding profile part Y of the generated screw profile of two-flight screw elements according to the invention. Profile part X is formed by arcs 1 , 2 , 3 , 4 , 5 and 6 . Profile part Y is formed by arcs 1 ′, 2 ′, 3 ′, 4 ′, 5 ′ and 6 ′ which correspond to the respective arcs of profile part X. The arcs are clearly defined by their respective centre points M 1 , M 2 , . . . , M 6 and M 1 ′, M 2 ′, . . . , M 6 ′ and their respective angles and radii (see FIG. 3 a ).
In the present example the centre distance is 48 mm, the outer diameter of a screw profile is 58 mm and the inner diameter is 38 mm Arc 1 is the tip arc of the generating profile part and arc 6 is the root arc. Arc 2 has a radius of 0, i.e. the generating profile has a kink at its tip arc.
In FIG. 3 b the labels of the arcs and the centre points have been removed in order to provide a better overview. Profile parts X and Y are identical to the profile parts shown in FIG. 3 a.
The overall profile of the two generating and generated screw profiles of the screw element can be obtained from the profile part X located between the adjacent lines K 1 and N 1 (see, for example, FIG. 4 and the text describing this figure). Line K 1 is horizontal and line N 1 vertical to the connecting line between the centres of rotation.
The following Table 1 depicts, in relation to a coordinate system whose origin is located at the point of rotation of the generating screw, whose x-axis is located in the direction of the point of rotation of the generated screw and whose y-axis is located vertically to the x-axis (i.e. in an upward direction in the figures), the radii of the arcs, the x and y coordinates of the centre points of the arcs, the starting angle of the arcs, the end angle of the arcs and the angle of the arcs for the arcs shown in FIGS. 3 a and 3 b . The starting angle of an arc is the angle of that boundary line of the arc which has the smaller value in a mathematically positive direction. For arcs in which the starting angle is greater than zero and the end angle is less than zero, the end angle is obtained by adding 2*π.
TABLE 1
Geometrical measurements for profile parts X and Y of screw elements
according to the invention, as depicted in FIGS. 3a and 3b.
center
center
point
point
on the x-
on the y-
starting
radius
coordinate
coordinate
angle
end angle
angle
arc
mm
mm
mm
rad
rad
rad
1
29
0
0
0.00000
0.08727
0.08727
2
0
28.8896
2.52750
0.08727
0.34907
0.2618
3
44
−12.4568
−12.5214
0.34907
0.53093
0.18187
4
3
22.8989
8.2385
0.53093
0.97032
0.43939
5
48
−2.5275
−28.8896
0.97032
1.48353
0.51321
6
19
0
0
1.48353
1.5708
0.08727
1′
19
48
0
−3.14159
−3.05433
0.08727
2′
48
76.8896
2.5275
−3.05433
−2.79253
0.2618
3′
4
35.5432
−12.5214
−2.79253
−2.61066
0.18187
4′
45
70.8989
8.2385
−2.61066
−2.17127
0.43939
5′
0
45.4725
−28.8896
−2.17127
−1.65806
0.51321
6′
29
48
0
−1.65806
−1.5708
0.08727
FIG. 4 depicts diagrammatic cross-sections of screw elements according to the invention with a dot-symmetrical screw profile obtained from FIG. 3 a or 3 b by continuing to replicate the profile parts shown in FIG. 3 a or 3 b by the dot-symmetrical method. All of the tip angles are identical and equal to 0.17454 (10°). One tip angle KW is shown by way of example. The sum of all of the tip angles SKW is 0.698, i.e. less than half of that of the prior art element. This is a considerable advantage over the prior art. This screw profile also has the advantage that, where the screw is rotated in a clockwise direction, the pushing flank forms a considerably larger angle to the barrel than the pulling flank, which, in the case of partial filling, once again results in a considerably lower input of energy. It is also possible for the direction of rotation to be reversed, thereby producing increased elongation at the tip.
FIG. 5 depicts diagrammatic cross-sections of screw elements according to the invention with mirror- and dot-symmetrical screw profiles. In this example, the centre distance is 48 mm, the outer diameter of the screw profile is 58 mm, the inner diameter is 38 mm and each of the tip angles is 0.175 (10°). One tip angle KW is shown by way of example. The sum of all of the tip angles SKW is 0.69813, i.e. less than half the sum of the tip angles of the prior art element. The advantage lies in the lower dissipation of energy.
FIG. 6 depicts diagrammatic cross-sections of profiles of two-flight screw elements known according to the prior art. The centre distance is 48 mm, the outer diameter of a screw profile is 56 mm, the inner diameter is 40 mm and the tip angle KW 0 is 0.4886. The sum SKW 0 of all of the tip angles of both elements is 1.954. If this screw profile is compared to that of FIG. 2 , the disadvantageous dependence according to the prior art of the tip angle on the ratio between the centre distance and the diameter according to equation 1 can be clearly identified.
FIGS. 7 a and 7 b depict two corresponding profile parts X (of a generating screw profile) and Y (of a generated screw profile) of screw elements according to the invention. Profile part X is formed by arcs 1 , 2 , 3 , 4 , 5 and 6 . Profile part Y is formed by the corresponding arcs 1 ′, 2 ′, 3 ′, 4 ′, 5 ′ and 6′. The centre points of the arcs are depicted by small circles. The boundary lines of the arcs are depicted in the form of thin lines. In the present example, the centre distance is 48 mm, the outer diameter of a screw profile is 56 mm and the inner diameter is 40 mm Arc 1 is the tip arc and arc 6 is the root arc of the generating profile part. Arc 2 , which follows on from the tip arc, has a radius of >0, i.e. the profile has no crest at this point, in contrast to the profile shown in FIGS. 3 a and 3 b . Arc 5 ′, which is adjacent to tip angle 6 ′, has a radius of 0, i.e. the generated profile has a kink at its tip arc. The centre point of arc 5 ′ coincides with this kink. The “size of this kink” is determined by the corresponding angle, i.e. the transition from arc 4 ′ to arc 6 ′ is obtained by rotation about the angle of arc 5 ′. Or, in other words, a tangent on arc 4 ′ at the centre point of arc 5 ′ intersects a tangent on arc 6 ′ also at the centre point of arc 5 ′ and at an angle which corresponds to the angle of arc 5 ′. With the inclusion of arc 5 ′, all adjacent arcs 4 ′→ 5 ′, 5 ′→ 6 ′ do however merge tangentially into each other in accordance with the invention.
The profile parts X and Y shown in FIG. 7 b are identical to the profile parts shown in FIG. 7 a . In FIG. 7 b the labels of the arcs, the centre points and the boundary lines have been omitted in order to provide a better overview. Instead lines K 1 and N 1 are shown. Line K 1 is horizontal and line N 1 is vertical to a connecting line through the centres of rotation. The overall profile of the two generating and generated screw profiles of the screw element can be obtained from the profile part X located between the adjacent lines K 1 and N 1 (see, for example, FIG. 8 and the text describing this figure). FIG. 7 c shows the x- and y-coordinates (Mx and My) of the centre points, the radii R and the angles α of the arcs for all of the arcs of FIG. 7 a . The angles are defined in terms of radian measurement; all of the other geometrical values are normalized in relation to the centre distance and are therefore dimensionless.
The following Table 2 depicts, in relation to a coordinate system whose origin is located at the point of rotation of the generating screw, whose x-axis is located in the direction of the point of rotation of the generated screw and whose y-axis is located vertically to the x-axis (i.e. in an upward direction in the figures), the radii of the arcs, the x and y coordinates of the centre points of the arcs, the starting angle of the arcs, the end angle of the arcs and the angle of the arcs for FIGS. 7 a and 7 b .
TABLE 2
Geometrical measurements for the profile parts X and Y of screw elements
according to the invention, as depicted in FIGS. 7a and 7b.
center
center
point
point
on the x-
on the y-
starting
radius
coordinate
coordinate
angle
end angle
angle
arc
mm
mm
mm
rad
rad
rad
1
28
0
0
0
0.06981
0.06981
2
3
24.9391
1.7439
0.06981
0.41888
0.34907
3
44
−12.5163
−14.9323
0.41888
0.72856
0.30968
4
3
18.0752
12.3654
0.72856
1.10954
0.38098
5
48
−1.9532
−27.9318
1.10954
1.50098
0.39144
6
20
0
0
1.50098
1.5708
0.06981
1′
20
48
0
−3.14159
−3.07178
0.06981
2′
45
72.9391
1.7439
−3.07178
−2.72271
0.34907
3′
4
35.4837
−14.9323
−2.72271
−2.41303
0.30968
4′
45
66.0752
12.3654
−2.41303
−2.03205
0.38098
5′
0
46.0468
−27.9318
−2.03205
−1.64061
0.39144
6′
28
48
0
−1.64061
−1.5708
0.06981
FIG. 8 depicts diagrammatic cross-sections of screw elements according to the invention with a dot-symmetrical screw profile obtained by continuing to replicate FIG. 7 by the dot-symmetrical method. In this example all of the tip angles are 0.14. One tip angle KW is shown by way of example. The sum SKW of all of the tip angles is 0.56. Using such a screw profile it is therefore possible to reduce the tip angle by a factor of about 3.5, thereby producing a considerably reduced input of energy. In addition—on rotating the screw in a counterclockwise direction—the crest of the pushing flank is rounded, thereby producing advantages from the point of view of wear.
FIGS. 9 a and 9 b show two corresponding profile parts X (of the generating screw profile) and Y (of the generated screw profile) of screw elements according to the invention. The profile part X is formed by arcs 1 , 2 , and 3 . Profile part Y is formed by the corresponding arcs 1 ′, 2 ′ and 3 ′. The centre points of the arcs are represented by small circles. The boundary lines of the arcs are depicted by thin lines. In this example the centre distance A is 48 mm, the diameter of the screw profile is 52 mm and the flight number Z is 3.
The profile parts X and Y shown in FIG. 9 b are identical to the profile parts shown in FIG. 9 a . In FIG. 9 b the labels of the arcs, the centre points and the boundary lines have been omitted in order to provide a better overview. Instead, lines K 1 and N 1 , the angle bisector W−K 1 /N 1 and the straight line FP vertical to the angle bisector are shown. The straight line FP touches arc 3 at one of its end points and forms a tangent to arc 3 at this end point. Using profile part X the entire profile of a preferred embodiment of a symmetrical three-flight screw element can be constructed (see FIG. 10 and the text describing this figure).
FIG. 9 c depicts the x- and y-coordinates (Mx and My) of the centre points, the radii R and the angles α of the arcs for all of the arcs in FIG. 9 a . The angles are defined in terms of radian measurement; all of the other geometrical values are normalized in relation to the centre distance and are therefore dimensionless.
The following Table 3 depicts, in relation to a coordinate system whose origin is located at the point of rotation of the generating screw, whose x-axis is located in the direction of the point of rotation of the generated screw and whose y-axis is located vertically to the x-axis (i.e. in an upward direction in the figures), the radii of the arcs, the x and y coordinates of the centre points of the arcs, the starting angle of the arcs, the end angle of the arcs and the angle of the arcs for FIGS. 9 a and 9 b .
TABLE 3
Geometrical measurements for profile parts X and Y of screw elements
according to the invention, as depicted in FIGS. 9a and 9b.
center point
center point
on the x-
on the y-
starting
end
radius
coordinate
coordinate
angle
angle
angle
arc
mm
mm
mm
rad
rad
rad
1
26
0
0
0
0.0524
0.0524
2
0
25.964
1.361
0.0524
0.3286
0.2762
3
44
−15.681
−12.839
0.3286
0.5236
0.1950
1′
22
48
0
−3.1416
−3.0892
0.0524
2′
48
73.964
1.361
−3.0892
−2.8130
0.2762
3′
4
32.319
−12.839
−2.8130
−2.6180
0.1950
FIG. 10 depicts cross-sectional diagrams of screw elements according to the invention with a mirror- and dot-symmetrical screw profile obtained by continuing to replicate the profile in FIG. 9 a or 9 b by the minor-symmetrical method. All of the tip angles are 0.1048 (6°), in contrast to a tip angle KW 0 of 0.2576 in conventional screw elements.
FIG. 11 a depicts, by way of example, two corresponding profile parts X 1 (of a generating screw profile) and Y 1 (of a generated screw profile) of dot- and mirror-symmetrical screw elements according to the invention. Profile part X 1 is formed by arcs 1 and 2 . Profile part Y 1 is formed by the corresponding arcs 1 ′ and 2 ′. Arcs 2 and 3 touch the straight line FP. This figure also shows the angles of the arcs in terms of radian measurement and the coordinates of the centre points of the arcs in a coordinate system whose origin is located at the point of rotation of the lefthand profile. The ratio between the outer radius and the centre distance is 0.6042.
FIG. 11 b shows how the profile of FIG. 11 a can be continued to be replicated by mirroring about a vertical straight line midway between the points of rotation of the two screw profiles, followed by rotation about the centre of rotation of the generated profile by π/Z. Using this method profile parts X 2 and Y 2 are obtained. The labelling of the arcs corresponds to that of FIG. 11 a.
FIG. 11 c shows the generating and generated screw profiles obtained by replicating the profile of profile 11 b by rotation and mirroring. The screw profiles thus obtained have tip angles of a size of 0.2795. Given such a ratio of outer radius to centre distance, a screw element according to the prior art would have a tip angle KW 0 of 0.379. The sum SKW of all of the tip angles is accordingly 1.117, whereas the sum of all of the tip angles according to the prior art is 1.515. An overall profile in this figure is composed of a total of 12 arcs, i.e. the minimum number of arcs for a profile with Z=2.
FIG. 12 a shows two corresponding profile parts X 1 (generating profile) und Y 1 (generated profile) of dot- and mirror-symmetrical screw elements. Profile part X 1 is defined by arcs 1 , 2 , and 3 . Profile part Y 1 is defined by the corresponding arcs 1 ′, 2 ′ und 3 ′. The distance between the points of rotation is normalized to 1. Arc 3 touches the line FP. In Table 4 the radii, angles, starting points of the arcs and center points of the arcs are listed.
TABLE 4
Geometrical measurements for profile parts X and Y of screw elements
according to the invention, as depicted in FIGS. 12a, 12b, and 12c.
starting
starting
center point
center point
point x-
point y-
on the x-
on the x-
radius
angle
Koordinate
coordinate
coordinate
coordinate
0.6
0.0799
0.6
0
0
0
0
0.3943
0.5981
0.0479
0.5981
0.0479
0.9
0.3112
0.5981
0.0479
−0.2026
−0.3631
FIG. 12 b shows the fully wiping profiles, which result from the profile parts depicted in FIG. 12 a by mirroring and rotating. The tip angle KW of one profile is 0.1598. The sum of the tip angles of both profiles SKW is 0.3196. A profile being state of the art has got a tip angle KW 0 of 0.399 and the sum of the tip angles of two corresponding profiles SKW 0 is 0.799.
FIG. 12 c shows two profiles which were constructed from the profiles depicted in FIG. 12 b by using the method of three-dimensional equidistant clearance. The barrel diameter is 0.61, and clearance δ between barrel and screw and clearance s between screw and screw zwischen Schnecke is 0.02. The incline is 1.2.
The tip angle of one of the profiles is KWA=0.208. The sum of the tip angles of both profiles SKWA is 0.319.
FIG. 12 d shows profiles being state of the art, having identical clearances and an identical inline according to the profiles depicted in FIG. 12 c . One profile has got a tip angle KWA 0 of 0.329; the sum of the tip angles of both profiles is 0.658. | The present invention relates to screw elements for multiscrew extruders with pairs of co-rotating and fully wiping screws, to the use of these screw elements in multiscrew extruders and to a method of generating screw elements according to the invention. | 8 |
FIELD OF THE INVENTION
This invention relates generally to a large enclosure constructed of plastic structural panels. More specifically, the present invention relates to a modular construction system utilizing injection molded plastic structural panels having integrated connectors to construct various sized enclosures using the same components.
BACKGROUND INFORMATION
Utility sheds are a necessity for lawn and garden care, as well as general all-around home storage space. Typically, items such as garden tractors, snow blowers, tillers, ATVs, motorcycles and the like consume a great deal of the garage floor space available, forcing the homeowner to park his automobile outside.
The prior art has proposed a number of different panel systems, or kits, comprising blow molded or extruded panels and connector members for forming a wide variety of smaller sized storage structures. These structures are generally suitable to store hand tools and smaller lawn equipment. Typically, such systems require extruded metal or plastic connector members having a specific cross-sectional geometry that facilitate an engagement between such members and one or more blow molded plastic panels having a complimentary edge configuration. Due to the nature of the manufacturing process, blow molded plastic components cannot be formed with the intricate shapes and/or sharp corners required for integrated connectors. In addition, blow molded plastic components are hollow and cannot be formed with the integral strengthening ribs and gussets possible with injection molding.
A particularly common structure for the connector members is the I-beam cross section. The I-beam defines free edge portions of the connector member which fit within appropriately dimensioned and located slots in the panel members. U.S. Pat. No. D-371,208, teaches a corner extrusion for a building sidewall that is representative of the state of the art I-beam connector members. The I-beam sides of the connector engage with the peripheral edge channels of a respective wall panel and thereby serve to join such panels together at right angles. Straight or in-line versions of the connector members are also included in the kits to join panels in a coplanar relationship to create walls of varying length.
Extruded components generally require hollow longitudinal conduits for strength. Due to the nature of the manufacturing process the conduits are difficult to extrude in long sections for structural panels. Thus, they require connectors to achieve adequate height for utility shed walls. A common structure for connecting extruded members has a center I-beam with upper and lower protrusions for engaging the conduits. However, wall panels utilizing connectors are vulnerable to buckling under loads and may have an aesthetically unpleasing appearance. Moreover, roof loads from snow and the like may cause such walls to bow outwardly due to the clearances required between the connectors and the internal bores of the conduits. U.S. Pat. No. 6,250,022 discloses an extendable shed utilizing side wall connector members representing the state of the art. The connectors have a center strip with hollow protrusions extending from its upper and lower surfaces along its length; the protrusions being situated to slidably engage the conduits located in the side panel sections to create the height needed for utility shed walls.
The aforementioned systems can also incorporate roof and floor panels to form a freestanding enclosed structure such as a small utility shed. U.S. Pat. Nos. 3,866,381; 5,036,634; and 4,557,091 disclose various systems having inter-fitting panel and connector components. Such prior art systems, while working well, have not met all of the needs of consumers to provide the structural integrity required to construct larger sized structures. Larger structures must perform differently than small structures. Larger structures require constant ventilation in order to control moisture within the building. Large structures must also withstand increased wind and snow loads when compared to smaller structures. Paramount to achieving these needs is a panel system which eliminates the need for extruded connectors to create enclosure walls which resist panel separation, buckling, racking; and a roof system which allows ventilation while preventing weather infiltration. A further problem is that the wall formed by the panels must tie into the roof and floor in such a way as to unify the entire enclosure. Also, from a structural standpoint, the enclosure should include components capable of withstanding the increased wind, snow, and storage loads required by larger structures. From a convenience standpoint, a door must be present which can be easily installed after assembly of the wall and roof components, is compatible with the sidewalls, and which provides dependable pivoting door access to the enclosure. Also from a convenience standpoint, the structure should allow natural as well as artificial lighting. The structure should be aesthetically pleasing in appearance to blend in with surrounding structures.
The assignee of the instant invention is also the assignee of various other plastic enclosure systems, U.S. Pat. No. 6,892,497 entitled Plastic Panel Enclosure System, U.S. patent application Ser. No. 10/674,103 Plastic Expandable Utility Shed, the contents of which are incorporated herein in their entirety.
There are also commercial considerations that must be satisfied by any viable enclosure system or kit; considerations which are not entirely satisfied by state of the art products. The enclosure must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The enclosure must also be capable of being packaged and shipped in a knocked-down state. In addition, the system must be modular and facilitate the creation of a family of enclosures that vary in size but which share common, interchangeable components.
Finally, there are ergonomic needs that an enclosure system must satisfy in order to achieve acceptance by the end user. The system must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the system must not require excessive strength to assemble or include heavy component parts. Moreover, the system must assemble together in such a way so as not to detract from the internal storage volume of the resulting enclosure, or otherwise detract from the internal storage volume of the resulting enclosure, or otherwise negatively affect the utility of the structure.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form an enclosure, commonly in the form of a large utility shed. The corner sections, roof, wall and floor panels are formed of injection molded plastic to interlock with one another without the need for separate I-beam connectors. The ends of the wall panels have receptacles to accept both roof and floor bosses for interlocking cooperative engagement to rigidly connect the components together.
The system incorporates a minimum number of components to construct a large heavy duty enclosure by integrally forming connectors into injection molded panels. This minimizes the need for separate extruded or molded connectors to assemble the enclosure. The symmetry of the corner sections, wall, roof, floor and door components also minimizes component shapes and simplifies enclosure construction. The heavy duty interlocking construction of the corner sections and the roof headers create a structural frame that allows construction of larger enclosures. Injection molding the wall panels allow them to be formed with adequate height for a large walk-in enclosure, eliminating the need for stacking panels to achieve such adequate height. Injection molding also allows the panels to be formed with integral cross-bracing, ribs, and gussets for increased rigidity when compared to blow molded or extruded panels.
In one embodiment, the enclosure system utilizes interlocking corner sections, roof headers, and floor panels to create a structural frame. Three types of panel constructions are integrated into the structural frame: the first being utilized for the side walls, the second being used for the door assembly, and the third being used for the roof. The wall panels are constructed to cooperate, via integrally formed connectors, with various members which allow the wall panels to be utilized for door frames as well as corner sections. The wall panels are also constructed to accept windows for natural lighting, and may include provisions for standard electrical current hookup. The internal surfaces of the wall panels include integrally formed connectors for easy assembly of added components such as shelving, baskets, slat wall storage and the like. The embodiment also incorporates a vented gabled roof assembly with anti-lift wind strapping and steel reinforcement. The system further includes a door assembly which may be locked in an open or closed position. The floor of the system is primarily constructed of a single type of floor panel in combination with front and rear edge assemblies to permit construction of sheds having various predetermined lengths and widths. The same wall, floor and roof components are used to create an entire family of utility enclosures of varying size, and the assembly of the system requires minimal hardware and a minimum number of hand tools.
Accordingly, it is an objective of the present invention to provide a utility enclosure system which utilizes plastic structural frame and panel members having integrated connectors for creating larger enclosures of varying dimension using common components.
A further objective is to provide a utility enclosure system wherein the structural panel members include integrated connectors which accommodate injection molding plastic formation of the panel components for increased structural integrity.
Yet a further objective is to provide a utility enclosure system which utilizes structural corner assemblies for increased enclosure rigidity.
Another objective is to provide a utility enclosure system constructed with panels having interlocking bosses and pockets as well as ridge and groove edges to increase rigidity and prevent panel bowing or separation.
Yet another objective is to provide a utility enclosure system which reduces the number of components required to assemble an enclosure and simplifies construction.
Still yet another objective is to provide a utility enclosure system constructed and arranged with panels that allow wood and/or steel supports to be easily incorporated therein for increased snow and/or wind load resistance.
An even further objective is to provide a utility enclosure system constructed and arranged to allow airflow through the enclosure while preventing weather related moisture from entering the enclosure.
Yet a further objective is to provide a utility enclosure system which may be optionally configured with clear windows thereby allowing natural light to enter the enclosure.
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 FIGURES
FIG. 1 is a front perspective view of an enclosure constructed using the instant utility enclosure system;
FIG. 2 is a rear perspective view of an enclosure constructed using the instant utility enclosure system;
FIG. 3 is an exploded view of the enclosure shown in FIG. 1 ;
FIG. 4 is a perspective view of one embodiment of the floor assembly utilized in the instant invention;
FIG. 5 is an exploded perspective view of the floor assembly shown in FIG. 4 ;
FIG. 6 is a bottom view of the floor assembly illustrating the integrally formed cross-bracing;
FIG. 7 is a partial section view taken along line 1 - 1 of FIG. 4 , illustrating the connection between a floor panel and a locking boss;
FIG. 8 is a partial section view taken along line 2 - 2 of FIG. 4 , illustrating the connection between a floor panel and a locking boss;
FIG. 9 is a partial section view taken along line 3 - 3 of FIG. 4 , illustrating the connection between a floor panel and a front end assembly;
FIG. 10 is a partial perspective view taken along line 4 - 4 of FIG. 4 , illustrating the lower hinge pin, door catch feature, a portion of the roof support structure, door gap seal, and wall key as utilized in the instant invention;
FIG. 11 is a perspective view illustrating one of the corner posts utilized in the instant invention;
FIG. 12 is a perspective view illustrating one of the corner posts utilized in the instant invention;
FIG. 13 is a perspective view illustrating assembly of first and second corner post members;
FIG. 14 is a rear perspective view illustrating a wall panel;
FIG. 15 is a partial section view illustrating assembly of adjacently positioned wall panels;
FIG. 16 is a partial section view illustrating the assembly of adjacently positioned wall panels;
FIG. 17 is a partial view illustrating the assembled wall panels;
FIG. 18A is a perspective view illustrating the inner surface of a reinforcement channel as utilized in the instant invention;
FIG. 18B is a partial perspective view illustrating the reinforcement channel in engagement with a wall assembly;
FIG. 19 is a perspective view illustrating the outer surface of a reinforcement channel as utilized in the instant invention;
FIG. 20 is a perspective view illustrating assembly of the door frame member to a wall panel;
FIG. 21 is a perspective view illustrating assembly of a wall panel to the floor assembly;
FIG. 22 is a perspective view illustrating assembly of the corner post assembly to the wall panels and floor assembly;
FIG. 23 is a perspective view illustrating the assembled wall and floor panels;
FIG. 24 is a perspective view illustrating one of the door panels utilized in the instant invention as well as assembly of a sliding door latch;
FIG. 25 is a perspective view illustrating one of the door panels utilized in the instant invention as well as assembly of a sliding door latch;
FIG. 26 is a perspective view illustrating assembly of a door panel to the assembled wall panels;
FIG. 27 is a perspective view illustrating assembly of a second door panel to the assembled wall panels;
FIG. 28 is an exploded view of the roof assembly as utilized in the instant invention;
FIG. 29 is a front perspective exploded view of a header assembly as utilized in the instant invention;
FIG. 30 is a rear perspective exploded view of a header assembly as utilized in the instant invention;
FIG. 31 is a rear perspective view of a header assembly as utilized in the instant invention;
FIG. 32 is a front perspective view of a header assembly secured to the front wall assembly and corner posts;
FIG. 33 is a perspective view illustrating the assembly of the roof header and roof support beams;
FIG. 34 is a perspective view illustrating a roof panel as utilized in the instant invention;
FIG. 35A is a partial perspective view illustrating the connection between the roof and wall panels;
FIG. 35B is a partial perspective view illustrating assembly of a connector boss to a roof panel;
FIG. 36A is a partial perspective view illustrating the assembled connection of a wall panel and a pair of roof panels;
FIG. 36B is a partial perspective view illustrating the assembled connection of a wall panel and a pair of roof panels;
FIG. 37A is a partial perspective view illustrating assembly of a connector boss to a roof support;
FIG. 37B is a partial perspective view illustrating a connected roof panel and roof support;
FIG. 38A is a partial perspective view illustrating a roof panel connected to the front header assembly and the ridge cap;
FIG. 38B is a partial perspective view illustrating a ramp-lock as utilized in the instant invention;
FIG. 39A is a partial top view of roof panels assembled to a header member;
FIG. 39B is a section view taken along line 5 - 5 of FIG. 39A ;
FIG. 39C is a rear view of the partial view shown in FIG. 39A ;
FIG. 40 is a section view taken along line 6 - 6 of FIG. 39A illustrating the overlapping connection between the roof panels;
FIG. 41 is a partial perspective view illustrating assembly of roof panels to the assembled ridge cap, headers and roof supports;
FIG. 42 is a partial exploded view illustrating assembly of the cupola walls;
FIG. 43 is a partially exploded view illustrating assembly of the cupola top member;
FIG. 44 is an assembled view of the cupola as utilized in the instant invention;
FIG. 45 is a partial perspective illustrating installation of a cantilever shelf embodiment securable to the inner surface of the wall panels;
FIG. 46 is a partial perspective view illustrating an assembled cantilever shelf embodiment secured to the inner surface of the wall assemblies;
FIG. 47 is a partial perspective view illustrating assembly of a stackable shelf arrangement securable to the inner surface of a wall assembly;
FIG. 48 is a partial perspective view illustrating assembly of a stackable shelf arrangement securable to the inner surface of a wall assembly;
FIG. 49 is a partial perspective view illustrating assembly of a stackable shelf arrangement securable to the inner surface of a wall assembly;
FIG. 50 is a partial perspective view illustrating an assembled stackable shelf arrangement secured to the inner surface of a wall assembly;
FIG. 51 is a front perspective view illustrating a larger utility enclosure constructed with the teachings of the instant invention;
FIG. 52 is a rear perspective view of the embodiment shown in FIG. 51 ;
FIG. 53 is a front perspective view illustrating a larger utility enclosure constructed with the teachings of the instant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
FIGS. 1-3 which are now referenced show isometric and exploded views of a heavy duty utility enclosure, generally referenced as 10 , constructed according to a preferred embodiment of the present invention. The enclosure is made up of a floor assembly 100 , left and right side wall assemblies 200 , corner post assemblies 300 , roof assembly 400 , rear wall assembly 500 , front wall assembly 600 and door assemblies 700 . In the preferred embodiment, the panels comprising the assemblies are formed of but not limited to a suitable plastic such as polystyrene, polypropylene or polyethylene, through the process of injection molding. The result is that the panels comprising the floor assembly 100 , post assemblies 300 , side wall assemblies 200 , roof assembly 400 , rear wall assembly 500 and front wall assembly 600 of the enclosure 10 are formed as unitary panels with integral connectors and cross bracing. Strengthening ribs and gussets 206 are formed within the inner surfaces of the various panels and components in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes, as shown in FIG. 1 . The injection molded construction is utilized for the floor assembly 100 , left and right wall assemblies 200 , the corner posts 300 , roof assembly 400 , rear wall assembly 500 , and front wall assembly 600 using a minimal number of components.
Referring to FIGS. 1-10 , the enclosure includes a plurality of like-constructed floor panels 102 . Each panel has a top surface 104 , bottom surface 106 , a closed first edge 108 , a second edge 110 opposite said first edge, said second edge including a first means for connecting to juxtapositioned panel members, a third edge 112 substantially perpendicular to and extending between said first and said second edges, the third edge including the first means for connecting to juxtapositioned panel members, and a fourth edge 114 opposite to and substantially parallel to said third edge, the fourth edge including the first means for connecting to juxtapositioned panel members. Adjacent to the closed edge 108 is a second means of attaching the floor assembly to the wall assemblies illustrated herein as a plurality of bosses 116 extending upwardly from the top surface 104 . The bosses 116 are constructed and arranged to cooperate with pockets 210 located at each longitudinal end of the structural wall panels 202 and the structural L-shaped post assemblies 300 for connecting and maintaining a substantially perpendicular relationship between the wall panel members and the top surface of the floor panel members. Within the preferred embodiment, the locking bosses 116 are removeable and replaceable, wherein each locking boss includes a first lower end 130 and a second upper end 132 . The first end includes a flange 134 constructed and arranged to cooperate with a floor panel to provide a secure connection between the panels and to prevent lifting or tipping of wall panels secured thereto. The locking boss is inserted through a conjugately shaped aperture 136 integrally formed within the floor panels until the integrally formed spring clips 138 engage surface 140 for a secure connection, wherein the locking boss extends upwardly above the top surface of the floor panel.
Along the edges 110 , 112 , and 114 of each floor panel 102 is the first means of connection illustrated herein as a series of spaced apart fingers 122 and recesses 124 for attaching the panels together into a floor assembly 100 , a portion of the fingers being provided with at least one countersank aperture 123 for receiving a fastener 113 . The fingers 122 and recesses 124 are constructed and arranged so that the fingers 122 of one panel overlap and mateably engage the recesses 124 of an adjacently positioned panel. The fasteners secure the panels together in an inter-fitting engagement with their respective top surfaces 104 in a co-planar arrangement. In a most preferred embodiment a portion of the fingers include an alignment boss 115 ( FIG. 9 ) projecting outwardly from a lower surface thereof. The alignment boss 115 mateably engages an alignment socket 117 positioned within an upper surface of an aligned recess 124 . In one embodiment the alignment boss may include an integrally formed spring clip (not shown) for interlocking engagement with the alignment socket 117 .
The floor panels 102 are interconnected to each other to form a utility shed floor assembly 100 having a width determined by the width of the panels and length determined by the number of panels assembled. The panels are assembled by juxtapositioning the edges of respective floor panels and sliding the fingers of one panel into the respective recesses of the adjacent panel while simultaneously engaging the alignment bosses into their respective sockets. The fingers 122 and recesses 124 along the second, third, and fourth edges of the floor panels 102 correspond in shape and size to that of the fingers and recesses integrally formed into the adjacently positioned panels. The result is a positive mechanical connection between the floor panels to create the floor assembly 100 . In this manner the length of the shed may be increased or decreased to suit the users needs by adding or subtracting the number of panels assembled.
Referring to FIG. 6 , the bottom surface of the floor assembly 100 is illustrated. The bottom surface 106 illustrates the cross-bracing 128 facilitated by injection molding of panels. Injection molding offers significant strength and stability advantages over blow-molding as utilized in the prior art. In this manner, the enclosure of the instant invention is capable of handling a significant amount of weight as compared to blow molded or extruded enclosures.
Referring to FIGS. 1-10 , in addition to the floor panels, the floor assembly includes a front end assembly 142 . The front end assembly preferably includes two front end members 144 . Each front end member includes a top surface 146 , a bottom surface 156 , a first ramp edge 148 , a second edge 150 opposite the first edge, an outer edge 152 , a an inner edge 154 . The second edge includes the first means of connection whereby the front end members may be juxtapositioned in interlocking engagement with assembled floor panel members 102 to finish the front portion of the floor assembly 100 . The inner edges 154 include a third means of connection for connecting to the inner edge of an adjacently positioned front end member, illustrated herein as an overlapping arrangement which includes fasteners to facilitate mechanical connection. It will be appreciated that the purpose of the overlapping arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The result is a mechanically secure connection between the two panels that resists separation when traversed with heavy loads. Adjacent to each of the ramp edges 148 is a pair of generally cylindrical hinge pins 176 extending upwardly. The hinge pins 176 cooperate with the door panels 702 to allow pivotal movement. Adjacent to each of the hinge pins is a cylindrical boss 178 constructed and arranged to cooperate with a roof support pillar 602 . The roof support is generally tubular and sized to encircle the cylindrical boss 178 as well as a like constructed cylindrical boss positioned on the bottom surface of the header assembly 450 ( FIG. 28 ) to provide increased wind and snow load capacity to the enclosure.
Referring to FIGS. 1-10 , in addition to the floor panels, the floor assembly includes a rear end assembly 160 . The rear end assembly preferably includes two rear end members 162 . Each rear end member includes a top surface 164 , a bottom surface 166 , a rear closed edge 168 , a second edge 170 opposite the first edge, an outer edge 172 , and an inner edge 174 . The second edge includes the first means of connection whereby the front end members may be juxtapositioned in interlocking engagement with assembled floor panel members 102 to finish the rear portion of the floor assembly 100 . The inner edges 174 include the third means of connection for connecting to the inner edge of an adjacently positioned rear end member, illustrated herein as an overlapping arrangement which includes fasteners to facilitate mechanical connection. It will be appreciated that the purpose of the overlapping arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The result is a mechanically secure connection between the two panels that resists separation.
Referring to FIG. 11 , a structural corner post assembly 300 is shown. The corner post assembly 300 constitutes one of a plurality of like-configured structural corner post assemblies in the system used to add significant strength and rigidity to the enclosure 10 . The corner post assemblies 300 are generally L-shaped having a first member 302 extending at least partially along the front or rear wall of the enclosure and a second member 304 extending at least partially along a side wall of the enclosure. The first corner post members 302 are each configured having a first longitudinal end 306 and a second longitudinal end 308 each including an integrally formed fourth means of attachment illustrated herein as an inwardly extending socket 210 . The socket is generally constructed and arranged to cooperate with either a floor assembly 100 or a roof assembly 400 boss in a generally perpendicular relationship. To facilitate mechanical connection with other structural panel members 202 in a co-planar relationship the first post member is provided a first horizontal edge 314 including a fifth means of attachment illustrated herein as a plurality of inwardly extending sockets 330 . The sockets include an inner wall 316 , an outer wall 318 , and a bottom wall 320 . The bottom wall includes an aperture 321 or notch therethrough for cooperative engagement with a hook-lock 322 included on an adjacently positioned wall panel or second corner post member 304 . In the preferred embodiment the horizontal edge 314 also includes a groove 324 extending from about the first longitudinal end 306 to about the second longitudinal end 308 of the edge 314 . The groove 324 is arranged to cooperate with a wall panel member 202 having a complimentary ridge in an interlocking coplanar relationship. The second member 304 includes a first end 330 and a second end 332 . Extending outward along the length of the second member is a plurality of bosses constructed and arranged to cooperate with sockets 330 integrally formed into the side of the first member 302 . A portion of the bosses include integrally formed hook-locks 322 for cooperation with the apertures or notches 321 provided in the first member or wall panels. The first and second members are attached together by sliding the bosses of the second member into the sockets of the first member and thereafter sliding the second member downward to engage the hook-locks ( FIG. 13 ). The result is a positive mechanical connection between the first member of the post 302 and the second member of the post 304 . The outer surface 326 of the corner post assemblies 300 are constructed generally smooth for aesthetic appearance, while the internal portion of the assembly includes a plurality of box structures 328 for added strength, rigidity and weight carrying capacity. The construction of the corner post assemblies increase the structural integrity of the enclosure 10 by preventing the corner posts 300 from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the enclosure 10 .
The L-shaped corner post assemblies 300 are attached to the interconnected floor assembly 100 by sliding the first longitudinal end of the corner post assembly over a plurality of the bosses 116 extending outwardly from the floor assembly 100 . The pockets 210 in each end of the panels 302 correspond in shape and size to that of the bosses 116 and spring tabs 126 ( FIG. 9 ) integrally formed into the bosses 116 align with apertures 336 in the pockets 210 to engage the corner post assembly 300 . The result is a positive mechanical connection between the corner post assemblies 300 and the floor assembly 100 .
Referring to FIGS. 3 and 14 , a structural wall panel 202 is shown. The wall panel 202 constitutes one of a plurality of like-configured panels in the system used to construct the left, right, front and rear wall assemblies 200 , 500 , 600 . The structural wall panels 202 are each configured having a first longitudinal end 208 including an integrally formed fourth means of attachment illustrated herein as a plurality of sockets 210 . A second longitudinal end 212 also including an integrally formed fourth means of attachment illustrated herein as a plurality of sockets 210 . The sockets 210 are generally constructed and arranged to cooperate with either a floor assembly 100 or a roof assembly 400 to facilitate mechanical connection in a generally perpendicular relationship. The outer surface 256 and inner surface 258 of the panels 202 are constructed generally smooth having a plurality of ribs 260 , extending from the first edge 214 across the panel 202 to the second edge 222 , for added strength and aesthetic appearance. The ribs 260 increase the structural integrity of the enclosure 10 by preventing the panels 202 from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure 10 .
To facilitate mechanical connection with other structural wall panel members 202 in a co-planar relationship the panels are provided a first horizontal edge 214 constructed with a fifth means of attachment illustrated herein as a plurality of sockets 330 . The sockets include an inner wall 316 , an outer wall 318 , and a bottom wall 320 . The bottom wall includes an aperture 321 ( FIG. 12 ) or notch therethrough for cooperative engagement with a hook-lock 322 included on an adjacently positioned wall panel or corner post. For additional structural rigidity between the side wall panels or between the side wall panels and the floor assembly, the wall panels may also include a groove 216 . The groove extends along first and second longitudinal ends as well as along the first horizontal edge of the panels. The groove 216 is arranged to cooperate with a corner post assembly 300 , wall panel member 202 , or floor assembly 100 having a complimentary ridge 180 in an interlocking coplanar relationship. The ridge 180 extends from about the first longitudinal end 208 of each panel to about the second longitudinal end 212 of each panel along the second edge 222 of the panels. An additional ridge 180 ( FIGS. 4 and 5 ) extends around the perimeter of the floor assembly. The cooperation between the floor assembly ridge and wall panel groove provides a weather and insect resistant seal around the lower perimeter of the enclosure.
The second horizontal edge 222 of each wall panel is constructed generally flat having a plurality of outwardly extending bosses 334 . The bosses are constructed and arranged to cooperate with sockets 330 integrally formed into the second edge of the wall panel 202 . A portion of the bosses include integrally formed hook-locks 322 for cooperation with the apertures or notches 321 provided in the first member of the corner post assembly or first edge of the wall panels. In addition, the side surfaces of the bosses may include a ramp-lock 250 ( FIG. 17 ) having a ramping surface 254 constructed to cooperate with apertures 252 positioned along the inner wall 316 .
Referring to FIGS. 14-17 , engagement of the bosses 334 and sockets 330 is illustrated. The wall panels 202 are attached together by sliding the bosses of one panel into the sockets of an adjacently positioned wall panel ( FIG. 15 ) and thereafter sliding the wall panel downward to engage the hook-locks ( FIG. 16 ). In addition to engagement of the hook-locks, the downward motion preferably causes the ramping surface 254 to flex the inner wall 316 until the ramp-lock 250 slips through aperture 252 allowing the inner wall to return to its normal position, locking the wall panels in an engaged position. The result is a positive mechanical connection between the wall panels. The overlapping connection between the panels resists weather infiltration and prevents lifting of the panels under high wind loads.
Referring to FIGS. 15-17 , and 20 , a door frame 750 member is attached to a wall panel 202 . The door frame member includes at least one hinge pin conduit 718 and a pair of hinge pin clearance pockets 728 integrally formed thereto. The door frame member also includes a door seal 752 integrally formed thereto to provide a weather resistant seal to the door assembly 700 . The wall panel 202 and the door frame member 750 are attached together by sliding the bosses of the panel into the sockets of the adjacently positioned door frame member, as shown in FIG. 15 , and thereafter sliding the wall panel downward to engage the hook-locks, as shown in FIG. 16 . In addition to engagement of the hook-locks, the downward motion preferably causes the ramping surface 254 to flex the inner wall 316 until the ramp-lock 250 slips through aperture 252 allowing the inner wall to return to its normal position locking the wall panels in an engaged position. The result is a positive mechanical connection between the wall panel and the door frame member 750 .
Referring to FIGS. 21-23 , the wall panels 202 are attached to the interconnected floor-panels 102 and corner post assemblies 300 by sliding the first longitudinal end of a wall panel 208 over a plurality of the bosses 116 . The pockets 210 in each end of the panels 202 correspond in shape and size to that of the bosses 116 and spring tabs 126 ( FIG. 8 ) integrally formed into the bosses 116 align with apertures 234 in the pockets 210 to engage the wall panel 202 . The result is a positive mechanical connection between the wall-panels 200 and the floor assembly 100 . The first wall panel being attached to the floor assembly 100 and the corner post assembly 300 with the first longitudinal end 208 downward interlocking the two panels via the ridge, groove and boss arrangement extending along the sides of the wall panels. The second wall panel is thereafter attached in a coplanar relationship to the first panel interlocking the two panels via the ridge, groove, and boss arrangement extending along the sides of the wall panels. It will be appreciated that the purpose of the ridge 180 and the groove 216 arrangement is to align two panels in an interlocking co-planar relationship and to facilitate their mechanical connection. The ridge 180 and the groove 216 are brought into an interlocking relationship wherein the ridge 180 enters the corresponding groove 216 ( FIG. 17 ). The result is a mechanically secure connection between the two panels. The interlocking edges between the panels as described above provides a secure connection and offers several advantages. First, the design allows the panels to be connected without the need for I-beam connectors. Second, the design allows the panels to be formed at sufficient height for a walk-in enclosure by creating a positive lock that prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another. Fourth, the design provides a sealed connection between the panels preventing weather infiltration. The resultant wall created by the combination of the interlocking wall panels benefits from high structural integrity and reliable operation.
Referring to FIGS. 18-19 , a wall panel reinforcement channel 701 is illustrated. The side wall reinforcement channel is generally C-shaped and includes a first end 740 , a second end 742 , an inner surface 746 , and an outer surface 747 . The inner surface includes a plurality of formed flexible hooks 748 . Each flexible hook includes a barb 749 . In operation the reinforcement channel is attached to the inner socket wall 316 of a pair of assembled wall panels 202 by inserting the flexible hooks through apertures 254 until the barbs 710 engage the inner surface of the socket 330 . The reinforcement channels are preferably constructed of steel or other suitable metal and provide significant rigidity and weight carrying capacity to the wall assemblies. In addition, the reinforcement channels prevent the panels 202 from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the enclosure 10 . Still yet, the reinforced ribs provide support for optional cantilever shelves 800 ( FIG. 45-46 ) or stackable shelves 900 ( FIGS. 47-50 ) by distributing any load applied to the shelves across the length of the wall panels.
Referring to FIGS. 3 , 24 and 25 , the door assembly 700 is illustrated. The door assembly includes a pair of door panels 702 , a pair of door frame members 750 , a hinge means 720 , a door handle assembly 726 , 728 , and a latch assembly 724 . The door panel 702 constitutes one of a plurality of like-configured panels in the system used to construct the door assembly. The door panels 702 are configured each having a first longitudinal end 708 , a second longitudinal end 712 , an inner surface 704 , an outer surface 706 , a first edge 714 , and a second edge 716 . To facilitate mechanical connection with door frame members 750 in a pivoting, relationship the first edge of the panels are provided with a pair of circular hinge conduits 718 and a hinge pin 720 . The hinge conduits and hinge pin are constructed and arranged to cooperate with hinge pins and conduits integrally formed onto the door frame members 750 to allow pivoting movement of the door panel. The second horizontal edge 716 is constructed generally flat with the exception of an optional overlapping seal 722 ( FIG. 3 ) extending the full length of the panel. The optional overlapping seal 722 may be attached by any suitable fastening means well known in the art or may be integrally formed with the panel. The door panels 702 are also provided with an upper and lower sliding latch mechanism 724 ( FIGS. 24-25 ) as well as left and right door handles 726 , 728 ( FIG. 3 ).
Continuing with regard to FIGS. 3 , 24 and 25 , the outer surface 706 of the panels 702 are constructed generally smooth having a plurality of raised panels 726 for added strength and aesthetic appearance. The inside surface of the panel 704 is constructed with a plurality of raised panels 726 for added strength and aesthetic appearance. The raised panels 726 increase the structural integrity of the enclosure 10 by preventing the panels 702 from bowing or bending, inwardly or outwardly and thus, adversely affecting the appearance or operation of the enclosure 10 .
Referring to FIGS. 26-27 , the door panels 702 are attached to the interconnected floor panels 100 , left and right corner post assemblies 300 , and front wall assembly 600 by sliding the respective hinge pin 720 into the corresponding hinge conduits 718 located along the edge of the door frame 750 and the front end member of the floor assembly. Either door panel 702 is aligned with the hinge pins by sliding it vertically into place over the respective pins. It should be appreciated that this construction provides economic advantage allowing hinge components to be integrally formed onto the door panels. The door panels are also provided with removable and replaceable door latching mechanisms including slide latches 724 , left door handle 726 and right door handle 728 ( FIG. 3 ).
Referring to FIGS. 24-25 , installation of the upper and lower slide latches 724 is illustrated. The slide latches are constructed and arranged to allow simple push-in installation. The latch housings 730 are merely pushed into apertures 732 located adjacent to edge 716 in the door panels 702 until the spring clips (not shown) engage an inner surface of the panel. Thereafter the one end of the door latch pin 734 is inserted through the housing 730 and downwardly until spring clip 736 is snapped into place. In this manner the door latches can be installed and removed as needed without the need for tools or screw type fasteners. By sliding the latch pin 734 to extend it outwardly to engage the roof assembly 400 or the floor assembly 100 , the contents contained within the enclosure 10 are secured. The door handles 726 , 728 are constructed and arranged to allow simple push-in installation. The handles are merely pushed into apertures 738 contained in door panels 702 until the spring clips (not shown) engage an inner surface of the panel 702 . In this manner the door handles can be installed and removed as need without the need for tools or screw type fasteners. The handles are also provided with lock apertures allowing the contents contained within the enclosure to be secured with a padlock or the like.
Referring to FIGS. 28-32 the roof assembly 400 includes a pair of like constructed header assemblies 450 . The header assembly is a truss like structure molded with an aesthetically pleasing generally smooth wall on its outer surface 452 and integrally formed box bracing 454 and a plurality of pockets 456 constructed and arranged to accept roof support beams on its inner surface 454 . In the preferred embodiment the header is constructed of a center member 472 and a pair of outer members 474 . This construction permits the center member to be exchanged for narrower or wider members to construct different sized enclosures while the outer members may remain the same. Each member of the header assembly includes an upper surface 458 and a lower surface 460 . The lower surface 460 includes a third means of connection illustrated herein as a plurality of inwardly extending engagement sockets 462 constructed and arranged to cooperate with removable and replaceable bosses 464 and/or door hinge pins 466 . The bosses 464 or hinge pins 466 are slid into their respective engagement sockets 462 until the integrally formed spring tabs 468 engage corresponding apertures 470 formed in the engagement sockets. The end surfaces 476 , 478 of the members include a ninth means of connection illustrated herein as a plurality of outwardly extending inter-fitting tubes 480 . The tubes are constructed and arranged to extend into an adjacently positioned header member until integrally formed spring locks engage. This construction provides a load distributing connection between the members that prevent separation and bowing of the assembly under load. In addition, the design provides a sealed connection between the panels preventing weather infiltration. The resultant header created by the combination of the interlocking members benefits from high structural integrity and reliable operation.
The front header is assembled to the floor and wall assemblies by sliding the hinge pins 466 into their respective hinge conduits 718 while simultaneously sliding the locking bosses 464 into the wall sockets 210 until the integrally formed spring clips engage the apertures 234 formed into the wall panels. The result is a positive lock that maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another.
Referring to FIGS. 28 , 33 , at least three and up to five roof supports 482 are inserted into their respective pockets 456 in each of the headers and secured in place with suitable fasteners. The support beams 482 are preferably constructed of steel, but may be constructed of other materials well known in the art capable of providing structural support to the roof assembly; such materials may include but should not be limited to plastic and/or wood as well as suitable combinations thereof. FIG. 33 is shown with a portion of the enclosure omitted for clarity, illustrating the placement of the support beams 482 in the preferred embodiment. The roof assembly 400 also includes a plurality of like constructed ridge cap members 484 and a plurality of like-constructed roof panels 402 . Each ridge cap member 484 includes a tenth means of connection illustrated herein as at least one outwardly extending boss 486 and at least one socket 488 for securing the ridge cap members together. The ridge cap members 484 are slid together until the ramp-locks 490 integrally formed into the bosses 486 engage corresponding apertures (not shown) formed in the sockets 488 . The assembled ridge cap is slid into place over the headers and fastened in cooperative engagement with the support beams 482 and the headers 450 . Ramp-locks 490 ( FIG. 38B ) integrally formed into the front surface 452 of the headers 450 cooperates with apertures 492 formed into a front depending wall 494 ( FIG. 38A ) to secure the ridge cap assembly in place. As the ridge caps are pushed into place over the header the depending wall is deflected by the ramp-lock until the aperture 492 snaps over the ramp-lock to secure the ridge cap assembly in place.
Referring to FIGS. 28-41 , each roof panel has a top surface 404 , bottom surface 406 , a first locking edge 408 , a second locking edge 410 , a third locking edge 412 and a closed edge 414 . Along the bottom surface 406 adjacent to the closed edge 412 is a fifteenth means of connection illustrated herein as a plurality of sockets 416 constructed and arranged to receive roof connectors 418 . The roof connectors are constructed and arranged to cooperate with pockets 210 located at second longitudinal end 212 of the structural wall panels 202 as well as the sockets 416 located on the lower surface 406 of the roof panels 402 . A series of spaced apart structural ribs 420 extend across the lower surface of each roof panel 402 to provide increased weight carrying capacity to the roof assembly 400 . The first and second locking edges of the roof panel 402 include a thirteenth and fourteenth means of connection illustrated herein as a W-shaped overlapping connection 416 ( FIG. 40 ). The distal portion 418 of the first edge overlapping connection including a plurality of ramp-locks 490 arranged to cooperate with apertures 492 formed into the second edge overlapping connection. The W-shaped overlapping connection provides a water resistant seal between the panels and prevents the panels from bowing or separating under wind or snow loads. The third locking edge 408 of each roof panel 402 includes a twelfth means of connection illustrated herein as an interlocking tube 422 constructed and arranged to cooperate with a ridge cap 484 having a conjugately shaped receiver 424 ( FIG. 41 ) to create a weather resistant seal. The roof panels 402 are slid into the receiver 424 until the integrally formed ramp-locks 490 engage corresponding apertures formed in the ridge cap 484 . For interlocking cooperation between the roof panels 402 and the roof supports 482 a sixteenth means of connection is provided. The sixteenth means of connection is illustrated herein as a second roof connector 420 . The second roof connector includes a first boss end 423 constructed and arranged to cooperate with sockets 416 and a second end 424 constructed and arranged to cooperate with the roof supports 482 . For installation, the third edge of each roof panel is secured to the ridge cap and the closed edge is pivoted downward to engage the first and second roof connectors.
Referring to FIGS. 42-44 a cupola 800 is illustrated. The cupola includes a pair of side walls 802 and a front and rear wall 804 . The cupola is generally constructed and arranged for shipment in a disassembled state and may thereafter be assembled at a desired site. The edges of the side panels are preferably constructed to receive the edges of the front and rear panels in an interlocking relationship. Thereafter the top panel may be assembled to the side walls to finish assembly of the cupola. In one embodiment the lower portion of the cupola side walls are contoured to fit over the ridge cap of the instant embodiment. The cupola may be secured to the enclosure by any suitable means which may include fasteners, spring locks, ramp-locks or suitable combinations thereof.
Referring to FIGS. 45-46 installation and assembled views of cantilever type modular shelving 800 are illustrated. The cantilever shelving includes cantilever wall mounts 802 constructed and arranged to cooperate with wall panels 202 for snap-in engagement. The cantilever shelf 804 is constructed and arranged to snap into engagement with the wall mounts. This arrangement permits assembly without the need for fasteners. The plurality of apertures 254 formed into the inner surface of the wall panels permits the shelving to be mounted in various predetermined positions within the enclosure to suit a user's needs.
FIGS. 47-50 illustrate assembly of stackable shelving 850 . The stackable shelving includes at least two horizontal members 852 , at least two vertical members 854 , and a shelf member 856 . The horizontal members are constructed and arranged to cooperate with aperture 254 formed into the inner surface of the wall panels at a first end and the vertical members 854 at a second end. The bottom portion of the vertical members include an integrally formed projection for interlocking cooperation with an indentation 856 ( FIG. 47 ) formed into the upper surface of the floor panels 102 . Additional shelves may be added to the assembly in a vertical manner by engaging additional vertical members into sockets 858 formed into the upper surface of the horizontal member 852 and thereafter assembling additional horizontal members thereto.
Referring to FIGS. 51-53 , alternative embodiments of the present invention are shown wherein the enclosures are made larger by adding floor panels, roof panels, and adding additional side wall panels. The enlarged enclosures may also include additional door panels to facilitate entering the shed at more than one position. In this manner the same construction can be utilized to build structures of varying size utilizing substantially the same components.
All patents and publications mentioned in this specification 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.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement 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.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | The present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form an enclosure, commonly in the form of a utility shed. The panels are formed of injection molded plastic to interlock with one another without the need for separate I-beam connectors. The ends of the wall panels have cavities to accept both roof and floor outwardly projecting locking bosses for interlocking cooperative engagement which serve to rigidly connect the components together. The symmetry of the wall, roof, floor and door components also minimizes component shapes and simplifies enclosure construction. | 4 |
BACKGROUND OF THE DISCLOSURE
The present invention relates to paperboard trays and more particularly to such trays which are formed from one piece blanks and retain their shape without gluing or interlocking any of their component parts.
Most paperboard tray constructions require the gluing or interlocking of component parts in order for the tray to retain its shape. The gluing or interlocking operation requires extra steps in the formation of the tray. In addition, the glued or interlocked sections comprise two or more layers of paperboard which represent an increased paperboard requirement. Frequently the paperboard requirement is further increased because the glued or interlocked components require that the blank be irregular in shape so as to require waste strips between adjacent blanks.
Gluing or interlocking operations and the paperboard requirements for such constructions add significantly to the cost of manufacturing paperboard trays.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a simple and inexpensive tray formed from a one piece paperboard blank without the gluing or interlocking of elements.
It is another object to provide such a tray from a paperboard blank which generates no paperboard waste.
The objects of the present invention are accomplished by providing a tray produced by folding a rectangular one piece paperboard blank which is cut and scored to provide horizontal edge strips, downwardly angled end strips, a central product supporting strip extending between the end strips, and stiffening members connected along fold lines to both the edge strips and the end strips.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention has been chosen for purposes of illustration and description, and is shown in the accompanying drawings, forming a part of the specification, wherein:
FIG. 1 is a plan view of the cut and scored paperboard blank before folding;
FIG. 2 is a plan view of the tray formed by folding the blank of FIG. 1;
FIG. 3 is a front elevational view of the tray of FIG. 2;
FIG. 4 is a side elevational view of the tray of FIG. 2;
FIG. 5 is a sectional view taken along line 5--5 on FIG. 2;
FIG. 6 is a sectional view taken along line 6--6 on FIG. 2;
FIG. 7 is a perspective view showing the tray in use.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail, there is shown a paperboard blank 10 and a tray 11 formed from the blank which are in accordance with the present invention.
The paperboard blank 10, as shown in FIG. 1, is rectangular in shape having ends 12 and edges 14. A first pair of parallel fold lines 15, each having segments 15A, 15B and 15C, extend across the blanks from edge to edge. A second pair of parallel fold lines 16 extend between the fold lines 15 perpendicular thereto defining strips 17. A first set of cut lines 19 parallel to the second fold lines 16 and positioned inwardly thereof extend past the first fold lines 15 to form a central strip 20. A third pair of fold lines 21 extend between the ends of the cut lines 19. A cut line 22 extends from each end of each cut line 19 toward the adjacent edge 14 in line with the fold lines 21. A fourth fold line 24, extends from the outer end of each cut line 22 to the end of the adjacent second fold line 16 at an angle of about 45 degrees to the line 16.
End strips 25 are defined at each end of the blank 10 by the fold lines 21, the cut lines 22, the fold lines 24, and the fold line segment 15A outwardly of lines 16. The fold line segments 15A together with the fold lines 21 and 24 are scored to allow the end strips 25 to be folded downwardly to form downwardly facing oblique angles between the strips 25 and the strips 17 as shown in FIG. 4.
The fold line segments 15B and 15C lying inwardly of the lines 16 are scored to fold in the opposite direction to form generally upwardly facing oblique angles. The fold line segments 15C divide the central strip 20 into end support portions 26 and a floor portion 27. The fold lines 21 are scored to permit the end portions 26 (as best shown in FIG. 6) to fold downwardly with respect to the strip 25 along the fold lines 21, and upwardly with respect to the floor portion 27 along the fold line segment 15C.
A pair of stiffening wall members 29 are defined by the cut lines 19, 22 and by the fold lines 16, 24. The stiffening wall members 29 are divided by the fold line segments 15B into central sections 30 and end sections 31. The fold lines 16 are scored to permit the central sections 30 to fold downwardly with respect to the strips 17. The scoring along fold lines 24 allow the end sections 31 to fold downwardly with respect to the strips 25 while the scoring along the line segments 15B allows the end sections 31 to fold upwardly and inwardly with respect to the central sections 30.
The blank 10 is preferably cut from a sheet of paperboard by a die which simultaneously cuts and scores the blank. The blank is then preferably subjected to a pre-break operation to facilitate the forming of the tray. In the pre-break operation, reciprocating forming members produce a slight bend in the desired direction along each of fold lines. The blanks are still in an essentially flat condition so that a number of them can be included within the carton in which the product packets are shipped.
To complete the formation of a tray, the pre-broken blank is held between the thumb and fingers of one hand, the thumb engaging one end 12 and the fingers engaging the opposite end 12. The thumb and fingers are moved toward each other causing the blank to fold in the proper direction along each of the fold lines, into the shape shown in FIGS. 2 through 7.
After the tray 11 is formed, the stiffening wall members 29 tend to hold the tray in its assembled condition. The formed tray is loaded with packets P which are shown in phantom lines in FIG. 7.
Preferably, the packets P are made of a relatively stiff material, for example, paper, so that they have a degree of rigidity. They can contain individual servings of commonly used edible products such as sugar, sugar substitutes, salt substitutes, or the like. The packets are placed in the tray on edge upon the floor portion 27 of the central strip 20. The ends of the packets engage the central sections 30 of the stiffening wall members 29 to add further rigidity to the tray. The loaded tray is then placed in use on a counter or table, for example, in a cafeteria.
It will be seen from the foregoing that the present invention provides a simple and inexpensive tray formed from a one piece blank without gluing or interlocking of elements and without generating paperboard waste. | A tray for holding individual serving packets which is formed by folding a one piece paperboard blank. The blank is cut and scored to provide horizontal edge strips, downwardly angled end strips, a central product supporting strip extending between the end strips and stiffening members connected along fold lines to both the edge strips and the end strips. | 1 |
This method relates to systems for, and methods of, producing electroencephalograms of a patient's brain. The system and method of this invention can be generalized for use to provide electroocular information and electrocardiographic information.
BACKGROUND OF THE INVENTION
It has been discovered in recent years that a significant percentage of people have sleep problems. These problems may result from a number of different causes. For example, such sleep problems may result from physical defects in the nose of a person or from involuntary movements of different parts of the body such as a person's arms or legs. Such physical defects or such involuntary movements of a person's arms or legs may cause the person to awaken subconsciously, thereby breaking the person's sleep patterns. Since these involuntary actions can occur to a person many times during a night, such person awakens in the morning incompletely refreshed.
Progress has been made over a period of at least twenty (20) years in determining the reasons why a person complains of insufficient sleep. For example, electrodes have been attached to a person's head to record signals representing brain waves at different locations in the person's brain. Electrodes have also been attached to different positions (e.g. legs of a person's body) to produce signals indicating whether or not the patterns of signals produced at such different positions on the person's body as a result of movements of the patient's body at such positions are correlated with the signals produced at the electrodes on the person's head to indicate the brain waves at such electrodes. The signals produced at the different electrodes are then analyzed to determine the reasons why such person has insufficient sleep.
Although considerable progress has been made in recent years to determine why a person has insufficient sleep, significant problems still remain. One of the major problems is that the signals produced at the different electrodes on the head are quite weak. This has made it difficult, and sometimes impossible, to obtain meaningful information from the signals at different electrodes even when such electrodes are attached to a person's head and signals are produced at such electrodes and are recorded for subsequent analysis. Another reason has been that the equipment associated with such electrodes is quite bulky and cumbersome and, even though bulky and cumbersome, is still unable sometimes to provide meaningful information.
A third problem has been that, at least partially as a result of the bulky and cumbersome equipment attached to the electrodes, the person undergoing examination is not ambulatory after the electrodes have been attached to such person. This has restricted the movements of such person, particularly while such person is sleeping. If anything, the confinement of such person against movement has inhibited such movement from sleeping properly. This has tended to qualify the legitimacy of the tests performed on such person.
As will be seen, although much progress has been made in recent years to determine the reasons for insomnia, or at least insufficient sleep, in people, much progress still remains to be accomplished. For example, it would be desirable to provide equipment which always provides accurate and meaningful information for subsequent analysis. Furthermore, it would be desirable for persons to be ambulatory, much as is now accomplished with heart monitors which have the size and weight of a light purse and thus are easily carried by persons for a period of twenty four (24) hours. In this way, persons can sleep in their beds at home to enhance the meaningfulness of the tests and to minimize any inconvenience to such persons.
BRIEF DESCRIPTION OF THE INVENTION
This invention provides a system which accomplishes the desirable features discussed above. The system provides sensitive and reliable measurements of the signals produced at the electrodes on a person's head in representation of the brain waves at such electrodes. The system is so light and small that the patient can be ambulatory. The system is so inexpensive that a person of relatively modest means can afford the costs of tests to determine the reasons for such person's insomnia or relative lack of sleep.
In one embodiment of the invention, electrodes, preferably paired on a person's head, produce signals representing the person's brain waves at one of the paired electrodes and reference signals at the other paired electrode. Pre-amplifiers juxtaposed to the paired electrodes and having a balanced operation even with impedance differences between the paired electrodes produce signals representing the difference in the signals between such electrodes.
After filtering to eliminate DC and band limit the upper frequency, the signals from each pre-amplifier pass to a post-amplifier displaced and electrically isolated from the pre-amplifier. The post-amplifier linearly amplifies the pre-amplifier signal and filters the signals at the lower and upper frequencies within a particular frequency range dependent upon the frequency range in which the investigator is interested.
The upper and lower limits of the frequency range are dependent upon the frequencies of controlling clock signals. The upper and lower clock frequencies may be varied progressively to determine the characteristics of the signals produced at the individual ones of the electrodes from brain waveshapes at such electrodes. The cut-off characteristics of the post-amplifier at the lower and upper frequency limits may be varied by adjusting impedance values in the filter.
An electrocular system constructed similarly to, and operative in timed relationship with, the electrode encephalographic system indicates whether signals at the electroencephalographic electrodes result from the person's eye movements. An electrocardiographic system constructed similarly to, and operative in timed relationship with, the electro-encephalographic system indicates the relationship between the patient's brain and heart waveforms.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic view of a plurality of a plurality of electrodes on a patient's head;
FIG. 2 is a schematic view similar to that shown in FIG. 1 but shows the position relative to the electrodes of pre-amplifiers and post-amplifiers which operate upon the signals from the electrodes;
FIG. 3 is a circuit diagram, partially in block form, of the electrical circuitry included in one of the pre-amplifiers;
FIG. 4 is a map showing the relative dispositions of FIGS. 4A-4D;
FIGS. 4A, 4B, 4C and 4D collectively show a circuit diagram, partially in block form, of the electrical circuitry included in a pair of the post amplifiers;
FIG. 4E shows strategic portions of another post-amplifier similar to the post-amplifier shown collectively in FIGS. 4A-4D;
FIG. 5 is a circuit diagram illustrating how the circuitry shown in FIGS. 4A-4D and in FIG. 4E can be employed to determine the characteristics of the signals at different ones of the electrodes;
FIG. 6 shows curves illustrating the different frequency responses of the signals at individual ones of the electrodes and the cut-off characteristics which can be provided in the signals produced by the circuitry shown in FIGS. 3 and 4;
FIG. 7 is a map showing the relative dispositions of FIGS. 7A-7C;
FIGS. 7A, 7B and 7C collectively show a circuit diagram of a post-amplifier, similar to that shown in FIG. 4, which may be used in a system for measuring the movements of the patient's eyes or for measuring the characteristics of the signals produced in the patient's heart;
FIG. 7D and 7E collectively show a circuit diagram of a post-amplifier similar to that shown in FIGS. 7A-7C;
FIG. 7F is a circuit diagram of a low pass filter included in the post-amplifiers shown in FIGS. 7A-7C and 7D-7E and corresponding to a low pass filter shown in FIG. 4B;
FIG. 7G is a circuit diagram of a high pass filter included in the post-amplifier shown in FIGS. 7A-7C and 7D-7E and corresponding to a high pass filter shown in FIG. 4C; and
FIG. 8 is a schematic diagram of signals produced in a timed relationship by the combination of the pre-amplifier shown in FIG. 3 and the post amplifier shown in FIG. 4 and by the circuitry shown in FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic diagram of a patient's head 10 and of electrodes 12A, 12B, 12C, 12D, etc. disposed on the patient's head to produce signals having characteristics corresponding to the characteristics of the brain waves produced at such electrodes. The electrodes may be attached to the patient's head in a manner well known in the art. The positions of the electrodes 12A, 12B, 12C, etc. on the patient's head are carefully chosen because each position provides individual information which may be different from the information at the positions of other electrodes.
FIG. 2 shows the disposition of a pre-amplifier generally indicated at 14 and of a post-amplifier, generally indicated at 16, relative to the electrodes 12A, 12B, 12C, 12D, etc. The circuitry of the pre-amplifier 14 is shown in detail, but partially in block form, in FIG. 3 and the circuitry of the post amplifier 16 is shown, partially in block form, in detail in FIG. 4. As will be seen, the pre-amplifier 14 in FIG. 2 is disposed in juxtaposition to the patient's head. The reason for this is that the signals on the electrodes 12A, 12B, 12C, 12D, etc. are relatively weak. Because of this, if the pre-amplifier 14 were displaced by any significant distance from the electrodes 12A, 12B, 12C, 12D, etc., noise generated in the leads extending from the electrodes would be so large that it would obfuscate the signals from the electrodes. The post amplifier 16 may be displaced by some distance from the electrodes 12A, 12B, 12C, etc. and the pre-amplifier 14 as shown in FIG. 2 because the signals introduced to the post-amplifier are relatively strong.
The electrodes 12A, 12B, 12C, 12D, etc. are preferably connected in pairs. For example, the electrode 12A may provide a signal indicating the brainwave at a first particular position on the patient's head 10 and the electrode 12B may provide a reference signal. Preferably the electrodes 12A and 12B are physically disposed close to each other on the patient's head to minimize any differences in the noise on the electrodes. The electrodes 12C and 12D may also be paired, preferably in close physical relationship to each other, with the electrode 12C disposed at a selected position to indicate the brainwave at that position and the electrode 12D disposed to provide a reference position.
The circuitry in the pre-amplifier 14 (FIG. 3) may include a low pass filter and protection circuit generally indicated at 18, a differential amplifier generally indicated at 20 and a high pass-filter generally indicated at 22. Each of the stages 18, 20 and 22 is defined by a box of broken lines, the boxes being respectively designated as 18, 20 and 22. The circuit 18 includes a terminal 24 for reproducing a signal representing the brainwaves at the electrode 12A and includes a terminal 26 for reproducing the reference signal at the electrode 12B.
The signals at the terminals 24 and 26 are respectively introduced to an RC filtering circuit defined by a resistor 28 and a capacitor 30 in series between the terminal 24 and a reference such as a ground 32. In like manner, the signals at the terminal 26 are introduced to an RC filtering circuit defined by a resistor 34 and a capacitor 36 in series between the terminal 26 and the reference such as the ground 32. A capacitor 38 is connected between the ungrounded terminals of the capacitor 30 and the capacitor 36.
A diode 40 is electrically disposed between the undergrounded terminal of the capacitor 30 and the reference such as the ground 32, and a diode 42 is electrically disposed between the ungrounded terminal of the capacitor 36 and the reference such as the ground 32. A resistor 43 extends electrically between the ungrounded terminal of the capacitor 30 and a first input terminal in the differential amplifier 20. In like manner, a resistor 45 extends electrically between the ungrounded terminal of the capacitor 36 and a second input terminal of the differential amplifier 20.
The amplifier 20 may be an INA102 amplifier manufactured by Burr Brown in Phoenix, Ariz. The amplifier has near its external periphery numbers individually designating the different pins in the amplifier. The pins are provided with "B" suffices to distinguish them from other components in the drawings. The output terminal of the differential amplifier 20 is common with one terminal of a capacitor 44, the other terminal of which has a connection to an ungrounded terminal of a resistor 46. An output line 48 extends from the output terminal of the resistor 46. The capacitor 44 and the resistor 46 are included in the high pass filter 22.
The signals produced at the electrodes such as the electrodes 12A and 12C have different frequency ranges dependent upon the location of such electrodes on the head. However, the different frequency ranges have maximum frequencies less than approximately one hundred hertz (100 Hz). The RC circuit defined by the resistor 28 and the capacitor 30 operates to pass signals from the terminal 24 at frequencies less than approximately one hundred (100 Hz) and to bypass signals above this approximate frequency to ground. The RC circuit defined by the resistor 34 and the capacitor 36 provides a similar filtering action on the signals from the terminal 26. The diodes 40 and 42 respectively pass to ground the negative portions of the signals below approximately one hundred hertz (100 Hz).
The differential amplifier 20 compares the wave shapes of the signals passing to the amplifier through the resistors 44 and 46 and produces an output signal constituting the difference between the wave shape of the signal from the terminal 24 relative to the signal from the terminal 26. This constitutes the portion of the signal from the terminal 24 that is different from the signal on the terminal 26. The differential amplifier 20 is constructed to provide a balanced operation of this common mode rejection even though the impedances of the signals on its input terminals are not equal. The signals from the differential amplifier 20 then pass to the high pass filter 22 which eliminates the DC component of the signal introduced to it.
The signals from the pre-amplifier 14 are introduced to the post-amplifier 16 (FIGS. 4A-4D). As shown in FIG. 2, the post amplifier 16 may be displaced from the pre-amplifier 14 because the signals on the electrodes such as the electrode 12A have been amplified by the pre-amplifier and are now relatively strong. Some of the stages in the post-amplifier 16 are shown in block form because they may be considered to be conventional. Other stages are shown in some detail because they contribute to the advantages of the post-amplifier 16 over the prior art.
FIG. 4 shows the relative layouts of the portions of the post-amplifier 16 as shown in FIGS. 4A-4D. The post-amplifier 16 includes a buffer 50 (FIG. 4A) which may be connected to the line 48 (also shown in FIG. 3) and which may be conventional. Because of this, the buffer 50 is shown in block form. The buffer 50 preserves the frequency characteristics of the high pass filter 22 in the pre-amplifier 14. The output signals from the buffer 50 pass to an isolation amplifier generally indicated at 54 and enclosed within a broken rectangle.
The isolation amplifier 54 includes as its primary element an optical coupler 56 which is designated by Burr-Brown as an ISO-100 coupler. This coupler has the advantage of providing an optical coupling between the output signal from the buffer 50 and an input signal to an amplifier 58 which is also supplied by Burr-Brown and which may be considered as a part of the optical coupler. The coupler 56 and the amplifier 58 preserve the signal characteristics of the output signal from the buffer 50 from a linearity standpoint while providing a ground in the coupler independent of the ground in the buffer 50. In effect, the optical coupler 56 and the amplifier 58 effectively isolate the post-amplifier 16 from the pre-amplifier 14.
As will be seen in FIGS. 4A-4E, the optical coupler 56 and the amplifier 58 and other stages in the post-amplifier 50 have a plurality of pins or terminals. These pins or terminals are designated by numerals. For example, the optical coupler 56 has two (2) pins or input terminals which are respectively designated as "15c" and "12c". The numerical designations of these pins or terminals correspond to the numerical designations provided by Burr-Brown for these pins or terminals. However, the pins in the optical coupler 56 have a suffix "c" to distinguish them from other components and from pins in other stages. The output from the amplifier 58 passes through a line 59 in FIGS. 4A and 4B to an amplifier 60 (FIG. 4B) which may be constructed in a conventional manner and which is accordingly shown in block form.
The output from the amplifier 60 is introduced to a low pass filter generally indicated at in FIG. 3 62. The low pass filter 62 includes a filter stage 64 which may be designated as a 1060A filter by Linear Technology. As with other stages in the post-amplifier 16, the filter 64 includes a number of terminals which have numerical designations corresponding to those used by Burr-Brown. The terminals in the filter 64 have a "d" suffix to distinguish them from other components and from terminals in other stages. These terminals include terminals designated as "10d" and "11d". The terminals 10d and 11d in the filter 64 receive clock signals on a line 66 (FIGS. 4A and 4B) from a clock source indicated at a terminal 68 (FIG. 4A). The clock signals have a frequency which limit the upper frequency range of the signals passed by the filter 64 in FIG. 4B.
As previously discussed, each of the electrodes 12A, 12B, 12C, 12D, etc., in FIG. 1 produces signals within a frequency range to approximately one hundred hertz (100 Hz). However, for each individual one of the electrodes such as the electrode 12A or the electrode 12C, the investigator is interested in only a particular portion of the maximum frequency range of approximately one hundred hertz (100 Hz). The limited frequency range of interest to the investigator at each electrode is dependent upon the position of the electrode on the patient's head. For example, the signals at the electrode 12A may have a frequency range of approximately sixty hertz (60 Hz) and the frequency range of the signals at the electrode 12C may be approximately seventy hertz (70 Hz). Since the post-amplifier 16 is operating on the signals at the electrode 12A when the frequency range of these signals is approximately sixty hertz (60 Hz), the clock signal on the line 66 has a frequency of approximately sixty hertz (60 Hz) in accordance with the example given above.
The cut-off characteristics of the signals from the filter 64 may be varied. For example, the signals from the filter 64 may be provided with sharp characteristics as indicated at 70 in FIG. 6. Alternatively, the cut-off characteristics may be relatively shallow or gradual as indicated at 72 in FIG. 6. The cut-off characteristics of the signal from the filter 64 may be varied by varying the values of the resistors connected to the filter 64. These include resistors 74a, 74b, 74c, 74d, 74e, 74f and 74g.
The signals from the filter 64 pass through the terminal 18 in the filter and a line 75 (FIGS. 4B and 4C) to a high pass filter generally indicated at 76 in FIG. 4(C). The high pass filter 76 may be a filter designated MF6-100 by National Semiconductor or Linear Technology. The filter 76 is provided with a plurality of terminals which have designations corresponding to the designation provided by the manufacturer. However, the terminal designations are followed by the suffix "e" to distinguish such terminal designations from the designations of other components and from the terminal designations of other stages.
The filter 76 also receives a clock signal on a line 78 from a clock source indicated at a terminal 80 in FIG. 4A. This clock signal controls the frequencies which are filtered by the filter 76 in FIG. 4(C) at the low end of the frequency range introduced by the filter 64 in FIG. 4(B) to the filter 76. For example, the frequency of the clock signal at the terminal 80 may be such that the filter 76 passes signals only at frequencies above approximately two hertz (2 Hz). The frequency range of the signals passing to a high pass filter 82 from the filter 76 may accordingly be between approximately two hertz (2 Hz) and sixty hertz (60 Hz) in the example given above.
The output from the pin or terminal 3e in the filter 76 in FIG. 4(C) passes through a line 80 to a high pass filter 82. The filter 82 may be constructed in a conventional manner. Because of this, it is shown in block form. It reconstitutes sine signals after the operation of the filter 76. The output from the filter 82 passes to a high pass filter 84 which may also be constructed in a conventional manner. The filter 84 is accordingly shown in block form. The filter 84 is also instrumental in converting the signals from the filter 76 to sine wave signals. The signals then pass through a line 85 to a buffer 86 in FIG. 4(D). The buffer 86 operates to reduce the impedance of the signals introduced to the buffer and to pass the low impedance signals to a driver generally indicated at 88. The buffer 86 may be conventional and is accordingly shown in block form.
The driver 88 has a first lead 90 which provides an output signal when the output signal is not being recorded in a recorder 92. The driver 88 also includes an amplifier 91 which introduces signals to the central conductor in a coaxial cable generally indicated at 94. The central connector of the coaxial cable 94 is connected to the recorder 92 which records the signals produced on the electrode 12A in FIG. 1. The signals are recorded with fidelity in the recorder 92 because of the low impedance provided by the buffer 86.
Just as the investigator is interested in only a first particular range of frequencies (e.g. 60 Hz) in the brain waves generated at the position of the electrode 12A, the investigator is interested in only a second particular range of frequencies (e.g. 70 Hz) in the brain waves generated at the position of the electrode 12C. Similarly, just as the electrode 12B provides a reference signal for the signal on the electrode 12A, the electrode 12D provides a reference signal for the signal on the electrode 12C. The electrodes in each pair (e.g. the electrodes 12A and 12B) are preferably disposed close to each other but this may not be necessary in all instances.
Pairing pairs of electrodes, one electrode in the pair to provide an information signal and the other electrode in the pair to provide a reference signal, is desirable in order to assure that there will not be crosstalk between the different ones of the electrodes providing the information signals. This pairing is in contrast to the systems of the prior art where one reference electrode provides a reference for a plurality of electrodes producing information signals. In the systems of the prior art, cross talk tends to occur through the reference electrode between different electrodes providing information signals. This crosstalk is particularly undesirable because the signals representing brain wave information as at the electrodes 12A and 12C have very low amplitudes such that the crosstalk constitutes noise which obscures the information in the information signals.
As will be appreciated, the pre-amplifier 14 provides a pre-amplification of the signals on the electrode 12A. A substantially identical pre-amplifier is provided for the electrode 12C. The output signals from the substantially identical pre-amplifier for the electrode 12C are introduced to a post-amplifier generally indicated at 98 in FIG. 4(E). The post-amplifier 98 has a construction substantially identical to the post-amplifier 16. Because of this, only portions of the post-amplifier 98 are shown in FIG. 4 (E).
The post-amplifier 98 in FIG. 4(E) includes a low-pass filter generally indicated at 100 and corresponding to the filter 62 in FIG. 4(B). The clock signal on the line 66 is introduced to a stage 101 in the low-pass filter 100 in FIG. 4(B) in a manner similar to the introduction of this clock signal to the stage 64 in the filter 62 in FIG. 4(B). Similarly, the post-amplifier 16 has a high pass filter generally indicated at 102 in FIG. 4(E). This filter is substantially identical to the high pass filter 76 in FIG. 4(C) in the post-amplifier 16. Clock signals on the line 78 are introduced to the high pass filter 102 in FIG. 4(E) in a manner similar to the introduction of the clock signals on the line 78 to the high pass filter 76 in FIG. 4(C).
The terminals in the low pass filter 100 are provided with a suffix "f" and the terminals in the high pass filter 102 are provided with a suffix "g". In this way, the terminals in the filters 100 and 102 are distinguished from other components and the terminals in other stages. In order to accommodate to the different frequency ranges of the signals on the electrodes 12A and 12C, the clock signals on the terminals 68 and 80 may be swept progressively through a range of frequencies. For example, the clock signals on the terminal 68 may be swept through a range of frequencies between approximately forty hertz (40 Hz) and one hundred hertz (100 Hz) to accommodate for the individual frequency ranges of the signals at the different electrodes such as the electrodes 12A and 12C. In this way, optimal outputs are provided in the post-amplifier 16 for the signals at the electrode 12A and in the post-amplifier 98 for the signals at the electrode 12C.
FIG. 5 provides a block diagram of a system for providing a sweep of frequencies for the clock signals on the terminal 68 and for introducing such clock signals at each instant through the line 66 to the filter 62 in the post-amplifier 16 and to the corresponding filter 100 in the post-amplifier 98. Such a system is shown in block form because sweep circuits are conventional in the prior art. Similar frequency sweeps may be provided for the low frequencies through the line 78 to the high pass filter 76 in the post-amplifier 16 and to the high pass filter 102 in the post-amplifier 98.
The signals produced at other electrodes in FIGS. 1 and 2 than the electrodes 12A-12D may result from movements of the patient's eyes. A post-amplifier generally indicated at 106 in FIGS. 7A-7D may be provided to detect movements of the patient's eyes and to provide electrooculograms of such eye movements. A map is shown in FIG. 7 to indicate the sequence in FIGS. 7A-7C of the post-amplifier 106. The post-amplifier 106 may include an electrode 108A (FIG. 7D) which is connected to the patient's head near the patient's eyes and may also include an electrode 108B for providing a reference.
The post-amplifier 106 does not have to include a pre-amplifier corresponding to the pre-amplifier 14 because the signals from the patient's eyes are relatively strong. Furthermore, the post-amplifier 106 may be displaced from the electrodes 108A and 108B (FIG. 7D) because of the strength of the signals at these electrodes. Instead, the post-amplifier 106 may include a low pass filter 112 and a differential amplifier 114. The low pass filter 112 and the differential amplifier 114 may be constructed in a conventional manner. The output of the differential amplifier 114 may be introduced to a high pass filter 116 which may also be constructed in a conventional manner. As will be appreciated, the low pass filter 112, the differential amplifier 114 and the high pass filter 116 may be respectively considered to correspond to the low pass filter 18, the differential amplifier 20 and the high pass filter 22 in the pre-amplifier 14 of FIG. 3.
The output of the high pass amplifier in FIG. 7A is introduced to a buffer 140. An isolation amplifier 142 receives the output of the buffer 142. The output of the isolation amplifier 142 passes through a line 143 in FIGS. 7A and 7B to a high pass filter 144 in FIG. 7B. The output from the high pass filter 144 in turn passes to a high pass filter 146. The output from the high pass 146 in turn passes to a buffer 148. The buffer 148 in turn passes signals through a line 149 in FIGS. 7B and 7C to a driver generally indicated at 150 in FIG. 7C. The driver 150 corresponds to the driver 88 in FIG. 4D.
As will be seen from a circuitry comparison, the circuitry shown in FIGS. 7A-7C is substantially identical, with certain minor exceptions, to the circuitry shown in FIGS. 4A-4D. The gain of the circuitry shown in FIG. 7 may be different from the circuitry shown in FIG. 4 because the signal at the electrode 108A is stronger than the signal at the electrode 12A. The frequency band of the post-amplifier 106 may also be different from the frequency band of the post-amplifier 16. For example, the frequency band of the post-amplifier 106 may be approximately forty hertz (40 Hz) as distinguished from a frequency band of approximately one hundred hertz (100 Hz) for the post-amplifier 16.
The system providing electrooculograms may include a second post-amplifier corresponding to the post-amplifier 106. This post-amplifier is generally indicated at 118 in FIGS. 7(D) and 7(E). The post-amplifier 118 may respond to information signals at an electrode 108C and reference signals at an electrode 108D. The post-amplifier 118 may include stages having the same designation as the stages in the post-amplifier 106 except that they are followed by the suffix "A". The post amplifier 118 includes a driver (not shown) corresponding to the driver 150 in FIG. 7C.
The operation of the post-amplifiers 106 and 118 may be controlled with respect to the frequency ranges of these post-amplifiers by the frequencies of clock signals on terminals 120 (FIG. 7(F)) and 122 (FIG. 7(G)). The clock signals on the terminal 120 pass through a line 121 to control the operation of the low pass filter 112 in the post-amplifier 106 and the operation of the low pass filter 124 in the post amplifier 112A in the post amplifier 118. These clock signals correspond to the clock signals on the line 68 in FIGS. 4A-4D. As will be seen, the construction of the low pass filters 112 and 112A corresponds to the construction of the low pass filter 62 in FIG. 4(B). The different terminals in the low pass filters 112 and 112A are respectively provided with suffices "h" and "i" to distinguish them from other components and from terminals in other stages.
In like manner, the clock signals on the terminal 122 in FIG. 7(G) pass through a line 127 to control the operation of a high pass filter 116 in the post- amplifier 106 and to control the operation of the high pass filter 116A in the post-amplifier 118. These clock signals correspond to the clock signals on the line 78 in the post-amplifier 16. As will be seen, the construction of the high pass filters 116 and 116A corresponds to the construction of the high pass filter 76 in FIG. 4(C). The different terminals on the low pass filter 124 and on the high pass filter 126 are respectively provided with suffices "j" and "k" to distinguish them from other components and from terminals in other stages.
The signals provided by the post-amplifiers 16 and 106 may be recorded in a recorder 131 (FIG. 8) in a side-by-side relationship in a synchronous time relationship as shown in FIG. 8. The signals provided by the post amplifiers 98 and 118 may also be recorded side-by-side simultaneously in a synchronous time relationship. A comparison may be made between the side-by-side signals to determine whether the signals at the electrode 12A result from movements of the eye rather than from brain waves at the electrode 108A. A similar determination may be made for the signals from the electrodes 12B and 108B.
The post-amplifier shown in FIGS. 7A-7C and the post-amplifier shown in FIGS. 7(D) and 7(E) may be also used to obtain electrocardiograms. The signals representing the electrocardiograms at the terminals 108a and 108c may be respectively recorded in side-by-side relationship synchronously with the signals in the post-amplifiers 16 and 98 to determine if there is any relationship between the signals representing the patient's brain waves and the signals produced at the patient's heart.
The system and method described above have several distinct advantages over the prior art. The system and method pair electrodes (e.g. 12A and 12B) on a person's head to obtain signals representing the brainwaves at one of the electrodes in the pair. These signals are introduced to the pre-amplifier 14 disposed in juxtaposition to the electrodes 12A and 12B to minimize noise in the pre-amplifier. The pre-amplifier 14 provides a balanced operation in amplifying the differential signals even when the impedance of the electrodes is significantly different.
The post-amplifier 16 may be disposed in displaced relationship to the pre-amplifier 14. The post-amplifier 16 isolates the signals in the post-amplifier electrically from the signals in the pre-amplifier 14 and establishes an independent electrical ground for the signals in the post-amplifier. The post amplifier 16 then provides an amplification in accordance with the individual range of frequencies at each individual one of the electrodes.
The system compares the electroencephalogram signals at the electrodes such as the electrode 12A with the signals representing the electrooculograms such as at the electrode 108a. In this way, the system is able to distinguish the electroencephalogram signals from the electrooculogram signals. A similar distinction can be made between the electroencephalogram signals and electrocardiogram signals.
Although this invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments which will be apparent to persons skilled in the art. The invention is, therefore, to be limited only as indicated by the scope of the appended claims. | Electrodes, preferably paired on a patient's head, produce signals representing the patient's brain waves at one of the paired electrodes and reference signals at the other paired electrode. Pre-amplifiers juxtaposed to the paired electrodes and having a balanced operation even with impedance differences between the paired electrodes produce signals representing the difference in the signals between such electrodes. After filtering to eliminate DC and band limit the upper frequency, the signals from each pre-amplifier pass to a post-amplifier displaced and electrically isolated from the pre-amplifier. The post-amplifier linearly amplifies the pre-amplifier signals and filters the signals at the lower and upper frequencies within a particular frequency range dependent upon the frequency range in which the investigator is interested. The upper and lower limits of the frequency range are dependent upon the frequencies of controlling clock signals. The upper and lower clock frequencies may be varied progressively to determine the characteristics of the signals produced at the individual ones of the electrodes from brain wave shapes at such electrodes. The cut-off characteristics of the pre-amplifier at the upper and lower frequency limits may be varied by adjusting impedance values in the filter. An electroocular system constructed similarly to, and operative in timed relationship with, the electrode encephalographic system indicates whether signals at the electroencephalographic electrodes result from the patient's eye movements. An electrocardiographic system constructed similarly to, and operative in timed relationship with, the electroencephalographic system indicates the relationship between the patient's brain and heart waveforms. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage of International Application No. PCT/EP2008/010540 filed Dec. 11, 2008, the disclosures of which are incorporated herein by reference, and which claimed priority to German Patent Application No. 10 2007 059 687.3 filed Dec. 12, 2007, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an actuator device with a processing unit for use in a motor vehicle, which comprises a main control device. The processing unit is subordinate to the main control device.
“Intelligent” actuators are frequently used in modern motor vehicles. They usually incorporate a processing unit which is subordinate to a main control device, which in turn transmits control commands, for example actuator setting commands, to the processing unit. The processing unit receives the control commands from the main control device and is provided to control the actuator according to the commands transmitted from the main control device. This main control device operates as a master unit and the processing unit functions as the slave unit. Such a concept is described, for example, in the document WO 2006/061238, and corresponding US patent No. 2008/105502 A1, the US document being incorporated by reference herein, and enables power electronics for activating the actuator to be arranged so that it is spatially separate from the main control device. The communication between the main control device and the processing unit normally takes place via a data bus. In motor vehicles, such a bus is frequently a LIN bus, a CAN bus or a FlexRay bus.
Intelligent actuators of this type may be used in motor vehicles in particular for safety-related systems such as electronically controllable parking brake systems. Problems may occur, however, if incorrect signals are transmitted via the bus or if the actuator receives, for example via a short circuit, erroneous signals. If safety-related systems are affected by a fault of this kind, there could be serious consequences for the vehicle safety. For example, in the case of a parking brake, an incorrect signal may cause the parking brake to be released without control on a slope, or may lead to unexpected and undesired braking while the vehicle is travelling. Both situations may significantly prejudice the safety of the driver and passengers of a motor vehicle and that of other road users.
A safety concept that counteracts faults of this kind can usually only be implemented at great expense. The need therefore exists for a simple, cost-effective yet reliable system for increasing vehicle safety.
BRIEF SUMMARY OF THE INVENTION
The invention proposes for this purpose an actuator device for use in motor vehicles, which comprises an actuator, a control unit to control the actuator, and a processing unit. The processing unit is or can be connected to an external main control device via a control connection and is subordinate to the main control device. In particular, provision may be made whereby the main control device and the processing unit have a master-slave relationship. The control connection is able to transmit actuator setting commands. The processing unit is furthermore connected to the control unit in order to control the actuator according to the actuator setting commands. In addition, provision is made whereby the control unit is or can be connected with the main control device via an activation connection. The control unit is equipped so as to enable the actuator to be controlled by the processing unit according to activation signals transmitted via the activation connection. The activation control may be run in parallel to the control connection. The activation connection between the control unit and the main control device enables an independent entity to be created via which it can be determined whether or not control of the actuator is to be permitted via the processing unit. A considerable improvement in safety for the actuator device may thus be achieved in a manner that is easy to set up.
The actuator device may have a monitoring unit via which the main control device is connected to the control unit by the activation connection. Such a monitoring unit connected in the activation connection between the control unit and the main control unit may carry out an additional check on signals transmitted via the activation connection. In particular, provision may be made whereby the monitoring unit is connected to the processing unit for signal transmission. This enables communication to be established between the monitoring unit and processing unit. It is advantageous if the monitoring unit is configured to detect faults occurring during the activation connection or the control connection and to forward an error message or deactivate the actuator device, or both.
In a further development the actuator device is connected to two separately operable control components of the main control device. In this case the control unit may be connected via the activation connection to a first control component and the processing unit may be connected via the control connection to a second control component. The connection to separately operable components of the main control device increases the system redundancy and the communication via the activation connection may be carried out separately and independently of the communication via the control connection.
An advantageous implementation makes provision whereby the control unit is or can be connected to the main control device directly via the activation connection. A direct connection of this type may also be provided alternatively to or in addition to indirect connections, for example via a monitoring unit where one is available.
The control connection for connecting the processing unit to the main control device may be a data bus. In particular, provision may be made for the data bus to be a LIN bus, a CAN bus or a FlexRay bus. Via a bus of this type, as is frequently used in vehicle technology, it is possible for signals to be transferred in a simple and well defined way.
It is possible for the main control device to be connected to the processing unit via the activation connection in parallel to and separately from the control connection. In this way an additional redundancy level may be provided for communication between the main control device and the processing unit.
According to one variant, the activation connection is able to transfer actuator setting commands or signals corresponding to actuator setting commands from the main control device. In this case provision may be made in particular whereby signals transferred via the activation connection are encoded (for example by modulation of the voltage level, pulse width modulation or frequency modulation). In this way, in addition to pure activation signals which generally allow or do not allow (i.e. block) control, it is possible for further commands to be transferred to the control unit and/or monitoring or processing unit.
Provision may furthermore be made whereby the processing unit and/or the monitoring unit is able to compare signals or actuator setting commands transferred from the main control device via the activation connection with actuator setting commands transferred from the main control device via the control connection. The signals used for the comparison may be transferred to the monitoring unit or to the processing unit via the activation connection. If signals transferred to the monitoring unit are to be compared, provision is made whereby a signal transmission may take place between the monitoring unit and the processing unit.
The processing unit may be adapted to control the actuator only when the signals or actuator setting commands compared to each other correspond. In addition to or alternatively to this, it is possible for the monitoring unit to carry out the comparison or to receive a signal corresponding to the comparison carried out by the processing unit. If appropriate, the monitoring unit—on the basis of the signal received or comparison carried out—may refrain from forwarding an activation signal or corresponding signal to the control unit or may send an express blocking command to the control unit.
According to a further development the processing unit, the monitoring unit and the control unit are all connected to the main control device via the activation connection. This results in an extremely high level of redundancy of signal transmission via the activation connection between the main control device and the units of the actuator device connected to it.
The activation line may also be adapted to provide power to units connected to it such as monitoring unit, processing unit and control unit.
The proposed actuator device is particularly suitable to be used with an actuator to activate a vehicle parking brake. However, a multitude of other applications are possible in which intelligent actuators as described here may be used, for example airbag systems, seat-belt pretensioners or similar.
The invention also comprises an actuator system, which comprises a main control device and at least one actuator device as described above. In particular, this may be a vehicle parking brake system comprising one or more actuator devices of a vehicle parking brake.
It is particularly useful if signals that are compared to each other must be present within a predefined time window so that they can actually be deemed to correspond to one another. It is also advantageous if the activation signals present on the control device permit control by the processing unit only within a predefined time window. Different time windows may be provided for various signal comparisons. The length of these time windows should be tailored precisely to the embodiment of the actuator device used and to the purpose for which it is used.
The invention further covers a method for controlling an actuator device for use in a motor vehicle. In this method provision is made whereby a subordinate processing unit receives actuator setting commands which are transmitted via a control connection from a superordinate main control device. A control unit receives activation signals which are transmitted from the main control device via an activation connection. The processing unit further transmits control commands to the control unit on the basis of the actuator setting commands, and the control unit controls an actuator on the basis of control commands received according to received activation signals.
The method may also make provision whereby actuator setting commands or signals corresponding to actuator setting commands are transmitted via the activation connection by the main control device to the processing unit. Actuator setting commands or signals corresponding to actuator setting commands may furthermore be transmitted, via the activation connection, by the main control device to a monitoring unit connected to the main control device via the activation connection.
Furthermore, provision may be made whereby the actuator setting commands or signals corresponding to actuator setting commands transmitted via the activation connection are compared with actuator setting commands transmitted via the control connection by the processing unit and/or the monitoring unit, wherein the control of the actuator is performed or permitted only if the compared actuator setting commands or signals correspond to each other.
Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an embodiment of an actuator device.
FIG. 2 is a flow chart showing an embodiment of a method for controlling an actuator.
FIG. 3 shows a possible coding of signals transmitted via the activation connection.
FIG. 4 is a detailed schematic view of a further embodiment of an actuator device which may be used in a motor vehicle-parking brake.
DETAILED DESCRIPTION OF THE INVENTION
Within this description a connection means a device for signal transmission or for transmission of electrical voltage or electrical power unless otherwise expressly mentioned. In particular, such a connection may comprise one or more electrical cables. Furthermore, when reference is made below to the transmission of signals or of actuator setting commands, this always means the transmission of one or more signals or actuator setting commands.
FIG. 1 is a schematic view of an actuator device 10 . The actuator device 10 has a monitoring unit 14 , a processing unit 16 and a control unit 18 . The control unit 18 is connected to an actuator 19 for the purpose of control. The actuator 19 may, for example, comprise a motor for releasing or activating a parking brake.
A connection 20 is provided between the monitoring unit 14 and the control unit 18 . The control unit 18 is further connected to the processing unit 16 via a connection 22 . The processing unit 16 and the monitoring unit 14 are able to communicate with each other via a connection 24 . A voltage source 30 a is provided to supply the actuator 19 with operating voltage. A vehicle battery (not shown), for example, may be used as voltage source 30 a.
The actuator device 10 is provided for connection to a main control device 12 . The main control device 12 may, for example, be a microprocessor of an on-board computer of a vehicle. The main control device 12 is preferably subdivided into two separately operable components 12 a and 12 b.
According to FIG. 1 the component 12 b of the main control device 12 is connected to the processing unit 16 via a data bus 26 constituting a control connection. This data bus 26 is designed, for example, as a standardized data bus for data transmission in vehicles, such as—for example—a CAN bus, a LIN bus or a FlexRay bus. The main control device 12 is superordinate to the processing unit 16 , and the main control device 12 and its components 12 b and the processing unit 16 respectively form a master-slave pair. In a master-slave relationship of this kind, provision is made whereby the main control device 12 can control the access to the data bus 26 , and the processing unit 16 cannot have write access to the data bus 26 without, for example, access rights issued by the main control device 12 .
Furthermore, an activation line 28 is provided for connecting the components 12 a of the main control device 12 to the actuator device 10 . As shown in FIG. 1 , the activation line 28 has three branches 28 a , 28 b and 28 c . The component 12 b of the main control device 12 is connected to the processing unit 16 via the branch 28 a , to the monitoring unit 14 via the branch 28 b and to the control unit 18 via the branch 28 c . The activation line 28 is able to transmit analogue electrical signals with different signal levels. In particular, it is possible—by the signal level on the activation line 28 —to show signals that completely or partially correspond to specific or to all actuator setting commands. The connection 20 , as part of the activation connection 28 , connects the control unit 18 indirectly via the monitoring unit 14 to the main control device 12 .
A voltage source 30 b is provided in order to supply electrical power to the main control device 12 and to its components 12 a , 12 b . The voltage source 30 b may be identical to the voltage source 30 a or may be a different voltage source.
The connections 20 , 22 and 28 are shown in FIG. 1 such that the signals are transmitted in only one direction. However, it is of course possible for one, more than one or all of these connections to be configured so that signals may be transmitted in both directions. It is important, however, that a signal transmission is at least possible in the direction shown. For example, provision may be made whereby the control unit 18 may transmit data such as error signals to the monitoring unit 14 or to the processing unit 16 , or both. The monitoring unit 14 and/or the processing unit 16 may also be configured and connected so that error signals may be transmitted to further components such as the main control device 12 .
During operation provision is made whereby the component 12 b of the main control device 12 transmit actuator setting commands to the processing unit 16 via the bus 26 . The processing unit 16 forwards these actuator setting commands as control commands to the control unit 18 via the connection 22 . In this way provision can be made whereby the processing unit 16 is able to convert or translate the actuator setting commands received from the main control device 12 or control component 12 b into control commands that can be understood by the control unit 18 should this be necessary. It is also possible for control switches and power electronics elements to be used as the control unit 18 . The processing unit 16 may in turn transmit signals to the main control device 12 via the bus 26 . The monitoring unit 14 is able to participate in the control via the connection 20 . In particular, provision is made whereby the monitoring unit 14 is adapted so that, depending on the situation, an activation signal or a signal corresponding to an activation signal is forwarded to the control unit 18 , such a signal is not forwarded, or a blocking signal is sent to the control unit 18 .
Provision is made whereby control of the actuator 19 according to actuator setting commands is carried out only if a corresponding activation signal is transmitted via the activation line 28 .
In the actuator device 10 shown in FIG. 1 an activation signal may be transmitted via the branches 28 a , 28 b , 28 c of the activation line 28 to the processing unit 16 , the control unit 18 and the monitoring unit 14 respectively. This enables a check to be carried out in several places as to whether actuator setting commands transmitted via the data bus 26 have actually been correctly transmitted or even should have been transmitted at all.
One option for checking occurs directly at the processing unit 16 , which receives actuator setting commands via the data bus 26 and corresponding signals (either activation signals only, or signals corresponding to the actuator setting commands) via branch 28 a of the activation line 28 . The processing unit 16 is able to determine whether the signals or actuator setting commands received via these two connections correspond to each other. In particular, provision may be made whereby the processing unit checks only whether an actuator setting command and a activation signal are present together. If signals that correspond to each other are present, the processing unit 16 transmits control commands to the control unit 18 . If, on the other hand, there is no correspondence between the signals, the processing unit 16 assumes that there is an error and refrains from forwarding the actuator setting commands. If an error is present the processing unit may transmit error reports, for example, to the main control device 12 or to a different unit or other component of the vehicle electronics. This takes place advantageously via the data bus 26 .
Furthermore, the monitoring unit 14 receives signals via branch 28 b of the activation line 28 . The monitoring unit 14 may exchange data with the processing unit 16 via the connection 24 . This enables a check to be carried out as to whether the commands transmitted to the processing unit 16 correspond to the commands transmitted to the monitoring unit 14 . This means that either of the units 14 , 16 may transmit data, via the connection 24 , to the other unit concerned, which then carries out the check. In particular, provision may be made whereby the monitoring unit 14 sends data to the processing unit 16 , which compares the signals received from the monitoring unit 14 with those that it has received itself. The comparison and/or checking for correspondence may take place on the basis of the activation signals received by the processing unit 16 or on the basis of the actuator setting commands, or both.
Provision may further be made whereby the monitoring unit 14 transmits signals to the control unit 18 via the line 20 on the basis of the result of comparison or check. If the compared signals correspond to one another, the monitoring unit 14 may forward the activation signals or signals corresponding to activation signals received by it to the control unit 18 . If there is no correspondence, the monitoring unit 14 refrains from forwarding the activation signals or transmits a blocking signal to the control unit 18 , whereupon the latter refrains from permitting the control of the actuator 19 .
Furthermore, activation signals are transmitted to the control unit 18 via branch 28 c of the activation line 28 . The control unit 18 is adapted to control the actuator only according to the processing unit 16 if an activation signal is transmitted via the activation line 28 c to the control unit 18 .
FIG. 2 is a basic schematic diagram showing a flow of a method for controlling an actuator of an actuator device. This may be an actuator device 10 as shown in FIG. 1 .
In stage V 10 a processing unit receives actuator setting commands which a main control device transmits via a control connection. Provision may be made whereby the processing unit receives activation signals in stage V 15 , which are transmitted from the main control device via an activation connection. These stages V 10 and V 15 may take place simultaneously or with a slight time delay, in which case it is irrelevant which stage takes place first. The processing unit then checks, in stage V 17 , whether the activation signals and the actuator setting commands correspond, in particular whether the activation signals correspond to the transmitted actuator setting commands. If this is the case, the processing unit transmits control commands to a control unit in stage V 20 on the basis of the actuator setting commands received. Stages V 15 and V 17 are optional in this case.
In parallel to stages V 10 to V 20 , in stage A 10 the control unit receives activation signals which the main control device transmits via the activation line.
In stage A 20 the control unit checks whether activation signals received by it correspond to control commands transmitted to it. In particular, the control unit may check whether a received activation signal is present that permits any control, or whether it permits only a certain type of control and corresponds to the relevant control command of the type of control permitted by the activation signal. If the control unit ascertains that signals and control commands that correspond to each other are present, in stage A 30 control of the actuator is carried out by the control unit according to the control commands. A time lag between receipt of the respective signals and commands may be used as a benchmark for the correspondence of the signals and control commands. In particular, provision may be made whereby signals and commands correspond to each other only if they are present within a predefined time window.
FIG. 3 shows a possible coding of the signal level on the activation line, for example the activation line 28 shown in FIG. 1 . It is assumed from this that the actuator may be opened and closed. Of course, end statuses other than open and closed—in particular non-binary end statuses—are possible for the actuator, for example such statuses that lead to a brake being applied and to a brake being released. In FIG. 3 , voltage level ranges to which an activation function is assigned are shown cross-hatched, and those to which no particular activation function is assigned are left blank. Ranges within which no activation is possible are shown chequered. The breadth of the ranges in FIG. 3 is selected merely for clarification purposes; the actual signal level ranges that are still assigned to a target value may be adapted to the requirements of a system.
The signal incorporates a possible voltage range from 0 to 12 V. At a signal level of 12V or above it is assumed that there is a short circuit in an activation line and the control unit is deactivated; controlling of the actuator according to a processing unit is not possible.
Control of the actuator is likewise not possible below a level of 5V (low signal status). The activation range is therefore between 5V and 12V in this example. As soon as the signal level rises above 5V (high signal level) but remains below 12V, control of the actuator is possible in principle.
In the signal level range within which control is possible, specific voltage values are assigned specific setting commands or setting command types in addition. For example, a signal level of 6V represents an activation signal for closing the actuator; if the activation line runs a level of 6V, the control unit permits control by the processing unit only in order to close the actuator. A signal level of 7V, on the other hand, represents an activation signal for opening the actuator. If such a level is present, the control unit controls the actuator only in order to open it; other control commands from the processing unit are not executed. It is possible, of course, for provision to be made in such a coding whereby a signal level that is within the control range but exceeds several voltage values, to which different control types are assigned, permits all these control types. In the example shown in FIG. 3 , a voltage level between 7V and 12V would then permit both the closing and the opening of the actuator. Furthermore, provision may be made whereby a signal level is defined in which all available types of control are permitted.
FIG. 4 shows an actuator device 100 in greater detail. The actuator device 100 has a motor M which functions as an actuator. The motor M is connected in the conventional manner via an H-bridge circuit 105 to two power transistors 110 on the upper surface and two power transistors 120 on the lower surface respectively (the bridge circuit is not shown in detail). The power transistors 110 and 120 are designed as field-effect transistors and are provided for actuation of the motor M. The power transistors 110 are connected to a positive pole 135 a of a voltage source via a cable 130 in order to supply electricity to the power transistors, and to a fuse 140 of the vehicle, usually the K30 fuse. A diode array 150 , which suppresses return power flow from the power transistors 110 , 120 to the fuse 140 , is connected between the fuse 140 and the power transistors 110 . A current measuring device 170 is connected to the power transistors 120 via a cable 160 . Furthermore, the current measuring device 170 is earthed via a cable 180 a.
A cable 190 is connected for linking the current measuring device 170 to a processing unit 200 . In this embodiment the processing unit 200 is a Freescale S08 microcontroller, which is not shown in full detail in FIG. 4 . Other suitable microcontrollers may also be used as the processing unit 200 ; the precise number and type of connections and elements present in the microcontroller will then be different from the unit shown here.
The processing unit 200 incorporates an analogue-digital converter (ADC) 210 , which is connected to the current measuring device 170 via the cable 190 for transmission of power measurement data. The analogue-digital converter 210 is furthermore connected to the bridge circuit 105 via two cables 220 a , 220 b . The signals relating to the actuator setting can be routed to the ADC 210 via the cables 220 a , 220 b.
An external temperature measuring device 235 is further connected to the ADC 210 via a cable 230 . The ADC 210 is also connected via a cable 240 to an internal temperature measuring device 245 for measuring the temperature of the processing unit 200 . A cable 250 connects the ADC 210 to a positive voltage pole 135 b , which provides a voltage setting. The ADC 210 is furthermore connected to an external main control device 400 (not shown in greater detail) via a branch 270 a of an activation line 270 . The cables 280 a and 280 b represent a connection from the processing unit 200 to the main control device 400 via a CAN bus. A cable 180 b provides an earth connection for the processing unit 200 . Furthermore, the processing unit 200 incorporates a voltage regulator 285 which, on the basis of signals routed to the ADC 210 via the cables 220 a , 220 b , 270 a , 230 , 235 , 240 , 190 , and on the basis of actuator setting commands transferred via the CAN bus 280 a and 280 b , outputs control commands for the motor M via a cable 290 .
A monitoring unit 300 is connected to the processing unit 200 via cables 310 . In the embodiment shown here the monitoring unit is an ATMEL ATA6823 unit which is connected in the conventional way via cables 310 to the Freescale S08 microcontroller, i.e. the processing unit 200 . Here, likewise, it is of course possible for another suitable electronic component to be used as the monitoring unit 300 . The details of the monitoring unit 300 will vary accordingly. The exact nature of the connection between the monitoring unit 300 and the processing unit 200 will depend in particular upon the components that are used as the processing unit 200 and monitoring unit 300 .
In the constellation shown in FIG. 4 , the cables 310 in the diagram comprise, from left to right, a cable for positive supply voltage (VCC), 3 status cables and 3 control cables, as well as a monitoring cable (WD) and a reset cable. The monitoring unit 300 is connected to positive voltage poles 135 c , 135 d by cables 320 a , 320 b . An earth cable 180 c connects the monitoring unit 300 to earth. A Schmitt trigger circuit 330 is connected to the main control device 400 via a branch 270 b of the activation line 270 . The monitoring unit 300 is provided inter alia with a supply voltage via the branch 270 b . A diode 275 is provided in the branch 270 b to prevent return power flow. The monitoring unit 300 is connected via two cables 340 a , 340 b with resistors 345 a , 345 b for control of the upper power transistors 110 of the bridge circuit 105 . In addition, the monitoring unit 300 is connected via cables 350 a , 350 b with resistors 355 a , 355 b to the lower power transistors 120 of the bridge circuit 105 .
The activation line 270 also has a further branch 270 c , in which a voltage divider 272 is installed. The branch 270 c is connected to a control circuit 410 . The control circuit 410 comprises transistors 415 , 420 , 425 and 430 , which are connected to earth via cables 435 a , 435 b , 435 c and 435 d respectively. Furthermore, the control circuit 410 has a resistor 440 with a positive voltage pole 135 e . The control circuit 410 is additionally connected to the processing unit 200 via the cable 290 and to the lower power transistors 120 for control via the cables 450 a , 450 b.
The branch 270 c of the activation line 270 is connected to the control circuit 410 such that the transistor 415 is switched through only if a suitable activation signal is present on the activation line. The transistors 415 , 420 , 425 , 430 are switched together so that the processing unit 200 can then activate the bridge circuit 105 and control the motor M via the cables 290 and 450 a or 450 b.
In accordance with the provisions of the patent statutes, the principal and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope. | The present invention relates to an actuator device for use in a motor vehicle, comprising an actuator, a control unit for controlling the actuator and a processing unit, which is or can be connected to an external main control device via a control connection in order to transfer actuator setting commands. Furthermore, the processing unit is subordinate to the main control device and is connected to the control unit in order to control the actuator according to the actuator setting commands. The control unit is or can be connected to the main control device via an activation connection and is equipped so as to enable the actuator to be controlled by the processing unit according to activation signals transmitted via the activation connection. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a foldable transportable structure that when deployed provides a truly collapsible, transportable, insulated and lightweight structure that is safe, reliable and internationally compliant. Its designed flexibility provides maximum convenience for the following: quick deployment to nearly any geographic location; use of varying component materials and sizes; and interconnectability of single units for multiple unit combinations. The ability of the structure to be air-dropped also allows service to the most remote locations where shelter or facility use is needed.
[0003] 2. Description of the Prior Art
[0004] Typically, supplied conventional structures offer only one or a few of a complete set of required properties that include: an easily erectable configuration for fast field installation; a requirement of NO tools or separate parts and pieces for assembly; a capability for remote deployment; a specific insulation value if needed; structural integrity; long-term durability; a design that allows for flexible use of materials choice and the potential to combine together multiple units.
[0005] U.S. Pat. No. 5,493,818 describes a “collapsible” structure having improved storage and shipping properties which are achieved by specific designing of the size, shape and hingeable connection positions whereas said structure is erectable and collapsible within minutes utilizing a minimal amount of tools and effort.
[0006] Geometric and dimensional limitations will not allow this structure to physically collapse into a stackable configuration as claimed. The roof panels will not be able to completely stretch out to lay flat when the roof panels are of a long enough dimension to form a gabled configuration, as their combined length when laying flat is much longer than the available length that the wall panels provide when they are in their folded flat configuration. An attempt to collapse the roof panels into a fully folded flat position will cause the wall panels below to hinge-bind dramatically resulting in neither of the roof or wall panels being able to lay completely flat. Alternately, when the wall panels are in a completely folded flat position the gable roof panels will not be allowed to fully stretch out and lay flat. In summary, the designed geometry will not allow full complete collapse of the stacked panels. All Sections and Claims within U.S. Pat. No. 5,493,818 refer to the invention as being a fully collapsible structure, which it will not be able to accomplish. This may be why it has not been adopted for large scale use.
[0007] U.S. Pat. No. 4,779,514 describes a “modular portable building unit” susceptible to air transport, and includes a roof, foldable side walls and foldable end walls having the same width as the height of the side walls. Three of the modular building units can be interfitted (sic) to form a building having four times as much floor space as the single modular building unit. The inclusion of a floor in the modular building is optional, and the inclusion of a separate pitched roof assembly for positive roof drainage is optional. Additional object of the invention is to provide a modular building unit that when folded down will allow transport by air or truck, and to allow combinations of multiple units together.
[0008] This method is limited by the gable end panels being separate components, and the separate fastening components and systems required to erect and/or collapse the unit. Redeployment and transport of this structure can be accomplished only after a very time consuming and tedious removal of many parts and pieces has been done. The lack of provisions for a passage opening, door, or other means shown for ingress or egress between the connected units is detrimental to the function and internal occupant flow of the connected units. Therefore no added value to the user from connecting the units together is recognized, and this may be why this system has not been adopted for large scale use.
[0009] U.S. Pat. No. 4,166,343 describes a hollow, generally rectilinear structure having a top, a bottom, sides and ends that can be constructed so as to be capable of being manipulated between a “normal” or unfolded type configuration and a collapsed or folded configuration in which the ends extend generally parallel to and beneath the top and in which the sides are folded so as to be located next to the ends generally between the bottom and the top. Such a structure includes hinges connecting the ends to the top so that they can be pivoted so as to lie generally parallel to the top. Such a structure is disclosed as having utility as a playhouse or storage shed but can be utilized for other purposes such as a container.
[0010] This structure is limited in that the gable end panels are separate panels that are hinged to the roof panel. The erection of the unit will not be manageable by the roof having to carry the added weight of the gable panels during erection of the side walls and roof panels at the same time. This will be completely unmanageable in the field. The structure also does not have means for combination of multiple units, or optional door placement locations, or a window to provide ventilation. This may be why this structure has not been adopted for field use, and is not a presently being manufactured.
[0011] U.S. Pat. No. 3,906,671 describes an adjustable door frame having frame portions formed by first and second frame sections cooperatively arrangeable (sic) on a wall of an opening.
[0012] This method provides adjustability only to the door frame for installation to variable wall thicknesses, and can only provide one of four possible door swing functions or configurations when installed. The mitered head jamb and casing pieces directly attach to the mitered hinge and strike jambs. This static configuration does not allow for the potential inversion of the hinge and strike jambs that would be required so that the entire door and frame assembly could be installed in either a right or left hand, or inside or outside, door swing configuration. In order for a door frame assembly to be completely and fully adjustable both of the hinge and strike jamb components must have the ability to be inverted and attachable to either the head or sill components so that the entire frame and door assembly can be installed in any of the 4 each possible swing configurations. This may be why this invention has not been adapted for field structures use.
[0013] U.S. Pat. No. 4,395,855 describes a pre-fabricated door frame assembly, the components which are adjustable and such that the assembly can be used for either right or left handed doors and can fit a wide variety of widths and heights of door openings through walls of varying thicknesses.
[0014] This method is designed to attach to standard constructed building walls that are normally much wider than the thinner wall panels typically used for flat-pack shelter units, and requires separate fasteners and tools for attachment to the wall system. This invention also does not include an integrated threshold or weather strip component for exterior wall use, which would be necessary for shelter units that would be deployed in hot or cold climates. This invention has limited use in that is does not offer diversity and the flexibility to be used in both interior and/or exterior applications, and it is not easily reversible or re-installable in the field without the use of tools or separate fasteners that may or may not be available.
[0015] U.S. Pat. No. 3,420,003 describes an adjustable door frame that adjusts to varying wall thicknesses, and can be installed quickly and easily with screws that go directly into the wall system. It consists of several longitudinal trim and jamb components that overlap and stay in place by ratchet teeth and backing plates that when the installation screw component is installed the separate pieces become locked into place.
[0016] This method is designed to attach to standard constructed building walls, and requires separate fasteners and tools for attachment to the wall system. This invention also does not include an integrated threshold or weather strip component for exterior wall use, which would be necessary for shelter units that would be deployed in hot or cold climates. This invention has limited use in that is does not offer diversity and the flexibility to be used in both interior and/or exterior applications, and it is not easily reversible or re-installable in the field without the use of tools or separate fasteners that may or may not be available.
[0017] U.S. Pat. No. 5,448,799 describes a hinge assembly for pivotally adjoining two panels together such as a shower door and its enclosure. A pair of continuous channel members are provided which are provided with an axial aligned rod and tubular channel for rotatably (sic) receiving the rod.
[0018] This method includes a weather strip component that protrudes beyond the profile of the wall panel extrusions. This component could not be utilized in a foldable structure as the protrusion will not allow adjacent and connected together wall panels to lay flat against each other when the structure is in a collapsed position.
SUMMARY OF THE INVENTION
[0019] The present invention is a folding transportable shelter with improved properties of: accurate folding hinge geometry, advanced interactive and integrated components that are designed to allow for either transportable or assembled structure configurations; advanced component materials for increased insulation; structural integrity; long-term dependability; built-in flexibility for optional placements of doors, windows or clear openings; and built-in flexibility for choice and use of varying materials and sizes for integrated components.
[0020] It is therefore a primary objective of the present invention to provide a foldable transportable structure that will significantly enhance the quality, functionality, stackable transportability, flexibility and affordability of moveable shelter structures.
[0021] It is another object of the present invention to include in the design a sophisticated geometric folding pattern means that significantly improves the allowance for integration and use of varying component materials, and also significantly improves the interactive complimentary relationships of folding accuracy, necessary clearances, and continual structural contact between adjacent components during the collapse and assembly functions of the unit.
[0022] It is another object of the present invention to include in the design same said sophisticated geometric folding pattern means that remains static, while allowing complete flexibility for: choice of overall structure size; use of any chosen dimension for panel thicknesses and relative connector widths; ability to combine together floor, wall and roof panels that are comprised of different individual thicknesses to obtain varying insulation values; without any of the above impacting the folding and assembly accuracy, or overall capabilities of the structure.
[0023] It is a further object of the present invention to provide specific designed continuous pivot hinge-to-panel connectors, an adjustable door assembly, a leveling foot assembly, a strap conveyance and tie-down assembly, and a flexible fillable bladder bag component to further improve the function, flexibility and use of the structure.
[0024] It is a further object of the present invention to provide a foldable transportable structure that has flexible integral components that are interchangeable during the manufacturing process for making structures that provide specific solutions for use in variable field conditions that include climatic, structural, deployment and usage considerations.
[0025] It is still another object of the present invention to provide a foldable transportable structure that contains the flexibility to be interconnected with additional like units of varying wall thicknesses to make larger structures, and includes removable wall panel sections for in-the-field-flexibility to interchange doors, windows or clear openings to create various configurations for maximum internal occupant flow and use.
[0026] These, and other objects of the present invention, will become apparent to those skilled in the art upon reading the accompanying description, drawings, and claims set forth herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of the erected foldable transportable structure according to the present invention.
[0028] FIG. 2 is a cross sectional view of the collapsed foldable transportable structure according to the present invention.
[0029] FIG. 3 is a cross sectional view of the geometric folding pattern included in the foldable transportable structure according to the present invention.
[0030] FIG. 4 is a detail cross sectional view of the roof eave-to-wall connector component according to the present invention.
[0031] FIG. 5 is a detail cross sectional view of the roof ridge-to-wall connector component, and connection to the separate adjacent continuous pivot hinge wall-to-roof connector component (as shown in FIG. 6 ), and the related hinging motion according to the present invention.
[0032] FIG. 6 is a detail cross sectional view of the continuous pivot hinge wall-to-roof connector component according to the present invention.
[0033] FIG. 7 is a detail cross sectional view of the continuous pivot hinge wall-to-wall connector component (as shown in FIG. 8 ), and connection between adjacent lower and upper wall panels, and the related hinging motion according to the present invention.
[0034] FIG. 8 is a cross sectional view of the continuous pivot hinge wall-to-wall connector component according to the present invention.
[0035] FIG. 9 is a detail cross sectional view of the floor-to-curb panel connector component according to the present invention.
[0036] FIG. 10 is a detail cross sectional view of the floor-to-curb panel connector component, and connection to the floor panel and adjacent lower wall panel, and the related hinging motion according to the present invention.
[0037] FIG. 11 is perspective view showing the architectural horizontal grid pattern that provides specific layout locations for removable and interchangeable wall panels, door and window components according to the present invention.
[0038] FIG. 12 is a detail cross sectional view of the removable wall panel interlocking edge trim component according to the present invention.
[0039] FIG. 13 is a perspective view showing a removable panel assembly according to the present invention.
[0040] FIG. 14 is a perspective view of the reversible and invertible door frame assembly according to the present invention.
[0041] FIG. 15 is a detail cross sectional view of the FlexFrame door components according to the present invention.
[0042] FIG. 16 is a perspective cutaway elevation view of the various door frame components showing their locking and invertible functions and capabilities according to the present invention.
[0043] FIG. 17 is a perspective cut-away view of the collapsed structure showing the adjustable strap conveyance and tie-down assembly, the adjustable leveling foot assembly, the spiral ground stake component, and the fillable bladder bag component according to the present invention.
[0044] FIG. 18 is a section and elevation view of the valance draw latch.
DETAILED DESCRIPTION OF THE INVENTION
[0045] FIG. 1 shows a perspective view of the best mode contemplated by the inventor of the erected foldable transportable structure 10 according to the concepts of the present invention. As seen by the drawings the foldable transportable structure 10 consist of a series of structural panels and continuous pivot hinge components connected together in a way that allows for either a folding up of the structure into a fully erected configuration as seen in FIG. 1 , or a folding down of the structure into a flat fully collapsed configuration for transportable methods as seen in FIG. 2 and FIG. 17 .
[0046] The foldable transportable structure 10 consists of a single floor panel 11 of which each of its long axis edges are connected to a floor-to-curb panel connector 19 , as seen in FIG. 9 and FIG. 10 . A continuous pivot hinge wall-to-wall connector 20 is attached between one of the floor-to-curb panel connectors 19 and the short side wall panel 13 as seen in FIG. 10 . A continuous pivot hinge wall-to-wall connector 20 is attached between the remaining floor-to-curb panel connector 19 and the tall side wall panel 17 as seen in FIG. 10 . A continuous hinge wall-to-wall connector 20 is attached between the short side wall panels 13 and 14 as seen in FIG. 7 . A continuous hinge wall-to-wall connector 20 is attached between the tall side wall panels 16 and 17 as seen in FIG. 7 . A continuous hinge wall-to-roof connector 21 is connected between the short side wall panel 14 as seen in FIG. 5 , and the roof eave-to-wall component 22 as seen in FIG. 4 . A continuous hinge wall-to-roof connector 21 is connected between the tall side wall panel 16 and the roof ridge-to-wall component 23 as seen in FIG. 5 . The single roof panel 15 is connected between the roof eave-to-wall connector 21 and the roof ridge-to-wall connector 23 as seen in FIG. 1 , FIG. 4 , and FIG. 5 . A continuous pivot hinge wall-to-wall connector 20 as seen in FIG. 8 is connected between the bottom of each of the gable end wall panels 12 and 18 and the floor panel 11 as seen in FIG. 1 . The exposed ends of the wall panels 13 , 14 , 16 and 17 , and the exposed edges of the roof panel 15 are capped off with a trim piece that includes a weather strip lip to provide a sealed positive stop for each of the gable panels 12 and 18 when erected.
[0047] FIG. 2 shows a cross section of the collapsed structure in its folded flat transportable configuration. For further reference FIG. 17 also shows a more detailed view of the individual panels when they are arranged in the folded flat configuration. When the structure 10 is in its fully erected configuration each individual wall panel is secured to its adjacent panel by a series of structural recessed draw latches 26 , as seen in FIG. 1 and FIG. 18 , that are located on the interior of the structure and must be disengaged in order to allow each individual wall panel to be folded down. To collapse the structure the following procedure is followed: gable end wall panels 12 and 18 are folded inward to lay flat on top of the single floor panel 11 ; the short side walls 13 and 14 are folded inward to lay flat on top of the gabled wall panels 12 and 18 ; the tall side walls 16 and 17 are folded inward to lay flat on top of the gabled wall panels 12 and 18 ; the single roof panel 15 follows the folding path of each side wall 14 and 16 , as each are folded down into their relative position, to then lay flat on top of walls 14 and 16 . To secure the panels together in the folded flat configuration for transportation a series of adjustable strap tie-down assemblies made up of components 46 , 47 and 48 are attached to the roof eave-to-wall connector 22 , and roof ridge-to-wall connector 23 as seen in FIG. 17 . To erect the structure simply reverse the process as described above.
[0048] FIG. 3 shows the vertical layout for the geometric folding pattern that formulates the static hinge-to-hinge centering relationships between the structure's individual panels, and establishes a guide for the finished panel widths or height dimensions for the floor panel 11 , the wall panels 13 , 14 , 16 and 17 , the roof panel 15 , the gabled wall panels 12 and 18 , and the vertical short and long points for the gabled wall panels 12 and 18 . The relative dimensions are defined using the following pattern formulation: a floor panel expressed as ‘A’ with an arbitrarily chosen width dimension being designated as ‘X’; a bottom short wall panel expressed as ‘B’ being of a height that is relative to 41.27617% of ‘X’; an upper short wall panel expressed as ‘C’ being of a height that is relative to 43.27018% of ‘X’; a bottom tall wall panel expressed as ‘D’ being of a height that is relative to 55.63310% of ‘X’; an upper tall wall panel expressed as ‘E’ being of a height that is relative to 57.76271% of ‘X’; a roof panel expressed as ‘F’ that is of a width that is relative to 103.98803% of ‘X’; a pair of gable panels expressed as ‘G’ that are of a width that is relative to 99.70089% of ‘X’; a pair of gable panels expressed as ‘G’ with a short point height that is of a length that is relative to 84.24725% of ‘X’ plus the chosen thickness width of the wall panels; a pair of gable panels expressed as ‘G’ with a long point height that is of a length that is relative to 112.96111% of ‘X’ plus the chosen thickness width of the wall panels.
[0049] FIG. 11 shows a perspective view of the grid layout system for the removable wall panel 24 locations to allow the creation of a door opening (as can also be seen in FIG. 1 Detail 28 ), or a window opening (as can also be seen in FIG. 1 Detail 27 ), or clear openings (as can also be seen in FIG. 1 Detail 24 ) in any one of variable locations within the tall or gable walls of the structure. The finished dimension width of the removable wall panel 24 and its respective rough opening is a result of two (2) times an Arbitrary Dimension expressed as ‘A’. FIG. 12 shows a detail cross sectional view of the interlocking edge trim 25 that is installed around the perimeter of each of the removable wall panel 24 components as seen in FIG. 13 . FIG. 13 shows a perspective elevation of the removable wall panel 24 , and the locations of the interlocking edge trims 25 and the continuous pivot hinge wall-to-wall connector locations.
[0050] FIG. 14 is a perspective elevation view of the overall configured door frame assembly 28 which includes a series of separate adjustable interlocking jamb components 29 and 30 , and a series of hinge components 31 .
[0051] FIG. 15 shows a detail cross section of the jamb components to include the following: an L′ shaped jamb component 29 that is used for the side jambs, header and sill components; an L′ shaped jamb component 30 that is used for the side jambs and header components only, and installs behind side jamb and header components 29 ; a thru-bolt and compression nut assembly 36 for securing jamb components 29 and 30 together; and a hinge component 31 for attachment of the door 42 and door panel trim 43 to the side jamb component 29 .
[0052] FIG. 16 shows a perspective cut-away elevation of the various door frame components to illustrate more specifically individual component relationships, details, and the reversible and invertible function of the door assembly. Jamb component 29 and separate hinge components 31 each include a round hollow profile 32 on their respective outside edges that allow insertion of a continuous hinge securing rod 33 to attach the two components together. The single hinge-side jamb component 29 includes a series of cut-out sections to allow insertion of hinge components 31 and corresponding vertical alignment of their respective round hollow profiles 32 . Side jamb, header and sill components 29 each include an extruded open slot to receive a continuous weatherstrip component 34 . Side jamb and header components 29 include a series of holes 35 where a finger-turn locking assembly 36 , comprised of a thru-bolt and a non-removable compression nut, is installed. Corresponding side jamb and header components 30 include a series of open-ended slots 37 that align with the series of thru-bolts 36 installed on jamb components 29 . Together components 36 and 37 allow for a sliding back and forth motion between jamb components 29 and 30 for adjustability to variable adjacent wall panel thicknesses. Jamb components 29 include a series of protruding ‘v’ shapes 38 that rest into a corresponding series of reverse retention ‘v’ shapes 39 that are integral to jamb components 30 . Jamb components 29 and 30 are then prevented from sliding apart when tightened together with the bolt and compression nut assembly 36 . The two each side jamb components 29 each include on their ends a pair of male tabs 40 that fit into a corresponding pair of female slots 41 that are punched into the top surfaces of the header and sill components 29 . The series of tabs 40 and slots 41 prevent potential horizontal movement between the two each side jamb components 29 and the header and sill components 29 . The series of tabs 40 and slots 41 also allow the hinge-side jamb component 29 and attached door components 42 and 43 to be inverted between the header and sill components 29 in order to change the door to either a right or left handed swing function. The entire door assembly 28 is also installable on either the exterior or interior of the wall to additionally provide for any of the 4 each possible swing functions required. A structural insulated door panel 42 as seen in FIG. 15 is wrapped on all 4 sides with a ‘U’ shaped trim cap component 43 , and is attached with a series of fasteners 44 to a series of symmetrically centered surface mounted hinge components 31 . A commercially available flush mounted latching and locking mechanism is installed in the door panel component 42 to complete the door assembly. Each of the door assembly components can be made from any variety or combination of metals, plastics, composites, fiber reinforced polymers, fiberglass or other types of material.
[0053] FIG. 17 shows a perspective cut-away view of the collapsed structure to illustrate details for the conveyance and tie-down strap and hook assembly, the dual-function pad leveler and stacking guide assembly, and the bladder bag assembly. A series of load compliant looped strap carrying handles 45 are attached to the floor curb component 19 for conveyance of the transportable structure 10 . Two separate continuing sections of the tie-down strap 46 are interconnected with a commercially available load compliant ratchet-tight buckle 48 . The remaining end of the tie-down strap 46 is attached to a commercially available load compliant flat hook 47 . Hook 47 connects to the roof-to-wall connector curb 23 for securing the structure 10 while it is in a flat collapsed transportable configuration, or alternately hooks onto either the eyelet 54 that is integral to bladder bag 53 , or onto a spiral ground stake 55 , for securing the fully erected structure 10 to the ground. The bladder bag 53 is filled with water, earth, sand, gravel, or other material to add hold-down ballast weight to the fully erected structure 10 . A series of adjustable leveling pad assemblies are installed inside of the floor-to-wall connector component 19 . A load compliant square tube 49 is securely installed in component 19 . A load compliant leveling tube adapter 50 is inserted into component 49 . A load compliant fast-turn threaded rod 51 of sufficient length is welded to a load compliant leveling foot 52 , and is then inserted into the receiving threads of the leveling tube adapter 50 . When the structure 10 is in its collapsed transportable configuration the leveling foot pad 52 is in a completely retracted position and alternately provides stacking guidance and transportation containment by sliding into and resting on the top track and curb of a lower structure's roof component 23 .
[0054] The problems addressed by the foldable transportable shelter 10 are many as can be easily seen by those skilled in this art. The foldable transportable structure 10 greatly enhances the ability and proficiency to deploy moveable structures and reduce transportation costs, by including a well-arranged series of structural panels, hinges and other components, which are connected together in a certain way that allows the structure to be folded down into a collapsed configuration to provide a very compact transportable structure. The foldable transportable structure 10 supports easy and complete assembly in the field, especially in more remote locations, by not requiring the use of power, separate hand tools, or separate loose connectors and fasteners that can be misplaced or lost. The foldable transportable structure 10 saves field time and labor costs by requiring only three to four unskilled persons less than fifteen minutes to fully erect it, and it can also be as easily collapsed and re-deployed to a different location in as little time. The foldable transportable structure 10 is environmentally responsible as all individual components are designed to provide more than just one integrated function, thus substantially reducing raw material quantities, environmental impact and production costs. The flexible design of the foldable transportable structure 10 allows for choice of varying raw materials to meet fluctuating market conditions or any user required specifications. The design of the foldable transportable structure 10 includes a geometric folding pattern, as seen in FIG. 3 that provides folding ability of the structure, and also establishes or allows for: combination of varying panel thicknesses for the floor, wall and roof panels; the guided folding motion and cohesive interaction of each individual structure component; maintaining minimal clearances and continual structural support between all adjacent components during the folding process or transportable configuration. The foldable transportable structure 10 provides additional value to the end user as units can be optionally equipped with an integrated removable wall panel system, as amply seen in FIGS. 11 through 13 to allow for the in-the-field switching of the door or window locations, or to create other clear opening locations for flexible flow-through configurations within multiple combined units. The reversible door assembly, as amply seen in FIGS. 14 through 16 saves raw materials and costs by providing a one-size-fits-all assembly. The foldable transportable structure 10 will find wide use anywhere disaster relief, military, and other civil types of operations are required. Private industry would be employed to manufacture the many units required.
[0055] Thus it will be appreciated by those skilled in the art that the present invention is not restricted to the particular preferred embodiments described with reference to the drawings, and that variations may be made therein without departing from the scope of the present invention as defined in the appended claims and equivalents thereof. | Disclosed is a foldable transportable structure with a three dimensional rectangular shed roof shape having improved component and structural properties, and improved shipping and deployment capabilities. The integrated unique geometric folding pattern means provides enhanced folding accuracy and correct placement of interactive panels during collapse or assembly of the structure, and also greatly increases the flexibility for multiple unit combinations and component materials selection. The folding transportable structure provides a strong, safe, insulated weatherproof structure with a quick setup time, and requires NO tools or separate loose components for assembly. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a transport device for automatically cutting and opening a package. A bundle of flattened packing container blanks, covered with packaging material on the outside, are provided for automatically supplying the blanks, after the blanks are opened, to a position relative to the cutting position of packaging material. The blanks are thereafter supplied to succeeding workstations. A series of transport devices are provided for transporting the blanks one at a time and raising the blanks into parallelepipeds with a square-shaped cross section.
2. Description of Background Art
Conventionally, various paper containers have been manufactured for a variety of uses. For example, singlelife packing containers are widely used for packaging liquid food product, such as milk and juice, and as shown in FIG. 24, some have a parallelepipedic form A'.
The blanks A for this type of packing container are invariably folded flat as shown in FIG. 23 for storage, transporting, and in order to facilitate other handling. As shown in FIG. 18, the blanks A are bundled and packaged on the outside with packaging material B.
As shown in FIG. 16, the blanks A' are raised into parallelepipedic form with a square-shaped cross section and are sent to a mandrel wheel E of the packing machine D for sealing the bottom before filling the container with liquid contents. However, in order to send the aforesaid blanks A' to a mandrel wheel E, the plurality of bare blanks A obtained by cutting and opening packaging material B of bundled package C must be supplied to a separate position removed from the cutting position and the blanks A must be transported forward while raising the blanks A into a parallelepipedic shape with a square-shaped cross section.
Hence, conventionally in most cases, the plurality of flattened blanks A are propped up on a platform before being delivered to a mandrel wheel E as shown, for example, in Japanese Pat. Pub. 62-201562.
Moreover, the cutting and opening work of packaging material B for package C involves either manual work or a device as disclosed in Japanese Pat. Pub. 62-271828. To supply a plurality of flattened blanks A to the aforesaid platform after cutting and opening also requires either manual work or a supplying device as disclosed in Japanese Pat. Pub. 62-201562.
Finally, after supplying to the platform, the flat blanks A must be raised into a parallelepipedic form with a square-shaped cross section in order to insert them in a mandrel wheel E. There is a known device that grasps a propped up blank A with a suction head and pulls it out, while at the same time forming a parallelepiped with a square-shaped cross section.
SUMMARY AND OBJECTS OF THE INVENTION
In order to prop up a plurality of flattened blanks A, at least a long horizontal platform is necessary. Thus, horizontal width of the equipment becomes equally long. Consequently, the equipment becomes disadvantageously large.
The supply of a plurality of bare blanks A after opening onto the platform becomes considerably inefficient under manual operation. Furthermore, a certain bundle of blanks A is relatively heavy and forces considerable labor upon the worker. A device developed to automate this work, as disclosed in Japanese Pat. Pub. 62-201562, has an unexpectedly complex structure and also requires detailed operation.
In addition, when applying the flat blanks A supplied to the platform one at a time to the mandrel wheels E using the conventional raising device, the initial folding tendency remains to make the formation of a square difficult. Thus, insertion to the mandrel wheels E does not proceed smoothly.
Incidentally, devices for automatically cutting and opening a package C of bundled flattened blanks A and covered on the outside with packaging material B and devices to automatically supply the plurality of bare blanks A after opening to a separate location from the cutting position have been individually developed. However, an ideal transport device that maximizes the characteristics of both devices and brings them together has yet to be developed. A series of processes are necessary to form a container beginning with raising the blanks A and sending them in parallelepipedic form with a square-shaped cross section, as shown in FIG. 24, into the packing machine D, creating bottoms, and filling the liquid contents at a filling area H. It is necessary for a device to handle a plurality of bare blanks A after opening which must be sent from some origin and automatically raised into parallelepipedic form with a square-shaped cross section and then sent to the packing machine. Conventional devices lacked reliability and were thus insufficient.
The present invention proposes to furnish a transport device closest to the ideal device that eliminates the above problems.
The transport device of the present invention consists of a platform for placing a package C, which is a bundle of a plurality of flattened packing container blanks A covered with packaging material B on the outside. A device is provided for cutting and opening the packaging material B of the package C on the platform. A main magazine stacks the plurality of bare blanks A after opening and supplies the blanks one at a time to the next process. A robot is provided for grasping the blanks A and moving the blanks to the platform after the blanks are opened from the main magazine.
In addition, the transport device is equipped so that at the front of the main magazine where a plurality of opened, bare blanks A are stacked in order to supply them one at a time to the next process, a lifting conveyor is placed in order to send in one flat blank A taken from the main magazine through a pair of discharging rollers. At the front of the pair of discharging rollers, a raising device is provided consisting of a front-and-back pair of members for supporting and constructing both rim edges of one, flat blank A that passes through the pair of discharging rollers into a parallelepiped with a square-shaped cross section. The aforesaid platform preferably can move either up or down to the opening position after cutting packaging material B of the package C on the platform.
In addition to the aforesaid main magazine, it is preferably to provide a separate storage magazine whereby the aforesaid robot can move between the platform, main magazine, and storage magazine.
The package C bundled with packaging material B, as shown in FIG. 18, is placed on the platform at the cutting position shown by chain line in FIG. 3.
The packaging material B covering the outside of the plurality of flattened blanks A is cut at this position, and the cut packaging material B is opened, for example, as shown in FIG. 17(g).
The plurality of bare blanks A after opening remain on the platform shown by the chain line in FIG. 13. The robot with a means of grasping comes over to pick up the plurality of blanks A on the platform, as shown by the solid line in FIG. 13. The robot proceeds to grasp the plurality of bare blanks A after opening as shown in FIG. 17(b).
Next, the robot moved from the solid-line position of FIG. 1 to the location of the main magazine, and inserts the plurality of bare blanks A into the main magazine at that position as shown in FIG. 17(i).
In this way, merely supplying a package C bundling a plurality of blanks A covered with packaging material B to the platform enables automatic cutting and opening of packaging material B and automatic supply of the plurality of bare blanks A after opening to the main magazine.
After cutting the packaging material B, if the platform with the package C moves either up or down to the opening position to differentiate between the cutting position and opening position of packaging material B, the use of vertical space can be maximized.
By placing a storage magazine separate from the main magazine whereby the aforesaid robot can move between the platform, main magazine, and storage magazine, the blanks A remaining in the main magazine can be stored in the storage magazine if the succeeding manufacturing line stops. Fast exchange between different sizes and types of blanks can take place between the main magazine and storage magazine.
The plurality of blanks A supplied to the main magazine can be taken out one at a time from the main magazine with a suction pad. Thereafter, a lifting conveyor supplies the blanks A taken out of the main magazine to a pair of discharging rollers, as shown in FIG. 14. One flattened blank A delivered from the discharging rollers has both its front and rear edge rims supported by a pair of members, as shown in FIGS. 15(a)-(d). The blank A is finally raised into a parallelepipedic form with a true square-shaped cross section, as shown in FIG. 15(d). Thus, as shown in FIG. 16, the blank A' can be sent to the mandrel wheel E for the following bottom-forming process, and enables smooth loading onto the mandrel wheel E.
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
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:
FIG. 1 is the abbreviated front view of the transport device according to the present invention;
FIG. 2 is a planar view of the transport device illustrated in FIG. 1;
FIG. 3 is a side view of the transport device illustrated in FIG. 1 as viewed along line III--III;
FIG. 4 is a side view of FIG. 1 as viewed along line IV--IV;
FIG. 5 is an enlarged planar view of only the package transporting device;
FIG. 6 is a profile view of FIG. 5 taken along line VI--VI;
FIG. 7 is an enlarged side view illustrating the relationship between the platform of the packaging material cutting device and the pusher that pushes the package onto the platform;
FIG. 8 is an enlarged front view of only the platform of the packaging material cutting device for the package;
FIG. 9 is an abbreviated planar view of the entire packaging material cutting device for the package;
FIG. 10 illustrates a positional relationship between the two platforms above the platform which is part of the packaging material cutting device for the package;
FIG. 11 is a partially cut side view illustrating the tilting of the platform which is part of the packaging material cutting device for the package;
FIG. 12 is an enlarged side view of the opening device combined with the cutting device after the package is cut;
FIG. 13 is an enlarged side view of the robot with a pair of grasping members;
FIG. 14 is a front view of only the device that raises blanks into parallelepipeds with square-shaped cross sections, the device normally is tilted, but is shown not tilted for clarity;
FIGS. 15(a), 15(b), 15(c), and 15(d) are side views in order of processing for the raising operation with this raising device;
FIG. 16 is a transport route from the raising device to the mandrel wheels, showing additional blanks raised into parallelepipeds with square-shaped cross sections and inserted into the mandrels;
FIGS. 17(a)-(i) are diagonal views in processing order of cutting and opening the package sent by the conveyor, of removing only the content blanks, and of supplying the blanks to the main magazine;
FIG. 18 is a diagonal view of only the package;
FIG. 19 is a diagonal view of the cutting positions of the package;
FIG. 20 is an enlarged view of the opening operation of the package after cutting;
FIG. 21 is an enlarged side view of vertically cutting the two mutually opposing planes of the package and of inserting the plates from those cuts;
FIG. 22 is a profile view of the embodiment illustrated in FIG. 21;
FIG. 23 is a diagonal view of the flattened blanks;
FIG. 24 is a diagonal view of the parallelepipedically raised conditions with square-shaped cross sections.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will now be described with reference to the accompanying figures.
Among packing container blanks, there are parallelepipedic forms with square-shaped cross sections as shown in FIG. 24. This type of blank A', however, is invariably folded as a flat blank A, as shown in FIG. 23, for storage and transporting and in order to facilitate other handling. Many of the blanks are bundled and covered on the outside, as shown in FIG. 18, with packaging material B.
In the package C, only the blanks must be sent to the succeeding manufacturing line. Therefore, the packaging material B covering the outside must be cut and opened. This operation takes place on the platform for this invention. The platform 1 is shown in FIGS. 3, 4, 12, and 13. The package C is placed on the platform 1.
In this embodiment, two conveyors 2, 2 feed in the package C, as shown in FIGS. 3 and 9, and either alternately or continuously from one side push the package out to the transport device 3 located between the two conveyors 2,2. As shown by the single-dot chain line in FIG. 6, the transport device rotates and then, as shown by the two dot chain line, lowers, and finally, the package is pushed onto the platform 1 by pusher 4 shown in FIGS. 6 and 7. Automatic supply of the package C to the two conveyors 2, 2 is enabled by installing a selective supplying device (not illustrated) that can lift a package C on a palette and supply the two conveyors 2, 2.
The transport device 3 is equipped with a storage box 3a that has a sideways L-shaped cross section as shown in FIG. 6, and the package C sent by the two conveyors 2,2 is pushed either alternately or continuously from one side into the storage box 3a from the two openings 3b and appear on the left and right in FIG. 3. To alternately push the package C into the storage box 3a, for example, pushers 3c, 3c' can be positioned above the two conveyors 2, 2 as shown in FIG. 5. The package C can be alternately moved from the solid-line position to the chain-line position of FIG. 5 by the cylinder 3d of pusher 3c and the cylinder 3d' of pusher 3c'. In order to continuously feed packages C to the storage box 3a from one of the two openings 3b, only one of the two cylinders 3d, 3d' shall be operated and the other cylinder shall be stopped.
The storage box 3a can rotate as shown in FIG. 6 from the solid-line position to the single-dot chain-line position, and lowered to the two-dot chain-line position retaining its orientation as shown in FIG. 6. To rotate the storage box 3a from the solid-line position to the single-dot chain-line position, for example, the storage box 3a can be joined to the end of the rod of the cylinder 3e with a lever 3f. When the rod of the cylinder 3e pulls in from the solid-line position shown in FIG. 6, the storage box 3a rotates 90 degrees from a horizontal position via the lever as shown by single-dot chain line in FIG. 6.
To lower the storage box 3a , while retaining its orientation to the position indicated by the two-dot chain line in FIG. 6, the storage box 3a can be joined directly to the rod 3g' of the cylinder 3g for moving the storage box up and down, for example. In this way, the package C delivered by the two conveyors 2,2 can be either alternately or continuously supplied from one side pushed into the storage box 3a . The orientation of the package C can be rotated 90 degrees and lowered to the position shown by the two-dot chain line in FIG. 6. At the lowermost position of the transport device 3, a pusher 4, shown in FIG. 3 is installed. The pusher 4 operates from one of the two openings 3b of the aforesaid storage box 3a to the other, i.e., from the right to the left in FIG. 7, and enables the package C to be pushed out from the storage box 3a.
In this embodiment, at the lowermost position of the storage box 3a, the aforesaid platform 1 is waiting and is designed so that a portion of the package C lowered from the storage box 3a lands on the platform 1. Hence, the pusher 4 can immediately push the package C lowered from the storage box 3a onto the platform 1. Until the storage box 3a lowers, the pusher remains tilted as shown by the solid line in FIG. 7. However, right before ending the lowering motion of the storage box 3a, a cylinder 4a renders the pusher vertical as shown by the chain line in FIG. 7. While acting as a guide, another cylinder 4b retains the orientation and the pusher moves to the left of FIG. 7, effectively pushing the package C out of the storage box 3a onto the platform 1.
The cutting and opening of the packaging material B of the package C on the platform 1 has been discussed. An embodiment of this device will now be described.
The packaging material B can be cut by applying and imparting motion to thin cutting blades on the packaging material B. In this embodiment, the position of applying the cutting blades on the packaging material B around the plurality of blanks A in FIG. 19 are along the vertical lines shown by c 1 on the two mutually opposing perpendicular planes C1, C1, along the symmetrical horizontal lines c 2 from s 1 to the perpendicular plane C2 that intersects perpendicularly with the two surfaces C1, C1, and along the connecting horizontal line c 3 between c 2 and c 2 on plane C2. Cutting blades are positioned to the side of the package C on the platform 1 in order to cut this portion of the packaging material B. The cutting blades 5 for cutting the vertical portion c1, c1 of the packaging material B are shown in FIG. 8. The cutting blades 6 for cutting the horizontal portion c 2 , c 2 are shown in FIG. 9. The cutting blade 7 for cutting the connecting horizontal portion c 3 between C 2 and C 2 is shown in FIG. 9.
Cutting blades 5, 5 are arranged as a pair on the left and right in FIG. 8. Cylinders 5a, 5a are located on the side of the platform 2 for moving the cutting blades 5, 5 up and down. By applying the left and right pair of cutting blades 5, 5 to the package C on the platform 1 and running the blades along from the solid-line position of FIG. 8 to the chain-line position in FIG. 8, the portion c 1 , c 1 of the packaging material B of the package C indicated in FIG. 19 can be cut. In addition in FIG. 5, cutting blades 5 have separate cylinders 5b installed in order to move to the left and right separately from the cylinders 5a. The cylinders 5b place cutting blades 5 temporarily in the back relative to the platform 1, as illustrated in the left and right outer sides of FIG. 8. Thereafter, the cutting blades 5 are advanced to the solid-line position in FIG. 8 in order to cut packaging material B. After cutting, the cutting blades 5 are returned by the cylinders 5b, and lowered by the cylinders 5a.
The cutting blades 6 in FIG. 9 are positioned so they emerge symmetrically vertical and advance to the left when facing the platform 1 from the solid-line position in FIG. 9. The portion c 2 , c 2 of the packaging material B of the package C on the platform 1 indicated in FIG. 19 can be cut. As a means for the pair of cutting blades 6, 6 to approach the platform and to return to the solid-line position in FIG. 9 after cutting the packaging material B, the embodiment employs a cylinder 6b for moving a frame 6a mounting the cutting blades 6, 6 to the left and right.
The cutting blade is positioned as shown in FIG. 9. By advancing from the solid-line position in the direction of the arrow, the portion c 3 of the packaging material B of the package C on the platform as indicated in FIG. 19 can be cut. As a means for the cutting blade 7 to advance and to return to the solid-line position in FIG. 9 after cutting the packaging material B, the embodiment employs a cylinder 7a for moving the cutting blade 7 up and down in FIG. 9.
When performing the aforesaid cuts, the preferred embodiment creates a space c 5 between the rim edges of the blanks A that are packaged so the package C on the platform 1 does not move. Thus, applying and running the aforesaid cutting blades 5 along the packaging material B does not injure the blanks A of the package C, while the package C remains held by holders 8, 8 and does not slip.
The portion c 1 cut by cutting blades 5 is in an open-mouth form. As shown in FIG. 17(e), ruler-like plates 10 are inserted into this portion. The plates 10 can be placed in the space c 5 as shown in FIG. 22 between the packaging material B pulled outward by suction pads 9, 9 and the packaged blanks A. Thus, when cutting the portion c 2 , c 2 as shown in FIG. 19, the plates 10 can be underlays to prevent injury to the rim edges of packaged blanks A. The outer surfaces of plates 10 should include longitudinal slots 10a. In this way, if the blade tips stay within the slots 10a when the aforesaid cutting blades 6 are moved along horizontally and cut the packaging material B, the blade tips do not fluctuate and the cutting position of packaging material B does not slip.
The ends of the inserted plates 10 from the cut portion c 1 of the package C stick outward from the other perpendicular plane C2 of the package C as shown in FIGS. 17(e) and 21. Thus, a space c 6 forms between packaging material B and rim edges of the packaged blanks A as shown in FIG. 21. In this way, cutting packaging material B on plane C2 by cutting blade 7 does not injure the rim edges of packaged blanks A. As shown in FIG. 21, if a slot 10f is formed on the ends of the plates 10, so that the blade tip stays within the slot 10f when the aforesaid cutting blade 7 runs along horizontally and cuts the packaging material B, the blade tip does not fluctuate and the cutting position of packaging material B does not slip.
Regarding the insertion of plates 10 shown in FIG. 17(e) from the portion c 1 cut by cutting blades 5 along plane C1 of the package C, for example, one end of the oscillating lever 10c centered around the pivoting axis 10b, as shown in FIG. 7, can be joined to the plates 10. The other end of said lever 10c may be connected to the end of a rod of the cylinder 10d with a lever 10e. When the rod of the cylinder 10d, shown with solid lines in FIG. 7, is reciprocated in, the lever 10c oscillates around pivoting axis 10b via the lever 10e, as shown by the chain line in FIG. 7. Thus, the plates 10, shown with solid lines in FIG. 7, advance to the right in FIG. 7 as the chain line shows, and are successively inserted from the ends of the package C.
When performing the respective cutting operations described above, a back plate 11 is installed on the left side relative to FIG. 12 toward the back of the platform 1 in order to determine the position of the package C on the platform 1. During the respective cutting operations described above, the back plate 11 should be aligned with a plane C3 of the package C as illustrated in FIG. 19.
The holders 8 and suction pads 9 are on a separate platform 12 above the platform 1, as shown in FIG. 9. The back plate 11 is also on a separate platform 13 above the platform 12, as shown in FIG. 10. The platform 1 can move relative to the frame 14 with a cylinder 1a, as shown in FIG. 12. The platform 12 can move relative to the platform 1 with a separate cylinder 1b mounted on the platform 1 and with a cylinder 12a mounted on the platform 12 as shown in FIG. 9. The platform 13 can move relative to the platform 12 with a separate cylinder 12b mounted on the platform 12 and with a cylinder 13a mounted on the platform 13 as shown in FIG. 10. By appropriate control of the cylinders whereby all are operated or part of them are not, the amount of movement of the platforms 1, 12 and 13 and the mutual positional relations between the platforms can be freely modified. In this way, even in the event that the length of blanks A or the length L, as illustrated in FIG. 18, of the package C of the blanks A bundled with the packaging material B differs according to a difference in volume, by providing a constant position of one plane C2 for each package before placing on the platform 1, for example, the platform 1 position to support one package, the cutting blades 5 position, the holders 8 position, the suction pads 9 position, and the back plate 11 position can be freely modified according to the length of the package. This means that when the package to be cut has a different length, the supporting platform 1 meets the package at the prescribed location and the cutting blades 5 can cut at the prescribed position on the mutually opposing two perpendicular planes C1, C1 for each package. In other words, even in the event of handling packages of different lengths, the packaging material B can be cut vertically at the prescribed position for each package.
In this way, the packaging material B of the package C on the platform 1 can be cut, and in this case the platform 1 is located at the solid-line position of FIG. 3. This position is the cutting position. In the preferred embodiment, the platform 1 lowers from this cutting position as shown by the chain line in FIG. 3 where the packaging material B is opened after cutting. In this way, vertical space usage is maximized and preferable. To lower the platform 1 from the solid-line position of FIG. 3 to the chain-line position of the same figure, for example, the cylinder 1c, as illustrated in FIG. 9, can be used to lower the entire platform 1 along with the frame 14.
As a means to open the packaging material B after cutting in the preferred embodiment, FIG. 12 shows a lever 15 that grasps the upper corner of cut package C', as illustrated in FIG. 19, on the platform 1. A catch 16 is movable from below in an upward direction. A catch 17 is movable from above in a downward direction. The lower end of the lever 15 is pivotally attached to the rod 15b of a cylinder 15a. According to the action of the cylinder 15a, the rod 15b extends toward the arrow direction of FIG. 12, and the rod moves from its solid-line position in FIG. 12 as shown by the chain line. Consequently, the end of the lever 15 grasps the upper corner of the package C'. Thereafter, the mouth of the cut packaging material B opens slightly as shown in FIG. 20. The end of the catch 16 enters the mouth, catches the edge of the open mouth, and rises. Thus, the upper half b1 of packaging material B opens, as shown in FIGS. 17(g) and 20. Next, the upper catch 17 lowers and an end of the upper catch catches the edge of the open mouth b' of b 2 , as illustrated in FIG. 20, of packaging material B, and lowers the packaging material B. Thus, the lower half b 2 of the packaging material B opens, as shown in FIG. 17(g) and 20. In this way, opening proceeds for the package C' after cutting on the platform 1. This opening operation, besides the preferred embodiment, can proceed by ripping off the packaging material B after cutting by pulling on any of the planes of package C' after cutting with suction pads.
Once opened, the packaging material B becomes unneeded, and only the contents need to be taken. The contents are stored first in the main magazine F, taken out and sent one at a time to the next process, raised into parallelepipedic form with a square-shaped cross section, and finally sent to the mandrel wheels E of the packing machine D in order to form the bottom of the blanks A' now in a parallelepipedic form with a square-shaped cross section. In the present invention, a robot performs the operation consisting of removing only the plurality of bare blanks A after opening and supplying them to the main magazine F.
The robot 18, as illustrated in FIGS. 1 and 3, can move at least between the platform 1 after opening and main magazine F. In the preferred embodiment, there are two main magazines F, as shown in FIG. 1. The robot 18 should run along a guide rail 19 located between the platform 1 and the two main magazines F, F.
The robot 18 has a means of grasping formed by a pair of upper and lower forks 18a, 18a, as shown in FIG. 13, and approaches the opened package C" on the platform 1, to remove only the plurality of bare blanks A, as shown in FIG. 17(h) with the upper and lower forks 18a, 18a running along the guide rail 19 toward the main magazine F. The plurality of blanks A are grasped with the upper and lower forks 18a, 18a and supplied to either of the two magazines F, F as shown in FIG. 17(i). The upper and lower forks 18a, 18a can freely change their mutual distance with the two cylinders 18b, 18c as needed, as illustrated in FIG. 13. When removing the plurality of bare blanks A from the platform 1, supplying them to the main magazine F, and removing the remaining blanks A in the main magazine F (discussed later), the pair of forks 18a, 18a should approach and return from the platform 1 and main magazine F. To enable this, example, as shown in the preferred embodiment, the base 18d of the robot 18 should slide to the left from the solid-line position of FIG. 13 along the guide rail 18e of the rack 18f. This base 18d should be lowered to the solid-line position in FIG. 13 when it moved between the platform 1 and main magazine F.
In the preferred embodiment, the portion 1d in front of the platform 1 tilts as shown by the chain line in FIG. 11. In this way, the lower fork of the pair of forks 18a, 18a does not contact the platform 1 when it picks up the plurality of bare blanks A on the platform 1, and can enter the place where the said blanks are exposed outside of the packaging material B.
Again, in the preferred embodiment, there is a storage magazine G separate from the main magazine F, as shown in FIG. 1, and the aforesaid guide rail 19 extends to this position. The storage magazine G can store remaining blanks A in the main magazine F when the succeeding manufacturing line stops, or can speed up exchanges between blanks of a different size or type between the main magazine F and storage magazine G.
Unillustrated suction pads remove the plurality of blanks A supplied to the main magazine F by the robot 18 one at a time. The main conveyor 20 is located directly below the blanks A and sends the blanks A forward. In the preferred embodiment, there are two main magazines F. The bottom positions of the magazines F are differentiated heightwise. The continuing main conveyors 20 are also positioned in two levels, upper and lower, as shown in FIG. 4. The lower main conveyor 20 extends further than the upper main conveyor as shown in FIG. 1.
Near their terminating ends, covers 20' rise 45 degrees upward relative to the advancing direction to cover the two main conveyors 20. The interior consists of a pair of charging rollers 21 followed by lifting conveyors 22 that rise 45 degrees, as shown in FIG. 14. In the case of the preferred embodiment, two sets of charging rollers 21, 21 are installed for each main conveyor 20 at the front and back, and the lifting conveyor 22 is located correspondingly. A movable guide plate 23 for guiding alternately placed, flat blanks A sent one after another from the main conveyor 20 to the lifting conveyor 23 in the front is installed near the charging rollers 21, 21 close to the main magazine F on the front, left side as illustrated in FIG. 14. A fixed guide plate 24 for guiding blanks A passed beneath the movable guide plate 23 by switching is installed near the other charging rollers 21, 21, as illustrated on the right side in FIG. 14.
When the movable guide plate 23 is in the position shown by the solid lines in FIG. 14, the movable guide plate 23 changes the transporting direction of the flattened blanks A delivered by the main conveyor 20. The blanks a pass through the first charging rollers 21, 21 to the first lifting conveyor 22. When the movable guide plate 23 is in the position shown by the chain lines in FIG. 14, the flattened blanks A delivered by the main conveyor 20 pass beneath the movable guide plate 23 and reach the fixed guide plate 24, where the fixed guide plate changes the transporting direction of the blanks. The blanks A pass through the second set of charging rollers 21, 21 to the second lifting conveyor 22. In this way, by switching the movable guide plate 23, the flattened blanks A are divided and sent from one main conveyor 20 into two streams, and sent 45 degrees upward via the respective lifting conveyors 22.
A pair of discharging rollers 25, 25 are located right in front of both lifting conveyors 22, followed by raising devices 26. The flattened blanks delivered by a lifting conveyor pass through a pair of discharging rollers 25, 25 and reach a raising device 26. The raising device consists of, relative to the advancing direction of the blanks A, a front-and-back pair of members 26a, 26b opened at 90 degrees. The member 26a mounted in the front can move forward and backward. The other member 26b mounted in the back right in front of the discharging rollers 25, 25 cannot move. As shown in FIG. 16, the member 26b that passes the blanks A through, contains a window hole 26c, and, as shown in FIG. 15, has a pair above and below of bearing pieces 26d, 26d separately above and below relative to the transporting direction.
The flattened blanks A sent from a lifting conveyor 22 pass between discharging rollers 25, 25 and once the great majority come out of the window hole 26c of the piece 26b, their front edge rims a 1 are supported by the front member 26a as shown in FIG. 15(b). When the piece 26a approaches as shown in FIG. 15(c), the front side of a blank A is pressed while the portions a 2 and a 3 are supported by bearings 26d, 26d, forming a thin rhombus momentarily. Next, by clearing the front piece 26a away, as shown in FIG. 15(d), a parallelepipedic form with a true square-shaped cross section can be raised. By momentarily forming a thin rhombus, the construction results in a parallelepipedic form with a square-shaped cross section from a flattened blank A even if the blank A has retained certain folding tendency. Constructions in this case provide smooth insertions into the mandrel wheels E of the packing machine D, more precisely a square-pillar mandrel e.
The series of devices from the movable guide plate 23 and fixed guide plate 24 to the raising device 26 are covered with a cover 20'. The blanks A' raised in square parallelepipedic form while passing through are shipped out of the cover 20' perpendicular to the paper surface in FIG. 14 by an unloading conveyor 27 and delivered to the right side of FIG. 16. The blanks A are further delivered to the right side of FIG. 16' by the loading conveyor 28.
In this way, the flattened blanks A removed from the main magazine F are sent via the main conveyor 20, a pair of charging rollers 21, 21, a lifting conveyor 22, and a pair of discharging rollers 25, 25, to the raising device that constructs the blanks into parallelepipeds with square-shaped cross sections. The blanks A are further sent via an unloading conveyor 27 to a loading conveyor 28. By directly connecting the series of transport devices to the packing machine D up to the loading conveyor 28, the flattened blanks A taken one at a time from the main magazine F can be raised into parallelepipedic form with a square-shaped cross section and automatically supplied to the packing machine D.
The entrance of the packing machine D is equipped with the mandrel wheels E shown in FIGS. 2-4. One blank A' in parallelepipedic form with a square-shaped cross section delivered from the loading conveyor 28 is inserted into a mandrel e of a mandrel wheel E as shown in FIG. 16. The bottom of the blank A' is created during the time the mandrel e rotates in the direction of the arrow, as illustrated in FIG. 16. The carton with its formed bottom is taken off the mandrel e, delivered to the filling area H and filled with liquid contents, sealed at the top, and finally delivered from the unit.
As shown in the preferred embodiment, by furnishing two main magazines F and placing the series of devices described above for each main magazine F, two sets of mandrel wheels E shown in FIG. 4 with solid lines and chain lines can be systematically supplied with blanks A' in parallelepipedic form with square-shaped cross sections. By placing two sets of a pair of charging rollers 21, 21 of a lifting conveyor 22, of a pair of discharging rollers 25, 25, of a raising device 26, of an unloading conveyor 27, and of a loading conveyor 28, two rows, left and right, of mandrels e, e on one mandrel wheel E can be systematically supplied as shown in FIG. 2 with blanks A' raised in parallelepipedic form with square-shaped cross sections. Since the supply can continue one after another, efficient and continuous manufacture of product proceeds by forming the bottom, filling the liquid contents, and sealing the top.
The two main magazines F, F in the preferred embodiment both tilt approximately 18 degrees relative to the horizontal as shown in FIG. 4. The main conveyors 20, 20 also tilt approximately 18 degrees in a corresponding fashion. Moreover, the continuing pair of charging rollers 21, 21, the lifting conveyor 22, the pair of discharging rollers 25, 25, and the raising device 26 all tilt in accordance with the main conveyor 20. In addition, the unloading conveyor 27 for exporting the blanks A' which are raised in parallelepipedic form with a square-shaped cross section and the loading conveyor 28 further ahead also tilt approximately 18 degrees to the horizontal as shown in FIG. 16. This tilt matches the tilt of the mandrel e where the blanks A' are raised in parallelepipedic form with square-shaped cross sections and are inserted into the mandrels e. In this way, the raised blanks A' can be directly inserted into the mandrels e.
In order to automatically supply the plurality of blanks A after opening to the main magazine F tilted approximately 18 degrees, the robot 18 forks 18a, 18a should also be tilted approximately 18 degrees. In the preferred embodiment, the robot 18 rack 18f, as shown in FIG. 13 by the chain lines, is entirely tilted. The rack 18f on the platform is horizontal when the plurality of bare blanks A are removed from the platform 1. However, the rack 18f tilts later as shown by the chain lines in FIG. 18 and supplies to the main magazine F location. In order to tilt the rack 18f as shown in FIG. 13, for example, a cylinder 18h can be mounted to the main base 18g which is tilted along the guide rail 19 and the end of the rod can be connected to the rack 18f. By operating the cylinder 18h so that the cylinder 18h rod can pull in, the rack 18f can be tilted relative to the main base 18 g. By operating the cylinder 18h in reverse, the rack 18f can return to a horizontal orientation.
As illustrated in FIG. 12, pusher 29 is operated to push out packaging material which is then a shell after the plurality of blanks A are removed by the pair of forks 18a, 18a. The pusher 29 can advance to the chain-line position from the solid-line position in FIG. 12 according to cylinder 29a movement. The packaging material shells pushed out by the pusher can be disposed of with a suitable, unillustrated device.
According to the present invention, a package of a plurality of bundles of flattened blanks for packing containers A is cut and opened automatically on a platform. Only the contents which are a plurality of blanks A are automatically taken out and automatically supplied to the main magazine. Thus, the series of transporting operations are completely unmanned and quite efficient. Since the plurality of flattened blanks A can be stored in a stacked fashion at the main magazine, the horizontal width of the unit can be small compared to conventional devices that propped up the blanks.
According to the present invention, the flattened blanks A can be definitely raised into parallelepipedic form with a square-shaped cross section. In addition, the blanks A can be loaded smoothly into mandrels. Thus, packing machine D breakdowns due to mis-inserting mandrels becomes virtually nonexistent, and product manufacturing efficiency improves dramatically.
According to the present invention, vertical space use is maximized. Therefore, the transport device can be made smaller.
According to the present invention, blanks remaining in the main magazine can be automatically returned to the storage magazine or blanks of different size or type can be quickly exchanged between the main magazine and storage magazine when needed for use. The unmanned operations are greatly enhanced.
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 transport device for packaging container blanks includes a platform for positioning a package of a plurality of flattened packaging container blanks covered with packaging material disposed around the plurality of flattened packaging container blanks. A cutting device is provided for cutting the packaging material disposed around the plurality of flattened packaging container blanks to expose the flattened packaging container blanks for further processing. A main magazine is provided for stacking the plurality of bare blanks after removal of the packaging material. The main magazine supplies individual bare blanks, one at a time to a subsequent processing station. A robot includes a grasping member for grasping a predetermined number of bare blanks disposed on the platform and delivering the bare blanks to the main magazine. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a sewing machine, and more particularly relates to a pattern selecting device of a sewing machine, in which the operating dial may be rotated over a range of rotation angle of 360° so as to obtain much more varied stitch patterns from a limited number of pattern cams. Further in this invention, the minimum rotation angle of the operating dial is made considerably large to select one of the pattern cams, and, therefore, the associated pattern selecting cam may be made simplified to provide smaller push angles for operating cam followers. Thus, the machine operator may easily and smoothly operate the pattern selecting device without need of much operating force. Further in this invention, another simplified pattern selecting device has been suggested to additionally obtain further modified stitch patterns.
In the conventional zigzag sewing machines having many pattern cams to be selected by the operating dial of onerotation type, the minimum rotation angle of the operating dial for selecting a pattern cam is considerably small. Therefore, the pattern selecting cam operated in association with the operating dial is very complex, and requires relatively large push angles for operating the cam followers. As a result, the machine operator has to exert a considerable manual force to operate the operating dial at each time in order to select so many pattern cams. Further, according to the prior art, the number of varied stitch patterns is very limited.
SUMMARY OF THE INVENTION
The invention has been provided to eliminate the defects and disadvantages of the prior art. It is a primary object of the invention to provide a sewing machine which produces many varied stitch patterns by utilizing a limited number of pattern cams.
It is another object of the invention to provide a sewing machine which is simple in structure, and is easily and smoothly operated.
It is still another object of the invention to provide a sewing machine having two separate pattern selecting devices to additionally provide modified stitch patterns.
These and other objects are achieved by provision a sewing machine with a first pattern selecting means including a pattern selecting cam and a first follower connected therewith, a feed setting cam and a second follower associated therewith and a feed selecting cam operatively connected with a third follower operative to selectively engage or disengage the feed control cams associated with the fabric feeding device to control the movement thereof. A second pattern selecting means is provided in the sewing machine of the foregoing type, operatively connected to the third follower which engages or disengages one of the feed control cams.
By this provision the pattern selecting device of the sewing machine may be easily and smoothly operated by the machine operator without applying a considerably large operating force.
Many other features and advantages of the invention will be apparent from the following description of the preferred embodiment in reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the mechanism of the invention;
FIG. 2 is a front elevational view of the invention, with a portion removed; and
FIG. 3 is an exploded view of a part of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In reference to FIGS. 1 and 2, the reference numeral 2 denotes a main shaft rotatably mounted on a machine housing 1A which is partly shown. A cam block 4 is rotatably mounted on a fixed transverse shaft 3. The cam block 4 is composed of a worm 6, needle control pattern cams 7 and fabric feed control cams 8. The worm 6 is in engagement with a gear 5 secured to the main shaft 2 to rotate the cam block 4 at a reduced speed. A transverse shaft 10 is rotatably supported on the machine housing 1A in parallel with the transverse shaft 3, and has an operating dial 11 secured to one end thereof which is protruded out of the machine housing on the front side thereof. Cams 13, 17, 18 are secured to the transverse shaft 10. The cam 13 is to select the pattern cams 7, the cam 17 is a feed control changeover cam and the cam 18 is to set the fabric feed in a constant condition with respect to a selected pattern. The cam 13 is formed with a side cam face and a cylindrical cam face 15 as shown.
A needle bar 20 with a needle is mounted on a needle bar support 21 for vertical reciprocating movement. The needle bar support 21 is turnably mounted to the machine housing 1 by means of a pivot 19. A transmission rod 23 is at one end thereof connected to the needle bar support 21 by means of a pivot 22, and has a follower 23a formed at the other end thereof for engaging with one of the pattern cams 7. A follower pin 25 is in engagement with the pattern selecting cam 13. The follower pin 25 is secured to the transmission rod 23 by means of a base plate 24 as shown in FIG. 2, and is normally pressed against the side cam face 14 of the pattern selecting cam 13 by means of a spring (though it is not shown), and is also pressed against the cylindrical cam face 15 of the pattern selecting cam 13 by means of a spring (not shown) which biases the needle bar support 21 in the rightward direction in FIG. 1.
In reference to FIGS. 1 and 3, a changeover arm 30 is at the base thereof turnably mounted on the transverse shaft 3. The changeover arm 30 has a follower pin 31 provided at the free end thereof, which is in contact with the feed control changeover cam 17 at the underside thereof by means of a tension spring 37 which is operatively connected to the changeover arm 30. A transmission rod 34 is at one end thereof turnably mounted on a pivot 32 of the changeover arm 30, and is at the other end 35 thereof connected to the upper end of a vertical rod 44 by means of an adjustable screw 45. The transmission rod 34 is normally biased in the counterclockwise direction by means of the tension spring 37. A follower 36 is turnably mounted on a transverse pin 38 at one end part of the transmission rod 34 and is shiftable therealong, and thus engages with any of the feed control cams 8 when the changeover arm 30 is turned in the counterclockwise direction and the pivot 32 comes to a lower position. The follower 36 is biased in one direction by a spring 39 as shown in FIG. 3.
A U-shape operating member 93 is turnably mounted on the transverse shaft 3. The operating member 93 is at one end thereof formed with a cam 94 which is arranged opposite to a projection 34-1 of the transmission rod 34. Adjacent to the cam 94, the operating member 93 is formed with an arcuated extension 94A providing two offset faces 95, 97 which are connected by an inclined part 96. These offset faces 95, 97 are each engaged by one side of a projection 36-2 of the follower 36 which is slidable on the pivot 38 due to the action of the spring 39 in dependence upon the operated positions (S 1 -S 2 ) of the operating member 93, so that the follower 36 with an engaging projection 36-1 may be displaced to the positions opposite to the feed control cams 8-1, 8-2 respectively.
As generally known, a feed adjuster 41 with an arm 41A is turnably mounted on a pin 42 which is arranged in parallel with the main shaft 2 of the sewing machine. The free end of the arm 41A is pivotally connected to the lower end of the vertical transmission rod 44 by means of a pin 43 which is biased in the clockwise direction by a tension spring 46 in such a manner that the feed adjuster 41 is inclined to produce a maximum fabric feeding amount in the forward direction, as shown in FIG. 1. A feed adjuster operating member 50 with an arm 53 is turnably mounted on the pivot pin 42 coaxially with the feed adjuster 41, and is biased in the same direction with the feed adjuster 41 by a comparatively weak spring (not shown). The feed adjuster operating member 50 is turned in the counterclockwise direction (in FIG. 1) until an engaging element 54 of the member 50 is pressed against the feed adjuster 41. As the operating member 50 is further turned in the same direction, the feed adjuster 41 is together turned in the same direction. As a result, in dependence upon the angular position of the feed adjuster 41, the fabric feeding amount is desirably determined in a condition reduced from the maximum feeding amount in the forward or backward feeding direction. On the other hand, if the operating member 50 is not activated at the free end of the arm 53, and is biased in the clockwise direction until a part 51 of the operating member 50 is stopped by a stopper (not shown) which may be provided at a desirable place of the machine housing 1, then the feed adjuster 41 can be freely turned irrespectively of the engaging element 54 of the operating member 50 by the vertical rod 44 against the action of the tension spring 46.
A vertical rod 55 is at the upper end thereof connected to one end of a transmission rod 60, which is at the intermediate part thereof turnably mounted on the machine housing by a pivot 62 and is at the other end thereof formed with a follower (not shown) which is in engagement with the feed control cam 8-1. The vertical rod 55 is formed with a vertical slot 55A at the lower end part thereof. The operating member 50 is connected to the vertical rod 55 by means of a pin 53A which is provided on the free end of the arm 53 and inserted into the vertical slot of the vertical rod 55.
The feed control changeover cam 17 is provided with a cam face 171 of a smaller diameter which maintains, substantially during the first one rotation thereof, the changeover arm 30 in an inoperative angular position, in which the pivot 32 supporting the transmission rod 34 and the follower 36 is in a raised position. The feed control changeover cam 17 is also provided with a cam face 172 of a larger diameter which maintains, in the second rotation thereof, the changeover arm 30 in an operative angular position in which the pivot 32 is in a lowered position.
On the other hand, the feed setting cam 18 is provided with a cam face 181 of a larger diameter which maintains, substantially during the first one rotation thereof, the feed adjuster 41 in a set position, in accordance with a selected pattern, through the transmission rod 60, the vertical rod 55 and the operating member 50. The feed setting cam 18 is also provided with a cam face of a smaller diameter (not shown) which maintains, in the second rotation thereof, the operating member 50 in a maximum angular position in the clockwise direction spaced from the feed adjuster (41).
A pattern indication panel 80 is provided on the front side of the sewing machine. Patterns 81, 82, 83 . . . are laterally arranged on the panel, as shown in FIG. 2, and are successively selected by turning the operating dial 11. A pattern pointer 85 is provided on a cord 84 which extends, as shown, from a drum 16 mounted on the transverse operating shaft 10 to one end of a tension spring 86 the other end of which is anchored to a part of the machine housing 1A, so that the pattern pointer 85 may be displaced along the laterally arranged patterns 81, 82, 83 . . . as the operating dial 11 is rotated. The panel 80 also indicates a group of patterns 81-1, 82-1, 83-1 . . . which are selected by turning the operating dial 11, and indexed by an arrow mark, and indicates another group of patterns 81-1A, 82-1A, 83-1A . . . indexed by an arrow mark S 2 .
Adjacent to the pattern indicating panel 80, there is provided a pattern changeover operating dial 90 on the front side of the sewing machine. The operating dial 90 is operatively connected to the U-shape member 93 through a connecting rod 92, and is provided on the face thereof with an arrow mark 91. The arrow mark 91 points the indexing mark S 1 and S 2 as the operating dial 90 is turned between two predetermined angular positions thereof. At the same time, the U-shape member 93 is angularly displaced between the two predetermined positions indicated by S 1 and S 2 as shown in FIG. 3.
With the foregoing structure of the invention, if the operating dial 11 is rotated substantially in the range of first one rotation, the follower pin 31 of the changeover arm 30 remains in engagement with the cam face 171 of a smaller diameter of the feed control changeover cam 17. Therefore, the pivot 32 of the changeover arm 30 supporting the transmission rod 34 and the follower 36 is held in the raised angular position as shown by the solid line in FIG. 3. The follower 36 is, therefore, positioned spaced from the feed control cams 8, and the transmission rod 34 gives no influence to the feed adjuster 41. On the other hand, since the follower (not shown) of the transmission rod 60 remains in engagement with the cam face 181 of larger diameter of the feed setting cam 18 providing various cam lifts in accordance to the patterns to be stitched, the feed adjuster 41, which is turnable around the pivot 62, is set to effect a predetermined constant feeding amount in accordance with a selected pattern by one of the pattern cams 7 which is, as afore-mentioned, selected through the end follower 23A of the transmission rod 23 which is operated in association with the pattern selecting cam 13. By the way, the cylinder cam face 15 of the pattern selecting cam 13 is to disengage the follower 23A of the transmission rod 23 from one of the pattern cams 7 prior to the pattern cam selecting operation, and the side cam face 14 is to displace the follower 23A along the pattern cams 7.
If the operating dial 11 is further rotated and comes into a range of second rotation, the follower (not shown) of the transmission rod 60 comes to engage the cam face of smaller diameter of the feed setting cam 18. Therefore the tramsmission rod 60 gives no influence to the feed adjuster 41. On the other hand, the follower pin 31 of the changeover arm 30 comes to engage the cam face 172 of larger diameter of the feed changeover cam 17. The changeover arm 30 is therefore turned in the counterclockwise direction and displaces the pivot 32 to the lowered position as indicated by the broken line in FIG. 3. The follower 36 is, therefore, brought into engagement with one of the feed control cams 8-1, 8-2 for controlling the feed adjuster 41 through the transmission rod 34 and the vertical rod 44. Simultaneously, one of the pattern cams 7 is selected by the pattern selecting cam 13 and the transmission rod 23 with the end follower 23A which is operated in association with the pattern selecting cam 13. Thus a pattern is produced which is accompanied by a varied feed control as shown in the groups of patterns 81-1, 82-1, 83-1 . . . , and 81-1A, 82-1A, 83-1A . . . shown in FIG. 2.
When the operating dial 90 is turned to the position as shown in FIG. 2 in which the arrow mark 91 points the indexing mark S 2 on the pattern indication panel 80, the U-shape member 93 is held, through the connecting rod 92, in the angular position indicated by the solid line S 2 in FIG. 3. In this set position of the U-shape member 93, the follower 36 is at one face thereof pressed against the offset side 95 of the arcuated extension 94A of the member 93 by the compression spring 39. In this position, the follower engages the feed control cam 8-2 to produce, in cooperation with a specific one of the pattern cams 7, one of the patterns 81-1A, 82-1A, 83-1A . . . which are of a modified feed control. If the operating dial 90 is operated to set the arrow mark 91 to point the indexing mark S 1 on the pattern indication panel 80, the U-shape member 93 is turned from the angular position indicated by the solid line S 2 in FIG. 3 to the angular position indicated by the broken line S 1 . In the meantime, the arcuated extension 94A is turned in the counterclockwise direction. As a result, the follower 36 is, due to the action of the compression spring 39, displaced on the inclined part 96 until one side of the follower 36 is pressed against the offset face 97 of the extension 94A while the cam 94 of the U-shape member 93 engages the downward projection 34-1 of the transmission rod 34 to disengage the follower 36 from the feed control cam 8-2. In this position, the follower 36 engages the feed control cam 8-1 to produce, in cooperation with the same one of the pattern cams 7 as to selection of the feed control cam 8-2, the corresponding one of the patterns 81-1, 82-1, 83-1, . . . which are of a further modified feed control. | A sewing machine comprises a housing, a needle bar adapted for reciprocating movement by a main shaft rotatably mounted in the housing and a fabric feeding device. A pattern control device is provided in the sewing machine which includes a number of needle bar control cams and fabric control cams operated by the main shaft. Two manually operated pattern selecting arrangements are mounted in the housing of the sewing machine including cams and cam followers and which are operatively connected to the fabric feeding device to control the movement thereof. In accordance with these pattern selecting arrangements the minimum rotation angle of the operating dial is made considerably large for selecting one of the pattern cams to thereby provide relatively small push angles for operating cam followers. | 3 |
TECHNICAL FIELD
The present invention relates to a drawing method, device and program for drawing a desired circuit pattern onto a sample, such as a mask substrate, by use of an electron beam. More particularly, the present invention relates to a technique for evaluating, at a high speed and with a high accuracy, an electron beam irradiation amount optimal to reduce size variation of the circuit pattern caused by a proximity effect.
BACKGROUND ART
With recent further integration of semiconductor integrated circuits, such as LSIs, circuit sizes and circuit line widths required of semiconductor devices have been miniaturized year by year. In order to form a circuit pattern of desired dimensions and line widths, a high-accuracy original pattern (reticle or mask) is required. As an example of a device for creating such an original pattern, there has heretofore been known a drawing device which employs a so-called lithography technique for drawing an original pattern, for example, by irradiating an electron beam onto a sample, such as a metal substrate (e.g., mask substrate), having a resist film applied thereto.
When an electron beam is irradiated onto a sample, such as a mask substrate, there would appear an influence called “proximity effect” that varies a size of a resist pattern formed on the sample. More specifically, the proximity effect is a phenomenon where the electron beam is irradiated even onto unintended portions of the sample due to front-scattered electron and backscattered electron produced by the irradiated electron colliding against the resist and metal substrate with the result that line widths etc. of the resist pattern are caused to vary depending mainly on a density of a circuit pattern. The conventionally-known drawing device would present the inconvenience that an adverse influence of the proximity effect becomes more noticeable with even further miniaturization of the circuit.
To address the foregoing inconvenience, there has been proposed an irradiation amount correction method which determines, in accordance with a density of a circuit pattern, an optimal electron beam irradiation amount of an electron beam (also referred to as “optimal irradiation amount” or “optimal dose amount”) to reduce the line width of a resist pattern etc. caused by a proximity effect. More specifically, according to the irradiation amount correction method, control is performed to reduce a time length of the electron beam irradiation in a region where the circuit pattern is dense because the substantive electron beam irradiation amount would become excessive in such a dense-circuit-pattern region, while control is performed to increase the time length of the electron beam irradiation in a region where the circuit pattern is coarse because the substantive electron beam irradiation amount would become insufficient or short in such a coarse-circuit-pattern region. Such arrangements can reduce line width variation of the resist pattern caused by the proximity effect. Among examples of the method for determining an optimal electron beam irradiation amount are ones disclosed in Non-patent Literature 1 and Patent Literature 1 identified below.
PRIOR ART LITERATURE
Non-Patent Literature
Non-patent Literature 1: M. Parikh, J. Appl. Phys 50 (1979), pp. 4371-4383
Patent Literature
Patent Literature 1: Japanese Patent Application Laid-open Publication No. HEI-9-289164
According to the method disclosed in Non-patent Literature 1, relationship between the electron beam irradiation amounts (dose amounts) and amounts of exposure at predetermined positions (hereinafter referred to as “evaluation points”) of a circuit pattern formed on a sample is expressed by a determinant (determinant of matrix) representation shown in Mathematical Expression 1 below, and then a reverse determinant of the determinant is evaluated to thereby evaluate or calculate an optimal electron beam irradiation amount at each of the above-mentioned positions; such a method is called “self-alignment method”, “determinant method” or the like. The determinant of matrix shown in Mathematical Expression 1 (where FD=E) represents, in an equation, a target condition that “stored energy is equal at all of the evaluation points” by taking into account respective influences from a plurality of rectangles regions obtained by dividing or segmenting various figures, constituting the circuit pattern formed on the sample, on a per-beam-irradiation-unit basis) and using mathematical expressions of energy scattering as shown in Mathematical Expression 2 and Mathematical Expression 3 below.
[
F
1
,
1
F
2
,
1
…
F
m
,
1
F
1
,
2
F
2
,
2
…
…
…
…
…
F
1
,
n
…
…
F
m
,
n
]
[
D
1
D
2
…
D
m
]
=
E
threashold
[
1
1
…
1
]
[
Mathematical
Expression
1
]
Note, however, that Mathematical Expression 1 is an equation assuming that there are n evaluation points and m rectangles. D i represents a dose amount of the rectangle i, and E threashold represents a target value of stored energy at each of the evaluation points (which is a common value or constant).
Here, elements (≡=1, . . . m, j=1, . . . n) F ij of the above correlation function matrix are calculated, for example, in accordance with Mathematical Expression 2 and Mathematical Expression 3 below.
Fij=∫psf ( {right arrow over (p)}−{right arrow over (p)} j ) dp [Mathematical Expression 2]
The elements F ij of the above correlation function matrix indicate magnitudes of scattering actions of energy from the rectangles i at the evaluation points j.
psf
(
r
)
=
C
1
+
η
(
1
α
2
exp
(
-
r
2
α
2
)
+
η
β
2
exp
(
-
r
2
β
2
)
)
[
Mathematical
Expression
3
]
Mathematical Expression 3 is a Double Gaussian approximation equation.
In Mathematical Expression 3 above, r represents a distance from an incident point, C represents a constant, η represents a ratio between an amount of exposure of a resist by front scattering of the electron beam and an amount of exposure of the resist by back scattering of the electron beam (proximity effect correction coefficient), and α and β are each a predetermined value representing extent of front scattering or back scattering (front scattering diameter or back scattering diameter) that is determined depending on an acceleration voltage. The values α and β are, for example, (27 nm and 2 μm) when the acceleration voltage is 20 Kev, (30 nm and 10 μm) when the acceleration voltage is 50 Kev, and (10 nm and 32 μm) when the acceleration voltage is 100 Kev.
Further, in Mathematical Expression 3 above, the PSF function represents an ultimate energy distribution measured when the electron beam has been irradiated onto a given point of the sample, and in many cases, the PSF function approximates, for example, front scattering and back scattering, in Gaussian distributions. In such cases, the PSF function can be represented by a Double Gaussian approximation equation like Mathematical Expression 3 above.
The advantages of the aforementioned self-alignment method are that an accurate optimal irradiation amount can be obtained if the rectangle, for which an irradiation amount is to be set, is made sufficiently small in size, and that it can be evaluated by using a Gaussian elimination as a solution to a simultaneous linear equation. On the other hand, the aforementioned self-alignment method would present the following disadvantage. Namely, because the quantity of necessary arithmetic operations or calculations is proportional to the cube of the number of the (segmented) rectangles, a minute circuit pattern, such as an LSI pattern, would be segmented into a greater number of rectangles as the size of the circuit pattern is reduced, and thus, an enormous calculation time (e.g., several hundreds hours to several thousands hours per LSI chip) would be required.
Further, the method disclosed in Patent Literature 1, on the other hand, is a method where a sample is segmented into a plurality of meshes on a per-chip basis and an optimal irradiation amount is calculated or evaluated collectively for each of the meshes rather than individually for each of the rectangles (this method is called “representative figure method”). To explain briefly a sequence of operations of the method, a representative figure (i.e., one of divided or segmented rectangles) is obtained, as a first step, for each of the meshes on the basis of parts of figures (circuit pattern) included in the mesh. Then, as a second step, an initial value of an approximate optimal irradiation amount D k (k=0: k represents a number of repetitions) of each of the meshes is set on the basis of Mathematical Expression 4 below.
D
k
=
0
=
1
/
2
+
η
1
/
2
+
η
∫
g
(
x
-
x
′
)
ⅆ
x
′
[
Mathematical
Expression
4
]
Here, η represents a ratio between an amount of direct exposure of a resist by an electron beam and an amount of exposure of the resist by a contribution of back scattering (proximity effect correction coefficient), and g(x) is, for example, a Gaussian function. Although various proposals have heretofore been made for a specific expression of the Gaussian function g(x) in view of a material of a substrate and approximation used, an explanation of such proposals is omitted here.
As a third step, a correction amount d k+1 is calculated in accordance with Mathematical Expression 5 below on the basis of the above-mentioned approximate optimal irradiation amount D k .
d k + 1 = - e k ( 1 / 2 + η ) 1 / 2 + η ∫ g ( x - x ′ ) ⅆ x ′ [ Mathematical Expression 5 ]
Here,
e
k
=
C
-
E
k
[
Mathematical
Expression
6
]
E
k
=
K
[
D
k
2
+
η
∫
D
k
g
(
x
-
x
′
)
ⅆ
x
]
[
Mathematical
Expression
7
]
E k in Mathematical Expression 7 above represents stored energy in each of the meshes when the assigned state of the irradiation amount is the above-mentioned approximate optimal irradiation amount D k . Further, e k in Mathematical Expression 6 above represents an error between a predetermined target energy value C (constant) in each of the meshes and the stored energy E k in the mesh calculated by Mathematical Expression 7 above.
As a fourth step, in order to correct the error e k between the target value C and the stored energy E k , the correction amount d k+1 calculated by Mathematical Expression 5 above is added to the approximate optimal irradiation amount D k calculated by Mathematical Expression 4, so that a new approximate optimal irradiation amount D k+1 (=D k + k+1 ) is re-set. Then, until the re-set, new approximate optimal irradiation amount D k+1 converges, until the error e k reaches within a predetermined value, or until the number of repetitions (k) reaches a predetermined number, the aforementioned third step and fourth steps are performed repeatedly, to thereby evaluate an optimal irradiation amount for each of the plurality of meshes (i.e., optimal irradiation amount common to rectangles included in the mesh).
The advantage of such a representative figure method is that an optimal irradiation amount can be obtained per mesh, i.e. an optimal irradiation amount common to one or more rectangles included in the mesh, can be obtained in accordance with only an influence of back scattering with an influence of front scattering ignored and thus necessary calculations can be performed at a high speed. On the other hand, the disadvantage of the representative figure method is that, with an influence of front scattering ignored, an optimal irradiation amount cannot be evaluated in a case where there is a need to draw, on a sample, a more miniaturized circuit pattern for which an influence of front scattering ignored cannot be ignored.
Namely, in the case where the proximity effect is corrected by the conventionally-know irradiation amount correction method, it is difficult to use the self-alignment method with highly-integrated semiconductor devices, such as LSI patterns, due to a time constraint because the aforementioned self-alignment method would require an even more calculation time to cope with presently-demanded miniaturization of circuit patterns. The aforementioned representative figure method, on the other hand, would present the problem that when used to draw, on a sample, a more miniaturized circuit pattern for which an influence of front scattering ignored cannot be ignored, it is unable to achieve a sufficient correction accuracy. Further, the aforementioned conventionally-known methods would also present the inconvenience that they cannot be used for so-called Gray Scale PEC “Proximity Effect Correction” designed to form a pattern of a three-dimensional shape after development of a resist.
SUMMARY OF INVENTION
In view of the foregoing, it is an object to provide an improved drawing method, device and program which can evaluate, with a high accuracy and at a high processing or calculating speed, an optimal electron beam irradiation amount in accordance with a conjugate gradient method taking into consideration not only an influence of back scattering but also an influence of front scattering, as well as a computer-readable storage medium containing such a program.
In order to accomplish the aforementioned object, the present invention provides an improved drawing method for evaluating an optimal irradiation amount of an electron beam for each position within a desired pattern to be drawn onto a sample and drawing the desired pattern onto the sample by irradiating the electron beam in accordance with the evaluated optimal irradiation amount, which comprises: a step of segmenting the pattern into a plurality of regions each having a predetermined size; a step of evaluating, for each of the segmented regions, stored energy that is a substantive irradiation amount of the electron beam; and a step of evaluating the optimal irradiation amount on the basis of a conjugate gradient method using the stored energy evaluated for each of the regions.
In a preferred embodiment of the present invention, the step of evaluating the optimal irradiation amount on the basis of a conjugate gradient method uses the evaluated stored energy, instead of calculating a determinant Ap k , in the following repeated calculation procedure based on the conjugate gradient method for finding a solution to a simultaneous linear equation of Ax=b with a matrix A as a coefficient:
α k =( r k ·r k )/( p k ·Ap k )
x k+1 =x k +α k p k
r k+1 =r k −α k Ap k
β k =( r k+1 ·r k+1 )/( r k ·r k )
p k+1 =r k +β k p k
k=k+ 1.
Further, the step of evaluating the stored energy includes a step of calculating stored energy caused by front scattering of the electron beam, and a step of calculating stored energy caused by back scattering of the electron beam.
According to the present invention, stored energy that is a substantive irradiation amount of the electron beam is evaluated for each of the segmented regions, and an irradiation amount optimal to minimize or reduce size variation of the circuit pattern caused by the proximity effect is evaluated in accordance with the conjugate gradient method using the stored energy evaluated for each of the regions. At that time, in the repeated calculation procedure based on the conjugate gradient method, designed to find a solution to the simultaneous linear equation of Ax=b with the matrix A as a coefficient, and including a calculation of the determinant Tp k , calculations are performed using the evaluated stored energy, instead of calculating the determinant Ap k . Also, in calculating the stored energy, stored energy by the front scattering of the electron beam and stored energy by the rear scattering of the electron beam are calculated separately from each other. By evaluating an optimal irradiation amount of the electron beam with the repeated calculation procedure based on the conjugate gradient by managing the value of the determinant Ap k with the stored energy as above, the present invention can eliminate the need for taking the trouble of managing the huge matrix A, comprising a multiplicity of elements corresponding to miniaturization of the circuit pattern, and calculating the determinant Ap k as done in the conventionally-known method, and thus, the present invention can evaluate an optimal irradiation amount of the electron beam with a high accuracy at a high processing speed, i.e. at a high calculating speed.
The present invention may be constructed and implemented not only as the method invention discussed above but also as an apparatus or device invention. Also, the present invention may be arranged and implemented as a software program for execution by a processor, such as a computer or DSP, as well as a storage medium storing such a software program.
Because stored energy that is a substantive irradiation amount of the electron beam is evaluated for each of the segmented regions and an irradiation amount optimal to minimize or reduce size variation of the circuit pattern caused by a proximity effect is evaluated with the conjugate gradient method using the stored energy evaluated for each of the regions, the present invention achieves the advantageous benefit that it can evaluate an optimal irradiation amount of the electron beam with a high accuracy at a high processing speed, i.e. at a high calculating speed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 a conceptual diagram showing an example of a general construction of a drawing device to which is applied a drawing method of the present invention;
FIG. 2 is a flow chart showing an example of an optimal irradiation amount calculation process performed by a conjugate-gradient-method-based calculation section for calculating an optimal irradiation amount of an electron beam for each of a plurality of rectangles;
FIG. 3 is a flow chart showing an example of a stored energy calculation process performed by a stored energy calculation section for calculating stored energy at each of a plurality of evaluation points;
FIG. 4 is a flow chart showing an example of a front-scattering-contributed stored energy calculation process performed by a front scattering contribution calculation section
FIG. 5 is a flow chart showing an example of a back-scattering-contributed stored energy calculation process performed by a back scattering contribution calculation section;
FIG. 6 is a conceptual diagram showing an example of a chip range for which an optimal irradiation amount is to be calculated on the basis of proximity effect correction;
FIG. 7 is a conceptual diagram explanatory of a sequence of operations for calculating a back scattering intensity the bilinear interpolation; and
FIG. 8 is a flow chart showing an example of an optimal irradiation amount calculation process with an influence of the back scattering taken into consideration
DESCRIPTION OF EMBODIMENTS
The following paragraphs describe in detail an embodiment of the present invention with reference to the accompanying drawings.
FIG. 1 a conceptual diagram showing an example of a general or overall construction of an embodiment of a drawing device to which is applied a drawing method of the present invention. The drawing device shown here is, for example, in the form of an electron-beam drawing device. Reference numeral 10 represents a sample chamber, 11 represents a target (or sample), 12 represents a sample table, 20 an electro-optic lens tube, 21 represents an electron gun, 20 a to 22 e represent various lens systems, 23 to 26 represent various polarization systems, 27 a represents a blanking plate, and 27 b and 27 c represent beam-forming aperture masks. Further, reference numeral 31 represents a sample table driving circuit section 31 , 32 represents a laser length measuring system, 33 represents a polarization control circuit section, 34 represents a blanking control circuit section, 35 represents a variable shaped beam size control circuit section 35 , 36 represents a buffer memory and control circuit section, 37 represents a control and computing section 37 , 38 represents a conjugate-gradient-method-based computing section, and 42 a CAD system.
Briefly speaking, the electron-beam drawing device shown in FIG. 1 behaves as follows. An electron beam irradiated from the electron gun 21 is turned on and off by the blanking polariscope 23 . The electron-beam drawing device is capable of changing an irradiation amount of an electron beam in accordance with a position of irradiation onto the target 11 placed on the sample table 12 by adjusting a time length of the electron beam irradiation onto the target 11 . The electron beam passed through the blanking plate 27 is formed into a rectangular beam and variable in size by the beam forming polariscope 24 and beam-forming aperture masks 27 b and 27 c . The electron beam having been thus formed into a rectangular shape as noted above is polarized and scanned over the target 11 by means of the scanning polariscopes 25 and 26 , so that a desired pattern is drawn onto the target 11 by the beam scanning. Namely, a desired pattern to be drawn on the target 11 is segmented into a plurality of combinations of rectangles, and the electron beam is irradiated for each of the segmented rectangles.
An optimal irradiation amount of the electron beam (i.e., irradiation time length of the electron beam) for each of the rectangles is calculated by the conjugate-gradient-method-based computing section 38 on the basis of electron beam exposing original data generated by the CAD system 42 . The conjugate-gradient-method-based computing section 38 , which is for example in the form of a computer comprising a CPU, ROM, RAM, etc., calculates an optimal irradiation amount of the electron beam for each of the rectangles by correcting a proximity effect. The conjugate-gradient-method-based computing section 38 solves a determinant (i.e., determinant of matrix) (for convenience, this determinant is referred to as “Ax=b”) as shown in Mathematical Expression 1 above by use of the conjugate gradient method. Using the conjugate gradient method, the determinant Ax=b can be solved by repetition of multiplication between a correlation function matrix (A) and a vector (x). Thus, the following paragraphs describe a sequence of operations (or procedure) for solving the determinant (Ax=b) by the conjugate gradient method.
First, assume that r k =b−Ax k , p k =r k (k=0) are set as initial values. p k and r k represent intermediate variable vectors, and k represents the number of repeated calculations. Then, arithmetic operations or calculations of Mathematical Expressions 8 to 13 are performed repeatedly until a predetermined repetition condition is satisfied, to thereby solve the determinant Ax=b to evaluate the value x. Note that each parenthesized dot (·) in the following mathematical expressions represent an inner product.
α k =( r k ·r k )/( p k ·Ap k ) [Mathematical Expression 8]
x k+1 =x k +α k p k [Mathematical Expression 9]
r k+1 =r k −α k Ap k [Mathematical Expression 10]
β k =( r k+1 ·r k+1 )/( r k ·r k ) [Mathematical Expression 11]
p k+1 =r k +β k p k [Mathematical Expression 12]
k=k+ 1 [Mathematical Expression 13]
“A” of AP k appearing in the aforementioned sequence of arithmetic operations represents a matrix of a m×n size, and “p k ” represents a vector of a magnitude of m (see Mathematical Expression 1 above). Therefore, m×m multiplications have to be performed in order to evaluate the determinant AP k in an ordinary manner, and such calculations have to be performed per repeated calculation. Thus, it can be understood that reducing the quantity of calculations in the instant processing is very important to reduce or shorten a necessary processing time. Further, because the number of elements in “A” amounts to the square of the number of the rectangles, a great calculating time would be required if the aforementioned calculating sequence is used as-is.
Thus, in order to solve the determinant (Ax=b) at a high speed, the conjugate-gradient-method-based computing section 38 in the instant embodiment includes a stored energy computing section 39 . The conjugate-gradient-method-based computing section 38 manages the value of the Ap k with one stored energy per rectangular element (having one energy evaluation point as will be later described), paying attention to the fact that Ap k appearing in the aforementioned sequence of operations (or procedure) is equal to stored energy at each energy evaluation point (hereinafter referred to also as “evaluation point”) when a dose amount in each of the rectangular elements is “p k ”. Namely, because the matrix “A” represents behavior of the system, “determinant Ax=b” means that the stored energy at each evaluation point when the dose amount of each of the rectangles is “x” has reached “b”. Therefore, the stored energy computing section 39 only has to calculate stored energy at each of the evaluation points and does not have to take the trouble of managing the huge matrix A, comprising a multiplicity of elements that increases or decreases in proportion to the number of the evaluation points and the number of the rectangles, to calculate the value Ap k .
Further, the stored energy computing section 39 includes a front scattering contribution calculation section 40 and a back scattering contribution computing section 41 to separately calculate stored energy contributed or caused by front scattering and stored energy contributed or caused by back scattering, to thereby calculate stored energy at each of the evaluation points. In this way, the instant embodiment of the invention can perform at a high speed the calculation of the optimal irradiation amount of an electron beam for each of the rectangles using the conjugate gradient method. A specific sequence of calculating operations (or calculating procedure) will be detailed later.
The following paragraphs describe a sequence of operations (or procedure) for calculating an optimal irradiation amount of an electron beam for each of the rectangles, with reference to FIG. 6 showing an example of a chip range for which an optimal irradiation amount (optimal dose amount) is to be calculated on the basis of proximity effect correction. FIG. 2 is a flow chart showing an example of an optimal irradiation amount calculation process performed by the conjugate-gradient-method-based calculation section 38 of FIG. 1 for calculating an optimal irradiation amount of an electron beam (i.e., optimal dose amount) for each of the rectangles.
At step S 1 , each of a plurality of figures (i.e., figures or shapes constituting a circuit pattern) Z 1 to Z 7 identified on the basis of electron beam exposing original data acquired from the CAD system 42 is appropriately segmented into a plurality of rectangles (or regions). For example, each of the figures Z 1 to Z 7 is segmented into a plurality of rectangles having a size of about 1/10 of a back scattering diameter. At that time, if the figure has an original shape other than a rectangular shape like the figures Z 1 , Z 3 , Z 4 and Z 5 shown in FIG. 6 , the figure is segmented into a combination of a plurality of rectangles of the aforementioned size. In the illustrated example, the figure Z 1 is segmented into three rectangles, the figure Z 3 into two rectangles, the figure Z 4 into four rectangles, and the figure Z 5 into two rectangles. In this manner, the figures Z 1 to Z 7 are each segmented into one or more rectangles different in size. Because such division of the figures Z 1 to Z 7 into one or more rectangles may be performed using any one of the conventionally-known methods, a detailed description of the segmentation of the figures is omitted here.
At next step S 2 , one energy evaluation point is determined for each of the segmented rectangles. In the instant embodiment, the middle position of one side of the longest outer peripheral portion of each of the rectangles is set as the energy evaluation point (indicated by a black circle in FIG. 6 ) in accordance with an ordinary PEC method, as shown in FIG. 6 . Such a PEC method employed in the instant embodiment is different from the conventionally-known self-alignment method where the middle position of each of the sides of each of the rectangles is set as the energy evaluation point. Note that, if the Gray Scale PEC method is employed, the center position of each of the rectangles may be set as the energy evaluation point.
At next step S 3 , initial value “0” is set as a (initial) dose amount x 0 of each of the rectangles and suitable target energy values are set as p 0 and r 0 (=b−A x 0 ), as an initial process for solving the determinant Ax=b as shown in Mathematical Expression 1 above. Here, b represents a m-dimensional vector. p k and r k represent intermediate variable vectors, and k represents the number of repeated calculations, as noted above. If the ordinary PEC method is employed, target energy values of the outer peripheral portions of the figures Z 1 to Z 7 to which the individual rectangles belong to are set as the target energy values. But, if the Gray Scale PEC is employed, target stored energy values the figures Z 1 to Z 7 to which the individual rectangles belong to (or layers including the figures Z 1 to Z 7 ) are set as the target energy values.
At step S 4 , Ap k appearing in the sequence of operations for solving the determinant (Ax=b) by the conjugate gradient method (see Mathematical Expression 8) is calculated by the stored energy computing section 39 . In order to calculate the Ap k value, the stored energy computing section 39 only has to calculate stored energy g k at the evaluation point, as noted above. The stored energy q k is energy (distribution) which a resist has obtained as a result of collision of electrons, and it can be calculated by an integral calculation (convolution) between a rectangle to be drawn and a PSF function.
Now, with reference to FIG. 3 , a description will be given about a sequence of operations (or procedure) for calculating the stored energy q k at each of the evaluation points. FIG. 3 is a flow chart showing an example sequence of operations (procedure) performed by the stored energy computing section 39 for calculating the stored energy q k at each of the evaluation points.
At step S 21 , the stored energy computing section 39 performs a “process for calculating stored energy contributed by front scattering”. At next step S 22 , the stored energy computing section 39 performs a “process for calculating stored energy contributed by back scattering”. At following step S 23 , the stored energy contributed or caused by front scattering and the stored energy to contributed by back scattering, calculated by the aforementioned respective operations, are added (accumulated) together for each of the evaluation points; in this manner, stored energy at each of the evaluation points is calculated.
The following paragraphs describe, with reference to FIG. 4 , the “process for calculating stored energy contributed by front scattering” (step S 21 of FIG. 3 ). FIG. 4 is a flow chart showing an example operational sequence of the “process for calculating stored energy contributed by front scattering” that is performed by the front scattering contribution calculation section 40 .
At step S 31 , a sample (one chip in this case) is segmented into meshes (hereinafter referred to as “evaluation point meshes”) each having an appropriate size (e.g., 500 nm), and all of the evaluation points are allocated to individual ones of the “evaluation point meshes”. In the illustrated example of FIG. 6 , four evaluation points, one evaluation point, three evaluation points and five evaluation points are allocated to evaluation point meshes 0 to 3 , respectively. At step S 32 , one of the rectangles obtained by dividing or segmenting the figures Z 1 to Z 7 is determined as a target of processing. At step S 33 , an “influencing range” which the one rectangle determined as the target of processing influences is determined. In the illustrated example of FIG. 6 , the hatched rectangle is determined as the target of processing, and the influencing range of the hatched rectangle is indicated as a range surrounded by broken lines. Here, the “influencing range” is determined, for example, by extending the outer periphery of the rectangle by about four times the front scattering diameter. Because an influence of the front scattering can occur in a range (nanometer range) near a direct electron beam irradiation position, the influencing range is limited to such a predetermined range in such a manner as to contribute to reduction of the quantity of necessary calculations. Needless to say, the influencing range is not limited to the aforementioned example, and, for example, a circular range having an appropriate radius four times the front scattering diameter about the center of the rectangle may be determined as the influencing range.
At next step S 34 , one of the evaluation points included in the evaluation point mesh positionally overlapping with the determined “influencing range” is specified (in the illustrated example of FIG. 6 , one of the evaluation points H 2 to H 5 other than the evaluation point H 1 of the determined rectangle is specified). Then, at step S 35 , stored energy at the specified evaluation point is calculated in accordance with Mathematical Expression 14 below that is representative of a stored energy distribution.
e
(
x
,
y
)
=
∫
b
t
∫
l
r
psf
(
(
x
-
X
)
2
+
(
y
-
Y
)
2
)
ⅆ
X
ⅆ
Y
[
Mathematical
Expression
14
]
Here, (X, Y) represent coordinates of the evaluation point (e.g., H 1 ) of the determined rectangle, and (x, y) represent coordinates of the specified evaluation point (e.g., one of the evaluation points H 2 to H 5 ) for which stored energy is to be calculated.
The PSF function included in Mathematical Expression 14 above is approximated by a Double Gaussian approximation equation as shown in Mathematical Expression 3 above. Here, by the provision of the abovementioned “influencing range”, only an influence of front scattering that may be caused by electron beam irradiation to other evaluation points is taken into consideration with an influence of back scattering eliminated. Thus, only the first term, indicative of a contribution of the front scattering, of the Double Gaussian approximation equation as shown in Mathematical Expression 3 is needed with the second term indicative of a contributory portion of the back scattering ignored. Thus, the PSF function employed in Mathematical Expression 14 can be simplified as shown in Mathematical Expression 15.
psf
(
r
)
=
C
1
+
η
(
1
α
2
exp
(
-
r
2
α
2
)
)
[
Mathematical
Expression
15
]
Then, at step S 36 , a determination is made as to whether the aforementioned stored energy calculation has been performed for all of the evaluation points included in the “evaluation point mesh” positionally overlapping with the determined “influencing range”. If the aforementioned stored energy calculation has not been performed for all of the evaluation points included in the “evaluation point mesh” positionally overlapping with the determined “influencing range” as determined at step S 36 (i.e., NO determination at step S 36 ), the process reverts back to the operation of step S 34 to calculate stored energy for another one of the evaluation points in the aforementioned manner. If, on the other hand, the aforementioned stored energy calculation has been performed for all of the evaluation points included in the “evaluation point mesh” positionally overlapping with the determined “influencing range” as determined at step S 36 (i.e., YES determination at step S 36 ), a further determination is made, at step S 37 , as to whether the aforementioned operations have been performed on all of the rectangles of the figures Z 1 to Z 7 .
If the aforementioned operations have not been performed on all of the rectangles of the figures Z 1 to Z 7 as determined at step S 37 (i.e., NO determination at step S 37 ), the process reverts back to the operation of step S 32 . If, on the other hand, the aforementioned operations have been performed on all of the rectangles of the figures Z 1 to Z 7 as determined at step S 37 (i.e., YES determination at step S 37 ), the stored energy at each of the evaluation points, calculated by the aforementioned process, is accumulated for each of the evaluation points, after which the process for calculating stored energy contributed by front scattering is brought to an end. In the aforementioned manner, stored energy contributed by the front scattering is evaluated for the one evaluation point determined for each of the rectangles defined by segmenting the figures. Namely, in the instant embodiment, in view of the fact that the range which the front scattering can influence is small and there is no interaction to most of the other evaluation points, an interaction is calculated with respect to only “nearby evaluation points” located within the influencing range which the front scattering can influence, so that the stored energy contributed by the front scattering can be evaluated at a high calculation speed.
The following paragraphs describe, with reference to FIG. 5 , the “process for calculating stored energy contributed by back scattering” (step S 22 of FIG. 3 ). FIG. 5 is a flow chart showing an example operational sequence of the “process for calculating stored energy contributed by back scattering” performed by the back scattering contribution calculation section 41 .
At step S 41 , a sample (one chip in this case) is segmented into meshes each having an appropriate size (e.g., in a range of 1 μm-(about 1/10 of a back scattering diameter)), and then, for each of the segmented meshes, a ratio of an area of figures to the area of the mesh is evaluated or calculated to thereby create a “density map”. Here, in view of the fact that an influence of back scattering occurs in positions (in a micrometer range) away from a direct electron beam irradiated position, the sample is segmented into meshes each being a large area of about 1 μm as compared to the mesh employed in the front scattering contribution calculation. For example, a part of the figure Z 1 , a part of the figure Z 2 , the whole of the figure Z 3 and a part of the figure Z 7 are contained in “mesh 3 ” shown in FIG. 6 . The abovementioned “density map” represents a ratio of a sum of respective areas of the parts and whole of the individual figures to the total area of mesh 3 . At step S 42 , one of the segmented meshes is determined as a target of processing.
At step S 43 , an integral calculation (convolution) between the “density map” and the PSF function obtained in accordance with Mathematical Expression 14 above. In this manner, stored energy contributed by back scattering (hereinafter referred to as “back scattering intensity”) at the center position of each of the meshes is calculated. Here, only an influence of the back scattering that can be caused by the electron beam irradiation is taken into consideration with an influence of the front scattering eliminated, and thus, only the second term, indicative of a contribution of the back scattering, of the Double Gaussian approximation equation shown in Mathematical Expression 3 is needed with the first term indicative of a contribution of the front scattering ignored. Thus, the PSF function employed in Mathematical Expression 14 can be simplified as shown in Mathematical Expression 16 below.
psf
(
r
)
=
C
1
+
η
(
η
β
2
exp
(
-
r
2
β
2
)
)
[
Mathematical
Expression
16
]
Then, at step S 44 , a determination is made as to whether the aforementioned calculation of the back scattering intensity has been performed for all of the segmented meshes. If the aforementioned calculation of the back scattering intensity has not been performed for all of the segmented meshes as determined at step S 44 (i.e., NO determination at step S 44 ), the process reverts back to the operation of step S 42 to calculate a back scattering intensity for another one of the meshes in the aforementioned manner. If, on the other hand, the aforementioned calculation of the back scattering intensity has been performed for all of the segmented meshes as determined at step S 44 (i.e., YES determination at step S 44 ), one of the evaluation points is specified at step S 45 .
At next step S 46 , a back scattering intensity (stored energy) at the specified evaluation point is evaluated on the basis of respective back scattering intensities of surrounding four meshes including the specified evaluation point. At that time, the back scattering intensity at the specified evaluation point (stored energy) is evaluated by bilinear interpolation. Assuming that the evaluation point H 1 has been specified in the illustrated example of FIG. 6 , a back scattering intensity at the specified evaluation point H 1 is calculated or evaluated on the basis of respective back scattering intensities of mesh 0 to mesh 3 .
The following paragraphs describe, with reference to FIG. 7 , a sequence of operations (procedure) for calculating the back scattering intensity by the bilinear interpolation. FIG. 7 is a conceptual diagram explanatory of the sequence of operations (procedure) for calculating the back scattering intensity by the bilinear interpolation.
Let it be assumed that coordinates of the respective center points of the surrounding four meshes including the specified evaluation point are (x, y), (x+m, y), (x+m, y+m) and (x, y+m), respectively, and that back scattering intensities at the individual coordinates are f 0 , f 1 , f 2 and f 3 , respectively. In such a case, a back scattering intensity at a given evaluation point (x+dx, y+dy) located inwardly of the respective center points of the four meshes can be evaluated using Mathematical Expression 17 below.
f
(
x
+
ⅆ
x
,
y
+
ⅆ
y
)
=
f
0
+
(
f
1
-
f
0
)
ⅆ
x
m
+
(
f
3
-
f
0
)
ⅆ
y
m
+
(
f
0
-
f
1
+
f
2
-
f
3
)
ⅆ
x
ⅆ
y
m
2
[
Mathematical
Expression
17
]
At step S 47 , a determination is made as to whether the aforementioned operations have been performed for all of the evaluation points. If the aforementioned operations have not been performed for all of the evaluation points as determined at step S 47 (i.e., NO determination at step S 47 ), the process reverts back to the operation of step S 45 . If, on the other hand, the aforementioned operations have been performed for all of the evaluation points as determined at step S 47 (i.e., YES determination at step S 47 ), the process for calculating stored energy contributed by back scattering is brought to an end. In the aforementioned manner, stored energy contributed by the back scattering is evaluated for each of the evaluation points. The instant embodiment of the invention can evaluate, at a high calculating speed, stored energy contributed by the back scattering by segmenting a chip range into a plurality of meshes and calculating an interaction of each of the meshes instead of calculating interaction of each of the rectangles.
Referring now back to FIG. 2 , (p k ·q k ) and (r k ·r k ) of all of the rectangles of the figures Z 1 to Z 7 are summed together at step S 5 ; namely, Σp k q k and Σr k r k are evaluated at step S 5 . At next step S 6 , a calculation of α k =Σr k r k /Σp k q k (which corresponds to the calculation of Mathematical Expression 8 in the operational sequence (procedure) of the conjugate gradient method) is performed. At following step S 7 , x and r of all of the rectangles of the figures are updated with:
x k+1 =x k +α k p k (which corresponds to the calculation of Mathematical Expression 9 in the operational sequence of the conjugate gradient method); and
r k+1 =r k −α k p k (which corresponds to the calculation of Mathematical Expression 10 in the operational sequence of the conjugate gradient method).
At next step S 8 , (r k+1 ·r k+1 ) of all of the rectangles of the figures are summed together (hereinafter referred to as “ΣrrNext”). Then, at step S 9 , a determination is made as to whether ΣrrNext is sufficiently small, i.e. whether a calculation error has become smaller than a preset allowance. If ΣrrNext is sufficiently small as determined at step S 9 (i.e., YES determination at step S 9 ), the repeated calculations are terminated, and a column vector x is output as an optimal irradiation amount of each of the rectangles at step S 13 .
If, on the other hand, ΣrrNext is not sufficiently small as determined at step S 9 (i.e., NO determination at step S 9 ), operations of steps S 10 , S 11 and S 12 are performed, after which the process reverts back to the operation of step S 4 to repeat the aforementioned calculation operations. At step S 10 , β k =ΣrrNext/Σr k r k (which corresponds to the calculation of Mathematical Expression 11 in the operational sequence of the conjugate gradient method) is evaluated. At step S 11 , p in all of the rectangles of the figures is updated with p k+1 =r k+1 +β k p k (which corresponds to the calculation of Mathematical Expression 12 in the operational sequence of the conjugate gradient method). Then, at step S 12 , “1” is added to the number of repetitions (which corresponds to the calculation of Mathematical Expression 13 in the operational sequence of the conjugate gradient method).
Note that a repetition condition for determining whether the aforementioned calculation operations are to be repeated or not is not limited to the one based on whether ΣrrNext is large or small (see step S 9 ). For example, numbers of repetitions that converge may be researched in advance through simulation or the like to set a particular number of repetitions, or there may be employed a scheme of confirming that the calculation error has become no longer fluctuating even when the repeated calculations are performed. Note that, logically, the maximum (upper-limit) number of the repetitions is m.
As set forth above, the instant embodiment of the invention evaluates an optimal irradiation amount of the electron beam by correcting a proximity effect by use of the conjugate gradient method. Namely, for that purpose, the instant embodiment evaluates stored energy, which is a substantive electron beam irradiation amount, for each of segmented regions obtained by segmenting a pattern to be drawn onto a sample and then evaluates an electron beam irradiation amount optimal to reduce variation in size of a circuit pattern, caused due to a proximity effect, by the conjugate gradient method using the evaluated stored energy of each of the segmented regions. More specifically, in the operational sequence (see Mathematical Expression 8 and Mathematical Expression 10), including a calculation of the determinant Ap k , of the repeated calculation sequence or procedure (see Mathematical Expression 8 to Mathematical Expression 13) based on the conjugate gradient method for finding a solution to a simultaneous linear equation with the matrix A as a coefficient, the instant embodiment performs calculations using the evaluated stored energy instead of performing a calculation of the determinant Ap k . Further, in evaluating stored energy, the instant embodiment calculates stored energy by the front scattering of the electron beam and stored energy by the rear scattering of the electron beam separately from each other. Namely, if an optimal irradiation amount of the electron beam is evaluated in accordance with the repeated calculation procedure based on the conjugate gradient by managing the value of the determinant of Ap k with the stored energy like this, the instant embodiment can eliminate the need for taking the trouble of managing the huge matrix A, comprising a multiplicity of elements corresponding to miniaturization of the circuit pattern, and calculating the determinant Ap k as done in the conventionally-known method, and thus, the instant embodiment of the invention can evaluate an optimal irradiation amount of the electron beam with a high accuracy at a high processing speed, i.e. at a high calculating speed.
Although the preferred embodiment of the present invention has been described above with reference to the accompanying drawings, it should be appreciated that the present invention is not necessarily limited to the above-described embodiment, and various other embodiments and modifications are also possible. For example, whereas the embodiment has been described above in relation to the case where stored energy is calculated taking into consideration of respective influences of front scattering and back scattering, the present invention is not so limited, and for example, stored energy may be calculated with a numerical value evaluated from Mathematical Expression 18 used as an influence of the front scattering; in this way, the integral calculation can be dispensed with, so that the necessary calculations can be performed at an increased speed.
psf
(
r
)
=
C
1
+
η
[
Mathematical
Expression
18
]
Alternatively, stored energy may be calculated with only an influence of the back scattering taken into consideration and with an influence of the front scattering ignored. FIG. 8 shows an example of an optimal irradiation amount calculation process performed by the conjugate-gradient-method-based computing section 38 shown in FIG. 1 for calculating an optimal irradiation amount (optimal dose amount) for each of the rectangles with only an influence of the back scattering taken into consideration.
At step S 51 , a chip range is segmented into meshes (corresponding to regions) each having a predetermined size. At next step S 52 , an area density d of each of the segmented meshes; the “area density” here is a ratio of an area of figures included in the mesh to the total area of the mesh. At following step S 53 , as an initialization operation for solving the determinant Ax=b as shown in Mathematic Expression 1 above, initial value “0” is set as a (initial) dose amount of each of the meshes, and suitable target energy values are set as p 0 and r 0 (b=b−Ax 0 ). If the ordinary PEC method is employed, various information, such as the area density d, does amount x, conjugate vector p, residual error r, is preserved for each of the meshes, but, if the Gray Scale PEC is employed, the above-mentioned information is preserved for each of the meshes and in correspondence with the number of layers. Thus, if the Gray Scale PEC is employed, an optimal irradiation amount to be evaluated ultimately is also evaluated for each of the meshes and in correspondence with the number of layers.
At next step S 54 , a product between the area density d and the vector p k is calculated for each of the meshes and (for each of the layers if the Gray Scale PEC is employed; the same hereinafter), and the thus-calculated product between the area density d and the vector p k is deemed as a dose amount when a rectangle equal in size to the mesh is to be drawn. Then, at step S 55 , Ap k (see Mathematical Expression 8) appearing in the sequencing of operations for solving the determinant (A=b) with the conjugate gradient method is calculated by the stored energy calculation section 39 . However, because an influence of the front scattering is ignored here, stored energy q k (back scattering intensity) at the middle position of each of the meshes based on the deemed dose amount is calculated only by the back scattering contribution calculation section 41 .
At step S 56 , (p k ·q k ) and (r k ·r k ) of all of the meshes are summed together. Namely, Σp k q k and Σr k r k are evaluated at step S 56 . At next step S 57 , a calculation of α k =Σr k r k /Σp k q k is performed. At following step S 58 , x and r of all of the meshes are updated with:
x k+1 =x k +α k p k ; and
r k+1 =r k −α k p k .
Then, at next step S 59 , (r k+1 ·r k+1 ) of all of the meshes are summed together (hereinafter referred to as “ΣrrNext”). Then, at step S 60 , a determination is made as to whether ΣrrNext is sufficiently small, i.e. whether a calculation error has become smaller than a preset allowance. If ΣrrNext is sufficiently small as determined at step S 60 (i.e., YES determination at step S 60 ), the instant optimal irradiation amount calculation process is brought to an end.
If, on the other hand, ΣrrNext is not sufficiently small as determined at step S 60 (i.e., NO determination at step S 60 ), operations of steps S 61 to 64 are performed, after which the process reverts back to the operation of step S 54 to repeat the aforementioned calculation operations. At step S 61 , β k =ΣrrNext/Σr k r k is evaluated. At next step S 62 , the dose amount p in each of the meshes is updated with p k+1 =r k+1 +β k p k . Then, at step S 63 , an optimal irradiation amount of each of the rectangles is calculated from the optimal dose amount x k+1 by use of bilinear interpolation. At next step S 64 , “1” is added to the number of repetitions k.
According to such a modified embodiment, it is possible to evaluate stored energy contributed by the back scattering, by merely segmenting a chip range into a plurality of meshes and calculating an interaction of each of the segmented meshes, instead of calculating an interaction of each of the rectangles, as in the conventionally-known representative figure method. Then, using the thus-evaluated stored energy and the conjugate gradient method, it is possible to evaluate an optimal irradiation amount at each of the evaluation points at a high calculating speed. Particularly, in the case where the Gray Scale PEC is used, it is possible to perform, at a high speed, calculations of a dose amount distribution for realizing a three-dimensional shape following desired resist development, by setting appropriate target stored energy values of rectangles belonging to the individual layers (see step S 53 ).
Note that a user may be allowed to select whether stored energy should be calculated with only an influence of the back scattering taken into consideration with an influence of the front scattering ignored, or stored energy should be calculated with not only an influence of the back scattering but also an influence of the front scattering taken into consideration. Alternatively, depending on whether the ordinary PEC is employed or the Gray Scale PEC is employed, a selection may be made automatically as to whether stored energy should be calculated with not only an influence of the back scattering but also an influence of the front scattering taken into consideration (in the case where the ordinary PEC is employed), or stored energy should be calculated with only an influence of the back scattering taken into consideration with an influence of the front scattering ignored (in the case where the Gray Scale PEC is employed).
Further, whereas the preferred embodiment of the invention has been described above in relation to the case where the PSF function is expressed by the Double Gaussian approximation equation shown in Mathematical Expression 3, the aforementioned Double Gaussian approximation equation is a mere example of the PSF function, and the PSF function may of course be expressed by another approximate equation. For example, in such a case, the PSF function (approximate equation) is determined depending mainly on an acceleration voltage of the electron beam and a material of the substrate.
Furthermore, whereas the embodiment has been described in relation to the case where the drawing method of the present invention is applied to the electron beam drawing device of a variable shaping beam type, the drawing method of the present invention is also applicable to drawing devices of other types. Further, the drawing method of the present invention is also applicable to an ion beam drawing device using an ion beam instead of an electron beam. Furthermore, the present invention is not limited to application purposes of electron beam drawing device. For example, the present invention is applicable to other purposes than forming a resist pattern directly on a wafer, such as creating an X-ray mask, optical stepper mask, reticle, etc. Moreover, the present invention may be modified variously within a range that does not depart from the gist of the present invention. | Stored energy is evaluated for each of segmented regions, and using the evaluated stored energy, an optimal irradiation amount for an electron beam is evaluated by a conjugate gradient method. The evaluated stored energy is used instead of calculating a determinant (Apk) in the procedure that includes calculation of the determinant (Apk) from among repeated calculation procedures that follow the conjugate gradient method and seek to answer a simultaneous linear equation (Ax=b) with a matrix (A) as a coefficient. Thus it is possible to evaluate the optimal irradiation amount for an electron beam with a high processing speed and a high degree of accuracy, and without expressly requiring the calculation of Apk, by managing the giant matrix (A) comprising numerous factors according to reduction of lines of circuitry in a circuit pattern. | 1 |
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates to an adhesive tape joining apparatus used when an adhesive tape is joined to a curved workpiece such as a door sash of an automobile.
[0003] (2) Description of the Related Art
[0004] In recent years, in a manufacturing process of an automobile, in place of black coating processing on a door sash, a technology to join a black adhesive tape has been developed. As this joining technology, an adhesive tape joining apparatus (an adhesive tape joining jig) has been suggested. Herein, an adhesive tape from which a separator is separated is elastically pressed against a tape joining face with a joining roller to be joined thereto while guiding and moving this adhesive tape joining apparatus on hand along a workpiece (refer to JP-A 2001-115117).
[0005] This adhesive tape joining apparatus (adhesive tape joining jig) is provided with four bottom guide rollers to be engaged on back and forth and right and left of a bottom face that is a tape joining face of the workpiece and four side guide rollers to be engaged on back and forth two places of the right and left side faces of the workpiece at its base. In addition, a single pressing roller to be elastically pressed against the upper face of the workpiece is mounted on a pressing lever that is pivotally connected to the base. Then, a bottom guide roller group and the pressing roller sandwich the workpiece vertically so as to hold the posture of the adhesive tape joining apparatus with respect to the workpiece. At the same time, by engaging the side guide rollers from right and left of the workpiece, positioning in a right and left direction of the adhesive tape joining apparatus with respect to the workpiece has been made.
[0006] Thus, moving the adhesive tape joining apparatus of which position and posture are determined along the workpiece due to the guidance of engagement by the roller group, the adhesive tape is elastically pressed against the bottom of the workpiece by an elastic roller arranged at the rear end of the base to be joined thereto. In addition, the adhesive tape to be supplied is curved and guided ahead of the elastic roller. In this case, the separator is separated to be fed forward in a joining moving direction through a gap formed between the base and a sliding plate.
[0007] However, the conventional apparatus has the following problems.
[0008] In other words, the suggested adhesive tape joining apparatus employs guiding means using four bottom guide rollers to be engaged with the bottom face of the workpiece and two pairs of side guide rollers that are engaged with the right and left side faces of the workpiece, respectively, so that there are many engagement guide operational places. Therefore, a function to hold the posture of the adhesive tape joining apparatus and a function to determine the position thereof with respect to the workpiece are sophisticated. These functions can be sufficiently practiced for a linear workpiece. However, the elastic roller to press the adhesive tape against the tape joining face is arranged at a rear part of the guide roller group, so that this involves a problem such that the appropriate joining is not performed to the workpiece having a curved part.
[0009] In other words, in the case that this adhesive tape joining apparatus is moved forward along a workpiece having a curved portion, when the guide roller group passes through, for example, the curved portion shaped in a mountain, the posture of the apparatus will be determined depending on the direction of the workpiece that is located over the curved portion. Therefore, since the elastic roller behind the guide roller group is located in front of the curved portion yet, the elastic roller will come close to the workpiece. Accordingly, in front of the curved portion, the elastic roller will be elastically transformed more than the normal case to be pressed against the tape joining face. As a result, the adhesive tape will be locally pressed by a large pressure and a stretch and a crease are generated on the adhesive tape.
[0010] In addition, there is a limit in the elastic transformation of the elastic roller, so that the apparatus cannot follow the sharp curve of the workpiece. In other words, the suggested adhesive tape joining apparatus can be effectively used for the workpiece having a linear or a gentle curved portion. However, this involves a problem such that the apparatus cannot continuously join the tape on the workpiece having a relatively sharp curved portion.
[0011] In addition, in the suggested adhesive tape joining apparatus, the separated separator is discharged forward in a joining moving direction of the adhesive tape joining apparatus. Therefore, in the case of carrying out the joining processing on the horizontally long bottom face of the workpiece, even if the separated separator moves forward in a moving direction of the adhesive tape joining apparatus, it is not obstructive to the forward moving because it hangs down downward by its own weight. However, in the case of performing the joining processing on the longitudinal directed place in the workpiece, the separator moved forward in the moving direction of the adhesive tape joining apparatus is obstructive to the forward moving. Accordingly, this involves a disadvantage such that the attention to the adhesive tape joining operation gets distracted due to the operation to wave aside the separator or the joining moving speed is lowered so as to deteriorate finish of joining.
SUMMARY OF THE INVENTION
[0012] The present invention has been made taking the foregoing problems into consideration and an object of which is to provide an adhesive tape joining apparatus that can carry out the adhesive tape joining processing with a high degree of accuracy with respect to the workpiece having the relatively sharp curved portion and can smoothly carry out the adhesive tape joining without being distracted by the separated separator.
[0013] In order to attain the aforementioned object, the present invention may comprise the following structure.
[0014] An adhesive tape joining apparatus which supplies an adhesive tape to a joining roller while moving forward along a workpiece and joins this adhesive tape on a tape joining face of the workpiece by pressing the adhesive tape against the tape joining face, the apparatus comprising:
[0015] a main body that is moved and operated along the tape joining face of the workpiece;
[0016] a joining roller which joins the supplied adhesive tape to the tape joining face of the workpiece by pressing the adhesive tape against the tape joining face and can be elastically transformed;
[0017] a tape supply roller which winds and guides the adhesive tape and introduces the tape to the joining roller;
[0018] a guide member which determines the position of the main body and keeps the posture of the main body with respect to the workpiece being engaged with the outer face of the workpiece at the opposite side of the tape joining face;
[0019] a separator guide arranged to be opposed to the tape supply roller, on which a separator guide face for guiding the separator separated from the adhesive tape to a direction different from the direction of joining the adhesive tape at a region where the tape of the tape supply roller is wound; and
[0020] a tape guide for preventing disengagement of the tape that is arranged adjacent to the side from which the adhesive tape is reeled out toward the separator guide.
[0021] Since the adhesive tape joining apparatus is sandwiched by the guide member to be engaged with the outer face of the workpiece at the opposite side of the tape joining face and the joining roller, the adhesive tape joining apparatus is guided and held at a predetermined posture and a predetermined position with respect to the workpiece using the outer face of the workpiece as a reference face. In addition, the joining roller is opposed to the joining face of the workpiece at a predetermined elastic pressed state.
[0022] By moving the adhesive tape joining apparatus of which posture and crosswise position are secured as stated above along the workpiece, the adhesive tape is guided and supplied to the joining roller via the tape supply roller, and the adhesive tape pressed by the joining roller is continuously joined to the tape joining face of the workpiece. In addition, being wound around the tape supply roller, the adhesive tape turns around to be guided to the joining roller. The separator does not turn around into a direction other than the direction to which this adhesive tape is guided and the separator is separated at the region where the tape is wound to move toward a separator guide. Then, the separator is guided to the separator guide face to be released in a direction that is not obstructive to joining of the tape.
[0023] In addition, if joining is progressed to reach the curved portion of the workpiece, the guide member only engaged with the outer face of the workpiece moves along the outer face of the curved workpiece. In this case, the joining roller opposed to the guide member absorbs change of the aspect of the joining face by its elastic transformation. Therefore, the joining roller certainly follows the relatively large curve to continue joining of the tape.
[0024] As described above, according to this apparatus of the invention, it is possible to carry out the joining processing of the adhesive tape with respect to the workpiece having the curved portion with a high degree of accuracy with no stretch and no crease of the adhesive tape generated. In addition, without being distracted by the separated separator, the adhesive tape can be smoothly joined on the workpiece.
[0025] Further, it is preferable that the guide member is configured by two kinds of guide members that are engaged with the outer face of the workpiece across a rib protruded along the tape joining direction on the outer face of the workpiece.
[0026] According to this structure, separating the guide member from the joining roller and widening the space between the guide member and the joining roller, the workpiece can be easily put in this space. Then, by approaching the guide member to the joining roller to be held at a predetermined position, a predetermined guided state such that the guide member is engaged with the outer face of the workpiece has been brought. In addition, if the joining processing is progressed, separating the guide member from the joining roller, the adhesive tape joining apparatus can be set aside from the workpiece. Accordingly, attachment and detachment of the adhesive tape joining apparatus to and from the workpiece can be easily carried out.
[0027] In addition, it is preferable that one of the two kinds of guide members is configured by a single guide roller that pivotally moves along the outer face of the workpiece and the other guide member is configured by a guide block that sidably moves in a predetermined range on the outer face of the workpiece in the tape joining direction while contacting the predetermined range on the outer face of the workpiece.
[0028] According to this structure, effectively using a rib on the outer face of the workpiece for positioning of a crosswise direction, it is possible to certainly hold the posture and the lateral positioning of the adhesive tape joining apparatus with respect to the workpiece by a few guide members.
[0029] It is preferable that the guide block includes a pair of back and forth sliding guides which are divided in the tape joining direction.
[0030] According to this structure, when the guide block passes through the curved portion of the workpiece, the guide block can slidably pass with a pair of back and forth sliding guide faces in the guide block stably engaged with the convex outer face of the workpiece. Therefore, even in the workpiece that is relatively much curved, the tape joining processing can be smoothly carried out. In other words, a concave portion is formed between the divided pair of back and forth sliding guide faces, and the guide block slidably passes while putting a convex portion of the curved workpiece into this concave portion.
[0031] It is preferable that the joining roller further includes the pair of back and forth rollers, and respective joining rollers are arranged so as to be substantially opposed to each other on the faces of the pair of back and forth sliding guides provided to the guide block across the workpiece.
[0032] According to this structure, the back and forth sliding guide faces of the guide block always slidably contact the outer face of the workpiece that is a reference face to stably hold the adhesive tape joining apparatus. Therefore, the position with respect to the back and forth joining faces of the joining roller substantially opposed to this sliding guide faces is always stabled. Then, it is possible to join the supplied adhesive tape in the just enough elastic pressing state.
[0033] It is preferable that the separator guide face is formed on a concave curved face moving to the tape supply roller.
[0034] According to this structure, the separated separator will turn around and guided in a desired direction different from the joining direction by the concave and curved separator guide face. Therefore, it is more certainly avoided to move the separated separator forward of the apparatus. In addition, this makes the adhesive tape joining apparatus to effectively move forward without being distracted by the separated separator.
[0035] It is preferable that the separator guide and the tape guide are configured so that the movement can be adjusted in accordance with the width of the tape.
[0036] In addition, it is preferable that the apparatus may further comprise a tape guide for guiding running which is attached on the lower face of the main body, wherein a gap for inserting the adhesive tape is formed between the lower face of the main body and the guide with its one end released, the other end side is attached and fixed to the main body, and a positioning part slidably contacting one end of the adhesive tape in a longitudinal direction is formed at the back side of this other end, and the tape guide for guiding running is disposed at a position opposed to the positioning part so as to sandwich the adhesive tape from the width direction.
[0037] According to this structure, since the adhesive tape to be supplied is sandwiched by the positioning part and the tape guide from the width direction, the adhesive tape can be easily set and time for setting can be shortened. In addition, the running position of the adhesive tape is not misaligned, so that the running can be stabled.
[0038] It is preferable that the joining roller is configured by a pair of back and forth rollers, and the diameter of the roller at the front side in the moving direction is set to be larger than the diameter of the roller at the rear side.
[0039] According to this structure, since the contact face with the adhesive tape to be wound is enlarged, the adhesive tape can be stably joined. Further, by making the diameter of the roller larger, the separation position of the separator can be brought close to the joining face of the workpiece, so that it is possible to prevent adhesion of dust or the like on the tape joining face.
[0040] In order to attain the object, the present invention may adopt the following structure.
[0041] An adhesive tape joining apparatus which supplies an adhesive tape to a joining roller while moving forward along a workpiece and joins this adhesive tape to a tape joining face of the workpiece by pressing the adhesive tape against the tape joining face, the apparatus comprising:
[0042] a main body that is moved and operated along the tape joining face of the workpiece;
[0043] a joining roller which winds and guides the adhesive tape to be supplied, joins the supplied adhesive tape to the tape joining face of the workpiece by pressing the adhesive tape against the tape joining face, and can be elastically transformed, wherein the diameter of the roller at the front side in the moving direction is larger than the diameter of the roller at the rear side;
[0044] a guide member which determines the position of the main body and keeps the posture of the main body with respect to the workpiece being engaged with the outer face of the workpiece at the opposite side of the tape joining face;
[0045] a separator guide arranged to be opposed to the tape supply roller, on which a separator guide face for guiding the separator separated from the adhesive tape to a direction different from the direction of joining the adhesive tape at a region where the tape of the tape supply roller is wound; and
[0046] a tape guide for preventing disengagement of the tape that is arranged adjacent to the side from which the adhesive tape is reeled out toward the separator guide.
[0047] The adhesive tape joining apparatus according to the present invention is configured in such a manner that the tape supply roller is omitted from the constituent features of the invention. Due to this structure, in addition to the aforementioned advantages of the invention, the following advantages may be realized.
[0048] In other words, during guiding the adhesive tape from the tape guide to the front side roller, the adhesive tape escapes from the effects of loose due to a rotation error between the tape supply roller and the front side roller or the like. In other words, it is possible to maintain a regular degree of a tension on the adhesive tape between the tape guide and the front side roller. As a result, the adhesive tape can be stably joined on the workpiece. In addition, since the running distance from the tape guide to the joining roller, it is possible to prevent adhesion of dust or the like on the adhesive tape after the separator is separated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] For the purpose of illustrating the invention, there are shown in the drawings several forms which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangement and instrumentalities shown.
[0050] FIG. 1 is a side view showing the joining processing state using an adhesive tape joining apparatus according to the present invention;
[0051] FIG. 2 is an outside perspective view of the adhesive tape joining apparatus;
[0052] FIG. 3 is an outside perspective view of the adhesive tape joining apparatus seen from the different direction;
[0053] FIG. 4 is a perspective view of the joining processing state;
[0054] FIG. 5 is a front view having a part of the joining processing state cut;
[0055] FIG. 6 is a sectional view taken along a line X-X in FIG. 5 ;
[0056] FIG. 7 is a longitudinal side view showing the joining processing state at a curved portion of a workpiece;
[0057] FIG. 8 is an outside perspective view at a rear face side of the adhesive tape joining apparatus according to a modification;
[0058] FIG. 9 is a front view of the adhesive tape joining apparatus according to the modification;
[0059] FIG. 10 is a bottom view of the adhesive tape joining apparatus according to the modification;
[0060] FIG. 11 is a front view of the adhesive tape joining apparatus according to the modification; and
[0061] FIG. 12 is a plan view of the adhesive tape joining apparatus according to the modification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0062] An embodiment of the present invention will be described below with reference to the drawings.
[0063] FIG. 1 is a side view showing a step of joining an adhesive tape T on a curved workpiece W using an adhesive tape joining apparatus A according to the present invention. FIGS. 2 and 3 are outside perspective views of the adhesive tape joining apparatus A. FIG. 4 is a perspective view of the adhesive tape joining step. FIG. 5 is a front view of the joining step.
[0064] Further, the workpiece W according to the present embodiment is a door sash in an automobile, and an apparatus for joining a black adhesive tape to an inner circumferential face inside of the car side of this door sash in place of black coating will be described below.
[0065] The workpiece W, as shown in FIGS. 4 and 5 , is configured by press polymerization of a single steel plate. This workpiece W has an outer frame w 1 shaped in a longitudinal wall at the lateral outside that is the outer face of the door, and the workpiece W is formed with a section that a hollow lateral frame w 2 thrusting from this outer frame w 1 toward the inside of the door (the left side in FIG. 5 ) is connected. Then, between a hollow region of the lateral frame w 2 and the outer frame w 1 , a window glass mounting groove m 1 is formed. In addition, at right and left middle region of the outer face of the hollow lateral frame w 2 (the upper face in FIG. 5 ), a rib w 3 is protruded along the longitudinal direction of the workpiece. Between this rib w 3 and the outer frame w 1 , a weather strip mounting groove m 2 is formed. Then, the inner face at the follow region at the lateral frame w 2 (the lower face in FIG. 5 ) becomes a tape joining face S. On this tape fasting face S, an adhesive tape T is joined by a manual fashion by using an adhesive tape joining apparatus A according to the present invention. As the adhesive tape T, an adhesive tape with a separator that is wider than the tape joining face S is used.
[0066] As shown in FIG. 1 , the adhesive tape joining apparatus A may join the adhesive tape T being guided and engaged to the workpiece W while moving along the workpiece longitudinal direction by the manual labor. Accordingly, in the following description, as a matter of convenience, a direction F of joining and moving the adhesive tape joining apparatus A is called as a front direction, and a door inside direction that is perpendicular to the tape joining direction is called as a lateral direction or a right and left direction.
[0067] The main body 1 of the adhesive tape joining apparatus A is formed by a hard resin material. As shown from FIGS. 2 to 5 , the main body 1 is configured by a first bracket 1 A shaped in a block, a second bracket 1 B that is coupled and fixed to be perpendicular to the lower end of this first bracket 1 A, and a movable bracket 1 C with a lever that is attached to the upper part of the first bracket 1 A so as to be opposed to the second bracket 1 B.
[0068] Here, the movable bracket 1 C is pivotally connected to the upper part of the first bracket 1 A via a support axis 2 to be capable of swinging around a back and forth directed support point p. In addition, as shown in FIG. 5 , the movable bracket 1 C is swingably biased downward by a twisting spring 3 externally fitted to the support axis 2 . In other word, due to abutting of the first bracket 1 A against a bottom face 1 a at a pivotally supporting concave portion, the swinging and biasing of this movable bracket 1 C is limited. In this limitation of the swinging and biasing, the movable bracket 1 C is perpendicular to the first bracket 1 A.
[0069] On the lateral side face of the lower part of the first bracket 1 A, a pair of back and forth joining rollers 4 that can freely idle around a horizontal lateral axial core is mounted like a cantilever. In addition, on the lateral side face of the front end of the movable bracket 1 C, as the guide member, a single guide roller 5 is mounted around the inclined lateral axial core of which end is slightly raised to freely idle. Further, on the lower face at the front end of the movable bracket 1 C, as another guide member, a guide block 6 is attached.
[0070] The guide roller 5 is formed by a hard resin material excellent in smoothness, for example, fluorine contained resin. Then, this guide roller 5 is inserted till the bottom face of a weather strip mounting groove m 2 at the workpiece W to be engaged with the outer face of the lateral frame w 2 .
[0071] The guide block 6 is also formed by a hard resin material excellent in smoothness. Then, a pair of back and forth sliding guide faces 6 a formed to be inclined on the lower face of this guide block 6 contacts the inclined outer face of the lateral frame w 2 at its face to be engaged therewith. Thus, by engaging the guide roller 5 with the guide block 6 on a plurality of back and forth and right and left places on the outer face of the lateral frame w 2 , the posture of the adhesive tape joining apparatus A with respect to the workpiece W is held at a predetermined posture. In addition, by sandwiching the rib w 3 between the lateral side face of the guide roller 5 and the lateral side face of the guide block 6 from right and left, the positioning in a lateral direction of the adhesive tape joining apparatus A with respect to the workpiece W is made.
[0072] Further, as shown in FIG. 2 , at the lateral side face of the front end of the movable bracket 1 C, three fitting holes 8 are formed in parallel in a back and forth direction to screw and mount a support axis 7 of the guide roller 5 . By selecting this fitting hole 8 , the position of the guide roller 5 can be adjusted back and forth in accordance with the workpiece W. In addition, as shown in FIG. 6 , the guide roller 5 at a reference position that is attached by using the fitting hole 8 in the middle of the back and forth direction is located between the back and forth sliding guide faces 6 a in the guide block 6 .
[0073] As shown in FIG. 5 , a joining roller 4 is configured by coating a tubular axis 10 externally fitted to a fixed core axis 9 to freely idle with an elastic layer 11 of a sponge type. In other words, the guide roller 5 and the guide block 6 of the movable bracket 1 C located in the swinging limit posture are pressed against the tape joining face S of the workpiece W to be elastically transformed in moderation engaged with the workpiece W engaged at a predetermined position and a predetermined posture. Further, the fixed core axis 9 of the joining roller 4 is attached so that its position can be adjusted in an upper and lower direction.
[0074] At a front end of the second bracket 1 B, a tape supply roller 12 is supported by an axis around a lateral axial core to freely idle so as to be opposed to the joining roller 4 at the front side in parallel. This tape supply roller 12 is formed by a hard resin material excellent in smoothness and it is supported by a fixed support axis 13 to be freely fitted.
[0075] In addition, on the lower face at the front end side of the second bracket 1 B, as shown in FIGS. 5 and 6 , a platy tape guide 14 made of a hard resin material is attached to be fixed. Between this tape guide 14 and the lower face of the second bracket 1 B, a tape insertion gap c released in a lateral direction is formed. In addition, the back end of the tape insertion gap c is formed at a tape positioning part 15 . In other words, by accepting and supporting the one edge of the adhesive tape T inserted in the tape insertion gap c by the tape positioning part 15 , the adhesive tape T is positioned in a width direction. Further, the tape guide 15 is attached so as to be positioned in the lateral direction, namely, in the tape width direction.
[0076] In addition, at the front side below the front end side in the second bracket 1 B, a separator guide 16 made of a hard resin material is attached to be fixed. This separator guide 16 is arranged to be opposed to the tape supply roller 12 with an appropriate interval at the front position of the tape supply roller 12 . In addition, the separator guide 16 is arranged to be slightly lower than the tape supply roller 12 , and at its backward face, a separator guide face 17 that is concave-curved opposed to the tape supply roller 12 is formed. Further, this separator guide 16 is also attached in the lateral direction, namely, in the tape width direction so that its position can be adjusted.
[0077] The adhesive tape joining apparatus A according to the present invention is configured as described above. Next, using the apparatus A of the aforementioned embodiment, a step of joining the adhesive tape T to the workpiece W will be described.
[0078] At first, an operator raises the movable bracket 1 C against the twisting spring 3 , then, widening the space between the guide roller 5 and guide block 6 , and the joining roller 4 , the operator covers the lateral frame w 2 of the workpiece W with the movable bracket 1 C. After that, adjusting the lateral position so as to sandwich the rib w 3 by the guide roller 5 and the guide block 6 , the movable bracket 1 C is biased and swung up to the limit. Then, the lateral frame w 2 is sandwiched from up and down directions by the guide roller 5 , the guide block 6 , and the joining roller 4 . Further, by suppressing a lever part 1 e of the movable bracket 1 C with the operator's fingers supported by a protrusion part id elongated from the base of the second bracket 1 B, the operator can raise and swing the movable bracket 1 C by one hand.
[0079] Next, inserting the adhesive tape T with the separator through the tape insertion gap c so that the side with this separator st becomes the lower face, then, the separator st is separated from the front end of the adhesive tape T to expose the adhesive face. Guiding and winding the adhesive tape T having the adhesive face exposed at the upper side by the tape supply roller 12 , this adhesive tape T is joined to a predetermined position of the joining face S in the workpiece W. In this case, the separator st separated from the adhesive tape T at the region of winding the tape of the tape supply roller 12 is guided on the separator guide face 17 of the separator guide 16 to be introduced downward.
[0080] After that, as shown in FIGS. 1 and 6 , winding the adhesive tape T having the adhesive face exposed by the joining roller 4 , the adhesive tape T is elastically pressed against the joining face S. By manually moving the adhesive tape joining apparatus A along the workpiece W to a front side F in this state, it is possible to continuously join the adhesive tape T on the tape joining face S positioning it in the width direction.
[0081] In this case, if the adhesive tape joining apparatus A is moved to the front side F, the adhesive tape T is moved relatively to the front side F, so that the separator st turns around to be guided on the separator guide face 17 of the separator guide 16 and then, the separator st is discharged into a direction separating from the joining roller 4 . Accordingly, even in the case of joining the tape while moving the adhesive tape joining apparatus A upward or downward at a vertically long place of the workpiece W, so that it has been avoided in advance that the separated separator st is entangled in the adhesive tape T to come close the tape joining face S or to be an obstacle of the forward moving of the adhesive tape joining apparatus A.
[0082] When the joining is progressed and the tape reaches a curved region b of the workpiece W, as shown in FIG. 7 , the curved portion of the lateral frame w 2 enters a gap g between the back and forth sliding guide faces in the guide block 6 . In this state, the adhesive tape joining apparatus A passes through the curved region smoothly and reasonably.
[0083] Further, the tape portion protruded from the tape joining face S is wound around the peripheral part of the lateral frame w 2 in the following step to be joined, and the appearance same as that applied with the coating processing is given.
[0084] In addition, with respect to the workpiece W of the different specification, it is possible to adjust the back and forth positions of the guide roller 5 and the upper and lower positions of the joining roller 6 according to need. Further, in accordance with change of the tape width, it is possible to adjust the positions of the tape guide 14 and the separator guide 16 in the lateral direction.
[0085] As described above, when joining the adhesive tape T on the inner face of the workpiece W, the adhesive tape joining apparatus A according to the present embodiment can put the curved portion of the lateral frame w 2 in the gap g between the back and forth sliding guide faces 6 a in the divided pair of guide blocks 6 when this apparatus A reaches the curved region b of the workpiece W. As a result, it is possible to reasonably and smoothly join the adhesive tape on the curved region b. Therefore, it is possible to avoid that the adhesive tape T is stretched and the crease is generated at the curved region b of the workpiece W.
[0086] In addition, by configuring one member for sandwiching the workpiece W by the guide block 6 having the rectangular sliding face 6 a , the contact area of the workpiece W is enlarged. As a result, as compared to the conventional apparatus that is moved along the workpiece W at a point contact in the case of sandwiching the workpiece W from up and down by the roller, the apparatus according to the present embodiment can be stably moved and operated. As a result, it is possible to join the adhesive tape T in a stable state.
[0087] The present invention is not limited to the aforementioned embodiment and it can be applied to a modification as follows.
[0088] (1) In the apparatus according to the aforementioned embodiment, as shown in FIG. 8 , a tape guide 18 for guiding running of the adhesive tape may be disposed to be opposed to the tape positioning part 15 so as to sandwich the width direction of the adhesive tape T in cooperation with the tape positioning part 15 . As shown in FIGS. 9 and 10 , this tape guide 18 is shaped in a plate and is attached and fixed to the rear face of the second bracket.
[0089] In a front view of the tape guide 18 seen from the rear face of the apparatus shown in FIG. 10 , the tape guide 18 is attached at a predetermined distance L from the front side end in a direction of supplying a tape of the tape guide 14 . This predetermined distance L is preferably 3 mm or more. In other words, by arranging the tape guide 18 at this predetermined distance L, attachment of the adhesive tape T to the tape guide 14 is not distracted upon attaching the tape.
[0090] In addition, a thickness H of the tape guide 18 is set to be more than the thickness of the adhesive tape T. According to the present embodiment, the thickness H is set to be 2 mm or less. Further, it is preferable that the width of the opposed portion W with the edge of the adhesive tape T is not more than 5 mm. If the width is 5 mm or less, when joining the adhesive tape T at the sharp curved portion, easily releasing the adhesive tape T running along the tape guide 18 from the guide, the rear part of the adhesive tape T can be made into a free state. In other words, the adhesive tape T can be easily treated.
[0091] Further, the tape guide 18 for guiding running is attached so that the setting of the tape guide 18 is changed depending on the width of the adhesive tape T.
[0092] (2) In the aforementioned embodiment, the adhesive tape T to be derived from the tape guide 14 is wound and guided to the joining roller 4 via the tape supply roller 12 , however, the adhesive tape T may be configured as follows. In other words, as shown in FIGS. 11 and 12 , a diameter of a joining roller 4 a provided at the front side in the moving direction of this apparatus is set to be larger than the diameter of a joining roller 4 b at the rear side.
[0093] According to this structure, during guidance of the adhesive tape T from the tape guide 14 to the joining roller 4 a , this adhesive tape T is not affected due to loose caused by a rotation error of the tape supply roller 12 and the joining roller 4 a or the like. In other words, it is possible to keep the tension on the adhesive tape T from the tape guide 14 to the joining roller 4 a constant. As a result, the adhesive tape T can be stably joined on the workpiece W. In addition, since the running distance from the tape guide 14 to the joining roller 4 a can be made shorter, it is possible to prevent adhesion of dust or the like to the adhesive tape T after the separator is separated.
[0094] Further, the diameter of the joining roller 4 at the front side of the apparatus according to the aforementioned embodiment provided with the tape supply roller 12 may be set to be larger than the diameter of the joining roller 4 at the rear side.
[0095] (3) According to the aforementioned embodiment, as two kinds of guide members to be engaged with the outer face of the workpiece W, a single guide roller 5 and the sliding guide faces 6 a of the pair of back and forth guide blocks 6 are used. In place of this guide block 6 , the pair of back and forth guide rollers with a small diameter can be also used.
[0096] (4) According to the aforementioned embodiment, the rib w 3 is sandwiched between the guide roller 5 and the guide block 6 from right and left and the positioning in the lateral direction of the apparatus is made. In place of this structure, by sliding the outer frame w 1 and the rib w 3 against the right and left side faces of the guide roller 5 engaged in the weather strip mounting groove m 2 , the positioning in the lateral direction of the apparatus is also possible.
[0097] (5) According to the aforementioned embodiment, pivotally supporting the movable block 1 C by the first bracket 1 A to be capable of swinging, the apparatus is configured so that the guide roller 5 and the guide block 6 can approach, can be separated, and can move with respect to the joining roller 4 , however, linearly and vertically sliding the movable bracket 1 C, the movable bracket 1 C may be slid and biased toward the joining roller 4 to be supported by the first bracket 1 A.
[0098] (6) According to the aforementioned embodiment, the tape guide 14 and the separator guide 16 are separately formed, however, by integrally forming them, the number of the components can be reduced and the places to be adjusted can be reduced.
[0099] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. | A main body to be moved and operated along a workpiece includes a joining roller which elastically presses the supplied adhesive tape against a tape joining face of the workpiece, guide members which determine the position of the main body and maintain the posture of the main body with respect to the workpiece being engaged with the outer face of the workpiece at the opposite side of the tape joining face, a separator guide which is arranged to be opposed to a tape supply roller, and a tape guide which is arranged in the vicinity of the side where the adhesive tape is reeled out toward the separator guide. On the separator guide, a separator guide face is formed, which guides a separator st separated from the adhesive tape into a direction different from an adhesive tape joining direction. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a polishing composition and more particularly to a polishing composition comprising an aqueous emulsion containing at least one water soluble polishing agent. By rubbing the polishing composition on a painted surface and washing it off with water, a surface having a glossy protective layer results without any unsightly residue remaining on the surface.
2. Description of the Related Art
Polishing compositions are generally used to produce a glossy finish on a surface. The gloss provided by the polishing composition is the result of the mixture of components in the polishing composition. Certain components clean the surface; others smooth the surface; and other components leave a protective film coating. For instance, floor polish produces a glossy finish by depositing a film on the floor surface. Motor vehicle polishing compositions produce a glossy and protective film and may include additional additives such as polishing agents and/or abrasives which assist in the removal of weathered paint, soil and old built-up polish. Metal polishes may contain polishing agents for abrasive smoothing and cleaning of the surface being treated and additional components that function to remove and prevent tarnish.
Motor vehicle polishing compositions are specially formulated from a number of components so that the polishing composition can perform different functions when a painted vehicle surface is treated with the polishing composition. For example, a motor vehicle polishing composition may include hydrocarbon solvents in order to facilitate the removal of greasy dirt from the vehicle surface and to slow the evaporation of the water in the polishing composition. Waxes may also be included in a motor vehicle polishing composition so that the polishing composition may be buffed to a high shine that provides resistance to weathering.
Silicone materials are increasingly being incorporated into motor vehicle polishing compositions as the silicone materials can perform many functions. For instance, the silicone materials act as lubricants for easing the application of the polishing composition to the vehicle surface. Also, the silicone materials form a film on the vehicle surface that provides a water repellant, durable, uniform high gloss to the surface. These silicone based surface films have been noted as having increased resistance to removal by environmental elements such as rain, sleet and snow.
A motor vehicle polishing composition may also contain surfactants, stabilizers, thickeners, and preservatives for the production of a homogeneous stable product of desired consistency and shelf life. Surfactants and stabilizers are added to the polishing composition in order to form an emulsion of the oil-based components and the water-based components of the composition and to keep the components in emulsion form. Both oil-in-water and water-in-oil emulsions are used in polishing compositions. Thickeners are added to the polishing compositions in order to control the form of the composition as the polish may be supplied in solid, semisolid, presoftened or liquid form. The preservatives added to the polishing composition are generally commercially available anti-microbial agents.
Motor vehicle polishing compositions also include at least one polishing agent and/or abrasive. The polishing agents are typically particulate materials that perform numerous functions in the polishing composition. For example, the polishing agent acts as an abrasive cleaner that assists in removing weathered paint, stubborn road soil and old built-up polish. The polishing agent may also provide for mild abrasive smoothing of the painted surface. However, the polishing agent must be mild enough to avoid scratching and dulling of the painted surface. Typically, the polishing agent is suspended in the emulsion formed between the oil-based and water-based components of the polishing composition.
The polishing agents used in motor vehicle polishing compositions are not water soluble; therefore, the polishing compositions must be applied to a vehicle surface in a two-step process. First, the polishing composition is applied to the surface with a wet sponge or towel. After the polishing composition has dried on the vehicle surface, a residue remains on the polished surface. Consequently, a buffing step is required to remove the residue from the vehicle surface. While the residue is generally easy to remove from relatively flat surfaces, it is very difficult to remove the residue from cracks, crevices and other hard-to-reach places. In addition, the residue is quite noticeable and aesthetically unsightly.
In currently available polishing compositions, one of the components of the residue that remains on the vehicle surface is the polishing agent or a blend of the polishing agents, such as kaolin clay or diatomaceous earth, used individually or in combination. The residue tends to lodge in cracks, crevices and around the numerous indicia on vehicle surfaces because the residue (i.e. the clay or diatomaceous earth) is not water soluble, i.e., it cannot be washed off with water. The residue remains lodged in these areas after the buffing process is completed and even after subsequent washings. As a result, the residue is a very unpleasant sight for the consumer and must be removed manually which is a tedious chore.
As detailed above, polishing agents are generally insoluble solid particulate cleaning or polishing agents which are an important component of polishing compositions as the polishing agents provide physical surface preparation and cleaning. The ability of a polishing agent to clean and smooth out surface imperfections depends upon the chemical type, particle size, shape and hardness of the particulates comprising the polishing agent. As noted above, the most common types of polishing agents used in polishing compositions are diatomaceous earth and kaolin clays. Kaolin clays are anhydrous aluminum silicates and are extensively used in polishing compositions. One commercially available type of kaolin clay is sold under the trade name Kaopolite® 1152 and is manufactured by Kaopolite, Inc., Elizabeth, N.J. It has an average particle size of 0.8 microns. Another commercially available kaolin clay is sold in the trade as Polestar 400A and is manufactured by E.C.C. America Inc., Atlanta, Ga. Diatomaceous earth is the soft earth rock composed of the siliceous skeletons of small aquatic plants. Two examples of diatomaceous earth used in polishing compositions are Celatom MN-23, which is available from Eagle-Picher Industries, Inc., Cincinnati, Ohio, and Snow Floss, which is available from Johns-Manville.
Another type of polishing composition is an aqueously dispersed polishing composition used primarily by commercial car washes. These aqueously dispersed polishing compositions do not contain any of the polishing agents in current use (such as kaolin clays and diatomaceous earths) because these polishing agents are not soluble in water and therefore, cannot be dispersed from an overhead spray arch onto a vehicle without clogging the spray nozzles.
Therefore, a consumer generally has two choices in motor vehicle polishing compositions. First, the consumer may choose a conventional polishing composition that includes a polishing agent that is insoluble in water. With this choice, it will be necessary to apply the polishing composition in the laborious two-step process described above. Second, the consumer may choose an aqueously dispersed polishing compound that does not contain a polishing agent. Usually, this choice involves running the motor vehicle through a car wash. However, when a consumer chooses an aqueously dispersed polishing composition without a polishing agent, he or she may sacrifice the benefits that a polishing agent imparts to a polishing composition, such as vastly improved surface cleaning and smoothing. Therefore, it can be appreciated that conventional motor vehicle polishing compositions do not provide the consumer with an optimum combination of polishing effectiveness and ease of use.
Rinse away one step polishes that eliminate the two-step polishing process described above have been proposed. For example, U.S. Pat. No. 5,330,787 discloses a multi-component polish composition that may be applied to a vehicle surface and rinsed away after the composition has dried on the vehicle. It is stated that this one step polishing system leaves a protective coating on the painted surface after the dried composition is rinsed away. However, it is believed that the protective coating formed by this one step polish composition does not provide for optimum durability, especially after the protective coating has been subjected to multiple detergent washings.
In light of the current consumer demand that polishing compositions be easy to use, highly effective in producing a clean glossy surface and durable, there is a continuing need for an effective polishing composition that eliminates the two-step polishing process described above yet still provides for maximum durability after repeated detergent washings. The improved polishing composition could be applied to a surface and then simply washed off with water. Furthermore, there is a long-felt need and inevitably a strong consumer demand for a polishing composition that may be rubbed onto a surface and washed off with water without leaving any unsightly white or light colored residue. Such a polishing composition would be faster and easier to use and would eliminate the unpleasant sight of residue deposited on the surface or in cracks or crevices between surfaces. In addition, the protective coating remaining on the surface after the residue of the composition has been rinsed off the surface would exhibit improved durability even after numerous detergent washings.
It is therefore an object of the present invention to provide a unique polishing composition comprising an emulsion of water-based components and oil-based components that includes at least one water soluble polishing agent.
Yet another object of the present invention is to provide a unique polishing agent for a polishing composition, the polishing agent being selected such that the polishing composition does not require buffing after the polishing composition has been applied to the surface being treated.
Still another object of the present invention is to provide a unique polishing composition including a water soluble polishing agent, the polishing composition capable of being removed with water without leaving a residue.
It is a further object of the present invention to provide an improved car polish that does not require a subsequent buffing process and produces a durable protective coating on the vehicle which can stand up to numerous detergent washings.
And another object of the present invention is to provide an improved car polish that does not require a subsequent buffing process and whereby the car polish is applied manually and hosed off without leaving any unsightly residue.
SUMMARY OF THE INVENTION
The present invention is an advance in the field of one-step polishing compositions that satisfies the foregoing needs by providing a polishing composition that includes a water soluble polishing agent. The polishing composition of the present invention is rubbed on a painted surface, hosed off with water and wiped or towel dried. All or substantially all of the polishing agent is washed away with the water because the polishing agent is water soluble. This is a significant departure from prior art polishing compositions containing polishing agents where the polishing composition must be used in a two step process, i.e., a first step wherein the composition is applied to the surface and allowed to dry, and a second step wherein the surface is buffed with a dry cloth.
The polishing composition of the present invention comprises an emulsion of at least one oil-based component and at least one water-based component, and a water soluble polishing agent. Preferably, the water soluble polishing agent is a carbonate. The most preferred water soluble polishing agent is sodium bicarbonate. Optionally, the polishing composition includes at least one hydrocarbon solvent.
The water soluble polishing agent may be added to the polishing composition in an amount that exceeds the solubility of the polishing agent in water at room temperature so that some of the polishing agent dissolves in the water-based component of the polish and some of the polishing agent is suspended in the polishing composition. The polishing agent in suspension is immediately available for use as a polishing agent once the polishing composition is applied to the surface to be polished. Further, as the polishing composition is spread out across the vehicle surface, the water evaporates and the dissolved polishing agent precipitates out onto the vehicle surface so that it can also serve as a polishing agent.
Alternatively, the polishing agent can be added to the polishing composition in an amount wherein all of the polishing agent dissolves in the water component of the polishing composition. In this version of the polishing composition, the polishing agent will act as a polishing agent once the composition is rubbed out onto the surface and the water begins to evaporate, i.e., the polishing agent will precipitate out as the water evaporates so that it can act as a polishing agent.
These and other features, aspects, objects, and advantages of the present invention will be become better understood upon consideration of the following detailed description and appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polishing compositions of the present invention may be applied to the body surface of a vehicle or other similarly hard metal surface substrate. While an automobile surface will be utilized as an exemplary substrate in the following description and examples, it should be understood that the present invention is not limited to the polishing of vehicle surfaces.
A polishing composition according to the present invention comprises as functional ingredients: a gloss agent, a water soluble polishing agent, a nonionic or anionic surfactant, and water. Optionally, the polishing composition may contain a solvent, mineral oil, wax, and a preservative.
Silicone materials are preferably employed as the gloss agent of the polishing composition of the present invention. After the polishing composition has been applied to a vehicle surface and rinsed off, the silicone materials remain as a film on the vehicle surface providing a water repellant, durable, uniform high gloss to the surface. In addition, the silicone materials also act as lubricants for easing the application of the polishing composition to the vehicle surface. Silicone materials which have proven to be suitable for incorporation into the polishing composition of the present invention include amino functional silicones, silicone oils, curable silicone resins, and mixtures of these silicone materials. Most preferably, the gloss agent is a mixture including at least one amino functional silicone, at least one silicone oil and at least one curable silicone resin.
The nonionic or anionic surfactant of the polishing composition of the present invention is added to the composition in order to emulsify the silicone materials, mineral oil and solvents. Numerous nonionic or anionic surfactants are suitable for forming an emulsion of the components of the polishing composition. Exemplary surfactants include: morpholine oleate soap, oleic acid triethanolamine soap, oleic acid/morpholine mixtures, oleic acid/triethanolamine mixtures, stearic acid/morpholine mixtures, stearic acid/triethanolamine mixtures, sodium oleate, sodium alkyl benzene sulfonate, polyoxyethylene alkylphenol ether, polyoxyethylene alkyl ether, polyoxyethylene fatty acid esters, ethylene oxide adducts of nonyl phenol, sorbitan mono-oleate, and mixtures of these surfactants. Depending on the formulation of components, the polishing compositions of the present invention may be oil-in-water emulsions, wherein water is the continuous phase and oil is the disperse phase (so called "water out emulsions"), or water-in-oil emulsions, wherein oil is the continuous phase and water is the disperse phase (so called "oil out emulsions"). It can be appreciated that the polishing compositions of the present invention that do not include a hydrocarbon solvent are solvent-free emulsions.
The water soluble polishing agent of the polishing composition of the present invention includes at least one inorganic material which exhibits solubility in water and which acts as an abrasive cleaner that assists in removing weathered paint, stubborn road soil and old built-up polish. As noted above, the water soluble polishing agent will be present in the polishing composition at one of two alternative concentration levels. In the first alternative concentration level, the water soluble polishing agent is added to the polishing composition in an amount that exceeds the solubility of the polishing agent in water so that some of the polishing agent dissolves in the water component of the polishing composition and some of the polishing agent is suspended in the polishing composition. In the second alternative concentration level, the polishing agent is added to the polishing composition in an amount wherein all of the polishing agent dissolves in the water component of the polishing composition.
When formulating a polishing composition according to the present invention, one can refer to a table of solubility parameters in order to determine the approximate level at which the water soluble polishing agent will begin to become suspended in the polishing composition. Depending on whether or not it is desirable to include some of the water soluble polishing agent in suspension in the polishing composition, the amount of water soluble polishing agent added to the water in the polishing composition formulation is adjusted accordingly. Table 1 lists water soluble polishing agents which are suitable for use in the polishing composition, along with the solubility of each polishing agent in cold and hot water. Accordingly, the water soluble polishing agent is an inorganic material selected from the group consisting of ammonium benzoate, ammonium bicarbonate, ammonium bromide, ammonium phosphate, potassium carbonate, potassium citrate, potassium phosphate, potassium sulfate, sodium bicarbonate, sodium carbonate, sodium citrate, sodium phosphate, sodium sulfate, and mixtures thereof.
TABLE 1__________________________________________________________________________ Solubility in Grams/100 cc H.sub.2 ONAME FORMULA Cold Water Hot Water__________________________________________________________________________Ammonium Benzoate NH.sub.4 C.sub.7 H.sub.5 O.sub.2 19.6 14.5° C. 83.3 100° C.Ammonium Bicarbonate NH.sub.4 HCO.sub.3 11.9 0° C. 27.0 30° C.Ammonium Bromide NH.sub.4 Br 68.0 10° C. 145.6 100° C.Ammonium Phosphate, Monobasic NH.sub.4 H.sub.2 PO.sub.4 22.7 0° C. 173.2 100° C.Potassium Carbonate K.sub.2 CO.sub.3 105.5 0° C. 156.0 100° C.Potassium Citrate K.sub.3 C.sub.6 H.sub.5 O.sub.7.H.sub.2 O 167.0 15° C. 200.0 31° C.Potassium Phosphate (Monobasic) KH.sub.2 PO.sub.4 14.8 0° C. 83.5 90° C.Potassium Sulfate (Arcanite) K.sub.2 SO.sub.4 7.35 0° C. 24.1 100° C.Sodium Bicarbonate NaHCO.sub.3 6.90 0° C. 16.4 60° C.Sodium Carbonate (Soda Ash) Na.sub.2 CO.sub.3 7.10 0° C. 48.5 104° C.Sodium Carbonate (Sal Soda) Na.sub.2 CO.sub.3.10H.sub.2 O 21.5 0° C. 238.0 30° C.Sodium Citrate Na.sub.3 C.sub.6 H.sub.5 O.sub.7.2H.sub.2 O 77.0 25° C. 170.0 100° C.Sodium Phosphate (Monobasic) NaH.sub.2 PO.sub.4.H.sub.2 O 71.0 0° C. 390.0 83° C.Sodium Phosphate (Tribasic) Na.sub.3 PO.sub.4 4.50 0° C. 77.0 100° C.Sodium Sulfate (Thenardite) Na.sub.2 SO.sub.4 5.00 0° C. 42.0 100° C.__________________________________________________________________________
The solvents optionally incorporated into the polishing composition of the present invention facilitate the removal of greasy dirt from the vehicle surface and slow the evaporation of the water in the polishing composition. Preferably the solvent is a hydrocarbon solvent. Suitable hydrocarbon solvents include mineral spirits, liquid hydrocarbons derived from petroleum, naphtha, kerosene, and mixtures of these hydrocarbon solvents.
For optimum performance, i.e., ease of use, gloss and providing a protective coating to the painted surface, the concentration of the components of the polishing composition can be varied. One version of a polishing composition with a water soluble polishing agent is formed by combining from about 0.20 to about 5.5 weight percent nonionic or anionic surfactant, from about 0.1 to about 2.0 weight percent amino functional silicone, from about 0.5 to about 6.0 weight percent of silicone oils, from about 0.01 to about 3.5 weight percent of a curable silicone resin, from about 0.1 to about 5.0 weight percent of a mineral oil, from 0.0 to about 15.0 weight percent of a blend of hydrocarbon solvents, from about 0.05 to about 1.0 weight percent of a preservative, from about 5.0 to about 15.0 weight percent of a water soluble polishing agent, and from about 60 to about 90 weight percent deionized water. A summary of the above formula is presented below in Table 2:
TABLE 2______________________________________ Weight Percent (asComponents Actives)______________________________________Hydrocarbon Solvents 0.0 to 15.0Silicone Oils 0.5 to 6.0Mineral Oil 0.1 to 5.0Amino Functional Silicone 0.1 to 2.0Silicone Resin 0.01 to 3.5Nonionic or Anionic Surfactant 0.20 to 5.5Water 60.0 to 90.0Water Soluble Polishing Agent 5.0 to 15.0Preservative 0.05 to 1.0______________________________________
This invention is further illustrated in the following Examples and comparative tests, which are intended as exemplifying the invention and are not intended to be taken as limiting.
EXAMPLE A
A polishing composition in accordance with the present invention was prepared using the following components. It can be seen that sodium bicarbonate was chosen as the water soluble polishing agent in Example A.
______________________________________ WeightComponents %______________________________________Part A1. Mineral Spirits (Flash Point 107° F. TCC) CAS 3.0075-85-02. Mineral Spirits (Flash Point 162° F. TCC) CAS 5.4545-37-93. Dimethyl Silicone, 350 centistoke 0.504. Dimethyl Silicone, 1,000 centistoke 0.505. Dimethyl Silicone, 10,000 centistoke 0.506. Dimethyl Silicone, 60,000 centistoke 0.207. Mineral Seal Oil (Kermac 600, Kerr-McGee Refining Corp.) 0.508. Amino Functional Silicone (GE SF-1706) 0.509. Dimethicone/Trimethyl Siloxysilicate (Dow Corning 593) 0.2510. Curable Silicone Resin (GE SR-107) 0.1011. Sorbitan mono-oleate (Span 80, ICI Corp.) 0.50Part B12. Deionized Water 82.9013. Sodium Bicarbonate 5.00Part C14. Ethylene Glycol MonoButyl Ether (butyl "Cellosolve") 0.0815. 1,2-dibromo-2,4-dicyanobutane (Tektamer 38, Merck) 0.02 100.00______________________________________
The polishing composition of Example A is prepared as follows. First, Part A is prepared by placing the two mineral spirits at room temperature (60°-70° F.) in a stainless steel container equipped with an adjustable mixer. Under slow agitation, the remaining components 3 to 11 are added. The resulting solution is mixed until uniform.
Separately, Part B is prepared by placing the deionized water at room temperature (60°-70° F.) in a stainless steel container equipped with a stirrer and, under slow mixing, adding the sodium bicarbonate. The solution is mixed until it is clear.
Part A and Part B are then emulsified by adding Part B, in increments, to Part A. For a 1,000 gram batch, Part B should be added in four increments. With the addition of each increment, there is viscosity build up and the mixer speed should be adjusted accordingly. The batch should look smooth and uniform before adding the next increment.
Part C is prepared separately by adding the butyl cellosolve to the Tektamer 38 under agitation and heating the mixture to 100°-105° F. The heated solution is mixed until a clear solution is obtained. This solution is added to the batch of Part A and Part B while mixing. The resultant product is a water-in-oil emulsion wherein oil is the continuous phase and water is the disperse phase. The product has a cold cream type consistency.
The polishing composition of example A is used as follows. A motor vehicle is first washed to remove major road soils and then dried. The polish of the present invention is applied with a soft cloth onto the painted surface of the motor vehicle and allowed to dry to a residue. The residue of the polishing composition of the present invention is then washed or hosed off with water and towel dried, thereby leaving the gloss agent as a coating on the vehicle surface.
All of the silicone materials used in Example A function as gloss agents and add to the durability of the gloss on the polished surface. Specifically, the gloss agents include silicone oils such as dimethyl silicone and a dimethicone/trimethyl siloxysilicate blend, an amino functional silicone, and a curable silicone resin. The curable silicone resin used in the composition of Example A is sold under the trademark SR-107 by General Electric Company and is available at 60 weight percent in a solvent mixture of Aromatic 150 and aliphatic hydrocarbons. The amino functional silicone used in the composition of Example A is sold under the trademark SF-1706 by General Electric Company and is a 25/75 mixture of methoxy terminated aminoethylaminopropyl polysiloxane and methoxy terminated siloxane resin. If too much gloss agent is used, the preparation may be hard to get off of the polished surface and may have a tendency to smear. The use of too much gloss agent may also add to the cost of the formulation. Further, if too little gloss agent is used, it will not be sufficiently effective in providing a high gloss shine.
The hydrocarbon solvents, e.g., mineral spirits, act to both clean the surface and slow the evaporation of the water. If too much solvent is used, the composition will be hard to emulsify. If too little solvent is used, the solvents may not effectively clean or slow down the evaporation of the water. The mineral oil also acts to slow the evaporation of water. The sorbitan mono-oleate is used as an emulsifier. The 1,2-dibromo-2,4-dicyanobutane (Tektamer 38) is a preservative.
EXAMPLE B
Another polishing composition in accordance with the present invention was prepared using the following components.
______________________________________ WeightComponents %______________________________________ Part A1. Mineral Spirit (Flash Point 105° F. TCC) 3.00 CAS #8052-41-32. Mineral Spirit (Flash Point 205° F. TCC) 5.45 CAS #6474-47-83. Ethoxylated nonylphenol (Igepal CO-430, 0.50 GAF Corp.), HLB: 4.64. Ethoxylated nonylphenol (Igepal CO-850, 0.50 GAF Corp.), HLB: 165. Dimethyl Silicone, 350 centistoke 0.506. Dimethyl Silicone, 1,000 centistoke 0.507. Dimethyl Silicone, 10,000 centistoke 0.508. Dimethyl Silicone, 60,000 centistoke 0.209. Mineral Seal Oil (Kermac 600, Kerr-McGee 0.50 Refining Corp.)10. Amino Functional Silicone (GE-1706) 0.5011. Dimethicone/Trimethyl Siloxysilicate 0.25 (Dow Corning 593)12. Silicone Resin (GE SR-107) 0.10 Part B13. Deionized Water 74.4314. Sodium Bicarbonate 10.00 Part C15. Acrylic Polymer (Alcogum SL-70, 30% Aqueous 3.00 Emulsion, Alco Chemical Co.) Part D16. 1-(3-chloroallyl)-3,5,7-triaza-1-azonia-adamantane 0.07 chloride (Dowicil 75 Antimicrobial Agent) or 1,2-benzisothiazolin-3-one (Proxel GXL, ICI Americas) 100.00______________________________________
The polishing composition of Example B is prepared as follows. First, Part A is prepared by placing the two mineral spirits at room temperature (60°-70° F.) in a stainless steel container equipped with an adjustable mixer. Under slow agitation, the remaining components 3 to 12 are added. The resulting solution is mixed until uniform.
Separately, Part B is prepared by placing the deionized water at 115°-120° F. in a stainless steel container equipped with a stirrer and, under slow mixing, adding the sodium bicarbonate. The solution is mixed until it is clear.
Part A and Part B are then emulsified by adding Part B, under moderate agitation, to Part A. Part C and Part D are then added under agitation. The batch is then homogenized at 1.000-1.500 PSIG. The resultant product is an oil-in-water emulsion wherein water is the continuous phase and oil is the disperse phase. The product is a liquid having a viscosity of 20-40 poise.
In Example B, a combination of two nonionic surfactants is used as the emulsifying agent. Specifically, an ethoxylated nonylphenol having an HLB of 4.6, commonly called Igepal CO-430, and an ethoxylated nonylphenol having an HLB of 16.0, commonly called Igepal CO-850 were used as emulsifying agents. These emulsifying agents produced an oil-in-water emulsion. In addition, a thickening agent, Alcogum SL-70, which is an acrylic polymer (ethyl acrylate), was added to the composition. In this example, Dowicil 75 or Proxel GXL were used as preservatives.
The polishing composition of Example B is applied to a motor vehicle surface and rinsed off in the same manner as the polishing composition of Example A, thereby leaving the gloss agent as a coating on the vehicle surface.
EXAMPLE C
Another polishing composition was prepared as follows:
______________________________________ WeightComponents %______________________________________ Part A1. Deionized Water 7.882. Morpholine 0.303. Dimethyl Silicone, 350 centistoke 0.504. Dimethyl Silicone, 1,000 centistoke 0.505. Dimethyl Silicone, 10,000 centistoke 0.506. Dimethyl Silicone, 60,000 centistoke 0.207. Mineral Seal Oil (Kermac 600, Kerr-McGee Refining 0.50.)8. Amino Functional Silicone (GE-1706) 0.509. Dimethicone/Trimethyl Siloxysilicate (Dow Corning 0.2510. Silicone Resin (GE SR-107) 0.5011. Oleic Acid 0.30 Part B12. Deionized Water 60.0013. Sodium Bicarbonate 10.00 Part C14. Ammonium Hydroxide 0.50 Part D15. Deionized Water 14.5016. Acrylic Polymer (Carbopol EZ-1 Resin, B.F. Goodrich 2.00 Part E17. Acrylic Polymer (Alcogum SL-70, 30% Aqueous Emulsion, 1.00 Alco Chemical Co.) Part F18. 1-(3-chloroallyl)-3,5,7-triaza-1-azonia-adamantane 0.07ride (Dowicil 75 Antimicrobial Agent) or 1,2-benzisothiazolin-3-one (Proxel GXL, ICI Americas) 100.00______________________________________
The polishing composition of Example C is prepared as follows. First, Part A is prepared by placing deionized water at room temperature (60°-70° F.) in a stainless steel container equipped with an adjustable mixer. Under slow agitation, the remaining components 2 to 11 are added. The resulting solution is mixed until uniform.
Separately, Part B is prepared by placing the deionized water at 140°-150° F. in a stainless steel container equipped with a stirrer and, under slow mixing, adding the sodium bicarbonate. The solution is mixed until it is clear.
Part A and Part B are then emulsified by adding Part B to Part A. Part A and B are mixed for 45 minutes to one hour. Part C is then added to Part A and B while mixing.
Part D is prepared separately by adding the Carbopol EZ-1 Resin to the deionized water under mixing. This slurry is then added to the batch of Parts A, B and C while mixing. Part E is then added to the batch of Parts A, B, C and D while mixing. The batch of Parts A to E are mixed for 1 hour. Part F is then added to the batch of Parts A to E.
The batch is homogenized at 1.000-1.500 PSIG. The resultant product is a solvent free emulsion as hydrocarbon solvents were not added to the polishing composition as in Examples A and B. The product has a viscosity of 60-70 poise.
In Example C, an anionic surfactant, morpholine oleate, was used as the emulsifying agent. In addition, another thickening agent, Carbopol EZ-1 Resin, an acrylic polymer containing residual acrylic acid, was added to the composition.
The polishing composition of Example C is applied to a motor vehicle surface and rinsed off in the same manner as the polishing composition Example A, thereby leaving the gloss agent as a coating on the vehicle surface.
It can be seen from Examples A, B and C that a polishing composition including a water soluble polishing agent can be prepared as a water-in-oil emulsion, an oil-in-water emulsion, and a solvent free emulsion.
When the polishing compositions of Examples A, B and C were applied to a painted surface and rinsed off, a good initial gloss was noted. In addition, no unsightly residue remained on the surface after the polishing composition was rinsed off of the surface.
Comparative Test Results
Car polish protective coatings are typically destroyed by attrition due to weathering or by the effects of detergents that may be applied when washing the car. The durability of a car protective coating can be measured scientifically by the "contact angle" of water beads on the car finish. High, round water beads indicate the presence of a protective coating. As the protective coating wears away, the water beads tend to flatten out and the contact angle gets smaller, i.e., the higher the contact angle, the greater the beading (protection). Liquid-solid contact angles may vary between 0 and 180 degrees.
Contact angle measurements were used to evaluate the products of Examples A and B against the multi-component polish composition of U.S. Pat. No. 5,330,787 in order to determine the durability of the protective coating obtained when using polishing compositions of the present invention. First, the multi-component polish composition of U.S. Pat. No. 5,330,787, which is commonly sold under the trademark "PRISM", was applied to a precleaned black car hood according to the label directions and evaluated for detergent resistance and contact angle. This multi-component rinse away polish left a protective coating which produced water beads having an average contact angle of 76 degrees. After 5 washings with a detergent solution containing 1 ounce of a detergent car wash solution sold under the trademark ZIPWAX per 1 gallon of cold tap water, the water beads had an average contact angle of 60 degrees.
Second, the water-in-oil composition of Example A of the present invention was applied to a precleaned car hood according to the method described in Example A above. The polish of Example A left a protective coating which produced water beads having an average contact angle of 92 degrees. After 13 washings with a detergent solution containing 1 ounce of a detergent car wash solution sold under the trademark ZIPWAX per 1 gallon of cold tap water, the water beads had an average contact angle of 90 degrees.
Third, the oil-in-water composition of Example B of the present invention was applied to a precleaned car hood according to the method described in Example B above. The polish of Example B left a protective coating which produced water beads having an average contact angle of 86 degrees. After 13 washings with a detergent solution containing 1 ounce of Turtle Wax® Zip Wax® Car Wash per 1 gallon of cold tap water, the water beads had an average contact angle of 82 degrees.
It can be seen from the comparative testing of the polish compositions of Examples A and B of the present invention and U.S. Pat. No. 5,330,787 that both the oil-in-water and water-in-oil emulsions of the present invention produced a protective coating having a durability (as measured by water-hood contact angles) well above another comparable commercial car polish. Therefore, it can be concluded that the polishes of the present invention provide increased durability over other comparable commercial car polishes while at the same time providing the convenience of a one step polishing process.
Although the present invention has been described in detail with reference to certain preferred embodiments that can be advantageously employed in polishing vehicle surfaces, one skilled in the art will appreciate that the present invention can be practiced by other than the preferred embodiments, which have been presented for purposes of illustration and not of limitation. For example, the polishing agent of the polishing compositions of the present invention would be suitable for use in rubbing compounds, polishing compounds and metal polishes. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein. | An improved polishing composition is provided that includes an emulsion of a oil-based components and water-based components and a water soluble polishing agent. The polishing composition of the present invention is rubbed on a painted surface, hosed off with water and wiped or towel dried. Because of the use of a water soluble polishing agent in the polishing composition, all or substantially all of the polishing agent is washed away with the water. This eliminates the need for a two-step polishing process wherein a polishing composition is applied to a surface and allowed to dry in a first step and the surface is buffed with a dry cloth in a second step. One preferred embodiment of the present invention includes silicones, water, a nonionic or anionic surfactant and a water soluble polishing agent. Optionally, the polishing composition may include a solvent, mineral oil, wax, and a preservative. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a charge coupled device, and more particularly to a bidirectional horizontal charge transfer device for a mirror image sensor which allows bidirectional transfer of a signal charge.
2. Description of the Prior Art
Generally, a horizontal charge transfer channel requires a rapid clocking to sense the charge transmitted in parallel from a vertical charge transfer channel within a short time period.
For this reason, the horizontal charge transfer channel typically adopts a 2-phase clocking, which is different from the clocking used in a vertical charge transfer channel.
A conventional horizontal charge coupled device (hereinafter referred to as "HCCD") will be described below with reference to the accompanying drawings.
FIG. 1A is a sectional view showing a structure of a conventional HCCD, FIG. 1B shows a potential profile of the conventional HCCD, and FIG. 1C shows clock signals applied to poly gates of the conventional HCCD.
The conventional HCCD includes a P-type well formed in an N-type semiconductor substrate, and a BCCD 1 formed on a predetermined portion of the P-type well to function as a horizontal charge transfer channel. A gate insulating layer 3 is formed on the BCCD 1 over the surface of the N-type semiconductor substrate. First and second poly gates 4a and 4b are alternatively formed over the gate insulating layer 3 while being insulated from each other. In addition, barrier regions 2 which are supplied with a clock signal H01 or H02 underlie one of the first and second poly gates 4a and 4b.
The conventional HCCD constructed as above, as shown in FIG. 1B, forms a step-type potential well to transmit the charge in one direction even though a same clock signal is applied through the barrier regions 2.
Referring to FIGS. 1B and 1C, since the bottom of the potential well is in the low energy level state, electrons are gathered thereto. That is, electrons are gathered to the potential well under the fourth poly gate 4', which is supplied with the high level clock signal H02 when t=1.
When t=2, a high voltage is applied to the first and second poly gates 1' and 2' so as to lower the energy level of the lower portions of the first and second poly gates 1' and 2', and a low voltage is applied to the third and fourth poly gates 3' and 4' so as to raise the energy level of the third and fourth poly gates 3' and 4'.
However, the electrons gathered around the lower potential well of the fourth poly gate 4' cannot migrate left due to the barrier region 2 under the third poly gate 3'.
If the energy level of the fifth and sixth poly gates 5' and 6' were to be lowered gradually to remove the barrier region on the right of the fourth poly gate 4', the electrons would migrate to the lower portions of the fifth and sixth poly gates 5' and 6' having the low energy level.
Then, when the bias of the fifth and sixth poly gates 5' and 6' is sufficiently raised, the step-type potential well is formed again to move the gathered electrons from the lower portion of the fourth poly gate 4' to the lower portion of sixth poly gate 6'.
In case that t=3, the first, second, fifth and sixth poly gates 1', 2', 5' and 6' are supplied with the low voltage while the third, fourth, seventh and eighth poly gates 3', 4', 7' and 8' are supplied with the high voltage so as to have the same result as when t=0.
A period of the clock signal is from t=1 to t=3. During a one clock signal period, the electrons migrate from the lower portion of the fourth poly gate 4' to the lower portion of the eighth poly gate 8'.
The conventional HCCD using the 2-phase clocking of signals H01 and H02, however, is disadvantageous, for example, in that the barrier layer is formed below one of the first and second poly gates such that a charge can migrate only in one direction.
Therefore, the conventional HCCD cannot be utilized in a mirror image sensor which requires a bidirectional charge transfer.
SUMMARY OF THE INVENTION
The present invention is devised to solve the above-described problems of the conventional horizontal charge transfer device.
Accordingly, it is an object of the present invention to provide a bidirectional horizontal charge transfer device capable of transmitting charges in two directions by dualizing a voltage supplied to poly gates. This forms a potential step without using an ion implantation process to form a barrier layer, as in the conventional HCCDs.
To achieve the above object of the present invention, there is provided a bidirectional horizontal charge transfer device which includes a charge transfer area formed within a surface of a semiconductor substrate, a plurality of first, second, third and fourth poly gates repeatedly formed over the charge transfer area, and an insulating layer provided for insulating the poly gates on the charge transfer area. Here, a first clock signal is applied to the first and second poly gates, and a second clock signal is applied to the third and fourth poly gates. Thus, different potential levels are formed in portions of the charge transfer area corresponding to the lower portions of the first and second poly gates, and different potential levels are formed in portions of the charge transfer area corresponding to the lower portions of the third and fourth poly gates.
Other objects and further scope of applicability of the present invention will becomes 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.
Briefly described, the present invention is directed to a bidirectional horizontal charge transfer device, including a charge transfer area formed within a substrate, first, second, third and fourth poly gates formed over the charge transfer area, an insulating layer formed between the first, second, third and fourth poly gates, a first clock signal applied to the first and second poly gates, a second clock signal applied to the third and fourth poly gates, and biasing means for selectively applying a bias signal to the first and second clock signals so as to selectively change a charge transfer direction.
Furthermore, the present invention is directed to a bidirectional horizontal charge transfer method including the steps of forming a charge transfer area within a substrate, forming first, second, third and fourth poly gates over the charge transfer area, applying a first clock signal to the first and second poly gates, applying a second clock signal to the third and fourth poly gates, and selectively biasing the first and second clock signals so as to selectively change a charge transfer direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1A is a sectional view showing a structure of a conventional HCCD;
FIG. 1B shows a potential profile of the conventional HCCD;
FIG. 1C shows clocks signals used in the conventional HCCD;
FIG. 2 is a sectional view showing a structure of a HCCD according to the embodiments of the present invention; and
FIGS. 3A and 3B show potential profiles of the HCCD according to the embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A bidirectional horizontal charge transfer device according to the embodiment of the present invention will be described in detail below with reference to the accompanying drawings.
FIG. 2 is a sectional view showing a structure of a HCCD according to the embodiments of the present invention, and FIGS. 3A and 3B show potential profiles of the HCCD according to the embodiments of the present invention.
For attaining a bidirectional horizontal charge transfer, the charge transfer device according to the present invention supplies a bias to poly gates for producing a potential barrier layer, without implanting ions such as boron into the lower sides of poly gates formed in a charge transfer area.
At this time, the bias for producing the potential barrier may be externally supplied or produced by an internal voltage distribution.
The bidirectional horizontal charge transfer device according to the present invention is constructed as follows.
First, a P-type well 23 is formed on an N-type semiconductor substrate 24, and a BCCD 20 is formed on a specific area of the P-type well 23 to be utilized as a channel for transferring a signal charge to both directions. Also, a plurality of poly gates 22a and 22b are alternatively formed on a gate insulating layer 21 formed on the BCCD 20 for gate insulation.
At this time, unlike the conventional HCCD, an ion implantation is not used to form a barrier layer in the BCCD 20 to provide step coverage by differing the potential level. But, the charge is bidirectionally transferred using the following clocking operation.
FIG. 3A shows a potential profile of the HCCD with the electrons moving to the right, whereas FIG. 3B shows a potential profile of the HCCD with the electrons moving to the left.
As shown in FIG. 3A, a plurality of first and second poly gates 1" and 2" are supplied with different levels of the same clock signal H01, and a plurality of third and fourth poly gates 3" and 4" are supplied with different levels of the same clock signal H02. Thus, the potential levels of the lower sides (portions) of the first and second poly gates 1" and 2" and of the third and fourth poly gates 3" and 4" differ from each other, thereby transferring the charge. Here, the clock signals H01 and H02 have opposite phases.
Now, signal lines for supplying the clock signals to the first, second, third and fourth poly gates will be described in detail.
The clock signal H01 is applied to the respective first poly gates 1" through a first signal line 30, and to the respective second poly gates 2" through a second signal line 31. The first and second signal lines 30 and 31 includes capacitors having the same storage capacitance.
The clock signal H02 is applied to the respective third poly gates 3" through a third signal line 32, and to the respective fourth poly gates 4" through a fourth signal line 33. The third and fourth signal lines 32 and 33 includes capacitors having the same storage capacitance.
Here, the capacitors of the signal lines have a storage capacitance which is insufficient to be charged within one unit (period) of the clock signal H01 or H02.
The first, second, third and fourth signal lines 30, 31, 32 and 33 have voltage input terminals C, D, A and B, respectively, for effectively changing the level of the clock signals H01 and H02 being applied to the poly gates. The voltage input terminals A and C are supplied with a same voltage level, and the voltage input terminals B and D are supplied with a same voltage level.
Thus, the transfer direction of the charge becomes opposite depending on whether the voltage is applied to the input terminals A and C or to the input terminals B and D.
An operation of the bidirectional horizontal charge transfer device according to the present invention will be described as below.
Once a voltage for changing the level of clock signals H01 and H02 is applied to the input terminals A and C, the charge migrates to the right as shown in FIG. 3A.
In other words, when t=1, the lower portion of the fourth poly gate 4" becomes the bottom of the potential well.
When t=2, a high level clock signal H01 is applied to the first and second poly gates 1" and 2" to lower third energy levels, whereas a low level clock signal H02 is applied to the third and fourth poly gates 3" and 4" to raise their energy levels. However, when a voltage is applied to the voltage input terminal A, the level of the clock signal H02 being applied to the poly gate 3", for example, changes. As a result, a barrier layer is produced in the lower portion of the third poly gate 3" and the electrons gathered around the lower portion of the fourth poly gate 4" migrate to the right.
That is, the level of the clock signals H01 and H02 being applied to the first and third poly 1" and 3" is changed by the voltage applied to the input terminals A and C. This forms the potential barrier layer in the lower portions of the first and third poly gates 1" and 3". Due to this potential barrier layer, the charge migrates in the right direction only.
Similarly, when the voltage for effectively changing the level of clock signals H01 and H02 being supplied to the poly gates, is applied to the input terminals B and D, the charge migrates to the left as shown in FIG. 3B.
In other words, when t=1, the lower portion of the fifth poly gate 5" (which receives the same voltage level as the first poly gate 1") becomes the bottom of the potential well.
When t=2, the high voltage clock signal H01 is applied to the fifth poly gate 5" and sixth poly gate 6" (the six poly gate receiving the same voltage level as the second poly gate 2") to lower the energy level, while the seventh and eighth poly gates 7" and 8" are applied with the low voltage clock signal H02 to raise their energy level. Here, the seventh and eighth poly gates receive the same voltage level as the third and fourth poly gates 3" and 4", respectively.
However, the electrons gathered around the lower side of the fifth poly gate 5" cannot migrate in the right direction since the potential barrier exists on the right of the fifth poly gate 5".
If the energy level of the third and fourth poly gates 3" and 4" is lowered to eliminate the potential barrier on the left of the fifth poly gate 5", the electrons around the lower side of the fifth poly gate 5" migrate to the lower side of the third and fourth poly gates 3" and 4" which have the low energy level.
When the energy level of the third and fourth poly gates 3" and 4" is sufficiently lowered, the step-type potential well is formed again to move the bottom of the potential well from the lower side of the fifth poly gate 5" to the lower side of the third poly gate 3".
In case t=3, the low level clock signal H01 is applied to the first, second, fifth and sixth poly gates 1", 2", 5" and 6", and the high level clock signal H02 is applied to the third, fourth, seventh and eighth poly gates 3", 4", 7" and 8". Thus, the resulting state becomes identical to the case when t=0.
When t=1 to 3, the clock pulse of clock signals H01 and H02 has one period. During this period and when the voltage is applied to the input terminals B and D, the electrons migrate from the fifth poly gate 5" to the first poly gate 1". That is, they migrate from the right to the left, as shown in FIG. 3B.
The bidirectional horizontal charge transfer device according to the present invention as described above produces a barrier layer in the charge transfer area by using an external or internal bias and without using an ion implantation process. As a result, the potential step is efficiently controlled while simplifying the process thereof.
Furthermore, the charge transfer direction can be easily changed by controlling the clock signals and the voltage applied to the voltage input terminals A and C or B and D. This is a desirable feature for a mirror image sensor and the like, which requires a bidirectional charge transfer device.
While the present invention has been particularly shown and described with reference to particular embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be effected therein without departing from the spirit and scope of the invention as defined by the appended claims. | A bidirectional horizontal charge transfer device and method includes a charge transfer area formed within a substrate, a plurality of first, second, third and fourth poly gates formed over the charge transfer area, an insulating layer formed between the first, second, third and fourth poly gates, a first clock signal applied to the first and second poly gates, a second clock signal applied to the third and fourth poly gates, and a biasing circuit for selectively applying a bias signal to the first and second clock signals so as to selectively change a charge transfer direction. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to a composition that augments plant disease resistance to microbial infection, etc., and/or plant branching, and a method for suppressing infectious disease in a plant and a method for augmenting plant branching using the same.
BACKGROUND ART
[0002] Microbial infection is inevitable for plants and usually causes serious stress to plant bodies. Against such microbial infection, particularly, pathogenic infection, plants have evolved their own protective or defensive systems, in addition to morphological adaptation. Specifically, the primary response of each plant to the pathogenic infection involves the specific recognition of the pathogens and the rapid induction of cell death (hypersensitive cell death) of infected cells to eliminate the pathogens together with the infected cells (Non Patent Literature 1). The secondary response of the plant is the induction of pathogen resistance called systemic acquired resistance (SAR), which is triggered by the hypersensitive cell death, in order to protect the plant body from further attacks by the pathogens (Non Patent Literatures 2 and 3). SAR has been confirmed in many plants and confers resistance to various plant pathogens to the uninfected portions of plants (Non Patent Literatures 4 and 5). Salicylic acid has been identified as a signaling factor inducing this SAR, in dicot plants such as Arabidopsis thaliana and tobacco (Non Patent Literatures 6 and 7). If other signaling factors inducing SAR are identified and the intracellular signals of plants can be controlled, disease resistance can be conferred to plant bodies without being mediated by hypersensitive cell death. Unfortunately, much remains to be revealed about this SAR-inducing signaling mechanism mediated by salicylic acid, and the whole picture of the mechanism has not yet been clarified.
CITATION LIST
Non Patent Literature
[0000]
Non Patent Literature 1: Ross, A. F. (1961) Virology, 14: 340-358
Non Patent Literature 2: Kuc J. (1982) Bioscience, 32: 854-860
Non Patent Literature 3: McIntyre J. L. et al., (1981) Phytopathology, 71: 297-301
Non Patent Literature 4: Chester K S., (1933) Q. Rev. Biol., 8: 275-324
Non Patent Literature 5: Durner J. et al., (1997) Trends in Plant Sci., 2: 266-274
Non Patent Literature 6: Delaney T P. et al., (1994) Science, 266: 1247-1250
Non Patent Literature 7: Gaffney T. et al., (1993) Science, 261: 754-756
SUMMARY OF INVENTION
Technical Problem
[0010] The present inventors have newly found that brassinosteroid can induce the disease resistance of a plant through a pathway different from the salicylic acid-mediated SAR-inducing signaling mechanism described above (Nakashita H. et al., 2003, The Plant Jour., 33: 887-898). Brassinosteroid (hereinafter, referred to as “BR”) is a phytohormone that is involved in the regulation of plant growth, photomorphogenesis, the control of vascular bundle formation, the functional regulation of chloroplasts, etc., and plays a principal role in various areas of plant growth cycles (Azpiroz R. et al., 1988, Plant Cell, 10: 219-230; Clouse S. & Sasse J., 1998, Annu. Rev. Plant Physiol. Plant Mol. Biol., 49: 427-451; Mandava N., 1988, Annu. Rev. Plant Physiol. Plant Mol. Biol., 39: 23-52; and Sakurai A. et al., 1999, Brassinosteroids, Steroidal Plant Hormones, Tokyo: Springer). On the basis of the novel BR-mediated disease resistance of a plant (brassinosteroid-mediated disease resistance; hereinafter, referred to as “BDR”), the development of a plant disease resistance-augmenting agent comprising BR as an active ingredient has been expected. BR, however, is synthesized by complicated steps and thus, is disadvantageously unpractical in terms of production cost in the agricultural field where such an agent is used in large amounts.
[0011] Thus, an object of the present invention is to develop and provide a novel plant disease resistance-augmenting agent that is capable of inducing BDR instead of BR and augmenting plant disease resistance in a more inexpensive way, and a method for preventing and treating infectious disease in a plant using the same.
Solution to Problem
[0012] To attain the object, the present inventors have predicted that a signaling factor (hereinafter, referred to as a “BR intracellular signaling factor”) that functions in an intracellular signaling pathway activated by BR (hereinafter, referred to as a “BR intracellular signaling pathway”) may also be involved, as in BR, in the induction of BDR-induced disease resistance. On the basis of this hypothesis, the present inventors have isolated many mutants involved in the pathway using Arabidopsis thaliana . Results of particularly analyzing a bil3 mutant, one of brassinosteroid signaling pathway mutants bil (Brz-insensitive-long hypocotyl) having resistance to a BR biosynthesis inhibitor brassinazole (Brz), have demonstrated that the BIL3 gene encodes a novel peptide hormone capable of being extracellularly secreted and its overexpression not only induces BDR but also increases the number of branching in the plant body. The control of plant branching is important for, for example, the control of the yields of agricultural or horticultural crops. The present invention is based on these new findings and provides the followings:
[0013] (1) A peptide consisting of a following amino acid sequence and having activities of augmenting plant disease resistance and/or branching, or a salt thereof:
[0014] (a) the amino acid sequence represented by SEQ ID NO: 1, or
[0015] (b) an amino acid sequence having identity to 4 or more amino acids in the amino acid sequence represented by SEQ ID NO: 1 and having
[0000] an alanine residue or a serine residue as an amino acid residue corresponding to position 2 of the amino acid sequence represented by SEQ ID NO: 1, nonpolar amino acid residues as amino acid residues corresponding to positions 3, 5, 7, and 8 thereof, proline residues as amino acid residues corresponding to positions 4 and 6 thereof, and a glycine residue as an amino acid residue corresponding to position 9 thereof.
[0016] (2) The peptide or the salt thereof according to (1), wherein the amino acid sequence (b) further has a valine residue, an isoleucine residue, or a proline residue as an amino acid residue corresponding to position 3 of the amino acid sequence represented by SEQ ID NO: 1, an isoleucine residue or a valine residue as an amino acid residue corresponding to position 5 thereof, a leucine residue or a phenylalanine residue as an amino acid residue corresponding to position 7 thereof, and/or a valine residue as an amino acid residue corresponding to position 8 thereof.
[0017] (3) The peptide or the salt thereof according to (1) or (2), wherein the amino acid sequence (b) has an alanine residue as an amino acid residue corresponding to position 2 of the amino acid sequence represented by SEQ ID NO: 1, a valine residue as an amino acid residue corresponding to position 3 thereof, an isoleucine residue as an amino acid residue corresponding to position 5 thereof, and/or a leucine residue as an amino acid residue corresponding to position 7 thereof.
[0018] (4) The peptide or the salt thereof according to (1), wherein the peptide having the amino acid sequence (b) consists of any of the amino acid sequences represented by SEQ ID NOs: 2 to 7.
[0019] (5) The peptide or the salt thereof according to (1), wherein the peptide having the amino acid sequence (b) consists of any of the amino acid sequences represented by SEQ ID NOs: 8 to 18.
[0020] (6) A composition for conferring disease resistance to a plant and/or for augmenting plant branching, comprising at least one of a peptide according to any of (1) to (5), a peptide according to any of (1) to (5) further having amino acid(s) added to the N terminus and/or the C terminus thereof, and salts thereof, as an active ingredient.
[0021] (7) A method for suppressing microbial infection in a plant, comprising the step of allowing a peptide or a salt thereof according to any of (1) to (5) and/or a composition according to (6) to act on the plant.
[0022] (8) A method for augmenting plant branching, comprising the step of allowing a peptide or a salt thereof according to any of (1) to (5) and/or a composition according to (6) to act on the plant.
[0023] (9) A plant with conferred disease resistance and/or augmented branching, comprising at least one exogenous nucleic acid expression system comprising, in an expressible state, a nucleic acid encoding a following peptide having activities of augmenting plant disease resistance and/or branching:
[0024] (a) a peptide that comprises the amino acid sequence represented by SEQ ID NO: 1; or
[0025] (b) a peptide that comprises an amino acid sequence having identity to 4 or more amino acids in the amino acid sequence represented by SEQ ID NO: 1 and having an alanine residue or a serine residue as an amino acid residue corresponding to position 2 of the amino acid sequence represented by SEQ ID NO: 1, nonpolar amino acid residues as amino acid residues corresponding to positions 3, 5, 7, and 8 thereof, proline residues as amino acid residues corresponding to positions 4 and 6 thereof, and a glycine residue as an amino acid residue corresponding to position 9 thereof.
[0026] (10) The plant according to (9), wherein the amino acid sequence of the peptide (b) further has a valine residue, an isoleucine residue, or a proline residue as an amino acid residue corresponding to position 3 of the amino acid sequence represented by SEQ ID NO: 1, an isoleucine residue or a valine residue as an amino acid residue corresponding to position 5 thereof, a leucine residue or a phenylalanine residue as an amino acid residue corresponding to position 7 thereof, and/or a valine residue as an amino acid residue corresponding to position 8 thereof.
[0027] (11) The plant according to (9) or (10), wherein the amino acid sequence of the peptide (b) has an alanine residue as an amino acid residue corresponding to position 2 of the amino acid sequence represented by SEQ ID NO: 1, a valine residue as an amino acid residue corresponding to position 3 thereof, an isoleucine residue as an amino acid residue corresponding to position 5 thereof, and/or a leucine residue as an amino acid residue corresponding to position 7 thereof.
[0028] (12) The plant according to (9), wherein the peptide (b) consists of any of the amino acid sequences represented by SEQ ID NOs: 2 to 7.
[0029] (13) The plant according to (9), wherein the peptide (b) consists of any of the amino acid sequences represented by SEQ ID NOs: 8 to 18.
[0030] (14) The plant according to any of (9) to (13), wherein the nucleic acid expression system overexpresses the nucleic acid incorporated therein.
[0031] (15) The plant according to any of (9) to (14), wherein the nucleic acid expression system constitutively expresses the nucleic acid incorporated therein.
[0032] (16) The plant according to any of (9) to (14), wherein the nucleic acid expression system inducibly expresses the nucleic acid incorporated therein.
[0033] (17) The plant according to any of (9) to (16), wherein the nucleic acid expression system is an expression vector.
[0034] (18) Progeny of a plant according to any of (9) to (17).
[0035] The present specification encompasses the contents described in the specification and/or drawings of Japanese Patent Application No. 2011-024394 on which the priority of the present application is based.
Advantageous Effects of Invention
[0036] The composition of the present invention can be applied to a plant to thereby confer activities of augmenting disease resistance and/or branching to the plant.
[0037] The composition of the present invention comprising a chemically synthesized active peptide as an active ingredient can provide an inexpensive plant disease resistance-augmenting agent and a method for preventing and treating infectious disease in a plant using the same.
[0038] The composition of the present invention can control the number of branching in a plant and can enhance the yields of agricultural or horticultural crops.
BRIEF DESCRIPTION OF DRAWINGS
[0039] FIG. 1 shows the full-length amino acid sequence of Arabidopsis thaliana BIL3 and its characteristic domain. As shown in this diagram, BIL3 has an N-terminal extracellular, a C-terminal active domain (indicated by italicized letters) that is extracellularly secreted and functions as a peptide hormone, and a cleavage site therebetween for cleaving the extracellular transport signal after secretion.
[0040] FIG. 2 shows the amino acid sequence alignment of BIL3 and its paralogs and orthologs, and an active domain (peptide hormone) cleaved off from each protein after processing. In each amino acid sequence, “-” represents a gap, and “X” represents an undetermined amino acid residue. Numbers in the active domain represent the position of each amino acid residue counted from a threonine residue located at the N terminus of the active domain of Arabidopsis thaliana ( A. thaliana ) BIL3 as position 1. The active domain of each paralog or ortholog, when aligned as shown in this diagram, exhibits the greatest degree of matching with amino acids in the active domain of Arabidopsis thaliana BIL3. Thus, the position of the active domain in each paralog or ortholog corresponds to the position of amino acid residues (shown in this diagram) defined in the active domain of BIL3 described above.
[0041] FIG. 3 morphologically shows the aerial parts of a wild-type strain and a bil3 mutant. As is evident from this diagram, the number of flower stalks and the number of branches were increased in the bil3 mutant.
[0042] FIG. 4 is a diagram statistically showing the number of flower stalks ( FIG. 4A ) and the number of branches ( FIG. 4B ) in the wild-type strain and the bil3 mutant shown in FIG. 3 .
[0043] FIG. 5 shows the expression level of the BIL3 gene in the wild-type strain and the bil3 mutant. In this diagram, the expression of the BIL3 gene is indicated by relative value with the expression level of the BIL3 gene in the wild-type strain detected by real-time RT-PCR as 1.
[0044] FIG. 6 shows the expression level of the BIL3 gene in the wild-type strain and a 35S::BIL3 transformant. In this diagram, the expression of the BIL3 gene is indicated by relative value with the expression level of the BIL3 gene in the wild-type strain detected by real-time RT-PCR as 1.
[0045] FIG. 7 shows the expression level of the PR1 gene in the wild-type strain and the bil3 mutant. In this diagram, the expression of the PR1 gene is indicated by relative value with the expression level of the PR1 gene in the wild-type strain detected by real-time RT-PCR as 1.
DESCRIPTION OF EMBODIMENTS
[0046] Hereinafter, embodiments of the present invention will be described specifically.
[0047] 1. Peptide Augmenting Plant Disease Resistance and/or Branching, or Salt Thereof
[0048] 1-1. Summary and Constitution
[0049] The first embodiment of the present invention relates to a peptide or a salt thereof. The peptide of the present embodiment or the salt thereof has activities of augmenting plant disease resistance and/or branching.
[0050] In the present specification, the “plant” corresponds to bryophytes, ferns, angiosperms, and gymnosperms. The angiosperms encompass both dicot and monocot plants. The plant also includes both herbs and arbores. In the present invention, particularly preferred examples of the plant include agriculturally or commercially important plants, for example, crop plants such as cereals, vegetables, fruits, and garden flowers. Specific examples of the plant include: monocot plants such as plants of the family Poaceae (including rice, wheat, barley, rye, oat, pearl barley ( Coix lacryma - jobi var. ma - yuen ), millet ( Panicum miliaceum ), Italian millet ( Setaria italica ), Japanese millet ( Echinochloa esculenta ), Finger millet ( Eleusine coracana (Linn.) Gaertn.), corn, Indian millet ( Sorghum bicolor ), kaoliang, sorghum ( Sorghum vulgare Pers.), sugarcane, bamboo, and bamboo grass) and the family Zingiberaceae (including ginger, myoga ginger ( Zingiber mioga ), and turmeric); and dicot plants such as plants of the family Solanaceae (including tobacco, tomato, eggplant, bell pepper, chili pepper, and petunia), the family Leguminosae (including soybean, peanut, azuki bean, green pea, common bean, lentil, pea, broad bean, kuzu vine, sweet pea, and tamarind), the family Rosaceae (including strawberry, rose, Japanese apricot, cherry, apple, pear, peach, loquat, almond, plum, flowering quince, and Japanese kerria), the family Cucurbitaceae (including cucumber, balsam apple, gourd, pumpkin, melon, watermelon, luffa, and bottle gourd ( Lagenaria siceraria var. gourda )), the family Liliaceae (including lily, tulip, hyacinth, lily of the valley, asparagus, Welsh onion, and onion), the family Brassicaceae (including lettuce, cabbage, radish, Chinese cabbage, turnip, and oilseed rape), the family Vitaceae, the family Rutaceae, the family Malvaceae (including cotton, okra, Chinese mallow ( Malva verticillata ), and rose of Sharon ( Hibiscus syriacus )), the family Primulaceae (including cyclamen), the family Theaceae (including tea plant), the family Moraceae (including fig and mulberry tree), the family Actinidiaceae (including kiwi fruit), the family Anacardiaceae (including pistachio and mango), the family Piperaceae, and the family Ericaceae (including rhododendron, satsuki azalea ( Rhododendron indicum ), azalea, erica, and Belgium azalea ( Rhododendron simsii cv))). The “plant” described in the present specification is not limited to a plant body and encompasses all of plant cells, tissues, and organs (embryos, meristems, seeds, shoots, roots, stems, leaves, and flowers).
[0051] In the present specification, the “disease” or the “plant disease” refers to a disease in a plant caused by a pathogen. In this context, the “pathogen” refers to any of agents, such as viroids, viruses, phytoplasmas, bacteria, fungi (including yeasts, molds, and basidiomycetes), slime molds, protozoans, or nematodes, which are infective to plants and bring about some pathological symptom to the plants through their infection. In the present invention, the pathogen preferably corresponds to, particularly, viroids, viruses, phytoplasmas, and bacteria. Examples thereof include microbes of the genera Bacillus, Aspergillus, Penicillium, Schizosaccharomyces, Paenibacillus , and Trichoderma.
[0052] In the present specification, the “disease resistance” refers to the effect of preventing or suppressing the pathogenic infection or the onset of a pathological symptom caused thereby. This effect is controlled by the natural immune system of a plant. Thus, the phrase “augmenting disease resistance” refers to the prevention or suppression of the pathogenic infection or the onset of a pathological symptom caused thereby by more potentiating the natural immune system of a plant.
[0053] In the present specification, the “branching” or the “plant branching” refers to the development and outgrowth of a lateral bud or an auxiliary bud serving as an apex from which a new shoot grows from the stem (including flower stalks), trunk, or branch of a plant. The branching of the present invention also encompasses “tillers”, which are new lateral buds developed and grown from a part near the root as found in monocot plants, etc. In the present specification, the number of branches or stems (including flower stalks) developed by the “branching” is referred to as the “number of branching”.
[0054] In the present specification, the phrase “augmenting branching” refers to the activation of branching of a plant in the process of growth of the plant. The plant with augmented branching has the increased number of branching and also has an increased weight ratio compared with common plant bodies of the same species.
[0055] 1-1-1. Peptide
[0056] In the present specification, the simply described “peptide” means a molecule containing two or more amino acids linked via an amide bond. Thus, the term “peptide” encompasses both oligopeptides and polypeptides. The term “oligopeptide” means a peptide consisting of 20 or less amino acid residues. The term “polypeptide” means a peptide consisting of 21 or more amino acid residues.
[0057] The amino acids constituting the peptide of the present invention may be in any of D, L, and DL forms (racemates). Particularly, an L form is preferred. The amino acids constituting the peptide of the present invention derived from a natural protein are all in an L form. In the case of preparing the peptide of the present invention by chemical synthesis, the peptide may consist of only L-amino acids or only D-amino acids or L-amino acid(s) and D-amino acid(s) in combination.
[0058] The “peptide having activities of augmenting plant disease resistance and/or augmenting plant branching” (hereinafter, referred to as an “active peptide”) refers to only an active domain (which corresponds to positions 53 to 61 of SEQ ID NO: 8), which is a region extracellularly secreted as a peptide hormone in BIL3 protein or its paralogs or orthologs, or refers to a peptide comprising the active domain. The active peptide may have any number of amino acids added to the N terminus and/or C terminus of the active domain as long as the active domain has the activities described above. Such amino acids may be amino acids naturally adjacent to the active domain or may be amino acids that are not naturally adjacent to the active domain.
[0059] The protein “BIL3 (Brz-insensitive-long hypocotyl 3)” is encoded by Arabidopsis thaliana BIL3 gene. BIL3 is an extracellular secretion-type protein that has a full length of 63 amino acids represented by SEQ ID NO: 8 (NCBI-ID No. At1g49500) and has an N-terminal extracellular transport signal (secretory signal; positions 1 to 32 of SEQ ID NO: 8), a C-terminal active domain (see FIG. 2 ; positions 53 to 61 of SEQ ID NO: 8) that is highly conserved across species, and a cleavage site (positions 48 to 49 of SEQ ID NO: 8) therebetween (see FIG. 1 ). BIL3 is cleaved at the cleavage site after translation to remove the extracellular transport signal peptide. The active domain undergoes N-terminal processing and C-terminal processing and is then extracellularly secreted as a peptide hormone. Similar processing of active peptides has been reported as to, for example, Arabidopsis thaliana PSY1 (Amano Y. et al., (2007) Proc. Natl. Acad. Sci. USA, 46: 18333-18338). Thus, the active domain of BIL3 is presumably composed of the sequence of 9 amino acids represented by SEQ ID NO: 1.
[0060] BIL3 has three Arabidopsis thaliana paralogs (NCBI-ID No. At3g19030, NCBI-ID No. At4g33960, and NCBI-ID No. At2g15830) consisting of the amino acid sequences represented by SEQ ID NOs: 9, 34, and 37, respectively, and also has BIL3 orthologs derived from other plant species. Specific examples of the BIL3 orthologs include proteins of Thlaspi caerulescens of the family Brassicaceae consisting of the amino acid sequences represented by SEQ ID NO: 10 (NCBI-ID No. DN925255) and SEQ ID NO: 11 (NCBI-ID No. DN923660), proteins of Thellungiella halophila consisting of the amino acid sequences represented by SEQ ID NO: 12 (NCBI-ID No. BM985618) and SEQ ID NO: 36 (NCBI-ID No. DN779022), proteins of Brassica rapa (oilseed rape) consisting of the amino acid sequences represented by SEQ ID NO: 13 (NCBI-ID No. EG019277), SEQ ID NO: 14 (NCBI-ID No. DV643336), SEQ ID NO: 15 (NCBI-ID No. CX281551), and SEQ ID NO: 35 (NCBI-ID No. CN727308), a protein of Brassica rapa var. glabra (Chinese cabbage) consisting of the amino acid sequence represented by SEQ ID NO: 16 (NCBI-ID No. DN960533), a protein of Brassica oleracea var. capitata (cabbage) consisting of the amino acid sequence represented by SEQ ID NO: 17 (NCBI-ID No. AM057684), and a protein of Gossypium hirsutum (upland cotton) of the family Malvaceae consisting of the amino acid sequence represented by SEQ ID NO: 18 (NCBI-ID No. DW511993). All of these BIL3 paralogs and orthologs have an N-terminal extracellular transport signal, a C-terminal active domain, and a cleavage site therebetween.
[0061] The “activities of augmenting plant disease resistance and/or augmenting plant branching” are activities possessed by, for example, the active domain of BIL3 or the active domain of each BIL3 paralog or ortholog. Specific examples of such domains include (A) the active domain of BIL3 consisting of the amino acid sequence represented by SEQ ID NO: 1 and (B) the active domain of a BIL3 paralog or ortholog that consists of an amino acid sequence having identity to 4 or more amino acids in the amino acid sequence represented by SEQ ID NO: 1 and having an alanine residue or a serine residue as an amino acid residue corresponding to position 2 of the amino acid sequence represented by SEQ ID NO: 1, nonpolar amino acid residues as amino acid residues corresponding to positions 3, 5, 7, and 8 thereof, proline residues as amino acid residues corresponding to positions 4 and 6 thereof, and a glycine residue as an amino acid residue corresponding to position 9 thereof.
[0062] The “amino acid identity” of the active domain (B) refers to the number of identical amino acid residues between the amino acid sequences of the active domain of BIL3 and the active domain of the BIL3 paralog or ortholog to be compared when the amino acid sequences are aligned with a gap introduced, if necessary, in one or both of the amino acid sequences so as to give the highest degree of matching between their amino acid residues. The amino acid identity can be preferably 4 or more amino acids (44% or higher), more preferably 5 or more amino acids (55% higher), even more preferably 6 or more amino acids (66% or higher), with respect to the amino acid sequence (9 amino acids) of the BIL3 active domain. In this context, “%” refers to the ratio (%) of the number of identical (to the amino acid residues in the amino acid sequence of BIL3) amino acid residues with the greatest degree of matching in the amino acid sequence to be compared to the total number of amino acid residues in the amino acid sequence of BIL3. The % identity can be determined easily using a program known in the art, such as a homology search program BLAST Search (http://www.ncbi.nlm.nih.gov/blast/Blast.cgi). The “gap” refers to 1 or several amino acid residue(s). In this context, the term “several” corresponds to 2 to 5, 2 to 4, or 2 to 3 amino acids. Specifically, the active domain (B), when aligned with the BIL3 active domain, may have the deletion or addition of 1 or several amino acid residue(s) compared with the BIL3 active domain.
[0063] In the active domain (B), the phrase “corresponding to position X of the amino acid sequence (represented by SEQ ID NO: 1)” (wherein X represents any number of 1 to 9) defines the position of an amino acid residue in the active domain (B) with respect to the amino acid sequence of the BIL3 active domain. Specifically, the positions of amino acid residues in the BIL3 active domain represented by SEQ ID NO: 1 are numbered 1 to 9 in order from the N terminus. Subsequently, the BIL3 active domain and the active domain (B) are aligned so as to give the highest degree of matching between their amino acid residues. In this respect, the phrase described above represents the position of an amino acid residue in the active domain (B) corresponding to a position in the BIL3 active domain. In this context, the “corresponding amino acid residue” is not necessarily required to be an amino acid residue identical to that in the BIL3 active domain. Preferably, this amino acid residue is an identical amino acid residue or a similar amino acid residue. In this context, the “similar amino acid” refers to an amino acid that belongs to the same group of amino acids classified on the basis of properties such as electric charges, side chains, polarity, and aromatic properties. Examples of such groups include a basic amino acid group (arginine, lysine, and histidine), an acidic amino acid group (aspartic acid and glutamic acid), a nonpolar amino acid group (glycine, alanine, phenylalanine, valine, leucine, isoleucine, proline, methionine, and tryptophan), a polar uncharged amino acid group (serine, threonine, asparagine, glutamine, tyrosine, and cysteine), a branched amino acid group (leucine, isoleucine, and valine), an aromatic amino acid group (phenylalanine and tyrosine), a heterocyclic amino acid group (histidine, tryptophan, and proline), and an aliphatic amino acid group (glycine, alanine, leucine, isoleucine, and valine).
[0064] The “amino acid residue corresponding” to a certain position in the amino acid sequence of the BIL3 active domain may be absent, and/or an amino acid residue present in the amino acid sequence of the active domain (B) may not correspond to an amino acid residue in the BIL3 active domain. Such a case corresponds to, for example, the case where 1 or several amino acid residue(s) are deleted or added when the BIL3 active domain and the active domain (B) are aligned as described above.
[0065] Preferably, the active domain (B) has a valine residue as an amino acid residue corresponding to position 3 of the amino acid sequence represented by SEQ ID NO: 1, an isoleucine residue as an amino acid residue corresponding to position 5 thereof, a leucine residue as an amino acid residue corresponding to position 7 thereof, and/or a valine residue as an amino acid residue corresponding to position 8 thereof. Specific examples of such active domains include active domains consisting of the amino acid sequences represented by SEQ ID NOs: 2 to 7.
[0066] The active domain may consists of an amino acid sequence represented by any of SEQ ID NOs: 30 to 33.
[0067] The peptide of the present embodiment consists of an active peptide comprising the active domains (A) and/or (B). The length of the active peptide is not limited as long as the active peptide retains the activities. In consideration of a peptide hormone as the active domain contained therein or the chemical synthesis of the active peptide, the active peptide is desirably a short-chain peptide. The length of the active peptide is preferably 100 or less amino acids, more preferably 70 or less amino acids, even more preferably 50 or less amino acids, further preferably 30 or less amino acids, further preferably 20 or less amino acids. Such an active peptide corresponds to, for example, an active peptide further having several amino acids added to the N terminus and/or the C terminus of the active domain. The active peptide is most preferably the active domain itself, which is the minimum unit capable of functioning as a peptide hormone. Hence, the length of the active peptide is most preferably the number of amino acid residues in the active domain, for example, 9 or 10 amino acids in the case of the active domains represented by SEQ ID NOs: 1 to 7.
[0068] The peptide comprising the active domains (A) and/or (B) may be modified as long as the resulting peptide has the activities of augmenting plant disease resistance and/or plant branching. The modification includes modification with a labeling material as well as glycosylation, acetylation, formylation, amidation, phosphorylation, and PEGylation.
[0069] The same labeling material as that described in Embodiment 1 can be used as the labeling material. The modification with the labeling material is useful in detecting the anti-marker antibody of the present embodiment and its antigen binding fragment described later.
[0070] The modification regarding glycosylation may be natural glycosylation or may occur at a modified glycosylation site obtained by modifying a natural glycosylation site by a recombinant DNA technique or chemical treatment. The glycosylation site can be modified by any method known by those skilled in the art. Examples of the method include a method based on the gene manipulation as mentioned above, a method using glycosylation mutants, a method based on coexpression with one or more enzyme(s), for example, DI N-acetylglucosamine transferase III (GnTIII), and a method involving causing the expression of the peptide in various organisms or cell lines derived from various organisms and purifying the peptide, followed by sugar chain modification. For the method for preparing a modified glycosylation site by gene manipulation, see, for example, Umana et al., 1999, Nat. Biotechnol 17: 176-180; Davies et al., 2001, Biotechnol Bioeng 74: 288-294; Shields et al., 2002, J Biol Chem 277: 26733-26740; and Shinkawa et al., 2003, J Biol Chem 278: 3466-3473. For the method for modifying a sugar chain, see, for example, U.S. Pat. No. 6,218,149; European Patent No. 0,359,09681; U.S. Patent Publication No. 2002/0028486; International Publication No. WO 03/035835; U.S. Patent Publication No. 2003/0115614; U.S. Pat. No. 6,218,149; and U.S. Pat. No. 6,472,511. The modification by PEGylation involves binding a water-soluble polymer molecule such as polyethylene glycol (PEG) to the peptide serving as an active ingredient. The PEGylation can be achieved by chemically binding PEG to the N-terminal amino group, C-terminal carboxyl group, or lysine (Lys) residue ε-amino group of the antibody, etc. The peptide modified by the PEGylation can have an enhanced in vivo half-life.
[0071] The active peptide of the present embodiment can be synthesized according to, for example, a chemical synthesis method such as a fluorenylmethyloxycarbonyl (Fmoc) or t-butyloxycarbonyl (tBoc) method (Lectures on Biochemical Experiments —1—, Chemistry of Proteins —IV—, Chemical Modification and Peptide Synthesis, The Japanese Biochemical Society ed., Tokyo Kagaku Dojin Co., Ltd. (Japan), 1981). Alternatively, the active peptide of the present invention may be synthesized by a method known in the art using various commercially available peptide synthesizers (e.g., PSSM8 manufactured by Shimadzu Corp. and Model 433A manufactured by Applied Biosystems, Inc. (ABI)). Alternatively, a nucleic acid encoding the active peptide can be prepared using a genetic engineering approach known in the art (see e.g., Sambrook, J. et al., (1989) Molecular Cloning: a Laboratory Manual Second Ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.) and then incorporated into an expression vector, which is in turn introduced into host cells to produce the active peptide of interest in the host cells. In the case of biosynthesizing the active peptide by a genetic engineering approach, the nucleic acid encoding the peptide is linked to a nucleic acid encoding an extracellular transport signal. This approach is convenient because the active peptide of interest can be secreted extracellularly from the host cells after protein expression and collected easily from a culture supernatant thereof. Alternatively, the culture supernatant or a culture solution containing the host cells may be used in itself as the composition of the second embodiment described later without collecting or purifying the active peptide.
[0072] 1-1-2. Salt of Peptide
[0073] The salt of the peptide of the present embodiment refers to a salt of the peptide described in the paragraph “1-1-1. Peptide”. In this context, the “salt” can be any agriculturally acceptable salt without particular limitations. Examples thereof include acid-addition salts and base-addition salts. Examples of the acid-addition salts include: salts with inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, and phosphoric acid; and salts with organic acids such as acetic acid, malic acid, succinic acid, tartaric acid, and citric acid. Examples of the base-addition salts include: salts with alkali metals such as sodium and potassium; salts with alkaline earth metals such as calcium and magnesium; and salts with ammonium and amines such as triethylamine.
[0074] 1-2. Advantage
[0075] The peptide of the present invention or the salt thereof can be applied to a plant to thereby confer activities of augmenting disease resistance and/or branching to the plant.
[0076] The peptide of the present invention or the salt thereof is rapidly decomposed in the natural world and as such, has the advantage that the peptide of the present invention or the salt thereof, even when used as an agricultural chemical, does not remain over a long period in soil, water, or plant bodies and has only small influence on environments or animals including humans.
[0077] The active domain that is responsible for the activities of the peptide of the present invention or the salt thereof is not a special substance such as alkaloid expressed only in particular plant species but a general plant peptide hormone also found in vegetables routinely used such as cabbage or Chinese cabbage and as such, is very safe.
[0078] The peptide of the present invention or the salt thereof even having around 10 amino acids has activities and as such, can be synthesized inexpensively in large amounts by chemical synthesis. Hence, the peptide of the present invention or the salt thereof can serve as an active ingredient, instead of expensive BR, in a plant disease resistance-augmenting agent and a plant disease-resistant composition.
[0079] The peptide of the present invention or the salt thereof can control plant branching. For example, the peptide of the present invention or the salt thereof can augment branching to increase the number of branching, particularly, the number of flower stalks, thereby increasing the yields of agricultural or horticultural crops. The peptide of the present invention or the salt thereof can enhance the weight ratios of plant bodies compared with wild-type strains grown for the same period in the same environment thereas. As a result, a plant biomass can be increased. Thus, the productivity of forestry, bioethanol, etc., can also be improved.
[0080] 2. Composition
[0081] 2-1. Summary and Constitution
[0082] The second embodiment of the present invention relates to a composition. The composition of the present embodiment comprises at least one peptide having activities of augmenting plant disease resistance and/or augmenting plant branching as an active ingredient thereof and has activities of augmenting plant disease resistance and/or branching.
[0083] 2-1-1. Active Ingredient
[0084] The composition of the present embodiment contains at least one active peptide described in the first embodiment as an active ingredient. The composition may contain two or more peptides. In such a case, the types of these peptides may be derived from the same organism species or may be a combination derived from different organism species. Also, these two or more peptides contained in the composition may have the same lengths or may have different lengths.
[0085] The amount of the active peptide contained in the composition of the present embodiment depends on conditions such as the type of the active peptide, the strength of its activities, the type of a carrier contained therein, the type of a recipient plant, intended application, an application method, and the type of a drug, if contained, having other pharmacological effects. The content thereof can be determined appropriately in consideration of conditions under which the composition applied to a target plant can augment disease resistance and/or branching in the plant.
[0086] 2-1-2. Agriculturally Acceptable Carrier
[0087] The composition of the present invention may also comprise, if necessary, an agriculturally acceptable carrier. The “agriculturally acceptable carrier” refers to a substance that facilitates the application of the composition to a plant and suppresses the decomposition of the active peptide serving as an active ingredient or/and controls the rate at which the active peptide acts. Examples of the agriculturally acceptable carrier include solvents and auxiliaries.
[0088] Examples of the “solvents” include water, aromatic compound solvents (e.g., benzene, toluene, xylene, tetrahydronaphthalene, alkylated naphthalene, and derivatives thereof), paraffins (e.g., mineral oil fractions), chloroform, carbon tetrachloride, ketones (e.g., acetone and cyclohexanone), pyrrolidones (e.g., NMP and NOP), acetate (glycol diacetate), glycols, aliphatic dimethylamides, fatty acids, fatty acid esters, and mixed solvents thereof. Alternatively, a medium for cell culture or microbial culture may be used.
[0089] Preferred examples of the auxiliaries include natural mineral powders, synthetic mineral powders, emulsifiers, dispersants, and surfactants.
[0090] The “natural mineral powders” correspond to, for example, kaolin, clay, talc, and chalk.
[0091] The “synthetic mineral powders” correspond to, for example, highly dispersible silica and silicate.
[0092] The “emulsifiers” correspond to nonionic emulsifiers and anionic emulsifiers (e.g., polyoxyethylene fatty alcohol ether, alkyl sulfonate, and aryl sulfonate).
[0093] Examples of the “dispersants” include lignosulfite waste liquors and methylcellulose.
[0094] The “surfactants” correspond to, for example, alkali metal salts, alkaline earth metal salts, and ammonium salts of lignosulfonic acid, naphthalenesulfonic acid, phenolsulfonic acid, and dibutylnaphthalenesulfonic acid, alkylaryl sulfonate, alkyl sulfate, alkyl sulfonate, fatty alcohol sulfate, fatty acid and sulfated fatty alcohol glycol ethers, condensates of sulfonated naphthalene or a naphthalene derivative and formaldehyde, condensates of naphthalene or naphthalenesulfonic acid, phenol, and formaldehyde, polyoxyethylene octyl phenyl ether, ethoxylated isooctylphenol, octylphenol, nonylphenol, alkylphenyl polyglycol ether, tributylphenyl polyglycol ether, tristearylphenyl polyglycol ether, alkylaryl polyether alcohol, condensates of alcohol or fatty alcohol and ethylene oxide, ethoxylated castor oil, polyoxyethylene alkyl ether, ethoxylated polyoxypropylene, lauryl alcohol polyglycol ether acetal, sorbitol ester, lignosulfite waste liquors, and methylcellulose.
[0095] Preferably, the carrier for use in the composition of the present embodiment has no harmful effect or only small influence on environments such as soil and water quality or on animals, particularly, humans, when applied to the plant of interest.
[0096] The composition of the present embodiment may contain one or more agriculturally acceptable carrier(s) described above. The composition of the present invention may further contain an additional disease resistance-augmenting agent and/or an additional branching-augmenting agent, and an active ingredient having other pharmacological effects, for example, a pesticide, an insecticide, a herbicide, a bactericide, or a fertilizer (e.g., urea, ammonium nitrate, and superphosphate), without influencing the effects or advantages of the branching-suppressing agent of the present invention.
[0097] The dosage form of the composition of the present embodiment may be any of a liquid form, a solid (including semisolid) form, and a combination thereof. The dosage form can be set to a conventional pharmaceutical form, for example, solutions, oily dispersions, emulsions, suspensions, dusts, powders, pastes, gels, pellets, tablets, and granules, which permit direct spraying, coating, and/or dipping.
[0098] 3. Method for Suppressing Microbial Infection
[0099] The third embodiment of the present invention relates to a method for suppressing microbial infection. The method for suppressing microbial infection according to the present embodiment activates the disease resistance of the plant of interest to prevent or suppress infection from a plant-infective microbe. In this context, the “plant-infective microbe” refers to a microbe that is infective to a plant and brings about some pathological symptom to the host plant through its infection.
[0100] The method for suppressing microbial infection according to the present embodiment comprises an action step. Hereinafter, this step will be described specifically.
[0101] 3-1. Action Step
[0102] The “action step” of the present embodiment is the step of allowing the peptide (i.e., active peptide) of the first embodiment and/or the composition of the second embodiment to act on a recipient plant. In this context, the phrase “acting on a plant” means that the active peptide and/or the composition are contacted with the recipient plant to cause the plant body to incorporate therein the active peptide serving as an active ingredient. The method for contacting the active peptide of the first embodiment and/or the composition of the second embodiment is not limited. The method can be selected appropriately according to a contact site with the recipient plant body.
[0103] For example, the active peptide of the first embodiment and/or the composition of the second embodiment may be contacted with the aerial part of the recipient plant body. In such a case, examples of the contact method include methods such as the nebulization, spraying, coating, injection, dipping, and wound inoculation (including needle prick inoculation) of the active peptide and/or the composition. Since the active peptide serving as an active ingredient is based on the peptide hormone, the active peptide and/or the composition can be absorbed easily from the surface of the plant body by any of these contact methods. In this case, the dosage form of the active peptide of the first embodiment and/or the composition of the second embodiment is preferably a liquid, powdery, or gel solid form. The contact site on the aerial part may be any desired area such as stems or the base of the petiole without particular limitations. The contact site may be a portion or the whole of the plant body and is preferably a site most commonly found in the route of infection of the recipient plant with the plant-infective microbe. Examples thereof include leaves and stems.
[0104] Alternatively, the active peptide of the first embodiment and/or the composition of the second embodiment may be contacted with the root of the recipient plant body. In this case, the active peptide of the first embodiment and/or the composition of the second embodiment is absorbed from the root and thereby spread throughout the plant body where the active ingredient can then exert the effects of the present invention. For example, for hydroponic cultivation, the contact method specifically involves applying the active peptide of the first embodiment and/or the composition of the second embodiment to the plant by addition into a hydroponic solution. This approach has the advantages that: the concentration of the active peptide serving as an active ingredient can be controlled in the hydroponic solution; the decomposition of the active peptide can be suppressed by sterilizing the hydroponic solution; etc.
[0105] Alternatively, the plant disease resistance-augmenting agent may be applied directly or indirectly into or onto soil. This application method is convenient when the agent is applied to a wide area such as an agricultural field. However, note that the active peptide serving as the active ingredient of the present invention tends to be decomposed in a relatively short time by the action of microbes or the like in soil. If short-term effects are desired by the transient action of the active peptide of the first embodiment and/or the composition of the second embodiment, the active peptide and/or the composition can be applied directly into soil. Alternatively, the composition of the second embodiment comprising the active peptide of the first embodiment enclosed in a sustained-release inclusion body may be applied indirectly to the plant of interest. This approach is also convenient because the active peptide in the composition is absorbed from the root of the recipient plant by escaping decomposition in soil and thereby spread throughout the plant body where the active ingredient can then exert the effects of the present invention in each cell.
[0106] The amount of the active peptide of the first embodiment and/or the composition of the second embodiment applied varies depending on the type of the active peptide (in the case of the composition of the second embodiment, the type of the active peptide contained therein) or the type of the recipient plant. The amount of the active peptide of the first embodiment and/or the composition of the second embodiment applied even to recipient plants of the same species varies between hydroponic cultivation and soil cultivation. This is because the active peptide serving as an active ingredient is generally decomposed by the action of microbial decomposition in soil at a faster rate than that in a hydroponic solution. Thus, the amount of the active peptide and/or the composition applied can be determined appropriately according to situations, purposes, and needs by those skilled in the art.
[0107] 3-2. Advantage
[0108] The method for suppressing microbial infection according to the present embodiment can apply the peptide of the first embodiment and/or the composition of the second embodiment to the desired plant to thereby confer disease resistance to the plant.
[0109] The method for suppressing microbial infection according to the present embodiment can produce the effects of the active peptide of the first embodiment and/or the active ingredient in the composition of the second embodiment by contact with a plant body because the active peptide and/or the active ingredient can act as a peptide hormone. Hence, the method of the present invention does not require preparing the desired plant into a transgenic plant for conferring disease resistance thereto and can be applied even to edible crops (vegetables, cereals, and fruits).
[0110] 4. Method for Augmenting Plant Branching
[0111] The fourth embodiment of the present invention relates to a method for augmenting plant branching. The method for augmenting plant branching according to the present embodiment comprises an action step. Hereinafter, this step will be described specifically.
[0112] 4-1. Action Step
[0113] The “action step” of the present embodiment is the step of allowing the active peptide of the first embodiment and/or the composition of the second embodiment to act on a recipient plant. The present step is basically similar to the action step of the method for suppressing microbial infection according to the third embodiment, and a specific method therefor follows the step, as a rule. Hence, only a point different from the action step of the method for suppressing microbial infection according to the third embodiment will be described below.
[0114] The method for augmenting plant branching according to the present embodiment differs from the method of the preceding embodiment in that the method of the present embodiment is aimed at allowing the active peptide of the first embodiment and/or the composition of the second embodiment to act on a recipient plant to activate the branching of the plant, resulting in increase in the number of branching. Of course, the peptide of the first embodiment and/or the active peptide serving as the active ingredient of the composition described in the second embodiment can augment the branching of the recipient plant and can also confer disease resistance to the plant. Thus, these effects can be achieved at the same time by the application of the active peptide of the first embodiment and/or the composition of the second embodiment.
[0115] Also in the action step of the present embodiment, a contact site on the plant body with the active peptide and/or the composition is not limited. Preferably, the active peptide and/or the composition is contacted directly with a site where cell differentiation or growth is active, in consideration of obtained results showing that the BIL3 gene is expressed in shoot apices, whole roots, and veins and the fact that plant branching generally occurs in shoot apices or the base of the petiole.
[0116] 4-2. Advantage
[0117] The method for augmenting plant branching according to the present embodiment can apply the active peptide of the first embodiment and/or the composition of the second embodiment to the desired plant to activate the branching of the plant, thereby increasing the number of branching. The method of the present embodiment can also increase the number of flower stalks and as such, can provide a method for enhancing the yields of horticultural or agricultural crops by increasing the number of flower buds.
[0118] The active peptide and/or the active ingredient in the composition for use in the method of the present embodiment, as in the method for suppressing microbial infection according to the third embodiment, are found in general plants and are spontaneously and highly decomposable. Thus, the active peptide and/or the active ingredient are highly safe to human bodies and have only small influence on the natural world by application.
[0119] 5. Transgenic Plant
[0120] 5-1. Summary and Constitution
[0121] The fifth embodiment of the present invention relates to a transgenic plant with augmented plant disease resistance and/or branching activity.
[0122] The “transgenic plant” refers to a transformed plant expressibly containing gene(s) derived from the same species and/or different species as or from the plant as an exogenous gene. In the present specification, the “transgenic plant” particularly refers to a transformed plant intracellularly comprising an exogenous nucleic acid expression system comprising, in an expressible state, a nucleic acid encoding the active peptide described in the first embodiment, whereby the disease resistance and/or branching activity of the plant is augmented compared with wild-type strains.
[0123] 5-1-1. Nucleic Acid
[0124] The nucleic acid encoding the peptide serving as the active ingredient described in the first embodiment will be described.
[0125] The “nucleic acid encoding the peptide serving as the active ingredient described in the first embodiment” refers to a nucleic acid encoding the active peptide described in the first embodiment. In the present invention, the term “nucleic acid” mainly refers to natural nucleic acids such as DNA and/or RNA and can also include artificially chemically modified or constructed nucleic acids or nucleic acid analogs. If necessary, the nucleic acid may be labeled, at its phosphate group, sugar moiety, and/or base moiety, with a nucleic acid-labeling material.
[0126] As described above, the active peptide comprises an active domain as the central active site of the active ingredient. This active domain corresponds to a peptide hormone which is a mature form of the Arabidopsis thaliana BIL3 protein or its paralog or ortholog. Specific examples of the nucleic acid include a nucleic acid comprising a nucleotide sequence encoding the active domain of BIL3 consisting of the amino acid sequence represented by SEQ ID NO: 1. Also, the nucleic acid refers to a nucleic acid encoding the active domain in each BIL3 paralog or ortholog, i.e., a nucleic acid encoding a peptide that comprises an amino acid sequence having identity to 4 or more amino acids in the amino acid sequence represented by SEQ ID NO: 1 and having an alanine residue or a serine residue as an amino acid residue corresponding to position 2 of the amino acid sequence represented by SEQ ID NO: 1, nonpolar amino acid residues as amino acid residues corresponding to positions 3, 5, 7, and 8 thereof, proline residues as amino acid residues corresponding to positions 4 and 6 thereof, and a glycine residue as an amino acid residue corresponding to position 9 thereof. Preferable examples of such nucleic acids include a nucleic acid encoding the peptide (b) that comprises an amino acid sequence further having a valine residue, an isoleucine residue, or a proline residue as an amino acid residue corresponding to position 3 of the amino acid sequence represented by SEQ ID NO: 1, an isoleucine residue or a valine residue as an amino acid residue corresponding to position 5 thereof, a leucine residue or a phenylalanine residue as an amino acid residue corresponding to position 7 thereof, and/or a valine residue as an amino acid residue corresponding to position 8 thereof, and a nucleic acid encoding the peptide (b) that comprises an amino acid sequence having an alanine residue as an amino acid residue corresponding to position 2 of the amino acid sequence represented by SEQ ID NO: 1, a valine residue as an amino acid residue corresponding to position 3 thereof, an isoleucine residue as an amino acid residue corresponding to position 5 thereof, and/or a leucine residue as an amino acid residue corresponding to position 7 thereof. More specific examples thereof include a nucleic acid comprising a nucleotide sequence encoding the active domain of the BIL3 paralog or ortholog consisting of any of the amino acid sequences represented by SEQ ID NOs: 2 to 7. Alternatively, the nucleic acid may be a nucleic acid comprising a nucleotide sequence encoding the active domain consisting of an amino acid sequence represented by any of SEQ ID NOs: 30 to 33.
[0127] In the transgenic plant of the present embodiment, the active domain contained in the expressed active peptide functions as a peptide hormone and confers plant disease resistance and/or branching activity to the plant. For this purpose, at least the active domain contained in the expressed active peptide needs to be extracellularly transported. Hence, the active peptide preferably comprises an extracellular transport signal and a cleavage site for cleaving the signal peptide after extracellular transport. For example, the full-length BIL3 protein ( FIG. 1 ) or the full-length protein of its paralog or ortholog comprises an extracellular transport signal and a cleavage site and is thus preferred as the active peptide that is expressed in the transgenic plant of the present embodiment. Thus, the nucleic acid according to the present embodiment is preferably BIL3 gene having the nucleotide sequence represented by SEQ ID NO: 19 or BIL3 paralog gene or ortholog gene having any of the nucleotide sequences represented by SEQ ID NOs: 20 to 29 and 38 to 41. In this context, the nucleotide sequences represented by SEQ ID NOs: 19 to 29 encode the amino acid sequences represented by SEQ ID NOs: 8 to 18, respectively. Alternatively, the nucleic acid is a nucleic acid that hybridizes under stringent conditions to the nucleic acid consisting of any of the nucleotide sequences described above and encodes the peptide having the activities described above. The stringent hybridization conditions are described in, for example, Sambrook, J. et al., (1989) Molecular Cloning: a Laboratory Manual Second Ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. Specific examples thereof include conditions involving incubation with a labeled probe at 68° C. in 6×SSC, 5×Denhardt's reagent, 0.5% SDS, and 100 μg/ml denatured and fragmented salmon sperm DNA, and washing starting at room temperature in 2×SSC and 0.1% SDS and continuing up to a salt concentration changed to 0.1×SSC and a temperature changed to 68° C. until background signals are no longer detected.
[0128] 5-1-2. Nucleic Acid Expression System
[0129] The transgenic plant of the present embodiment comprises at least one exogenous nucleic acid expression system comprising, in an expressible state, a nucleic acid encoding the active peptide of the first embodiment.
[0130] The “exogenous nucleic acid expression system” refers to a foreign nucleic acid expression system transferred from outside via artificial operation. Thus, the exogenous nucleic acid expression system does not correspond to an endogenous nucleic acid expression system originally located at a predetermined locus on the plant genome. However, even such an endogenous nucleic acid expression system, when mutated from outside via artificial operation such as mutagenesis or whose origin is derived from an exogenous nucleic acid expression system, as in the progeny of the transgenic plant, is also included in the exogenous nucleic acid expression system of the present invention.
[0131] The “nucleic acid expression system” refers to one expression system unit that can cause expression of the nucleic acid (mainly, a gene or a fragment thereof) incorporated in the system. Thus, the nucleic acid expression system according to the present embodiment incorporates the nucleotide sequence of the nucleic acid encoding the active peptide serving as the active ingredient described in the first embodiment and can express the active peptide in the cell of the transgenic plant. The nucleic acid expression system has expression regulatory regions essential for gene expression, in addition to the nucleic acid region. The essential expression regulatory regions include, for example, a promoter and a terminator. The system may additionally comprise an enhancer, a poly A addition signal, a 5′-UTR (untranslated region) sequence, a marker or selective marker gene, a multicloning site, a replication origin, and the like. The nucleic acid expression system includes the whole of one expression system unit necessary for the expression of the particular gene or the like isolated from the genome as well as a system artificially constructed, for example, by combining expression regulatory regions or the like derived from various organisms. Any of these nucleic acid expression systems may be used in the present invention.
[0132] General plants also usually have endogenous BIL3 gene or its paralog gene or ortholog gene (hereinafter, referred to as a “BIL3 gene, etc.”). Hence, the plants have endogenous disease resistance and/or branching activity attributed to the expression of these genes. In order to allow the transgenic plant of the present embodiment to have more augmented disease resistance and/or branching activity compared with wild-type plants of the same species thereas, the nucleic acid expression system needs to express the BIL3 gene, etc. at a level exceeding the usual expression level. Thus, the nucleic acid expression system used in the present embodiment desirably has, for example, the property of being capable of overexpressing the incorporated nucleic acid encoding the active peptide and/or constitutively expressing or inducibly expressing the incorporated nucleic acid. This exogenous nucleic acid expression system may further have the property of being capable of maintaining a plurality of its own copies (multicopy) in the plant cell.
[0133] The nucleic acid expression system capable of overexpression can express the incorporated nucleic acid encoding the active peptide at 2 or more times, preferably 5 or more times, more preferably 10 or more times or 20 or more times, the expression level of the endogenous BIL3 gene, etc. per nucleic acid expression system.
[0134] The nucleic acid expression system capable of constitutive expression can continuously express the active peptide all the time, regardless of timing or an expression site. Hence, the nucleic acid expression system having this property is very effective because the system can provide the active peptide, etc. independently of the temporal or positional control, if any, of the expression of the endogenous BIL3 gene, etc.
[0135] In contrast to the nucleic acid expression system capable of constitutive expression, the nucleic acid expression system capable of inducible expression can express the active peptide in a time- or site-specific manner. Thus, this nucleic acid expression system is very effective when the endogenous BIL3 gene, etc. undergoes the temporal and/or site-specific control of expression or when the active peptide is expressed at the desired timing and the desired site.
[0136] The multicopy nucleic acid expression system has the advantage that, even if each individual nucleic acid expression system expresses the BIL3 gene, etc. at a low expression level, the nucleic acid expression system itself can increase in number, resulting in an increased expression level per cell as a whole. In the present embodiment, the multicopy nucleic acid expression system can be used in combination with the nucleic acid expression system capable of overexpression, the nucleic acid expression system capable of constitutive expression, or the nucleic acid expression system capable of inducible expression to thereby more effectively confer pathogen resistance and/or branching activity to the plant.
[0137] The constitution of the exogenous nucleic acid expression system having the property described above is not limited as long as the system has components essential for expression and incorporates the active peptide-encoding nucleic acid in an expressible state. In this context, the phrase “incorporating in an expressible state” means that the active peptide-encoding nucleic acid is expressibly inserted in the nucleic acid expression system. Specifically, this means that the active peptide-encoding nucleic acid is placed under the control of a promoter and a terminator in the nucleic acid expression system. Specific examples of the nucleic acid expression system thus constituted include expression vectors.
[0138] In the present invention, the “expression vector” refers to a nucleic acid expression system that can transport the incorporated active peptide-encoding nucleic acid, etc. into the plant cell of interest so that the active peptide can be expressed in the plant cell. Specific examples thereof include expression vectors based on plasmids or viruses.
[0139] In the case of the expression vector based on a plasmid (hereinafter, referred to as a “plasmid expression vector”), for example, a vector of pPZP, pSMA, pUC, pBR, pBluescript (Stratagene Corp.), or pTriEX™ (Takara Bio Inc.) series, or a binary vector of pBI, pRI, or pGW series can be used as a plasmid moiety.
[0140] In the case of the expression vector based on a virus (hereinafter, referred to as a “viral expression vector”), cauliflower mosaic virus (CaMV), bean golden mosaic virus (BGMV), tobacco mosaic virus (TMV), or the like can be used as a virus moiety.
[0141] The expression vector comprises, as described above, a promoter and a terminator as expression regulatory regions. The expression vector may additionally comprise an enhancer, a poly A addition signal, a 5′-UTR (untranslated region) sequence, a marker or selective marker gene, a multicloning site, a replication origin, and the like. The respective types of these components are not limited as long as these components can exert their functions in the plant cell. Those known in the art can be selected appropriately according to the plant to be transformed or according to purposes (e.g., expression pattern) in the plant.
[0142] The promoter used can be selected, for example, according to the desired expression pattern, from an overexpression-type promoter, a constitutive promoter, a site-specific promoter, a stage-specific promoter, and/or an inducible promoter. Specific examples of the overexpression-type constitutive promoter include cauliflower mosaic virus (CaMV)-derived 35S promoter, Ti plasmid-derived nopaline synthase gene promoter Pnos, maize-derived ubiquitin promoter, Oryza sativa -derived actin promoter, and tobacco-derived PR protein promoter. Ribulose bisphosphate carboxylase small subunit (Rubisco ssu) promoters or histone promoters of various plant species may be used. Specific examples of the site-specific promoter include root-specific promoter described in JP Patent Publication (Kokai) No. 2007-77677 A (2007).
[0143] Examples of the terminator include nopaline synthase (NOS) gene terminator, octopine synthase (OCS) gene terminator, CaMV 35S terminator, E. coli lipopolyprotein lpp 3′ terminator, trp operon terminator, amyB terminator, and ADH1 gene terminator. The terminator is not limited as long as its sequence can terminate the transcription of the gene transcribed by the action of the promoter.
[0144] Examples of the enhancer include an enhancer region containing an upstream sequence in the CaMV 35S promoter. The enhancer is not limited as long as the enhancer can enhance the expression efficiency of the active peptide-encoding nucleic acid, etc.
[0145] Examples of the marker or selective marker gene include drug resistance genes (e.g., tetracycline resistance gene, ampicillin resistance gene, kanamycin resistance gene, hygromycin resistance gene, spectinomycin resistance gene, chloramphenicol resistance gene, and neomycin resistance gene), fluorescent or luminescent reporter genes (e.g., luciferase, β-galactosidase, β-glucuronidase (GUS), and green fluorescence protein (GFP) genes), and enzyme genes such as neomycin phosphotransferase II (NPT II), dihydrofolate reductase, and Blasticidin S resistance genes. The marker or selective marker gene may be ligated with the same expression vector as the expression vector incorporating the active peptide-encoding nucleic acid, etc. or may be ligated with an expression vector different therefrom. In the latter case, the plant of interest can be co-transformed with both the expression vectors to thereby produce effects equivalent to those brought about by transformation with the single expression vector incorporating both the nucleic acid and the gene.
[0146] 5-2. Method for Preparing Transgenic Plant
[0147] 5-2-1. Preparation of Nucleic Acid Expression System
[0148] The nucleic acid expression system can be prepared according to a method known in the art, for example, a method described in Sambrook, J. et al., (1989) Molecular Cloning: a Laboratory Manual Second Ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.
[0149] Hereinafter, the preparation of the plasmid expression vector or the viral expression vector will be described with reference to specific examples, though the preparation of the nucleic acid expression system is not limited thereto.
[0150] (1) Preparation of Plasmid Expression Vector
[0151] First, of the nucleic acids described in the paragraph 5-1-1, the desired nucleic acid is cloned. For example, in the case of cloning the Arabidopsis thaliana BIL3 gene, an appropriate region is selected from the nucleotide sequence represented by SEQ ID NO: 19, and an oligonucleotide having the nucleotide sequence thereof is chemically synthesized. The chemical synthesis can utilize a custom synthesis service provided by each life science manufacturer.
[0152] Next, the BIL3 gene is isolated with the oligonucleotide as a probe from an Arabidopsis thaliana cDNA library according to a method known in the art, for example, plaque hybridization. For the details of the isolation method, see Sambrook, J. et al., (1989) (supra). Since the Arabidopsis thaliana cDNA library is commercially available from each life science manufacturer such as Stratagene Corp., such a commercially available product may be used. Alternatively, oligonucleotides serving as a primer pair may be chemically synthesized on the basis of the nucleotide sequence represented by SEQ ID NO: 19, and the BIL3 gene of interest can be amplified from an Arabidopsis thaliana genomic DNA or cDNA library by a nucleic acid amplification method such as PCR using the primer pair. In the case of performing the nucleic acid amplification, high-fidelity DNA polymerase having 3′-5′ exonuclease activity, such as Pfu polymerase, is preferably used. For detailed conditions, etc., for the nucleic acid amplification, see, for example, a method described in Innis M. et al (Ed.), (1990), Academic Press, PCR Protocols: A Guide to Methods and Applications. The isolated BIL3 gene is inserted, if necessary, to an appropriate plasmid and cloned in a host microbe such as E. coli . Then, its full-length nucleotide sequence is confirmed according to a technique known in the art.
[0153] Subsequently, the BIL3 gene is integrated into a predetermined site in the core of the desired nucleic acid expression system (backbone portion of the nucleic acid expression system). For example, the BIL3 gene is cleaved with appropriate restriction enzymes on the basis of the determined nucleotide sequence. Meanwhile, the nucleic acid expression system is cleaved at the corresponding restriction enzyme sites. A multicloning site, if present, in the nucleic acid expression system is conveniently used. Subsequently, the BIL3 gene is inserted to the nucleic acid expression system by the ligation of both the nucleic acids at their ends using ligase or the like to complete the nucleic acid expression system for the BIL3 gene of interest. These series of gene manipulation procedures are technically well known in the art. For the details of the method, see, for example, Sambrook, J. et al., (1989) (supra).
[0154] (2) Preparation of Viral Expression Vector
[0155] Basic procedures therefor can follow the method for preparing the plasmid expression vector. First, a plant virus genome is prepared by a method known in the art and then inserted to an appropriate cloning vector, for example, of E. coli -derived pBI, pPZP, pSMA, pUC, pBR, or pBluescript series, to obtain a recombinant. Next, the active peptide-encoding nucleic acid is inserted to a predetermined site in the viral genome contained in the recombinant, and cloned. Subsequently, a plant virus genome region can be excised from the recombinant using restriction enzymes. In this way, the viral expression vector of interest can be obtained.
[0156] (3) Method for Transferring Nucleic Acid Expression System into Plant Cell
[0157] The nucleic acid expression system incorporating the active peptide-encoding nucleic acid can be transferred into a plant cell, i.e., a plant cell can be transformed, by an arbitrary appropriate method known in the art. In the case of using a plasmid expression vector as the nucleic acid expression system, for example, a protoplast, particle gun, or Agrobacterium method can be used preferably as the transformation method.
[0158] The protoplast method involves removing cell walls from plant cells by enzymatic (e.g., cellulase) treatment and transferring the gene of interest into the resulting plant cells (protoplasts). This method can be further classified into electroporation, microinjection, and polyethylene glycol methods, etc., depending on an approach for the gene transfer. The electroporation method involves applying an electric pulse to a mixed solution of the protoplast and the gene of interest to transfer the gene into the protoplast. The microinjection method involves directly transferring the gene of interest into the protoplast under a microscope using a microneedle. The polyethylene glycol method involves transferring the gene of interest to the protoplast by the action of polyethylene glycol.
[0159] The particle gun method involves attaching the gene of interest to microparticles of gold, tungsten, or the like, and intracellularly injecting the resulting microparticles into plant tissues using high-pressure gas to transfer the gene of interest into the cells. This method can produce transformed cells containing the gene of interest integrated in the genomic DNA of the recipient plant cells. The successfully transformed cells are usually selected on the basis of the marker gene product in the nucleic acid expression system.
[0160] The Agrobacterium method involves transforming plant cells using, as transforming factors, a bacterium of the genus Agrobacterium (e.g., A. tumefaciens and A. rhizogenes ) and Ti plasmid derived therefrom. This method can transfer the gene of interest into the genomic DNA of recipient plant cells.
[0161] These methods are all known in the art. For the details thereof, see appropriate protocols described in, for example, Shokubutsu Taisha Kogaku (Plant Metabolic Engineering in English) Handbook (2002, NTS Inc.) or Shinban Model Shokubutsu No Jikken Protocol: Idengakuteki Shuhou Kara Genome Kaiseki Made (Experimental Protocol of Model Plant, New Edition: From Genetic Technique To Genomic Analysis in English) (2001, Shujunsha Co., Ltd.).
[0162] Alternatively, in the case of using a viral expression vector (e.g., using CaMV, BGMV, or TMV described above) as the nucleic acid expression system, the plant cells of interest can be infected with the viral expression vector containing the integrated active peptide-encoding nucleic acid to obtain transformed cells. For the details of such a gene transfer method using the viral vector, see, for example, the method of Hohn et al. (Molecular Biology of Plant Tumors (Academic Press, New York) 1982, pp. 549) and U.S. Pat. No. 4,407,956.
[0163] The present invention does not necessarily require that the plant species from which the active peptide-encoding nucleic acid is derived should be identical to the plant species of plant cells to be transformed. For example, the cells of tobacco ( Nicotiana tabacum ) of the family Solanaceae may be transformed with the nucleic acid expression system incorporating the BIL3 gene derived from Arabidopsis thaliana of the family Brassicaceae. This is because: the BR signaling pathway involving BIL3 universally exists in plants; and, as shown in FIG. 2 , each individual BIL3 peptide hormone (active domain) is highly conserved across species; thus, even if a plant species is transformed with a nucleic acid expression system comprising a nucleic acid encoding an active peptide derived from species different therefrom, the nucleic acid expression system transferred to the plant species can exert functions similar to those brought about by the transformation of the plant species with a system derived from the same species thereas.
[0164] In the present invention, preferably, the plant to be transformed with the nucleic acid expression system has at least a wild-type gene cluster involved in the BR signaling pathway and a wild-type gene cluster involved in the natural immunity-inducing signaling pathway mediated by salicylic acid. This is because: the augmentation of plant disease resistance of the present invention is based on the augmented signals of these pathways; and even if signals are augmented by increasing the expression level of a polypeptide located upstream in the signaling pathway, subsequent signals cannot be transduced in the presence of its downstream factor having a loss-of-function mutation or the like, resulting in unsuccessful obtainment of the disease-resistant plant.
[0165] In the present invention, two or more nucleic acid expression systems differing in the active peptide-encoding nucleic acid incorporated therein can be transferred, in a range that can coexist with each other, into one plant cell. Two nucleic acid expression systems, for example, a nucleic acid expression system incorporating the Oryza sativa BIL3 ortholog gene and a nucleic acid expression system incorporating the Arabidopsis thaliana BIL3 gene, may be transferred into one plant cell (e.g., Oryza sativa cell).
[0166] After this step, the transformed plant cell can be regenerated into a transgenic plant according to a method known in the art. Examples thereof include an in vitro regeneration method which involves regenerating plant bodies through the formation of callus composed of undifferentiated grown cells. This method is known in the art. For the details thereof, see, for example, Shokubutsu Taisha Kogaku (Plant Metabolic Engineering in English) Handbook (2002, NTS Inc.) or Shinban Model Shokubutsu No Jikken Protocol: Idengakuteki Shuhou Kara Genome Kaiseki Made (Experimental Protocol of Model Plant, New Edition: From Genetic Technique To Genomic Analysis in English) (2001, Shujunsha Co., Ltd.) described above. Alternatively, an in planta method may be used, which involves directly transferring the nucleic acid expression system to the cells of the plant individual of interest without the callus or cell culture step. A phytohormone such as auxin, gibberellin, and/or cytokinin may be used for promoting the growth and/or division of the transformed cells.
[0167] The first-generation transgenic plant thus obtained by the method is a disease-resistant and/or branching-active plant. In the present invention, this first-generation transgenic plant also encompasses clones having genetic information identical thereto. The clones correspond to, for example, a plant obtained by the cutting, grafting, or layering of a portion of the plant body collected from the first-generation transgenic plant, a plant body regenerated through callus formation from cultured cells, or a vegetative plant newly formed vegetative reproductive organs (e.g., rhizomes, tuberous roots, corms, and runners) obtained by asexual reproduction from the first-generation transgenic plant.
[0168] The active peptide is expressed from the nucleic acid expression system transferred to this transgenic plant. The expression level of the active peptide per cell of the plant is increased compared with the wild-type individual of the same species thereas. As a result, the natural immune system is enhanced to improve disease resistance, while branching activity is augmented to increase the number of branching.
[0169] 6. Progeny of Transgenic Plant
[0170] The sixth embodiment of the present invention relates to progeny of the transgenic plant. In the present specification, the “progeny of the transgenic plant” refers to offspring that is obtained via sexual reproduction from the first-generation transgenic plant of the fifth embodiment and intracellularly retains the nucleic acid expression system described in the fifth embodiment. The progeny corresponds to, for example, a seedling of the first-generation transgenic plant.
[0171] The progeny can be obtained from the transgenic plant of the fifth embodiment by a method known in the art. For example, the first-generation transgenic plant is allowed to fruit, and seeds can be obtained as first-generation progeny and also as a second-generation transgenic plant. As an example of a method for further obtaining second-generation progeny from the first-generation progeny of the present invention, the seeds are rooted on an appropriate medium, and the resulting shoots are transplanted in a pot containing soil. The second-generation progeny can be obtained by growth under appropriate cultivation conditions. The progeny of the present embodiment is not limited by its generation as long as the progeny retains the nucleic acid expression system described in the second embodiment. Thus, third or later generation progeny can be obtained by repeating a method similar to the method for obtaining the second-generation progeny.
EXAMPLES
Example 1
Phenotyping of Bil3 Mutant
[0172] A semidominant bil3 mutant selected from activation tagging lines (Nakazawa M. et al., (2003) Plant J., 34: 741-750) because of its phenotype as Brz resistance and hypocotyl elongation in the dark place was observed and functionally analyzed.
[0173] (Method)
[0174] A plurality of seeds of the wild-type strain or bil3 mutant of Arabidopsis thaliana were inoculated over a ½ MS agar medium (½× Murashige & Skoog Medium Including Vitamins (Duchefa Biochemie B.V.)/1.5% Sucrose, pH 5.6), then placed in a dark box, and left standing at 4° C. for 2 days or longer. Then, the seeds were continuously irradiated with 100 μmoL/m 2 s white light at 22° C. for 4 hours and grown in the dark place again at 22° C. for 7 days. After light irradiation again for 2 days in the bright place, the seedlings were transplanted to soil. Six seedlings per pot were transplanted so that their hypocotyls and roots were completely buried under the ground. The soil used was 1 bag of horticultural soil supplemented with approximately 2 L of vermiculite and then sterilized by autoclaving. The seedlings were grown at 22° C. under long-day conditions (16-hour bright pace/8-hour dark place). Four weeks after the transplantation to soil, the morphology of plant bodies and the numbers of flower stalks and branches were measured for 10 individuals each of the wild-type strain and the bil3 mutant.
[0175] (Results)
[0176] FIG. 3 shows the morphology of the aerial parts of the wild-type strain and the bil3 mutant. FIG. 4 shows the numbers of flower stalks ( FIG. 4A ) and branches ( FIG. 4B ) in the wild-type strain and the bil3 mutant. The bil3 mutant exhibited significant increases in the number of flower stalks by approximately 2 times and in the number of branches by approximately 1.6 times, compared with the wild-type strain.
Example 2
Expression Level Analysis of BIL3 Gene in Bil3 Mutant
[0177] Since the bil3 mutant is a semidominant mutant, the phenotypes of the bil3 mutant confirmed in Example 1 were presumably due to the overexpression of the BIL3 gene resulting from tag insertion. Thus, the expression level of the BIL3 gene in the bil3 mutant was analyzed by real-time PCR.
[0178] (Method)
[0179] Total RNA was extracted from each of the bil3 mutant and the wild-type strain using RNeasy Plant Mini Kit (Qiagen N.V.). First, less than 0.1 mg (fresh weight) of rosette leaves was collected from each plant, then frozen in liquid nitrogen, and then disrupted using a mortar. To the disrupted sample, 450 μL, of a β-mercaptoethanol (10 μL/buffer RLT (1 μL) mixed solution was added, and the mixture was vortexed. Specific procedures therefor followed the protocol included in the kit. Finally, total RNA obtained by ethanol precipitation was dissolved in 50 μL of RNase-free water.
[0180] Subsequently, cDNA was synthesized from the extracted total RNA using TaKaRa PrimeScript RT reagent Kit (Perfect Real Time). Specific procedures therefor followed the protocol included in the kit. The synthesized cDNA was diluted 10-fold, and the diluted solution was used as cDNA for real-time PCR. The primers used were At1g49500-RT-F (SEQ ID NO: 42) and At1g49500-RT-R (SEQ ID NO: 43) specifically amplifying the BIL3 gene. PCR reaction conditions involved preparing 30 μL in total of a reaction solution (12.5 μL at of SYBR Premix Ex Taq™ II; 0.1 μL each of 100 μM At1g49500-RT-F and -R primers; 5 μL of cDNA; and water), and treating the reaction solution at 95° C. for 30 seconds, followed by 40 cycles each involving 95° C. for 5 seconds and 60° C. for 30 seconds. A calibration curve was prepared using the dilution series of cDNA for real-time PCR.
[0181] (Results)
[0182] The results are shown in FIG. 5 . As shown in this diagram, the bil3 mutant was shown to overexpress the BIL3 gene compared with the wild-type strain. This suggested that the phenotypes of the bil3 mutant confirmed in Example 1 were induced by the overexpression of the BIL3 gene.
Example 3
Preparation of BIL3-Overexpressing Transgenic Plant and Phenotyping Thereof
[0183] The results of Example 2 suggested that the phenotypes of the bil3 mutant were induced by the overexpression of the BIL3 gene. Thus, in order to verify this, transgenic Arabidopsis thaliana overexpressing the BIL3 gene linked downstream of 35S CaMV promoter was prepared and phenotyped.
[0184] (Method)
[0185] (1) Cloning of Wild-Type BIL3 Gene
[0186] First, total RNA extraction and cDNA synthesis for cDNA library preparation were performed according to the method of Example 2.
[0187] Next, in order to obtain the full-length ORF of the BIL3 gene, PCR reaction was performed using the prepared cDNA library and KOD-plus-DNA polymerase (Toyobo Co., Ltd.). The BIL3 primers used were primers bil3-GW-F (SEQ ID NO: 44) and bil3-GW-R (SEQ ID NO: 45) designed for the 5′ terminus and 3′ terminus of the BIL3 gene, respectively. The BIL3 gene was cloned using pENTR/D TOPO cloning kit (Invitrogen Corp.). Specific procedures therefor followed the protocol included in the kit. The nucleotide sequence of the subcloned BIL3 gene was confirmed by cycle sequencing using BigDye Terminator Cycle Sequencing Kit (Applied Biosystems, Inc.). In this way, a BIL3 gene entry clone pENTR-BIL3 was obtained.
[0188] Recombination was performed between the entry clone and a destination vector pGWB2 (Nakagawa et al., 2007, JBB, 104: 34-41) through LR reaction according to the Gateway technique to prepare an expression vector pGWB5-BIL3 for plant transformation (Gateway Vector) containing an insert of the gene of interest in the destination vector. A mixed solution of pENTR-BIL3, the pGWB2 vector, 5×LR Reaction Buffer, topoisomerase I, and LR Clonase™ was prepared and left standing at 25° C. for 1 hour. Then, 1 μL of protease K was added thereto, and the mixture was left standing at 37° C. for 10 minutes. Subsequently, the reaction solution was mixed with DH5α competent cells, and the mixture was left standing for 30 minutes on ice. Then, heat shock was applied at 2° C. for 30 seconds to the cells, which were immediately transferred onto ice and left standing for 2 minutes. The cells were applied to an LB medium containing 50 μL/mL each of kanamycin and hygromycin and cultured overnight. Plasmids were extracted from the resulting transformants to obtain the pGWB5-BIL3 vector of interest.
[0189] (2) Preparation of Transgenic Arabidopsis Thaliana
[0190] 1 μL of pGWB2-BIL3 with respect to 200 μL of Agrobacterium competent cells (C58) was added thereto, then well mixed, and left standing for 30 minutes in ice. Subsequently, the cells were left standing for 1 minute in liquid nitrogen and then thawed in a block incubator set to 37° C. After addition of 1 mL of a YEP medium, the cells were cultured at 28° C. for 2 to 4 hours with shaking at 200 rpm. The cells were spread over a YEP medium containing 50 μg/mL each of kanamycin and hygromycin and 100 μg/mL rifampicin and cultured at 28° C. for 2 to 3 days. The successful transformation with the vectors was confirmed by colony PCR.
[0191] The colony thus transformed with the vector was precultured overnight at 28° C. in a YEP liquid medium. The volume of the culture solution was brought up to 500 ml by the addition of a YEP medium, followed by overnight culture. The culture solution was centrifuged at 5000 rpm for 10 minutes, and the supernatant was discarded. After addition of 400 mL of an infiltration medium (MS medium, 1000× Gamborg's vitamin, sucrose, benzylaminopurine, silwet, pH 5.7), the pellet was suspended at 28° C. at 177 rpm/minute for approximately 20 minutes. The suspension was transferred to a 300-mL beaker. A pot where 6 individuals of the wild-type strain grew was placed upside-down so that the plant bodies were dipped in the infiltration medium. In this state, the plants were left standing for 20 minutes. The plant bodies were wrapped in plastic wrap and left overnight. The plant bodies were grown, and the obtained seeds were inoculated to an MS medium containing 25 μg/mL kanamycin to select T1 transformants. The obtained T1 seeds were inoculated to an MS medium containing 20 μg/mL kanamycin to select T2 transformants. The obtained transformant was designated as a “35S::BIL3 transformant” and grown in the same way as in Example 1, followed by morphological observation thereof.
[0192] The expression of the BIL3 gene was further analyzed by real-time PCR. The real-time PCR was performed according to the method of Example 2.
[0193] (Results)
[0194] Fifty 35S::BIL3 transformants were obtained as BIL3-overexpressing transgenic strains. As shown in FIG. 6 , the 35S::BIL3 transformants were confirmed to express the BIL3 gene at a level equivalent to that of the bil3 mutant and have a significantly higher expression level thereof than that of the wild-type strain. Also, increases in the number of flower stalks and the number of branches similar to those of the bil3 mutant were observed in all the 35S::BIL3 transformants.
[0195] These results demonstrated that increases in the number of plant flower stalks and the number of branches, i.e., the number of branching, observed in the bil3 mutant were due to the overexpression of the BIL3 gene. This showed that BIL3 is a protein having the activity of augmenting plant branching.
Example 4
Induction of PR1 Gene Expression in Bil3 Mutant
[0196] The gene expression of a pathogen resistance marker PR1 (pathogenesis related 1D) was tested in the bil3 mutant. PR1 is an antibacterial protein whose expression is induced by the bacterial pathogen infection of a plant, and is known to typically function downstream in the pathogen resistance signaling pathway mediated by salicylic acid. Hence, the increased expression of the marker PR1 gene in a plant can serve as an index showing that the plant has disease resistance even without bacterial pathogen infection. Meanwhile, Nakashita et al. (The Plant Jour., 2003, 33: 887-898) have found that BR increases the expression of the PR1 gene, showing the presence of a BDR-inducing pathway that is different from the induced disease resistance mediated by salicylic acid. Thus, the increased expression of the PR1 gene in the bacterial pathogen-uninfected bil3 mutant suggests that this bil3 strain has acquired disease resistance.
[0197] (Method)
[0198] Individuals of the wild-type strain and the bil3 mutant grown in the same way as in Example 1 were treated or untreated with brassinolide (BL), one type of BR, to prepare samples. Total RNA was extracted from the rosette leaf of each strain using RNeasy Plant Mini Kit (Qiagen N.V.). Next, cDNA was synthesized from the extracted total RNA using PrimeScript First-Strand cDNA Synthesis Kit (Takara Bio Inc.). Specific procedures for the total RNA extraction and the cDNA synthesis followed the protocol included in each kit. Subsequently, the expression of the PR1 gene was analyzed by real-time PCR with the synthesized cDNA as a template using primers PR1-RT-F represented by SEQ ID NO: 46 and PR1-RT-R represented by SEQ ID NO: 47, SYBR Premix EX Taq kit (Takara Bio Inc.) and a real-time PCR apparatus Thermal Cycler Dice (Takara Bio Inc.).
[0199] (Results)
[0200] The results are shown in FIG. 7 . In this diagram, the expression level of the PR1 gene is indicated by relative value with the value of the BL-untreated (BL-) wild-type strain as 1. The expression level of PR1 was increased by approximately 3 times even in the BL-untreated bil3 mutant and by approximately 40 times in the BL-treated bil3 mutant, compared with the wild-type strain. This suggests that the bil3 mutant acquired disease resistance. As shown in Example 2, the bil3 mutant is a BIL3 gene-overexpressing mutant. Thus, this result shows that BIL3 is also involved in the BR intracellular signaling pathway and the induction of PR1 gene expression, i.e., the induction of disease resistance, in the bil3 mutant is attributed to BIL3.
[0201] All publications, patents, and patent applications cited herein are incorporated herein by reference in their entirety. | The objective of the present invention is to develop and provide: a composition that more inexpensively and safely augments plant disease resistance and/or plant branching by inducing new plant disease resistance via a brassinosteroids; and a method for suppressing microbial infection of plants and a method for augmenting branching using the composition. Provided is a composition containing as the active ingredient a peptide hormone obtained on the basis of isolating a disease resistant brassinosteroid variant and analyzing the causative gene thereof. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a turbojet and in particular a sealing device for a turbojet oil enclosure.
2. Description of the Related Art
A turboshaft for an aircraft generally comprises, arranged in the direction of the gas flow: a fan, one or more compressor stages, for example a low-pressure compressor and a high-pressure compressor, a combustion chamber, one or more turbine stages, for example a high-pressure turbine and a low-pressure turbine, and a gas exhaust nozzle. Each compressor may be associated with a turbine, the two elements being linked by a shaft, thereby forming, for example, a high-pressure core and a low-pressure core.
Turbojets generally have, substantially around the upstream extremity of the high-pressure core, an “upstream enclosure” containing bearing and gear members. They also generally have, substantially around the downstream extremity of the high-pressure core, a “downstream enclosure” containing oil-lubricated bearing and gear members. The oil, projected by these rotary parts , forms a mist (or suspension) of suspended droplets within the enclosures. Furthermore, they are traversed by a gas flow (air), in particular for ventilation purposes. To prevent the oil from being carried out of the enclosures by the gas flow, the gases are evacuated into “oil separators” generally formed by radial chimneys arranged in the low-pressure shaft, the oil being captured on the walls thereof and returned to the corresponding enclosure by centrifugal force. The oil separators communicate with a degassing tube (also rotary) concentric to the low-pressure shaft and in the enclosure of which the gases are carried from the oil separators to the outlet of the degassing tube where they are ejected, generally around the turbojet nozzle.
The upstream and downstream enclosures are formed and delimited by the walls of the stationary structure of the turbojet, but also by the walls of the rotary elements. They must enable the passage of a gas flow, but retain as much oil as possible therein, and for this reason the seal between the stationary elements and the rotary elements of an oil enclosure is a particularly delicate problem.
Traditionally, the seal is effected using a labyrinth joint, i.e. formed by ribs rigidly connected to a rotary part and an abradable material rigidly connected to a stationary part against which the ribs rub. This rubbing occurs with a given clearance to enable the passage of a gas flow coming from the low-pressure or high-pressure compressors; these gases oppose the egress of oil through the labyrinth joint; the flow rate thereof is dimensioned to be sufficient at slow speeds and is therefore excessive in other flight phases (in which the flow rate of the air aspirated by the fan of the turbojet is greater). This excessive flow in the other flight phases has at least two detrimental effects: firstly, it proportionately reduces the efficiency of the engine and, secondly, it tends to draw a greater quantity of oil out of the enclosure, around the oil separators.
It has therefore been envisaged to replace the labyrinth joints with “brush” seals, i.e. having a plurality of juxtaposed, substantially radial fibers that are attached to a stationary part, the free extremities of which are in contact with a rotary part (or very close thereto), the fibers being preferably slightly inclined in the direction of rotation of the rotary part; the fibers of the brush seal may for example be made of carbon. Such a device is in particular described in patent application US 2004/0256807 filed by General Electric.
Such brush seals have the advantage of needing to be traversed by a gas flow having a flow rate that is not too high to guarantee the oil seal thereof On the other hand, they have the drawback of tending to cause coking of the oil they come into contact with. Coking is the transformation of oil into a solid deposit; it is caused by reheating oil stuck to the carbon fibers; it reduces the effectiveness of the brush seal. Furthermore, the rubbing of the bristles on the track of the rotary part designed to touch the extremities thereof causes them to wear and therefore also reduces the effectiveness thereof over time.
BRIEF SUMMARY OF THE INVENTION
The invention is intended to mitigate these drawbacks and in particular to propose a sealing device for a turbojet oil enclosure that is effective and that has features that are durable over time.
Accordingly, the invention relates to a sealing device for an enclosure that is formed by at least one rotary member and at least one static member of a turbojet and that is intended to contain a suspension of lubricating oil droplets, the sealing device comprising at least one brush seal, with juxtaposed strands, arranged to create a seal between at least one rotary member and at least one stationary member (from the rotary member or members and the stationary member or members presented above), the device being characterized in that it comprises means for recovering some of the oil suspended within the internal volume of the enclosure and means for channeling said recovered oil that are arranged such as to generate an oil flow along the strands of said brush seal towards the rotary member.
The invention creates a flow of oil along the strands of the brush seal, which guarantees a recirculation of the oil in contact therewith, since said oil is drawn along the strands. The residual oil is therefore drawn by the oil supplied and does not have time to degrade; coking phenomena are thereby reduced, which prevents the strands from sticking together, thereby improving both the effectiveness and longevity of the seal. Furthermore, the strands are lubricated and therefore less degraded by the rotary contact thereof with the members of the turbojet.
The invention is particularly notable in that it addresses a problem related to the presence of oil on the joint precisely by supplying said joint with oil; thus, although it could be considered that the best way to protect the joint from oil would be to improve the oil seal thereof, the oil seal of the joint is in fact improved using oil.
The means for channeling the recovered oil can be dimensioned to control the oil flow along the strands of the brush seal.
The oil flow can thereby be arranged to reduce the temperature of the brush seal, thereby further reducing coking phenomena.
In one embodiment, the device has means for returning the oil to the interior of the enclosure after it has flowed over the strands. This encourages the oil to flow, the oil being drawn between the means for channeling the recovered oil and the means for evacuating the oil.
In one embodiment in this case, the device is arranged such that the return means include a gas flow passing through the brush seal. The gas-flow evacuation effect may be reinforced by a centrifugal force related to the rotation of the rotary parts.
Preferably, if the strands of the brush seal (more specifically the free extremities of the strands thereof) are intended to rub against a track of an opposing part, said channeling means are arranged such that the oil flow along the strands supplies oil to the track. The friction zone between the seal and the track is therefore lubricated, which reduces the wear of these parts.
Also preferably, as the lubricating oil is degraded by temperature (oxidation and coking), it includes at least an additive designed to prevent coking. Such an additive is known, but it loses effectiveness over time. The oil supply provided for in the invention recirculates the oil (and therefore the additive thereof), preserving the anti-coking properties thereof.
In a preferred embodiment, the means for channeling the recovered oil include at least one gravitational channel for guiding the oil from the recovery means to the brush seal.
In an embodiment in this case, as the seal includes an at least partially hollow torus (i.e. having an internal volume) to which the strands are attached, the channeling means include at least one channel for guiding the oil from the recovery means to the interior of the torus (i.e. into the internal volume thereof) to impregnate the strands where they are attached to the torus. This further improves lubrication of the strands of the seal.
In one embodiment, the oil recovery means include, in the top of the turbojet, a gravitational recovery tank for the oil in the oil suspension.
In one embodiment, the oil recovery means include at least one oil retention rib combined with a slot for guiding the oil from the rib to the brush seal (the slot in this case forming the guide channel).
According to a preferred embodiment, the means for channeling the recovered oil include an oil source specific to the brush seal, i.e. dedicated to supply it.
The invention also concerns a turbojet with a sealing device having the features of the sealing device disclosed above.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The description can be better understood from the description below of the preferred embodiment of the turbojet according to the invention, with reference to the attached drawings, in which:
FIG. 1 is a global axial profile of the turbojet according to the invention;
FIG. 2 is a schematic axial profile of the upstream enclosure of the turbojet in FIG. 1 , in a first embodiment of the invention;
FIG. 3 is a partial cross section of the upper part of the enclosure in FIG. 2 ;
FIG. 4 is a schematic axial profile of the upstream enclosure of the turbojet in FIG. 1 , in a second embodiment of the invention;
FIG. 5 is a schematic axial profile of the upstream enclosure of the turbojet in FIG. 1 , in a third embodiment of the invention;
FIG. 6 is a partial cross section of the upper part of the enclosure in FIGS. 5 and
FIG. 7 is a schematic axial profile of the upstream enclosure of the turbojet in FIG. 1 , in a fourth embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 , a turbojet 1 according to the first embodiment of the invention conventionally comprises a fan 1 a , a low-pressure compressor 1 b , a high-pressure compressor 1 e , a combustion chamber 1 d , a high-pressure turbine 1 e , a low-pressure turbine 1 f and an exhaust nozzle 1 g . The high-pressure compressor 1 e and the high-pressure turbine 1 e are joined by a high-pressure shaft 2 and form therewith a high-pressure core. The low-pressure compressor 1 b and the low-pressure turbine if are joined by a low-pressure shaft 3 and form therewith a low-pressure core.
The turbojet 1 comprises static (or stationary) members and rotary members, forming the different functional elements above, in a known manner.
The turbojet 1 has, close to the upstream extremity of the high-pressure core, an “upstream enclosure” 4 containing the bearing and gear members and, near to the downstream extremity of the high-pressure core, a “downstream enclosure” 5 containing bearing and gear members. These enclosures 4 , 5 are conventionally referred to by the person skilled in the art as oil enclosures 4 , 5 as they contain a suspension of oil droplets, as explained below.
The turbojet 1 extends globally along an axis A which is the axis of rotation of the rotary members thereof and in particular the axis of the low-pressure and high-pressure shafts 3 , 2 . In the remainder of the description, the concepts longitudinal, radial, internal and external shall relate to this axis A.
The different embodiments of the invention are described in relation to the upstream enclosure 4 , but it shall be understood to apply equally to the downstream enclosure 5 and in general to any other enclosure containing or housing members with an oil suspension for the lubrication thereof.
The upstream enclosure 4 defines a volume in which are housed the bearing and gear members. In this case, the upstream enclosure 4 houses a first bearing 6 , a second bearing 7 and a third bearing 8 , these bearings 6 , 7 , 8 each having an internal ring 6 a , rigidly connected to the low-pressure shaft 3 , an external ring 6 b , rigidly connected to the stationary structure of the turbojet and rolling means 6 c such as balls or rollers between the rings 6 a , 6 b to enable the rotation of the internal ring 6 a in relation to the external ring 6 b (only rings 6 a , 6 b and rolling means 6 c of the first bearing 6 have been referenced in the figures). The upstream enclosure 4 also contains the internal extremity 9 of an output shaft 10 connected to the high-pressure shaft 2 , the external extremity of this shaft 10 being connected to an accessory gearbox (not shown), commonly referred to as an AGB, for Accessory Gear Box, by the person skilled in the art.
The upstream enclosure 4 defines an internal volume V delimited by stationary members and rotary members, more specifically by the walls of the stationary members and the rotary members. In this case, the upstream enclosure 4 is notably delimited on the internal side by the upstream extremity portion of the low-pressure shaft 3 and the parts rigidly connected to this shaft, on the upstream external side by a housing 12 rigidly connected to the stationary structure of the turbojet and supporting the external ring 6 b of the first bearing 6 and on the downstream side by a housing 13 partially delimiting the internal envelope of the gas path (between the low-pressure compressor 1 b and the high-pressure compressor 1 e ).
The bearings contained in the internal volume V of the enclosure 4 are supplied with lubricating oil in a known manner; the oil, projected by the parts in rotation, forms a mist (or suspension) of suspended droplets within the enclosure 4 . This oil supply to the bearings of the enclosure 4 may be accomplished in different ways. In this case, the internal ring 6 a of the first bearing 6 is provided with orifices (not shown) to enable oil to enter the bearing 6 before moving, by centrifuging, towards the internal volume V of the enclosure 4 , as shown schematically by the arrow F 1 in FIG. 2 ; the oil is projected into the enclosure 4 and more specifically centrifuged when the internal ring 6 a rotates. In another embodiment not shown, one or more oil supply sprinklers may be arranged near to the rolling means 6 c of the first bearing 6 , in a known manner.
The upstream enclosure 4 also includes, on the upstream side thereof, a seal 14 used to provide the oil seal of the enclosure 4 , between the rotary members and static members thereof, in this case between the housing 12 and the low-pressure shaft 3 , more specifically between the housing 12 and an intermediate part 15 rigidly connected to the low-pressure shaft 3 , as detailed below. This seal 14 is a brush seal 14 . It includes a ring torus 16 , rigidly connected to a wall of the stationary structure of the turbojet (in this case rigidly connected to the housing 12 of the stationary structure), to which are attached the strands 17 or bristles 17 , in this case made of carbon, arranged to come into contact with a wall of a rotary member of the turbojet. The torus 16 is rigid and for example made of a metal, in this case steel. More specifically in this case, the housing 12 of the stationary structure has, in the upstream portion thereof, a groove in which the torus 16 is seated, this latter being locked in position by a nut 18 in a known manner.
The enclosure 4 is located, on the upstream side, close to the upstream extremity of the low-pressure shaft 3 . The internal ring 6 a of the first bearing 6 is attached directly to the low-pressure shaft 3 . This latter has, upstream of this internal ring 6 a and separated therefrom, a radial shoulder 3 ′ forming a rim towards the external side. An intermediate part 15 performing a plurality of functions is attached between the internal ring 6 a and the radial shoulder 3 ′. In this case, this intermediate part 15 is a one-piece part; as a whole, it is a core of revolution; it comprises a first annular longitudinal portion 15 a , on the downstream side, prolonged by a radial portion 15 b from which are arranged two portions, namely a radial flange 15 c and a second annular longitudinal portion 15 d , the upstream extremity 15 e of which is attached to the low-pressure shaft 3 . The first longitudinal downstream portion 15 a of the intermediate part 15 is attached between the internal ring 6 a and the shoulder 3 ′ of the low-pressure shaft and is used to attach the intermediate part 15 . The radial portion 15 b thereof extends along the radial wall of the shoulder 3 ′ and beyond the external side thereof. The radial flange thereof 15 c forms a screen for the oil supplying the enclosure 4 coming from the internal ring 6 a of the first bearing 6 , to prevent it from being projected directly onto the seal 14 ; the person skilled in the art conventionally refers to such a flange 15 c forming a screen for oil droplets as an “oil slinger”. In this case in particular it enables the supply of oil to the seal 14 to be controlled. The second annular longitudinal portion 15 d has an external surface 15 f that forms a track for the strands 17 of the brush seal 14 , i.e. this surface 15 f is arranged such that the free extremities of the strands 17 come into contact therewith; it will be noted that the intermediate part 15 is rigidly connected to the low-pressure shaft 3 and therefore driven in rotation therewith, while the brush seal 14 is static since it is rigidly connected to the housing 12 of the stationary structure. The strands 17 of the seal 14 are preferably inclined in the transversal plane in the direction of rotation of the low-pressure shaft 3 , in a known manner, to accompany the rotation of the track 15 f with which they are in contact.
According to the invention, the seal 14 is supplied with lubricating oil h to generate, guide and draw an oil flow along the strands 17 thereof; thereby guaranteeing a flow of oil along the strands 17 and thus guaranteeing the long-term effectiveness of the seal 14 , as explained above in the introduction of the description.
In the first embodiment shown in FIGS. 2 and 3 , the turbojet 1 includes a gravitational recovery tank 19 for the oil h in the oil suspension of the enclosure 4 . This tank 19 is therefore intended to capture or recover some of the oil in suspension in the internal volume V of the enclosure 4 . The turbojet 1 also has channels 20 for carrying and guiding the oil from the tank 19 to the brush seal 14 and more specifically to the strands 17 thereof.
The top and the bottom, as well as the concepts of upper and lower, are defined in relation to the vertical, this latter being defined, for a turbojet, as the vertical direction in the assembly position thereof on a stationary airplane, i.e. an airplane placed on a horizontal plane. A vertical axis B is drawn on the figures. The axis A of the turbojet 1 is therefore horizontal in the figures.
More specifically, with reference to FIG. 3 , the tank 19 is placed at the top of the turbojet 1 . It takes the form of a enclosure closed on all of the faces thereof except the upper face thereof More specifically, it is formed by a downstream wall 19 a facing an upstream wall 19 b formed by an internal portion of the housing 12 of the stationary structure, by a lower (internal) wall 19 c formed by a redirection (towards the downstream side) of the housing 12 of the stationary structure, linking the upstream walls 19 b and 19 a , and by two sidewalls 19 d , 19 e located on either side. The upper face thereof 19 f is open. The downstream wall 19 a and the side walls 19 d , 19 e are vertical flat walls, the lower wall 19 c matches the annular shape of the housing and the open upper face 19 f is horizontal.
The oil is projected against the internal surface of the housing 12 of the stationary structure, as shown schematically by the arrow F 1 . Some of the oil is in suspension in the enclosure 4 and on the different members that it contains; some of the oil flows on the internal surface of the housing 12 of the stationary structure and flows by gravity from the top of the turbojet 1 downwards; indeed, the housing 12 is conical and the diameter thereof decreases from the downstream side to the upstream side, thereby enabling such a flow. Some of this oil therefore runs into the tank 19 where it is received, forming a bath of oil h.
The channels 20 extend radially and lead firstly to the tank 19 and secondly to near the external side of the strands 17 of the brush seal 14 , the channels 20 surrounding the torus 16 to guide the oil towards the external side of the strands 17 . In this case, and more specifically, the turbojet 1 has two channels 20 located on either side of the tank 19 , as shown in FIG. 3 . The oil h contained in the tank 19 flows by gravity through the channels 20 and supplies an annular chamber 22 (on 360°) arranged between the internal part of the downstream wall 19 a forming the tank 19 and the internal part of the torus 16 of the brush seal 14 ; the annular chamber 22 is “flooded” with oil, i.e. the volume thereof is completely filled with oil. A plurality of small channels 23 , in this case equidistant lunules, for carrying oil from the annular chamber 22 to the strands 17 , are formed and enable the distribution of the oil along the strands 17 , through the joint effects of gravity and capillarity. The flow rate of the oil h supplying the brush seal 14 is regulated and defined by the volume of the tank 19 and the dimensions of the annular chamber 22 and of the channels 20 , 23 . The oil flows along the strands 17 of the seal 14 to the track 15 f with which these strands 17 are in contact.
Furthermore, the brush seal 14 is arranged to enable the passage of a gas flow (air) from the exterior to the interior V of the enclosure 4 , as symbolized by the arrow F 2 . This gas flow prevents oil from leaking out of the enclosure 4 , in a known manner. Furthermore, this gas flow forms a means for evacuating the oil once it has reached the internal extremity of the strands 17 of the seal 14 and the track 15 f , thereby encouraging the oil to flow along the strands 17 . More specifically, the gas flow is combined with the oil slinger 15 c to evacuate the oil h: the oil is carried by the gas flow F 2 to the oil slinger 15 c by which it is driven by centrifuging into the enclosure 4 where it is again suspended in the form of droplets. The gas flow F 2 flows through the enclosure 4 and escapes through oil-removal chimneys or oil separators (not shown but known and already presented in the introduction of the description) before being guided into a degassing tube 21 that extends concentrically to the low-pressure shaft 3 , in a known manner.
It will be noted incidentally that if the airplane were to adopt a position in which the tank 19 was no longer oriented horizontally, oil could leak from this latter; this may apply for example, in a military application, to an inverted flight of a fighter plane. Where this occurs, it would not have problematic consequences since such situations do not usually last long, and a temporary interruption of the oil supply to the seal is not problematic.
Other embodiments of the turbojet according to the invention are described below. These embodiments are very similar to the preceding embodiment, with only the elements related to the oil supply to the brush seal 14 being changed. This is why the references used for the elements of the turbojets in FIGS. 4 to 7 having identical, equivalent, similar or comparable function or structure to the elements of the turbojet in FIGS. 1 to 3 are the same, to simplify the description. Furthermore, the entire description of the turbojet in FIGS. 1 to 3 is not reproduced, this description applying to the turbojets in FIGS. 4 to 7 where not incompatible. Only notable, structural and functional differences are described.
The arrows F 3 show one or more possible trajectories for the droplets of oil h in these embodiments.
In the embodiment in FIG. 4 , the sealing device again includes a tank 19 for the gravitational recovery (or capture or withdrawal) of oil h from the oil suspension of the enclosure 4 and the channels 20 carrying the oil from the tank 19 to the brush seal 14 . The channels 24 are also arranged in the torus 16 holding the strands 17 , which is hollow; they lead at one extremity to the channels 20 carrying the oil from the tank 19 and at the other extremity to an internal volume of the torus 16 communicating with the external radial extremity of the strands 17 . Thus, the channels 20 , 24 are arranged to fluidly connect the oil tank 19 to the external radial extremity of the strands 17 , thereby enabling the strands 17 to be directly impregnated with the oil, via the external extremities thereof. The flow of oil along the strands 17 is thereby further improved. As previously, the oil h is evacuated from the internal side of the strands 17 to encourage the flow thereof and to prevent the agglomeration thereof on the strands 17 .
In the embodiment in FIG. 5 , the sealing device includes means for recovering oil from the oil suspension of the enclosure 4 comprising at least one set of one oil retention or stopping rib 25 and one slot 26 to guide the oil from the rib 25 towards the strands 17 of the seal 14 ; in this case, it comprises four sets of one rib 25 and one slot 26 , which are arranged at the top of the turbojet, as shown in FIG. 6 . More specifically, each rib 25 extends radially outwards from the external surface of the internal wall 19 c formed by a redirection (towards the downstream side) of the housing 12 of the stationary structure; it extends longitudinally along the entire length of this internal wall 19 c ; the function thereof is to form a retaining dam for the oil flowing along the external surface of this wall 19 c ; some of the oil is therefore retained just upstream of each rib 25 and the remainder passes above this latter. Each slot 26 is arranged in the downstream surface of the downstream wall 27 of the groove in which the torus 16 is seated; the slot 26 extends radially along this downstream wall 27 ; it is also arranged just above the rib 25 , level with the oil dam, the oil then being guided in the slot 26 from the retention zone thereof above the rib 25 . The oil is therefore guided towards the internal part of the strands 17 upon which it is distributed by the joint effects of gravity and capillarity; the oil is here evacuated in the same manner as in the previous embodiments.
The embodiment in FIG. 5 is the preferred embodiment of the invention. Indeed, it is simple to manufacture since simple pairs of ribs 25 and slots 26 are required. The operation thereof is also very simple since the oil is drawn by gravity towards the bottom of the turbojet and is held in this movement by the ribs 25 and guided from the ribs 25 to the seal 14 by the slots 26 .
In the embodiment in FIG. 7 , the sealing device comprises means for supplying oil from a source specifically dedicated to supplying the brush seal 14 with oil. More specifically, the device comprises channels 28 for guiding the oil from the low-pressure shaft 3 (supplied from the same oil source as the oil supplying the bearing); these channels 28 form the specific dedicated source of oil. The oil is guided to the orifices 29 provided in the second annular longitudinal portion 15 d of the intermediate part 15 , at the base of the oil slinger 15 c ; in this case there are two of these orifices 29 , although a different number may be used. The oil is projected centrifugally against a scoop 30 formed by a rounded wall protruding from the downstream wall 27 of the groove in which the torus 16 is seated. Channels 31 are provided in the downstream wall 27 of the groove, beneath the scoop 30 , and they communicate with an annular chamber 22 provided between the internal part of the downstream wall 19 a, forming the tank 19 and the internal part of the torus 16 of the brush seal 14 ; the scoop 30 is then finally arranged to guide the oil projected thereupon towards the annular chamber 22 , which is thereby “flooded” with oil, i.e. the volume thereof is completely filled with oil. As in the embodiment in FIG. 2 , a plurality of small channels 23 for carrying oil from the annular chamber 22 to the strands 17 are provided and they enable the distribution of the oil along the strands 17 . In this case, the oil is evacuated in the same manner as in the previous embodiments.
The invention is described in relation to the preferred embodiments, but other embodiments are naturally possible. In particular, the features of the different embodiments described may be combined, where they are not incompatible. | A sealing device for a chamber including at least one rotary member and at least one static member of a jet engine and can contain a lubricating oil droplet suspension. The sealing device includes at least one brush seal that includes juxtaposed strands and is set to ensure sealing between at least one rotary member and at least one stationary member, a mechanism to recover part of the oil suspended within the inner space of the chamber, and a mechanism to deliver the recovered oil. The delivery mechanism is set up to generate a flow of oil along the strands of the brush seal, the oil flow being oriented in the direction of the rotary member. The brush seal thus provides better resistance to coking. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor laser, and in particular to a semiconductor laser used as the light source for an optical disk system, for information processing, or for optical communications.
2. Description of Related Art
Conventional semiconductor lasers employed as the light source in optical disk systems have been manufactured, for example, by the following process. First, a first crystal growth step is conducted to form at least a first conduction-type cladding layer, an active layer, and a second conduction-type cladding layer in that order on a first conduction-type semiconductor substrate. Then a stripe formation process for forming a region where current is introduced to the active layer is performed, and then epitaxial growth to bury the stripe portion is performed.
For example, the process for manufacturing a ridge-type semiconductor laser element like that shown in FIGS. 9A to 9 E generally includes three crystal growth steps (formation of the double heterostructure, formation of the current blocking layer, and formation of the burying layer). First, as shown in FIG. 9A , an n-type cladding layer 2 , an active layer 3 , and a p-type cladding layer 4 are deposited and grown on an n-type substrate 1 in that order by a first crystal growth step. Then, as shown in FIG. 9B , the p-type cladding layer 4 is etched to form a ridge portion 4 a by a process employing photolithography. Next, as shown in FIG. 9C , an n-type current blocking layer 8 is formed through a second crystal growth step. Then, as shown in FIG. 9D , a p-type burying layer 9 is formed through a third crystal growth step. Lastly, as shown in FIG. 9E , a p-side ohmic contact electrode 13 is formed on the p-type burying layer 9 and an n-side ohmic contact electrode 12 is formed on the bottom surface of the n-type substrate 1 .
The groove-type semiconductor laser element shown in FIGS. 10A to 10 D also requires two crystal growth steps (formation of the double heterostructure and formation of the burying layer). First, as shown in FIG. 10A , an n-type cladding layer 2 , an active layer 3 , a p-type cladding layer 4 , and an n-type current blocking layer 8 are deposited and grown in that order on an n-type substrate 1 through a first crystal growth step. Next, as shown in FIG. 10B , the n-type current blocking layer 8 is etched to form a groove portion 8 a by a process employing photolithography. Then, as shown in FIG. 10C , a p-type burying layer 9 is formed in a second crystal growth step. Lastly, as shown in FIG. 10D , a p-side ohmic contact electrode 13 and an n-side ohmic contact 12 are formed.
This plurality of crystal formation steps was a major hurdle in reducing the manufacturing costs for laser chips. Accordingly, as a method for omitting the burying crystal growth step so as to fabricate a semiconductor laser element through a single crystal growth step, an element that has a ridge-type waveguide structure and that constricts the current and confines light by a dielectric film made of SiO 2 or Si 3 N 4 or the like has been developed and produced (for example, see J. Hashimoto et. al., IEEE J. Quantum Electron, vol. 33, pp. 66-70, 1997). An example of this method is shown in FIGS. 11A to 11 D. First, as shown in FIG. 11A , in a first crystal growth step, an n-type cladding layer 2 , an active layer 3 , and a p-type cladding layer 4 are deposited and grown in that order on an n-type substrate 1 so as to form a double heterostructure. Next, as shown in FIG. 11B , the p-type cladding layer 4 is etched to form a ridge portion 4 a by a process employing photolithography. Then, as shown in FIG. 1C , an insulating film (dielectric film) 11 is formed and then etched using a photoresist mask (not shown) to expose the p-type cladding layer 4 . Lastly, as shown in FIG. 1D , a p-side ohmic contact electrode 13 and an n-side ohmic contact electrode 12 are formed.
However, with the element shown in FIG. 11D , the unevenness formed in the element surface is affected by the ridge portion and becomes large because a burying crystal growth step is not performed after the stripe is formed. When the electrode side surface having this uneven surface is adopted as the bonding surface during assembly of the semiconductor laser, there is the problem that stress during chip bonding tends to concentrate in the ridge portion 4 a , thereby deteriorating the properties of the semiconductor laser.
In a presentation by Miyashita et. al. at the Japan Society of Applied Physics Annual Meeting in the spring of 2000 (presentation No. 29a-N-7, “Effective Refractive Index Type High-Output Low-Operation-Current Laser for DVD-RAM”), it was reported that by also forming protruding portions to the left and right of the ridge portion, it is possible to reduce damage during bonding, and that a significant improvement in laser properties can be achieved by adopting such a structure for a high output red semiconductor laser element. However, the height difference between the ridge portion and the other protruding portions was the thickness of the SiO 2 film employed for current confinement (approximately 0.1 μm).
Also, JP H12-164986A discloses a method to keep stress from concentrating at the ridge portion during assembly by using regrowth to form protruding portions that are higher than and sandwich the ridge portion. This example is shown in FIGS. 12A to 12 D. First, as shown in FIG. 12A , an n-type cladding layer 2 , and active layer 3 , and a p-type cladding layer 4 are deposited and grown in that order on an n-type substrate 1 through a first crystal growth step, and furthermore an oxidation prevention layer 10 is laminated. Next, as shown in FIG. 12B , a protective film 14 serving as an insulation layer is deposited, and photolithography is used to form a resist mask to remove the outside regions of the protective film 14 , after which an n-type current blocking layer 8 is formed in those regions in a first selective growth step. Then, as shown in FIG. 12C , photolithography is used to provide an aperture portion for ridge formation in the center portion of the protective film 14 , and a p-type second cladding layer 15 and a p-type contact layer 16 are deposited and grown in that order on this aperture portion and on the n-type current blocking layers 8 on both sides in a second selective growth step. Finally, as shown in FIG. 12D , a p-side ohmic contact electrode 13 and an n-side ohmic contact electrode 12 are formed. However, the selective growth steps required by this manufacturing method make it difficult to reduce the cost of the chip.
Moreover, JP H11-25 1679A discloses the use of the structure shown in FIG. 13 as a method for reducing damage due to unevenness during bonding in a ridge-type semiconductor laser for which a burying growth step is performed. That is, a second p-side ohmic contact electrode 14 is provided to make the thickness of the electrode on the uneven surface side thick at the recessed portion and thin at the protruding portion, so that the unevenness in the semiconductor surface is reduced. It should be noted that a protruding portion is also unsatisfactory in conventional ridge-type semiconductor lasers for which a burying growth step is performed.
The following four points are the main problems for the semiconductor laser element fabricated by a single crystal growth step and shown in FIGS. 11A to 11 D.
The first problem is the deterioration of laser properties due to damage caused during bonding, as mentioned above. With the structure proposed by Miyashita et. al., the difference in height between the ridge portion and the other protruding portions is too small, and thus damage during bonding cannot be reduced sufficiently and there is a high risk that large stress will be applied to the ridge portion as well. Furthermore, with the procedure mentioned in JP H11-251679A, a difference of about several m in the electrode film thickness must be formed at the chip surface, the increase in thickness of the electrode film leads to larger discrepancies in the electrode film thickness, and so mass-productivity drops for devices that are assembled with the uneven surface as the reference surface.
The second problem is that a semiconductor laser element with this structure has a larger thermal resistance than conventionally structured elements. This is because the dielectric film made of SiO 2 or Si 3 N 4 , for example, has a considerably lower thermal conductivity than the semiconductor film, and thus a semiconductor laser element with the majority of its surface covered by a dielectric film has inferior heat dissipation properties as compared with conventionally structured elements. This leads to concerns regarding the deterioration of laser properties, especially at elevated temperatures, and a drop in reliability.
The third problem is that damage at a ridge portion due to the concentration of stress at the ridge portion and production defects such as cracks occur more easily during the cleavage process in the direction perpendicular to the stripe direction, which is performed for the purpose of forming in the chip end surface the mirror necessary to form a Fabry-Perot resonator. It is thought that the primary reason why stress tends to concentrate at the ridge portion is that there is a larger difference in height at the protruding portions than in a conventionally structured element because burying growth is not performed in the former. On the other hand, if the structure proposed by Miyashita et. al. or the method mentioned in JP H12-164986A is adopted, then a plurality of protruding portions are formed in the element surface, and thus it is conceivable that the stress concentrating at the ridge portion will be reduced. However, simply having a plurality of protruding portions is not enough, and no effect can be anticipated if the other protruding portions are spaced considerably from the ridge portion. There is no mention by Miyashita et. al. of the spacing between the ridge portion and the other protruding portions. Also, with the structure mentioned in JP H12-164986A, regrowth of the ridge portion is performed with the insulation film serving as a mask, and thus the insulation film is not formed at the ridge portion slope. Consequently, stress is easily concentrated at the boundary portion between the ridge bottom portion and the insulation film, and the regrowth interface is close, so that crystallinity differences near the ridge bottom portion tend to cause damage such as cracking to the ridge bottom portion.
The fourth problem is a reduction in the contact area with the electrode as a result of the burying growth step not being performed, resulting in an increase in element resistance. The increase in resistance leads to diminished frequency properties for the element and more power consumption, among others. JP H12-164986A discloses a method for forming an electrode at the ridge portion slope in order to increase the contact area and reduce the resistance. However, in general, the ridge portion is designed to have a composition with high concentration of Al, and a semiconductor layer surface with a high Al composition oxidizes quickly, frequently leading to the problem of electrode peeling.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a semiconductor laser which can be manufactured in a process that includes only one crystal growth step, which has a low cost structure in which a dielectric film constricts the current and confines the light, and in which stress concentrating at the ridge portion during assembly is reduced, thus increasing its capacity for mass production.
It is a further object of the present invention to improve the heat dissipation properties of the element, to reduce production defects such as end surface cracking during the cleavage process, and to reduce element resistance.
A semiconductor laser of the present invention is of a ridge-type current confinement structure, and has a first conduction-type cladding layer, a second conduction-type cladding layer, and an active layer sandwiched between these cladding layers, formed on a first conduction-type semiconductor substrate. The second conduction-type cladding layer has mesa-type stripe-shaped recessed portions in at least four spots, thereby forming a central ridge portion, which constitutes a ridge-type current confinement portion, and two or more lateral ridge portions of a height larger than that of the central ridge portion, which are positioned on both sides of the central ridge portion, and which include the second conduction-type cladding layer. An insulation film with a lower refractive index than the second conduction-type cladding layer is formed in a pair of stripes disposed respectively in the regions from the side surface of the second conduction-type cladding layer on both side portions of the central ridge portion toward the outside. The insulation film is not formed on the central ridge portion.
This configuration dissipates the pressure that is received by the element surface during assembly through the lateral ridge portions and alleviates stress concentrated at the central ridge portion. Moreover, the existence of the lateral ridge portions allows a reduction in defects such as end surface cracking during the cleavage process.
Furthermore, it is possible to adopt a configuration where a current blocking layer is formed on the lateral ridge portions, the insulation film is not formed on the lateral ridge portions, and the height of the central ridge portion is lower than the height of the lateral ridge portions. Thus, the heat dissipation properties of the element are improved because a dielectric film with a low thermal conductivity is not formed on the lateral ridge portions.
It is also possible to adopt a configuration in which a current blocking layer is formed on the uppermost layer of the lateral ridge portions, or in which the current blocking layer is a first conduction-type semiconductor layer or a high resistance semiconductor layer. Also, by adopting a configuration in which the current blocking layer is formed concurrent with the first crystal growth step, it is possible to achieve a reduction in element resistance. This is because, for example, forming an n-type semiconductor layer of at least a certain film thickness (greater than about 0.3 μm) on the surface of a p-type semiconductor layer inhibits hydrogen atom-induced passivation of the Zn impurities in the p-type semiconductor layer and increases the activation yield of the Zn. A similar effect also can be achieved in an undoped semiconductor layer, but the present configuration makes it possible to obtain the above effects with a minimum number of crystal growth layers and with a simple process.
The current confinement layer of the above configured semiconductor laser can be formed with either of a semiconductor layer with a different conduction-type than the central ridge portion or a surface layer of the lateral ridge portions provided with high resistance by ion implantation, for example. In a current confinement structure achieved by a semiconductor layer, an insulation film made of SiO 2 or the like with a high thermal resistance must be formed between the ridge portions, but in a current confinement structure achieved by a high resistance layer, the insulation film only needs to be formed on the side surfaces of the central ridge portion (in the case of a gain guide laser, an insulation film is not necessary), and thus the heat dissipation properties of the element can be increased further.
In the problem at hand of further increasing the heat resistance properties, it is preferable that the lateral ridge portions in the above configuration have the widest area possible and are near the central ridge portion. On the other hand, giving consideration to the stabilization of the ridge portion formation process, a wide etching area must be secured in order to confirm the end point of the etching. Consequently, in the above configuration, it is preferable that (a+b)/L is 0.5 or less, where a symbol a represents a width of the central ridge portion, a symbol b represents a total width of the lateral ridge portions, and a symbol L represents a width at which the central ridge portion is repeated. Also, it is preferable that a spacing d between the central ridge portion and the lateral ridge portions is 30 μm or less.
The value of d influences the action of inhibiting cracking, for example, around the central ridge portion during cleavage. Thus, as shown in FIGS. 14A and 14B , by forming a wide etching region outside the lateral ridge portions, it is possible to suppress leaks (short circuits) in the element that are caused by an adhesive agent such as solder when assembly is performed with the epitaxial surface as the junction surface. In FIG. 14A , the numeral 20 denotes a laser element with the above configuration, and which has a central ridge portion 21 and lateral ridge portions 22 formed on either side of the central ridge portion 21 . The laser element 20 is joined to a sub-mount 24 by an adhesive agent 23 . As shown in FIG. 14A , by increasing the distance Y 1 from the junction surface to the surface of the semiconductor layer (the same applies for the distance Y 2 in FIG. 14 B), it is possible to inhibit wraparound of the adhesive agent 23 and obtain stable element properties.
Also, in a device (holographic element) where the semiconductor laser, the receiving element, and optical components such as a mirror are made into a single unit, a joining portion (stage) 25 of the laser element 20 is designed narrower than the width of the laser element, as shown in FIG. 14 B. Thus, a configuration is achieved in which the adhesive agent 23 easily flows downward and short circuits in the laser element 20 are further suppressed. This configuration conversely obviates the formation of the lateral ridge portions up to the chip boundary. For the above reasons, the element of the present invention, as shown in FIGS. 14A and 14B , more preferably has a configuration in which the boundary portion of the element is etched. An etching region 26 is a region at the edge of the element that is shaved away by the etching performed during formation of the ridge portions, and is preferably set as wide as possible from the element edge. The value set for the etching region 26 will change depending on the above values of a, h, d, and L, but it is preferably at least 10 μm.
By forming a window structure in the end face portion of the above configured semiconductor laser element, it is possible to suppress the deterioration of the end surface that accompanies a semiconductor element having a low operating current and a high output. Such a window structure has a configuration in which a region that absorbs only small amounts of light at the emission wavelength is made in a predetermined region in the vicinity of the end surface by high concentration doping of the active layer with a dopant such as Zn or Si, and in which the injection of carriers into the active layer does not occur due to current confinement. The width of the window region is preferably 15 to 30 μm from the element end surface.
The above configuration can be adopted for not only a configuration in which the burying crystal growth step has been omitted, but also for a ridge-type semiconductor laser for which a burying growth step is performed. Fabricating the element so that the lateral ridge portions are highest, even after the burying crystal growth step, makes it possible to solve the above problem. Furthermore, element resistance also can be reduced because there is an increase in the contact area with the electrodes.
Also, with a semiconductor laser of the above configuration, and in particular with a configuration in which the burying crystal growth step has been omitted, the contact area with the electrodes is equivalent to the area of the contact layer on the central ridge portion, so that the tendency for an increase in element resistance cannot be avoided. In the case of a ridge-type semiconductor laser, the dimensions of the ridge bottom portion determine the current confinement area (stripe width), so that by forming a ridge with a reverse mesa structure (the width at the top portion of the ridge is greater than the width at the bottom portion of the ridge) it is possible to reduce element resistance without changing element properties such as the flare angle. The major problem with reverse mesa structures is element damage during the cleavage process. However, by providing lateral ridge portions the cleavage process is stabilized. On the other hand, if a configuration in which the burying crystal growth step is performed or if the stripe width can be designed sufficiently wide and a sufficiently wide width can be taken for the top portion of the central ridge portion, then an ordinary regular mesa structure (the width at the top portion of the ridge is smaller than the width at the bottom portion of the ridge) can be adopted.
In order to achieve the above configuration, the semiconductor laser manufacturing method according to the present invention, in a case where a burying crystal growth step is not performed, includes: forming at least a first conduction-type semiconductor layer, an active layer, and a second conduction-type semiconductor layer on a first conduction-type semiconductor substrate with (100) as a primary face; etching the second conduction-type semiconductor layer in a stripe shape in the <011> direction to form at least four recessed portions; forming an insulation layer with a lower refractive index than the second conduction-type cladding layer over the surface; removing the insulation film on the second conduction-type semiconductor layer by etching; and forming an electrode that forms an ohmic junction with the second conduction-type semiconductor layer.
In a case where the heat dissipation properties of the element are increased by adopting a configuration in which a current blocking layer is formed on the lateral ridge portions and the insulation film is not formed on the surface of the lateral ridge portions, a manufacturing method includes: forming a first conduction-type cladding layer, an active layer, a second conduction-type cladding layer, a second conduction-type contact layer, and a first conduction-type current blocking layer on a first conduction-type semiconductor substrate with (100) as a primary face; etching the first conduction-type current blocking layer in a stripe shape in the <011> direction to leave the lateral ridge portions; etching the exposed second conduction-type contact layer in a stripe shape in the <011> direction, leaving the central ridge portion and the lateral ridge portions; using the second conduction-type contact layer as a mask and etching the second conduction-type cladding layer in a stripe shape in the <011> direction; forming an insulation film with a lower refractive index than the second conduction-type cladding layer over the surface; removing the insulation film on the central ridge portion and the lateral ridge portions by etching; and forming an electrode that forms an ohmic junction with the second conduction-type contact layer.
Also, for the purpose of reducing element resistance, a manufacturing method in a case where the Zn activation yield is to be increased adopts a crystal growth step in which in the above method the first conduction-type current blocking layer is an n-type semiconductor layer and the second conduction-type cladding layer and the second conduction-type contact layer are p-type semiconductor layers.
For the purpose of further increasing the heat dissipation properties, in a case of a semiconductor laser element where current confinement is performed by providing high resistance through ion implantation, for example, the above manufacturing method is modified to substitute the first conduction-type current blocking layer with a second conduction-type semiconductor layer and provide high resistance through ion implantation to the second conduction-type semiconductor layer.
To suppress end surface deterioration that accompanies giving the semiconductor element a low operating current and a high output, the manufacturing method also can be modified to form a window structure in the end surface portion of the semiconductor laser element.
It is possible to use the following structural materials in the semiconductor laser element and the manufacturing method thereof according to the present invention.
(1) The semiconductor substrate is GaAs, and the cladding layers, the active layer, the current blocking layer, and a burying layer are Group III-V compound semiconductors including at least one chosen from the group consisting of Al, Ga, As, P, and In.
(2) The semiconductor substrate is InP, and the cladding layers, the active layer, the current blocking layer, and a burying layer are Group III-V compound semiconductors including at least one chosen from the group consisting of Al, Ga, As, P, and In.
(3) The semiconductor substrate is GaN, sapphire, or SiC, and the cladding layers, the active layer, the current blocking layer, and a burying layer are Group III-V compound semiconductors including at least one chosen from the group consisting of Ga, In, and N.
It is also preferable that the insulation film is formed in a single layer or a plurality of layers chosen from the group consisting of SiO 2 , SiN x , SiON, Al 2 O 3 , ZnO, SiC, and amorphous Si.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1 E are cross-sectional views showing the structure and manufacturing method of the ridge-type semiconductor laser according to a first embodiment of the present invention.
FIGS. 2A to 2 C are cross-sectional views showing a magnification of the ridge portion of the ridge-type semiconductor laser of FIG. 1 E.
FIGS. 3A to 3 E are cross-sectional views showing the structure and the manufacturing method of the ridge-type semiconductor laser according to a second embodiment of the present invention.
FIGS. 4A and 4B are cross-sectional views showing an applied example of the ridge-type semiconductor laser according to the second embodiment.
FIGS. 5 A 1 and 5 A 2 are cross-sectional views showing the structure and manufacturing method of the ridge-type semiconductor laser according to a third embodiment of the present invention.
FIGS. 5 B 1 and 5 B 2 are cross-sectional views showing the structure and the manufacturing method of an applied example of the ridge-type semiconductor laser according to the third embodiment.
FIGS. 6 A 1 and 6 A 2 are cross-sectional views showing the structure and the manufacturing method of the ridge-type semiconductor laser according to a fourth embodiment of the present invention.
FIGS. 6 B 1 and 6 B 2 are cross-sectional views showing the structure and the manufacturing method of a modified example of the ridge-type semiconductor laser according to the fourth embodiment.
FIG. 6C is a cross-sectional view showing the structure of a modified example of the ridge-type semiconductor laser of the fourth embodiment.
FIG. 7 is a cross-sectional view of the ridge-type semiconductor laser according to a fifth embodiment of the present invention.
FIGS. 8A to 8 C are cross-sectional views showing various different examples of the ridge-type semiconductor laser according to a sixth embodiment of the present invention.
FIGS. 9A to 9 E are cross-sectional views showing the manufacturing method of a conventional ridge-type semiconductor laser.
FIGS. 10A to 10 D are cross-sectional view showing the manufacturing method of a conventional groove-type semiconductor laser.
FIGS. 11A to 11 D are cross-sectional views showing the manufacturing method of a conventional ridge-type semiconductor laser.
FIGS. 12A to 12 D are cross-sectional views showing the manufacturing method of another conventional ridge-type semiconductor laser.
FIG. 13 is a cross-sectional view showing another conventional ridge-type semiconductor laser.
FIGS. 14A and 14B are cross-sectional views for describing the effect attained by the ridge-type semiconductor laser of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
FIGS. 1A to 1 E show the structure and the manufacturing process of the semiconductor laser element according to a first embodiment of the invention. The first embodiment is an example in which the present invention is adopted for a ridge-type semiconductor laser element that uses an AlGaAs based material.
The structure and manufacturing process of the present semiconductor laser element are described with reference to FIGS. 1A to 1 E. First, an n-GaAs substrate 101 is set inside a crystal growth apparatus (not shown), and as shown in FIG. 1A , an n-AlGaAs cladding layer 102 , a non-doped quantum well active layer 103 , a p-AlGaAs first cladding layer 104 , a p-AlGaAs etching stop layer 105 , a p-AlGaAs second cladding layer 106 , a p-GaAs contact layer 107 , an n-AlGaAs current blocking layer 108 , and an n-GaAs protection layer 109 are deposited and grown in that order on the n-GaAs substrate 101 in a first crystal growth step.
The n-AlGaAs cladding layer 102 has a composition of n-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 1.0 μm. The non-doped quantum well active layer 103 is formed in a triple quantum well structure made of an Al 0.07 Ga 0.93 As well layer (65 Å thickness), an Al 0.3 Ga 0.7 As barrier layer (50 Å thickness), and a guide layer (550 Å thickness) of the same composition. The p-AlGaAs first cladding layer 104 has a composition of p-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 0.2 μm. The p-AlGaAs etching stop layer 105 has a composition of p-Al 0.20 Ga 0.80 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 100 Å. The p-AlGaAs second cladding layer 106 has a composition of p-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 1 μm. The p-GaAs contact layer 107 has a carrier concentration of 1×10 19 cm −3 and a thickness of 0.3 μm. The n-AlGaAs current blocking layer 108 has the composition of n-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 0.1 μm. The n-GaAs protection layer 109 has a carrier concentration of 1×10 18 cm −3 and a thickness of 0.4 μm.
Next, the n-GaAs substrate 101 on which the above semiconductor layers are formed is removed from the growth apparatus, and using a photolithographic method well known in the art, a stripe-shaped SiO 2 mask 110 a is formed on the n-GaAs protection layer 109 as shown in FIG. 1 B. This SiO 2 mask serves as an etching mask, and a well known selective etching method is employed to etch the n-AlGaAs current blocking layer 108 and the n-GaAs protection layer 109 down to the p-GaAs contact layer 107 .
Then, as shown in FIG. 1C , a well known photolithography method is used to form a striped SiO 2 mask 110 b on the p-GaAs contact layer 107 . The SiO 2 mask 110 b serves as an etching mask, and using a well known selective etching method, the p-AlGaAs second cladding layer 106 and the p-GaAs contact layer 107 are processed into a ridge shape down to the p-AlGaAs etching stop layer 105 .
In the first embodiment, hydrofluoric acid is used as the selective etchant for the AlGaAs layers, and a solution of hydrogen peroxide added to ammonia water is used as the selective etchant for the GaAs layers. The width at the bottom portion of the ridge (stripe width) is 1 to 4 μm.
This is followed by the use of a well known photolithography method to form a SiO 2 insulation film 111 (0.1 to 0.3 μm thickness) on the side surfaces of the ridge portion as shown in FIG. 1 D. Next, as shown in FIG. 1E , a p-side ohmic electrode 113 is formed on the top surface on the p-GaAs contact layer 107 side and an n-side ohmic electrode 112 is formed on the bottom surface of the n-GaAs substrate 101 . Lastly, using a cleavage method, the resonator length is adjusted to 200 μm, and a coating film with 30% reflectance is formed on the emission side end surface and a coating film with 50% reflectance is formed on the opposite side end surface (coating films are not shown).
The ridge-type semiconductor laser was fabricated through the above processes, and its emission wavelength was measured to be 800 nm.
With the conventionally structured ridge-type semiconductor laser shown in FIG. 1D , the assembly yield is 10% or less, with most of the defects being laser oscillation failure, when it is assembled onto a SiC sub-mount with the p-side ohmic contact electrode 13 serving as the bonding surface. Analysis of the defects showed that in most of the chips there were cracks at or near the bottom portion of the ridge. The cracks likely are caused due to stress during assembly being concentrated at the ridge portion, which is the only protruding portion. Cracks also are thought to occur for the same reason during the cleavage process, and it is possible that the ridge portion is severely damaged in both processes. Also, even with the elements that did emit laser light, the majority were found to have problems such as an increased current threshold value or very conspicuous deterioration at elevated temperatures (in a lifetime test at 70° C., 5 mW, the change in operating current after 100 hours was 10% or more). It is believed that the primary reason for this is diminished heat dissipation properties of the element due to most of the surface of the conventionally structured element being covered by a high thermal resistance SiO 2 film.
On the other hand, the result for the ridge-type semiconductor laser of the first embodiment was an assembly yield of 95% or more, with very few defects due to failure of the laser to oscillate, when the laser was similarly assembled onto a SiC sub-mount with the p-side ohmic electrode 113 serving as the bonding surface. This is likely due to the alleviation of stress to the central ridge portion A, because the stress during assembly is concentrated to the other ridge portions (lateral ridge portions B shown in FIG. 2 A), which are higher than the ridge portion where the current is confined (the central ridge portion A shown in FIG. 2 A). The same applies to the cleavage process, where the defects during production such as, for example, cracking or the like are considerably reduced because stress concentrated at the central ridge portion A is alleviated by the surrounding lateral ridge portions B.
Also, superior results were obtained, with a 25% drop in the threshold current (20 mA→15 mA) of the element compared to the conventional structure and 90% or more of the elements after assembly showing a 10% or less change in operating current after 1000 hours in a high temperature lifetime test (70° C., 5 mW). This is presumably because there was a significant improvement in the heat dissipation properties of the element, because the ridge-type semiconductor laser of the first embodiment does not have a low thermal conductivity SiO 2 film formed on the n-AlGaAs current blocking layer 108 , and it is connected to the sub-mount via a high thermal conductivity metal electrode. Although the heat resistance value of the element is dependent on the film thickness and the area of the various layers, the thermal conductivity with an AlGaAs layer, although the difference varies with the Al composition, is about 10 W/m/K, which is approximately one order of magnitude higher than that with a SiO 2 film, which is about 1 W/m/K. Because the film thickness of the n-AlGaAs current blocking layer 108 (0.5 to 0.7 μm) in the ridge-type semiconductor laser according to the first embodiment is on the same order as the SiO 2 film thickness (0.1 to 0.3 μm), the heat resistance value of the element is presumably smaller with the ridge-type semiconductor laser of the first embodiment.
Another method for lowering the heat resistance value of the element is to give the central ridge portion A a reverse mesa shape, as shown in FIG. 2 B. The SiO 2 film 111 is not formed on the central ridge portion A for the purpose of forming a contact with the electrode, so that with the conventionally structured element (FIG. 11 D), where most of the element surface is covered by a dielectric film, the central ridge portion is an essential heat dissipation route and the area of the ridge top that forms a junction with the electrode greatly influences the heat dissipation properties of the element. Adopting a reverse mesa structure makes it possible to expand the area of the ridge top without changing the stripe width (bottom portion dimensions of the central ridge portion A), which influences the properties of the element, and thus this approach is effective in improving the heat dissipation properties.
To further increase the heat dissipation properties, it is preferable that the lateral ridge portions B have the widest area possible and that they are close to the central ridge portion. On the other hand, giving consideration to stabilizing the ridge portion formation process, a wide etching region must be secured in order to confirm the end point of the etching. Consequently, as shown in FIG. 2A , when the width of the central ridge portion is a, the width of the lateral ridge portions is b1, b2, . . . for a total of h (b=b1+b2+ . . . ), and the repetition width between central ridge portions is L, then it is preferable that (a+h)/L is 0.5 or less.
With the present embodiment, it is possible to use a hydrofluoric acid based anistropic etchant to etch the AlGaAs layer formed on the GaAs substrate, for which the (100) face is the primary face, in a stripe-shape in the <011> direction to obtain a ridge portion with the regular mesa structure shown in FIG. 2C , or in the stripe direction rotated 90° to obtain a ridge portion with the reverse mesa structure. The speed at which the hydrofluoric acid based etchant etches the (111) crystal face is small enough compared to that for the (100) face that the side surface of the ridge portion is formed at the (111) crystal face. A geometric calculation shows that the area of the top of the central ridge portion A of a reverse mesa structure is approximately 2 to 3 times that of a regular mesa structure (if ridge height=1.0 μm, stripe width=3 to 5 μm). Thus, with a reverse mesa structure it is possible to achieve a considerable improvement in heat dissipation properties.
Furthermore, adopting a reverse mesa ridge structure increases the contact area with the electrode for the same reason as above, thus reducing the contact resistance. One resulting advantage of this is that the series resistance of the element can be reduced.
The first embodiment has been described with regard to a case where the semiconductor laser element is adopted for a low-output semiconductor laser element used to read out CDs or the like, but the present invention likewise can be adopted for a high-output semiconductor laser element used to read/write CD-R/RW disks, for example. In this case as well, it is possible to achieve stabilized element properties through the reduction of stress to the central ridge portion during assembly, reduced cracking during the cleavage process, and improved element properties at elevated temperatures through the increase in heat dissipation properties.
Moreover, the element of the present embodiment may be made to further suppress the deterioration at the end surface that accompanies the increasing of the element output, by adopting a window structure that is obtained by high concentration doping through dispersion or ion implantation of a dopant such as Zn into the active layer near the end surface, and forming a current blocking layer near that end surface in order to inhibit carrier implantation into the active layer.
The present invention can be adopted for a self-oscillating semiconductor laser element, in which case a p-Al 0.07 Ga 0.93 As layer (carrier concentration 1×10 18 cm −3 , 100 Å thickness) can be used as the etching stop layer 105 in the above structure so that the etching stop layer serves as a saturable absorption layer.
Also, with the conventional structure shown in FIG. 11D , the p-GaAs contact layer is the final layer that is grown, but this causes the phenomenon of the Zn dopants being made inactive by atomic hydrogen (Akazaki Isamu, editor, “III-V Compound Semiconductors” Baifukan, pp. 312-313), which leads to the problem of increased element resistance. In response, with the structure of the present invention shown in FIG. 1E , an n-type semiconductor layer is grown on top of the p-GaAs contact layer 107 , which has the benefit of inhibiting hydrogen-induced inactivation. This effect is particularly noticeable in the case of AlGaInP-based red semiconductor lasers.
Second Embodiment
In the second embodiment, the current blocking layer is formed not by the n-AlGaAs layer 108 , as was the case in the first embodiment, but instead by providing the GaAs layer and the AlGaAs layer with high resistance through ion implantation. Aside from this, the second embodiment has the same configuration as that of the first embodiment.
The structure and the manufacturing process of the semiconductor laser element according to the present embodiment are described with reference to FIGS. 3A to 3 E. First, an n-GaAs substrate 201 is set inside a crystal growth apparatus (not shown), and as shown in FIG. 3A , an n-AlGaAs cladding layer 202 , a non-doped quantum well active layer 203 , a p-AlGaAs first cladding layer 204 , a p-AlGaAs etching stop layer 205 , a p-AlGaAs second cladding layer 206 , a p-GaAs contact layer 207 , a p-AlGaAs third cladding layer 217 , and a p-GaAs protection layer 218 are deposited and grown in that order on the n-GaAs substrate 201 in a first crystal growth step.
The n-AlGaAs cladding layer 202 has a composition of n-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 1.0 μm. The p-AlGaAs first cladding layer 204 has a composition of p-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 0.2 μm. The p-AlGaAs etching stop layer 205 has a composition of p-Al 0.08 Ga 0.92 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 100 Å. The p-AlGaAs second cladding layer 206 has a composition of p-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm −3 , and a thickness of 1 μm. The p-GaAs contact layer 207 has a carrier concentration of 1×10 19 cm −3 and a thickness of 0.3 μm. The p-AlGaAs third cladding layer 217 has a composition of p-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 18 cm 3 , and a thickness of 0.7 μm. The p-GaAs protection layer 218 has a carrier concentration of 1×10 18 cm −3 and a thickness of 0.1 μm.
The configuration of the non-doped quantum well active layer 203 and the band gap of the p-AlGaAs etching stop layer 205 , which serves as a saturable absorption layer, are identical to those of the first embodiment.
Next, the n-GaAs substrate 201 on which the above semiconductor layers are formed is removed from the growth device, and using a photolithographic method well known in the art, a stripe-shaped SiO 2 mask 210 a is formed on the p-GaAs protection layer 218 , as shown in FIG. 3 B. This SiO 2 mask 210 a serves as an etching mask, and a selective etching method well known in the art is employed to etch the p-AlGaAs third cladding layer 217 and the p-GaAs protection layer 218 until reaching the p-GaAs contact layer 207 .
Then, a well known photolithography method is used to form a striped SiO 2 mask 210 b on the p-GaAs contact layer 207 . The SiO 2 mask 210 b serves as an etching mask, and a well known selective etching method is used to etch the p-AlGaAs second cladding layer 206 and the p-GaAs contact layer 207 down to the p-AlGaAs etching stop layer 205 and process them into a ridge shape.
The same selective etchant as that used in the first embodiment is used in the second embodiment as well. Also, the width of the ridge bottom portion (stripe width) is 1 to 4 μm.
Next, as shown in FIG. 3C , a photolithography method well known in the art is used to form a SiO 2 insulation film 211 (0.1 to 0.3 μm thick) on the side surfaces of the central ridge portion in the center. Then, as shown in FIG. 3D , the p-GaAs contact layer 207 and the SiO 2 insulation film 211 are covered by an ion implantation mask 215 made of a thick film resist (2 μm or more thick), and the p-GaAs protection layer 218 and the p-AlGaAs third cladding layer 217 , which are not covered by the thick film resist 215 , are provided with high resistance through ion implantation to form the high resistance layer 214 shown in FIG. 3 E. After the ion implantation mask 215 is removed, ohmic electrodes 213 and 212 are formed on the top surface on the p-GaAs contact layer 207 side and the bottom surface of the n-GaAs substrate 201 , respectively, as shown in FIG. 3 E. Lastly, using a cleavage method, the resonator length is adjusted to 200 μm, and a coating film with 30% reflectance is formed on the emission side end surface and a coating film with 50% reflectance is formed on the opposite side end surface.
The ridge-type semiconductor laser of the second embodiment was fabricated through the above process steps, and like in the first embodiment, its emission wavelength was measured to be 800 nm.
The result with the ridge-type semiconductor laser of the second embodiment was that as in the first embodiment, the assembly yield was 95% or more, with very few defects due to failure of the laser to oscillate, when the laser was assembled onto a SiC sub-mount with its p-side ohmic electrode 113 serving as the bonding surface. With the present embodiment, the current blocking layer may be made thinner than in the first embodiment because ion implantation is used to carry out current confinement. Consequently, because the distance from the active layer to the surface in the lateral ridge portions on both sides of the central ridge portion can be made small (the total film thickness can be set thin), there is the benefit that the heat dissipation properties can be further increased, even if the surface area of the lateral ridge portions is the same as that in the first embodiment.
As an application example for the present embodiment, it is possible to adopt the configuration shown in FIGS. 4A and 4B . Here, the n-AlGaAs current blocking layer 208 and the n-GaAs protection layer 209 are formed, and the lateral ridge portions serve as current blocks due to the n-type semiconductor layers. The regions where the p-type semiconductor layers are exposed, other than between the central ridge portion and the lateral ridge portions, are provided with high resistance through ion implantation as shown in FIG. 4A , so as to form the high resistance layer 214 , as shown in FIG. 4B , and thereby achieve current blocking. Thus, in the configuration of the first embodiment, there is a reduction in the surface area covered by the SiO 2 insulation film 111 , which has a low thermal conductivity, and the heat dissipation properties are improved further. The above configuration simultaneously also achieves a reduction in stress at the ridge portion during assembly, and thus a laser with stable properties can be fabricated at low cost.
Third Embodiment
The third embodiment adopts the same basic configuration as the first or second embodiments, except that the GaAs and AlGaAs layers are given high resistance by ion implantation in order to confine the current at the central ridge portion. Apart from this, it has the same configuration as the first and second embodiments.
The structure and the manufacturing process of a first example of the semiconductor laser element according to the present embodiment are described with reference to FIGS. 5 A 1 and 5 A 2 . Like in the first embodiment, the n-GaAs substrate 101 is set inside a crystal growth apparatus (not shown), a first crystal growth step is performed, and then the processing steps up to FIG. 1B are performed.
Next, a well known photolithography method is used to form an ion implantation mask 315 made of a stripe-shaped thick film resist (at a thickness of 2 μm or more) over the p-GaAs contact layer 107 as shown in FIG. 5 A 1 . Then, the p-GaAs contact layer 107 that is not covered by the ion implantation mask and the p-AlGaAs second cladding layer 106 , are provided with high resistance by ion implantation so as to form a high resistance layer 314 a as shown in FIG. 5 A 2 . Once the resist 315 has been removed, ohmic electrodes 313 and 312 are formed on the top surface on the p-GaAs contact layer 107 side and on the bottom surface of the n-GaAs substrate 101 , respectively, as shown in FIG. 5 A 2 . The resonator length is then adjusted to 200 μm by a cleavage method, and a coating film with 30% reflectance is formed on the emission side end surface and a coating film with 50% reflectance is formed on the opposite side end surface.
The ridge-type semiconductor laser of the third embodiment was fabricated through the above process steps, and like in the first embodiment, its emission wavelength was measured to be 800 nm.
The same selective etchant as that used in the first embodiment is used in the third embodiment as well. Also, the width of the ridge bottom portion (stripe width) is 1 to 4 μm.
The result with the ridge-type semiconductor laser of the third embodiment was that, like in the first embodiment, the assembly yield was 95% or more, and there were extremely few defects due to failure of the laser to oscillate, when the laser was assembled onto a SiC sub-mount with its p-side ohmic electrode 313 serving as the bonding surface. With the present embodiment, the current blocking layer may be made thinner than in the first embodiment because ion implantation is used to perform current confinement, and the distance from the active layer to the surface in the lateral ridge portions can be made small (the total film thickness is set thin), so that there is the benefit that the heat dissipation properties can be increased further, even if the surface area of the lateral ridge portions is the same as that in first embodiment.
As another example of an application for the present embodiment, FIGS. 5 B 1 and 5 B 2 show a configuration in which the current block of the lateral ridge portions is achieved by providing the semiconductor layers with high resistance through ion implantation. In the same way as in the second embodiment, each of the layers is deposited as shown in FIG. 3 A and the p-AlGaAs third cladding layer 217 and the p-GaAs protection layer 218 are etched to form the lateral ridge portions as shown in FIG. 5 B 1 . Then, ion implantation is performed through an ion implantation mask 316 made of a thick film resist in order to provide the p-GaAs contact layer 207 , the p-AlGaAs second cladding layer 206 , the p-AlGaAs third cladding layer 217 , and the p-GaAs protection layer 218 with high resistance and form a high resistance layer 314 b as shown in FIG. 5 B 2 .
In this case, the lateral ridge portions can be p-type semiconductor layers, but by forming an n-type semiconductor layer or an undoped semiconductor layer of approximately 0.3 μm or more on the p-type semiconductor layers, it is possible to reduce element resistance by increasing Zn activation as mentioned above.
This configuration has the problem of being unstable in lateral modes because the stripe portion also confines the current due to ion implantation, however, it can be adopted for a gain guide laser.
Fourth Embodiment
In the fourth embodiment, a burying crystal growth step is added to the configuration of the first and second embodiments. This configuration is not suited for reducing costs because a plurality of crystal growth steps are performed. However, it does achieve the effects of reducing the concentration of stress at the ridge portion during assembly, improving the heat dissipation properties, reducing cracks during cleavage, and reducing element resistance. Aside from the addition of a burying growth step, this embodiment has the same configuration as that of the first and second embodiments.
The structure and the manufacturing process of the semiconductor laser element according to the present embodiment are described with reference to FIGS. 6 A 1 and 6 A 2 . Like in the first embodiment, a photolithography method and a selective etching method well known in the art are used to perform the processing steps up to FIG. 1D to obtain the state shown in FIG. 6 A 1 , where the ridges and the SiO 2 insulation film 111 (0.1 to 0.3 μm thickness) are formed. The same selective etchant as that used in the first embodiment is used in the fourth embodiment as well, and the width of the ridge bottom portion (stripe width) is 1 to 4 μm.
Then, as shown in FIG. 6 A 2 , a p-GaAs burying layer 416 is formed. Lastly, ohmic electrodes 413 and 412 are formed on the top surface on the p-GaAs burying layer 416 side and on the bottom surface of the n-GaAs substrate 101 , respectively.
In the configuration shown in FIGS. 6 B 1 and 6 B 2 , current confinement is performed by an n-type current blocking layer 408 (AlGaAs or GaAs) instead of the SiO 2 insulation film 111 in the configuration shown in FIGS. 6 A 1 and 6 A 2 . As shown in FIG. 6 B 1 , the n-type current blocking layer 408 is formed by a selective growth step in which an SiO 2 mask 410 is used as the etching mask during ridge formation. The fabrication steps thereafter are the same as in FIGS. 6 A 1 and 6 A 2 , and as shown in FIG. 6 B 2 , the p-GaAs burying layer 416 and the ohmic electrodes 413 and 412 are formed.
The configuration shown in FIG. 6C is the configuration in FIGS. 6 B 1 and 6 B 2 without the p-GaAs burying layer 416 being formed but with the ohmic electrodes 413 and 412 formed on the top surface of the n-type current blocking layer 408 and on the bottom surface of the n-GaAs substrate 101 , respectively.
In the configurations shown in FIGS. 6 B 1 , 6 B 2 , and 6 C, it is not absolutely necessary that the n-type semiconductor layer of the lateral ridge portions is formed. There is less of a difference in height between the central ridge portion and the lateral ridge portions in a configuration without the n-type semiconductor layer, and therefore there is a risk that the effect of reducing stress concentrated at the central ridge portion during assembly may be lessened. However, this can be overcome by choosing an appropriate thickness for the n-type current blocking layer.
Fifth Embodiment
FIG. 7 shows the semiconductor laser element according to the fifth embodiment. The fifth embodiment is an example in which the present invention is adopted for a ridge-type semiconductor laser element that employs an AlGaInP-based material.
The structure and the manufacturing process of the present semiconductor laser element are described with reference to FIG. 7 . First, an n-GaAs substrate 501 is set inside a crystal growth apparatus (not shown), and an n-AlGaInP cladding layer 502 , a non-doped quantum well active layer 503 , a p-AlGaInP first cladding layer 504 , a p-GaInP etching stop layer 105 , a p-AlGaInP second cladding layer 506 , a p-GaAs contact layer 507 , an n-AlGaAs current blocking layer 508 , and an n-GaAs protection layer 509 are deposited and grown in that order on the n-GaAs substrate 501 in a first crystal growth step.
The n-AlGaInP cladding layer 502 has a composition of n-(Al 0.7 Ga 0.3 ) 0.5 In 0.5 P, a carrier concentration of 1×10 18 cm −3 , and a thickness of 1.2 μm. The non-doped quantum well active layer 503 is formed in a strained quadruple quantum well structure made of a Ga 0.6 In 0.4 P well layer (53 Å thickness), an (Al 0.5 Ga 0.5 ) 0.5 In 0.5 P barrier layer (50 Å thickness), and a guide layer (400 Å thickness) of the same composition. The p-AlGaInP first cladding layer 504 has a composition of p-(Al 0.7 Ga 0.3 ) 0.5 In 0.5 P, a carrier concentration of 4×10 17 cm 3 , and a thickness of 0.3 μm. The p-GaInP etching stop layer 505 has a composition of p-Ga 0.5 In 0.5 P, a carrier concentration of 1×10 18 cm −3 , and a thickness of 90 Å. The p-AlGaInP second cladding layer 506 has a composition of p-(Al 0.7 Ga 0.3 ) 0.5 In 0.5 P, a carrier concentration of 1×10 18 cm −3 , and a thickness of 1 μm. The p-GaAs contact layer 507 has a carrier concentration of 1×10 19 cm −3 and a thickness of 0.2 μm. The n-AlGaAs current blocking layer 508 has a composition of n-Al 0.5 Ga 0.5 As, a carrier concentration of 1×10 8 cm −3 , and a thickness of 0.1 μm. The n-GaAs protection layer 509 has a carrier concentration of 1×10 18 cm −3 and a thickness of 0.4 μm.
Next, the n-GaAs substrate 501 on which the above semiconductor layers are formed is removed from the growth apparatus, and using a photolithographic method well known in the art, a stripe-shaped SiO 2 mask is formed on the n-GaAs protection layer 509 . This SiO 2 mask serves as an etching mask, and a well known selective etching method is used to etch the n-AlGaAs current blocking layer 508 and the n-GaAs protection layer 509 down to the p-GaAs contact layer 507 .
Then, a photolithography technique well known in the art is used to form a striped SiO 2 mask on the p-GaAs contact layer 507 . This SiO 2 mask serves as an etching mask, and a selective etching method well known in the art is used to etch the p-AlGaInP second cladding layer 506 and the p-GaAs contact layer 507 until reaching the p-GaInP etching stop 505 and process them into a ridge shape.
In the fifth embodiment, a hydrofluoric acid based-etchant is used as the selective etchant for the AlGaAs layers, a solution of hydrogen peroxide added to ammonia water is used as the selective etchant for the GaAs layers, and a hydrochloric acid based-etchant is used to etch the AlGaInP layers. Also, the width of the ridge bottom portion (stripe width) is 3 to 5 μm.
This is followed by the use of a well known photolithography method to form a SiO 2 insulation film 511 (thickness of 0.1 to 0.3 μm) on the side surface of the ridge portions. Lastly, ohmic electrodes 513 and 512 are formed on the top surface on the p-GaAs contact layer 507 side and on the bottom surface of the n-GaAs substrate 501 , respectively, a cleavage method is used to adjust the resonator length to 350 μm, and a coating film with 30% reflectance is formed on the emission side end surface and a coating film with 75% reflectance is formed on the opposite side end surface.
The ridge-type semiconductor laser of the fifth embodiment was fabricated through the above process steps, and its emission wavelength was measured to be 660 nm.
Like in the first embodiment, the result with the ridge-type semiconductor laser of the fifth embodiment was that the assembly yield was 90% or more, and there were extremely few defects due to failure of the laser to oscillate, when the laser was assembled onto a SiC sub-mount with the p-side ohmic electrode serving as the bonding surface. This is likely due to the alleviation of stress at the central ridge portion, because the stress during assembly is concentrated at the lateral ridge portions, which are higher than the central ridge portion where current confinement is performed. The same applies to the cleavage process, where the defects during production such as, for example, cracking or the like are considerably reduced because stress concentrated at the central ridge portion is alleviated by the surrounding lateral ridge portions. Also, superior results were obtained, with a 20% drop in the threshold current (25 mA→20 mA) of the element compared to the conventional structure, and 90% or more of the elements after assembly showing a 10% or less change in operating current after 1000 hours in a high temperature lifetime test (70° C., 7 mW). This is presumably because there was a significant improvement in the heat dissipation properties of the element, because the ridge-type semiconductor laser of the fifth embodiment, like that of the first embodiment, does not have a SiO 2 film with low thermal conductivity formed on the n-type current blocking layer, and it is connected to the sub-mount via a metal electrode having high thermal conductivity.
As is the case with the first embodiment, in the fifth embodiment it is possible to form the central ridge portion in a reverse mesa shape, as shown in FIG. 2B , as one method to lower the heat resistance value of the element. With the present element, it is possible to use a hydrochloric acid-based anistropic etchant to etch the AlGaInP layer formed on the GaAs substrate, for which the (100) face is the primary face, in a stripe-shape in the <011> direction to obtain a regular mesa structure, or rotated 90° in the stripe direction to obtain a reverse mesa structure.
Adopting a reverse mesa structure ridge leads to an increase in the contact area with the electrode, with the benefit that the contact resistance can be reduced and thus the series resistance of the element can be reduced.
The fifth embodiment has been described with regard to a case where the semiconductor laser element is adopted for a low-output semiconductor laser element used to read DVDs or the like, but the present invention can be similarly adopted for a high-output semiconductor laser element used to read/write DVD-R/RW and RAM disks, for example. In this case as well, it is possible to achieve stabilized element properties through the reduction of stress at the central ridge portion during assembly, reduced cracking during the cleavage process, and improved element properties at elevated temperatures through the increase in heat dissipation properties.
In order to suppress the end surface deterioration that accompanies increasing the output of the element, the non-doped quantum well active layer 503 was given a strained triple quantum well structure made of a Ga 0.6 In 0.4 P well layer (60 Å thickness), an (Al 0.5 Ga 0.5 ) 0.5 In 0.5 P barrier layer (50 Å thickness), and a guide layer (250 Å thickness) of the same composition.
Moreover, this element can be made to suppress further the end surface deterioration that accompanies making the element high output, by adopting a window structure that is obtained by high concentration doping through dispersion or ion implantation of a dopant such as Zn into the active layer near the end surface, and forming a current blocking layer near the same end surface in order to inhibit carrier implantation into the active layer.
Also, in the conventional structure shown in FIG. 11D , the p-GaAs contact layer is the final crystal growth layer, and as mentioned above, this causes the phenomenon of the Zn dopants being made inactive by atomic hydrogen, which results in the problem of increased element resistance. However, with the structure of the present embodiment shown in FIG. 7 , an n-type semiconductor layer is grown on the p-GaAs contact layer 507 , and this has the benefit of inhibiting hydrogen-induced inactivity.
Sixth Embodiment
FIGS. 8A to 8 C show the semiconductor laser element according to a sixth embodiment. The present embodiment relates to other examples of the configuration for the lateral ridge portions according to the first to fifth embodiments.
The configuration in FIG. 8A is identical to that of the first embodiment, where two lateral ridge portions are formed to either side of the central ridge portion and the outer side of the lateral ridge portions has been etched flat. In contrast, in the configuration shown in FIG. 8B , two lateral ridge portions are formed, but the outer side of the lateral ridge portions has not been etched. Consequently, an SiO 2 insulation film 811 a is formed only between the central ridge portion and the lateral ridge portions. In the configuration shown in FIG. 8C , four lateral ridge portions are formed, and an SiO 2 insulation film 811 b is formed between each of the ridge portions.
In any of these configurations, if at least two ridge portions are formed higher than the central ridge portion, then it is possible to achieve the effect of a reduction in stress during assembly. The heat dissipation properties can be increased by removing the insulation film on the ridge portions. With respect to the cleavage properties, cracking can be kept from occurring if the configuration is one with lateral ridge portions formed on both sides of the central ridge portion (with a spacing between the central ridge portion and the lateral ridge portions of 30 μm or less). Also, element resistance can be reduced if in the configuration an n-type semiconductor layer is crystal grown on a p-type cladding layer. As above, there are no problems as long as the configuration of the lateral ridge portions meets the above conditions.
The present invention can also be applied to a similar semiconductor laser that is manufactured by a process that includes a burying growth step, and by doing so the same effects can be obtained.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof The embodiments disclosed in this application are to be considered in all respects as illustrative and not restrictive, the scope of the invention being 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 intended to be embraced therein. | A semiconductor laser has a first conduction-type cladding layer, an active layer, and a second conduction-type cladding layer formed on a first conduction-type semiconductor substrate. The second conduction-type cladding layer has a mesa-type stripe-shaped recessed portion in at least four spots, so as to form a central ridge portion, which constitutes a ridge-type current confinement portion, and two or more lateral ridge portions, which are positioned on both sides of the central ridge portion, have a height larger than to that of the central ridge portion, and include the second conduction-type cladding layer. An insulation film with a lower refractive index than the second conduction-type cladding layer is formed in a pair of stripes disposed respectively in the regions from the side surface of the second conduction-type cladding layer on both side surfaces of the central ridge portion toward the outside. The insulation film is not formed on the central ridge portion. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a process for recovering hydrocarbons from tailings produced by a dilution centrifuging circuit within an oil sand operation employing the known hot water extraction process. It also encompasses the hydrocarbon froth product obtained by the practise of the process.
The hot water extraction process, used commercially to recover bitumen from the Alberta oil sands, involves the following series of steps:
(1) SLURRING, HEATING AND CONDITIONING THE OIL SAND IN A ROTATING DRUM IN WHICH IT IS MIXED WITH STEAM, HOT WATER AND CAUSTIC;
(2) DILUTING THE SLURRY WITH MORE HOT WATER AND INTRODUCING IT INTO A PRIMARY SEPARATION VESSEL WHERE IT IS RETAINED TO PERMIT BUOYANT BITUMEN PARTICLES TO RISE TO THE SURFACE AND FORM PRIMARY FROTH;
(3) WITHDRAWING A STREAM OF MIDDLINGS FROM THE MIDPOINT OF THE SEPARATION VESSEL AND SUBJECTING IT TO INDUCED AIR FLOTATION IN A SECONDARY RECOVERY FLOTATION CALL TO CAUSE CONTAINED BITUMEN TO FORM SECONDARY FROTH; AND
(4) COMBINING THE PRIMARY AND SECONDARY FROTHS TO FORM A COMBINED FROTH PRODUCT.
The dilution centrifuging process used to remove water and solids from the froth product of the hot water extraction process involves the following steps:
(1) DILUTING THE COMBINED FROTH PRODUCT WITH NAPHTHA TO ALTER THE VISCOSITY AND SPECIFIC GRAVITY OF THE CONTAINED BITUMEN; AND
(2) INTRODUCING THE DILUTED FROTH INTO A TWO-STAGE CENTRIFUGAL SEPARATION CIRCUIT WHERE THE COARSE SOLIDS ARE SEPARATED FROM THE STREAM IN A SCROLL-TYPE CENTRIFUGE AND THE WATER AND FINE SOLIDS ARE SEPARATED IN A DISC-TYPE CENTRIFUGE.
The combined hot water extraction and dilution centrifuging processes are hereinafter collectively termed "hot water extraction operation".
There is a significant loss of hydrocarbons in the dilution centrifuging (D.C.) tailings produced by the scroll and disc centrifuges. More particularly, in the plant presently being constructed by the assignee of this invention, there will be approximately 1.6 million pounds/hour of D.C. tailings produced containing approximately 3.5% by weight bitumen, 2.1% hydrocarbon diluent, 24.0% solids and 70.4% water. The losses of bitumen and diluent per day will be approximately 3,900 barrels and 3,200 barrels, respectively. These figures are only given by way of example, as it is expected that they will vary significantly with plant operating conditions and throughput.
The tailings composition shown above corresponds to the predicted values for a commercial plant. The tailings actually used in developing this invention were derived from pilot plant operations and contained a significantly greater proportion of water, as indicated in Example I. This extra water is a direct result of the mechanical configuration of the pilot plant centrifuges. However, the recovery of hydrocarbon from the pilot plant tailings is more difficult than it will be from the actual tailings, because the hydrocarbon content of the pilot plant tailings is reduced by the extra water.
A problem which has heretofore existed was how to economically recover the hydrocarbons contained in the D.C. tailings. If such a process could be developed, it would also be desirable that the diluent and bitumen be recovered in a single step. In this regard, it needs to be kept in mind that the D.C. tailings is a unique and difficult material to deal with. It contains a relatively small amount of bitumen and diluent distributed throughout a large quantity of water and solids. The bitumen in the tailings is originally recovered as part of the froth produced by the hot water extraction process. Its rejection to the D.C. tailings together with the proportionate amount of diluent suggests that these hydrocarbons are physically associated with the froth solids. Hence, despite the fact that the specific gravity of the diluted bitumen is less than 1.0, it still reports to the tailings. This is borne out by simple settling tests on D.C. tailings, in which it is found that only minor quantities of the hydrocarbons present float and the bulk of them are found in the solids which settle out.
SUMMARY OF THE INVENTION
It has now been found that induced gas flotation can successfully applied to D.C. tailings to recover the major portion of the bitumen and diluent. While minimum amounts of aeration and agitation are required to achieve hydrocarbon flotation, it has been determined that recovery varies significantly only with retention time up to a definite limit, at which point the process becomes relatively insensitive to changes in the operating conditions. It has also been determined that the relationship between retention time and recovery holds true for feedstocks of different compositions. Thus a preferred process employing multiple flotation cells has been outlined. In this process, the retention time for each cell falls within the predicted range wherein recovery from that cell is significantly sensitive to retention time. The process has successfully been practised to recover most of the bitumen and diluent contained in the D.C. tailings. The unique froth product holds the hydrocarbons in a contaminated but concentrated form which can be either fed directly to the primary upgrading process or subjected to additional treatment to remove solids and water.
When the flotation cell is open to the atmosphere, it is found that some of the diluent is lost while the greatest part of the balance reports in the froth. In a preferred form of the invention, flotation is carried out in one or more sealed flotation cells using an inert gas, such as nitrogen, as the flotation agent. The excess gas collected from these cells is recycled to the flotation cells and ultimately becomes saturated with diluent vapors. When this state is reached, the recycled flotation gas no longer strips diluent from the tailings and the diluent then reports to the froth in the same proportion as the bitumen. Tests have shown that the flotation efficiency, using nitrogen as the flotation gas, is unaffected by diluent vapor.
An alternative to the procedure of recycling saturated nitrogen to the flotation cell, involves employing a condensor to remove diluent vapor from the vent gas before it is recycled. In this manner, some diluent can be recovered as liquid, and some is recovered in the froth. Both methods are effective to reduce the losses incurred by running the flotation cells open to the atmosphere.
In another preferred feature of this invention, it has been found desirable to maintain the aeration rate in the flotation vessel below 0.2 SCFM of gas per cubic foot of vessel capacity, while maintaining a minimum power input of 0.04 horsepower per cubic foot of vessel capacity. (It is to be understood that the term "aeration" as used herein is to be interpreted broadly to include introduction of an inert gas as the flotation agent.)
The froth product obtained from this flotation process practised on D.C. tailings is unique in composition. It comprises 8 to 28% by weight hydrocarbons (that is bitumen plus diluent), 70 to 37% water and 22 to 43% solids. In comparison to the original D.C. tailings, the hydrocarbons are present in greater concentration in this product and some solids and most of the water have been rejected; in comparison to combined primary and secondary froth, the present product contains perhaps twice as much water and three times as many solids. In any event, the product is a feedstock which can feasibly be treated to recover contained hydrocarbons as a pure product.
The invention is characterized by the following advantages:
(1) A large proportion of the hydrocarbons in the D.C. tailings can now economically be recovered in a more concentrated form and water and solids can simultaneously be rejected; and
(2) The froth product is proportionately small in volume when compared with the original D.C. tailings and is amenable to further treatment at reasonable cost to recover the bitumen in pure form.
DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a block diagram setting forth the steps of the process;
FIG. 2 is a schematic diagram of the circuit used to carry out the experiments involved in developing the invention; and
FIG. 3 is a plot of hydrocarbon recovery versus retention time for a single cell system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Starting Material
The pilot plant D.C. tailings, which formed the feedstock for the development work involved in this invention, comprised a mixture of scroll centrifuge tailings and disc centrifuge tailings provided in a ratio of about 1 to 12. These two streams were blended and usually heated in a mix tank to form a mixture having a temperature of about 170° F.
Flotation
This mixture was introduced into a conventional induced gas flotation cell or into the first of a bank of such cells. The laboratory pilot plant used to develop the invention is illustrated in FIG. 2. It comprised an agitated heating tank 1 to which cold disc and scroll tailings were fed manually and mixed and heated to about 170° F. The product was pumped through a line 2 to a series of 3 Denver ™ induced air flotation cells from which the froth and tailings products were obtained.
As previously mentioned, the most significant parameter with respect to the operation of the flotation cell was its retention time. As shown in FIG. 3, the slope of the curve obtained by plotting hydrocarbon recovery against retention time was consistently steep until it changed suddenly at point "A", after which increased retention time yielded little increase in recovery. This finding requires that one should choose a cell having sufficient volume to provide a retention time corresponding with or close to the retention time at which the slope of the curve changes suddenly, for the particular D.C. tailings feedstock being processed. Now this choice will, of course, be also influenced to some extent by the economics of cell size and the limited range of sizes which are commercially available.
It has also been found that the recovery-retention time curve for a single cell, such as is shown in FIG. 3, provides a reliable indication of the performance of additional cells placed in series downstream from the first cell. In other words, a reliable scale up is achieved by using the data from a single cell for a plurality of cells operating downstream from it and receiving its underflow.
There is a minimum agitation level required in the cell, below which "sanding out" can occur. More particularly, it is preferred to operate the vessel above a minimum power input of about 0.04 H.P./ft. 3 of cell volume.
It has also been found that there is an air injection rate above which there is little improvement in recovery. More particularly, it is preferred to operate the flotation cells at an aeration rate of less than 0.2 SCFM/cu. ft. of cell volume, as this is sufficient to recover the hydrocarbon.
It is also preferred to use multiple cells in series to improve the ultimate recovery. These cells can all be operated at the same condition.
If desired, nitrogen may be used with sealed cells to avoid losing diluent to the atmosphere and to eliminate the safety hazard associated with air-naphtha vapor mixtures.
The invention is illustrated by the following examples.
EXAMPLE I
This example involves the operation of a single cell open to the atmosphere. About 250 pounds of scroll tailings and 350 Imperial gallons of disc tailings were placed in a tank and heated to 170° F. with agitation. The time required to accomplish this heating was approximately 1 hour. The analyses of the two tailings was as follows:
TABLE I______________________________________(Run L13) Typical Typical Measured% by weight Scroll Tailings Disc Tailings D.C. Tailings______________________________________hydrocarbons 6.46 1.50 1.70solids 75.00 4.00 6.85water 18.50 94.50 91.45______________________________________
This mixture was fed at 23.5 lbs./min. into a 0.8 cubic foot capacity flotation cell equipped with a Denver Sub-A type aeration impellor. Air was fed into the body of tailings through the impellor mechanism. The cell operating conditions were as follows:
______________________________________retention time 2.26 minutesimpellor speed 750 r.p.m.air rate 0.175 SCFM/cu. ft. of cell volumepower input 0.09 HP/cu. ft. of cell volume______________________________________
Froth and tailings products were obtained at respective rates of 1.59 and 21.91 lbs./min. and had the following compositions:
TABLE II______________________________________% by weight Froth Tailings______________________________________hydrocarbons 15.61 0.73Solids 30.44 5.57Water 53.95 93.70______________________________________
EXAMPLE II
This example illustrates that a reliable scale up is obtained by using recovery data developed by a single cell and applying it to a bank of cells operating under similar conditions.
The underflow or tailings from Example I was subjected to two additional flotation stages. With the exception of retention time, the cell design and operating conditions were identical to those of Example I. The retention time varied slightly from cell to cell by virtue of the froth produced which tended to reduce the volume of material fed to the next cell. Table III summarizes the experimental results:
TABLE III______________________________________Run L13 Cell 1 Cell 2 Cell 3______________________________________Retention Time perCell - minute 2.26 2.42 2.47Froth Producedlb./minute 1.59 0.39 0.27Froth Composition -% by weighthydrocarbons 15.61 18.09 17.64solids 30.44 36.54 32.28water 53.95 45.37 49.98______________________________________
The total froth and final (Cell 3) tailings were obtained at respective rates of 2.25 and 21.25 lb./minute and had the following composition:
TABLE IV______________________________________Run L13% by weight Total Froth Final Tailings______________________________________hydrocarbons 16.28 0.19solids 31.73 4.66water 51.99 95.15______________________________________
Cell 1 recovered 60.89% of the hydrocarbon (bitumen plus naphtha) fed to the bank of cells. This number was used to calculate the hydrocarbon recovered in cells 2 and 3. Table V shows a comparison between calculated and measured performance. The total hydrocarbon recovery for the cell bank was adequately predicted from the single cell value.
TABLE V______________________________________Run L13 Total Cell 2 Cell 3 (Cell 1 + Cell 2 + Cell 3)______________________________________% of Cell 1Feed Hydrocar-bonRecoveredMeasured 17.56 11.62 90.08Calculated 23.81 9.32 94.02______________________________________
EXAMPLE III
This example illustrates that hydrocarbon recovery is insensitive to increases in cell air input in the range 0.175 to 0.512 SCFM/cu. ft. of cell volumen. Therefore the preferred air input is less than 0.175 SCFM/cu. ft. of cell volume. Runs L25, L26 and L27 were carried out at three different air rates while other operating conditions remained essentially constant. Runs L43, L44 and L45 were accomplished in a similar manner. The major difference between these two sets of runs was in cell retention times which were nominally 0.9 minutes and 1.25 minutes respectively.
TABLE VI______________________________________ Av. Input Cell 1Run SCFM/cu. ft. cell Recovery______________________________________L25 0.175 23.41L26 0.325 23.86L27 0.512 23.52L43 0.175 40.36L44 0.325 46.58L45 0.512 39.97______________________________________
EXAMPLE IV
This example illustrates the single cell relationship between hydrocarbon recovery and retention time. Such a correlation can be used in sizing banks of multiple cells.
An important feature is that recovery initially increases steadily with retention time but eventually the slope of the curve changes abruptly and becomes flat, so that further increases in residence time yield relatively little improvement in recovery.
A number of experiments were undertaken in which tailings were prepared and passed through the flotation cell as described in Example I. Feed rates to the cell were varied such that cell retention times ranged from about 0.9 minutes to 5.2 minutes. Impellor speed and power input were maintained constant at 750 rpm and 0.09 H.P./cu. ft. of cell volume. Air rates ranged from 0.175 to 0.512 SCFM/cu. ft. of cell, but as shown in Example III the recovery is independent of air rate. FIG. 3 shows the recovery-retention time relationship obtained from this series of runs. | The invention has to do with treatment of dilution centrifuging tailings ch are produced in connection with a hot water extraction operation for recovery of bitumen from oil sands. The tailings are subjected to induced gas flotation for a predetermined period of time to recover contained hydrocarbons as froth. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to provisional application no. 60/024,527, filed Aug. 23, 1996, incorporated herein by reference to the extent not inconsistent herewith.
BACKGROUND OF THE INVENTION
Normal articular cartilage functions to absorb shock, to bear load and to provide articulating surfaces for diarthorodinal joints. Articular cartilage differs from other musculoskeletal tissues in that it does not have the ability to repair itself following traumatic or pathologic afflictions. Because adult articular cartilage is avascular and acellular, healing of this tissue is very difficult to achieve Bora, F. W. and Miller, G. "Joint Physiology, cartilage metabolism, and the etiology of osteoarthritis." Hand Clin. 3: 325-336, 1987!. The composition of articular cartilage varies with anatomical location on the joint surface, with age and with depth from the surface Lipshitz, H. et al., "In vitro wear of articular cartilage." J. Bone Jt. Surg., 57:527-534, 1975!.
Once the disease or trauma affects the health of articular cartilage, an inevitable degenerative process can occur Convery, F. R., Akeson, W. H., and Keown, G. H., "The repair of large osteochondral defects." Clin. Orthop. Rel. Res., 82:253-262, 1972!. During cartilage degeneration, the amount of interstitial water increases, the proteoglycan content decreases, and the aggregation of proteoglycans decreases McDevitt, C. A. and Muir, H. "Biochemical changes in the cartilage of the knee in experimental and natural osteoarthritis in the dog." J. Bone Jt. Surg. Br!, 58-B:94-101, 1976!. When the proteoglycan content decreases, cartilage becomes softer Kempson, G. E. et al., "Correlations between stiffness and the chemical constituents of cartilage on the human femoral head." Biochem. Biophys., 215: 70-77, 1970; Jurvelin, J. et al., "Softening of canine articular cartilage after immobilization of the knee joint." Clin. Orthop. Rel. Res., 207:246-252, 1986!.
The condition of cartilage can be evaluated using various methods including visual examination, mechanical probing, imaging diagnostics, and biopsies. Clinically it is very difficult to evaluate cartilage health in a non-destructive manner and most often visual observations made arthroscopically in conjunction with mechanical probing are used. Visual examination is basically a subjective, qualitative determination of the structural integrity of the surface and includes a description of the articular cartilage damage present. Numerous systems have been proposed over the years, including the Outerbridge and Noyes classification systems Noyes, F. R. and Stabler, C. L., "A system for grading articular cartilage lesions at arthroscopy." The Journal of Sports Medicine., 17:505-513, 1989; Outerbridge, R. E., J. Bone Jt. Surg. 43B:752-757, 1961!. Mechanical probing utilizes a hand-held probe like a nerve hook to subjectively evaluate the stiffness of the articular cartilage. This instrument has traditionally been easy to use in an arthroscopic setting, but the information obtained is not traceable over time. Imaging diagnostics, specifically Magnetic Resonance Imaging (MRI), can be used to diagnose internal derangements of joints. Even though its overall accuracy range is acceptable Fisher, S. P., Fox, J. M., and Del Pizzo, "Accuracy of diagnosis from magnetic resonance imaging of the knee." J. Bone Jt. Surg., 73:2-10, 1991!, its cost, lack of sensitivity for lesions of the articular cartilage Halbrecht, J. L. and Jackson, D. W., "Office arthroscopy: A diagnostic alternative." Arthroscopy, 8:320-326, 1992!, and unsuitability for some patients makes it undesirable in many cases.
Many researchers have confirmed the correlation of the cartilage stiffness with the condition of the cartilage Kempson, G. E. et al., "Correlations between stiffness and the chemical constituents of cartilage on the human femoral head." Biochem. Biophys., 215: 70-77, 1970!, and it has been shown that the compressive stiffness of the cartilage is primarily determined by proteoglycans Armstrong, C. G. and Mow, V. C. "Variations in the intrinsic mechanical properties of human articular cartilage with age, degeneration, and water content." J. Bone Jt. Surg., 64-A:88-94, 1982!. Kempson, supra, reported that the greater the proteoglycan content, the stiffer the cartilage. Indentation of cartilage has been used extensively in vitro Athanasiou, K. A. et al., "Biochemical properties of hip cartilage in experimental animal models." Clin. Orthop. Rel. Res., 316:254-266, 1995; Schenck, R. C. et al., "A biomechanical analysis of articular cartilage of the human elbow and a potential relationship to osteochondritis dissecans." Clin. Orthop. Rel. Res., 299:305-312, 1994; Hale, J. E. et al., "Indentation assessment of biphasic mechanical property deficits in size-dependent osteochondral defect repair." J. Biomechanics, 26:1319-1325, 1993; Mak, A. F. and Mow, V. C., "Biphasic indentation of articular cartilage--I. Theoretical analysis." Biomechanics, 20:703-714, 1987; Rasanen, T. and Messner, K. "Regional variations of indentation stiffness and thickness of normal rabbit knee articular cartilage." J. Biomed. Mater. Res., 31:519-524, 1996! and in situ Lyyra, T. et al., "Indentation instrument for the measurement of cartilage stiffness under arthroscopic control." Med. Eng. Phys., 17:395-399, 1995; Tkaczuk, H. "Human cartilage stiffness: In vivo studies." Clin. Orthop. Rel. Res., 206:301-312, 1986; Dashefsky, J. H., "Arthroscopic measurement of chondromalacia of patella cartilage using a microminiature pressure transducer." Arthroscopy, 3:80-85, 1987! to measure the material properties of articular cartilage including stiffness. To biomechanically evaluate the articular cartilage, in vitro biphasic and even triphasic creep indentation and stress relaxation tests have been used to determine the intrinsic mechanical properties (aggregate modulus, Poisson's ratio, permeability) of the articular cartilage Mow, V. C. et al., "Biphasic indentation of articular cartilage--II. A numerical algorithm and an experimental study." J. Biomechanics, 22:853-861, 1989; Lai, W. M. et al., "A triphasic theory for the swelling and deformation behaviors of articular cartilage." J. Biomechanical Eng., 113:245-258, 1991!. In addition in situ indentation tests have been used to map various regions of articular cartilage in several animal models and show significant variations in stiffness among the various test sites Rasanen, T. and Messner, K. "Regional variations of indentation stiffness and thickness of normal rabbit knee articular cartilage." J. Biomed Mater Res., 31:519-524, 1996!.
In the literature a few devices for the measurement of cartilage stiffness in a clinical setting have been reported e.g. Lyyra, T. et al., "Indentation instrument for the measurement of cartilage stiffness under arthroscopic control." Med. Eng. Phys., 17:395-399, 1995; Tkaczuk, H. "Human cartilage stiffness: In vivo studies." Clin. Orthop. Rel. Res., 206:301-312, 1986; Dashefsky, J. H., "Arthroscopic measurement of chondromalacia of patella cartilage using a microminiature pressure transducer." Arthroscopy, 3:80-85, 1987!. Lyyra et al. use an indentation instrument for the measurement of cartilage stiffness under arthroscopic control. Based on tests in laboratory conditions with elastomer and cadaver knee joint cartilage samples, the authors concluded that such an instrument was suitable for qualitative detection of cartilage stiffness.
The desire to test compressive mechanical properties of a material existed long before a correlation between articular cartilage stiffness and the existence of articular degenerative diseases was recognized. Many devices are known for use in material indenting which are unsuitable for use for measuring cartilage stiffness due to their design. Some of the devices such as those of U.S. Pat. No. 5,146,779 (Sugimoto), U.S. Pat. No. 4,896,339 (Fukumoto), and U.S. Pat. No. 5,067,346 (Field) are designed for use on a tabletop. Since they cannot be used arthroscopically, a sample of tissue would have to be removed from the body or the patient would have to be subjected to major invasive surgery in order to allow these devices to indent the articular cartilage. Due to the injury to the patient and the expense these procedures would necessarily entail, a nonarthroscopic design is not effective for testing the in vitro stiffness of articular cartilage.
U.S. Pat. No. 5,433,215 (Athanasiou et al.) and Tkaczuk, H. "Human cartilage stiffness: In vivo studies." Clin. Orthop. Rel. Res., 206:301-312, 1986 disclose devices useful for cartilage testing; however, these devices are larger and more awkward to use than would be desirable. These devices cannot be used arthroscopically and require the joint surfaces to be tested to be completely exposed.
In order to prevent the invasive steps and awkwardness involved in the use of the above designs to measure articular cartilage, hand-held materials testers have been designed which require no more surgery than a visual arthroscopic evaluation. These, however, suffer from a plethora of other problems. U.S. Pat. No. 4,159,640 (Leveque) describes a hand-held device which is not usable for arthroscopic surgery. Leveque's device requires a necessarily wide base suited for surface tissue measurements such as skin or the surface of muscle, but is unsuited for use within joints for measurement of articular cartilage. In addition, Leveque's device must be positioned relatively perpendicular to the material to be tested and the entire device must rest on material of similar stiffness in order to accurately measure.
U.S. Pat. No. 4,503,865 (Shishido) is primarily designed to measure differences between compressibilities. The device rolls over the material and allows measurement of changes of stiffness. The device however has no means for measuring absolute stiffness and providing an objective display of stiffness. The force the operator uses to position the device will affect the results, and this force exerted by the operator is not controlled. The device can thus be used to find hard or soft spots within a specific material, but the device cannot provide a concrete determination of whether the material is soft or hard as compared to an objective standard.
The major limitation with arthroscopic devices intended to be used for measurement of mechanical properties of materials is that they do not compensate for the indenting tip being positioned at angles other than perpendicular with the material being tested. This can either be due to natural variation in the surface of the material or to difficulty on the part of the operator to maneuver the tip to a position where the tip is perpendicular. Some devices have tried to compensate for this by forcing the material to be placed perpendicular to the indenting tip (the table-top models listed above), while others have tried to ensure that the operator can effectively know when the tip is perpendicular to the material. U.S. Pat. No. 4,364,399 (Dashefsky) discloses a probe whose compressible tip is pressed into the cartilage. Due to the shape of the end of the cannula, when the operator can push no further, the compressible portion of the probe registers the appropriate stiffness (see FIG. 3B of Dashefsky for the position for a proper reading). The probe is positioned manually and perpendicularity of the probe is subjectively determined. There is no guarantee that the operator has correctly aligned the probe for any given measurement. The manual identification process is not sufficiently accurate to allow repeatable, objective measurements. U.S. Pat. No. 4,132,224 (Randolf) also discloses a device which is positioned manually and provides no means for compensation for movement. It is clear from the description of its operation that any tilting leading to the tip not being perpendicular will result in significantly inaccurate readings due to premature touching of the forked beam of this device. U.S. Pat. No. 5,503,162 (Athanasiou et al.), U.S. Pat. No. 5,494,045 (Kiviranta et al.), and Lyyra, T. et al., "Indentation instrument for the measurement of cartilage stiffness under arthroscopic control." Med. Eng. Phys., 17:395-399, 1995 describe devices having a contact surface around the tip to aid in aligning the tip perpendicular to the material being tested (in addition to using machine controls to aid alignment in Athanasiou et al.), but such additions, although aiding the operator in positioning the tip perpendicular to the test material, do not help if the operator cannot get the tip perpendicular. In all of these devices, and others, the indenting tip must be perpendicular in order for an accurate measurement of stiffness to be made. No matter how many structures are added to these devices to try and insure perpendicularity, they will all give significantly inaccurate readings if the indenting tip cannot be aligned perpendicular to the material to be tested. In articular cartilage measurements, especially in small joints such as finger, ankle, or temporal mandibular joints, there is a high possibility that the device cannot be aligned perpendicular to the material being tested due to intervening structures such as bone, muscle, or other body parts. There is thus a need in the art for a materials tester that does not have to place its indenting tip perpendicular to the material being tested in order to provide accurate measurements.
In addition to these limitations, devices known to the art are usually unable to compensate for temperature variations during the measurement. The art makes limited reference to compensating for temperature effects although such effects can significantly impact the measurements of the device, especially when measurements are taken in situ in the body with devices calibrated outside the body.
These devices often also indent the material great distances over long periods of time. Although for many materials such indentation time and distance are not relevant, in the case of articular cartilage, long, deep indentation steps can result in significant tissue damage.
Furthermore, the operator may introduce error due to the varying amounts of force the operator uses to bring many prior art devices into contact with the material to be tested. In a table top device this is not a problem since the operator need not hold the device against the material, but may place the material on a prepared surface and allow indentation controlled by machine or computer. In many hand-held devices known to the art, however, if the operator changes the force used to depress the testing tip of the device into the material to be tested, the device will report compressibilities of different values.
Finally, none of these devices are designed to allow the portion inserted into the patient's body to be for single use only. Since a device for single use is significantly more sterile and sanitary than a reused device, such a quality is to be desired. Known devices are generally not completely watertight and thus submersible which affects their ability to be sterilized via liquid sterilization methods and also makes them vulnerable to splashes, from body fluids or otherwise, that could damage their delicate electronic components. For a device used in situ for the measurement of body tissue stiffness, survivability under surgical conditions where fluids are prevalent is a highly desired quality.
It is an object of the invention to provide a novel materials testing device which is free of the above-mentioned defects of the art.
SUMMARY OF THE INVENTION
The present invention provides a materials testing device for measuring the compressive properties of a material by indenting the material surface and measuring the resistance of the material to the indention. Compressive properties include but are not limited to: stiffness, Young's modulus, and hardness.
The following discussion is primarily directed to measuring stiffness; however, Young's modulus and hardness may also be measured by the device. "Stiffness" in the context of this application is generally taken to mean the resistance of a material to a force exerted upon it.
The device of this invention allows measurements in positions where the tip physically cannot be aligned perpendicular to the material being tested, simplifies the operation by allowing the operator more freedom in aligning the device, and improves accuracy by being resistant to error from the positioning of the device.
"Perpendicular" alignment in this instance refers to the angle made between the axis of motion of the indenting tip and the flat surface of the material to be tested at the point of contact. The indenting tip need not be perpendicular to any structures on the device.
The device of the present invention measures compressive properties (stiffness) of a material and comprises: an indenting tip, a loading system moving a certain linear distance and pushing said indenting tip into the material to be tested, a force detection system for measuring force exerted on said indenting tip by the material being tested, a variable angle compensation system for compensating for the effects of tilt of the indenting tip away from perpendicular alignment on the force detected by said force detection system, and a rendering system for converting output of said force detection system to a display representative of the desired compressive properties.
The device may further comprise a temperature compensation system for allowing the device to measure accurately even when calibrated at a temperature significantly different from the temperature at which the device is measuring. The device may also incorporate an applied force compensation system to compensate for the effects of the user applying force on the device into the material to be tested. The device is preferably constructed of two separable parts where the part entering the body of a patient is designed for single use only to increase sterility. The device, and specifically the non-disposable portion of the device, may also be watertight so that its delicate electronic components are not damaged by fluids and the device can be subjected to sterilization methods involving the use of fluids.
The device is usable for measuring the properties of multiple different types of materials including, but not limited to, body tissues known to the art, e.g., cartilage, skin, or organ fibers including soft tissues known to the art, e.g., muscle or connective tissue, or man-made synthetic materials known to the art, e.g., plastics, rubber, or foam. These materials can be measured in vitro, in situ, in vivo, or under any other working conditions where measurement of compressive properties is desired.
The indenting tip is a piece of rigid material capable of indenting the material to be tested and capable of having force exerted upon it without deforming.
The loading system comprises any system known to the art for moving a certain linear distance and pushing the indenting tip into the material to be tested. The distance moved by the loading system must be "certain" in that it has to either be set in advance, or the loading system must contain structures allowing accurate measurement of the distance the loading system has moved. In a preferred embodiment, the loading system comprises a computer-controlled linear actuator (stepper motor) and a drive shaft assembly moved by said motor which may comprise multiple components for translating the movement of the actuator in one direction to movement of the testing tip in another direction. The number of steps taken by the motor is also recorded via a computer-controlled feedback system in one embodiment.
The force detection system may be any system known to the art for measuring the force that is exerted on the indenting tip by the material being tested. In the preferred embodiment the system comprises a combination of one or more semi-conductor strain gauges attached to a sensing arm which holds the indenting tip. The force detection system may also comprise an electrical circuit attached to the strain gauges that can interpret the output of the strain gauges as uncompensated (raw) force on the indenting tip.
The variable angle compensation system comprises any means known to the art for compensating for the effects of tilt of the indenting tip on the force measurement. This may be either a passive system comprising means for ensuring that tilt has little or no effect on the force exerted by the indenting tip against the material being tested, e.g., a properly shaped indenting surface on the indenting tip, or may be an active system that allows for the calculation of the force on the indenting tip by the material, compensating for tilt. Both pitch, the tilt caused by the handpiece of the device being raised and lowered, and roll, the motion caused by the handpiece being circularly rotated side to side, must be compensated for and are considered "tilt" in this device. In a preferred embodiment, this system comprises or consists essentially of a rounded surface of the indenting tip, most preferably of paraboloid shape. This system passively compensates for tilt of the indenting tip. Other systems for correcting tilt may also be used. The system can incorporate other apparatuses such as those described in U.S. Pat. No. 4,888,490 (Bass et al.) incorporated herein by reference, lasers, or other light sources or external markings to be used to determine the exact offset of the testing tip from perpendicular alignment based on physical principles. Any of these systems may incorporate computer-controlled feedback mechanisms or other systems known to the art to calculate and mathematically compensate for the angle of the tip. The system may also incorporate an angle error system that warns the user if the error due to the angle of the tip with respect to the surface of the material being tested goes outside a specified range for accuracy in the desired stiffness readings.
A "rendering system" as used herein is a system comprising means for converting the stiffness measurement received or computed by a processor into a useful representation of a desired compressive property and displaying said useful representation, e.g., by printing, electronic digital display, audio means, or otherwise, which renders a desired representation of the measured property, such as a numerical, graphical, symbolic, or other representation.
The temperature compensation system is a system that is either passively resistant to changes in temperature or actively compensates for errors caused by the temperature at which the measurements are taken. In a preferred embodiment, the temperature compensation system comprises strain gauges and associated circuitry used in the force detection system which compensate for and/or are resistant to changes in temperature. The temperature compensation system may also comprise compensation means such as a temperature detector known to the art combined with a computerized compensation calculation known to the art. The system is preferably able to compensate for temperature independent of the medium in which the device is submerged, including media such as water, body fluids, or air.
The device may also comprise an applied force compensation system comprising any means known to the art of mechanical or electrical design which passively or actively compensates for force applied by the user. In the preferred embodiment this comprises mechanical design elements such as chamfering of the indentation hole or similar outer shaft contouring. In addition mechanical support to prevent the drive shaft from flexing, such as reinforcements to the drive shaft or alternative structures to prevent flexing, is used. Alternatively the applied force compensation system could be a second strain gauge system dedicated to the measurement of user-applied force. The system may also incorporate an internal computer-controlled feedback mechanism which measures the user's applied force and adjusts the value of the measured output or limits the range at which testing may occur. Other systems known to the art to ensure that the measured value remains within acceptable accuracy may also be utilized.
Preferably the device consists of two primary parts with the piece designed for use within the body (probe) being disposable after single use. In order to insure that the probe is only used once, it preferably contains structures which cause it to cease functioning after single use or any attempt to sterilize it. Some means for doing this include heat sensors or fuses which allow the device to turn on only once, a "safety pin" design that springs open and breaks after use, or a circuit with a filler that melts during the first use resulting in a destroyed electrical connection.
In order for the device to be watertight, all connections need to be properly sealed. This is generally accomplished through the use of sealants such as, but not limited to, epoxies or silicones as known to the art for permanent connections or screw and O-ring combinations for connections which are desired to be opened for storage, two-part construction, or repair. "Watertight" means that all delicate electrical components, or any other components that would be affected by being submerged, are protected by a casing having substantial impermeability not only to water, but also to other common liquids present in medical applications including sterilizing solutions and body fluids. For safety, a watertight device of the present invention is not assumed to be watertight when attached to its power system but is disconnected prior to immersion of parts containing electronic components. The present invention can also be adapted to be watertight when attached to its power system under any forseen usage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a three-dimensional front view of the device.
FIG. 2 shows a three-dimensional rear view of the device.
FIG. 3 depicts an exploded view of the main components of the handpiece.
FIG. 4 depicts a rear view of the handpiece.
FIG. 5 depicts a longitudinal cross-section of the handpiece along line 5--5 of FIG. 4 with all of its components in place. Wiring is not shown
FIG. 6 depicts an enlarged view of the section of FIG. 5 indicated by dotted circle 6 showing the structures on the front end of the device.
FIG. 7 shows an exploded view of the main components of the probe.
FIG. 8 shows details of the sensing arm and force-detection system. 8A is a side view, 8B is a bottom view.
FIG. 9 shows the mechanisms of the loading system during operation. 9A shows the loading system before activation, 9B shows the loading system during measurement.
FIG. 10 shows a rear view of the probe.
FIG. 11 shows a longitudinal cross-section along line 11--11 of FIG. 10 of the probe with all its components in place. Wiring is not shown.
FIG. 12 shows a longitudinal section of part of the device including the connection between the probe and the handpiece when the device is ready for use.
FIG. 13A shows a front view of the convex indenting tip providing variable angle compensation for roll tilting.
FIG. 13B shows a side view of the device having a convex indenting tip providing variable angle compensation for pitch tilting.
FIG. 14 is a graph showing the effectiveness of the preferred variable angle compensation system on pitch tilting on two material standards with drastically different compressibilities.
FIG. 15 is a graph showing the effectiveness of the preferred variable angle compensation system on roll tilting on two material standards with drastically different compressibilities.
FIG. 16 is a graph showing the effectiveness of the preferred applied force compensation system on two material standards with drastically different compressibilities.
FIG. 17 is a block diagram of the electrical system.
FIG. 18 indicates the signal levels during a single measurement of the device.
FIG. 19 is a graph plotting the frequency of the various Outerbridge Scores (O.S.) versus the stiffness readouts (grouped in ranges of 10) from the instant device.
FIG. 20 is a graph showing the effectiveness of a preferred temperature compensation system when tested wet over a wide temperature range for two material standards with drastically different compressibilities.
DETAILED DESCRIPTION
The device consists of two main components shown in FIG. 1 and FIG. 2: the handpiece 101 and the probe 102. In the preferred embodiment the probe 102 is made for single use and inexpensive enough to make such single use worthwhile, and the handpiece 101 is designed to be reused. The probe preferably contains mechanical means to make it inoperative if an additional sterilization attempt were made, e.g. heat sensors or fuses which allow the device to turn on only once, a safety pin design that springs open and breaks after a single use, or a circuit with a filler that melts during the first use so the device will no longer function. Preferably, the probe 102 can also be of varying diameters from about 2 mm for very small joints such as fingers, ankles or temporal mandibular joints to larger diameters, such as about 5 mm for other joints, thus allowing the operator to select a probe most suitable for the given task.
FIGS. 3 and 5 show the primary components of the handpiece 101. FIG. 3 shows the major components of the handpiece exploded. FIG. 4 is a rear view of the handpiece showing display 14 and alignment screws 26 while FIG. 5 is a cross-section of the handpiece along line 5--5 of FIG. 4 and shows the components in place as they would be when the device is assembled.
Referring to FIG. 3, the handpiece 101 primarily consists of the housing 1, and the handle 2. At the forward end of the housing 1 is the coupler ring 10 for engaging the probe 102 (FIG. 1). A tightener 11 screws down over coupler ring 10 when the probe 102 is in place to firmly secure the probe to the handpiece 101. When the components are connected correctly, the handpiece contact holder 6 at the front end of housing 1 will be in electrical connection with the probe which is now inside handpiece 101, and the connection will be watertight. The housing 1 further contains a motor 3, which in the preferred embodiment is a linear actuator (stepper motor), but could be any kind of motor so long as systems are present to determine its movement a certain linear distance. At the moveable end of the motor 3 an interface button 5 is attached. The interface button 5 allows the motor's movement to be translated to components within the probe. The motor is held in position by a motor retainer 4 which preferably is a plastic ring able to screw tightly behind the motor 3 but could be any means for maintaining the position of the motor 3. The housing 1 also further contains the main electronics module 12 which preferably is a printed circuit board containing the necessary components for the processor 37 as well as the electronic components of the rendering system, the motor drive circuit, and for amplification of the raw force signal. The main electronics module 12 need not contain all of these structures and may contain alternative electronic structures or a combination of these structures and alternative structures. The main electronics module 12 is preferably attached to the housing by a removable chassis 220 which in the embodiment shown is the same as the circuit board of module 12. The rendering system for converting a signal preferably has multiple components including a display 14, visible through back window 13, and speaker 216 connected to the main electronics module 12. In a preferred embodiment, the display 14 is a liquid crystal display (LCD) designed to provide the user with the measurement data as well as error feedback, low battery, and battery exhausted displays. The LCD screen is positioned so that it is visible through a back window 13 contained within a rear panel 217. Alternatively the display 14 could consist of a graphic LCD, a collection of LEDs, an external monitor or video overlay connected to the handpiece 101 by way of cable, IF or RF, or any other display or combination of displays as known in the art. In a preferred embodiment Speaker 216 will further emit audio signals, e.g., tones, digitized speech, or any other form of audio to supplement the visual message on display 14. The rear panel 217 is attached to the housing 1 by means of a watertight seal. In a preferred embodiment this seal is created through the use of a rear O-ring 15 and rear screws 16, most preferably four in number.
The handle 2 is attached to the housing 1 by any means known to the art, preferably using handle screws 17 and a sealant means such as liquid sealant, an O-ring, or adhesive at the handle junction 218; most preferably the handle 2 is attached by two handle screws 17 of different length and with liquid sealant. The handle junction 218 allows electrical contact between the handle electronics module 21 and the components within the housing 1. At the upper front of the handle 2 is a switch 19, preferably a momentary action switch. Within handle 2 is handle electronics module 21, seated atop and engaged with aligner 22, and electronically connected to power system 23 within aligner 22. These components are held in place by handle base 24 attached using screw threads or otherwise attachable to handle 2.
Referring to FIG. 5, the switch 19 is secured at the top of the handle 2 with a bezel 20. Preferably, an adhesive is used to hold the bezel 20 in place and provide for a seal.
The handle electronics module 21 rests against a lip 205 on the inside diameter of the handle 2 and is held in place by any means known to the art, preferably an adhesive, most preferably an epoxy. A handle electronics module O-ring 202 around the handle electronics module 21 provides a watertight seal. The handle electronics module 21 preferably contains electrical components for regulating the power supplied by the power system 23 to all electrical components of the device. In a preferred embodiment the power system 23 is a battery pack consisting of multiple nickel-cadmium (NiCd) batteries of about 9.6 total voltage connected in series, the battery pack being rechargeable on an external recharging system (not shown) like those known to the art. Most preferably 8 size 2/3 AA batteries rated at 270 mAh are used. Alternatively, disposable (nonrechargeable) batteries could be used. The power system may also consist of an external cable system allowing the use of external AC or DC power sources (not shown). The power system 23 is secured by the aligner 22 and handle base 24 when in use. In the most preferred embodiment, the handle base 24 contains screw threads allowing the handle base 24 to be screwed into the bottom of the handle 2. Alternatively the handle base 24 may utilize a snap-in mechanism consisting of latching features on the battery pack which engage inside the handle and allow for quick release when the latches are depressed. Additionally the handle base 24 can be secured by other permanent or removable attachment mechanisms as recognized in the art. The aligner 22 is any material known to the art allowing electronic leads on the power system 23 to be placed securely in contact with electronic leads on the handle electronics module 21 preferably through the use of a contact spring. The power system 23 is then secured by the above mentioned handle base 24. The aligner 22 is fastened inside the handle by any means known to the art, preferably alignment screws 26 (not shown in this view; see FIG. 4), most preferably numbering two.
FIG. 6 provides further details from within the dotted line -6- of FIG. 5 of the front of the handpiece and the handpiece contact holder 6. The handpiece contact holder 6 comprises handpiece electrical contacts 7 which in a preferred embodiment may consist of a bellow spring welded onto a pin and sit flush with the housing face 201. Contact holder O-ring 8 located in an external groove of the housing contact holder 6 provides a tight fit with the housing 1 holding the housing contact holder 6 in place and providing a watertight seal. The motor 3 with the interface button 5 attached sits in the front part of the housing with the motor shaft 18 extending through a central hole 204 in the housing contact holder 6. Motor O-ring 9 is located in an internal groove of housing contact holder 6 and provides a watertight seal between interface button 5 and housing contact holder 6.
The main components of probe 102 are shown in FIG. 7. The probe 102 primarily consists of a sensing arm 25, the indenting tip 206, outer shaft 29, drive shaft 30, connecting base 31, probe electronics module 28, probe O-ring 36 and probe contact holder 32.
FIG. 8A is a side view and FIG. 8B is a bottom view of the device showing details of a preferred embodiment of the force detection system. The sensing arm 25 has a bend shown as 90° in FIG. 8A near the end which terminates in the indenting tip 206 and a ridge 219 capable of contacting drive shaft 30 (not shown, see FIG. 11). The bend can be any angle allowing the indenting tip 206 to extend through a corresponding indenting hole 207 (FIG. 11) near the front of the outer shaft 29 (FIG. 11) to allow for additional flexibility in positioning of the device during measurement. In order to accomplish angles other than 90°, additional components of the drive shaft, or a different shape of sensing arm may be required (not shown). The strain gauges 27 measure the bend in the sensing arm 25 producing a raw force signal S215 (FIG. 17) by any means known to the art which allows a computation of the force applied on the indenting tip 206, preferably using the different force values from each strain gauge. The strain gauges 27 are preferably semiconductor strain gauges but could alternatively be thin film strain gauges or other strain gauges as is known to the art. The strain gauges are electrically connected to appropriate structures on the probe electronics module 28 (FIG. 11) through wiring 209 which is preferably a ribbon cable but alternatively could be insulated wires or any other means of transferring electrical signals as is known to the art. In the preferred embodiment the strain gauges 27 and the probe electrical contacts 33 (FIG. 11) are watertight. This can be achieved by any means known to the art but is preferably accomplished by covering the strain gauges 27 and the probe electrical contacts 33 (FIG. 11) with an impermeable coating.
FIG. 9 shows the preferred force detection system during an indenting step. FIG. 9A shows the device in neutral position when not activated. When the device is activated, drive shaft 30 slides against ridge 219, causing sensing arm 25 to flex downward, which in turn extends indenting tip 206 through indenting hole 207 in the distal end of the outer shaft 29 and against the material specimen 221. The portion of sensing arm 25 between ridge 219 and indenting tip 206 flexes as the indenting tip 206 encounters resistance from the material specimen 221. The degree of said flexion is measured by one or more strain gauges 27 (not shown, see FIGS. 8A and 8B) located on the upper and/or lower surfaces of the sensing arm 25. After the above steps are completed, the force detection system is in the position shown in FIG. 9B.
The force detection system may alternatively be a different system known to the art. A mechanical system to measure the beam deflection and then convert it to an electrical signal for processing by any means known to the art including but not limited to a potentiometer whose resistance is varied by the mechanical system. Other systems could also be used which include, but are not limited to, systems utilizing a light source, including but not limited to, laser, infrared, or fiber optics to measure the amount of beam deflection or surface indentation for calculating the stiffness of the material. Another suitable system comprises mounting the indenting tip 206 on a piston head and mounting a pressure sensor within a piston opposite said piston head inside the outer shaft 29. As the indenting tip was pressed against the material, the piston would compress and the pressure sensor would sense the difference in pressure within the piston.
In the preferred embodiment, semi-conductor strain gauges with temperature compensation circuitry have been found to provide accurate measurements in a temperature range from about 10° C. to about 38° C. being most accurate between about 16° C. and about 32° C. (FIG. 20). The temperature compensation system may also be any system, active or passive, known to the art that would allow the device to measure at different temperatures without significant error and need not be part of the force detection system.
FIG. 10 shows a rear view of the probe's connecting base 31 comprising probe contact holder 32, probe electrical contacts 33 and probe O-ring 36.
FIG. 11 is a cross section of probe 102 along line 11--11 of FIG. 10, showing details of the preferred force detection system. The outer shaft 29 is securely attached to the connecting base 31 using any method known to the art. Preferably the flat end of the outer shaft 29 is flush with the inner wall of the connecting base 31. The sensing arm 25 is preferably rigidly attached to the outer shaft 29 at attachment point 208 by any method known to the art. The attachment allows the sensing arm 25 to bend when the drive shaft 30 is moved, pushing the indenting tip 206 through the indenting hole 207. A probe electronics module 28 rests against the inside surface of the connecting base 31. The probe electronics module 28 contains electronics to convert output from the strain gauges 27 to a force measurement and preferably a bridge circuit to balance the raw force signal as well as temperature compensation circuitry for the strain gauges 27. The probe contact holder 32 is press-fitted into the connecting base 31 and secured for a watertight seal. The probe contact holder 32 further contains probe electrical contacts 33 positioned so that when the probe 102 is connected with the handpiece, the probe contact holder 32 is in electrical connection with the handpiece contact holder. Retainer cap 35 is securely attached to the drive shaft 30 to retain a spring 34 mounted on the drive shaft 30 and sitting inside probe contact holder 32. When the drive shaft is moved forward by the action of the motor, spring 34 gets compressed between the face of the probe contact holder 32 and the retainer cap 35. When the motor retracts, spring 34 returns to its initial length, retracting the drive shaft 30.
Preferably, drive shaft 30 extends nearly the entire length of probe 102, through holes in the probe contact holder 32, the probe electronics module 28 and the attachment point 208 of the sensing arm 25.
FIG. 12 shows detail of the probe 102 and handpiece 101 when connected. The probe contact holder 32 and the handpiece contact holder 6 are flush against each other. The probe electrical contacts 33 and the handpiece electrical contacts 7 are connected allowing electricity to pass between them. The connecting base 31 has structures which allow it to securely attach to the coupler ring 10. In the preferred embodiment this is a bayonet-type coupler where pins on the coupler ring 10 are slid into pathways along the length of the connecting base 31. The probe 102 is then rolled relative to the handpiece 101, positioning the pins so that the probe 102 cannot move away from the handpiece 101. Other types of connectors known to the art can also be used including but not limited to, pin connectors, screw connectors, or adhesive connectors. To insure a good seal, tightener 11 is screwed down over coupler ring 10 with connecting base 31 in place. Tightener 11 does not allow probe 102 to move, thereby providing a locking seal, and also presses the probe O-ring 36 securely into the housing face 201 of the handpiece contact holder 6 creating a watertight seal between the probe 102 and the handpiece 101.
Alternatively, the probe 102 could be connected to the handpiece 101 is such a way that the probe 102 could be rotated around its main axis while maintaining the position of the handpiece 101. This design would provide the user with additional flexibility to maneuver the indenting tip 206 into hard-to-reach areas, especially when testing body tissues in situ. Such a design would require the electrical contacts between the probe 102 and the handpiece 101 to use a sliding contact system (not shown) such as, but not limited to, a cylindrical slip ring assembly.
FIG. 13 shows a preferred embodiment of the variable angle compensation system comprising the shape of the indenting tip 206. FIG. 13A illustrates as an example that for roll tilting of 0 to 20 degrees, the size of the contact surface between the indenting tip 206 and the material to be tested 221 is very similar, limiting the effect of the misalignment angle (off-perpendicularity) on the force reading. FIG. 13B illustrates the same effect for pitch tilting. Any shape of the tip which compensates for the misalignment angle's effect on both displacement and force reading is recommended. The indenting tip 206 may therefore be of any mathematical convex shape including but not limited to hemispherical, hyperboloid, or paraboloid. A hemispherical shape is preferred with a paraboloid being most preferred.
FIG. 14 shows the effect of pitch on measured results using the device of this invention. FIG. 15 shows the effect of roll on measured results. A tip of hemispherical shape was used for both Figures, and in both tests, both stiff and soft material standards were used. To normalize the results, readings were divided by the average stiffness readings of durometer standards obtained at 0 degrees pitch and roll.
The applied force compensation system could comprise design modifications such as, but not limited to, chamfering of the indentation hole 207 to prevent the material being tested from puckering inside the hole, elevation of the indenting tip 206 within the outer shaft 29, a dedicated strain gauge system of one or more strain gauges and associated electronics to measure any flexion of the outer shaft 29, a drive shaft 30 constructed so as to prevent it from significant flexion either through reinforcement or additional structures, or an indenting step of extremely short duration to limit any applied force effects. In the preferred embodiment the applied force compensation system comprises mechanical support to the drive shaft 30 and chamfering of the indention hole 207. The effectiveness of this system is shown for two material standards of significantly different stiffness in FIG. 16.
FIG. 17 shows a block layout of the preferred embodiment of the processor 37 as well as the electrical system. Processor 37 is an electrical circuit comprising an analog-to digital converter (ADC) 37A to convert any received analog signals to digital for processing; non-volatile memory 37B, most preferably programmable read-only memory (PROM) to hold a software program and program constants; volatile memory 37C, preferably random access memory (RAM), to hold program variables, a central processing unit (CPU) 37D to run the program stored in PROM 37B and perform calculations as required; and digital input/output (digital I/O) ports 37E to receive signals from and supply signals to the rest of the electronics system. Most preferably the processor 37 contains about 32 kilobytes of PROM and about 512 bytes of RAM. Other processing circuits as known to the art may alternatively be utilized.
The operator places the indenting tip of the device against the material to be tested. When the operator activates switch 19, switch 19 supplies test activation signal S19 to the processor 37 via digital input/output port 37E. Processor 37 then sends out via motor control signal S38 to motor drive circuit 38 a command to move a certain linear distance. The motor drive circuit 38 then converts the motor control signal S38 into motor drive signal S3. The motor 3 receiving the motor drive signal S3 then begins to displace the drive shaft 30 (see FIG. 7). Drive shaft 30 contacts ridge 219 on the sensing arm 25 forcing indenting tip 206 to extend from the head of outer shaft 29 at indenting hole 207 and indent the material specimen 221 (see FIG. 9). In the preferred embodiment, the indentation of the material specimen 221 comprises a set number of motor steps after the device detects contact with the material specimen 221. Most preferably the indenting tip 206 extends no more than about 100 μm into the material specimen 221 after force detection signal 215 indicates force being applied against the tip. The force detection system 215 measures the force being exerted on indenting tip 206 (see FIG. 8) and supplies raw force signal S215 to processor 37. Processor 37 then uses the raw force signal S215 in addition to a distance signal S213 to calculate the stiffness. There need not be an independent distance signal S213. The distance traveled by the indenting tip can be calculated by using a memory in volatile memory 37C of the motor control signals S38 previously sent, preferably a memory record indicating the number of steps after surface detection; or a separate signal on a feedback loop such as that measured using a linear voltage displacement transducer (LVDT), a magnetic position sensor, or a potentiometer and associated circuitry may be used to record the displacement of the drive shaft.
If active compensation systems are used, as opposed to the preferred passive methods, the processor 37 also receives one or more of the following. An angle signal S210 from variable angle compensation system 210, a temperature signal S211 from temperature compensation system 211, and an applied force signal S212 from applied force compensation system 212. These signals are all utilized by processor 37 in addition to distance signal S213 and raw force signal S215 to compensate for the appropriate variables in the calculation of stiffness. After calculating the stiffness, processor 37 then sends rendering signal S214 to rendering system 214 which displays the stiffness on display 14 and signals the user via speaker 216 (FIG. 3).
If errors should occur in measurement due to damage to the probe 102, failure of the power system 23, or other errors predetermined by the manufacturer, the rendering system 214 will display an error message on display 14 and/or an audio signal via speaker 216 instead of or in addition to the computed stiffness. A measurement cycle is completed when one of two alternatives occurs; either the drive shaft 30 has extended to at least a preset distance, or the indenting tip is no longer extending due to its contact with a highly rigid material such as bone. After completion of the measurement cycle, the motor 3 reverses and the drive shaft is returned to its original starting position. In the preferred embodiment this is done by the motor 3 retracting the same number of steps it has moved out and spring 34 using returning force to keep drive shaft 30 in contact with interface button 5. Alternatively any type of method known to the art could be employed which provides for drive shaft 30 returning to its original starting position, including, but not limited to, proximity switches or position sensors.
All necessary power to generate electrical signals, operate electric circuits, or power motor 3 is generated by power system 23 which is regulated by appropriate structures on handle electronics module 21 to insure smooth operation without electrical spikes. In the preferred embodiment, the electrical system is entirely contained within the device's handpiece and probe although, alternatively, the electrical system could be arranged utilizing a mixture of internal circuit boards and external components or additional external support devices including but not limited to displays, input devices, printers, or storage.
FIG. 18 shows signal levels of the device over time. When the user activates switch 19 (FIG. 3) at t0, the test activation signal S19 becomes active and both motor control signal S38 and motor drive signal S3 order the motor to move forward. The total number of motor steps taken, m, begins to be recorded at this time.
At t2' the indenting tip contacts the material to be tested and raw force signal S215 begins.
At t2 the indentation begins, raw force signal S215 rises to V1, and the device begins recording the number of steps taken to indent the material, as well as the raw force signal's S215 rise from V1 to V2.
At t3 the device has completed its forward movement since n1 steps indenting the material (a preset number of steps) have been taken, or raw force signal S215 has reached a preset maximum value V2 indicating contract with a rigid material. At this point, the total number of steps taken, m, has reached m2. Note that the number of steps taken by the motor, m, is greater than the number of steps, n, indenting the material. In fact, n1-n0=m2-m1. The raw force signal S215 now sends the value V2 indicating the maximum force detected. Finally, S38 and S3 command the motor to reverse.
At t4 the indenting tip is no longer in contact with the material's surface but the device has not fully reset to its original starting conditions.
At t6 the total number of steps taken, m, has returned to its original value, m0, so the motor has returned to its original position. S3 and S38 thus command the motor to stop and the device is now reset in preparation of a new measurement.
Experimental results
Clinical studies were performed on human resected knee articular cartilage. A total of 19 patients scheduled for a total knee joint replacement participated in the study. Patients were of both genders, with ages varying from 56 to 84 years old. Testing of the knee joint surfaces, distal femur, proximal tibia, and patella when available, was performed immediately after resection from the patient. Each test site was tested with the device under two conditions to simulate open joint and arthroscopic settings: non-submerged (in air), NS, and submerged in saline, S. Prior to measuring the stiffness of the joint surface, the device output was verified under both conditions using a range of durometer standards. For each site, at least three measurements were obtained to ensure reproducibility. Following the stiffness measurements, the orthopedic surgeon qualitatively evaluated each test site using a nerve hook probe and visual observations by giving a score of I to IV based on the Outerbridge classification system (O.S.). During the entire testing period, the tissue was kept moist with saline. Data was statistically analyzed to determine significant differences.
As shown in Table 1, prior to each clinical case, verification of the device using the durometer standards indicated that for both non-submerged and submerged conditions mean stiffness values were within 10% of the mean stiffness values of the standards. FIG. 19 shows the graph plotting the frequency of the various Outerbridge Score (O.S.) versus the stiffness readouts (grouped in ranges of 10) from the device. Results indicate that the device readouts correspond well with the condition of the cartilage. For example, for stiffness measurements between 50-80, indicative of stiffer and healthier cartilage, about 75% of the sites were graded O.S. I and II. For stiffness measurements between 0-30, indicative of softer degenerated cartilage, about 48% of the sites were graded with an O.S. III. For stiffness measurements in the 90's, 96% of the sites were graded with an O.S. IV, indicative of cartilage having eroded down to bone.
TABLE 1______________________________________Verification of the device using durometer standards:Durometer Calibrated Device DeviceRange Standard (NS) (S)______________________________________blue 35 35 ± 3.1 35 ± 3.1yellow 55 57 ± 6.5 62 ± 4.1black 81 75 ± 5.3 81 ± 5.8______________________________________
The results indicate that during clinical evaluation of surface joints, the device subject of the present invention may give the orthopedic surgeon critical information about cartilage degeneration which may not be visible. This is evidenced by the lower stiffness measurements which had been scored as an O.S. I, visually intact cartilage.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but merely providing illustrations of some of the presently-preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | A handheld materials testing device is provided for measuring compressive properties of a material, preferably articular cartilage in vivo. The device is computer-controlled and provides a readout indicative of the desired compressive property, which in the case of bodily tissue, may be indicative of the state of health of the tissue. The device does not require precise perpendicular alignment and is preferably capable of compensating for force applied by the user against the tissue. | 0 |
BACKGROUND
1. Field of the Invention
The invention refers to a reception, containing and compacting system of solid wastes. The system is based on the combined use of a truck with crane, a truck box forming a compacting machine for wastes or solid materials, and a reception container for such waste. The reception container is directly handled by means of said crane to unload the wastes into a compacting box.
2. Description of the Prior Art
At present, the collection and elimination of urban and industrial wastes is carried out by municipal trucks that drive through the streets, industrial polygons and places in which containers containing solid wastes are located. These trucks reach the places where the solid wastes are located and by hooking the waste containers, the containers are either carried out (these ones being transported in the container properly hooked to the truck), or emptied into a milling hopper which is incorporated into the truck itself.
With the present art, the participation of some operators is necessary to carry out the hooking/unhooking of the containers. This produces two main problems. The first problem relates to the requirement of the operator or operators to carry out the mentioned operations. The second problem relates to the risk to which such operators are subjected to in the hooking/unhooking operations, sometimes accidents may happen which can be severe due to the disablement or loosing of fingers, hands, etc.
One system is described in document SU 1.272.638. In this case, the system comprises one track with a compacting box based on a backward and forward movement of a vertical wall driven by a hydraulic cylinder against an unloading back door. The load of the compacting box takes place by the knocking over of the container which is open in its upper part, on the loading gate of the compacting box. This knocking over takes place by means of an articulated arms crane. The most serious inconvenient of this device lies in the fact that it requires a tremendous skilfulness on the part of the worker, given that he/she must knock over the container exactly on the loading gate of the compacting box. Should the worker make a mistake, the unloading of the container could take place in any point within the work space. This would create a great danger for the passers-by.
In document FR 2.539.112, one can find an invention with a container with a bottom unloading gate. Such gate is held in a closed position by a vertically guided rod being locked in position by a latch mechanism. This container presents two types of problems; on the one hand, it is possible for the content of this type of containers to be stolen by people who operate by hand the latching mechanism. Furthermore, as a result of this kind of unskilled manipulation or due to ground unevenness, a failure of the latching mechanism can occur and the container could be raised, without taking notice, with the bottom unloading gate open, flooding the pavement with rubbish.
The present invention solves the aforesaid problems given that the worker only has to make sure that the crane boom is over the longitudinal axe of the truck. With the present invention, it is impossible for the automatic opening of the bottom unloading gate of the container to be in any other point in space other than over the loading opening of the compacting box. Additionally, in any other point in space, other than that cited, the bottom unloading gate of the container remains closed thanks to the positive action of a spring, making it impossible to manually operate the latching mechanism thus avoiding thefts, manipulations and even accidents due to lack of proper operation of the latching mechanism.
SUMMARY OF THE INVENTION
The system which is proposed, is based on an assembly formed by a truck with its compacting box, with a crane and an independent container. The present invention is designed to protect the operators from the risk of accidents, since the hooking/unhooking of a container is directly carried out by the crane driven by the operator.
Also the compacting box, as well as the container and the crane itself, have some new characteristics of which the functional and operational advantages of the assembly are derived.
More precisely, the compacting box is a box forming an integral part of the truck. The box is equipped with a back unloading door hydraulically driven. It also has a loading door located in the upper part. A vertical wall is installed inside the box in transversal position, displaceable towards the front and towards the back by means of a hydraulic cylinder driving a wall that in its displacement towards the back will carry out the compacting of the wastes against the back door when the door is in its closed position.
In reference to the reception and containing of the wastes in the container, the container is equipped with an internal mechanism based on connecting rods and levers in relation to some gates on its bottom so that such mechanism will maintain closed gates when they are in a resting position, and if it is driven by means of the crane the movement of the mechanism and the corresponding opening of the gates will be produced, emptying the wastes into the compacting box when such container has been previously hooked by the hooking device associated to the end of the crane boom, being this hooking device displaceable along the boom of the crane in order to arrange the container facing the upper loading opening of the compacting box and to make possible the emptying of the wastes from such container to said compacting box.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a representation according to a lateral schematic view of the truck assembly with a compacting box and the crane, as well as the container.
FIG. 2 shows same truck, crane and container but now the container is in the unloading position.
FIG. 3 shows a perspective schematic view of the hooking device.
FIG. 4 shows a lateral view of the hooking device.
FIG. 5 shows a plant view of the hooking device.
FIG. 6 shows a sectional view form VI—VI of the hooking device.
FIG. 7 shows a detail of one of the gates that close the bottom of the container.
FIG. 8 shows a detail of the opening mechanism on top of the container.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As it can be seen in the figures, the system of the invention comprises a truck ( 1 ) with a compacting box ( 2 ) and a crane ( 3 ), being complemented with an independent container ( 4 ) which will be directly handled by means of the crane ( 3 ) to carry out the emptying or unloading of the previously deposited wastes in such container ( 4 ) over the compacting box ( 2 ).
Such compacting box ( 2 ) is equipped with a back unloading door ( 5 ) driven by means of a hydraulic cylinder ( 6 ). This unloading door ( 5 ) will constitute the means of unloading the compacted wastes and will open upwards by tilting or rotating.
In the upper part, the compacting box ( 2 ) will be equipped with a upper loading opening ( 7 ).
Internally, the compacting box ( 2 ) is equipped with a transversal and vertical wall ( 9 ) which is displaceable towards the front and towards the back by means of a hydraulic cylinder ( 10 ), in order to carry out the corresponding pressing and compacting of the wastes deposited in the box itself ( 2 ), when the back unloading door ( 5 ) is in the closing position and the cylinder ( 10 ) is displaced backwards, and in order to unload by pushing the compacted wastes when the back unloading door ( 5 ) opens.
In reference to the crane ( 3 ) of the truck, it is equipped with driving hydraulic cylinders ( 11 ), as well as with a hooking device ( 12 ) which is displaceable between the end of the boom and a stop ( 13 ).
Such hooking device ( 12 ) consists of two parallel block and tackle mechanisms from which is suspended a fork ( 14 ) by way of cable ( 70 ). Said cable ( 70 ) passes over a first block ( 64 ) and goes backwards horizontally to a second block ( 66 ) from which it returns forward to embrace a third block ( 68 ), being the cable end ( 72 ) made fast to the hooking device frame ( 60 ) which can be mounted on the crane boom by way of mounting hole ( 62 ) and bolt. The third block ( 68 ) of the block and tackle mechanism are joined by a sliding axle ( 74 ) that can slide horizontally on a corresponding frame slot ( 76 ) when the sliding awe ( 74 ) is pushed forward by crane stop ( 13 ) as a result of the entire hooking device ( 12 ) being forced upon the stop ( 13 ) when the crane boom retracts as can be seen on FIGS. 2, 3 , 4 , 5 and 6 .
The fork ( 14 ) presents two bumps ( 25 ) for retaining the flange ( 26 ), and a bearing ( 78 ) through which a vertical push rod slides ( 15 ) fixed by a cube ( 84 ) in an articulate manner to the frame ( 60 ) thanks to a bolt ( 86 ) that passes through two parallel lugs ( 82 ) of the transverse member ( 80 ) of the frame ( 60 ).
Over the central part of the top of the container ( 4 ) is provided an opening mechanism ( 16 ). Its housing ( 24 ) has a cylindrical shape with perimetral flange ( 26 ) so as to permit the coupling of fork ( 14 ) of the hooking device ( 12 ) integral to the crane boom ( 3 ).
A push-button ( 21 ) protrudes from the top of the mechanism housing ( 24 ) in front of the vertical push rod ( 15 ) of the hooking device ( 12 ).
In FIG. 8 we can see the push button ( 21 ) being pushed upwards by a very strong main spring ( 23 ) by way of a disc ( 22 ) integral to the push-button ( 21 ) This push-button ends in a transverse rod ( 20 ) that drives the bottom unloading doors ( 17 ) through two front and rear identical links.
FIG. 7 shows one of the four identical and symmetrical links which consist of a first rod ( 18 ) that acts upon a lever ( 28 ) fixed to the container ( 4 ) through its lever axle ( 30 ), the outer end ( 32 ) of this lever ( 28 ) acting upon a second rod ( 19 ) whose extreme end is attached to an oscillating plate ( 36 ) at an attachment point ( 34 ). This oscillating plate ( 36 ) can have a very slight oscillating movement over its plate axle ( 39 ), as will be explained later, driving the button unloading door ( 17 ) through a plate support ( 38 ) integral to the doors and on which plate axle is mounted ( 39 ). Finally, the oscillating plate ( 36 ) acts through latch axle ( 41 ) over the latch slot ( 42 ) of a latch fork ( 44 ) of a latch ( 48 ) that retains the door ( 17 ) as it is positioned over latch stop ( 50 ).
As can be seen in FIG. 1, after the fork ( 14 ) has been coupled to the opening mechanism ( 16 ) the container ( 4 ) may be lifted from the floor suspended from the crane boom ( 3 ). Then, the crane boom ( 3 ) retracts until the horizontal rod of the stop ( 13 ) pushes to the right the third block ( 68 ) of the hooking device ( 12 ). See FIGS. 2, 3 and 4 .
This movement of the second block ( 68 ) of the hooking device causes the cable ( 70 ) to pull the fork ( 14 ) upwards and the container ( 4 ) with it, until the push button ( 21 ) of the opening mechanism ( 16 ) is pushed against the vertical push rod ( 15 ) fixed vertically on the hooking device ( 12 ). At this moment the push rod ( 21 ) is forced downwards inside the housing ( 24 ) against the spring ( 23 ) and together with it the transverse rod ( 20 ). As can be seen from FIGS. 7 and 8 this downward movement of the transverse rod ( 20 ) causes the first rod ( 18 ) to act upon lever ( 28 ) that rotates downwardlly, drawing second rod ( 19 ) attached to the oscillating plate ( 36 ) at attachment point ( 34 ). In a first moment, the oscillating plate ( 36 ) turns clockwise and through latch axle ( 41 ), latch fork ( 44 ) and latch stick ( 46 ) draws latch ( 48 ) out of latch stop ( 50 ) and against latch spring ( 54 ) housed inside latch housing ( 52 ) integral to unloading doors ( 17 ). At this moment the unloading door ( 17 ) begin to rotate clockwise over door hinges ( 56 ) as latch fork ( 44 ) is resting against plate support ( 38 ), and play ( 58 ) between them has disappeared. So, the unloading doors ( 17 ) have reached the position showed in FIG. 2 and the unloading of the container ( 4 ) takes place in the compacting box ( 2 ).
When the crane boom ( 3 ) expands, the second block ( 66 ) and third block ( 68 ) of the hooking device ( 12 ) get nearer, and the fork ( 14 ) goes down, releasing the pressure mechanism ( 16 ) of the container ( 4 ). The main spring ( 23 ) pushes now the transverse rod ( 20 ) upwards, and together with it, the first rod ( 18 ), lever ( 28 ) and second rod ( 19 ), the unloading door ( 17 ) rotating counterclockwise as plate stops ( 40 ) integral to oscillating plate ( 36 ) rest on plate support ( 38 ). At the end of the closing operation of the unloading doors, the latch ( 48 ) must retract inside latch housing ( 52 ) to overshoot the latch stop ( 50 ) what becomes possible by latch slot ( 42 ) and play ( 58 ) between latch fork ( 44 ) and plate support ( 38 )
The description above contains many specificities. This description should not be construed as limiting the scope of the invention but as merely providing illustrations of the presently preferred embodiments of this invention. The scope of the invention should be determined by the appended claims and their legal equivalents. | The system defines an assembly formed by a truck with a compacting box of wastes and handling crane ( 3 ) of a receptor container, and containing the wastes assigned to be compacted, the compacting is carried out by a displaceable wall in the inside of compacting box, the crane ( 3 ) including a hooking device ( 12 ) of the container in order to place this one facing the upper loading door ( 7 ) of the compacting box ( 2 ), as well as a mechanism ( 16 ) to produce the opening of the corresponding unloading gates foreseen to such effect in the container ( 4 ) itself, when the hooking device ( 12 ) reaches the stop ( 13 ) in its displacement over the crane boom, the unloading gates ( 17 ) ot the container ( 4 ) being closed automatically when the hooking device ( 12 ) is in any other position over the crane boom. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to the processing of binary words by calculation functions. The present invention more specifically relates to the execution, by a state machine in wired logic of an integrated circuit, of a calculation representing a function likely to be used by several applications within this same circuit.
[0003] 2. Discussion of the Related Art
[0004] An example of application of the present invention relates to the implementation, within a same circuit, of several processings all using a same operating function. For example, it may be a public key signature processing, a data integrity control or a random generator for cryptography. In all the above cases, a so-called “Hash” discriminating function is generally used, for example, functions known as SHA, MD5, etc.
[0005] Most of these discriminating functions are based on an iterative processing of a message divided into blocks taking into account the result of the previous iteration. They thus generally use a single work register which is updated at each iteration and forms, at the function end, an output register providing the desired result (calculated signature, integrity control authentication code, or random bit train) to be exploited by the rest of the circuit.
[0006] It would be desirable, for miniaturization, to be able to share a same logic operator for several processings exploiting a same function.
[0007] However, this poses several problems due to the very nature of the functions to which the present invention applies.
[0008] A first problem is linked to the existence of a work register storing the results of the different iterations. Indeed, this means in practice that the result of the functions is only obtained at the end of the multiple iterations.
[0009] A solution would consist of having interrupts generated by other applications wait until the iteration calculation is over. This is however incompatible with a desire of real time execution required by some applications needing the operator. For example, in the context of an integrity control requiring the discrimination operator for an authentication message calculation, it cannot be awaited until the operator is freed by another application.
[0010] It could also have been devised to memorize an intermediary state of an interruptible application to leave the work register and the operator available for another priority-holding application. However, a memorization followed by a restoring of the states of the work register associated with the operator adversely affects the system performances and weakens it as concerns security against possible piracies of the handled quantities.
[0011] In practice, the only acceptable conventional solution when several applications (signature, integrity, random number generation) must use a Hash-type discrimination function, is to provide as many circuits (operator+register) as there are applications.
SUMMARY OF THE INVENTION
[0012] The present invention aims at providing a solution to the problem of the sharing of a logic operator by several applications exploiting a same iterative discrimination function.
[0013] The present invention also aims at providing a solution which is compatible with the desired miniaturization of integrated circuits.
[0014] The present invention also aims at enabling sharing of the operator in wired logic without adversely affecting the need for real time processing of a priority-holding application.
[0015] To achieve these and other objects, the present invention provides a circuit for calculating a discriminating function with successive iterations and with a work register on data divided into blocks, comprising:
[0016] a single operator in wired logic for executing the function;
[0017] a plurality of work registers sharing said operator; and
[0018] an element for selecting one of the work registers to be associated with the operator.
[0019] According to an embodiment of the present invention, each register stores a current state of the operator and the rank of the corresponding iteration.
[0020] According to an embodiment of the present invention, said function is a Hash function.
[0021] According to an embodiment of the present invention, a multiplexer forming the selection element is controlled by a priority decoder associated with an integrated processor containing said calculation circuit.
[0022] The foregoing objects, features and advantages of the present invention will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 very schematically shows in the form of blocks an embodiment of the circuit for calculating a discrimination function according to the present invention; and
[0024] [0024]FIG. 2 is a flowchart of a function exploited by the calculation circuit of FIG. 1 according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0025] For clarity, only those steps and those elements which are necessary to the understanding of the present invention have been shown in the drawings and will be described hereafter. In particular, the exploitation made of the calculations by the discrimination function have not been detailed and are no object of the present invention, the present invention applying whatever the application requiring use of the wired operator. Further, the other components of an integrated circuit containing the calculation circuit of the present invention are conventional and have not been described.
[0026] A feature of the present invention is to dissociate, in a calculation circuit implementing an iterative discriminating function with a work register, the actual operator from the work register. According to the present invention, it is provided to share the operator between several work registers individually dedicated to different applications.
[0027] [0027]FIG. 1 very schematically shows in the form of blocks an embodiment of a shared calculation circuit according to the present invention.
[0028] Circuit 1 essentially comprises a logic operator 2 (f(PSi-1, Bi)) executing an operation using as operands a binary block B and a state PS representing the result of the operation at a previous iteration.
[0029] The processed data (in the example of FIG. 1, block B) forms a portion of a data word for which an application requires use of the discriminating function.
[0030] The previous state PSI-1 combined by logic state machine 2 with current block Bi is initialized at the beginning of an iteration by an initial value IS, and corresponds after the last iteration of the discriminating function to final result FS required by the application.
[0031] Up to this point, what has been described corresponds to a wired operator of a conventional discriminating function. For example, it may be a so-called Hash function.
[0032] According to the present invention, the input (PS) and the output (CS) states of operator 2 correspond to the successive contents of a single work register per application. However, as many work registers 3 (REG 1 , . . . , REGj, . . . REGn)) as there are applications to share circuit 1 are provided.
[0033] Each register 3 is equivalent to a conventional work register associated with a wired operator 2 . However, according to the present invention, inputs/outputs of registers 3 are connected to the multiple inputs of a multiplexer 4 having a single input/output connected to the input (signal PS)) of operator 2 and to the output (signal CS) of operator 2 . Multiplexer 4 receives a selection signal (SEL) coming, for example, from a priority control (not shown) associated with the central processing unit of the processor integrating circuit 1 .
[0034] Initial states IS 1 , . . . ISj, . . . ISn are loaded under control of the CPU into each register 3 . The final states FS 1 , FSj, . . . FSn of function f after the required iterations are read individually from each register, by the processor circuits having required the application of the Hash function to a given binary word.
[0035] Conventionally, number m of iterations depends on the number of data blocks to be processed. According to the present invention, number n of registers depends on the number of applications which require operator 2 .
[0036] [0036]FIG. 2 is a simplified flowchart of the function performed by operator 2 .
[0037] The function starts (block 10 , IS) from an initial state. This state is, in the example of FIG. 1, previously loaded into one of the work registers associated with the application having requested the function. In a specific example applied to a so-called SHA function, this initial state is predetermined.
[0038] The initial state becomes, when multiplexer 4 assigns operator 2 to the concerned register, first input value PS0 of the operator (block 11 , PS0=IS).
[0039] The function of the logic operator is then executed (block 12 , CSi=f(PSi-1, Bi) on the first data couple, here the first data block to be processed BI and the first input state PS0. This operation is repeated for the m data blocks to be processed. Accordingly, this amounts to testing (block 13 , i=m ?) the end of the data word to be processed. If the result is negative, the iteration rank is incremented (block 14 , i=i+1) and operator f is executed again with as input values PSi-1 and a new data block Bi. If the result is positive, output word CSi provided with the operator is considered as being the final state FS for the application having required the function.
[0040] According to the present invention, after each execution (block 12 ) of the operator, current state CSi and rank i of the iteration are stored in the concerned register. This feature of the present invention enables, in case the function is interrupted to make operator 2 available for a higher-priority application, to keep the current rank of the function to avoid restarting it from the beginning.
[0041] Of course, to implement the present invention, the data words to be processed by the discriminating function are also stored in adapted memorization elements (for example, registers). Rank i stored in register 3 assigned to the application is used to select the appropriate data block upon resumption of the iterations for the concerned application.
[0042] Generally, for the application to a Hash function, the data words are divided into blocks Bi of 512 bits each.
[0043] An advantage of the present invention is that it enables sharing a same operator in wired logic for several discriminating functions executed by different applications of an integrated processor.
[0044] Another advantage of the present invention is that by avoiding storage of the intermediary calculation states in an external memory of the integrated circuit, the present invention preserves the security character generally required for applications of discriminating functions.
[0045] Another advantage of the present invention is that its implementation is particularly simple in an integrated processor. In particular, the implementation of the present invention is compatible with the hardware circuits and control processes generally used in integrated processors. Further, the application processed by operator 2 is transparent for said operator, in that all operates as if it was only connected to one register.
[0046] According to a preferred example of application of the present invention, operator 2 is shared by several applications among which at least one real time data integrity control. In this case, this application is considered as holding the highest priority.
[0047] A second possible application may be a signature or authentication code calculation having a lower priority rank.
[0048] To hold the third priority rank, it may be provided to use operator 2 in the generation of a pseudo-random number which then holds the lowest priority rank.
[0049] Of course, the present invention is likely to have various alterations, modifications, and improvements which will readily occur to those skilled in the art. In particular, the practical forming of the calculation circuit according to the present invention is within the abilities of those skilled in the art based on the functional indications given hereabove. Further, the commands necessary to the multiplexer and to the different register by using conventional control means are within the abilities of those skilled in the art. Moreover, although this has not been detailed, the selection of the block Bi assigned to the data word of the application may be performed in several manners. For example, the integrated circuit CPU manages the reading of the desired blocks according to the decided priorities.
[0050] Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto. | A circuit for calculating a discriminating function with successive iterations and with a work register on data divided into blocks, comprising: a single operator in wired logic for executing the function; a plurality of work registers sharing said operator; and an element for selecting one of the work registers to be associated with the operator. | 6 |
BACKGROUND OF THE INVENTION
Plasmodium is a genus of parasitic protozoa. Infection with this genus is known as malaria. The parasite always has two hosts in its life cycle: a mosquito vector and a vertebrate host. At least ten species infect humans including P. falciparum, P. vivax, P. malariae , and P. ovale . Malaria is an infectious disease that is widespread in tropical and subtropical regions. Malaria represents a threat to survival of men, women and children. It infects between 300 and 500 million people every year and causes between one and three million deaths annually, mostly among young children in Sub-Saharan Africa.
Malaria is one of the most common infectious diseases and an enormous public-health problem. The disease is caused by protozoan parasites of the genus Plasmodium . The most serious forms of the disease are caused by Plasmodium falciparum and Plasmodium vivax , but other related species ( Plasmodium ovale and Plasmodium malariae ) can also infect humans. Determining the infectious species helps determine the course of treatment for the patient.
The preferred and most reliable diagnosis of malaria is microscopic examination of blood films because each of the four major parasite species has distinguishing characteristics. Two sorts of blood film are traditionally used. Thin films are similar to usual blood films and allow species identification because the parasite's appearance is best preserved in this preparation. Thick films allow the microscopist to screen a larger volume of blood and are about eleven times more sensitive than the thin film, so picking up low levels of infection is easier on the thick film, but the appearance of the parasite is much more distorted and therefore distinguishing between the different species can be much more difficult.
From the thick film, an experienced microscopist can detect parasite levels (or parasitemia) down to as low as 0.0000001% of red blood cells. However, microscopic diagnosis can be difficult because the early trophozoites (“ring form”) of all four species look identical and it is never possible to diagnose species on the basis of a single ring form; species identification is always based on several trophozoites.
In areas where microscopy is not available, there are antigen detection tests that require only a drop of blood. OptiMAL-IT® (TCS Bio Sciences, Buckingham, England) will reliably detect falciparum down to 0.01% parasitemia and non-falciparum down to 0.1%. Paracheck-Pf® (Orchard Biomedical Systems, India) will detect parasitemias down to 0.002% but will not distinguish between falciparum and non falciparum malaria. Parasite nucleic acids may also be detected using polymerase chain reaction. This technique is more accurate than microscopy. However, it is expensive and requires a specialized laboratory. Moreover, levels of parasitemia are not necessarily correlative with the progression of disease, particularly when the parasite is able to adhere to blood vessel walls. Limited molecular methods are available in some clinical laboratories and rapid real-time assays, for example, QT-NASBA (real-time quantitative nucleic acid sequence-based amplification) based on the polymerase chain reaction) but are only now being developed. Therefore, sensitive, low-tech diagnosis tools need to be developed for in order to detect low levels of parasitaemia in the field.
What is need are reagents and methods for the rapid and accurate detection and discrimination of various malaria causing Plasmodium species.
SUMMARY OF THE INVENTION
This invention relates to nucleic acid probes that detect and discriminate between different species of Plasmodium parasites in, for example, hybridization assays. Accordingly, in a first aspect, the invention features nucleic acid fragments to be used as probes for detecting Plasmodium in a hybridization assay. The invention also includes probes (DNA, RNA and PNA) that can discriminate between P. falciparum, P. vivax, P. malariae and P. ovale . In the context of the present invention the term “discriminates between” (or similar terms) means that the probe binds to nucleic acid (e.g., RNA, DNA, rRNA [ribosomal RNA] or rDNA [ribosomal DNA]) from one species more favorably than the other 3 species.
In a second aspect, the invention features a nucleic acid fragment containing a sequence selected from, preferably, at least five, more preferably at least ten or most preferably at least fifteen consecutive nucleotides or the entire sequence of one or more of probes designated PGenus1, PGenus2, Mal F1, MalF2, Mal1.8F, Mal1.8R, PV1, PV2, PF1, PF2, PF3, PF4, PF5, PM1, PO1 or the partial or full-length complementary sequences thereof.
In a third aspect, the invention features a nucleic acid fragment containing a sequence selected from at least five, preferably, at least ten, more preferably at least thirteen or most preferably at least fifteen consecutive nucleotides or the entire sequence of one or more of probes designated SEQ ID NO: 1 through SEQ ID NO.: 15 or the partial or full-length complementary sequences thereof.
In a final aspect, the invention features a method for detecting the presence of Plasmodium in a sample. In this method, a sample is contacted with a nucleic acid fragment containing a sequence selected from, preferably, at least five, at least ten, more preferably at least thirteen or most preferably at least fifteen consecutive nucleotides or the entire sequence of a PGenus1, PGenus2, Mal F1, MalF2, Mal1.8F, Mal1.8R, PV1, PV2, PF1, PF2, PF3, PF4, PF5, PM1 or PO1, probe selected from or the partial or full-length complementary sequence thereof (or any combination thereof); under conditions that permit the nucleic acid fragment to hybridize to Plasmodium nucleic acid. Detection of the nucleic acid fragment bound to the Plasmodium nucleic acid in the sample is used as an indication of the presence of Plasmodium in the sample. Detection with probes of the present invention that discriminate between the four species of Plasmodium listed above indicates the presence of that species of Plasmodium.
In one embodiment of this aspect of the invention, the nucleic acid fragment contains a sequence selected, preferably, from at least five, more preferably at least ten or most preferably at least fifteen consecutive nucleotides or the entire sequence of probe PGenus1 or the full-length complementary sequence thereof.
In a second embodiment of this aspect of the invention, the nucleic acid fragment contains a sequence selected, preferably, from at least five, more preferably at least ten or most preferably at least fifteen consecutive nucleotides or the entire sequence of probe PGenus2, or the full-length complementary sequence thereof.
In a third embodiment of this aspect of the invention, the nucleic acid fragment contains a sequence selected from, preferably, at least five, more preferably at least ten or most preferably at least fifteen or the entire sequence of probe MalF1 or the full-length complementary sequence there of.
In yet another embodiment of this aspect of the invention, the nucleic acid fragment contains a sequence selected from, preferably, at least five, more preferably at least ten or most preferably at least fifteen nucleotides, or the entire sequence of probe MalF2 or the full-length complementary sequence thereof.
In yet another embodiment of this aspect of the invention, the nucleic acid fragment contains a sequence selected from, preferably, at least five, more preferably at least ten or most preferably at least fifteen nucleotides or the entire sequence of probe Mal1.8F or the full-length complementary sequence thereof.
In yet another embodiment of this aspect of the invention, the nucleic acid fragment contains a sequence selected from, preferably, at least five, more preferably at least ten or most preferably at least fifteen nucleotides or the entire sequence of probe Mal1.8R, or the full-length complementary sequence thereof.
An advantage of probes PGenus 1, PGenus2, MalF1, MA1F2, Mal1.8F and Mal1.8R is that while they detect all three species of Plasmodium tested and, thus, are not limited to detecting a single Plasmodium species. Other features and advantages of the present invention will be apparent from the following detailed description thereof and also from the appended claims.
In specific aspects, the present invention contemplates a method for detecting the presence of Plasmodium in a sample, said method comprising the steps of: contacting said sample with a probe for detecting Plasmodium in a hybridization assay, wherein said probe discriminates between Plasmodium species, under conditions that permit said probe to hybridize to Plasmodium nucleic acid; and detecting said probe bound to said Plasmodium nucleic acid in said sample as an indication of the presence of Plasmodium in said sample.
In the preceding embodiment, the nucleic acid fragment comprises a sequence that is selected from at least five consecutive nucleotides of probe PV1, PV2, PF1 PF3, PF4, PF5, PM1 or PO1 the full-length complementary sequence thereof.
In other aspects, the present invention contemplates a method for detecting the presence of Plasmodium in a sample, said method comprising the steps of: contacting said sample with a nucleic acid fragment comprising a sequence selected from at least five consecutive nucleotides of a probe selected from a group consisting of PGenus1, PGenus2, MalF1, MalF2, Mal1.8F, Mal1.8R, PV1, PV2, PF1, PF2, PF3, PF4, PF5, PM1 and PO1 or full-length complimentary sequence thereof, under conditions that permit said nucleic acid fragment to hybridize to Plasmodium nucleic acid; and detecting said nucleic acid fragment bound to said Plasmodium nucleic acid in said sample as an indication of the presence of Plasmodium in said sample.
In the preceding embodiment, the nucleic acid fragment comprises of a sequence selected from the full length sequence, at least fifteen consecutive nucleotides, at least ten consecutive nucleotides, at least five consecutive nucleotides of a probe selected from a group consisting of PGenus1, PGenus2, MalF1, MalF2, Mal1.8F, Mal1.8R, PV1, PV2, PF1, PF2, PF3, PF4, PF5, PM1 and PO1 or full-length complimentary sequence thereof.
The present invention also contemplates a nucleic acid fragment comprising a sequence selected from at least five consecutive nucleotides of a probe selected from a group consisting of PGenus1, PGenus2, MalF1 and MalF2, Mal1.8F, Mal1.8R, PV1, PV2, PF1, PF2, PF3, PF4, PF5, PM1, PO1 or the full-length complementary sequence thereof.
The present invention also contemplates a nucleic acid fragment comprising a sequence selected from at least ten consecutive nucleotides of a probe selected from a group consisting of PGenus1, PGenus2, MalF1 and MalF2, Mal1.8F, Mal1.8R, PV1, PV2, PF1, PF2, PF3, PF4, PF5, PM1, PO1 or the full-length complementary sequence thereof.
The present invention also contemplates a nucleic acid fragment comprising the complete sequence selected of a probe selected from a group consisting of PGenus1, PGenus2, MalF1 and MalF2, Mal1.8F, Mal1.8R, PV1, PV2, PF1, PF2, PF3, PF4, PF5, PM1, PO1 or the full-length complementary sequence thereof.
In specific aspects, the present invention contemplates a method of selecting nucleic acid probes that discriminate between the species P. falciparum, P. vivax, P. malariae and P. ovale , the method comprising: preparing a nucleic acid fragment or polypeptide nucleic acid, PNA corresponding to, or complementary to, a sequence of at least five nucleotides of nucleic acid from P. falciparum, P. vivax, P. malariae and P. ovale ; comparing the ability of the probe to detect one or more of the Plasmodium species in a hybridization assay; and selecting the probe or probes that detect one, two or three species of Plasmodium but not all four species of Plasmodium.
The present invention also contemplates a method for detecting and differentiating between P. falciparum, P. Vivax, P. malariae and P. ovale in a sample, said method comprising: providing: i) a sample from a subject suspected of having malaria and ii) probes comprising nucleic acid suitable for detecting and differentiating between P. falciparum, P. Vivax, P. malariae and P. ovale ; contacting said sample with said probes under conditions suitable for hybridization of said probes to targets; and determining the presence of P. falciparum, P. Vivax, P. malariae and P. ovale , if any, in the sample.
In one embodiment, the method contemplates that the probe for detecting P. falciparum is selected from a nucleic acid sequence of at least five contiguous nucleotides of one or more of PF1, PF2, PF3, PF4 or PF5. In another embodiment, the method contemplates that the probe is selected from a nucleic acid sequence of at least ten contiguous nucleotides of one or more of PF1, PF2, PF3, PF4 or PF5. In yet another embodiment, the method contemplates that the probe is selected from a nucleic acid sequence of at least fifteen contiguous nucleotides of one or more of PF1, PF2, PF3, PF4 or PF5.
In one embodiment, the method contemplates that the probe for detecting P. Vivax is selected from a nucleic acid sequence of at least five contiguous nucleotides of one or more of PV1 or PV2. In another embodiment, the method contemplates that the probe is selected from a nucleic acid sequence of at least ten contiguous nucleotides of one or more of PV1 or PV2. In yet another embodiment, the method contemplates that the probe is selected from a nucleic acid sequence of at least fifteen contiguous nucleotides of one or more of PV1 or PV2.
In one embodiment, the method contemplates that the probes for detecting P. malariae are selected from a nucleic acid sequence of at least five contiguous nucleotides of PM1 and one or more of PF1, PF2, PF3, PF4 or PF5 and wherein a sample is positive for P. malariae if the probe of at least five contiguous nucleotides of PM1 tests positive and the probe of at least five contiguous nucleotides of PF1, PF2, PF3, PF4 or PF5 tests negative. In another embodiment, the method contemplates that the probes are selected from a nucleic acid sequence of at least ten contiguous nucleotides of one or more of PF1, PF2, PF3, PF4 or PF5 and at least ten contiguous nucleotides of PM1. In yet another embodiment, the method contemplates that the probes are selected from a nucleic acid sequence of at least fifteen contiguous nucleotides of one or more of PF1, PF2, PF3, PF4 or PF5 and at least fifteen contiguous nucleotides of PM1.
In one embodiment, the method contemplates that the probes for detecting P. ovale are selected from a nucleic acid sequence of at least five contiguous nucleotides of PO1 and one or more of PF1, PF2, PF3, PF4 or PF5 and wherein a sample is positive for P. ovale if the probe of at least five contiguous nucleotides of PO1 tests positive and the probe of at least five contiguous nucleotides of PF1, PF2, PF3, PF4 or PF5 tests negative. In another embodiment, the method contemplates that the probes are selected from a nucleic acid sequence of at least ten contiguous nucleotides of one or more of PF1, PF2, PF3, PF4 or PF5 and at least ten contiguous nucleotides of PO1. In yet another embodiment, the method contemplates that the probes are selected from a nucleic acid sequence of at least fifteen contiguous nucleotides of one or more of PF1, PF2, PF3, PF4 or PF5 and at least fifteen contiguous nucleotides of PO1.
In any of the preceding embodiments, the probe or probes used may be of the entire nucleotide sequence as disclosed herein or the complementary strand thereof as well as the complementary sequence of the five, ten or fifteen contiguous nucleotides of the probes.
DETAILED DESCRIPTION OF THE INVENTION
The invention features nucleic acid probes for detecting Plasmodium parasites (e.g., P. falciaprum, P. vivax, P. malariae and P. ovale ) in, for example, hybridization assays. The probes of the invention may be used in methods for detecting the presence of Plasmodium in a biological sample. In these methods, a probe of the invention is contacted with a biological sample (e.g., whole blood, CSF or a tissue sample) in a hybridization assay and detection of the probe bound to the nucleic acid in the sample is used as an indication of the presence of Plasmodium in the sample. Probes included in the invention may be identified by:
A (1) preparing a nucleic acid fragment or polypeptide nucleic acid, PNA (i.e., a probe) corresponding to, or complementary to, a sequence of at least ten nucleotides of nucleic acid from P. falciparum and (2) comparing the ability of the probe to detect all the Plasmodium species in a hybridization assay. Probes that hybridize to P. falciparum more favorably than to other three species are included in the invention.
B (1) preparing a nucleic acid fragment or PNA (i.e., a probe) corresponding to, or complementary to, a sequence of at least ten nucleotides of nucleic acid from P. vivax and (2) comparing the ability of the probe to detect all the Plasmodium species in a hybridization assay. Probes that hybridize to P. vivax more favorably than to other three species are included in the invention.
C (1) preparing a nucleic acid fragment or PNA (i.e., a probe) corresponding to, or complementary to, a sequence of at least ten nucleotides of nucleic acid from P. malaiiae and (2) comparing the ability of the probe to detect all the Plasmodium species in a hybridization assay. Probes that hybridize to P. malariae more favorably than to other three species are included in the invention.
D (1) preparing a nucleic acid fragment or PNA (i.e., a probe) corresponding to, or complementary to, a sequence of at least ten nucleotides of nucleic acid from P. ovale and (2) comparing the ability of the probe to detect all the Plasmodium species in a hybridization assay. Probes that hybridize to P. ovale more favorably than to other three species are included in the invention.
P. falciaprum, P. vivax, P. malariae and P. ovale nucleic acid may be obtained from biological samples (such as whole blood, bone marrow, CSF) from infected individuals, using standard nucleic acid isolation methods in the art. P. falciaprum (as well as P. vivax, P. malariae and P. ovale ) can also be obtained from culture. For example, DNA encoding Plasmodium ribosomal RNA may be obtained by PCR amplification of DNA prepared from a whole blood sample of an infected patient using the methods and primers described herein and known in the art.
Any Plasmodium sequence (e.g., a sequence encoding 58, 5.8S, 18S, or 28S ribosomal RNA) may be selected as a candidate sequence for the identification of probes. Preferred sequences are those that diverge from analogous sequences in non-human Plasmodium or other protozoan parasites like, for example, Babesia or Thileria , as determined by phylogenetic comparison. The nucleic acid probes of the invention are at least 10 nucleotides in length and may contain deoxyribonucleotides (DNA probes), ribonucleotides (RNA probes), peptide nucleic acid (PNA probes) or combinations or modifications thereof. The probes may be single stranded or double stranded and may be prepared by any of a number of standard methods in the art. For example, the probes may be made by chemical synthesis, restriction endonuclease digestion of a vector (e.g., a plasmid containing a sequence corresponding to the probe), polymerase chain reaction (PCR) amplification, or in vitro transcription of a vector containing a sequence corresponding to the probe (see, e.g., Ausubel, et al., Current Protocols in Molecular Biology, Greene Publishing, New York, N.Y., 1994, incorporated herein by reference). The probes may be labeled during or after synthesis. For example, labeled nucleotides containing, e.g., radioisotopes (e.g., p32, S35, or H3), biotin or digoxigenin may be incorporated into the probe during synthesis. Probes containing biotin are detected by the use of a secondary reagent such as avidin or streptavidin, which contains a detectable label such as a fluorochrome (e.g., fluorescein or rhodamine) or an enzyme (e.g., alkaline phosphatase or horseradish peroxidase). Similarly, probes containing digoxigenin may be detected by using a labeled antidigoxigenin antibody. Probes may also be labeled after synthesis by, e.g., nick translation or the use of T4 RNA ligase, poly(A) polymerase, terminal transferase or T4 polynucleotide kinase, in standard methods (see, e.g., Ausubel, et al., supra). The probes may also contain modified nucleotides in order to increase the stability of the probe. For example, ribonucleotides containing 2′-0-alkyl groups on the ribose group may be used. The probes may also contain modifications that facilitate capture of the probe onto a solid support. For example, poly-dA or poly-deaza-guanosine tails may be added to the 3′ ends of the probes, using terminal transferase, in order to facilitate probe binding to a solid support, e.g., poly-dT or poly-dC labeled magnetic particles. The probes may be purified prior to use, using standard methods such as denaturing polyacrylamide gel electrophoresis, high performance liquid chromatography or gel filtration chromatography (see, e.g., Ausubel, et al., supra). The probes of the invention may be used in any standard hybridization assay to detect the presence of Plasmodium in a sample. For example, Southern blot, dot blot, in situ hybridization, real-time hybridization detection by biosensors or dual probe, sandwich-type hybridization assays may be used (see, e.g., U.S. patent application Ser. No. 07/826,657 [now U.S. Pat. No. 5,519,127] and U.S. Pat. No. 5,629,156 [International Publication Number WO 94/10335], all of which are incorporated herein by reference). Alternatively, the probes may be used as primers in a polymerase chain reaction assay (see, e.g., Ausubel, et al., supra). Biological samples that may be analyzed using the probes and methods of the invention include whole blood, CSF, bone marrow and tissue samples from, e.g., the spleen. Nucleic acid is extracted from the sample by standard methods (except in the case of in situ hybridization, where the cells are kept intact) and is analyzed using the probes in the assays listed above. A single probe or combinations of probes may be used in the assay. The hybridization conditions used with the probes (e.g., in the methods of the invention) fall within the range of, for example, 30-50% formamide at 25° C.-42° C. or mixtures of GuSCN and formamide between 25-37° C. As is “known by one skilled in the art,” selection of hybridization conditions depends on the length and nucleotide content (i.e., GC compared to AT) of the probe. Accordingly, hybridization conditions may be adjusted to accommodate these factors. In addition, the use of different salts (e.g., guanidine thiocyanate or guanidine hydrochloride compared with NaCl) and denaturing agents (e.g., NP-40, sodium dodecyl sulfate) may require adjustment of the salt concentration and the temperature, as can readily be determined by one skilled in the art.
Non-limiting examples of hybridization conditions that may be used in the present invention are as follows. In Southern blot analysis, the following hybridization conditions may be used: 30% to 50% formamide in 2×SSC at 42° C. After hybridization, the filters are washed using standard methods. For example, three 15 minute post-hybridization washes at 25° C. in 2×SSC to 0.1×SSC and 0.1% SDS may be carried out in order to remove unbound probes. For RNA blots hybridizations in 30% formamide at room temperature overnight were performed. Excess probes were removed by washing three 15 min washes in 2×SSC with 0.1% SDS.
The term “hybridization” refers to the pairing of complementary nucleic acids. Hybridization and the strength of hybridization (i.e., the strength of the association between the nucleic acids) is impacted by such factors as the degree of complementary between the nucleic acids, stringency of the conditions involved, the T m of the formed hybrid, and the G-C ratio within the nucleic acids. A single molecule that contains pairing of complementary nucleic acids within its structure is said to be “self-hybridized.”
It is well known that numerous equivalent conditions may be employed to comprise suitable hybridization conditions; factors such as the length and nature (DNA, RNA, base composition) of the probe and nature of the target (DNA, RNA, base composition, present in solution or immobilized, etc.) and the concentration of the salts and other components (e.g., the presence or absence of formamide, dextran sulfate, polyethylene glycol) are considered and the hybridization solution may be varied to generate conditions of low stringency hybridization different from, but equivalent to, the above listed conditions. In addition, the art knows conditions that promote hybridization under conditions of high stringency (e.g., increasing the temperature of the hybridization and/or wash steps, the use of formamide in the hybridization solution, etc.).
For in situ hybridization, the following conditions may be used as described in U.S. Pat. No. 6,165,723 and US Patent Publication No. 2007/0042358 (which are herein incorporated by reference): GuSCN (1.5 to 3.5 M depending on the probe sequence) between room temperature and 37° C. or mixtures of GuSCN and formamide between room temperature and 37° C. for 30 minutes to one hour, followed by washes in SSC (2× to 0.1×) and 0.1% SDS.
Exemplification
Without further elaboration, it is believed that one skilled in the art can, based on the description herein, utilize the present invention to its fullest extent. The following specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
Hybridization of probes PGenus1, PGenus2, Ma1F1, Ma1F2, Mal1.8F, Mal1.8R to P. falciaprum, P. vivax, P. ovale and P. malariae Samples.
Dot-blot analysis data is shown in Table 1. In these experiments, approximately 0.1 ug of a plasmid containing nucleotide sequences encoding the respective 18S rRNA subunits was used per spot. The blots were hybridized with dig-labeled probes under the hybridization conditions described above.
In case of RNA, RNA was synthesized and 0.1 ug in 6×SSC was spotted on nitrocellulose membrane. Hybridization with the dig-labeled probes (digoxigenin-labeled probes) was performed overnight at room temperature in formamide. This method was used to compare hybridization signals between the different organisms and probes.
Probes which hybridize to all species of 18 rDNA of all species of Plasmodium are PGenus1, PGenus2, MalF1, MalF2, Mal1.8F and Mal1.8R. Probes PGenus1, PGenus2 and Mal1.8R hybridized to 18S rRNA of all the Plasmodium species.
Plasmodium Genus 18S rRNA-Specific Probes
Plasmodium genus specific probes of the invention include probes PGenus1, PGenus2, MalF1, MalF2, Mal1.8F and Mal1.8R which have the sequences:
PGenus1
(SEQ ID NO: 1)
5′-TCTCGCTTGCGCGAATACTCG-3′
PGenus2
(SEQ ID NO: 2)
5′-CCAAAGACTTTGATTTCTCAT-3′
Malf1
(SEQ ID NO: 3)
5′-CAGATACCGTCGTAATCTTA -3′
Malf2
(SEQ ID NO: 4)
5′-CGAAAGTTAAGGGAGTGAAGAC-3′
Mal1.8F
(SEQ ID NO: 5)
5′-atgtagaaactgcgaacggc -3′
Mal1.8R
(SEQ ID NO: 6)
5′-cagcacaatctgatgaatcatgc-3′
Plasmodium Species 18S rRNA-Specific Probes
Plasmodium species specific probes of the invention include probes PV 1 which have the sequences of a probe selected from PV1, PV2, PV3, PF1, PF2, PF3, PF4, PF5, PF6 PF7, PF8, PM1, PO1 or the full-length complementary sequence thereof.
P. vivax Specific Probes
PV1
(SEQ ID No: 7)
5′-TCTAAGAATAAACTCCGAAGAGAAAATTCTTATTTT-3′
PV2
(SEQ ID No: 8)
5′-TACACACTCAAGAAATGAATCAAGAGTGC-3′
P. falciparum Specific Probes
PF1
(SEQ ID NO: 9)
5′-GCAATCTAAAAGTCACCTCGAAAGATGACTT-3′
PF2
(SEQ ID No: 10)
5′-CCTAACAAATACTTATCCAAAGATAAAAATCAAGGA-3′
PF3
(SEQ ID No: 11)
5′-ATTTTTAACACTTTCATCCAACACCTAGTCG-3′
PF4
(SEQ ID No: 12)
5′-TTACAAAACCAAAAATTGGCCTTGCATTGTTATTT-3′
PF5
(SEQ ID No: 13)
5′-TCCAATTGTTACTCTGGGAAGG-3′
P. malariae Specific Probe
PM1
(SEQ ID No: 14)
5′-GAAACACTCATATATAAGAATGTCTC-3′
P. ovale Specific Probe
PO1
(SEQ ID No: 15)
5′-AATTTCCCCGAAAGGAATTTTC-3′
TABLE 1
Probes
P. falciparum
P. vivax
P. malariae
P. ovale
PGenus1
Positive
Positive
Positive
Positive
PGenus2
Positive
Positive
Positive
Positive
MalF1
Positive
Positive
Positive
Positive
MalF2
Positive
Positive
Positive
Positive
Mal1.8F
Positive
Positive
Positive
Positive
Mal1.8R
Positive
Positive
Positive
Positive
PV1
Negative
Positive
Negative
Negative
PV2
Negative
Positive
Negative
Negative
PF1
Positive
Negative
Negative
Negative
PF2
Positive
Negative
Negative
Negative
PF3
Positive
Negative
Negative
Negative
PF4
Positive
Negative
Negative
Negative
PF5
Positive
Negative
Negative
Negative
PM1
Positive
Negative
Positive
Negative
PO1
Positive
Negative
Negative
Positive
Note:
All the probes except MalF1, MalF2 and Mal1.8F hybridize to rRNA also.
In one exemplification of the present invention, samples are tested for the presence of Plasmodium sp. and detected Plasmodium species are differentiated by use of the probes of the present invention. A sample is tested with probes of at least five, ten or fifteen contiguous nucleotides of probes PV1 and/or PV2, probes PF1, PF2, PF3, PF4 and/or PF5, probes PM1 and probe PO1, or the entire probe or the complementary sequences thereof. Samples that test positive for probes PV1 and/or PV2 are determined to be infected with P. vivax . Samples that test positive for probes PF1, PF2, PF3, PF4 and/or PF5 are determined to be infected with P. falciparium . Samples that test positive for probes PM1 but not for PF1, PF2, PF3, PF4 and/or PF5 are determined to be infected with P. malariae . Samples that test positive for probes PO1 but not for PF1, PF2, PF3, PF4 and/or PF5 are determined to be infected with P. ovale.
From the above description, one skilled in the art can easily ascertain the essential characteristics of the present invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. Thus, other embodiments are also within the claims. | This invention relates to novel nucleic acid probes and methods for detecting Plasmodium parasites as well as detecting different Plasmodium parasites selectively from one another. | 2 |
BRIEF SUMMARY OF THE INVENTION
The invention concerns the needleless hypodermic injection of medications, by means of an ampoule having holes and a flexible membrane, forming a cavity holding medication in liquid form. The ampoule is stretched in a hypodermic pistol, in the cocking of the pistol, the pistol having a spring loaded punch which upon discharge of the pistol engages the membrane and forces the medication through the holes.
The device is especially useful and effective for performing a large number of vaccinations in a short period of time.
Patent DE-OS 1 491 695 shows an ampoule for needleless injection, but the ampoule therein has only one opening and the device in being emptied could possibly injure the skin.
Another patent, DE OS 1 907 296, also for needleless injection, includes several holes through which the medication is simultaneously ejected. However, in the latter instance the holes are formed in outwardly directed sharp needle points, so that the mere pressing of the ampoule to the skin can injure it. Additionally, in that device, there exists a danger because of the numerous needle-shaped holes in the ampoule, the front surface of the ampoule is positioned obliquely across the injection location, so that the simultaneous ejection of the medication through all of the holes of the ampoule cannot be guaranteed.
An object of the present invention is to provide a device for needleless hypodermic injection, wherein in the operation thereof the injection is facilitated, and it is assured that the ampoule is placed with its front or effective surface on the injection location in a constantly repeatable manner, and the holes of the ampoule are positioned evenly at the intended location on the skin.
A more specific object is to provide a device of the character referred to, capable of carrying out the intended function, wherein the ampoule includes a flat front plate which covers the front effective surface of the injection pistol utilized, and in which the holes of the ampoule are formed as in nozzles in flat, short truncated cones, and in which these holes are arranged in a circular pattern.
An additional advantage lies in the specific construction wherein because of the flat front plate referred to, the openings lie evenly on the skin of the patient in a constantly repeatable manner.
A further advantage exists in the specific construction in that the user need only to ascertain that the front plate lies on the skin, and the necessary consequence is that the holes in the ampoule inject the medications evenly into the location of the injection.
In previously known devices, there was always the danger that the ampoule would be held in an improper oblique position so that the medication would often be ejected inaccurately, or even be discharged sideways. Additionally in the use of a plurality of needle-sharp nozzles there is always the danger that the skin would be harmed merely by applying the nozzles to the skin.
A still further advantage is accomplished by the specific construction wherein the ampoule has a front plate at the front forming a shield, and the front plate can be placed on the skin at the location of the injection with a large surface engaging the skin, whereby it is assured that the flat, short nozzles provided, evenly contact the skin.
An another object of the invention is to provide another advantage, by means of a specific construction which includes a front plate and means for mounting a flexible membrane thereon, in such a way that the membrane forms a bellows utilized in injecting the medication.
Still another advantage is provided in a specific mechanical construction of an ejection pistol, for mounting the ampoule therein for performing the injection operation, wherein the pistol has a cavity receiving the bellows and confining it whereby in the striking of the bellows by a driving punch in the discharge of the pistol, the membrane is protected.
Another advantage is to provide means for coding the active substances in the ampoules in a recognizable manner, such as by either color or texture.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIGS. 1-4 show different forms of ampoules embodying the features of the invention.
FIGS. 5-7 show an arrangement of an ampoule in an injection pistol, in different phases of operation of the pistol.
FIGS. 8 and 9 show devices forming storage means for the ampoules.
FIG. 10 shows an arrangement of codings on the front plate of the ampoule.
FIG. 11 shows an arrangement of different permutations of coding elements.
FIG. 12 shows a storage device or plate having an additional arrangement of coding elements.
DETAILED DESCRIPTION
FIGS. 1 and 2 show the device of the invention in its simplest forms. In these figures an ampoule is shown, which includes only a front plate 1 and a membrane 3. The front plate is provided with a nozzle 2 and the membrane 3 is flexible, holding medication at 4 in the form of a liquid.
FIG. 3 shows an additional form of the device of the invention, including a front plate 1 and a large membrane 6 forming a roll bellows. The front plate is essentially larger in diameter than the bellows, the latter being bound at the edge 7 of the front plate by means of welding or glue.
FIG. 4 shows the device of FIG. 3 from left of the latter. The front plate 1 in this case (FIGS. 3, 4) includes six nozzles 8 which are arranged in a circular pattern around the central nozzle 2, the latter being incorporated in the forms of FIGS. 1, 2.
FIGS. 8 and 9 show a form of plate 9 having a plurality of mounting holes 10, in this case fifteen in number, in which the ampoules 11 are inserted and supported.
The plate 9, has on its front side (left side, FIG. 8) a film 12 which is applied to the plate by vacuum. The film covers the plate itself and the ampoules 11, and the film holds the ampoules firmly in place and closes and covers the nozzles 13.
The ampoules are removed or released from the plate, as indicated at the bottom of FIG. 8, and following that removal, the film 12 remains in place on the plate 9, as shown in FIG. 8 and does not disturb or interfere with any additional steps in the operation or use of the device. The plate 9 serves as a storage device, holding the ampoules until they are used. The ampoule is removed by means of the pistol itself (14) by applying the front end of the pistol to the ampoule, by inserting elements 23 of the pistol into the circumferential groove 5, whereby the ampoule is taken off by a light tilting motion. This removes the ampoule from the hole in the plate, and from the film, the latter remaining in place on the plate.
An important feature of the invention resides in the injection pistol which is shown in different phases or positions in FIGS. 5-7. In FIG. 5 the pistol 14 is in cocked condition. A punch 15 is slidable in a casing 18 which is also slidable, the punch in this cocked position being in a rear position to which it is moved by a driving motor 16. A spindle 17 is driven by the motor and is provided with threads, and serves to move the casing 18 rearwardly by means of cooperating threads 19. This moves the casing 18 against the compression spring 20 and moves the spring plate 22, on the punch 15, therewith, and the punch/plate compresses the spring 20 to a position in which the trigger 21 engages the spring plate 22, cocking the pistol. The ampoule 11 is held in the forward end of the pistol by means of elements 23 in the groove 5, acting as gripper or uptake elements.
Reference is now made to FIG. 6 showing the pistol still in cocked position, but with the casing 18 in a forward position. In the step of cocking the pistol as described in connection with FIG. 5, the casing 18 was moved rearwardly by the driving motor 16. After the pistol is cocked in this manner, the driving motor is reversed, through a reversing switch 24, and the driving motor, acting through the spindle 17, drives the casing 18 forwardly (to the left, FIG. 6). The casing 18 at its forward end has a predetermined shaped cavity 25 for receiving the membrane or roll bellows 6, and thereby prevents bursting of the bellows or any other part of the ampoule by the punch 15. The trigger 21 is released or pulled, shown in such released position in FIG. 6, and the spring 20 drives the punch 15 forwardly in a fast action. In this step, the punch 15 engages the membrane or bellows 6, and therethrough engages the ampoule, as shown in FIG. 7. In this action, the roll bellows 6, under the pressure of the punch 15 has been rolled in, substantially eliminating the cavity previously formed therein. The driving motor 16 is now again reversed by means of the switch 24 and it brings the punch 15 and casing 18 rearwardly to the position shown in FIG. 5, and the ampoule 11 can now be removed from the pistol and a new one taken from the storing plate 9 and utilized in the pistol.
The specific constructions and arrangements illustrated and described above are to be understood only as schematic; for example the reversing switch 24 could be a combination of end switches and automatic ejection of the used ampoule can be provided according to the invention. Thus, the examples presented are not to be considered as limiting.
In certain cases, such as for use of the device by diabetics, an advantage is produced by providing a coding arrangement. In such use of the device, it is ordinarily necessary to inject doses of different values, and convenient to provide codes indicating different values, such as 1, 2, 4, 8, 16, 24, 32, and 40 units. A number of ampoules, such as eight can be digitally numbered with notches, as shown in FIG. 11. These notches may be formed in the front plate 1 of the ampoule, as shown in FIG. 10.
By utilizing different numbers of notches, to six places or positions, it is also possible not only to provide a code for numbering, but also digitally coding the number of the units in a single ampoule. The coding shown in FIG. 10 includes a digital indication at the first position by the notch 36, and at the third position the notch 37 would indicate a unit count of one plus four, that is, five units. The small notches 38 serve as orientation aids in applying the device to the skin.
In a similar manner, coding notches, such as 36, 37, can also be applied to the rim of the plate 9 as shown in FIG. 12, in order to identify the contents of the whole package that is constituted by the plate and the ampoules.
Coding elements 39, 40, are in elevated form, in FIGS. 10 and 12, and these serve the same purpose as the notches 36, 37, 38, but being raised are in the form of traditional braille.
The device of the invention is not necessarily limited to the devices here shown, but the invention in its broad scope covers applying the features to ampoules currently in use.
The coding step can also be used to indicate color. Because of limitations to black and white in the drawings, it is pointed out that color may be utilized, for example in color coding the plate 9 to indicate ampoules according to FIGS. 1-4, or coloring the plate 9 of FIGS. 8, 9, 12, in corresponding colors.
It is also possible within the scope of the invention to provide computer-readable bar code or other common coding devices, in the device.
The device eliminates not only human error in the scoring of doses, but also simplifies the operation and increases the security against mistakes, when used by the sick. Neither the color coding nor the coding with notches or similar indicators, would entail substantial manufacturing costs. | An ampoule is provided with openings and a flexible membrane, forming a cavity, in which medication is stored in liquid form. The membrane is extended into the front end of an injection pistol which has a spring loaded punch which upon release, empties the ampoule through the openings. The ampoule has a flat front plate which covers the front end of the injection pistol. The openings of the ampoule are formed as nozzles in short truncated cones arranged in circular fashion on the front plate. | 0 |
This application claims priority to U.S. Provisional Application Nos. 61/125,515, filed Apr. 25, 2008 and 61/206,953, filed Feb. 6, 2009, the disclosures of which are hereby incorporated by reference in their entireties for all purposes.
BACKGROUND OF THE INVENTION
MicroRNA (miRNA) are tiny posttranscriptional gene regulators, ˜20 nt oligoribonucleotides, that are differentially expressed during various diseases, such as heart failure and cancer, and have been implicated in the underlying pathogenesis. Each has the potential to regulate a set of specific genes that are involved in a common cellular function. For example, an array of growth-promoting genes are targeted by miR-1, and require its downregulation at the onset of cardiac hypertrophy. Since miRNA levels are posttranscriptionally regulated, they, therefore, have the potential to elicit an immediate and specific change in translation by attaching to, or detaching from, mRNA targets. Thus, an increase or a decrease in a specific miRNA may underlie the mechanism of these diseases.
Although mammalian miRNAs are commonly known for inhibiting translation vs. inducing mRNA degradation, there is now substantial evidence to support the latter as well. Therefore, it is plausible that transient exposure of an mRNA to a targeting miRNA will inhibit its translation while chronic exposure will result in its degradation.
Antisense miRNA is a critical tool for understanding the functions of the different miRNAs. Designing an expression vector of choice enhances the spectrum of our studies in the different cell lines and tissues as well as animal models. For example, cardiac myocytes are poor candidates for transfection and uptake of the cholesterol-linked oligos, in addition, to having a non-specific response to the cholesterol itself. On the other hand, they have great affinity to adenoviral vectors. The expression vectors can also be used to create transgenic mice models as a much faster alternative means for creating a knockout of a specific miRNA.
One approach to target a specific miRNA of interest has been to develop antisense sequences and deliver them to the cells via lipid based transfection methods or by attaching a cholesterol moiety to the oligonucleotide to render it cell permeable. The latter may be delivered in vivo with some success and has the potential to be used as a therapeutic agent. But like anything else this approach has its limitations and alternatives for different applications are always necessary.
This invention relates to an alternative strategy in which the antisense sequence of an miRNA of interest was expressed through an expression vector using a specific design that would allow for successful expression of 20-40 nucleotide sequences. This expression cassette can be delivered via plasmid DNA or viral vectors for more efficient in vivo and in vitro delivery. This system allows for continuous production of the antisense sequence and subsequently complete knockdown of the targeted miRNA.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows downregulation of miR-199a is required for anoxia-induced proapoptotic genes;
FIG. 2 shows MiR-199a targets and inhibits Hif-1α;
FIG. 3 shows Knockdown of miR-199a induces upregulation of Hif-1α, iNOS, and downregulation of PHD2, mimicking hypoxia preconditioning;
FIG. 4 shows Hif-1α associates with mitochondria and is required for HPC-mediated protection;
FIG. 5 shows Sirt1 is a direct target of miR-199a, is upregulated during HPC, and is required for downregulation of PHD2; and
FIG. 6 shows MiR-199a is downregulated during IPC in porcine hearts and is associated with upregulation of Hif-1α and Sirt1.
FIG. 7 shows Mir-21 is upregulated during cardiac hypertrophy.
FIG. 8 shows Mir-21 induces cardiocyte outgrowth and down-regulation of SPRY2.
FIG. 9 shows β-Adrenergic receptors induces cellular outgrowths and down-regulation of SPRY2 in cardiocytes.
FIG. 10 shows cardiocyte outgrowths connect cells via gap junctions.
FIG. 11 shows cardiac hypertrophy is associated with connexin-43 positive side-branch connections and down-regulation of SPRY2.
FIG. 12 shows over-expression of SPRY2 or knockdown of miR-21 in colon cancer cells abrogates formation of the microvilli-like protrusions.
OBJECTS AND SUMMARY
The present invention is directed to certain miRNA and their antisense RNA that can be derivatized to a pharmaceutical acceptable form and used in the treatment of miRNA-related conditions.
In particular, the present invention is directed to the use of expressed antisense miRNA using plasmid or viral vectors.
In certain embodiments, the present invention is directed to the treatment of cardiovascular disease or heart failure using miRNA and their antisense RNA.
In other embodiments, the present invention is directed to the treatment of cancer using miRNA and their antisense RNA.
In certain embodiments, the present invention is directed to the use of miR-21 and its antisense RNA in the treatment of diseases associated with this particular miRNA.
In certain embodiments, the present invention is directed to the use of mi-R-199a and its antisense RNA in the treatment of diseases associated with this particular miRNA.
In certain embodiments, the present invention is directed to an expression vector comprising a double stranded DNA, wherein the double stranded DNA comprises DNA complements of at least two repeats of at least one sequence of antisense miRNA.
In other embodiments, the present invention is directed to a plasmid comprising the expression vectors described herein.
In yet other embodiments, the present invention is directed to a cell comprising the expression vectors described herein.
In certain embodiments, the present invention is directed to a method of inhibiting the expression of miRNA in a subject, comprising administering to the subject an expression vector comprising a double stranded DNA, wherein the double stranded DNA comprises DNA complements of at least two repeats of at least one sequence of antisense miRNA, wherein the antisense miRNA is complementary to the miRNA.
As used herein, the term “subject” includes any human or non-human animal. In some embodiments, the subject is a human. In further embodiments, the subject is a rodent or a primate.
The above and still further objects, aspects, features and attendant advantages of the present invention will be better understood from a consideration of the following detailed description of the invention as represented by certain preferred methods and embodiments thereof, taken in conjunction with the accompanying drawings.
DETAILED DESCRIPTION
Cardiac hypertrophy is characterized by a change in the gene expression pattern that recapitulates the neonatal profile. This switch is triggered by transcriptional and post-transcriptional regulators. Several labs have recently reported an array of post-transcriptional miRNA regulators that are differentially expressed and play a role in the development of cardiac hypertrophy. The underlying mechanisms involved in cardiac hypertrophy are reminiscent of those employed in cancer, overlapping in many growth promoting molecules and pathways.
One such miRNA is the post-transcriptional regulator miR-21, which is upregulated in many forms of cancer, as well as, during cardiac hypertrophic growth. Its knockdown activates caspases and induces apoptosis in glioblastoma cells and sensitizes cholangiocytes to chemotherapeutic agents, while its over-expression inhibits apoptosis in myeloma cells. miR-21 is shown to target and down-regulate the expression of the tumor suppressors tropomyosin 1, phosphatase and tensin homolog (PTEN), and programmed cell death 4 (Pdcd4) and promote cell invasion and metastasis. Moreover, anti-miR-21 inhibits tumor growth in vivo and in vitro. In human colorectal cancer the levels of miR-21 positively correlated with the development of metastasis but not tumor size. Most interestingly, out of 37 differentially expressed miRNA (26 upregulated and 11 down-regulated) in colon adenocarcinoma, upregulation of miR-21 singularly correlated with lower survival rates and poor response of patients to therapy. Thus, miR-21 is poised to be a major therapeutic target in colon carcinoma.
To understand its roll, miR-21 was over-expressed in cardiocytes where it revealed a unique type of cell-to-cell ‘linker’ in the form of long slender outgrowths/branches. miR-21 directly targets and down-regulates the expression of sprouty2 (SPRY2), an inhibitor of branching morphogenesis and neurite outgrowths. β-adrenergic receptor (βAR) stimulation induces upregulation of miR-21 and down-regulation of SPRY2 and is, likewise, associated with connecting cell branches. Knockdown of SPRY2 reproduced the branching morphology in cardiocytes, and vice versa, knockdown of miR-21 using a specific ‘miRNA eraser’ or over-expression of SPRY2 inhibited βAR-induced cellular outgrowths. These structures enclose sarcomeres and connect adjacent cardiocytes through functional gap junctions. To determine how this aspect of miR-21 function translates in cancer cells, it was knocked down in colon cancer SW480 cells. This resulted in disappearance of their microvillus-like protrusions, which was reproduced by over-expression of SPRY2. Thus, an increase in miR-21 appears to be involved in the formation various forms of cellular protrusions through directly targeting and down-regulating SPRY2.
In addition to miR-21, the present inventors have discovered that miR199a is acutely downregulated in cardiac myocytes upon a decline in oxygen tension. Early ischemia or hypoxia preconditioning (IPC or HPC) is an immediate cellular reaction to brief hypoxia/reoxygenation cycles that involves de novo protein, but not mRNA, synthesis. It was first described as a mechanism that protected the heart against subsequent prolonged ischemia- or ischemia/reperfusion (I/R)-induced damage. It is mediated, at least in part, by adenosine, which is produced upon hydrolysis of ATP, and released from the cell to stimulate a surface receptor. Central to early preconditioning effects is the protection of mitochondria against hypoxic damage, mainly through inhibiting the opening of MPTP. PKCε has been shown to interact with the MPTP proteins and inhibit mitochondrial swelling, possibly through a GSK3β-mediated effect.
Hif-1α is a well-established transcription factor that is rapidly induced by hypoxia through a posttranscriptional mechanism, in all tested cell types. It accounts for the transcription of 89% of genes that are upregulated during hypoxia. In the heart, overexpression of Hif-1α during hypoxia resulted in a smaller infarct size following ischemia/reperfusion and was associated with higher capillary density, VEGF, and iNOS, in the peri-infarct zone. This suggested that Hif-1α plays a role in late IPC. Recently, a study showed that mice heterozygous for Hif-1α fail in early preconditioning, while it was also reported that knockdown of Hif-1α abolished the effect of early ischemia preconditioning. But the mechanism of Hif-1α-mediated early preconditioning remains unexplained.
Replenishing miR199a during anoxia inhibits Hif-1α expression and its stabilization of p53, and, thus, reduces apoptosis. On the other hand, knockdown of miR-199a during normoxia results in the upregulation of Hif-1α and Sirtuin 1 (Sirt1) and reproduces hypoxia preconditioning. Sirt1 is also a direct target of miR-199a and is responsible for downregulating prolyl hydroxylase 2 (PHD2), required for stabilization of Hif-1α.
Thus, it is concluded that miR-199a is a master regulator of a hypoxia-triggered pathway and can be exploited for preconditioning cells against hypoxic damage. In addition, the data demonstrate a functional link between two key molecules that regulate hypoxia preconditioning and longevity.
Expressing the antisense sequences of miRNAs, such as miR-21 and miR-199a can therefore be a valuable tool in the treatment of related diseases. The advantage of one of the embodiments of the present invention, expressing antisense miRNA using plasmid or viral vectors, is compared to currently available technologies in the table below.
TABLE 1
Modified non-
Expressed
hydrolysable
antisense
Modified non-
antisense
microRNA using
hydrolysable
microRNA with
plasmid or viral
antisense
end-linked
vectors
microRNA
cholesterol
Cost
Cost effective large
Requires continued
Requires continued
scale amplification
costly oligo synthesis
very costly oligo
of plasmid or viral
synthesis
vectors in the lab
Cell specificity
A choice of plasmid
Limited to cells that
Cell permeability is
transfection or viral
can be efficiently
dictated by the cell
vector that will
transfected with
membrane
accommodate any
naked DNA or RNA,
composition.
cell type
which excludes
cardiac and skeletal
muscle cells.
Mode of delivery
A choice of plasmid
Transfection
The reagent is cell
transfection or viral
permeable
transduction
Bioavailability
Continuous
Although the oligo is
Although the oligo is
expression.
non-hydrolysable, it
non-hydrolysable, it
The plasmid may be
will be diluted out in
will be diluted out in
stably transfected
proliferating cell
proliferating cell
into cells or using
types
types
viral vectors that
integrate into the
genome.
Applicability
In vivo and in vitro
In vitro studies
In vivo and in vitro
studies including
studies not including
transgenic animal
transgenic models
models
Design
1. Unmodified
Modified antisense
Modified antisense
advantage
antisense that is
that may not pair as
and a bulky
continuously
efficiently with the
cholestryl moiety at
produced and ideal
target miRNA.
one end that may not
for pairing with the
pair as efficiently
target.
with the target
2. Uses a U6
miRNA
promoter with
defined start and
stop sites
EXAMPLES
Example 1
Vector Creation
Two repeats of a specific antisense microRNA sequence is synthesized as a double strand DNA with ApaI- and HindIII restriction site-compatible overhangs at the 5′ and 3′ ends respectively.
In addition, at the end of the antisense sequence 6 deoxythymidine residues are added, which is a stop signal for RNA polymerase III.
This double strand DNA is cloned downstream of a U6 RNA polymerase III-dependent promoter (Ambion) in the plasmid vector pDC311 (from Microbix). This plasmid can be used as such, or delivered to the cells via a lipid-based transfection method.
In an additional step, the plasmid was cloned it into recombinant adenovirus serotype 5 (Microbix) for efficient delivery in cardiac myocytes both in culture and in vivo.
Example 2
MiR-199a
Downregulation of MiR-199a During Anoxia is Required for Induction of Proapoptotic Genes
Results of studies regarding differentially expressed miRNA in the heart, shown in FIG. 1 wherein:
a. C57Bl/6 mice were subjected to left coronary artery occlusion for 16 h. The ischemic and remote regions of the left ventricle, and the sham-operated ventricle, were isolated and total RNA was extracted and analyzed by Northern blotting (n=3).
b. Mice were subjected to left coronary artery occlusion for 0.5, 3, and 6 h and analyzed as in (a).
c. Myocytes were infected with a control or miR199a-expressing adenoviruses before exposure to anoxia for 24 h in complete culture medium with serum (where marked by +). Protein was extracted and analyzed by Western blotting (n=3).
d. Myocytes were treated as in (c). Total RNA was extracted and analyzed by Northern blotting (n=3), revealed that mature miR199a was reduced to undetectable levels during cardiac ischemia, while its precursor continued to accumulate ( FIG. 1 a ). A time course revealed that this occurred as early as 30 minutes after ischemia ( FIG. 1 b ). To investigate its function, it was over-expressed in myocytes exposed to anoxia. Western blot analysis revealed that miR-199a resulted in complete inhibition of anoxia-induced caspase-3, -6, -9, 12, FasL, AIF, and Bnip1 ( FIG. 1 c ). While Northern blots analysis showed that miR-199a, but not miR199a* or miR-21, was completely abolished by anoxia and that the adenoviral delivered construct was able to rescue this downregulation ( FIG. 1 d ). This suggested that miR-199a downregulation is required for upregulation of hypoxia-induced apoptotic genes.
MiR-199a Targets and Inhibits Hif-1α
Results are shown in FIG. 2 wherein:
a. The alignment between mus musculus miR-199a and the 3′UTR of HIF1A, identified by TargetscanS software.
b. The miR-199a target region, or a mutant, was cloned into the 3′UTR of a luciferase gene (represented in the graph by black and white bars, respectively). These constructs were delivered to myocytes via adenovirus, in addition to exogenous miR-199a (where marked by +) or a control virus (n=6). After 24 h luciferase activity was measured, averaged, and plotted. The y-axis represents arbitrary luciferase activity normalized to μg protein content. Error bars represent standard error of the mean (SEM) and *=p<0.01, miR-199a treated luciferase-Hif-1α 3′UTR target vs. control.
c. Wild type Hif-1α cDNA or a mutant lacking miR199a target site (Hif-1 αΔ199a) were delivered to cardiac myocytes or HEK293 cells. After 24 h protein was extracted and analyzed by Western blotting (n=2).
d. Myocytes were plated on gelatin-coated glass chamber slides. They were then treated with a control or a miR-199a overexpressing virus for 24 hr before subjecting them to various periods of anoxia as indicated on the top of each panel. Parallel slides were stained separately with anti-Hif-1α (green) or anti-p53 (red) antibodies, and DAPI (blue) (n=4).
e. Myocytes were cultured as in (d.) and treated with a control or Hif-1 αΔ199a virus, in absence or presence of a control or miR-199a virus for 24 h. Cells were then exposed to anoxia for an additional 24 h where indicated, before they were fixed and co-stained with anti-Hif-1α (green), anti-p53 (red), and DAPI (blue) (n=3).
f. Myocytes were treated as in (e.). Protein was extracted and either assayed for caspase 3 activity (graph, n=6) or analyzed by Western blotting (n=3). The treatments are indicated in the grid below the graph by + signs and each aligned with its Western blot results. Results were averaged, normalized to protein content, and plotted as fold change after adjusting basal levels to 1. Error bars represent SEM, *=p<0.001 miR-199a-treated vs. untreated cells during hypoxia, **=p<0.01 miR-199a-treated plus Hif-1aΔ199a vs. miR-199a-treated.
Computational analysis predicted that Hif-1α is a miR-199a target. FIG. 2 a shows the alignment between miR-199a and a highly conserved region within the 3′UTR of mouse Hif-1α. Inclusion of the target sequence within the 3′UTR of a luciferase gene rendered it a target of miR-199a, as demonstrated by the inhibition of its activity upon overexpression of miR-199a ( FIG. 2 b ). For further confirmation, the Hif-1α cDNA was cloned with or without a deletion of its miR-199a recognition site. The deletion resulted in ˜4× higher expression of the Hif-1α protein in cardiac myocytes, but not in HEK293 cells that are devoid of endogenous miR-199a ( FIG. 2 c ). The data demonstrate that miR-199a directly targets and inhibits Hif-1α.
To determine the effect of miR-199a on endogenous Hif-1α, its stabilization of p53, and myocyte apoptosis during anoxia, the myocytes were subject to anoxia in the absence or presence of excess miR-199a. FIG. 2 d shows that Hif-1α is robustly induced within 15 h of oxygen deprivation. Initially Hif-1α is seen throughout the cell, but upon longer periods of anoxia it becomes more restricted to the nucleus and coincides with the increase in p53 after 24 h. Overexpression of miR-199a completely abolished Hif-1α and p53 during the first 24 h of anoxia, but started losing effectiveness after 48 h. The results suggest that downregulation of miR-199a during anoxia is required for upregulation of Hif-1α and stabilization of p53.
Unlike Hif-1α, p53 is not a direct target of miR-199a, but has been shown to require Hif-1α for its stabilization during hypoxia. To test this possibility in cultured myocytes, myocytes were supplemented with Hif-1α lacking the miR-199a responsive element (Hif-1αΔ199a, FIG. 2 e ). This sustained the levels of Hif-1α during anoxia after overexpression of miR-199a, and completely rescued the downregulation of p53 ( FIGS. 2 e and 2 f ). The results confirm that p53 is not a direct target of miR-199a and that it requires Hif-1α for its stability during prolonged periods of anoxia. The expression levels of p53 positively correlated with caspase 3 activity in these cells, which was dramatically reduced by miR199a, but partially rescued by Hif-1αΔ199a ( FIG. 2 f ). Therefore, the results suggest that downregulation of miR-199a is required for induction of hypoxia-induced apoptosis, at least partly, through the Hif-1αp53 pathway.
Knockdown of miR-199a Recapitulates Hypoxia Preconditioning
It was postulated whether knockdown of miR-199a during normoxia is sufficient for induction of Hif-1α as shown in FIG. 3 wherein:
a. Cardiac myocytes plated on gelatin coated glass chamber slides were treated with a control or miR-199a eraser-expressing adenovirus for 24 h, or HPC, as indicated on the left. A parallel set of myocytes were similarly treated and subsequently subjected to anoxia for 24 h, as indicated on the top. Myocytes were then fixed and co-stained with anti-Hif-1α (green), anti-p53 (red), and DAPI (blue) (n=5). The lower set of panels show myocytes exposed to anoxia for 24 h, miR-199a eraser, or hypoxia+eraser, as indicated. Cells were co-stained with a rabbit polyclonal anti-Hif-1α and anti-myosin heavy chain (MHC, red) (n=2).
b. Myocytes were treated as described in (a.) and as indicated in the grid by + signs. Protein was extracted and analyzed by Western blotting (n=3).
c. Myocytes were subjected to HPC before or after pretreatment with a control, miR-199a-, and Hif-1α short interfering RNA (Hif-1α-si)-expressing adenoviruses for 24 h, where indicated by + signs. Protein was extracted and analyzed by Western blotting for the molecules indicated on the left.
d. Myocytes were subjected to 24 h anoxia or HPC, before or after treatment with a control or miR-199a-expressing virus for 24 h where indicated by + signs. Protein was extracted and analyzed by Western blotting for the molecules indicated on the left.
e. Myocytes were subjected to 15, 20, 24, or 48 h anoxia before or after treatment with a control or miR-199a eraser for 24 h, as indicated. Protein was extracted and assayed for caspase 3 activity (n=6). Results were averaged, normalized to protein content, and plotted as fold change, after adjusting basal levels to 1. Error bars represent SEM, *=p<0.01 anoxia vs. normoxia; #=p<0.01 miR-199a eraser-pretreated plus 24 h anoxia vs. control-treated plus 24 h anoxia; **=p<0.5 miR-199a eraser-pretreated plus 48 h anoxia vs. control-treated plus 48 h anoxia.
f. Myocytes were subjected to HPC or 24 h anoxia as indicated with the + sign. Total RNA was then extracted and analyzed by Northern blotting for the miRNA indicated on the left (n=2).
g. Myocytes were stimulated with 100 μM adenosine for 16 h. Total RNA was then extracted and analyzed by Northern blotting for the miRNA indicated on the left (n=2).
h. Myocytes were treated as in (g). Protein was extracted and analyzed by Western blotting (n=2).
FIG. 3 a shows that abrogation of miR-199a with an antisense miR-199a expression vector (miR-199a eraser) resulted in the upregulation of Hif-1α. Interestingly, its distribution favored the cytosol, where it was punctate in appearance, similar to that observed during HPC, and in contrast to its predominant nuclear localization seen during anoxia. Moreover, HPC or miR-199a knockdown inhibited hypoxia-induced Hif-1α transport to the nucleus, as well as, upregulation of p53. In the lower panels it is demonstrated that miR-199a eraser-induced upregulation of Hif-1α occurs in myosin heavy chain (MHC)-positive myocytes, which proves that miR-199a is intrinsic to these cells.
Results of the immunostaining were confirmed by Western blot analysis ( FIG. 3 b ). In addition, it is shown that HPC and miR-199a knockdown, but not anoxia, were associated with robust upregulation of iNOS. Pretreatment of cells with HPC or miR-199a eraser provided cells with iNOS during anoxia and inhibited upregulation of p53. iNOS expression was dependent on downregulation of miR-199a and upregulation of Hif-1α, as it was abolished by overexpression of miR-199a during HPC or by Hif-1α knockdown ( FIG. 3 c ).
MiR-199a eraser-induced upregulation of Hif-1α during normoxia suggested that it might be associated with inhibition or downregulation of prolyl hydroxylase 2 (PHD2). Indeed, PHD2 was reduced more than 90% in eraser-treated cells and during HPC or anoxia ( FIG. 3 b ). This decrease was reversed by overexpression of miR-199a, suggesting that it requires downregulation of the miRNA under these conditions ( FIG. 3 d ). Not only did the miR-199a eraser elicit a gene expression pattern that mimicked HPC, but it also retarded the increase in caspase-3 activity induced by anoxia ( FIG. 3 e ).
The above results suggest that downregulation of miR-199a might be a mediator of HPC. As observed in FIG. 3 f , miR-199a, but not miR-21, was rendered undetectable by HPC. Moreover, adenosine, an established mediator of ischemia preconditioning (IPC), induced miR-199a downregulation ( FIG. 3 g ). This was associated with upregulation of Hif-1α that was blocked by overexpression of miR-199a ( FIG. 3 h ). This suggests that HPC or IPC require downregulation of miR199a.
Hif-1α Associates with and Protects Mitochondria During HPC
As noted earlier, during preconditioning of cells with hypoxia or miR-199a eraser, Hif-1α exhibited a punctate appearance in the cytosol. Since mitochondrial protection is central to preconditioning, it was questioned whether Hif-1α might associate with this organelle as shown in FIG. 4 wherein:
a. Cardiac myocytes were subjected to HPC, 24 h anoxia, or treated with a control or the miR-199a eraser-expressing virus for 24 h, as indicated in the grid by + signs. Cells were fractionated into cytosol, mitochondria, and nuclei and analyzed by Western blotting for the proteins indicated on the left (n=3).
b. The Hif-1α signal shown in (a.) was quantitated in all fractions, for each treatment, and the % of total was calculated and plotted (n=3).
c. Cardiac myocytes were plated on gelatin-coated glass chamber slides. Cells were treated with a control or a Hif-1α-si-expressing adenovirus for 48 h before applying miR-199a eraser or HPC. They were then exposed to anoxia for 24 h. Following that, JC-1 dye was applied and the cells imaged live (n=4).
The results revealed that Hif-1α co-purifies with mitochondria during HPC or miR-199a eraser treatment of cells, but was undetectable in that fraction after 24 h anoxia ( FIG. 4 a ). On the other hand, there was more nuclear Hif-1α during the latter condition than was observed during preconditioning ( FIG. 4 b ).
To determine whether miR-199a eraser treatment protects against hypoxia-induced mitochondrial damage and if it requires Hif-1α, mitochondrial integrity was monitored using the JC-1 dye. FIG. 4 c shows that hypoxia-induced mitochondrial damage was rescued by HPC or miR-199a eraser pretreatment. This is reflected by low levels of green florescent monomeric dye in the cytosol and higher levels of red florescent aggregates in intact healthy mitochondria and vice versa during anoxia. Knockdown of Hif-1α abrogated the mitochondrial protective effect of preconditioning. Thus, Hif-1α is required for mitochondrial protection during preconditioning, plausibly mediated through a mechanism that involves a direct interaction.
MiR-199a Targets Sirt1
Intriguingly, Sirt1, a class III histone deacetylase and a longevity gene, is another miR-199a predicted target as shown in FIG. 5 wherein:
a. The alignment between mus musculus miR-199a and a 3′UTR region of Sirt1.
b. The miR-199a target site, or a mutant, was cloned into the 3′UTR of a luciferase gene (represented in the graph by black and white bars, respectively). These constructs were delivered to myocytes via adenovirus, in addition to exogenous miR-199a (where marked by +) or a control virus (n=6). After 24 h, luciferase activity was measured, averaged, and plotted. The y-axis represents arbitrary luciferase activity normalized to μg protein content. Error bars represent standard error of the mean (SEM) and *=p<0.01, miR-199a-treated, luciferase-Sirt13′UTR target vs. control.
c. Myocytes were treated with 40 μM resveratrol (RSV) for 24 h or HPC, with or without exogenous miR-199a for an additional 24 h, or with miR-199a eraser for 24 h, where indicted by + signs (n=3). Protein was then extracted and analyzed by Western blotting.
d. Myocytes were treated with Sirt1-short interfering RNA (Sirt1-si) adenovirus for 48 h. These cells were then exposed to anoxia for 24 h or HPC, where indicated by + signs. Protein was then extracted and analyzed by Western blotting (n=3).
e. Myocytes were treated with a control or Sirt1-overexpressing virus in the absence or presence or 20 mM nicotinamide (NAM). Protein was extracted and analyzed by Western blotting (n=3).
f. Myocytes were plated on gelatin-coated glass chamber slides. Cells were treated with a control, miR-199a eraser, or a Sirt1-si-expressing adenovirus for 48 h, followed miR-199a eraser. A parallel set of similarly treated slides was then exposed to 24 h anoxia, as indicated above. Cells were then fixed and stained with anti-Hif-1α (green) and DAPI (blue) (n=3).
FIG. 5 a shows a conserved alignment between the 2 molecules. Inclusion of this target sequence within the 3′UTR of a luciferase gene rendered it a target of miR-199a, as demonstrated by the inhibition of its activity upon overexpression of miR-199a, relative to a mutant sequence ( FIG. 5 b ). In concordance, overexpression of miR-199a reduced endogenous Sirt1 by 50%, whereas its knockdown enhanced its expression 2.2× ( FIG. 5 c ). This suggested that Sirt1 should increase during HPC as a result of the reduction in miR-199a. It was found that this was indeed the case, where Sirt1 was upregulated 9× after HPC and was completely reversed by replenishing miR-199a. But unlike Hif-1α, there was no increase in Sirt1 during anoxia (see FIGS. 5 d and f ). An increase in Sirt1 by resveratrol was also inhibited by overexpression of miR-199a and was associated with upregulation of Hif-1α. The results suggest that Sirt1 plays a role during HPC but not anoxia.
Sirt1 Induced Downregulation of PHD2 is Required for Hif-1α Accumulation
To examine the role of Sirt1 during HPC a loss-of-function approach was used. Unexpectedly, knockdown of Sirt1 resulted in loss of Hif-1α ( FIG. 5 d ). This led us to speculate that Sirt1 may be regulating Hif-1α expression through regulating PHD2. Western blot analysis shows that the downregulation of PHD2 during HPC was blocked by the loss of Sirt1. On the other hand, Sirt1 did not increase during anoxia nor did its knockdown influence upregulation of Hif-1α or downregulation of PHD2. Thus, Sirt1 is necessary for ablation of PHD2, but only during HPC. To determine whether it is sufficient, wild type Sirt1 was overexpressed in myocytes. The results of this experiment show >90% knockdown of PHD2 that was reversed by 20 mM nicotinamide (NAM), which inhibits the NAD-dependent deacetylase activity of Sirt1 ( FIG. 5 e ). In addition, Sirt1 knockdown inhibited eraser-induced Hif-1α ( FIG. 50 . Conversely, anoxia-induced Hif-1α, which is predominantly nuclear, was unaffected, except when the cells were pretreated with miR-199a eraser first. Thus, Sirt1 is necessary during HPC, and sufficient, for downregulating PHD2, and the effect is dependent on its deacetylase activity.
MiR-1.99a is Downregulated During IPC in Porcine Hearts
Lastly, it was examined whether miR-199a, Hif-1α, and Sirt1 are regulated during early IPC in vivo as shown in FIG. 6 wherein:
a. Porcine hearts were preconditioned via 2×10 minute cycles of ischemia/reperfusion of the left ventricle (n=3). A second set of animals was subjected to a sham operation. The IPC area of the left ventricle, remote zone, and sham-operated ventricles, were immediately dissected (early/first window IPC) and analyzed by Northern and Western blotting. The top 2 panels are the results of a Northern blot and the lower 3 panels are Western blots.
b. Cultured adult rat cardiac myocytes were treated with miR-199a eraser for 24 h or HPC. Protein was extracted and analyzed by Western blotting for the molecules indicated on the left of each panel (n=3).
For that purpose IPC was induced in porcine hearts and analyzed the tissue by Northern and Western blots. FIG. 6 a shows that miR-199a was reduced to undetectable levels in the preconditioned area of the heart, while the remote area exhibited modest downregulation of miR-199a, relative to a sham operated heart. This was associated with upregulation of Hif-1α and Sirt1, as predicted. Moreover, when knocked down in isolated adult rat myocytes, miR-199a derepressed Hif-1α and Sirt1 expression, proving that miR-199a is intrinsic to adult myocyte ( FIG. 6 b ).
The results unveil a unique aspect of miRNA function: serving as molecular switches that trigger an immediate change in gene expression in response to a stimulus. Here it is shown that miR-199a is sensitive to low oxygen levels and is rapidly degraded and reduced to undetectable levels, thereby, releasing mRNA targets from its inhibitory effect. It was concluded that this was a posttranscriptional event, since it did not affect miR-199a*, which is expressed from the same stem-loop precursor. It is also shown that it was not a generalized effect, as there no changes observed in miR-21 or miR-1. Moreover, after longer periods of anoxia or ischemia, miR-199a precursor started to accumulate, suggesting that its transcription and primary transcript processing were unaffected by hypoxia. On the other hand, processing of the stem-loop precursor was inhibited. There is indeed accumulating evidence that miRNAs are widely regulated by posttranscriptional events. Our data further suggest that selective miRNA stability and processing of the stem-loop are subject to regulation in response to external stimuli. The question remains, though, as to what proteins are involved in the specific stabilization, or degradation, of miR-199a.
Hif-1α is the ‘master transcriptional regulator’ of hypoxia-induced gene expression. It is regulated by a posttranscriptional oxygen-sensitive mechanism that triggers its prompt expression upon a drop in oxygen levels. Prolyl hydroxylases (PHDs) hydroxylate Hif-1α during normoxia, which allows von Hippel-Lindau (VHL) to bind and ubiquitinate Hif-1α, marking it for proteasomal degradation. This process is inactivated during hypoxia, thus, permitting rapid accumulation of Hif-1α. Our results introduce miR-199a as an obligatory regulator of this process. It is shown that miR-199a directly targets and inhibits translation of Hif-1α mRNA during normoxia. This not only ensures suppression of Hif-1α during normoxia, but also circumvents the need for perpetual energy consumption required for its proteosomal degradation. Conversely, downregulation of miR-199a is required for upregulation of Hif-1α during hypoxia or HPC. But when miR-199a were knocked down during normoxia, it was not expected that it would be sufficient for inducing Hif-1α expression, since this would also require inhibition of PHD2. Surprisingly, a robust increase in its protein was observed, which indicated that miR-199a effects were mediated through a broader range of targets.
PHD2 is the primary prolyl hydroxylase family member that hydroxylates Hif-1α during normoxia. PHDs in general require O2, 2-oxoglutarate, and ascorbic acid for their full catalytic activity, and, thus, the availability of these factors regulates their function. On the other hand, the regulation of PHD2 protein availability during hypoxia has not been reported. In cardiac myocytes the level of PHD2 during hypoxia remains unexamined. Our results show that HPC or anoxia induces downregulation of PHD2 in cardiac myocytes, which is dependent on the reduction in miR-199a levels. Unexpectedly, it was discovered that Sirt1 is a direct target of miR-199a and mediates downregulation of PHD2 during HPC, through a NAD-dependent deacetylase function. Although there are no prior reports on its involvement in hypoxia or HPC, its activator, resveratrol, was reported to mediate preconditioning of the heart, brain and kidney, against hypoxic damage.
Hif-1α and its targets are generally considered mediators of late preconditioning versus early preconditioning in the heart. This idea was supported by earlier findings that showed that de novo protein synthesis was not required for IPC. These results have since been challenged by other studies that demonstrated an opposite outcome. In concordance, Cai et al recently showed that mice heterozygous for Hif-1α fail to exhibit early preconditioning, while Eckle et al reported that knockdown of Hif-1α abolished the effect of early ischemia preconditioning. But the mechanism for Hif-1α-mediated early preconditioning remains obscure. Since early preconditioning occurs immediately after brief episodes of hypoxia/reoxygenation, it is unlikely that it involves transcriptional events. Indeed, Rowland et al showed that de novo mRNA synthesis is not required for IPC. Interestingly, immunostaining of the myocytes for Hif-1α revealed its preferentially localization to the cytosol in a punctate appearance, but only during HPC or miR-199a eraser treatment. It was thus predicted, and, later, confirmed that it associates with mitochondria under these conditions. Although it is unclear what its role there may be, it is known now that it is required for HPC-mediated mitochondrial protection ( FIG. 4 b ).
Example 3
Mi-R-21
Materials and Methods
Cell cultures and adenovirus Infection—Neonatal cardiac myocytes were prepared from Sprague Dawley rat hearts as previously described, using both pre-plating and percoll gradients for enriching of myocytes. Adult cardiac myocytes were prepared as previously described.
All exogenous recombinant DNA were delivered to the myocytes via recombinant adenoviruses using 10-20 multiplicity of infection.
Construction of adenoviruses—Recombinant adenoviruses were constructed, propagated and titered. The viruses were purified on a cesium chloride gradient followed by dialysis against 20 mM Tris buffered saline with 2% glycerol.
DNA Constructs cloned into recombinant Adenovirus—The stem-loop precursor of mmu-miR-199a-1 was synthesized and cloned into pDC316 vector under the control of a CMV promoter. For a negative control, a nonsense sequence was used in place of miR-199a, as previously described. The miR-199a-eraser is a tandem repeat of the anti-sense of mature miR-199a sequence, cloned into adenovirus vector under the regulation of a U6 promoter. Human Hif-1α (NM — 001530.2) cDNA was purchased from Origene and cloned into the adenovirus vector. A mutant (Hif1αΔ199a) was constructed by excising nt 2761-2921 that encompass the miR-199a target sequence. Hairpin-forming oligonucleotides encompassing nt 2465-2485 of rat HIF1A (NM — 024359) or nt 2211-2231 of mouse Sirt1 (NM — 019812.1), were synthesized and cloned into adenoviruses.
Northern blotting—As previously described.
Cellular fractionation and Western blotting—Mitochondria was isolated using ProteoExtract Cytosol/Mitochondria Fractionation Kit (Calbiochem, NJ), according to the manufacturer's protocol. Fifteen μg of protein was separated on a 4% to 20% gradient SDS-PAGE (Criterion gels, Bio-Rad, CA) and transferred onto TransBlot Transfer membrane (Bio-Rad, CA).
The Antibodies used include: anti-Procaspase 12, anti-Caspase 9, anti-Caspase 6, and anti-GAPDH (Chemicon, MA); anti-cleaved Caspase 3 (Cell Signaling Technologies, MA), anti-BNip1 (B. D. Biosciences, CA), anti-Hif-1alpha (Novus Biologicals, CO), anti-p53 (Genscript, NJ), anti-H2B (Upstate biotechnology, MA), anti-actin (Santa Cruz), anti-cytochrome c (Santa Cruz Biotechnologies, CA), anti-iNOS (Ana Spec, CA), anti-Sir-2a (Upstate biotechnology, MA), anti-pHD2 (Novus Biologicals, CO), and anti-myosin-heavy chain (MHC) (Hybridoma Bank, University of Iowa, 10).
Hypoxia and Hypoxia Preconditioning (HPC)—Cultured myocytes were subjected to anoxia in a hypoxic chamber (Billups-Rothenberg Inc., CA). The chamber was filled with gas mixture of 95% N and 4.8%±0.2% CO2 (Inhalation Therapy, NJ) at 7 psi/12,000 kPa filling pressure for 15 minutes. The chamber was then placed in a 370 C incubator. For hypoxia preconditioning, cultured myocytes were subjected to anoxia/reoxygenation for 4×1 hour cycles.
Luciferase assay—A concatamer of miR-199a-predicted target sequence within the HIF1A 3′-UTR (GTTGGTTATTTTTGGACACTGGT(SEQ ID NO: 1))×3, the SIRT1 3′-UTR (GGACAGTTAACTTTTTAAACACTGG(SEQ ID NO: 2))×3, or a mutant sequence lacking any complementarity with miR-199a seed sequence, as previously described, were cloned in the 3′UTR of the luciferase gene driven by CMV promoter, generating Luc.Hif13′UTR, Luc.Skt13′UTR, and Luc.control vectors, respectively. Myocytes were transfected with these constructs, using Lipofectamine (Invitrogen, CA), in the presence or absence of virally-delivered miR-199a. After 24 h luciferase activity was assayed using an Lmax multiwell luminometer.
Caspase assay—Caspase-3 activity was measured using ApoTarget Caspase-3 Protease Assay (Biosource, Invitrogen, CA), as recommended by the manufacturer. The activity was normalized to total protein content.
Immunocytochemistry—As previously described 31. The Antibodies used include: anti-Hif-1alpha (Novus Biologicals, CO), anti-p53 (Genscript, NJ), and anti-myosin-heavy chain (MHC) (Hybridoma Bank, University of Iowa, 10).
Monitoring mitochondrial membrane potential—Mitochondrial Membrane potential was monitored using JC-1 cationic dye (Molecular Probes, Invitrogen, CA) as recommended by the manufacturer. Briefly, the cells were incubated with JC-1 (0.35 ug/ml) for 20 mins at 370 C. The cells were then washed with 1×PBS and imaged live.
Cardiac ischemia in C57Bl/6 mice—Through a left 3rd intercostal thoracotomy the pericardial sac is opened and an 8-0 nylon suture is passed under the left anterior descending coronary artery 2-3 mm from the tip of the left auricle. Then a nontraumatic silicone tubing is placed on top of the vessel and a knot tied on top of the tubing to occlude the coronary artery and to induce a permanent occlusion.
Early ischemia preconditioning (IPC) of porcine hearts (first window)—IPC was induced by 2 cycles of 10 min coronary artery occlusion followed by 10 min of reperfusion.
Statistical Analysis—Calculation of significance between 2 groups was performed using an unpaired, two-tailed, t-test.
Results
MiR-21 is Upregulated During Cardiac Hypertrophy and Through Stimulation of the β-Adrenergic Receptor
An array of microRNAs including miR-21 that was upregulated during cardiac hypertrophy was previously reported. MiR-21 increases by 4±1.5 and 8.3±0.6 fold, at 7 and 14 day, respectively, post-induction of hypertrophy using transverse aortic constriction (TAC) versus a sham operation in a mouse model ( FIG. 7 a ). This was associated with 27±6% and 35±5% increase in heart/body weight, respectively, and an increase in skeletal actin, which is a marker of hypertrophy ( FIG. 7 a ). The increase in miR-21 was sustained through 18 days post-TAC but started declining thereafter, concurrent with the onset of cardiac dysfunction (supplementary FIG. 7 s ). The levels of miR-21 in other genetic mouse models of cardiomyopathies were also assessed, the results of which revealed its upregulation in transgenic mice over-expressing β2-adrenergic receptor (β2AR) in the heart prior to development of any phenotype ( FIG. 7 b ). βAR receptor stimulation plays a role in the development of cardiac hypertrophy, where studies have shown that infusion of its agonist, isoproterenol, increases cardiac contractility and hypertrophy in rodent models. It was confirmed that isoproterenol induces upregulation of miR-21 in isolated rat cardiocytes to almost the same extent as seen in the transgenic hearts ( FIG. 7 c - d ). This suggests that the βAR receptors are upstream regulators of miR-21. MiR-21, which is ubiquitously expressed in adult human and mouse tissue, is relatively low in the normal adult heart, consistent with the sham-operated hearts seen in FIG. 7 ( FIG. 7 e ). It is developmentally regulated, which in contrast to the muscle specific miR-1 is higher in the neonatal heart, which is known to grow though a process of cardiocyte hypertrophy ( FIG. 7 f ). Thus, an increase in miR-21 accompanies hypertrophic growth, with the βAR receptor being one of its upstream regulators.
MiR-21 Targets sprouty2 and Induces Cellular Outgrowths
In order to address the role of miR-21 in cardiocytes a 320 nt sequence that encompasses the miR-21 stem-loop was cloned into a recombinant adenovirus ( FIG. 8 a ). A tandem repeat of the anti-sense sequence of mature miR-21 was also cloned under the control of the U6 promoter ( FIG. 8 a ). Northern blots analysis of cardiocytes treated with the former vector exhibit ˜3 fold higher mature miR-21 versus control, although the premature construct accumulated at much higher levels, reflecting a rate limiting step in the processing of miR-21 ( FIG. 8 b ). On the other hand, the anti-sense miR-21 was highly expressed and resulted in knockdown of endogenous miR-21, but not miR-1, to the extent that it was undetectable by Northern blotting ( FIG. 8 b ). For that reason this construct was dubbed ‘miR-21 eraser’.
Over-expressing miR-21 in cardiocytes did not influence hypertrophic growth in the absence or presence of growth factors as monitored by [3H]leucine incorporation (data not shown). But after 48-72 h in culture extensive cellular outgrowths (4±3 branches/cell) were noticed that varied in length (44±28 μm) depending on the distance between neighboring cells ( FIG. 8 c ). Sprouty, a known inhibitor of branching morphogenesis and neurite outgrowth, is predicted to be a miR-21 target by TargetScanS and PicTar miRNA target prediction software, each using a unique set of algorithms. To confirm its potential in mediating miR-21's branching effects, it was independently knocked down using adenoviral delivered short-hairpin RNA (see FIG. 8 e ). This elicited even more impressive cardiocyte outgrowths, which suggested that miR-21's effect might be mediated through this putative target ( FIG. 8 c ).
Using Western blot analysis down-regulation of endogenous SPRY2 (52±4%) was confirmed upon over-expression of miR-21 for 48 hr ( FIG. 8 d ). Since sprouty negatively regulates erk1/2, phospho-erk1/2 was used as a marker for monitoring changes in Spry2 function that would be regulated by changes in its levels. The results of this show that down-regulation of SPRY2 by miR-21 or shRNA (67±9%) is accompanied by an increase in basal phosph-erk1/2 by 5±1.5 and 1.5±0.15 fold, respectively. In contrast, over-expression of SPRY2, or knockdown of miR21 using the miR-21 eraser, resulted in partial inhibition of fetal bovine serum-induced phosphoerk1/2 ( FIG. 8 f - g ). Thus, SPRY2 is a downstream target of miR-21 (could be a direct or indirect target at this juncture) and has limiting cellular concentrations.
To determine if SPRY2 is a direct target of miR-21, the miR-21 predicted target sequence that is contained within its 3′UTR was cloned, downstream of a luciferase gene (Luc.SPRY2, FIG. 8 h ). This sequence conferred miR-21-induced inhibition of the luciferase activity by 76±4% ( FIG. 8 h ). For confirming specificity, a mutated miR-21 SPRY2 target sequence was cloned, in which the seed-binding sequence was completely altered (Luc.mtSPRY2), downstream of the luciferase gene. As seen in FIG. 8 h , not only did this abolish the effect of exogenous miR-21 on the reporter, but it also relieved it from inhibition by the endogenous miR-21. Thus, it was concluded that SPRY2 is a direct target of miR-21.
β-Adrenergic Receptor Stimulation Induces Down-Regulation of SPRY2, which is Accompanied by Cell-to-Cell Connecting Cellular Outgrowths
The physiological relevance of these miR-21-induced outgrowths were assessed. After treatment of the cells with isoproterenol and staining them with an antibody against the sarcomeric protein titin, cellular outgrowth that were connecting or reaching out to adjacent cells was observed ( FIG. 9 a ). The striated pattern of titin staining reflects the presence of sarcomeres even within these branches. This effect was wide spread in all observed fields (4±3 branches/cell). Impressively, these outgrowths were abrogated by the miR-21 eraser or over-expression of SPRY2 ( FIG. 9 a ). Co-immunostaining the cells with anti-SPRY2 reveals that SPRY2 is depressed in the presence of isoproterenol but restored in the presence of the miR-21 eraser or exogenous SPRY2. Similar results were obtained when cells were treated the a virus over-expressing β2AR (supplementary FIG. 9 s ). While FIG. 7 confirms that isoproterenol and β2AR induce upregulation of miR-21, FIG. 9 b confirms that they also induce 70±22% downregulation of SPRY2 protein ( FIG. 9 b ). Thus, cell-cell connecting cardiocyte outgrowths are a morphological change that accompanies βAR stimulation and is mediated by miR-21 through down-regulation of SPRY2.
Cellular Outgrowths Connect to Cardiocytes Via Gap Junctions
To verify the type of cell-cell connections conferred by these outgrowths Ad.miR-21- or isoproterenol-treated cardiocytes was immustained with anti-connexin43 (Cx43) and anti-βcatenin for detection of gap or adherens/tight junctions, respectively. Isoproterenol induced redistribution of Cx43 and βcatenin where they became distinctly localized at the points of contact with cell outgrowths ( FIG. 10 a ). It appears that Cx43 alone is more prevalent at points of contact (white arrowheads), where βcatenin was occasionally found to co-exist (yellow arrowheads). On the other hand, while miR-21 induced outgrowths, minimal Cx43 or βcatenin could be seen at the contact sites, leading to the conclusion that additional factors induced by isoproterenol are required for Cx43 redistribution.
To test the functionality of these gap junction connections, two groups of cardiocytes, one loaded with cytosolic calcein AM (green) and the other labeled with the membrane dye Vybrant DiI (red) were co-plated. This approach enables us to distinguish any cells that might acquire calcein AM de novo from the originally loaded cells. While the untreated cells show 2 distinct single color populations of cells, after treatment with isoproterenol Vybrant DiI labeled cells (red arrowheads) were identified that have acquired the green dye from an adjacent calcein-only positive cell (white arrowheads), where the transferring dye could also be seen in the connecting branch ( FIG. 10 b ). Thus, interconnecting cardiocyte branches serve the purpose of conduction of molecules between cells.
Since the experiments described above were performed in neonatal cultured cardiocytes, which are generally more plastic, it was postulated how these outgrowths might develop in the morphologically uniform rod-shaped adult cardiocytes in vivo. For this purpose hypertrophied hearts from the TAC mouse model were sectioned and immunostained them with anti-Cx43. Compared to normal hearts, these showed connecting, short, lateral outgrowths between adjacent cardiocytes, where Cx43, which is normally strictly localized to the intercalated discs, demarcated the sites of contact ( FIG. 11 a ). The figure shows three different depictions of these connections. To determine if miR-21 mediates this effect, normal adult cardiocytes that were treated with the miR-21-expressing adenovirus were isolated for 72 h. After immunostaining with antiCx43, Cx43-demarcated lateral protrusions ( FIG. 11 b , arrowheads) were observed. The levels of SPRY2 in the hypertrophied heart were also determined. The change in SPRY2 protein was only detected in the slower migrating form, both in the membrane and nuclear fractions, but was not associated with an increase in phosph-erk1/2 ( FIG. 11 c ). Thus, the upregulation of miR-21 in the adult cardiocytes evokes a rudimentary form of the cellular outgrowths of that observed in the neonatal cardiocytes.
Mir-21 Mediates the Formation of Microvillus-Like Protrusion in Colon Cancer Cells
MiR-21 is over-expressed in many cancer forms. To determine how miR-21's effects seen in cardiocytes translate in cancer cells, it was over-expressed, SPRY2, or miR-21 eraser, in the colon cancer cells SW480. Over-expression of miR-21 results in minimal increase over the already very high endogenous levels, while miR-21 eraser results in ˜70% reduction in endogenous miR-21 ( FIG. 12 a ). Staining the cells with actin-binding phalloidin reveal microvillus-like protrusion that are enriched throughout the surface of the cell ( FIG. 12 b ). Although further loading of these cells with exogenous miR-21 results in no obvious change in cell morphology, SPRY2 and miR-21 eraser resulted in abrogation of the microvilli-like structures. Coimmunostaining the cells with anti-SPRY2 show more intense staining of SPRY2 in miR-21 eraser or SPRY2 over-expressing cells, as expected. The results suggest miR-21 and SPRY2 play a role in the formation of microvilli-like protrusions in colon cancer cells. This supports the role of miR-21 in cell metastasis.
Discussion
MiR-21, its Association with Cell Growth and its Upstream Regulators
Mir-21 has attracted more attention than any other miRNA, as it is one of the most highly upregulated in various cancers, cardiac hypertrophy, and neointimal formation, suggesting that it has a fundamental role in cell growth. In agreement, its level is fairly higher in the neonatal vs. adult heart, where it is upregulated upon induction of hypertrophic growth. On the other hand, its level starts declining with the onset of cardiac failure, ultimately dropping to basal levels. This also coincides with down-regulation and desensitization of the βARs. Moreover, β2AR-over-expressing mice exhibit upregulation of miR-21 in the heart, while isoproterenol stimulation of cultured cardiocytes induces upregulation of miR-21, downregulation of SPRY2 and enhanced myocyte branching. Collectively, these data suggest that βARs are upstream regulators of miR-21 in the heart. Interestingly, it was recently reported that stress mediated through βAR stimulation enhances ovarian cancer cell invasiveness. Thus, it is also plausible that βAR also plays a role in enhancing miR-21 in cancer cells, where it may induce upregulation of miR-21, down-regulation of SPRY2, and increase microvilli and, thereby, cell migration.
Evidence Supporting a Role for βAR in Inducing Cardiocyte Connectivity and its Association with Cardiac Hypertrophy
In support of a role for βAR stimulation in cell-cell connections and conduction, it was recently reported to increase the expression of connexin43 and conduction velocity in cultured neonatal cardiocytes. Conduction velocity, which is partly regulated by the abundance of gap junctions, is increased during early hypertrophy but decreased during later decompensation stages, which coincides with the decline in βARs and connexin43. Similarly, stretch and cAMP, induce upregulation of connexin43 and gap junction density in parallel with an increase in conduction velocity in cultured cardiocytes. These data reconcile well with our results in FIG. 3 a showing extensive interconnecting cellular branches induced by isoproterenol treatment of isolated cardiocytes.
Cardiocytes adjacent to infarct zones or those subjected to aortic banding-induced hypertrophy or pulmonary hypertension-induced hypertrophy, exhibit extensive remodeling of gap junctions. This remodeling is in the form of punctate distribution of connexin43 throughout the perimeter of the cell, which is normally confined to its end intercalate discs. This is similar to its diffuse distribution in neonatal heart cardiocytes. Interestingly, a similar pattern of connexin43 labeling after TAC and in isolated adult cardiocytes over-expressing miR21 was observed ( FIG. 11 b ). It is proposed that the lateralization of connexin43 demarcate sites of cell-to-cell connecting branches, which are induced by upregulation of miR-21 and down-regulation of its target SPRY2. Similarly, in normal human hearts connexin43 is predominantly (91.7%) restricted to the intercalated discs. During early stages of cardiac hypertrophy connexin43 is increased by 44.3%, but only 60.3% is localized to intercalated discs while more of the protein appears on the lateral sarcolemma. But during later stages of hypertrophy and decompensation, connexin43 levels are reduced and the lateral distribution disappears. This distribution and expression profile of connexin43 agrees with a scenario in which increased miR-21 during compensatory hypertrophy is associated with increased Cx43positive, cell-cell connecting side branches, which is reversed during failure commensurate with the decline of miR-21.
The Role of SPRY in Branching and Cancer
Sprouty was first discovered as an inhibitor of FGF signaling and branching of Drosophila airways. This effect is conserved as shown by knockdown of SPRY2 in mouse lungs. Sprouty inhibits MAPK activation by fibroblast growth factor (FGF) and endothelial growth factor (EGF). Inhibition of branching is not restricted to the lungs, but SPRY2 also inhibits ureteric, as well as, chorionic vellous branching and reduces trophoblast cell migration. Although the branches referred to here are tubular multicellular structures that underlie organogenesis, they are initiated by single cell sprouting. But most relevant to this study, is inhibition of neurite outgrowths by SPRY2.
A previous report shows that spouty1 was upregulated after unloading of a human heart, which agrees with the finding of the present invention that SPRY2 is down-regulated during hypertrophy. SPRY was also found in vascular endothelial cells and has been shown to inhibit vasculargenesis. Likewise, sprouty4 inhibits FGF and vascular endothelial growth factor (VEGF)-induced endothelial cell migration and proliferation, while SPRY2 inhibits migration and proliferation of smooth muscle cells. This reconciles well with the observed upregulation of miR-21 during neointimal formation, which has been shown to enhance smooth muscle proliferation, and our discovery of SPRY2 being one of its targets.
Sprouty is down-regulated in prostrate cancer, breast cancer, hepatocellular carcinoma, and non-small cell lung cancer. While independently, it was shown that these forms of cancer are also associated with upregulation of miR-21. Like down-regulation of SPRY2, upregulation of miR-21 enhances cell proliferation and migration. This also agrees with a pathway in which upregulated miR-21 targets and down-regulates SPRY2, thereby, enhancing proliferation and migration. But in addition, it has been shown that miR-21 can contribute to carcinogenesis through inhibition of apoptosis, or downregulation of other tumor suppressors, such as phosphatase and tensin homolog deleted on chromosome 10 (PTEN) and tropomyosin 1 (TPM1). The results of the present invention suggest that miR-21 through down-regulating SPRY2 may enhance metastasis through promoting the formation of microvilli.
The ‘Eraser’ is a Powerful Tool for Specific Knockdown of Endogenous miRNA
Inhibition or knockdown of a specific miRNA is key in understanding its function. For that purpose several approaches have been devised. Those include the 2′-O-methyl or LNA-modified oligoribonucleotides, and ‘antagomirs’, which have a phosphorothioate backbone, a cholesterol-moiety at 3′-end, and 2′-O-methyl modifications. In contrast to these transiently delivered oligonucleotides, it was recently reported the delivery of anti-sense miRNA sequence using expression vectors termed ‘sponges’. The ‘miRNA eraser’ is similar in concept to the latter, but differs in the mechanism of inhibition of the miRNA. While the sponges induce a modest variable decrease of the endogenous miRNA the ‘eraser’ wipes it out. The loss of the miRNA signal on the Northern blots cannot be explained by competition of the complementary eraser RNA with the labeled miRNA probe used for the detection, since Northern blots are normally performed under extreme denaturing conditions. While it reduced endogenous miR-21 to undetectable levels in cardiocytes, it appeared less effective in cancer cells only because it was diluted out by the rapidly proliferating cultures. The eraser differs from the sponge in 2 physical aspects; one, the lack of stem-loop sequences at the 5′ and 3′ ends of tandem repeat sequence and, two, its delivery via a viral vector. Other plausible reasons for the difference in the outcome are the nature of the cell types or the targeted microRNA tested in both studies.
CONCLUSION
In conclusion, miR-21 plays a role in inducing the formation of cellular outgrowths that connect cardiocytes through gap junctions, which are usually confined to the intercalated discs in the normal adult heart. This change is provoked by βAR stimulation and mediated through down-regulation of SPRY2, an established negative regulator branching morphogenesis. It is proposed that this is an adaptive effect seen during cardiac hypertrophic growth and is associated with gap junction remodeling and enhanced conduction velocity but is reversed during cardiac failure. On the other hand, miR-21 promotes microvilli formation in colon cancer cells, which would potentially enhance extravasation and metastasis. It is also postulated that βAR stimulation may also induce upregulation of miR-21 and microvilli in cancer cells. | The present invention relates to an alternative strategy for expressing the antisense sequence of a miRNA. This system allows for continuous production of the antisense sequence and subsequently complete knockdown of the targeted miRNA. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a backpack structure having a lifesaving function, more particularly to a novel backpack structure having a lifesaving function by which users can not only cross rivers safely so as to increase survival possibility in the field, but also personnel goods can be carried or emergency relief can be conducted on water. Therefore, the present invention can increase the practical effect and characteristics of the backpack structure.
2. Brief Description of Prior Art
Ordinary folk hiking in suburbs or military personnel conducting wilderness survival training in mountain area often carry backpacks. As a backpack has a plurality of accommodation spaces for receiving various goods and it can be carried on the back of user, not only can a user's both hands be freed up to swing freely so as to make the user feel less fatigued while hiking, but also having empty hands make it easy to grab another object, so as to facilitate walking safely on steep and rugged terrain. It is this reason that has made a backpack become popular and its popularity is widespread.
Although the above described backpack can achieve the above expected effects, it is, however, found in its practical implementation that the conventional backpack only has the simple function of carrying various goods for users. Thus, it appears to be a monotonic product with respect to diversification of society nowadays in pursuit of innovation and change. Additionally, these conventional backpacks are incapable of floating on water, such that the backpack will sink when immersed in water when users are wading or crossing a river. This will result in a great inconvenience in usage; therefore the design of the overall structure still has room for improvement.
In view of the above disadvantages, the inventor of the present invention hereby proposes a novel backpack structure having a lifesaving function according to state-of-art research and improvements on the conventional structure and based on his abundant experience of R&D and manufacturing in relevant field and skillful contemplation in many ways.
SUMMARY OF INVENTION
This invention relates to a backpack having a lifesaving function which is made of material capable of floating on water. Connection straps are provided on the end surfaces of the backpack, which can be buckled with connection straps of the other backpack and which can be buckled with connection straps of a water bag filled with air inside. Configuring the backpack like this, not only can users cross rivers safely by means of the backpack structure, so as to increase the possibility of survival in the field, but also users can carry personnel, goods or conduct emergency relief on water. Therefore, the invention's implementation can increase the practical effect and characteristics of a backpack.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective exploded view showing the backpack embodying the present invention.
FIG. 2 is a perspective view showing the backpack of the present invention.
FIG. 3 is a perspective view showing another embodiment of the backpack of the present invention.
FIG. 4 is a schematic view showing the combination state of another embodiment of the backpack of the present invention.
FIG. 5 is a perspective view showing still another embodiment of the backpack of the present invention.
FIG. 6 is a schematic view showing the combination state of another embodiment of the backpack of the present invention.
FIG. 7 is a schematic exploded view showing the combination state of usage of the backpacks of the present invention.
FIG. 8 is a schematic exploded view showing the combination state of usage of the backpacks of the present invention.
FIG. 9 is another schematic view showing the state of usage of the backpacks of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The objects, the technical content and the expected effectiveness of the present invention will become more apparent from the detailed description of the preferred embodiments in conjunction with the accompanying drawings.
Firstly, referring to FIG. 1 , the backpack having a lifesaving function of the present invention comprises a backpack ( 1 ), water bags ( 2 ) and a sub-backpack ( 3 ).
As shown in FIGS. 1 and 2 , the backpack ( 1 ) is made of materials capable of floating on water, such as plastic materials, EVA etc. The backpack ( 1 ) has many accommodation spaces for receiving various goods, and two shoulder straps ( 11 ) are provided on the inner end face thereof. Chest straps ( 12 ), capable of buckling together, are connected between the two shoulder straps ( 11 ) and waist straps ( 13 ), also capable of buckling together, are provided at the lower edges on both sides of the inner end faces thereof. When a user carries the backpack ( 1 ) on his back by the shoulder straps ( 11 ), he can allow the backpack ( 1 ) to be carried more stably on his back by simultaneously buckling the chest straps ( 12 ) at his chest and the waist straps ( 13 ) at his waist. In addition, connection straps ( 14 ) are also provided on upper, lower, left and right end surfaces of the backpack ( 1 ), which can be buckled with connection straps ( 14 ) of another backpack ( 1 ).
The water bags ( 2 ) are received in the interior of the backpack ( 1 ). A closed space for filling with either water or air can be formed in each water bag ( 2 ). Further, connection straps ( 21 ) corresponding to the connection straps ( 14 ) of the backpack ( 1 ) are respectively provided on both sides of each water bag ( 2 ) in such a manner that the connection straps ( 14 ) on both sides of the backpack ( 1 ) can be buckled with connection straps ( 21 ) of two corresponding water bags ( 2 ).
The sub-backpack ( 3 ) is similarly provided with several accommodation spaces for receiving various goods. Connection straps ( 31 ) corresponding to the connection straps ( 14 ) of the backpack ( 1 ) are also provided on the sub-backpack ( 3 ) so that the sub-backpack ( 3 ) can be combined with the backpack ( 1 ) by the buckling of the connection straps ( 31 ) with the corresponding connection straps ( 14 ) of the backpack ( 1 ). Hence, the loading capacity of goods carried by users can thereby be increased.
The connection straps ( 14 ) of the backpack ( 1 ) have a male buckle ( 141 ) on one side and a matching female buckle ( 142 ) on the other side. Two backpacks ( 1 ) can be combined together by the buckling of the male buckle ( 141 ) and the corresponding female buckle ( 142 ). Further referring to FIG. 3 , the connection straps ( 14 ) of the backpack ( 1 ) have a strap ( 143 ) one side and a cooperating buckle ( 144 ) on the other side so that two backpacks ( 1 ) can be combined together by penetrating the strap ( 143 ) inside the cooperating buckle ( 144 ) so as to be fastened in a manner as shown in FIG. 4 . FIG. 5 is a perspective view showing still another embodiment of a backpack of the present invention. As shown in the figure, the connection straps ( 14 ) of the backpack ( 1 ) have a strap ( 143 ) on one side and a cooperating pair of D rings ( 145 ) on the other side so that two backpacks ( 1 ) can be combined together by penetrating the strap ( 143 ) inside the pair of D rings ( 145 ) to be fastened in a manner as shown in FIG. 6 .
Configuring a plurality of backpacks as shown in FIGS. 7 and 8 , wherein the plurality of backpacks ( 1 ) are laid down in matrix arrangement. Each backpack ( 1 ) can be combined with neighboring backpacks ( 1 ) by the buckling of its upper, lower, left and right connection straps ( 14 ) with that of the neighboring backpacks ( 1 ) so that the backpacks ( 1 ) are formed into a planar matrix configuration. In addition, as the backpacks ( 1 ) are made of materials capable of floating on water, such as plastic material, EVA etc., the backpacks ( 1 ) formed into the matrix configuration will float on water, when immersed in water. Hence, it can be used to carry personnel or goods for crossing a river or for emergency relief on water.
Alternatively, the water contained in each water bag disposed inside the backpack ( 1 ) can be poured out after the water bag ( 2 ) is taken out from the backpack ( 1 ), and then the water bag ( 2 ) filled with air. In turn, the backpack ( 1 ) is then combined with the two air filled water bags ( 2 ) on both sides thereof by the buckling of its connection straps ( 14 ) with the connection straps ( 21 ) of the water bags ( 2 ). When a user carries the backpack ( 1 ) on his back by the shoulder straps ( 11 ), he can allow the backpack ( 1 ) to be carried more stably on his back by simultaneously buckling the chest straps ( 12 ) at his chest and the waist straps ( 13 ) at his waist. When crossing a river, not only does the material of the backpack ( 1 ) itself provide buoyancy, but the air filled in the water bags ( 2 ) that are connected at both sides of the backpack ( 1 ) further contribute to the buoyancy of the backpack ( 1 ). Thus, this arrangement can facilitate a user's ability to cross a river.
Referring to FIG. 9 , a plurality of the backpacks ( 1 ) of the present invention can be aligned in matrix arrangement to match the width of a river. Then, the backpacks ( 1 ) can be combined together by the buckling of their upper, lower, left and right connection straps ( 14 ) with that of the neighboring backpacks ( 1 ) so that the backpacks ( 1 ) are formed into a planar matrix configuration. Further, the connection straps ( 14 ) of the outermost backpacks ( 1 ) at both ends are tied up with rods ( 4 ) spanning between both sides of the river. As the backpacks ( 1 ) are made of materials capable of floating on water, the backpacks ( 1 ), formed into a planar matrix, spanning over the river can float on the water to serve as a bridge. When the backpacks ( 1 ) spanning over the river are used as a bridge, ropes or other rods can be provided above the rods ( 4 ), spanning between both sides of river, to serve as armrests ( 5 ), so as to enhance convenience and safety in crossing the river.
Aforementioned embodiments and drawings are not to restrict the product structure or implementation modes. Appropriate variations and modifications done by those people having general knowledge in the art without departing from the scope and features of the present invention are considered to be still within the scope of the present invention. | A backpack structure having a lifesaving function is made of material capable of floating on water. Connection straps are provided on each end surface of the backpack, which can be buckled with connection straps of another backpack and which can be buckled with connection straps of a water bag filled with air inside. The backpack structure enables users to cross rivers more safely, so as to increase survival possibility in the field, and also to carry personnel, goods or conduct emergency relief on water. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a process for producing wood composite material by combining wood particles with a mixed polymethylene poly(phenylisocyanate)/solid novolac phenolic resin binder composition, followed by molding or compressing the combined wood particles and the binder composition.
Composite materials such as oriented stand board, particle board and flake board are generally produced by blending or spraying lignocellulose materials such as wood flakes, wood fibers, wood particles, wood wafers, strips or strands, pieces of wood or other comminuted lignocellulose materials with a binder composition while the materials are tumbled or agitated in a blender or like apparatus. After blending sufficiently to form a uniform mixture, the materials are formed into a loose mat, which is compressed between heated platens or plates to set the binder and bond the flakes, strands, strips, pieces, etc., together in densified form. Conventional processes are generally carried out at temperatures of from about 120 to 225° C. in the presence of varying amounts of steam generated by liberation of entrained moisture from the wood or lignocellulose materials. These processes also generally require that the moisture content of the lignocellulose material be between about 2 and about 20% by weight, before it is blended with the binder.
Plywood production is accomplished by roll coating, knife coating, curtain coating, or spraying a binder composition onto veneer surfaces. A plurality of veneers are then laid-up to form sheets of required thickness. The mats or sheets are then placed in a heated press and compressed to effect consolidation and curing of the materials into a board.
Binder compositions which have been used in making such composite wood products include phenol formaldehyde resins, urea formaldehyde resins and isocyanates. See, for example, James B. Wilson's paper entitled, “Isocyanate Adhesives as Binders for Composition Board” which was presented at the symposium “Wood Adhesives—Research, Applications and Needs” held in Madison, Wis. on Sep. 23-25, 1980, in which the advantages and disadvantages of each of these different types of binders are discussed.
Isocyanate binders are commercially desirable because they have low water absorption, high adhesive and cohesive strength, flexibility in formulation, versatility with respect to cure temperature and rate, excellent structural properties, the ability to bond with lignocellulosic materials having high water contents, and no formaldehyde emissions. The disadvantages of isocyanates are difficulty in processing due to their high reactivity, adhesion to platens, lack of cold tack, high cost and the need for special storage. U.S. Pat. No. 3,870,665 and German Offenlegungs-schrift No. 2,109,686 disclose the use of polyisocyanates (and catalysts therefor) in the manufacture of plywood, fiberboard, compression molded articles, as well as various technical advantages when used as binders.
It is known to treat cellulosic materials with polymethylene poly(phenyl isocyanates) (“polymeric MDI”) to improve the strength of the product. Typically, such treatment involves applying the isocyanate to the material and allowing the isocyanate to cure, either by application of heat and pressure (see, e.g., U.S. Pat. Nos. 3,666,593, 5,008,359, 5,140,086, 5,143,768, and 5,204,176) or at room temperature (see, e.g., U.S. Pat. Nos. 4,617,223 and 5,332,458). While it is possible to allow the polymeric MDI to cure under ambient conditions, residual isocyanate groups remain on the treated products for weeks or even months in some instances. It is also known to utilize toluylene diisocyanate for such purposes.
Isocyanate prepolymers are among the preferred isocyanate materials which have been used in binder compositions to solve various processing problems, particularly adhesion to press platens and high reactivity. U.S. Pat. No. 4,100,328, for example, discloses isocyanate-terminated prepolymers which improve product release from a mold. U.S. Pat. No. 4,609,513 also discloses a process in which an isocyanate-terminated prepolymer binder is used to improve product release. A binder composition in which a particular type of isocyanate prepolymer is used to improve adhesiveness at room temperature is disclosed in U.S. Pat. No. 5,179,143.
A major processing difficulty encountered with isocyanate binders is the rapid reaction of the isocyanate with water present in the lignocellulosic material and any water present in the binder composition itself. One method for minimizing this difficulty is to use only lignocellulosic materials having a low moisture content (i.e., a moisture content of from about 3 to about 8%). This low moisture content is generally achieved by drying the cellulosic raw material to reduce the moisture content. Such drying is, however, expensive and has a significant effect upon the economics of the process. Use of materials having low moisture contents is also disadvantageous because panels made from the dried composite material tend to absorb moisture and swell when used in humid environments.
Another approach to resolving the moisture and isocyanate reactivity problem is disclosed in U.S. Pat. No. 4,546,039. In this disclosed process, lignocellulose-containing raw materials having a moisture content of up to 20% are coated with a prepolymer based on a diphenylmethane diisocyanate mixture. This prepolymer has a free isocyanate group content of about 15 to about 33.6% by weight and a viscosity of from 120 to 1000 mPa·s at 25° C. This prepolymer is prepared by reacting (1) about 0.05 to about 0.5 hydroxyl equivalents of a polyol having a functionality of from 2 to 8 and a molecular weight of from about 62 to about 2000 with (2) one equivalent of a polyisocyanate mixture containing (a) from 0 to about 50% by weight of polyphenyl polymethylene polyisocyanate and (b) about 50 to about 100% by weight isomer mixture of diphenylmethane diisocyanate containing 10 to 75% by weight of 2,4′-isomer and 25 to 90% by weight of 4,4′-isomer.
U.S. Pat. No. 5,002,713 discloses a method for compression molding articles from lignocellulosic materials having moisture contents of at least 15%, generally from 15 to 40%. In this disclosed method, a catalyst is applied to the lignocellulosic material. A water resistant binder is then applied to the lignocellulose with catalyst and the coated materials are then compression shaped at a temperature of less than 400° F. to form the desired composite article. The catalyst is a tertiary amine, an organometallic catalyst or a mixture thereof. The binder may be a hydrophobic isocyanate such as any of the polymeric diphenylmethane diisocyanates, m- and p-phenylene diisocyanates, chlorophenylene diisocyanates, toluene diisocyanates, toluene triisocyanates, triphenyl-methane triisocyanates, diphenylether-2,4,4′-triisocyanate and polyphenol polyisocyanates. The catalyst is included to ensure that the isocyanate/water reaction is not slowed to such an extent that the pressing time necessary to produce the molded product is significantly increased.
Pressing of wafer board, oriented strand board, and parallel strand lumber using steam injection and a conventional binder such as a urea-formaldehyde resin or a polymeric diphenylmethane diisocyanate (MDI) is known. Examples of such known pressing processes are disclosed in U.S. Pat. Nos. 4,684,489; 4,393,019; 4,850,849; and 4,517,147. These processes yield a product having satisfactory physical properties if the binder is completely cured.
The completeness of binder cure may, of course, be determined by destructive testing of samples which have been permitted to cure for varying amounts of time under the process conditions. The cure time to be used during the production process is determined on the basis of the sample which had completely cured in the least amount of time. The disadvantages of this method are readily apparent. Valuable product is destroyed in the testing. Further, any variation in wood composition, extent of binder dispersion on the wood particles, etc. or processing conditions which would affect the rate of binder cure are not taken into consideration in the above-described method.
Binding compositions comprising urea extended polyisocyanates derived from a combination of a polyisocyanate and urea which is in solution with water, and the process for preparing the binding compositions is disclosed in U.S. Pat. No. 5,128,407. This reference also describes a process for preparing a composite material from comminuted particles or veneers of a lignocellulose material comprising coating the particles or veneers with these binding compositions.
A process for producing compression molded articles of lignocellulose type materials by use of an organic polyisocyanate compound as a binder is disclosed by U.S. Pat. No. 5,744,079. The binders comprise (A) an organic polyisocyanate such as, for example, MDI or PMDI, (B) an aqueous emulsion of a wax having a melting point ranging from 50° C. to 160° C., (C) an organic phosphate ester derivative, and (D) optionally, water.
It has been known that organic polyisocyanate resins have excellent adhesion properties and workability as the adhesive for thermo-compression molded articles such as particle boards and medium-quality fiber boards produced from a lignocellulose type material such as wood chips, wood fibers, and the articles exhibit excellent physical properties. However, the excellent adhesiveness of the organic polyisocyanate resins causes disadvantage that the compression molded article adheres firmly to the contacting metal surface of the heating plate in a continuous or batch thermo-compression process.
To solve the disadvantages of the undesired adhesion to the heating plate, it is required that a releasing agent is preliminarily sprayed onto the heating plate surface to form a releasing layer. Japanese Patent Publication No. 3-21321 discloses a method different from the external releasing agent spray, in which a mixture of an organic polyisocyanate and a mineral wax is sprayed onto the lignocellulose type material prior to thermo-compression molding. Japanese Patent laid open application No. 4-232004 discloses a method of thermo-compression molding of a lignocellulose type material by addition of a neutral ortho-phosphate ester as a compatibilizing agent, the wax and the polyisocyanate.
The large scale industrial manufacture of composite materials which are bonded exclusively with polyisocyanates have previously been limited. The use of some of the polyisocyanates, particularly the better performing isocyanates, such as polymethylene diisocyanate has been limited by their cost. Because of the cost constraints, the level of use of these expensive isocyanates is kept low for a given material. One approach to the use of levels of these isocyanates has involved chain extending the isocyanate with inexpensive extenders.
U.S. Pat. No. 4,944,823 describes a composition for bonding solid lignocellulosic materials. Suitable binder formulations are based on the reactive mixture of an isocyanate and a carbohydrate material. These are both effective and inexpensive, and eliminate health hazards associated with the use of formaldehyde. Carbohydrate materials include, for example, sugars and starches, in the presence or absence of other active materials. These carbohydrates are mixed with a liquid diisocyanate and applied to the wood, which is then pressed to form a composite product.
Binder compositions comprising phenolic resins and polyisocyanates are known and described in, for example, U.S. Pat. Nos. 3,905,934, 4,293,480, 4,602,069, 4,683,252, 5,001,190, 5,101,001 and 5,733,952, and WO 88/03090 and WO 89/07626. These binder compositions are disclosed as being suitable for foundry cores and molds. The materials are typically applied in an organic solvent and cured most often in the presence of gaseous amine vapors.
U.S. Pat. No. 3,905,934 discloses dialkyl phthalate ester solvent systems for phenolic resin-polyisocyanate binder systems. The phenolic resins are preferably benzylic ether resins, including novolac resins. These binder compositions are described as improving the ultimate tensile strength of the resultant foundry core products.
Phenolic resin and polyisocyanate binder systems containing a phosphorus component are set forth in U.S. Pat. Nos. 4,602,069 and 4,683,252. The binder compositions of U.S. Pat. No. 4,602,069 require a phosphorus based acid such as, for example, metaphosphoric, hypophosphoric, orthophosphoric, pyrophosphoric or polyphosphoric acid, or phosphorous, hydrophosphorous or pyrophosphorous acid or an organic derivative of these compounds, and optionally, an acid halide and/or a base. U.S. Pat. No. 4,683,252 describes binder comprising a phenolic resin, a polyisocyanate and an organohalophosphate. Novolacs and resoles are disclosed by both of these patents as suitable phenolic resins.
U.S. Pat. No. 5,001,190 and PCT application WO 88/03090 disclose a process for filling a space within a structure with a polyurethane composite in the presence of water. Suitable polyurethane composites comprise (a) adding a coarse aggregate to the space in the structure to be filled, (b) adding a polyurethane binder to the aggregate, wherein the binder comprises (i) a phenolic resin component comprising a resole phenolic resin and a hydrophobic solvent system, and (ii) a polyisocyanate component comprising an aromatic polyisocyanate and a hydrophobic solvent, and (iii) a urethane promoting catalyst.
Foundry binders based on phenolic resole resins and polyisocyanates are described in U.S. Pat. Nos. 5,101,001 and 5,733,952, and PCT application WO 89/07626. The compositions of U.S. Pat. No. 5,733,952 also comprise an epoxy resin and, preferably, paraffinic oil. Polymerized linseed oil is utilized in the binders of WP 89/07626.
Isocyanates are known to be suitable components for treating cellulosic fiber and wood products. Some processes for this treatment are described in, for example, U.S. Pat. Nos. 5,179,143 and 5,674,568. The binders of U.S. Pat. No. 5,179,143 comprise polyisocyanates, compounds containing at least two isocyanate reactive hydrogen atoms and alkylene carbonates. The binders for modified cellulosic products of U.S. Pat. No. 5,674,568 comprise a polymethylene poly(phenylisocyanate), water, and an organic compound having a hydroxy functionality of from 2 to 8 and a molecular weight of about 60 to 8000 and being selected from the group consisting of ester group-free polyhydric alcohols, polyether polyols and mixtures thereof.
Binders comprising polyisocyanates and phenolic resins are known and described as being suitable for preparing wood composite products by U.S. Pat. Nos. 4,209,433, 4,961,795, and 5,217,665. Suitable phenolic resins disclosed by these references are resole resins. U.S. Pat. No. 4,209,433 requires that the polyisocyanate be added to the wood particles prior to the application of the phenolic resin, thereby producing enhanced adhesive characteristics. The binder compositions of U.S. Pat. No. 4,961,795 may be cured with a curing agent comprising an ester, a lactone or an organic carbonate, which may be moderated by an aliphatic mono- or polyhydric alcohol.
A method of producing waferboard is described by U.S. Pat. No. 5,217,665. This method comprises applying first a liquid phenol formaldehyde resin to the surface of the wafers, then a powdered phenol formaldehyde resin. This is followed by forming layup and pressing at elevated temperature and pressure using steam pressing techniques to consolidate the layup into a board and to set the phenolic resin adhesive.
It is the purpose of this invention to make a mixed adhesive for wood composite manufacture that utilizes the strength of both the polyisocyanate and phenolic resins. These compositions do not contain organic solvents and do not require catalysts to cure. The curing temperatures are lower than that of the phenolic alone. Typically, novolac resins are cured by adding a compound which generates formaldehyde. The compositions of the present invention contain no formaldehyde. The water resistance of the composites is better than that of the phenolic alone. Less polyisocyanate can be used which results in a cost savings, and the tendency of the adhesives to stick to the platens is reduced.
SUMMARY OF THE INVENTION
This invention relates to a process for the production of wood composite materials comprising A) combining wood particles with a binder composition, and B) molding or compressing the combination of wood particles and binder composition formed in A). The compression or molding typically occurs at pressures of from about 200 to 1000 psi (preferably 300 to 700 psi) for about 2 to 10 (preferably 4 to 8) minutes at temperatures of from about 120° C. to 220° C. (preferably 150 to 200° C.). Suitable binder compositions to be combined with the wood particles in step A) consist essentially of:
(1) a polymethylene poly(phenylisocyanate) component having a functionality of about 2.1 to about 3.5, an NCO group content of about 25 to 33%, and a monomer content of from about 30% to about 90% by weight, wherein the content of the monomer comprises up to about 5% by weight of the 2,2′-isomer, from about 1% to about 20% by weight of the 2,4′-isomer, and from about 25% to about 65% by weight of the 4,4′-isomer, based on the entire weight of the polyisocyanate; and
(2) a solid novolac resin.
In accordance with the present invention, wood particles are combined with from about 1 to 25% by weight, preferably from 2 to 10% by weight, most preferably with from 3 to 8% by weight of the binder compositions, based on the total weight of the wood composite. The weight ratio of component A)(2) the solid novolac resin to component A)(1) the polymethylene poly(phenylisocyanate) is from 2:1 to 10:1, preferably from 3:1 to 7:1.
When the binders are combined in this ratio, they typically do not flow as the novolac does not dissolve in the polyisocyanate. Also, they are not free flowing powders. Rather, these binders have the consistency of brown sugar.
DETAILED DESCRIPTION OF THE INVENTION
Polymeric MDI as used herein, refers to the three-ring and/or higher ring products derived by the phosgenation of aniline-formaldehyde condensation products.
Suitable polyisocyanates to be used as component 1) of the compositions in the present invention include (a) those polymethylene poly(phenylisocyanate) blends having an NCO group content of about 25% to 33% by weight, and having a viscosity of less than about 2,000 cps at 25° C. The polyisocyanates of the present invention have a functionality of from about 2.1 to about 3.5, preferably 2.3 to 3.0 and most preferably of 2.6 to 2.8, and an NCO group content of about 30% to about 33%, preferably about 30.5% to about 32.5%, and a monomer content of from about 30% to about 90% by weight, preferably from about 40% to about 70%, wherein the content of monomer comprises up to about 5% by weight of the 2,2′-isomer, from about 1 to about 20% by weight of the 2,4′-isomer, and from about 25 to about 65% by weight of the 4,4′-isomer, based on the entire weight of the blend. The polymeric MDI content of these isocyanates varies from about 10 to about 70% by weight, preferably from about 30% to about 60% by weight.
It is preferred that the polyisocyanates used as component (1) in the present invention have an average functionality of about 2.3 to about 3.0, most preferably of about 2.4 to about 2.8, and a monomer content of preferably 40 to 80%, most preferably of 40 to 70% by weight. The content of monomeric MDI preferably comprises less than 1 % by weight of the 2,2′-isomer of MDI, less than 5% by weight of the 2,4′-isomer of MDI and from about 30 to about 60% by weight of the 4,4′-isomer of MDI, based on the entire weight of the polyisocyanate. Preferred polyisocyanates have viscosities of 10 to 1000 cps, more preferred polyisocyanates have viscosities of 40 to 400, and most preferred polyisocyanates have viscosities of 100 to 300 cps.
A preferred polymethylene poly(phenylisocyanate) blend has a functionality of from 2.2 to 2.4, an NCO group content of from about 31.2 to about 32.8% by weight, and a monomer content of from about 55% to about 80%, wherein the content of monomer comprises no more than about 3% by weight of the 2,2′-isomer, from about 15% to about 20% by weight of the 2,4′-isomer and from about 40% to about 55% by weight of the 4,4′-isomer, based on the entire weight of the blend. This polyiso-cyanate blend comprises from about 20 to about 45% by weight of polymeric MDI.
Most preferred polyisocyanates include, for example, polymethylene poly(phenylisocyanate) blends having an average functionality of from about 2.5 to about 3.0, preferably about 2.6 to about 2.8, an NCO group content of about 30 to 32% by weight, and a monomer content of from about 40 to 50% by weight, wherein the content of monomer comprises no more than about 1% by weight of the 2,2′-isomer, from about 2 to about 10% by weight of the 2,4′-isomer and from about 35 to about 45% by weight of the 4,4′-isomer, based on the entire weight of the blend. This isocyanate blend comprises from about 50 to about 60% by weight of polymeric MDI.
Suitable polyisocyanates for component (1) of the present invention also include, for example, mixtures of polyisocyanate blends as described above with adducts of MDI including, for example, allophanates of MDI as described in, for example, U.S. Pat. Nos. 5,319,053, 5,319,054 and 5,440,003, the disclosures of which are herein incorporated by reference, and carbodiimides of MDI as described in, for example, U.S. Pat. Nos. 2,853,473, 2,941,966, 3,152,162, 4,088,665, 4,294,719 and 4,244,855, the disclosures of which are herein incorporated by reference.
Phenolic resins, obtained by the condensation of a phenolic compound with an aldehyde, are generally divided into two categories, the “novolac” resins and the “resole” resins or A-stage resins and their more highly polymerized derivatives, the “resitole” or B-stage resins. Novolac resins are permanently soluble, fusible resins in which the polymer chains have phenolic end-groups. They react to form crude to insoluble, infusible products upon the addition of a source of formaldehyde, such as hexamethylenetetraamine or paraform. Novolac resins have an excess of phenol. Resole and resitole resins are prepared generally using an alkaline catalyst with excess formaldehyde and result in polymers having pendant methylol groups. In the resitole stage, the resins are characterized by high viscosity. Since each methylol group constitutes a potential cross-linking site, the resole and resitole resins are readily converted to the cross-linked, infusible polymers by heating. Conversely, these resins are highly unstable.
Suitable solid novolac resins to be used as component (2) in the present invention include, for example, the phenolic resins in which the phenolic nuclei are joined by methylene bridges located at the ortho- and para-positions relative to the phenolic hydroxyl group. It is generally accepted that conventional acidic catalysts produce resins with a predominance of 4,4′- and 4,2′-linkages, although some 2,2′-linkages are also formed. Acid catalyzed resins have not been found fully acceptable where fast curing results are required as a result of the 4,4′- and 4,2′-linkages. Recently, novolac resins have been prepared which contain significant proportions of 2,2′-linkages using metal oxide or metal salt catalysts. This polymerization process is frequently referred to as an “ionic” polymerization. These ortho-resins cure faster and produce cross-linked phenolic resins of improved mechanical properties. Theoretically, the more ordered structure of the polymer molecule is obtained with 2,2′-linkages. The formation of phenolic resins of this type has, however, been limited to methods in which an excess of phenol is employed, which is necessary to prevent gelation of the resins during polymerization.
Suitable phenolic resins for the present invention compositions are
(a) a mixture of dimethylol compounds having the formulas:
and
wherein:
R: represents a hydrogen atom or a phenolic substituent meta to the phenolic hydroxyl group, said component (a)(iii) being a minor constituent in the mixture;
and
(b) at least one compound corresponding to the formula:
and
wherein:
each R: independently represents a hydrogen atom or a phenolic substituent meta to the phenolic hydroxyl group;
and
(c) higher molecular weight condensation products of said mixture having the general formula:
wherein:
R: represents a hydrogen atom or a phenolic substituent meta to the phenolic group;
X: represents an end group from the group consisting of hydrogen and methylol, wherein the molar ratio of methylol to hydrogen end groups is less than 1:1; and
m and n: are each independently selected from a number between 0 and 20.
The phenolic compositions of the present invention as well as other highly valuable phenolic condensation products are prepared by a process which comprises reacting at temperatures below about 130° C. a phenol with an aldehyde under substantially anhydrous conditions in the liquid phase in the presence of a metal ion as the catalyst, the preferred metal ion being a divalent metal ion such as zinc, cadmium, manganese, copper, tin, magnesium, cobalt, lead, calcium and barium.
These solid novolac resins are typically prepared by the polymerization reaction of a suitable phenol group containing compound with an aldehyde, wherein a stoichiometric excess of the phenol group containing compound is present. Suitable phenolic components include nonyl phenol, as well as virtually any of the phenols which are not substituted at either the two ortho-positions or at one ortho and the para-positions. It is necessary that these positions be unsubstituted for the polymerization reaction with the aldehyde to occur. Any one, all, or none of the remaining carbon atoms of the phenol ring can be substituted. The nature of the substituent can vary widely, and it is only necessary that the substituent not interfere in the polymerization of the aldehyde with the phenol at the ortho- and/or para-positions, substituted phenols employed in the formation of the novolac resins include, for example, alkyl-substituted phenols, aryl-substituted phenols, cyclo-alkyl-substituted phenols, alkenyl-substituted phenols, alkoxy-substituted phenols, aryloxy-substituted phenols, and halogen-substituted phenols, the foregoing substituents containing from 1 to 26 and preferably from 1 to 12 carbon atoms. Specific examples of suitable phenols include, for example, phenol, 2,6-xylenol, o-cresol, m-cresol, p-cresol, 3,5-xylenol, 3,4-xylenol, 2,3,4-trimethyl phenol, 3-ethyl phenol, 2,5-diethyl phenol, p-butyl phenol, 3,5-dibutyl phenol, p-amyl phenol, p-cyclohexyl phenol, p-octyl phenol 3,5-dicyclohexyl phenol, p-phenyl phenol, p-crotyl phenol, 3,5-dimethoxy phenol, 3,4,5-trimethoxy phenol, p-ethoxy phenol, p-butoxy phenol, 3-methyl-4-methoxy phenol, and p-phenoxy phenol. Such phenols can be described by the formula:
wherein:
A, B, and C: each independently represent hydrogen, hydroxyl radicals, hydrocarbon radicals, oxyhydrocarbon radicals or a halogen radical.
Also, suitable phenolic compounds are those compounds containing a second phenolic group such as, for example, catechol, resorcinol and hydroquinone.
The aldehydes reacted with the phenol can include any of the aldehydes theretofore employed in the formation of phenolic resins such as, for example, formaldehyde, acetaldehyde, propionaldehyde, furfuraldehyde, and benzaldehyde. In general, the aldehydes employed have the formula: R′CHO wherein R′ is a hydrogen or a hydrocarbon radical of 1 to 8 carbon atoms. Formaldehyde is the most preferred aldehyde.
The novolac resins of the present invention are typically prepared by reacting a stoichiometric excess of the phenol group containing compound with a suitable aldehyde, thereby forming a solid novolac resin. Additional information relative to the preparation of the novolac resins can be found in, for example, Encyclopedia of Chemical Technology by Kirk Othmer, Fourth Edition, Volume 18, pp. 606-609.
Known catalysts for accelerating the isocyanate addition reaction may in principle be used in forming these binder compositions. The use of catalysts is not, however, necessary to the present invention. Suitable catalysts for this purpose include, for example, tin compounds such as dibutyl tin dilaurate or tin(ll) octoate; and tertiary amines such as, for example, triethylene diamine, dimethylethyl amine, pyridine, 4-phenylpropyl pyridine, bis(N,N-dimethylaminoethyl) ether, N,N′-dimethylaminoethyl-N-methyl ethanolamine, N,N-dimethylaminoethyl morpholine, quinoline, morpholine, N-methyl morpholine, etc. Other catalysts are described in “Kunstoff Handbuch”, Volume VII, published by Becker and Braun, Carl Hanser Verlag, Munich, 1983 on pages 92-98. The catalysts are used, if at all, in a quantity of about 0.001 to 10% by weight, preferably about 0.002 to 0.1% by weight, based on the total quantity of reactants.
Other optional additives and/or auxiliary agents which may be included in the binding compositions of the present invention include, for example, wax emulsions for reduced water absorption, preservatives, surface active additives, e.g., emulsifiers and stabilizers, mold release agents such as, for example, zinc stearate, etc. As stabilizing agents which reduce swelling and water absorption, there may be mentioned sodium chloride, sodium sulfate, paraffin, fatty acids or their salts such as zinc stearate and other similar materials. At the same time, paraffin and fatty acids and their salts may serve as release agents. Use of other active materials may shorten pressing and curing time.
As indicated above, the percentages of ingredients in the wood binder compositions according to the present invention can vary widely according to needs and conditions of a particular application. In general, however, quantities in the following ranges have been found suitable, bearing in mind that the other active materials may comprise one or more of the catalysts, stabilizing agents and release agents.
A preferred formulation for the composite products, such as particle board, comprises a blend of novolac resins, together with isocyanate (PMDI), with or without stabilizing agent, catalyst or release agent. The binder formulation for a particular product will depend upon wood species, requirements of physical properties of the resultant product, and pressing conditions, For example, a formulation range for Douglas fir commercial furnish requirements for interior particle board pressed at a press platten temperature of 350° F. for 4.4 minutes press time, to give a high quality commercial product is as follows:
Components
Preferred range
Novolac Resin
50-70%
PMDI
5-35%
Stabilizer
20-35%
Wax
3-10%
This binder formulation may be used in an amount of 1 to 25% by weight, expressed as a percentage of the total wood weight, or about 0.25 to 8.0% of PMDI based on the wood weight. Preferably, the quantity of binder formulation based on the weight of the wood is about 2 to 10%, depending on the configuration of the particulate wood and the requirements of the products. Also, if a small amount of isocyanate is used in the binder formulation (e.g., about 10 to 20% based on the total binder formulation, providing a relatively dry powder), then relatively greater proportions of binder formulation will be used (e.g., 8 to 10% binder formulation, or 1 to 2% isocyanate based on the wood weight). On the other hand, when relatively small quantities of binder formulation are used (e.g., 2 to 6% binder formulation) then the quantity of isocyanate in the powdery binder should be somewhat greater (e.g., 25 to 35%) to provide sufficient bonding, this provides a minimum percentage of isocyanate based on the quantity of wood of about 0.5 to 2%. In general, using a preferred powdery binder formulation, the maximum amount of isocyanate present will be about 20% based on the binder, or 2% based on the wood when 10% binder is used.
Although much less preferred, it is also possible to make liquid binder formulations according to the present invention using small quantities of inert, polar, non-aqueous solvent such as, for example, methylene chloride, or plasticizers such as, for example, butyl benzylphthalate or dioctyl phthalate, or solutions of novolac resins in inert, polar, non-aqueous solvents can also be used. Liquid binder formulations can have limited potlife. Care must also be exercised in minimizing the water content of these dissolved novolac resins because of the undesirable reaction between the isocyanate and the water prior to the wood bonding operation.
Liquid binder formulations according to the present invention can also be made by first mixing a relatively large quantity of dry novolac resin with a relatively small quantity of isocyanate, letting the mixture react to the point where free isocyanate is no longer present and then adding inert solvent or plasticizer to form a viscous mass. Thus, such a viscous mass can be obtained by first blending isocyanate with a novolac resin in the ratio of 10 to 50% by weight isocyanate and 50 to 90% by weight of powdered novolac, then letting the mixture react for 5 to 60 minutes, and finally adding 30 to 70%, based on the weight of the mixture, of inert solvent or plasticizer to obtain a viscous mass suitable for roller spreading on veneers in plywood manufacture. Viscosity can be controlled by adjusting the ratio of components in the mixture.
Binder formulations according to the present invention are made by blending together the various components in the proper sequence as noted above. When producing the preferred powdery binders, such blending preferably involves vigorous agitation for several minutes, such as in a suitable mill, in order to insure thorough blending of the isocyanate with the other components. It is preferable to blend together first the isocyanate with the stabilizing agent, catalyst and release agent (if one or more of these latter components are used) and then to add the novolac resin. Of course, the blending should be carried out for a time sufficient to produce a homogeneous blend, and under vigorous blending conditions, this will usually occur after several minutes of vigorous agitation.
The powdered binder formulations are applied to wood particles in the manufacture of particle board, wafer board, fiber board, etc., by intermixing a stream of wood particles with a stream of the powdered binder formulation at the desired ratio and using mechanical agitation which is in common usage in the manufacture of composite products such as particle board. When using powdered binders to make particle board or the like, the wood may have a wide range of moisture content, i.e., from about 0.5 to about 10% by weight, based on the total weight of the wood particles. However, it is advantageous if the moisture content of the wood particles is relatively low, i.e., on the order of about 1 to 6%, and after initial pressing and prior to final compacting in a hot press, the pre-formed particle board is sprayed with water to increase its moisture content to 10 to 11%.
Alternatively, although less preferred, binders can be added separately and subsequently blended together with the wood particles. This is less preferred because, at least in some cases, the two co-reactants are not intimately mixed in the proper ratios. As soon as the binder according to the invention comes into contact with wood, it starts reacting with the water contained in the wood.
The binder and resultant products are free of formaldehyde and the composite is produced at a cost competitive to the cost of making wood products using urea-formaldehyde resin which has the serious problem of formaldehyde emission. The binder formulation can also be applied to wood at higher moisture content which saves energy by reducing the degree of drying normally required prior to pressing.
The following examples further illustrate details for the process of this invention. The invention, which is set forth in the foregoing disclosure, is not to be limited either in spirit or scope by these examples. Those skilled in the art will readily understand that known variations of the conditions of the following procedures can be used. Unless otherwise noted, all temperatures are degrees Celsius and all parts and percentages are parts by weight and percentages by weight, respectively.
EXAMPLES
The following components were used in the working examples of this invention:
Isocyanate A:
polymethylene poly(phenyl isocyanate) blend having
an NCO group content of 31.5% and a viscosity of
about 200 mPa.s, commercially available from Bayer
Corporation
Cascophen ®
a Novolac resin, commercially available from
SD-838A:
Borden Chemical, Inc.
Varcum ®
a Novolac resin, commercially available from
29-615:
Occidental Chemical, Inc. (CAS Registry Number
= 4021 6-08-8)
Stabilizer A:
sebacic acid
The procedure used to prepare the boards containing the Cascophen and Varcum resins were the same, only differing in the amounts of each perspective resin (Novolac or Varcum) used in conjunction with the isocyanate. This procedure consisted of two parts, preparation of the binder, and preparation of the board.
Procedure for Preparation of Binder:
200 parts by weight of Isocyanate A were combined with 100 parts by weight of Stabilizer A in a 32-oz. jar and mixed well. Then, 100 parts by weight of the solid resin (Novolac or Varcum) was ball-milled and screened using a #40 US-mesh sieve. This material was then placed in a separate container from the mixture of Isocyanate A and Stabilizer A (sebacic acid). The Isocyanate/Stabilizer mixture was added to the dried resin in the amounts shown in the Tables, and burundum cylinders were added to the 32-oz. jar. The jar was then rolled on a roller table for 1 to 1½ hours. The container was periodically opened and material clinging to the container walls was scraped off. The binder mix was then sieved once more through a #40 US-mesh sieve and placed in a catch pan. The catch pan containing the binder was placed in a dessicator for 3 to 4 hours.
Procedure for Preparation of Boards:
According to the amounts shown in the Tables, particleboard furnish was placed in a stainless steel bowl (for use in a KitchenAid KSM90 mixer). The binder mixture, now semi-dried, was added in 5 to 10 g increments, and the furnish was mixed by hand initially to promote uniform dispersion of the binder to the furnish. The stainless bowl was transferred to the KitchenAid mixer and mixed at lowest speed for 5 minutes. The resin-coated furnish was then placed in an eight inch by eight inch form and pre-pressed by hand. The form was then placed in a Carver Press (Model M), and pressed at 350° F. for four and one half minutes.
The resultant boards were tested for Internal Bond Strength and Thickness Swell in accordance with ASTM method D1037: Evaluating Properties of Wood-Base Fiber and Particle Panel Materials. The results are set forth in Tables 1 through 3 below.
TABLE 1
Example
1
2
Percent of each resin
7:1
7:1
based on total weight
Varcum 29-615/
Varcum 29-615/
of composite board
Isocyanate A
Isocyanate A
Percent Wood*
91.5%
91.5%
Percent Sebacic Acid
0.5%
0.5%
Curing Temperature
350
400
(° F.)
Average Density (pcf)
56.32
53.09
Internal Bond Strength
190
144
(psi)
Thickness Swell (%)
17.7
16.1
*Weight of wood, excluding moisture.
TABLE 1
Example
1
2
Percent of each resin
7:1
7:1
based on total weight
Varcum 29-615/
Varcum 29-615/
of composite board
Isocyanate A
Isocyanate A
Percent Wood*
91.5%
91.5%
Percent Sebacic Acid
0.5%
0.5%
Curing Temperature
350
400
(° F.)
Average Density (pcf)
56.32
53.09
Internal Bond Strength
190
144
(psi)
Thickness Swell (%)
17.7
16.1
*Weight of wood, excluding moisture.
TABLE 3
Example
5
6
Percent of each resin
6:2
3:1
based on total weight
Cascophen SD-838/A
Cascophen SD-838/A
of composite board
Isocyanate A
Isocyanate A
Percent Wood*
91%
91.5%
Percent Stabilizer
1.0%
0.5%
Curing Temperature
400
400
(° F.)
Density (pcf)
52.45
51.14
Internal Bond Strength
242
179
(PSI)
Thickness Swell (%)
12.5
30.2
*Weight of wood, excluding moisture
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | This invention relates to a process for the production of composite wood products. This process comprises a) applying a binder composition to wood particles, and b) molding or compressing the wood particles treated with the binder to form a composite wood product. Suitable binder compositions comprise a polymethylene poly(phenyl isocyanate) and a solid novolac resin. | 2 |
FIELD OF THE INVENTION
This invention relates to standard solutions containing protein, buffer, stabilizers and analytes adjusted to specific levels for calibration of chemical analyzers. In particular, this invention relates to a stabilized standard solution for the calibration of clinical assays useful in assessing thyroid function, including total thyroxine, unbound thyroxine, total triiodothyronine, unbound triiodothyronine, and thyroid stimulating hormone.
BACKGROUND OF THE INVENTION
The thyroid gland is an endocrine gland located within the neck which synthesizes thyroxine (T 4 ) and also small amounts of triiodothyronine (T 3 ) by incorporation of inorganic iodide into tyrosine residues of thyroglobulin. T 4 is the principal circulating thyroid hormone but its effects are mediated after intracellular conversion to T 3 . T 4 and T 3 circulate in the blood predominantly bound (>99%) to the serum proteins thyroxine binding globulin (TBG), thyroxine binding prealbumin (TBPA), and albumin. Some physiologic actions of thyroid hormone include stimulation of metabolism, heart rate, protein synthesis, and carbohydrate metabolism in target tissues. The unbound (free) hormone is thought to be the physiologically active form while the protein bound fraction serves as a reservoir of available hormone. This complicates the determination of thyroid status because changes in the levels of binding proteins may lead to an increased total T 4 content in serum without affecting the level of free hormone (e.g. during pregnancy).
The production of T 4 is normally regulated by a feedback control loop which includes the hypothalamus and pituitary gland. In response to a lack of circulating T 4 , the hypothalamus stimulates the pituitary gland to produce TSH. TSH in turn stimulates the production of T 4 by the thyroid gland. When circulating T 4 levels are adequate, the hypothalamus dictates that TSH production and thus, T 4 production decrease. Disruption of the feedback control loop in the hypothalamic-pituitary-thyroid axis leads to non-specific symptoms which can be diagnosed and effectively treated with the aid of laboratory tests. Primary hypothyroidism occurs due to destruction of the thyroid gland itself and results in decreased availability of T 4 to tissues. Failure of the pituitary to produce TSH also leads to hypothyroidism. Primary hyperthyroidism (an oversupply of T 4 to tissues) occurs due to excessive activity of the gland. Overproduction of TSH also leads to hyperthyroidism. Diagnostic tests aid in the detection of thyroid disease, in determining its mechanism, and in following its treatment.
From the discussion above, it is dear that a full understanding of thyroid function requires accurate assessments of the amounts of T 3 , T 4 and TSH. In carrying out immunoassay procedures for determining concentrations of these thyroid analytes, a common practice is to use a family of controlled formulation solutions, hereinafter called standard or calibration solutions, each of which contains accurately predetermined quantities or concentrations of T 4 , free T 4 , T 3 , free T 3 , and TSH. Concentrations that are substantially lower and higher than normal are generally employed. Since the immunoassay procedures are normally designed to analyze serum samples, it is preferred that the calibration solutions be formulated using a matrix that is identical to or bioactively equivalent to serum. Human serum has typically been used as starting material for calibration solutions, however, the techniques used for stripping away endogenous thyroxine are known to produce process artifacts and wide lot-to-lot variations making it difficult to manufacture these solutions reproducibly. An additional disadvantage of calibration solutions containing human serum is that they cannot be stored for longer periods since serum contains many labile components which negatively affect the stability of the product. For this reason calibration materials are often provided in a dry state (lyophilized), however, inaccurate rehydration of these materials commonly leads to inaccurate calibration measures.
Liquid calibration solutions avoid the possibility of inaccurate rehydration of lyophilized calibration materials. Thus, there is a commercial advantage to providing liquid-stable materials which require no preparation by the end user. However, liquid calibration solutions must contain stabilizers and preservatives that act to increase the useful life and ensure against contaminants. Such reagents are known in the industry. However, the requirements placed on the formulation chemist to produce a combination of matrix, analyte, and preservative that are compatible with the analytical system, which can contain the desired concentrations of all desired analytes, and at the same time are able to maintain stability are known to be quite restrictive. Consequently, in practice, as many as five different calibration solutions may be required to support calibration protocols for T 3 , free T 3 , T 4 , free T 4 and TSH. This imposes undesirable production expenses by the manufacturer as well as increased inventory and handling expenses by the clinical laboratory.
U.S. Pat. No. 5,342,788 discloses a serum-free standard solution containing TBG, albumin, and buffer. When T 4 or T 3 is added to this solution an equilibrium is established between bound and free hormone resembling that observed in human serum. Stability of the synthetic standard solution was superior to a solution based in human serum and furthermore, bovine TBG afforded superior stability than TBG derived from human serum.
A remaining shortcoming in the industry involves the addition of multiple thyroid-related analytes within a single liquid calibration solution for use in determination of thyroid function so as to increase flexibility in use as well as reduce production and inventory requirements. However, experience has shown that the simple addition of multiple analytes plus various anti-microbial agents within a single calibration solution would be expected to interfere with the analytical measurement of the other analytes in a sample or to even adversely affect the stability of another analyte in the solution. Accordingly, it was an object of the present invention to provide a single, stabilized calibration solution which included known amounts of T 3 , T 4 , free T 4 , free T 3 , and TSH so that the advantages of having a multi-analyte calibration solution could be realized over an extended period of time.
SUMMARY OF THE INVENTION
The present invention is based upon the discovery that a physiologic equilibrium of bound and free thyroid hormones can be established in a single liquid standard or calibration solution containing only albumin as a binding protein without the expected requirement for inclusion of TBG. Consequently, a calibration solution can be formulated simultaneously with specific amounts of triiodothyronine (T 3 ) in combination with specific amounts of thyroxine (T 4 ), which dictate levels of free T 3 and free T 4 , respectively. In an alternate embodiment of this invention, purified TSH is also added to this thyroid hormone calibration solution even though TSH does not circulate in such a bound/free equilibrium so that a multiple-analyte assay calibration protocol may be accomplished using the single calibration solution. Unexpectedly, the presence of each one of the analytes has no adverse effect on the utility of the calibration solution in measuring the other analytes nor on the stability of the solution as a whole. In addition, an extended period of usage or stability of the calibration solution is achieved by including a combination of anti-microbial agents demonstrated to be active against bacteria and fungi and which do not adversely affect the utility of the calibration solution.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a calibration curve for a heterogeneous sandwich immunoassay for TSH using a calibration solution according to this invention.
FIG. 2 compares the results of a TSH assay using a calibration solution made according to the present invention with results obtained using a known commercial system.
FIG. 3 is a calibration curve for a competitive hapten immunoassay for free T 4 using a calibration solution according to this invention.
FIG. 4 compares the results of a free T 4 assay using a calibration solution made according to the present invention with results obtained using a known commercial system.
FIG. 5 depicts a calibration curve for free triiodothyronine assay using a calibration solution according to this invention.
FIG. 6 depicts a calibration curve for total triiodothyronine assay using a calibration solution according to this invention.
FIG. 7 depicts a calibration curve for a total L-thyroxine assay using a calibration solution according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
Various methods are known for determining T 4 , T 3 , free T 4 , free T 3 , and TSH. Methods based on immunoassays are particularly useful in a routine clinical setting because automated platforms exist for the performance of these methods. Calibration of these automated platforms involves defining a mathematical relationship between the concentration of the analyte of interest and the detection signal generated. These relationships in immunoassays are commonly non linear such that a system requires multiple standard solutions to define the signal-analyte relationship.
As described herein and according to the invention, a standard solution, or calibration solution, with extended stability and being capable of simultaneous use in methods for determination of multiple thyroid-related analytes is provided which can be produced in a simple manner from easily obtainable starting materials. The calibration solution according to the present invention contains only serum albumin as a protein component. The protein serves as an acceptable binding reservoir for both T 4 and T 3 and an acceptable stabilizing milieu for TSH. Preferably, albumin from bovine serum is used as the albumin, although other sources of albumin are acceptable. Serum albumin is useful in a range between 40 g/L and 80 g/L which mimics the physiologic protein concentration of serum. Likewise, to mimic the ionic environment in serum, NaCl is added in a range between 100 and 200 mmoles/L solution. The amount of NaCl may vary depending on the sensitivity of the analytical system to ionic strength. If the analytical system is insensitive to ionic strength, NaCl addition may not be required. Likewise, to enhance the buffering capacity of the calibration solution, buffers which maintain pH in a range between 6.0 to 8.0 may be required. An example of such a buffer is HEPES (N- 2-hydroxyethyl!piperazine-N'- 2-ethanesulfonic add!). If the analytical system is insensitive to pH, the protein component of the matrix may supply all the buffering capacity that is required.
Subsequent to addition of protein, salt, and buffer, agents active against contaminating microbes are included in the calibration solution to achieve a desired amount of stabilization. These agents may consist of any number of compounds which are effective against bacteria and fungi, are inert in the analytical system, and are unreactive towards components of the matrix of the calibration solution and the specific analytes contained therein. In an exemplary embodiment, Polymyxin B, is added at a concentration of 0.02 g/L along with sodium pyrithione at a concentration of 0.2 g/L. At these concentrations, Polymyxin B is active mainly against bacteria and sodium pyrithione is active primarily against fungi. It is also useful to add a broad spectrum anti-microbial agent to reinforce the activities of the others. As an example, 0.1 g/L polyhexamethylene biguanide may be added. This particular combination of agents has been found to be very effective in providing a sterile environment for the calibration solution of the present invention for an extended period of six months or more as discussed hereinafter.
Subsequent to the preparation of the base matrix, the specific analytes of interest are added. Thyroxine is preferably added in a range between 0-500 μg/L, a range which covers the physiologically relevant concentrations found in human serum. Exemplary solutions are prepared with thyroxine content of 0, 17, 50, 100, and 400 μg/L (microgram per deciliter). In the presence of 60 g/L bovine serum albumin, these solutions dictate free thyroxine concentrations of approximately 0, 7, 20, 40, and 160 ng/L (nanogram per liter). Free T 4 measurements are poorly standardized in the diagnostic industry so free T 4 results may vary widely at a given concentration of T 4 depending on the analytical instrumentation.
Triiodothyronine is preferably used in a range between 0 and 12 μg/L solution since these concentrations span the physiologically relevant range of triiodothyronine concentrations found in human serum. Exemplary solutions are prepared with triiodothyronine content of 0, 1.0, 2.0, 4.0, and 9.0 μg/L . In the presence of 60 g/L bovine serum albumin, such solutions dictate free triiodothyronine content of approximately 0, 5, 11, 25, and 45 ng/L. Likewise, free T 3 measurements are poorly standardized in the diagnostic industry and the same degree of variation observed in free T 4 analyses may also be seen in free T 3 analyses at any given concentration of T 3 depending on the analytical instrumentation.
Thyroxine and triiodothyronine have the same structure independent of species so the source of these compounds may vary, also including synthetic material. TSH, however, varies according to animal species. Thus, for human diagnosis, TSH derived from humans or synthesized from the human gene sequence is required. TSH does not circulate in a bound/free equilibrium. The amount added is normally completely recovered without the addition of agents which release molecules from binding proteins. TSH is added to an exemplary solution in amounts of 0, 1, 4, 20, and 55 mIU/L (bioactivity units defined by World Health Organization standard material). Amounts of all analytes added are dictated by the relevant physiologic ranges and the requirements for defining a signal vs. concentration response for the specific analytical system.
Any combination of T 4 , free T 4 , T 3 , free T 3 , and TSH levels may be formulated depending on specific needs. The only limitations are the interdependence of total hormone levels and the free hormone levels. These cannot be adjusted independently.
This invention will be better understood by reference to the following example which is included here for purposes of exemplification and is not to be considered as limitative. Formulation techniques such as fluid handling, weighing, and mixing are done using standard laboratory equipment (e.g. pipettes, balances, and magnetic stirrers) and techniques known in the industry.
CALIBRATION SOLUTION
1. Preparation Of Matrix Preserved against Microbial Contamination.
a) Salt/buffer solution: 135 g of NaCl, 89.3 g of HEPES, and 97.5 g of Na-HEPES are dissolved in 15 L of water. Solute and solvent are mixed with a magnetic stirring apparatus until solute is completely dissolved. Mixing for 60 minutes at 25° C. is adequate. This buffer mixture is effective at maintaining the pH of the solution within a range of 7.0 to 8.0, preferably at 7.5.
b) Addition of antimicrobial agents: 3 g of sodium-pyrithione, 0.3 g of polymyxin B, and 1.5 g of polyhexamethylene biguanide are added sequentially to the salt/buffer solution and dissolved by stirring for 60 minutes at 25° C.
c) Addition of protein: To the preserved salt/buffer solution 900 g of bovine serum albumin is added and dissolved by mixing for 60 minutes at 25° C.
d) Following dissolution of the albumin the matrix is sterilized by filtration through a 0.2 micron filter. This solution is referred to hereinafter as a "preserved matrix".
2. Addition of analyte to the preserved matrix to generate a 5 level multi-analyte calibrator solution.
a) Level 1 consists only of preserved matrix and contains none of the analyte substances.
b) Four other solutions known as the "calibration solutions" (Levels 2-5) are formulated to contain analyte in specific concentrations from low concentrations (Level 2) to high concentrations (Level 5).
c) A 50 mg/L stock solution of T 4 is prepared by dissolution of T 4 -sodium salt in 0.05N NaOH. Stock concentration is confirmed using the molar extinction coefficient of T 4 at 325 nm. Dilutions of this stock solution to 5 mg/L and 15 mg/L are prepared in 0.2 g/L bovine albumin solution and are referred to as "working dilutions". These working dilutions are prepared to allow accurate delivery to a specific level of the calibration solution and are formulated 100-200 times the desired final concentration to avoid large dilutions of the calibration solution upon their addition. The working dilutions are added to specified amounts of the preserved matrix to attain final concentrations of 100 and 400 μg/L of T 4 in levels 4 and 5, respectively. Levels 2 and 3 are prepared by dilution of level 4 with appropriate amounts of the preserved matrix to obtain concentrations of 17 μg/L and 50 μg/L, respectively. Levels 2-5 are mixed for 60 minutes at 25° C. These quantities of T 4 equilibrate between the bound and unbound state in the matrix to result in predictable unbound (free) T 4 concentrations of approximately 7, 20, 40, and 160 ng/L in levels 2, 3, 4, and 5, respectively.
d) A stock solution of purified human TSH is prepared by dissolving lyophilized TSH in cold (2°-8° C.) 9 g/L saline. Working dilutions containing 100, 400, 2000, and 4400 mIU/L of TSH are prepared in the preserved matrix. Levels 2, 3, 4, and 5 are formulated to contain 1.0, 4.0, 20.0, and 55.0 mIU/L TSH, respectively, using the appropriate working dilution. Levels 2-5, now containing T 4 and TSH, are mixed thoroughly for 60 minutes at 25° C.
e) Likewise, a 50 mg/L stock solution of T 3 (sodium salt) is prepared in 0.05N NaOH and its concentration confirmed by use of the known extinction coefficient of T 3 at 325 nm. Working dilutions are prepared in a 2 g/L bovine albumin solution containing 200, 400, 800, 1800 μg/L of T3 and used to formulate levels 2, 3, 4, and 5 containing 1.0, 2.0, 4.0, and 9.0 μg/L, respectively. Levels 2-5, now containing thyroxine, TSH, and T 3 are mixed for 60 minutes at 25° C. These quantities of T 3 equilibrate in the matrix to yield unbound (free) T 3 concentrations of approximately 0, 5, 11, 25, and 45 ng/L in levels 2, 3, 4, and 5, respectively.
g) No change in analyte concentrations (TSH, total T 4 , free T 4 , total T 3 , and free T 3 ) are observed over a period of up to 5 days following the formulation stage. Mixing periods are designed to insure a homogenous product. Longer or shorter mixing periods and many modes of mixing are permissible.
Large glycoprotein hormones like TSH are commonly measured by two-site "sandwich" immunoassay technology. FIG. 1 depicts a calibration curve for a heterogeneous sandwich immunoassay for TSH utilizing the calibration solution according to this invention on a Dimension® RxL Clinical Chemistry System, available from Dade International Inc., (Newark, Del.). FIG. 2 demonstrates the accuracy of the calibration solution in FIG. 1. Aliquots from 86 patient sera were measured on the Dimension® RxL Clinical Chemistry System calibrated with standard solution according to this invention and compared with an AXSYM® commercial analytical system calibrated with material and by instructions supplied by its manufacturer, Abbott Laboratories (Abbott Park, Ill.). The data show agreement between the two systems.
Molecules of smaller size and concentration such as free T 4 , total T 3 and free T 3 are often determined by competitive hapten immunoassays and the signal resulting from such an assay is inversely proportional to the concentration of molecule. FIG. 3 depicts calibration curves for a competitive hapten immunoassay for free T 4 utilizing the same calibration solution of FIG. 1 according to this invention also using the Dimension® RxL Clinical Chemistry System. FIG. 4 demonstrates the accuracy of the calibration solution in FIG. 2. Aliquots from 138 patient sera were measured on the Dimension® RxL Clinical Chemistry System calibrated with standard solution according to this invention and compared with an IMx® commercial analytical system calibrated with material and by instructions supplied by its manufacturer, Abbott Laboratories. The data show agreement between the two systems.
Assays for free T 3 are performed in a similar fashion. FIG. 5 depicts a free T 3 calibration curve using a standard solution produced according to the present invention produced on an IMx® commercial system. A Total T 3 assay can be performed similarly to free hormone assays by use of an agent which releases T 3 from protein binding sites. FIG. 6 depicts a calibration curve for total T 3 using a competitive hapten immunoassay on the IMx® commercial analytical system.
Unlike, TSH, free T 4 , free T 3 , and total T 3 , total T 4 concentrations are large enough in human serum to be determined by immunoassay techniques which do not require a step to concentrate the molecule of interest. An example of a total T 4 calibration curve on the Dimension® commercial analytical system made using a calibration solution according to the present invention is shown in FIG. 7.
As illustrated in the Table below, all of the above calibration solutions have been found to be stable for six months or more when stored at 2°-8° C. A change in analyte value of 5% or more is normally considered unacceptable for commercial application of the calibration solutions. Stability of the analytes in the calibration solution was determined through measurement of these analytes by various commercial analytical systems. Samples of calibrator stored at 2°-8° C. were measured in parallel with samples stabilized by freezing at -70° C. Recovery of material is shown as the determined amount of the specific analyte in the material stored at 2°-80° C. divided by the determined amount of the specific analyte in the frozen material expressed as a percent. For all levels and analytes, virtually no change in analyte concentration at 2°-8° C. is detected.
TABLE______________________________________ % of analyte recovered after 6 months storage at 2-8° C. in comparisonAnalyte to storage at -20° C.______________________________________Total Thyroxine 99.5%Free Thyroxine 100.8%Total Triiodothyronine 100.4%Free Triiodothyronine 100.4%Thyroid Stimulating Hormone 99.8%______________________________________
The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, it being recognized that various modifications are possible within the scope of the invention. | A stabilized liquid standard solution for use in calibrating assays of thyroid function containing albumin and known amounts of at least two analytes selected from a group consisting of total thyroxine, free thyroxine, total triiodothyronine, and free triiodothyronine, and optionally, thyroid stimulating hormone. | 8 |
FIELD OF THE INVENTION
[0001] The invention concerns a radial roller bearing according to the features set forth in the preambles of the independent claim 1 or 4 , which bearing can be used particularly advantageous as a movable bearing for high radial forces and low axial forces for the mounting of shafts and rotating parts.
BACKGROUND OF THE INVENTION
[0002] It is general knowledge in the field of rolling bearings technology that shafts and rotating parts, are mostly mounted at two mounting points configured as a fixed bearing and a movable bearing because, in this way, manufacturing tolerances and length variations caused by thermal expansions between the shaft and a housing or between an axle and the rotating part can be compensated for without additional clamping forces acting on the bearing. The fixed bearing that is fixed in axial direction takes up, in addition to its radial force fraction also all axial forces in both directions, whereas the movable bearing transmits only its radial load fraction because it is not fixed in axial direction and therefore, as a result, cannot take up any axial force. The compensation of manufacturing tolerances and thermal expansions is thus effected exclusively through the movable bearing, more specifically at the two seating point of the inner ring, at the seating point of the outer ring of in the bearing itself.
[0003] A generic radial rolling bearing for a typical movable mounting of a radially highly loaded shaft is known, for example, from DE 2 931 348 A1. This movable bearing configured as a radial cylindrical roller bearing is made up substantially of a smooth cylindrical outer ring which is inserted into a housing and of a roller crown ring arranged in this outer ring, this crown ring being formed by a plurality of rolling elements which are inserted into a bearing cage and retained by this uniformly spaced in peripheral direction. The rolling elements configured as cylindrical rollers roll on an outer raceway formed by the inner peripheral surface of the outer ring and on an inner raceway formed by the outer peripheral surface of a smooth cylindrical inner ring which is slipped onto the shaft, which inner raceway is formed in other applications also by the outer peripheral surface of the shaft itself. In addition, for an axial guidance of the roller crown ring, two separate flanged disks are arranged on the axial sides of the outer ring, which flanged disks, together with the outer ring, are fixed in place against an axial displacement, on one side by a snap ring that engages into a circumferential groove in the housing and, on the other side by a fixing element configured as an adjustable tension ring.
[0004] Further, another generic radial roller bearing configured as a double row needle roller bearing for a movable mounting of a radially highly loaded rotating part is known from a catalogue of the applicant, October 2008 Edition, page 742, under the designation NAO..-ZW-ASR1. In this needle roller bearing likewise made up substantially of a smooth cylindrical inner ring that is slipped onto an axle, a roller crown ring arranged on the inner ring and a smooth cylindrical outer ring that is inserted into a rotating part, the axial guidance of the roller crown is, however, effected through two separate flanged disks that bear against the axial sides of the inner ring, which flanged disks, together with the inner ring, are fixed in place in axial direction by two fixing elements that are configured as snap rings and engage into circumferential grooves in the axle.
[0005] A drawback of both the aforesaid radial roller bearings is, however, that the axial fixing of the outer and the inner ring as also of the adjoining flanged disks in the housing or on the axle is effected through two additional components that, in the case of large bearing piece numbers, are delivered by the bearing manufacturer in separate magazines, in addition to the flanged disks that are likewise already delivered in a loose state. The, as it is high complexity and costs of assembly of such radial roller bearings are thus further increased by the laborious step of removing the fixing elements out of the magazine and through the necessary use of separate assembly tools for these fixing elements, so that such bearings have proved to be extremely uneconomical.
OBJECT OF THE INVENTION
[0006] Starting from the aforesaid drawbacks of the known state of the art, the object of the invention is therefore to conceive a radial roller bearing of the two initially described types, the assembly of which is simplified and possible without the use of separate assembly tools and which is therefore characterised by low assembly costs.
DESCRIPTION OF THE INVENTION
[0007] This object is achieved both through a radial roller bearing according to the preamble of claim 1 and through a radial roller bearing according to the preamble of claim 4 by the fact that the fixing elements for the flanged disks and for the outer and inner ring, as well as the flanged disks are configured as a fixedly connected assembly.
[0008] The invention is therefore based on the not very obvious perception that it is possible, through a suitable form of integration of the fixing elements with the flanged disks, to minimise on the one hand the number of components and thus the delivery quantity required for such radial roller bearing from the manufacturer and, on the other hand, at the same time, to considerably reduce the complexity and costs of assembly because the step of removing the fixing elements out of the magazine can be omitted and insertion or placement of the flanged disks into a housing or on an axle can be performed in one single work step without separate assembly tools.
[0009] Preferred embodiments and advantageous developments of the two types of a radial roller bearing configured according to the invention will be described in dependent claims 2 and 3 as also in dependent claims 5 to 7 .
[0010] Thus, according to claim 2 , in a first preferred form of embodiment of a radial roller bearing configured according to claim 1 , the fixing elements are formed by two spring rings with an elliptical shape, the transverse axes of which are smaller and the longitudinal axes of which are larger than the diameter of the flanged disks, the spring rings being fixed with their smaller diameter regions on the outer sides of the flanged disks and having an elastically inwards yielding configuration in their larger diameter regions. Thus, the elliptical spring rings are fixed with their smaller diameter regions in such a way on the flanged disks that their larger diameter regions protrude slightly beyond the flanged disks. During the assembly of the flanged disks, the spring rings are deformed by force of hand onto the diameter of the flanged disks in order to be able to insert the flanged disks into the bearing bore of the housing and to push them in this bearing bore up to the outer ring. In the end position of the flanged disks, the larger diameter regions of the snap rings then spring automatically into a circumferential groove in the housing, so that both the flanged disks as well as the outer ring of the radial roller bearing are fixed in axial direction.
[0011] According to claim 3 , in a further preferred form of embodiment of the radial roller bearing configured according to claim 1 , the fixing elements are formed respectively by two shortened semi-segments of two spring rings having an elliptical shape that are split longitudinally centrally, the transverse axes of which are smaller and the longitudinal axes of which are larger than the diameter of the flanged disks, the semi-segments being fixed respectively with their central regions on the outer sides of the flanged disks and having an elastically inwards yielding configuration in their end regions. This form of embodiment thus differs from the first form of embodiment by the fact that the elliptical spring rings are split along their longitudinal axes into two semi-segments that are slightly shortened in their respective ends but protrude slightly beyond the flanged disks with these ends. The assembly of the flanged disks configured with these fixing elements is then performed in the same manner as in the first form of embodiment till the end regions of the semi-segments yield automatically inwards into a circumferential groove in the housing. Alternatively, it would however also be possible, in place of the semi-segments of elliptical spring rings, to fix respectively two straight spring rods in such a way with their central regions on the outer sides of the flanged disks that the end regions of the spring rods protrude slightly beyond the outer diameter of the flanged disks and likewise have an elastically inwards yielding configuration.
[0012] In the case of a radial roller bearing according to the invention configured according to claim 4 , the invention proposes a preferred form of embodiment in claim 5 in which, in contrast, the fixing elements are formed by two respective parallel spring wire segments arranged in a secant-like relationship to the inner diameter of the flanged disks, which spring wire segments are fixed with their ends on the outer sides of the flanged disks and are configured to yield elastically outwards in their central regions. Because the inner diameter of the flanged disks corresponds approximately to the diameter of the radial roller bearing, this means that the distance between the spring wire segments is smaller than the diameter of the axle and that through their central regions, the spring wire segments narrow the bores in the flanged disks partially. During assembly of the flanged disks, these spring wire segments are then likewise widened by force of hand to the diameter of the axle in order to be able to push the flanged disks onto the axle and to displace them on the axle up to the inner ring of the radial roller bearing. In the end position of the flanged disks, the spring wire segments then yield automatically elastically into a circumferential groove in the axle, so that both the flanged disks as well as the inner ring of the radial roller bearing are fixed in axial direction. In place of the fixing of the spring wire segments with their ends on the outer sides of the flanged disks, it is likewise conceivable to fix them only with one end on the outer sides of the radial roller bearing so as to enhance their elasticity.
[0013] According to claim 6 , in another advantageous form of embodiment of the radial roller bearing configured according to the invention according to claim 4 , the fixing elements are formed by two respective parallel spring wire segments arranged in a secant-like relationship to the inner diameter of the flanged disks, which spring wire segments are fixed with their ends on the outer sides of the flanged disks and the central regions of the spring wire segments are cut apart and configured to yield elastically outwards. This form of embodiment differs from the aforesaid form of embodiment above all by the fact that each spring wire segment is additionally split longitudinally centrally into two semi-segments in order to enable the use of stiffer spring wire segments and to thus enhance their elasticity. The assembly of the flanged disks configured with such fixing elements is then performed in the same manner as in the aforesaid form of embodiment till the spring wire segments yield automatically inwards into a circumferential groove in the axle.
[0014] Finally, claim 7 proposes an advantageous feature for all the forms of embodiment of both types of radial roller bearings configured according to the invention. According to claim 7 , the fixing of the fixing elements on the outer sides of the flanged disks is performed either by fusion of materials through welding, soldering or gluing points, or by positive engagement through stampings that are coped out of the flanged disks and surround the fixing elements. For these stampings for each fixing point, two metal strips are coped out of the flanged disks in such a way that the distance between these strips corresponds to the width of the fixing element and the strips project at a right angle from the flanged disks. The fixing element is then placed between these metal strips and, in a last step, the metal strips are bent around the fixing elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above-described types of a radial rolling bearing configured according to the invention will be elucidated more closely below with reference to two preferred forms of embodiment of each type and to the appended drawings. The figures show:
[0016] FIG. 1 , a schematic representation of the cross-section A-A according to FIG. 2 through a bearing arrangement showing a first type of a radial rolling bearing configured according to the invention;
[0017] FIG. 2 , a schematic representation of a side view of a first form of embodiment of the radial rolling bearing configured according to the invention according to FIG. 1 ;
[0018] FIG. 3 , a schematic representation of a side view of a second form of embodiment of the radial rolling bearing configured according to the invention according to FIG. 1 ;
[0019] FIG. 4 , a schematic representation of the cross-section B-B according to FIG. 5 through a bearing arrangement showing a second type of a radial rolling bearing configured according to the invention;
[0020] FIG. 5 , a schematic representation of a side view of a first form of embodiment of the radial rolling bearing configured according to the invention according to FIG. 4 ;
[0021] FIG. 6 , a schematic representation of a side view of a second form of embodiment of the radial rolling bearing configured according to the invention according to FIG. 4 .
DETAILED DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 shows a schematic representation of a first type of a radial roller bearing 1 which is made up substantially out of a smooth cylindrical outer ring 3 which is inserted into a housing 2 and of a roller crown ring 4 which is arranged in this outer ring 3 . This roller crown ring 4 is formed by a plurality of roller-shaped rolling elements 6 which are inserted into a bearing cage 5 and retained uniformly spaced in peripheral direction by the cage 5 . These rolling elements 6 roll on an outer raceway 8 formed by the inner peripheral surface 7 of the outer ring 3 and on an inner raceway 12 formed by the outer peripheral surface 9 of a smooth cylindrical inner ring 11 which is slipped onto a shaft 10 . It is to be seen clearly that the axial guidance of the roller crown ring 4 is accomplished through two separate flanged disks 15 , 16 that bear against the axial sides 13 , 14 of the outer ring 3 , which flanged disks 15 , 16 together with the outer ring 3 are fixed in axial direction by fixing elements 19 , 20 which engage into circumferential grooves 17 , 18 in the housing 2 , which fixing elements 19 , 20 and flanged disks 15 , 16 , are configured according to the invention as a fixedly connected assembly.
[0023] It can be further seen in FIG. 2 that the fixing elements 19 , 20 in a first form of embodiment of the radial roller bearing 1 according to the invention are formed by two spring rings 21 , 22 of elliptical shape which are smaller along their transverse axes 23 , 24 and larger along their longitudinal axes 25 , 26 than the diameter of the flanged disks 15 , 16 . The spring rings 21 , 22 are fixed with their smaller diameter regions 21 a, 21 b, 22 a, 22 b by welding, soldering or gluing points 39 , 40 , 41 . 42 on the outer sides 27 , 28 of the flanged disks 15 , 16 and are configured in their larger diameter regions 21 c, 21 d, 22 c, 22 d which protrude slightly beyond the flanged disks to yield elastically inwards in such a way that, during assembly of the flanged disks 15 , 16 , these regions can be deformed by force of hand onto the diameter of the flanged disks 15 , 16 and spring in their end position automatically into the circumferential grooves 17 , 18 in the housing 2 .
[0024] In contrast, in the second form of embodiment of the radial roller bearing 1 configured according to the invention illustrated in FIG. 3 , the fixing elements 19 , 20 are formed respectively by two shortened semi-segments 29 , 30 , 31 , 32 of two elliptically shaped and longitudinally centrally split spring rings which, similar to the first form of embodiment, are smaller along their transverse axes 23 , 24 and larger along their longitudinal axes 25 , 26 than the diameter of the flanged disks 15 , 16 . These semi-segments 29 , 30 , 31 , 32 , too, are fixed their central regions 29 a, 30 a, 31 a, 32 a by welding, soldering or gluing points 39 , 40 , 41 , 42 on the outer sides 27 , 28 of the flanged disks 15 , 16 , and their end regions 29 b, 29 c, 30 b, 30 c, 31 b, 31 c, 32 b, 32 c are configured to yield elastically inwards in such a way that, during assembly of the flanged disks 15 , 16 , these regions be deformed by force of hand onto the diameter of the flanged disks 15 , 16 and spring in their end position automatically into the circumferential grooves 17 , 18 in the housing 2 .
[0025] Further, FIG. 4 shows a schematic representation of a second type of a radial roller bearing 1 . 1 which differs from the first type through a reversal of functions and is made up substantially of a smooth cylindrical inner ring 3 . 1 which is slipped onto an axle 2 . 1 and of a roller crown ring 4 . 1 which is arranged on this inner ring 3 . 1 . This roller crown ring 4 . 1 is likewise formed by a plurality of roller-shaped rolling elements 6 . 1 which are inserted into a bearing cage 5 . 1 and retained uniformly spaced in peripheral direction by the cage 5 . 1 . These rolling elements 6 . 1 roll on an inner raceway 8 . 1 formed by the outer peripheral surface 7 . 1 of the inner ring 3 . 1 and on an outer raceway 12 . 1 formed by the inner peripheral surface 9 . 1 of a smooth cylindrical outer ring 11 . 1 which is inserted into a rotating part 10 . 1 . It is to be clearly seen that the axial guidance of the roller crown ring 4 . 1 is accomplished in this case through two separate flanged disks 15 . 1 , 16 . 1 that bear against the axial sides 13 . 1 , 14 . 1 of the inner ring 3 . 1 and which together with the inner ring 3 . 1 are fixed in axial direction by fixing elements 19 . 1 , 20 . 1 which engage into circumferential grooves 17 . 1 , 18 . 1 in the axle 2 . 1 , which fixing elements 19 . 1 , 20 . 1 and flanged disks 15 . 1 , 16 . 1 , are likewise configured according to the invention as a fixedly connected assembly.
[0026] The first form of embodiment of such a radial roller bearing 1 . 1 according to the invention shown in FIG. 5 is characterised by the fact that the fixing elements 19 . 1 , 20 . 1 are formed respectively by two parallel spring wire segments 33 , 34 , 35 , 36 arranged in a secant-like relationship to the inner diameter of the flanged disks 15 . 1 , 16 . 1 , which spring wire segments are fixed with their ends 33 a, 33 b, 34 a, 34 b, 35 a, 35 b, 36 a, 36 b on the outer sides 37 , 38 of the flanged disks 15 . 1 , 16 . 1 through stampings 43 , 44 , 45 , 46 coped out of the flanged disks 15 . 1 , 16 . 1 and are configured to yield elastically outwards in their central regions. It is to be clearly seen that the distance of the spring wire segments 33 , 34 , 35 , 36 from one another is smaller than the diameter of the axle 2 . 1 , so that through their central regions 33 c, 34 c, 35 c, 36 c, the spring wire segments narrow the bores in the flanged disks 15 . 1 , 16 . 1 partially. During assembly of the flanged disks, 15 . 1 , 16 . 1 the spring wire segments 33 , 34 , 35 , 36 are then likewise widened by force of hand onto the diameter of the axle 2 . 1 and the flanged disks 15 . 1 , 16 . 1 are slipped onto the axle 2 . 1 , so that, in their end position, the spring wire segments 33 , 34 , 35 , 36 yield automatically inwards into the circumferential groove 17 . 1 , 18 . 1 in the axle 2 . 1 .
[0027] Finally, FIG. 6 further shows a second form of embodiment of a radial roller bearing 1 . 1 . configured according to the invention, in which the fixing elements 19 . 1 , 20 . 1 are formed respectively by two parallel spring wire segments 33 , 34 , 35 , 36 arranged in a secant-like relationship to the inner diameter of the flanged disks 15 . 1 , 16 . 1 , which spring wire segments, however, are fixed with their ends 33 a, 33 b, 34 a, 34 b, 35 a, 35 b, 36 a, 36 b through welding, soldering or gluing points 39 , 40 , 41 , 42 on the outer sides 37 . 1 , 38 . 1 of the flanged disks 15 . 1 , 16 . 1 and are additionally cut apart in their central regions 33 c, 34 c, 35 c, 36 c to enhance their elasticity. The assembly of the flanged disks 15 . 1 , 16 . 1 configured with these fixing elements 19 . 1 , 20 . 1 is then performed in the same manner as in the first form of embodiment till the spring wire segments 33 , 34 , 35 , 36 yield automatically inwards into the circumferential groove 17 . 1 , 17 . 2 in the axle 2 . 1 .
[0000]
List of reference symbols
1
Radial roller bearing
1.1
Radial roller bearing
2
Housing
2.1
Axle
3
Outer ring of 1
3.1
Inner ring of 1.1
4
Roller crown ring of 1
4.1
Roller crown ring of 1.1
5
Bearing cage of 1
5.1
Bearing cage of 1.1
6
Rolling element of 1
6.1
Rolling element of 1.1
7
Inner peripheral surface of 3
7.1
Outer peripheral surface of 3.1
8
Outer raceway for 6
8.1
Inner raceway for 6.1
9
Outer peripheral surface of 10/11
9.1
Inner peripheral surface of 10.1/11.1
10
Shaft
10.1
Rotating part
11
Inner ring of 1
11.1
Outer ring of 1.1
12
Inner raceway for 6
12.1
Outer raceway for 6.1
13
Axial side of 3
13.1
Axial side of 3.1
14
Axial side of 3
14.1
Axial side of 3.1
15
Flanged disk on 3
15.1
Flanged disk on 3.1
16
Flanged disk on 3
16.1
Flanged disk on 3.1
17
Groove in 2
17.1
Groove in 2.1
18
Groove in 2
18.1
Groove in 2.1
19
Fixing element for 15
19.1
Fixing element for 15.1
20
Fixing element for 16
20.1
Fixing element for 16.1
21
Spring ring
21a
Small diameter region of 21
21b
Small diameter region of 21
21c
Large diameter region of 21
21d
Large diameter region of 21
22
Spring ring
22a
Small diameter region of 22
22b
Small diameter region of 22
22c
Large diameter region of 22
22d
Large diameter region of 22
23
Transverse axis of 21
24
Transverse axis of 22
25
Longitudinal axis of 21
26
Longitudinal axis of 22
27
Outer side of 15
28
Outer side of 16
29
Semi-segment
29a
Central region of 29
29b
End region of 29
29c
End region of 29
30
Semi-segment
30a
Central region of 30
30b
End region of 30
30c
End region of 30
31
Semi-segment
31a
Central region of 31
31b
End region of 31
31c
End region of 31
32
Semi-segment
32a
Central region of 32
32b
End region of 32
32c
End region of 32
33
Spring wire segment
33a
End of 33
33b
End of 33
33c
Central region of 33
34
Spring wire segment
34a
End of 34
34b
End of 34
34c
Central region of 34
35
Spring wire segment
35a
End of 35
35b
End of 35
35c
Central region of 35
36
Spring wire segment
36a
End of 36
36b
End of 36
36c
Central region of 36
37
Outer side of 15.1
38
Outer side of 16.1
39
Welding, soldering or gluing point
40
Welding, soldering or gluing point
41
Welding, soldering or gluing point
42
Welding, soldering or gluing point
43
Stamping
44
Stamping
45
Stamping
46
Stamping | A radial roller bearing comprises a smooth cylindrical outer ring inserted in a housing with a roller race arranged in the outer ring. The roller race is formed by a plurality of roller-shaped rolling elements inserted in a bearing cage, which holds said rolling elements evenly spaced in a circumferential direction. The rolling elements roll off an outer raceway formed by the inner shell surface of the outer ring, and off an inner raceway formed by the outer shell surface of a shaft to be mounted, or formed by a smooth cylindrical inner ring fitted onto the shaft. The axial guidance of the roller race is accomplished by way of two separate flanged rings abutting the axial sides of the outer ring which, together with the outer ring are axially fixed in place by way of safety elements engaging with circumferential grooves in the housing. The safety elements for the flanged rings and the outer ring, and the flanged rings are fixedly connected. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device having quantum-wave interference layers that reflect carriers, or electrons and holes, effectively. In particular, the invention relates to light-emitting semiconductor devices including a laser (LD) and a light-emitting diode (LED) with improved luminous efficiency by effectively confining carriers within an active layer. Further, the present invention relates to semiconductor devices including a field effect transistor (FET) and a solar cell with improved carrier reflectivity.
2. Description of the Related Art
An LD has been known to have a double hetero junction structure whose active layer is formed between n-type and p-type cladding layers. The cladding layers function as potential barriers for effectively confining carriers, or electrons and holes, within the active layer.
However, a problem persists in luminous efficiency. Carriers overflow the potential barriers of the cladding layers, which lowers luminous efficiency. Therefore, further improvement has been required, as presently appreciated by the present inventors.
As a countermeasure, forming cladding layers with a multi-quantum well structure of a first and a second layers as a unit has been suggested by Takagi et al. (Japanese Journal of Applied Physics. Vol. 29, No. 11, November 1990, pp. L1977-L1980). This reference, however, does not teach or suggest values of kinetic energy of carriers to be considered and the degree of luminous intensity improvement is inadequate.
SUMMARY OF THE INVENTION
The inventors of the present invention conducted a series of experiments and found that the suggested thicknesses of the first and the second layers by Takagi et al. were too small to confine electrons, and that preferable thicknesses of the first and second layers are 4 to 6 times larger than those suggested by Takagi et al. Further, the present inventors thought that multiple quantum-wave reflection of carriers might occur by a multi-layer structure with different band width, like multiple light reflection by a dielectric multi-film structure. And the inventors thought that it would be possible to confine carriers by the reflection of the quantum-wave. As a result, the inventors invented a preferable quantum-wave interference layer and applications of the same.
It is, therefore, a first object of the present invention to provide a quantum-wave interference layer, with high reflectivity to carriers, functioning as a reflecting layer. It is a second object of the present invention to improve quantum-wave reflectivity by additionally providing a new layer structure with a multi-layer structure whose band width is different with respect to each other. It is a third object of the invention to provide variations of a quantum-wave interference layer for effectively reflecting quantum-waves.
In light of these objects a first aspect of the present invention is a semiconductor device constituted by a quantum-wave interference layer having plural periods of a pair of a first layer and a second layer, the second layer having a wider band gap than the first layer. Each thickness of the first and the second layers is determined by multiplying by an odd number one fourth of a quantum-wave wavelength of carriers in each of the first and the second layers existing around the lowest energy level of the second layer.
The second aspect of the present invention is a semiconductor device constituted by a quantum-wave interference layer having plural periods of a first layer and a second layer as a unit. The second layer has a wider band gap than the first layer. A δ layer is included for sharply varying an energy band and is formed between the first and the second layers. Each thickness of the first and the second layers is determined by multiplying by odd number one fourth of quantum-wave wavelength of carriers in each of the first and the second layers, and a thickness of the δ layer is substantially thinner than that of the first and the second layers.
The third aspect of the present invention is to define each thickness of the first and the second layers as follows:
D W =n W λ W /4 =n W h/ 4[2 m W ( E+V )] ½ (1)
and
D B =n B λ B /4 =n B h/ 4(2 m B E ) ½ (2)
In Eqs. 1 and 2, h, m W , m B , E, V, and n W , n B represent a plank constant, effective mass of carrier in the first layer, effective mass of carrier in the second layer, kinetic energy of carriers at the lowest energy level around the second layer, potential energy of the second layer to the first layer, and odd numbers, respectively.
The fourth aspect of the present invention is a semiconductor device having a plurality of partial quantum-wave interference layers I k with arbitrary periods T k including a first layer having a thickness of D Wk and a second layer having a thickness of D Bk and arranged in series. The thicknesses of the first and the second layers satisfy the formulas:
D Wk =n Wk λ WK /4 =n Wk h/ 4[2 m Wk ( E k +V )] ½ (3)
and
D Bk =n Bk λ Bk /4= n Bk h/ 4(2 m Bk E k ) ½ (4).
In Eqs. 3 and 4, E k , m Wk , m Bk , and n Wk and n Bk represent plural kinetic energy levels of carriers flowing into the second layer, effective mass of carriers with kinetic energy E k +V in the first layer, effective mass of carriers with kinetic energy E k in the second layer, and arbitrary odd numbers, respectively.
The plurality of the partial quantum-wave interference layers I k are arranged in series from I 1 to I j , where j is a maximum number of k required to form a quantum-wave interference layer as a whole.
The fifth aspect of the present invention is a semiconductor device having a quantum-wave interference layer with a plurality of partial quantum-wave interference layers arranged in series with arbitrary periods. Each of the plurality of partial quantum-wave interference layers is constructed with serial pairs of the first and second layers. The widths of the first and second layers of the serial pairs are represented by (D W1 , D B1 ), . . . , (D Wk , D Bk ), . . . , (D Wj , D Bj ). (D Wk , D Bk ) is a pair of widths of the first and second layers and is defined as Eqs 3 and 4, respectively.
The sixth aspect of the present invention is to form a δ layer between a first layer and a second layer, which sharply varies the energy band and has a thickness substantially thinner than that of the first and second layers.
The seventh aspect of the present invention is a semiconductor device having a quantum-wave interference layer constituted by a plurality of semiconductor layers made of a hetero-material with different band gaps. The interference layer is constituted by a plurality of δ layers for sharply varying the energy band and being formed at an interval of one forth of a quantum-wave wavelength of carriers multiplied by an odd number. The thickness of the δ layers is significantly thinner than the width of the interval.
When a single level E of kinetic energy is adopted, the interval D B between the δ layers is calculated by Eq. 2. When plural levels E k of kinetic energy are adopted, the interval D Bk between the δ layers are calculated by Eq. 4. In the latter case, several partial quantum-wave interference layers I k with the δ layers formed at an interval D Bk in T k periods may be arranged in series from I 1 to I j to form a quantum-wave interference layer as a whole. Alternatively, the partial quantum-wave interference layer may be formed by serial S layers with intervals of D B1 , . . . , D Bk , . . . , to D Bj , and the plurality of the partial quantum-wave interference layers may be arranged in series with an arbitrary period.
The eighth aspect of the present invention is to use the quantum-wave interference layer as a reflecting layer for reflecting carriers.
The ninth aspect of the present invention is to constitute a quantum-wave incident facet in the quantum-wave interference layer by a second layer with enough thickness for preventing conduction of carriers by a tunneling effect.
The tenth aspect of the present invention is a light-emitting semiconductor device constituted by an n-type layer, a p-type layer, and an active layer that is formed between the n-type layer and the p-type layer, and wherein one of the n-type layer and the p-type layer is the quantum-wave interference layer described in one of the first to ninth aspects of the present invention.
The eleventh aspect of the present invention is a light-emitting semiconductor device with a hetero-junction structure whose active layer is formed between an n-type conduction layer and a p-type conduction layer and one of the n-type and p-type conduction layers is the quantum-wave interference layer described in one of the first to tenth aspects of the present invention. The n-type and p-type conduction layers respectively function as an n-type cladding layer and a p-type cladding layer and carriers are confined into the active layer by being reflected by the quantum-wave interference layer.
The twelfth aspect of the present invention is a field effect transistor including the quantum-wave interference layer, described in one of the first to ninth aspects of the present invention, positioned adjacent to a channel.
The thirteenth aspect of the present invention is a photovoltaic device having a pn junction structure including an n-layer and a p-layer. At least one of the n-layer and p-layer is made of a quantum-wave interference layer described in one of the first to ninth aspects of the present invention for reflecting minor carriers as a reflecting layer.
(first and third aspects of the invention)
The principle of the quantum-wave interference layer of the present invention is explained hereinafter. FIG. 1 shows a conduction band of a multi-layer structure with plural periods of a first layer W and a second layer B as a unit. A band gap of the second layer B is wider than that of the first layer W. Electrons conduct from left to right as shown by an arrow in FIG. 1 . Among the electrons, those that exist around the bottom of the second layer B are likely to contribute to conduction. The electrons around the bottom of the second layer B has a kinetic energy E. Accordingly, the electrons in the first layer W have a kinetic energy E+V which is accelerated by potential energy V due to the band gap between the first layer W and the second layer B. In other words, electrons that move from the first layer W to the second layer B are decelerated by potential energy V and return to the original kinetic energy E in the second layer B. As explained above, kinetic energy of electrons in the conduction band is modulated by potential energy due to the multi-layer structure.
When thicknesses of the first layer W and the second layer B are equal to order of quantum-wave wavelength, electrons tend to have characteristics of a wave. The wave length of the electron quantum-wave is calculated by Eqs. 1 and 2 using kinetic energy of the electron. Further, defining the respective wave number vector of first layer W and second layer B as K W and K B , reflectivity R of the wave is calculated by:
R =(| K W |−|K B |)/(| K W |+|K B |)
=([ m W ( E+V )] ½ −[m B E ] ½ )/([ m W ( E+V )] ½ +[m B E ] ½ )
=[1−( m B E/m W ( E+V )) ½ ]/[1+( m B E/m W ( E+V )) ½ ] (5).
Further, when m B =m W , the reflectivity R is calculated by:
R=[ 1−( E /( E+V )) ½ ]/[1+( E /( E+V )) ½ ] (6).
When E/(E+V)=x, Eq. 6 is transformed into:
R =(1 −x ½ )/(1 +x ½ ) (7).
The characteristic of the reflectivity R with respect to energy ratio x obtained by Eq. 7 is shown in FIG. 2 .
When the second layer B and the first layer W have S periods, the reflectivity R S on the incident facet of a quantum-wave is calculated by:
R S =[(1 −x S )/(1 +x S )] 2 (8).
When the formula x≦1/10 is satisfied, R≧0.52. Accordingly, the relation between E and V is satisfied with:
E≦V/ 9 (9).
Since the kinetic energy E of conducting electrons in the second layer B exists around the bottom of the conduction band, the relation of Eq. 9 is satisfied and the reflectivity R at the interface between the second layer B and the first layer W becomes 52% or more. Consequently, the multi-layer structure having two kinds of layers with different band gaps to each other enables effective quantum-wave reflection.
Further, utilizing the energy ratio x enables the thickness ratio D B /D W of the second layer B to the first layer W to be obtained by:
D B /D W =[m W /( m B x )] ½ (10).
Thicknesses of the first layer W and the second layer B are determined for selectively reflecting one of holes and electrons, because of a difference in potential energy between the valence and the conduction bands, and a difference in effective mass of holes and electrons in the first layer W and the second layer B. Namely, the optimum thickness for reflecting electrons is not optimum for reflecting holes. Eqs. 5-10 refer to a structure of the quantum-wave interference layer for reflecting electrons selectively. The thickness for selectively reflecting electrons is designed based on a difference in potential energy of the conduction band and effective mass of electrons. Further, the thickness for selectively reflecting holes is designed based on a difference in potential energy of the valence band and effective mass of holes, realizing another type of quantum-wave interference layer for reflecting only holes and allowing electrons to pass through.
(fourth aspect of the invention)
As shown in FIG. 3, a plurality of partial quantum-wave interference layers I k may be formed corresponding to each of a plurality of kinetic energy levels E k . Each of the partial quantum-wave interference layers I k has T k periods of a first layer W and a second layer B as a unit whose respective thicknesses (D Wk , D Bk ) are determined by Eqs. 3 and 4. The plurality of the partial quantum-wave interference layer I k is arranged in series with respect to the number k of kinetic energy levels E k . That is, the quantum-wave interference layer is formed by a serial connection of I 1 , I 2 , . . . , and I j . As shown in FIG. 3, electrons with each of the kinetic energy levels E k are reflected by the corresponding partial quantum-wave interference layers I k . Accordingly, electrons belonging to each of the kinetic energy levels from E 1 to E j are reflected effectively. By designing the intervals between the kinetic energies to be short, thicknesses of the first layer W and the second layer B (D Wk , D Bk ) in each of the partial quantum-wave interference layers I k vary continuously with respect to the value k.
(fifth aspect of the invention)
As shown in FIG. 4, a plurality of partial quantum-wave interference layers may be formed with an arbitrary period. Each of the partial quantum-wave interference layers, I 1 , I 2 , . . . is made of serial pairs of the first layer W and the second layer B with widths (D Wk , D Bk ) determined by Eqs 3 and 4. That is, the partial quantum-wave interference layer, e.g., I 1 , is constructed with serial layers of width (D W1 , D B1 ), (D W2 , D B2 ), . . . , (D Wj , D Bj ), as shown. A plurality I 1 , I 2 , . . . of layers such as layer I 1 are connected in series to form the total quantum-wave interference layer. Accordingly, electrons of the plurality of kinetic energy levels E k are reflected by each pair of layers in each partial quantum-wave interference layers. By designing the intervals between kinetic energies to be short, thicknesses of the pair of the first layer W and the second layer B (D Wk , D Bk ) in a certain partial quantum-wave interference layer varies continuously with respect to the value k.
(second and sixth aspects of the invention)
The second and sixth aspects of the present invention are directed to forming a δ layer at the interface between the first layer W and the second layer B. The δ layer has a relatively thinner thickness than both of the first layer W and the second layer B and sharply varies an energy band. Reflectivity R of the interface is determined by Eq. 7. By forming the δ layer, the potential energy V of an energy band becomes larger and the value x of Eq. 7 becomes smaller. Accordingly, the reflectivity R becomes larger.
Variations are shown in FIGS. 8A to 8 C. The δ layer may be formed on both ends of the every first layer W as shown in FIGS. 8A to 8 C. In FIG. 8A, the δ layers are formed so that an energy level higher than that of the second layer B may be formed. In FIG. 8B, the δ layers are formed so that an energy level lower than that of the first layer W may be formed. In FIG. 8C, the δ layers are formed so that the energy level higher than that of the second layer B and the energy level lower than that of the first layer W may be formed. As an alternative to each of the variations shown in FIGS. 8A to 8 C, the δ layer can be formed on one end of the every first layer W.
Forming one δ layer realizes large quantum-wave reflectivity at the interface between the first layer W and the second layer B and a plurality of the δ layers realizes a larger reflectivity as a whole.
(seventh aspect of the invention)
The seventh aspect of the present invention is to form a plurality of δ layers in second layer B at an interval D B determined by Eq. 2. Variations are shown in FIGS. 5 to 7 . In FIG. 5, the δ layer is formed so that an energy level higher than that of the second layer B may be formed. In FIG. 6, the δ layer is formed so that an energy level lower than that of the second layer B may be formed. In FIG. 7, the δ is formed alternately so that the higher and lower energy levels than the second layer B may be formed.
When a plurality of energy levels of electrons are set, the interval D B between the δ layers in the second layer B corresponds to thicknesses D Bk of the second layer B in FIGS. 3 and 4. Accordingly, a quantum-wave interference layer can be made from a serial connection of a number j of partial quantum-wave interference layers I k as shown in FIG. 3 . In this case, δ layers are disposed at an interval D Bk with period T k in each partial interference layers and the number j corresponds to the kinetic energy of electrons. Alternatively, the δ layers may be arranged at an interval from D B1 to D Bj in series and may be formed in the second layer B so as to make the partial quantum-wave interference layers and the plurality of the partial quantum-wave interference layers, arranged in series as shown in FIG. 4 .
(eighth aspect of the invention)
The eighth aspect of the present invention is directed to a quantum-wave interference layer that functions as a reflecting layer and selectively confines carriers in an adjacent layer. As mentioned above, the quantum-wave interference layer can be designed to confine either electrons or holes selectively.
(ninth aspect of the invention)
The ninth aspect of the present invention, or forming a thick second layer B 0 at the side of an incident plane of the quantum-wave interference layer, and effectively prevents conduction by tunneling effects and reflects carriers.
(tenth and eleventh aspects of the invention)
According to the tenth and eleventh aspects of the present invention, the quantum-wave interference layer is formed in at least one of the p-type layer and an n-type layer sandwiching an active layer of a light-emitting semiconductor device and effectively realizes confinement of carriers in the active layer and increases output power.
(twelfth aspect of the invention)
According to the twelfth aspect of the present invention, a quantum-wave interference layer is formed adjacent to a channel of a field effect transistor realizes effective confinement of carriers therein which conduct through the channel so as to improve an amplification factor of the transistor and signal-to-noise (S/N) ratio.
(thirteenth aspect of the invention)
According to the thirteenth aspect of the present invention, a quantum-wave interference layer is formed in a photovoltaic device with a pn junction structure and reflects minor carriers to the p-type or n-type layer and prevents drift of the carriers to a reverse direction around the junction, improving opto-electric conversion efficiency.
BRIEF DESCRIPTION OF THE DRAWING
Other objects, features, and characteristics of the present invention will become apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of the specification, and wherein reference numerals designate corresponding parts in the various in the various figures, wherein:
FIG. 1 is an explanatory view of a conduction band of a multi-layer structure according to first and third aspects of the present invention;
FIG. 2 is a graph showing a relation between an energy ratio x and a reflectivity R;
FIG. 3 is an explanatory view of partial quantum-wave interference layers I k according to the fourth aspect of the present invention;
FIG. 4 is an explanatory view of partial quantum-wave interference layers I k according to the fifth aspect of the present invention;
FIGS. 5 - 7 are explanatory views of δ layers according to the seventh aspect of the present invention;
FIGS. 8 A- 8 C are explanatory views of δ layers according to the second and the sixth aspects of the present invention;
FIG. 9 is a sectional view showing a first exemplary structure of a light-emitting device (Example 1);
FIGS. 10A and 10B are views showing energy diagrams of the light-emitting device (Example 1 and 3);
FIG. 11 is a sectional view showing a second exemplary structure of a light-emitting device (Example 2);
FIGS. 12A and 12B are views showing energy diagrams of the light-emitting device in Example 2;
FIG. 13 is a graph showing a relationship between thickness of the first layer W and luminous intensity in Example 1;
FIG. 14 is a graph showing the relationship between thickness of the second layer B and luminous intensity in Example 1;
FIG. 15 is a graph showing the relationship between thickness of a δ layer and luminous intensity in Example 3;
FIG. 16 is a view showing an energy diagram of the MOSFET in Example 4; and
FIG. 17 is a view showing the energy diagram of the photovoltaic device in Example 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will be more fully understood by reference to the following examples.
EXAMPLE 1
FIG. 9 is a sectional view of a light-emitting diode (LED) 100 in which a quantum-wave interference layer is formed in a p-type cladding layer. The p-type cladding layer of the LED 100 has a substrate 10 made of gallium arsenide (GaAs). A GaAs buffer layer 12 of n-type conduction, having a thickness generally of 0.3 μm and an electron concentration of 2×10 18 /cm 3 , is formed on the substrate 10 . An n-Ga 0.51 In 0.49 P contact layer 14 of n-type conduction, having a thickness generally of 0.3 μm and electron concentration of 2×10 18 /cm 3 , is formed on the buffer layer 12 . An n-Al 0.51 In 0.49 P cladding layer 16 of n-type conduction, having a thickness generally of 1.0 μm and an electron concentration of 1×10 18 /cm 3 , is formed on the contact layer 14 . A non-doped Ga 0.51 In 0.49 P emission layer 18 , having a thickness generally of 14 nm, is formed on the cladding layer 16 . An electron reflecting layer 20 functioning as a quantum-wave interference layer is formed on the emission layer 18 . A p-Al 0.51 In 0.49 P cladding layer 22 of p-type conduction, having a thickness generally of 1.0 μm and a hole concentration of 1×10 18 /cm 3 , is formed on the electron reflecting layer 20 . A Ga 0.51 In 0.49 P second contact layer 24 of p-type conduction, having a thickness generally of 0.2 μm and a hole concentration of 2×10 18 /cm 3 , is formed on the cladding layer 22 . A p-GaAs first p-type contact layer of p-type conduction, having a thickness generally of 0.1 μm, is formed on the second contact layer 24 . An electrode layer 28 made of gold and germanium (Au/Ge), having a thickness generally of 0.2 μm, is formed so as to cover the entire back of the substrate 10 . Another electrode layer 30 made of gold and zinc (Au/Zn), having a thickness generally of 0.2 μm, is formed on some portion of the first contact layer 26 . The substrate 10 has a diameter of 2.0 inch and the normal direction of its main surface is offset toward [011] axis by 15 degree from plane (100).
The LED 100 was manufactured by gas source molecular beam epitaxial deposition (GS-MBE), which is an epitaxial growth method performed under extremely a high vacuum condition. GS-MBE is different from a conventional MBE, which supplies group III and V elements both from the sources. In GS-MBE, group III elements such as indium (In), gallium (Ga), and aluminum (Al) are supplied from a solid source and group V elements such as arsenic (As) and phosphorus (P) are supplied by heat decomposition of gas material such as AsH 3 and PH 3 .
In the energy diagrams of FIGS. 10A and 10B, the n-type cladding layer 16 , the emission layer 18 , and the electron reflecting layer 20 are shown. FIG. 10A shows an energy level of conduction and valence bands on the condition that no external voltage is applied to the LED 100 , and FIG. 10B shows the energy level on the condition that the external voltage is applied thereto. The electron reflecting layer 20 , or a quantum-wave interference layer, has a multi-quantum layer structure with 15 periods of a p-Ga 0.51 In 0.49 P well layer as a first layer W and a p-Al 0.51 In 0.49 P barrier layer as a second layer B. A δ layer made of p-Al 0.33 Ga 0.33 In 0.33 P is formed at each interface between the first layer W and the second layer B. Thicknesses of the first layer W and the second layer B are respectively determined according to Eqs. 1 and 2. Only the first second layer B 0 is designed to have enough thickness to prevent conduction of carriers by tunneling effects. The δ layer is formed to have a thickness of 1.3 nm. Accordingly, electrons injected from the n-type cladding layer 16 into the emission layer 18 are reflected effectively by the electron reflecting layer 20 and confined into the emission layer 18 . Although the valence band of the electron reflecting layer 20 also has a multiple period of energy level, holes are designed not to be reflected thereby. The respective thickness of the first layer W and the second layer B in the reflecting layer 20 is designed to reflect electrons only. Therefore, holes injected from the p-type cladding layer 22 pass through the electron reflecting layer 20 thus reaching the emission layer 18 easily and being confined therein by the cladding layer 16 .
Luminous intensity was measured by varying the respective thickness of the first layer W and the second layer B. FIG. 13 shows a result when the thickness of the second layer B was fixed at 7 nm and that of the first layer W was varied. As shown in FIG. 13, a peak of luminous intensity was obtained when the thickness of the first layer W was 5 nm. Then, luminous intensity was measured fixing the thickness of the first layer W at 5 nm and varying that of the second layer B, the result being shown in FIG. 14 . When the second layer B has a thickness of 7 nm, luminous intensity showed its peak. As a result, the LED 100 with the electron reflecting layer 20 was found to have a maximum luminous intensity when the first layer W had a thickness of 5 nm and the second layer B had a thickness of 7 nm. The maximum luminous intensity was eightfold of that of a LED without the electron reflecting layer 20 .
EXAMPLE 2
FIG. 11 shows an LED 200 used in the present embodiment. The LED 200 has a hole reflecting layer 32 additionally to the LED 100 structure for reflecting holes. The hole reflecting layer 32 is formed between the n-type cladding layer 16 and the emission layer 18 and has a same structure as the electron reflecting layer 20 of the LED 100 . The thickness of the first layer W is 1.0 nm and that of the second layer B is 1.2 nm. FIG. 12A shows an energy level of conduction and valance bands on the condition that no external voltage is applied to the LED 200 and FIG. 12B shows a condition where the external voltage is applied thereto. As a result, the LED 200 thus obtained provides a luminous intensity of 16 fold compared with an LED with as same structure as the LED 200 but without the electron reflecting layer 20 and the hole reflecting layer 32 .
EXAMPLE 3
In this embodiment, an LED has a structure as same as that of the LED 100 of FIG. 10A. A thickness of the δ layer is varied in many samples and a measured luminous intensity of the LED for the various thicknesses is shown in FIG. 15 . The luminous intensity reaches its peak when the thickness of the δ layer is about 1.3 nm while the thicknesses of the first layer W and the second layer B are 5.6 nm and 7.5 nm, respectively, which slightly differed from the optimized thickness in Example 1. The obtained luminous intensity of the LED 300 was 1.5 fold of that of an LED without the δ layer.
EXAMPLE 4
FIG. 16 is an energy diagram of a MOSFET according to the present embodiment. A conventional MOSFET has a channel of an inversion layer just beneath an insulation film 40 , conducting minor carriers through the channel. A larger voltage is applied to a gate electrode 42 of the conventional MOSFET and thus more carriers in the channel of the inversion layer overflow. As a result, signal-to-noise (S/N) ratio decreases. In order to solve the problem, a quantum-wave interference layer 20 was formed below the channel as shown in FIG. 16 having a multi-layer structure with arbitrary periods including the second layer B made of silicon (Si) and the first layer W made of Ge. As a result, more carriers were confined in the channel of the inversion layer. In addition, S/N ratio was improved, response time was shortened, and driving voltage was lowered. When an n-type channel and electrons as a carrier were used, the most preferable thickness of the second layer B was 6.8 nm and that of the first layer W was 2.0 nm.
EXAMPLE 5
A quantum-wave interference layer can be formed in a photovoltaic device with a pn junction structure. As shown in FIG. 17, an electron reflecting layer 20 is formed in a p-layer, and a hole reflecting layer 32 is formed in an n-layer. When light is incided on the pn junction of a conventional device without the reflecting layers 20 and 32 , pairs of an electron and a hole are formed. Most of the electrons in the conventional device are accelerated to the n-layer due to potential declination of conduction bands while the rest of the electrons drift to the p-layer so as not to contribute to induction of voltage. The larger the intensity of the incident light becomes, the more electrons overflow to the p-layer. Accordingly, the electron reflecting layer 20 , or a quantum-wave interference layer, was formed in the p-layer in this embodiment. As a result, drifting of electrons were prevented, which enabled more electrons to conduct to the n-layer. Similarly, some of holes do not contribute to induction of voltage on account of holes drifting to the n-layer in a conventional element. Accordingly, in this embodiment the hole reflecting layer 32 , or a quantum-wave interference layer, was formed in the n-layer. As a result, drifting of holes were prevented and enabled more holes to conduct to the p-layer. Consequently, leakage of current was minimized and efficiency of electro-optic conversion was improved.
In the present invention, embodiments of LEDs with quantum-wave interference layers are shown and discussed as Example 1-5. Alternatively, the quantum-wave interference layer can be applied to a laser diode. Further, in Example 1-5, the quantum-wave interference layer was formed to have a multi-layer structure made of ternary compounds including Ga 0.51 In 0.49 P and Al 0.51 In 0.49 P. Alternatively, the interference layer can be made of quaternary compounds such as Al x Ga y In 1-x-y P, selecting arbitrary composition ratio within the range of 0≦x≦1, 0≦y≦1, and 0≦x+y≦1. As another alternative, the quantum-wave interference layer can be made of group III-V compound semiconductor, group II-VI compound semiconductors, Si and Ge, and semiconductors of other hetero-material.
While the invention has been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, the description is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The present document claims the benefit of Japanese priority document, filed in Japan on Apr. 25, 1997, the entire contents of which is incorporated herein by reference.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A semiconductor device is constituted by a quantum-wave interference layer with plural periods of a pair of a first layer W and a second layer B. The second layer B has wider band gap than the first layer W. Each thickness of the first layer W and the second layer B is determined by multiplying by an odd number one fourth of wavelength of quantum-wave of carriers in each of the first layer W and the second layer B existing around the lowest energy level of the second layer B. A δ layer, for sharply varying energy band, is formed at an every interface between the first layer W and the second layer B and has a thickness substantially thinner than the first layer W and the second layer B. The quantum-wave interference layer functions as a reflecting layer of carriers for higher reflectivity. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of PCT International Application PCT/JP2009/001007 filed on Mar. 5, 2009, which claims priority to Japanese Patent Application No. 2008-176828 filed on Jul. 7, 2008. The disclosures of these applications including the specifications, the drawings, and the claims are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] The present disclosure relates to a coupled ring oscillator which is capable of producing a highly accurate fine phase using a plurality of ring oscillators.
[0003] To record information on an optical disc medium such as a digital versatile disc (DVD), a Blu-ray Disc (BD), and the like, it is necessary to generate a specific write waveform for reducing interference of a write signal. Generation of such a specific write waveform requires a highly accurate fine phase, and more specifically, a fine phase equal to or finer than one-fortieth of a write data rate is necessary. However, it is difficult to realize such very fine phase accuracy by a single inverter chain (a ring oscillator), because a phase delay thereof is smaller than a delay of a single inverter circuit.
[0004] Therefore, conventionally, a finer phase than a phase generable by a single ring oscillator is generated using a plurality of ring oscillators, specifically, by connecting inverter circuits in the plurality of ring oscillators together by phase coupling circuits so that an output phase of each of the ring oscillators is slightly shifted. As another example, a resistance ring in which a plurality of resistors are connected, and connection nodes of the resistors in the resistance ring are connected to connections nodes of phase delay elements in a plurality of ring oscillators, thereby generating a fine phase.
[0005] In the above-described coupled ring oscillator including a plurality of ring oscillators and a phase coupling ring comprised of phase coupling circuits each of which couples output phases of inverter circuits between the ring oscillators, the phase coupling ring is electrically disconnected at arbitrary parts to cause the ring oscillators to oscillate in a state where coupling of the output phases of the inverter circuits is weakened between different ring oscillators, and then, the phase coupling ring is closed again, thereby performing initialization.
[0006] The prevent inventors have found the following fact. A coupled ring oscillator has the same number of different oscillation states as the number of ring oscillators provided in the coupled ring oscillator. When the coupled ring oscillator falls into an undesired abnormal oscillation state, the oscillation frequency is reduced, and thus, a fine phase cannot be obtained. This mechanism will be hereinafter described.
[0007] FIG. 13 is a diagram illustrating a typical configuration of a conventional coupled ring oscillator. The coupled ring oscillator includes three ring oscillators 10 and a single phase coupling ring 20 . Each of the ring oscillators 10 includes three inverter circuits 11 which are coupled together to form a ring shape. The phase coupling ring 20 includes the same number of phase coupling circuits 21 as the total number of the inverter circuits 11 , i.e., nine phase coupling circuits 21 , which are coupled together to form a ring shape. Each of the phase coupling circuits 21 couples an output of one of the inverter circuits 11 in one of the ring oscillators 10 to an output of one of the inverter circuits 11 in another one of the ring oscillators 10 in phase or in reverse phase with respect to one another. Then, outputs P 1 -P 9 of the ring oscillators 10 serve as outputs of the coupled ring oscillator. Each ring oscillator 10 can generate only the same number of phases as the number of the inverter circuits 11 provided in the ring oscillator 10 (e.g., three in the example of FIG. 13 ). However, when being combined, a plurality of the ring oscillators 10 can generate more phases (e.g., nine in the example of FIG. 13 ). For convenience, it is assumed that each of the phase coupling circuits 21 is an inverter circuit, the following description will be given.
[0008] When a signal passes through one of the phase coupling circuits 21 , a phase is delayed by an angle obtained by adding θ which is an internal delay of the phase coupling circuit 21 (e.g., a time required for an electron passes through the inside of a transistor, and the like) to 180° caused by logic inversion. That is, a phase difference φ (which will be hereinafter referred to as a “phase coupling angle”) between two points coupled by a single one of the phase coupling circuits 21 is expressed by:
[0000] φ=180+θ
[0009] In the coupled ring oscillator, adjacent outputs (e.g., the outputs P 1 and P 2 ) are coupled via two of the phase coupling circuits 21 , and thus, a phase difference between the adjacent outputs is 2×(180+θ). Since a phase difference of 360° can be considered as 0°, the phase difference between the adjacent outputs is 2θ. Considering the symmetry of the circuit, a phase difference between any adjacent two of the outputs is 2θ, which is a minimum phase difference that the coupled ring oscillator can generate. When the coupled ring oscillator is in a stable state, a phase of each output is returned to its original phase with one cycle delay (i.e., 360°) due to the periodicity of the phase. Therefore, the minimum phase difference 2θ of the coupled ring oscillator of FIG. 13 is 40°, which is one ninth of 360°. Assuming that p is the number of the inverter circuits 11 in each of the ring oscillators 10 , and q is the number of the ring oscillators 10 , when θ is generalized, θ can be expressed by following equation:
[0000] θ=180 /pq
[0010] The smaller the internal delay θ of the phase coupling circuit 21 is, i.e., the smaller the phase coupling angle φ is, the more stable state of the coupled ring oscillator can be obtained. When the phase coupling circuit 21 is an inverter circuit, the minimum value of the phase coupling angle φ is 180°. When each of the ring oscillators is configured to include four stages of single-ended inverter circuits, the phase coupling angle φ is maximum, i.e., 270°. Therefore, it is presumed that, when 180<φ≦270°, the coupled ring oscillator stably oscillates. It is also presumed that, when the phase coupling angle φ is out of the range indicated above, the coupled ring oscillator falls into an abnormal oscillation state.
[0011] Next, a general expression for the phase coupling angle φ is derived. For convenience, each of p and q is an odd number. First, the minimum value φ min of the phase coupling angle φ is expressed by the following equation:
[0000] φ min =180+180 /pq
[0000] The phase difference between the outputs of two of the inverter circuits 11 connected together in each of the ring oscillators 10 (e.g., the outputs P 1 and P 7 in the example of FIG. 13 ) is q times of the phase coupling angle φ (i.e., qφ), since a signal passes through q phase coupling circuits 21 in the phase coupling ring 20 . Then, based on the above,
[0000]
q
ϕ
=
q
ϕ
min
+
360
n
=
q
(
180
+
180
/
pq
)
+
360
n
=
180
(
q
+
1
/
p
+
2
n
)
[0000] Note that n is an integer of 0 or greater, and 360n is a phase delay determined in consideration of the periodicity of the phase. Therefore, the phase coupling angle φ is expressed by the following general expression:
[0000] φ=180( pq+ 1+2 np )/ pq
[0012] Furthermore, when m=(pq+1+2np)/2, the above-indicated general expression can be changed to:
[0000] φ=360 m/pq
[0000] This shows that the phase coupling angle φ corresponds to the output phase of one of the inverter circuits 11 in one of the ring oscillators 10 . That is, the phase coupling circuit 21 might couple the outputs of two of the inverter circuits 11 together with an unintended phase coupling angle φ, and thus, the oscillation operation of the coupled ring oscillator might be stabilized in the unintended phase coupled state.
[0013] In the coupled ring oscillator of FIG. 13 , a phase coupling angle φ relative to n and a phase difference Δφ between the inverter circuit 11 and the phase coupling circuit 21 are as follows. Note that, assuming that a phase difference between input and output of the inverter circuit 11 is θ′, Δφ is defined as Δφ=360−(θ′+φ). As shown in FIG. 13 , in the ring oscillator 10 including three inverter circuits 11 coupled together to form a ring shape, θ′=120.
[0000] n φ Δφ 0 200 40 1 320 −80 2 440 (=80) 160 3 560 (=200) 40 4 680 (=320) −80
Here, when n≧3, the same state is held as a state where there is a remainder when n is divided by 3. Based on this, it is understood that the coupled ring oscillator of FIG. 13 has three coupled states or oscillation states. The phase difference Δφ is 40°, when n=0. Also, the phase difference Δφ is −80° when n=1, and is 160° when n=2. That is, the phase difference Δφ greatly differs according to the state of the coupled ring oscillator. When an absolute value of the phase difference Δφ is large, a logic collision between the H level and the L level occurs between the ring oscillator 10 and the phase coupling ring 20 , and a through current flows, so that the slew rate of an output signal is reduced. As a result, the oscillation frequency of the coupled ring oscillator is reduced. Therefore, to generate a fine phase by the coupled ring oscillator, in other words, to cause the coupled ring oscillator to oscillate at a high frequency, the absolute value of the phase difference Δφ is preferably set to be as small as possible.
[0014] In general, a coupled ring oscillator including q ring oscillators has q oscillation states. Normally, the phase coupling angle φ is in the range from 180° to 270°, and thus, an abnormal oscillation state where n is 1 or larger is hardly caused. However, when, in order to obtain a finer phase, the number of inverter circuits provided in each ring oscillator is increased, or the number of ring oscillators provided in the coupled ring oscillator is increased, the number of unintended phase coupling states is increased accordingly, and thus, the risk that the coupled ring oscillator may fall into an abnormal oscillation state is increased. Specifically, when a great number of ring oscillators are provided, or when each of inverter circuits of the coupled ring oscillator has low drive capability, the phase coupling strength between the ring oscillators is reduced, and more phase errors are accumulated, so that the coupled ring oscillator possibly falls into an abnormal oscillation state. Once the coupled ring oscillator falls into an abnormal oscillation state, the coupled ring oscillator is stabilized in the abnormal oscillation state, and thus, the coupled ring oscillator cannot be recovered to a normal oscillation state. This problem cannot be solved by a conventional initialization method in which the phase coupling ring is electrically disconnected at arbitrary parts.
SUMMARY
[0015] The present invention may advantageously allow a coupled ring oscillator to oscillate in a normal oscillation state without causing the coupled ring oscillator to fall into an abnormal oscillation state, or a coupled ring oscillator which has been stabilized in an abnormal oscillation state to be recovered to a normal oscillation state.
[0016] For example, a method for initializing a coupled ring oscillator, the coupled ring oscillator including q ring oscillators each including p inverter circuits connected together to form a ring shape, where each of p and q is an integer of 2 or greater, and a phase coupling ring including (p×q) phase coupling circuits each of which is configured to couple an output of one of the p inverter circuits in one of the q ring oscillators to an output of one of the p inverter circuits in another one of the q ring oscillators in a predetermined phase relationship, and which are connected together to form a ring shape, and the method includes: fixing, for at least one group made up of selected one of the p inverter circuits in each of the q ring oscillators, outputs of the selected ones of the q inverter circuits belonging to the at least one group in phase with one another; causing the q ring oscillators to oscillate in the in-phase fixed state; and releasing, after causing the q ring oscillators to oscillate, the outputs of the q inverter circuits are released from the in-phase fixed state (see FIG. 1 ).
[0017] Thus, when starting or resetting the coupled ring oscillator, first, the phase relationship of outputs of inverter circuits in each of the ring oscillators is forced to be equal for all of the ring oscillators. This operation is called “phase equalization.” Phase equalization may be performed to one of the inverter circuits in each of the ring oscillators or all of the inverter circuits. Even when outputs of the inverter circuits are coupled via the phase coupling circuit, the relationship between the outputs of the inverter circuits is forced to be fixed in phase with one another by phase equalization. That is, the phase coupling strength between the ring oscillators is reduced. Then, in a state where phase equalization has been performed, all of the ring oscillators are caused to oscillate. Phase equalization may be performed in a state where each of the ring oscillators is in operation. Thus, in any cases, all of the ring oscillators are caused to oscillate in the same phase relationship. Thereafter, when phase equalization is released, the phase of an output of each of the inverter circuits can freely move, and shortly thereafter, the phases are coupled by the phase coupling circuits, so that the coupled ring oscillator is in the above-described state of n=0, i.e., in a normal oscillation state where the phase difference Δφ is minimum. Therefore, even when the number of the ring oscillators is large, or the drive capability of each of the inverter circuits provided in each of the phase coupling circuits is low, the coupled ring oscillator can be caused to oscillate in a normal oscillation state without falling into an abnormal oscillation state, or the coupled ring oscillator which has been stabilized in an abnormal oscillation state can be recovered to a normal oscillation state.
[0018] As a coupled ring oscillator which can perform the above-described initialization, a coupled ring oscillator includes: q ring oscillators each including p inverter circuits connected together to form a ring shape, where each of p and q is an integer of 2 or greater; a phase coupling ring including (p×q) phase coupling circuits each of which is configured to couple an output of one of the p inverter circuits in one of the q ring oscillators to an output of one of the p inverter circuits in another one of the q ring oscillators in a predetermined phase relationship, and which are connected together to form a ring shape; and a switching circuit configured to switch between a short circuit state and an open-circuit state between an output of one of the p inverter circuits in each of the q ring oscillators and an output of one of the p inverter circuits in an associated one of the q ring oscillators.
[0019] Thus, the outputs of the plurality of inverter circuits are short-circuited together, so that the outputs can be forced to be fixed in phase with one another. Also, the in-phase fixed state of the outputs of the inverter circuits can be released by releasing the short circuit state. Thus, the above-described initialization can be executed.
[0020] Preferably, the switching circuit is provided for each of the p inverter circuits in each of the q ring oscillators, and the coupled ring oscillator further includes p off-state switching elements provided so that one of the p off-state switching elements is arranged between any two of the p switching circuits. Thus, the symmetry of the circuit of the coupled ring oscillator is maintained, so that a highly accurate fine phase can be generated.
[0021] Specifically, the switching circuit includes (q−1) switching elements configured to perform an identical open/close operation, and each of the (q−1) switching elements is provided between an output of one of the p inverter circuits in one of the q ring oscillators and an output of one of the p inverter circuits in another one of the q ring oscillators. As another alternative, the switching circuit includes q switching elements configured to perform an identical open/close operation, and each of the q switching elements is provided between an output of one of the p inverter circuits in each of the q ring oscillators and a common voltage node which is provided for the switching circuit. Preferably, the coupled ring oscillator further includes: a plurality of off-state switching elements each being provided between an output of one of the p inverter circuits in each of the q ring oscillators in which the switching circuit is not provided and the common voltage node. Thus, the symmetry of the circuit of the coupled ring oscillator is maintained, so that a highly accurate fine phase can be generated.
[0022] As another coupled ring oscillator which can perform the above-described initialization, a coupled ring oscillator includes: q ring oscillators each including p inverter circuits connected together to form a ring shape, where each of p and q is an integer of 2 or greater; and a phase coupling ring including p first phase coupling circuits and (p×(q−1)) second phase coupling circuits, each of which is configured to couple an output of one of the p inverter circuits in one of the q ring oscillators to an output of one of the p inverter circuits in another one of the q ring oscillators in phase with one another, and which are connected together to form a ring shape so that one of the first coupling circuits is inserted after every (q−1) of the second phase coupling circuits, and each of the p first phase coupling circuits is configured so that an impedance of each of the p first phase coupling circuits can be switched between a normal impedance and a high impedance.
[0023] Thus, by switching the impedance of the first phase coupling circuit to a high impedance, the outputs of the plurality of inverter circuits can be forced to be fixed in phase with one another by the second phase coupling circuit. Also, the in-phase fixed state of the outputs of the inverter circuits can be released by switching the impedance of the first phase coupling circuit to a normal impedance. Thus, the above-described initialization can be executed.
[0024] Specifically, each of the p first phase coupling circuits includes a resistive element, and a switching element whose one end is connected to one end of the resistive element, and the switching elements of the p first phase coupling circuits perform an identical open/close operation. Preferably, each of the (p×(q−1)) second phase coupling circuits includes a resistive element, and an on-state switching element connected to one end of the resistive element. Thus, the symmetry of the circuit of the coupled ring oscillator is maintained, so that a highly accurate fine phase can be generated.
[0025] Each of the p first phase coupling circuits may further include a switching element which is connected to the other end of the resistive element and performs an identical open/close operation to that of the switching element connected to the one of the resistive element. Preferably, each of the (p×(q−1)) second phase coupling circuits includes a resistive element, and on-state switching elements each being connected to one of both ends of the resistive element. Thus, the symmetry of the circuit of the coupled ring oscillator is maintained, so that a highly accurate fine phase can be generated.
[0026] As another alternative, specifically, each of the p first phase coupling circuits includes a switching element, and resistive elements each being connected to one of both ends of the switching element, and the switching elements in the p first phase coupling circuits perform an identical open/close operation. Preferably, each of the (p×(q−1)) second phase coupling circuits includes an on-state switching element, and resistive elements each being connected to one of both ends of the on-state switching element. Thus, the symmetry of the circuit is maintained, so that a highly accurate fine phase can be generated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a diagram illustrating procedures for initializing a coupled ring oscillator.
[0028] FIG. 2 is a diagram illustrating a configuration of a coupled ring oscillator according to a first embodiment.
[0029] FIG. 3 is a diagram illustrating a configuration of a coupled ring oscillator according to a second embodiment.
[0030] FIG. 4 is a diagram illustrating a configuration of a coupled ring oscillator according to a third embodiment.
[0031] FIG. 5 is a circuit diagram illustrating a specific configuration of the coupled ring oscillator of FIG. 4 .
[0032] FIG. 6 is a diagram of a variation of FIG. 5 .
[0033] FIG. 7 is a diagram illustrating a configuration of a coupled ring oscillator according to a fourth embodiment.
[0034] FIG. 8 is a diagram illustrating a configuration of a coupled ring oscillator according to a fifth embodiment.
[0035] FIG. 9 is a diagram illustrating a configuration of a coupled ring oscillator according to a sixth embodiment.
[0036] FIG. 10 is a diagram illustrating a configuration of a coupled ring oscillator according to a seventh embodiment.
[0037] FIG. 11 is a diagram illustrating a configuration of a coupled ring oscillator according to an eighth embodiment.
[0038] FIG. 12 is a diagram illustrating a configuration of a major part of an optical disc apparatus including a coupled ring oscillator.
[0039] FIG. 13 is a diagram illustrating a configuration of a conventional coupled ring oscillator.
[0040] FIG. 14 is a diagram illustrating a configuration of a conventional coupled ring oscillator.
DETAILED DESCRIPTION
[0041] Embodiments of the present invention will be hereinafter described with reference to the accompanying drawings. Note that each component having a similar function is identified by the same reference character throughout the following embodiments, and the description thereof is not repeated.
First Embodiment
[0042] FIG. 2 is a diagram illustrating a configuration of a coupled ring oscillator according to a first embodiment. The coupled ring oscillator of this embodiment is obtained by adding three switching circuits 30 to the coupled ring oscillator of FIG. 13 . Each of the switching circuits 30 includes two switching elements 31 which perform an identical open/close operation. Each of the switching elements 31 is provided between an output of one of inverter circuits 11 in one of ring oscillators 10 and an output of one of inverter circuits 11 in another one of the ring oscillators 10 (e.g., between an output P 1 and an output P 2 ).
[0043] When the two switching elements 31 in each of the switching circuits 30 are put into a conductive state, the output of one of inverter circuits 11 in one of the ring oscillators 10 and the output of one of inverter circuits 11 in another of the ring oscillators 10 are short-circuited together, and are forced to be fixed in phase with one another. When the two switching elements 31 in each of the switching circuits 30 are put into a non-conductive state, the short circuit of the outputs is released. When the short circuit of the outputs of the inverter circuits 11 is released, the outputs of the inverter circuits 11 are phase-coupled together by an associated one of phase coupling circuits 21 in a phase coupling ring 20 .
[0044] The coupled ring oscillator of this embodiment is started or restarted in the following manner. First, the two switching elements 31 in each of the switching circuits 30 are put into a conductive state to cause each of the ring oscillators 10 to oscillate. Thereafter, the switching elements 31 are put into a non-conductive state. Thus, the coupled ring oscillator can be caused to oscillate in a normal oscillation state without falling into an abnormal oscillation state, or the coupled ring oscillator which has been stabilized in an abnormal oscillation state can be recovered to a normal oscillation state.
[0045] Note that even when the coupled ring oscillator is configured to include only a single switching circuit 30 , similar advantages can be achieved. However, it is preferable that, as in the example of FIG. 2 , a switching circuit 30 is provided for each of the inverter circuits 11 in each of the ring oscillators 10 . Thus, at a start of initialization of the coupled ring oscillator, the ring oscillators 10 can be caused to be in the same oscillation state in a shorter time.
[0046] The configuration of the switching circuits 30 is not limited to the example of FIG. 2 . For example, the switching element 31 may be provided between the output P 1 and the output P 3 , not between the output P 1 and the output P 2 , or may be provided between the output P 1 and the output P 3 , not between the output P 2 and the output P 3 .
Second Embodiment
[0047] FIG. 3 is a diagram illustrating a configuration of a coupled ring oscillator according to a second embodiment. The coupled ring oscillator of this embodiment is obtained by adding three off-state switching elements 32 , each of which is provided between one of the switching circuits 30 and another one of the switching circuits 30 , to the coupled ring oscillator of FIG. 2 .
[0048] Each of the switching elements 31 is normally a transistor. When the switching element 31 is connected to the coupled ring oscillator, for example, a parasitic capacitance of the transistor is applied between the outputs P 1 and P 2 , but a parasitic capacitance is not applied between the outputs P 1 and P 9 , so that the symmetry of the circuit is lost. In such a case, the oscillation phase of each of the ring oscillators 10 cannot be accurately divided into equal portions, thus resulting in reduction in phase accuracy. Therefore, the off-state switching elements 32 are provided as dummy switches at parts where no switching element 31 is provided. Thus, the symmetry of the circuit is maintained, so that a highly accurate fine phase can be generated.
Third Embodiment
[0049] FIG. 4 is a diagram illustrating a configuration of a coupled ring oscillator according to a third embodiment. The coupled ring oscillator of this embodiment is obtained by adding three switching circuits 30 ′ to the coupled ring oscillator of FIG. 13 . Each of the switching circuits 30 ′ includes three switching elements 31 which perform an identical open/close operation. Each of the switching elements 31 is provided between an output of one of inverter circuits 11 in each of ring oscillators 10 and an associated one of common voltage nodes 40 each being provided for an associated one of the switching circuits 30 ′. Specifically, the switching element 31 can be comprised of an nMOS transistor in which a reset signal RST is applied to a gate thereof (see FIG. 5 ). Note that one of the three common voltage nodes 40 may be fixed to a ground potential or a power supply potential. Thus, the three ring oscillators 10 can be forced to be in the same oscillation state.
[0050] When the three switching elements 31 in each of the switching circuits 30 ′ are put into a conductive state, an output of one of inverter circuits 11 in one of the ring oscillators 10 and an output of one of inverter circuits 11 in another one of the ring oscillators 10 are short-circuited together, and are forced to be fixed in phase in one another. When the three switching elements 31 in each of the switching circuits 30 ′ are put into a non-conductive state, the short circuit of the outputs is released. When the short circuit of the outputs of the inverter circuits 11 is released, the outputs of the inverter circuits 11 are phase-coupled together by an associated one of phase coupling circuits 21 in a phase coupling ring 20 .
[0051] The coupled ring oscillator of this embodiment is started or restarted in the following manner. First, the three switching elements 31 in each of the switching circuits 30 ′ are put into a conductive state (the reset signal RST is caused to be “H” in the example of FIG. 5 ) to cause each of the ring oscillators 10 to oscillate. Thereafter, the switching elements 31 are put into a non-conductive state (the reset signal RST is caused to be “L” in the example of FIG. 5 ). Thus, the coupled ring oscillator can be caused to oscillate in a normal oscillation state without falling into an abnormal oscillation state, or the coupled ring oscillator which has been stabilized in an abnormal oscillation state can be recovered to a normal oscillation state.
[0052] Note that, similar to the above, even when only a single switching circuit 30 ′ is provided, similar advantages can be achieved. In such a case, it is preferable that, in each of the other inverter circuits 11 in which the switching circuit 30 ′ is not provided, an off-state switching element 32 is provided between an output of the inverter circuit 11 and an associated one of the common voltage nodes 40 . Specifically, the switching element 32 can be comprised of an nMOS transistor in which a power supply potential Vss is applied to a gate thereof (see FIG. 6 ). Thus, the symmetry of the circuit is maintained, so that a highly accurate fine phase can be generated.
[0053] When a device which couples two points together in phase with one another (such as a resistive element, and the like) is employed as a phase coupling circuit, the coupled ring oscillator has a configuration of FIG. 14 . The coupled ring oscillator of FIG. 14 is different from the coupled ring oscillator of FIG. 13 , and includes a phase coupling ring 20 ′ including nine phase coupling circuits 21 ′ each of which couples two points in phase with one another and which are connected together to form a ring shape. Thus, the coupled ring oscillator of FIG. 14 can also generate a fine phase. Furthermore, the coupled ring oscillator of FIG. 14 has an advantage over the coupled ring oscillator of FIG. 13 in the point that each of the phase coupling circuits 21 ′ does not include an inverter circuit, and therefore, the design of the coupled ring oscillator can be simplified, and that an advantage resulting from averaging of output phase errors caused by resistor coupling can be achieved. Embodiments based on the coupled ring oscillator of FIG. 14 will be described below.
Fourth Embodiment
[0054] FIG. 7 is a diagram illustrating a configuration of a coupled ring oscillator according to a fourth embodiment. The coupled ring oscillator of this embodiment is obtained by adding three switching circuits 30 and three off-state switching elements 32 to the coupled ring oscillator of FIG. 14 , and corresponds to the coupled ring oscillator of the second embodiment. According to this embodiment, advantages similar to those of the second embodiment can be achieved.
[0055] Note that the three switching elements 32 can be omitted. Also, only a single switching circuit 30 may be provided.
Fifth Embodiment
[0056] FIG. 8 is a diagram illustrating a configuration of a coupled ring oscillator according to a fifth embodiment. The coupled ring oscillator of this embodiment includes a phase coupling ring 20 ′ comprised of three phase coupling circuits 22 and six phase coupling circuits 21 ′. Each of the phase coupling circuits 21 ′ is comprised of a single resistive element 211 . Each of the phase coupling circuits 22 is comprised of a single resistive element 211 and two switching elements 31 , each being connected to one of both ends of the resistive element 211 . All of the switching elements 31 perform an identical open/close operation. The phase coupling ring 20 ′ is configured so that one of the phase coupling circuits 22 is inserted after every two of the phase coupling circuits 21 ′ and the phase coupling circuits 22 are arranged to form a ring shape as a whole.
[0057] When the two switching elements 31 in the phase coupling circuit 22 are put into a no-conductive state, the phase coupling circuit 22 has a high impedance, and the phase coupling strength between outputs of inverter circuits 11 each being connected to one of both ends of the phase coupling circuit 22 is reduced. On the other hand, outputs of the inverter circuits 11 each being connected to one of both ends of the phase coupling circuit 21 ′ are maintained to be phase-coupled by the resistive element 211 . Thus, the outputs of three of the inverter circuits 11 of two adjacent ones of the phase coupling circuits 21 ′ are strongly coupled in phase with one another, so that a state corresponding to that in Step 1 of FIG. 1 can be achieved. That is, when the phase coupling ring 20 ′ is electrically decoupled, each of the decoupled parts has similar results to those achieved when a short circuit is caused by a switching element.
[0058] The coupled ring oscillator of this embodiment is started or restarted in the following manner. First, the two switching elements 31 in each of the phase coupling circuits 22 are put into a non-conductive state to cause each of the ring oscillators 10 to oscillate. Thereafter, the switching elements 31 are put into a conductive state. Thus, the coupled ring oscillator can be caused to oscillate in a normal oscillation state without falling into an abnormal oscillation state, or the coupled ring oscillator which has been stabilized in an abnormal oscillation state can be recovered to a normal oscillation state.
[0059] Note that even when each of the phase coupling circuits 22 is configured to include only a single switching circuit 31 , similar advantages can be achieved.
Sixth Embodiment
[0060] FIG. 9 is a diagram illustrating a configuration of a coupled ring oscillator according to a sixth embodiment. The coupled ring oscillator of this embodiment is obtained by replacing all of the phase coupling circuits 21 ′ in the coupled ring oscillator of the fifth embodiment (see FIG. 8 ) with phase coupling circuits 23 . Only differences of this embodiment from the fifth embodiment will be hereinafter described.
[0061] Each of the phase coupling circuits 23 includes a single resistive element 211 and two on-state switching elements 33 each being connected to one of both ends of the resistive element 211 . That is, each of the phase coupling circuits 23 has the same circuit configuration as that of the phase coupling circuit 22 , except that the two switching elements 33 are fixed in an on state. As described above, the symmetry of the circuit is maintained by inserting the on-state switching elements 33 as dummy switches, so that a highly accurate fine phase can be generated.
[0062] Note that even when each of the phase coupling circuits 22 is configured to include only a single switching element 31 , and each of the phase coupling circuits 23 is configured to include only a single switching element 33 , similar advantages can be achieved.
Seventh Embodiment
[0063] FIG. 10 is a diagram illustrating a coupled ring oscillator according to a seventh embodiment. The coupled ring oscillator of this embodiment includes a phase coupling ring 20 ′ comprised of three phase coupling circuits 22 ′ and six phase coupling circuits 21 ′. Each of the phase coupling circuits 21 ′ includes two resistive elements 211 connected together in series. Each of the phase coupling circuits 22 ′ includes a single switching element 31 and two resistive elements 211 each being connected to one of both ends of the resistive element 211 . All of the switching elements 31 perform an identical open/close operation. The phase coupling ring 20 ′ is configured so that one of the phase coupling circuits 22 ′ is inserted after every two of the phase coupling circuits 21 ′ and the phase coupling circuits 22 ′ are arranged to form a ring shape as a whole.
[0064] According to this embodiment, the number of the switching elements 31 to be inserted in the phase coupling ring 20 ′ can be reduced, compared to the fifth embodiment. Thus, a signal delay due to a parasitic capacitance of each of transistors of the switching elements 31 is reduced, so that a signal travels through the phase coupling ring 20 ′ at high speed, and a more accurate fine phase can be generated.
[0065] Note that even when each of the phase coupling circuits 22 ′ is configured to include only a single resistive element 211 , similar advantages can be achieved.
Eighth Embodiment
[0066] FIG. 11 is a diagram illustrating a configuration of a coupled ring oscillator according to an eighth embodiment. The coupled ring oscillator of this embodiment is obtained by replacing all of the phase coupling circuits 21 ′ in the coupled ring oscillator of the seventh embodiment (see FIG. 10 ) with phase coupling circuits 23 ′. Only differences of this embodiment from the seventh embodiment will be hereinafter described.
[0067] Each of the phase coupling circuits 23 ′ includes a single on-state switching element 33 and resistive elements 211 each being connected to one of both ends of the switching element 33 . That is, each of the phase coupling circuits 23 ′ has the same circuit configuration as that of the phase coupling circuit 22 ′, except that the switching elements 33 are fixed in an on state. As described above, the symmetry of the circuit is maintained by inserting the on-state switching element 33 as a dummy switch, so that a highly accurate fine phase can be generated.
[0068] Note that even when each of the phase coupling circuits 22 ′ is configured to include only a single resistive element 211 , and each of the phase coupling circuits 23 ′ is configured to include only a single resistive element 211 , similar advantages can be achieved.
[0069] Moreover, in the fifth to eighth embodiments, as a means for causing the phase coupling circuits 22 , 22 ′ to have a high impedance, besides causing the switching elements 31 to be in a non-conductive state, a resistance value may be changed to a large value.
[0070] In each of the above-described embodiments, each of the switching elements 31 and 32 can be comprised of an nMOS transistor, a pMOS transistor, a CMOS transistor, and the like. In view of the ease of switching control and the symmetry of the circuit, it is preferable that all of the switching elements 31 and 32 are transistors of the same type.
[0071] The number of the inverter circuits 11 of each of the ring oscillators 10 is not limited to three, and the number of the ring oscillators 10 of the coupled ring oscillator is not limited to three.
[0072] <<Embodiments of Application Product of Coupled Ring Oscillator>>
[0073] FIG. 12 is a diagram illustrating a configuration of a major part of an optical disc apparatus for recording information on an optical disc medium such as a DVD, a BD, and the like. A coupled ring oscillator 100 is one of the coupled ring oscillators of the above-described embodiments. A pulse generation circuit 200 generates a write pulse for writing information on an optical disc medium (not shown) in synchronization with a signal with a fine phase generated by the coupled ring oscillator 100 . A write amplifier 300 writes information on the optical disc medium (not shown) according to the write pulse generated by the pulse generation circuit 200 .
[0074] When writing information on an optical disc medium such as a DVD, a BD, and the like, it is necessary to generate a write pulse based on a fine phase which is equal to or larger than one fortieth of a write data rate in order to reduce interference of a write signal. The coupled ring oscillator of one of the above-described embodiments can generate a desired highly accurate fine phase, and thus, the optical disc apparatus including the coupled ring oscillator can write information on an optical disc medium with high accuracy at high speed. | In a coupled ring oscillator including q ring oscillators each including p inverter circuits connected together to form a ring shape, and a phase coupling ring including (p×q) phase coupling circuits each of which is configured to couple an output of one of the p inverter circuits of one of the q ring oscillators to an output of one of the p inverter circuits of another one of the q ring oscillators in a predetermined phase relationship, and which are connected together to form a ring shape, for at least one group made up of one of the p inverter circuits in each of the q ring oscillators, outputs of the q inverter circuits belonging to the at least one group are fixed in phase with one another, the q ring oscillators are caused to oscillate in the in-phase fixed state, and then, the outputs of the q inverter circuits are released from the in-phase fixed state. | 7 |
BACKGROUND OF THE INVENTION
1) Field of the Invention
The present invention relates to a changeable combination lock, a structure that allows the combination to be changed according to the need and prevents the intruder from easily unlocking the lock so the user can obtain more protection.
2) Description of the Prior Art
Accordingly, the general combination lock of the prior art comprises a male lock body, a female lock body, a sealing ring, a retaining body, a ring sleeve, a digit disc and a lock chain ring; wherein the male lock body has several retaining teeth disposed on the upper end surface of a sleeve rod thereof; a concave portion is defined between two retaining teeth; a rectangular locating portion is disposed at one end of the sleeve rod of the said male lock body; a flange is disposed in a proper area of the said locating portion; a receiving segment is disposed on the adjacent side of the location portion; a female lock body is a rod body disposed with a groove and a stop block with a through hole is disposed at one end thereof; a notch is connectively disposed opposite the upper aspect of the through hole; another receiving segment is disposed at another end of the rod body of the said female lock body; there are two sealing rings and the outer rim of one of them is disposed with a projecting alignment block in a proper area; a communicated hole is disposed among several digit discs; a notch is disposed in a proper area of the communicated hole; digits are carved on the outer periphery of the digit disc; a rectangular pass-through hole is disposed on the inner wall surface of the said sealing ring; a concave hole is disposed in a proper area on the inner periphery of the digit disc; a round hole is disposed between two retaining bodies and a retaining block is disposed in a proper area at one end surface thereof; two ring sleeves have receiving chambers at one end thereof; a vertical hole and a horizontal hole are respectively disposed inside the ring sleeve; the vertical hole and the horizontal hole are communicated; a notch is disposed at the upper end of the horizontal hole; the inside of a locating sleeve is a square through hole; a locating block fitting in with the concave hole on the digit disc is disposed in a proper area on the outer rim thereof; a lock chain ring is a chain ring with a proper strength and has two retaining segments disposed at two ends.
Thereby, after the locating sleeve is sleeved at one end of the male lock body, the sealing ring, a resilient element, the retaining body and the ring sleeve are sleeved on sequentially; one end of the lock chain ring is inserted into the vertical hole of the ring sleeve; through the push of the resilient element, the retaining block of the retaining body and the retaining segment mutually engage so as to position the male lock body, the sealing ring, the retaining body, the ring sleeve and one end of the lock chain ring; after that, the locating sleeve is sleeved onto the rod body of the female lock body, then, several teeth discs, the sealing ring, the resilient element, the retaining body and the ring sleeve are mounted on the female lock body; the other end of the lock chain ring is inserted into the vertical hole; through the push of the resilient element, the retaining block engages in the retaining segment of the lock chain ring. However, since the said combination lock can only set one combination for unlocking the lock and the combination is set before the product is shipped from the factory, it is very easy for the outsiders to guess the combination and further unlock the lock.
In view of the mentioned reasons, the inventor of the present invention, in order to improve the abovementioned shortcomings of the device structure of the prior art, strove to research and experiment for a long term, finally developed and designed the present invention of a changeable combination lock.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide a changeable combination lock with a design permitting the installer to easily change the combination for unlocking the lock and further achieving the objective of being a simple and practical invention for easy access.
Another objective of the present invention is to provide a combination lock disposed with a lock body; a lock bolt is disposed in the said lock body; more than one digit wheels set are sleeved onto the lock bolt; a retaining ring is disposed at one end of the said lock body; a notch is on the said retaining ring; a mark is carved on the surface of the retaining ring for matching with the notch; an actuator and a retaining member are disposed on the said retaining ring; when in use, a set of combination is made according to the need by rotating the digit wheel to align the mark on the retaining ring with the said combination in a straight line; then a lock bar inserts into a lock hole to make the lock bolt pressed by the lock bar move toward the digit wheel sets; the cooperation of the actuator and the retaining member disengages the actuating member from the digit wheel sets; therefore, the action of changing the combination is accomplished; contrarily, it is only necessary to rotate the digit wheel to the preset combination to align with the mark on the retaining ring in a straight line, thereby the actuating member resumes to the original position; at the same time, the lock bolt moves from the notch on the retaining ring toward the lock hole to disengage the lock bolt retained on the lock bar from the lock bar; therefore, different from the combination lock of the prior art having only one set of combination, the user can continuously change the combination according to the need and further prevent the outsider from easily unlocking the lock.
To enable a further understanding of the objective, the configuration, the device features and the efficiency of the present invention, the brief description of the drawings below is followed by the detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded and pictorial drawing of the present invention.
FIG. 2 is a schematic drawing of the pictorial and external view of the present invention.
FIG. 3 is a schematic drawing of the cross-sectional view of the assembled present invention.
FIG. 4 is a schematic drawing of the action of releasing a lock bar of the present invention.
FIG. 5 is a schematic drawing of the locking action of the present invention.
FIG. 6 is the first schematic drawing of the action of the cut surface of a digit wheel of the present invention.
FIG. 7 is the second schematic drawing of the action of the cut surface of a digit wheel of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 , the present invention is a changeable combination lock disposed with a lock body ( 10 ); the said lock body ( 10 ) is comprised by two case bodies ( 11 ) in the same shape, as shown in FIG. 2 ; two ends of the said lock body ( 10 ) are respectively disposed with two lock holes ( 12 , 13 ); wherein the lock hole ( 13 ) communicates with a concave slot ( 14 ) situated at the said end rim of the said lock body; a lock bar ( 20 ) fitting in with the lock hole ( 12 ) is disposed on the said lock body ( 10 ) and is a U-shaped bar in this embodiment (for those skilled in this art, other element can be used for replacement); one end of the said lock bar ( 20 ) is disposed with a pivot joint hole ( 21 ) permitting an insert pin ( 211 ) to insert into the pivot joint hole ( 21 ) and to be pivotally jointed in the lock hole ( 12 ) communicating with the lock body ( 10 ); a resilient element ( 121 ) is disposed in the said lock hole ( 12 ), it is a spring in this embodiment; one end of the resilient element ( 121 ) pushes against the closed end of the lock hole ( 12 ); the other end thereof presses against the end rim of the lock bar ( 20 ) inserted in the lock hole ( 12 ); the other end of the said lock bar ( 20 ) is disposed with a concave and annular insert groove ( 22 ).
First and second spaces ( 16 , 17 ) adjacent to each other and divided by a partition ( 15 ) are disposed between two lock holes ( 12 , 13 ) of the lock body ( 10 ); the ends of the said first and second spaces ( 16 , 17 ), not adjacent to each other, are respectively adjacent to the lock holes ( 12 , 13 ); wherein, one end of the first space ( 16 ) adjacent to the second space ( 17 ) is disposed with an opposite column cotter ( 161 ); a sleeve ( 30 ) situated over the first and second spaces ( 16 , 17 ) is fixedly mounted on the column cotter ( 161 ); a stop plate ( 301 ) is disposed at one end of the sleeve ( 30 ); the other end of the stop plate ( 301 ) connects with a convex ear ( 31 ); a through hole ( 311 ) is disposed on the convex ear ( 31 ) for the column cotter ( 161 ) to insert; the other end of the said sleeve ( 30 ) is adjacent to the lock hole ( 13 ); an axially extending open slot ( 32 ) passing through the inside thereof is disposed on the said sleeve ( 30 ); in the area adjacent to the lock hole ( 13 ), an adjacent annular groove ( 33 ) is disposed in a certain distance on the sleeve ( 30 ); an opening ( 34 ) radially extending but not through the whole sleeve ( 30 ) is disposed between the annular grooves ( 33 ).
A resilient element ( 35 ) is sleeved on the said sleeve ( 30 ) and it is a spring in this embodiment; one end of the said resilient element ( 35 ) presses against onto the stop plate ( 301 ), the other end is attached by a bushing ( 36 ) sleeved on the said sleeve ( 30 ); more than one digit wheels ( 40 ) are sleeved on the sleeve ( 30 ); the said digit wheels ( 40 ) are installed in the second space ( 17 ) adjacent to the lock hole ( 13 ); a locating partition ( 171 ) capable of locating the digit wheel ( 40 ) is disposed on the inner wall of the said second space ( 17 ) for fixing the digit wheel ( 40 ) at its position and keeping it from deviating; the surfaces of the digit wheels ( 40 ) are disposed with consecutive digits ( 41 ), they are digits 0 to 9 in this embodiment; the side rims of the said digit wheels ( 40 ) just protrude in the fitting lock hole ( 113 ) on the lock body ( 10 ) for facilitating the user to rotate; a concave groove ( 42 ) is disposed respectively in the opposite area toward each digit in the digit wheel ( 40 ); a set of actuating members ( 50 ) are disposed respectively in the said digit wheels ( 40 ); the actuating members ( 50 ) are controlled by the digit wheels ( 40 ) for setting: a locating seat ( 51 ) is disposed on the said actuating member ( 50 ); the said locating seats ( 51 ) are respectively clamped between the sleeve ( 30 ) and the digit wheels ( 40 ); one end of the said locating seat ( 51 ) is disposed with a flange ( 511 ) extending axially inwardly; the said flanges ( 511 ) are disposed respectively with a slide slot ( 512 ) extending axially; a live ring ( 52 ) is respectively attached on the said flanges ( 511 ); a resilient retainer ( 521 )tightly attached onto the surface of the flange ( 511 ) is disposed on the said live rings ( 52 ); a concave opening ( 522 ) aligned with the slide slot ( 512 ) is disposed on the said live rings ( 52 ); a locating point ( 513 ) is disposed on one end surface on the said locating seats ( 51 ); inside the said end of the said locating seats ( 51 ), a ring retainer ( 53 ) in an open form is disposed for the limiting function of the rotating locating seat ( 51 ).
A lock bolt ( 60 ) is inserted at the end in an open form of the said sleeve ( 30 ); a locating step ( 611 ) fitting in with the digit wheel ( 40 )is disposed on the said lock bolt ( 60 ); the said locating step ( 611 ) protrudes outwards from the inside of the opening slot ( 32 ) of the sleeve ( 30 ); a resilient element ( 61 ) is pressed against one end of the said lock bolt ( 60 ) sleeved on the sleeve ( 30 ) and it is a spring in this embodiment; the other end of the resilient element ( 61 ) pushes against the inside of a closed end of the sleeve ( 30 ); the other end of the said lock bolt ( 60 ) is disposed with a retainer member ( 62 ) extending into the lock hole ( 13 ); a retaining hook ( 621 ) is disposed at the free end of the said retaining member ( 62 ); the said retaining hook ( 621 ) just retains on the insert slot ( 22 ) of the lock bar ( 20 ); a retaining ring ( 70 ) partially projecting in the slot hole ( 14 ) of the lock body ( 10 ) is disposed in the adjacent area between the said second space ( 17 ) and the lock hole ( 13 ); through the clamping of a C-shaped clamp ( 71 ) inserted in the annular slot ( 33 ) of the sleeve ( 30 ), the said retaining ring ( 70 ) is sleeved on the sleeve ( 30 ); a mark ( 72 ) is disposed on the periphery surface of the said retaining ring ( 70 ); a notch ( 73 ) corresponding to the said mark ( 72 ) and extending axially is disposed in the said retaining ring ( 70 ); an actuating member ( 74 ) inserted on the inner lateral rim of the retaining ring ( 70 ) is disposed on the side of the retaining ring ( 70 ) facing the digit wheel ( 40 ); a live retaining member ( 75 ) is disposed on the retaining ring ( 70 ) to position the said actuating member ( 74 ) within the inner lateral rim of the retaining ring ( 70 ); a washer ( 76 ) is inserted in the said retaining ring ( 70 ); a concave opening ( 761 ) aligned with the notch ( 73 ) is disposed on the said washer ( 76 ).
When in use, referring to FIGS. 1 , 2 , 3 , 4 , 5 , 6 and 7 , first the digit wheel ( 40 ) is rotated to the preset digit ( 41 ) to align the locating point ( 513 ) of the locating seat ( 51 ) and the resilient retainer ( 521 ) on the live ring ( 52 ) such that the locating seat ( 51 ) and the live ring ( 52 ) are slidable along to the concave groove ( 42 ) opposite the preset digit ( 41 ) and the slide slot ( 512 ) on the locating seat ( 51 ) opposite the locating step ( 611 ) of the lock bolt ( 60 ). Then the mark ( 72 ) on the retaining ring ( 70 ) is rotated to align with the preset digit ( 41 ) in one straight line, thereby to make the notch ( 73 )of the retaining ring ( 70 ) opposite the locating step ( 611 ) of the lock bolt ( 60 ). After that, the end of the lock bar ( 20 ) not pivotally jointed with the lock body ( 10 ) is inserted in the lock hole ( 13 ) to press and force the lock bolt ( 60 ) to smoothly slide passing the notch ( 73 ) and the slide slot ( 512 ). The digit wheel ( 40 ) drives the locating seat ( 51 ) to interact with the locating step ( 611 ) on the lock bolt ( 60 ) and moves the lock bolt ( 60 ), thereby moving the lock bolt ( 60 ) in a direction towards the sleeve ( 30 ). As the lock bolt is moving toward the convex ear ( 31 ) of the sleeve ( 30 ), the retaining member ( 75 ) on the retaining ring ( 70 ) is pressed and forced by the actuating member ( 74 ) to disengage the actuating member ( 74 ) and to press toward the locating seat ( 51 ), so as to press the said locating seats ( 51 ) to separate from the digit wheel ( 40 ). After that, the digit wheel ( 40 ) and the retaining ring ( 70 ) are rotated at will, as shown in FIGS. 3 , 5 and 7 ; therefore, under the blocking of the locating seat ( 51 ), the lock bolt ( 60 ) does not tend to move outwards; furthermore, the retaining hook ( 621 ) of the retaining member ( 62 ) just retains onto the insert slot ( 22 ) of the lock bar ( 20 ) and the setting action is thereby accomplished.
On the contrary, if trying to disengage one end of the lock bar ( 20 ) from the lock hole ( 13 ), it is only necessary to rotate the set digit ( 41 ) of the digit wheel ( 40 ) to a certain position, then rotate the mark ( 72 ) on the retaining ring ( 70 ) to align with the preset digit ( 41 ) in one straight line to make the notch ( 73 ) of the retaining ring ( 70 ) opposite the locating step ( 611 ) of the lock bolt ( 60 ); therefore, the lock bolt ( 60 ) moves toward the outside of the sleeve ( 30 ) to make the locating seat ( 51 ) move along back to the original position and further make the retaining hook ( 621 ), retained on the insert slot ( 22 ) of the lock bolt ( 20 ) and of the retaining member ( 62 ), separate from the lock bar ( 20 ), thereby unlock the lock, as shown in FIGS. 3 , 4 and 6 .
The mentioned embodiment of the present invention is only an exemplary description of one of the feasible implementations of the present invention, those who are skilled in this art might be able to conduct various changes for the detail shapes with equal efficiency; however, those changes should be included in the spirit and the scope of the present invention. | The present invention relates to a changeable combination lock disposed with a lock body. A lock bolt is disposed inside the lock body. More than one digit wheel is sleeved on the lock bolt. One end of the lock body is disposed with a retaining ring. A notch is on the retaining ring. A mark is disposed on the surface of the retaining ring for fitting in with the notch. An actuator and a retaining member are disposed on the retaining ring. When in use, a set of combination is decided and the mark on the retaining ring is aligned with the combination so that a lock bar inserts into a lock hole, therefore, the combination can be changed according to the need for preventing the intruder from easily unlocking the lock. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Pistol Structure.
2. Description of the Prior Art
In prior art pistols, the barrel axis is disposed a substantial distance above the longitudinal axis of the hand and forearm of the user. As a result the recoil force of the explosion causes the muzzle of the gun to rise making it impossible to effectively fire the gun in full automatic and interfering with rapid fire semi-automatic.
The primary purpose in devising the present invention is to supply a pistol that will overcome these operational disadvantages of prior art pistols.
SUMMARY OF THE INVENTION
The invention comprises an automatic recoil operated pistol of such design that when the handle thereof is gripped, the barrel is nearly axially aligned with the center of mass of the hand and with the axis of the forearm. The pistol includes a spring-loaded breechblock which slidably operates within a breechblock reciprocating space. This reciprocating space is totally compartmented within the handle of the pistol. Within the breechblock is a spring-loaded firing pin which is operated by a hammer and trigger mechanism which are positioned above the axis of the barrel and breechblock reciprocating space. The trigger system of the pistol is also located above the axis of the barrel. The extractor and ejector are located above the axis of the barrel. The extractor and ejector are located on the breechblock in such a manner that the ejection port is located to the left of the pistol. A magazine is located within a magazine space in the handle of the pistol below and rearward of the firing chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-sectional view of the pistol, with the bolt in abutting contact with the case of the cartridge that is to be fired, and the trigger just pivoting into a position where it strikes the firing pin;
FIG. 2 is the same view as shown in FIG. 1, but with the bolt moving to its rearward-most position after the firing of a cartridge, and the spring-loaded magazine having advanced a cartridge upwardly where it will be engaged by the bolt as the bolt moves forwardly due to spring means to the position shown in FIG. 1;
FIG. 3 is a transverse cross-sectional view of a portion of the pistol taken on the line 3--3 of FIG. 1; and
FIG. 4 is a fragmentary top plan view and longitudinal cross-sectional view of the pistol taken on the line 4--4 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The automatic recoil operated pistol as may be seen in FIG. 1 includes a frame B that has a hollow handle C in which a magazine clip D of cartridges E may be removably disposed. The frame B movably supports a spring-loaded bolt F, which bolt has a spring-loaded firing pin G mounted thereon. A hammer H is pivotally supported by the frame B, and is adapted to strike the firing pin G when the bolt F is in a firing position. The frame B supports a tubular interiorly rifled barrel J that has a first end 18 and second end 20. the barrel J is so disposed that when the pistol is gripped by the handle C, the axis of the barrel J is nearly aligned with the center of mass of the hand and with the longitudinal axis of the forearm of a user (not shown). As a result of such a geometrical configuration when the pistol A recoils as the cartridges E are fired, the force of the recoil has substantially no turning moment relative to the forearm of the user and has reduced recoil velocity due to the combined inertia of the gun-hand-forearm system.
The pistol A includes a trigger K that is disposed above the barrel J as shown in FIG. 1, and the pistol when fired having the forefinger of the user extending over the rearward portion of the barrel J to engage the trigger. A first rod L as seen in FIG. 4 is provided that has a first end 22 and second end 24. The trigger K is secured to the first end 22 of the first rod L. Also attached to the trigger K is a trigger return rod 23 which is in abutting contact with a trigger return spring 25. The spring 25 which is mounted on the spring guide 27 is also in abutting contact with the frame of the pistol and at all times tends to slidably push the trigger K to its forwardmost position as shown in FIG. 1.
A second rod M is provided that has a first end 28 and second end 30. This second rod M as shown in FIG. 4 has a detent 32 defined therein adjacent to the first end 28 thereof. The frame B includes first, second, third, fourth, and fifth transverse partitions 34, 36, 38, 40 and 42 as shown in FIG. 1 that serve to subdivide the interior of the frame into first, second, third, fourth and fifth confined spaces 34a, 36a, 38a, 40a, and 42a. A sear N is slidably movable relative to the second partition as shown in FIG. 4 and is actuated by a linkage assembly P, which assembly is connected to the second end of the first rod L. The linkage assembly P includes a lever 44 shown in FIG. 4 that by a first transverse pin 46 is pivotally supported from the frame B. A second pin 48 pivotally connects one end of the lever 44 to the second end portion 24 of the first rod L. A third pin 50 secured to the sear N engages a slot in the lever 44 and pivotally connects the sear N to the lever 44. The sear N when the pistol is not in use will engage the detent 32 as shown in FIG. 4 and the sear when so engaging the detent preventing the hammer H from pivoting to a position where it strikes the firing pin G. The hammer H is pivotally supported on a transverse pin 26 as shown in FIG. 1.
A rod 52 extends forwardly from the frame B in the confined space 38a and slidably engages a longitudinally extending bore 54 formed in the bolt F. A compressed helical spring 68 encircles the rod 52 and at all times tends to urge the bolt F forwardly to the firing position shown in FIG. 1 where the hammer H may pivot to forceful contact with the firing pin G. The firing pin G has a head 56 mounted on the rearward end thereof, which head is slidably movable in an elongate cavity 58 defined in the bolt F. A bore 60 extends forwardly in the bolt F from the cavity 58, and serves to slidably support the pin G. The cavity 58 and bore 60 at their junction define a body shoulder 62 as shown in FIG. 1. A helical spring 64 is disposed in the cavity 58 and has one end in abutting contact with the body shoulder 62 and the other end in engagement with the head 56.
When the bolt F moves forwardly in the frame B to the firing position as shown in FIG. 1 as will later be explained, the hammer H pivots clockwise and strikes the head 56 to force the firing pin G forwardly within the bore 60 to contact the detonator cap (not shown) to fire the cartridge E disposed in the rearward breech portion of the barrel J.
A transverse rod 66 is secured to the bolt F and extends outwardly from a longitudinally extending slot (not shown) in the frame B. The rod 66 is used in manually cocking the pistol A to move the bolt F initially from the position shown in FIG. 1 to that illustrated in FIG. 2 to permit a compressed spring 69 to move the uppermost one of the cartridges E in the magazine clip D into a position in the frame B where it is axially aligned with the bore of the barrel J. When the bolt F is moved from the firing position as shown in FIG. 1 to the position shown in FIG. 2 by use of the rod 66, the hammer H is pivoted counterclockwise to the position shown in FIG. 2. When the hammer G is so disposed, the sear N moves into engagement with the detent 32, and the hammer H cannot pivot to strike the firing pin G until the trigger K is moved rearwardly to release the sear N from engagement with the detent 32.
After the pistol A has been cocked as abovedescribed, the pistol is fired by pressing the trigger K to move the same rearwardly and release the sear N from engagement with the detent 32. A compressed helical spring 68 encircles the rod 52 and at all times urges the bolt F into a position shown in FIG. 2. A second compressed helical spring 70 encircles a portion of the second rod M, with one end of the spring in abutting contact with the partition 36 at the opposite end of the spring in engagement with an enlarged portion 72 of the second rod M. Upon the detent 32 being disengaged from the sear N, the compressed spring 70 expands and in so doing the firing pin also forcefully contacting the detonator cap (not shown) to explode the cartridge E situated in the rearward breech portion of the barrel J.
As a result of the explosion on the base of the cartridge case a rearwardly directed force is exerted thereon on the base of the cartridge case as well as on the bolt F, to move the case rearwardly where it is ejected through an opening 73 formed in the frame B and the bolt F being moved to the position shown in FIG. 2. As such rearward movement of the bolt F takes place, the hammer H is pivoted counterclockwise to the position shown in FIG. 2. The spring 68 now tends to move the bolt F forwardly, and as the bolt so moves the uppermost one of the cartridges E in the magazine clip D is engaged by the forward end of the bolt and forced into the breech portion of the barrel J as the bolt F moves forwardly. Concurrently with the forward movement of the bolt F, the hammer H pivots clockwise and strikes the head 56 of the firing pin G when the bolt F moves into the firing position shown in FIG. 1. The cartridge E in the breech portion of the barrel J is now fired in the manner previously described, and the above-described operation is successively repeated each time one of the cartridges E is moved from the magazine clip D into a firing position in the breech.
Firing of the cartridges is terminated by relieving pressure on the trigger to allow the sear N to engage the detent 32 and hold the hammer H in a fixed position relative to the frame B.
The use and operation of the invention has been described previously in detail and need not be repeated. | The invention comprises a recoil operated pistol in which the barrel is positioned below the index finger of the hand. Therefore, when the handle of the pistol is gripped by the hand, the axis of the barrel, and, therefore the axis of recoil, is nearly aligned with the center of mass of the hand, and with the axis of the forearm of the user. In this manner, muzzle rise is eliminated and the velocity of recoil is considerably reduced by the combined inertia of the gun-hand-forearm weapon system. These geometrical and mechanical considerations make it possible for the pistol to be effectively fired as a machine gun, and for its structure to have the lightweight and compact dimensions of a pocket pistol. | 5 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates to a method for operating at least one wind turbine. In addition, the present invention relates to a wind turbine and also relates to a wind farm comprising a number of wind turbines.
[0003] 2. Description of the Related Art
[0004] Wind turbines are generally known. They produce electrical energy from wind and feed the electrical energy into an electric power grid. In addition, it was already proposed many years ago for wind turbines to feed into the electrical power grid such that they also support the electrical power grid beyond the pure provision of energy.
[0005] By way of example, U.S. Pat. No. 6,784,564 describes a method in which the fed active power is reduced in accordance with the grid voltage. A method that concerns a power regulation dependent on the grid frequency can be inferred from U.S. Pat. No. 6,891,281. The setting of a phase angle in accordance with the grid voltage is described in U.S. Pat. No. 6,965,174.
[0006] Such measures are important and, in particular in decentralized grids, may help improve the grid quality and sometimes even enable for the first time a stable operation of the electrical power grid or at least a portion thereof or ensure this permanently. Nowadays, however, at least in the Federal Republic of Germany, which will surely be followed by many other countries, the proportion of wind turbines in the grid is increasing. A great, and in all likelihood growing, responsibility will thus also be bestowed in the future upon wind turbines for the stabilization of electrical power grids. The ability of wind turbines to support the grid must therefore be developed and improved further where possible.
BRIEF SUMMARY
[0007] One or more embodiments provide support of an electrical power grid by wind turbines. At the very least, a solution alternative to known methods or systems is to be proposed.
[0008] The German Patent and Trademark Office has performed a search of the following prior art for the priority application relating to the present PCT application: DE 10 2005 041 927 B4, DE 10 2005 049 426 B4, DE 10 2008 037 449 B4, DE 10 2011 007 037 A1 and WO 2003/058 063 A1. A method is proposed. The method controls at least one wind turbine, which is set up to feed electrical power into an electrical power grid. Where technically expedient, explanations in conjunction with an individual wind turbine also apply to a number of wind turbines as well as a wind farm comprising a number of wind turbines, even without this being mentioned together with each individual feature and in each individual advantage. This is then true in particular when it is clear from the explanation that this is also applicable for wind turbines or a wind farm.
[0009] It is thus proposed for the at least one wind turbine to feed electrical active power into the electrical power grid or to remove electrical active power from the electrical power grid in a manner dependent on a supply of power in the electrical power grid. In particular, in “normal operation”, electrical active power is fed into the electrical power grid, but, in the case of an excess supply of power in the grid, electrical active power is removed from the grid by the at least one wind turbine. This removed active power is then fed to at least one electrical consumer, which is present in the at least one wind turbine or a wind farm. This consumer does not necessarily have to be arranged physically in the wind turbine, although this is often the case. Here, it is proposed in particular to use existing consumers.
[0010] In addition, electrical reactive power is fed into or removed from the electrical power grid depending on a further state variable of the electrical power grid, such as the grid frequency or the grid voltage of the electrical power grid.
[0011] A “4-quadrant operation” is thus proposed, therefore specifically both the fed active power and the fed reactive power can be positive or negative independently of one another. The proposed method thus expressly also includes the two quadrants in which electrical active power is removed from the electrical power grid and reactive power is fed in, which constitutes one quadrant, and in which electrical active power is removed from the electrical power grid and reactive power is likewise removed, which constitutes a further quadrant.
[0012] At least one of the electrical consumers preferably has no electrical resistor banks. Thus, at least one consumer is preferably used that is not provided exclusively as a resistor bank or the like in order to destroy electrical energy, that is to say, expressed technically correctly, in order to convert electrical energy into thermal energy without further purpose. Rather, it is proposed to use consumers that are provided anyway in a wind turbine or a wind farm. Thus, progress can be achieved already by the proposed method alone for operating at least one wind turbine, without the need to provide additional apparatuses.
[0013] The electrical consumer(s) used to take up the electrical power which in one case is removed from the electrical power grid may comprise, for example, a blade heater for heating a rotor blade. Likewise, a generator heater for heating a generator can be used. As a further example, a nacelle heater is mentioned, which can heat the interior of a nacelle of a wind turbine. Furthermore, a tower heater for heating a wind turbine tower is conceivable. Particularly, the use of existing heaters or heating devices enables the conversion of a not insignificant quantity of electrical energy into thermal energy, which can be radiated to the surrounding environment.
[0014] Nonetheless, however, other consumers are also considered, such as the generator of the respective wind turbine, which can be operated in motor operation. Some of the energy could thus be converted into air movement. In principle, however, it is also conceivable here to operate the generator such that it heats up and in this regard is used as a further consumer in order to convert electrical energy into thermal energy. Nonetheless, this must be performed carefully accordingly so as not to damage the generator.
[0015] In particular, it is proposed for the consumers to then be operated when there is a need for a power decrease. The aforementioned consumers, which are also to be used here, are each provided in order to perform a certain function, specifically the consumer function associated therewith respectively. In the case of the blade heater, this is the function of heating the blade. In the case of the generator heater, this is the function of heating the generator and also thus drying the generator where applicable. This respective consumer function is usually performed only on specific occasions, that is to say a blade heater is then operated particularly when icing has been identified and the ice is to be thawed. Here, however, it is proposed to operate the corresponding consumer independently of the need for such a consumer function, that is to say for example to also operate the blade heater at the height of summer.
[0016] Accordingly, it is also proposed in accordance with one embodiment to use the electrical power removed from the electrical power grid to operate at least one de-icing device, in particular a blade heater, independently of whether there is a need for de-icing. In particular, independently of whether icing is present, is expected or is even possible. The de-icing device is thus also operated at the height of summer. Wind turbines are preferably equipped with a de-icing device even for locations in which icing is never expected per se.
[0017] In addition or alternatively, it is proposed to use the removed power or a portion thereof to operate at least one drying device for drying a generator or for drying another functional unit of the wind turbine, independently of whether there is a need for drying. A generator heater provided anyway or other drying arrangement can thus be used as a consumer in this case of power removal from the electrical power grid.
[0018] The supply of power in the electrical power grid can be considered as a state variable of the electrical power grid. The further state variables, in accordance with which reactive power is fed or removed, preferably include the grid frequency of the electrical power grid and/or the grid voltage of the electrical power grid. In accordance with these embodiments, the feed or removal of electrical active power is thus set depending on the supply of power, and the feed or removal of reactive power is performed depending on grid frequency and/or grid voltage. Here, the grid-frequency-dependent and/or grid-voltage-dependent feed or removal of reactive power can depend both qualitatively and quantitatively on the aforementioned state variables. Both the level of reactive power and a dynamic rise or drop can be dependent on the aforementioned grid state variables.
[0019] Likewise, the level and/or the behavior of the grid state variables can be considered as criteria.
[0020] The method preferably uses a frequency inverter in order to feed or remove the active power and the reactive power into/from the electrical power grid. It is hereby possible to decouple this feed or removal operation completely from the functioning of the wind turbine, in particular of the generator. Any plant controller, with adapted specifications, can initially continue to be operated in an unchanged manner. Of course, the controller then adapts the operation of the wind turbine, where applicable, when less power is required or when the power is even negative. However, the immediate response when feeding or removing active power and/or reactive power can be implemented initially independently of the frequency converter.
[0021] The wind turbine or all concerned wind turbines is/are preferably operated in what is known as full converter operation. In the case of this full converter operation, in order to explain this for the normal generation operation, the total energy of the generator removed by said generator from the wind is rectified and transferred into a corresponding DC intermediate circuit. From this DC intermediate circuit, the frequency inverter or a number of frequency inverters cooperating accordingly produces/produce the power to be fed, that is to say the current to be fed, in accordance with frequency, phase and amplitude.
[0022] During operation of the power removal, this frequency inverter, which is also referred to just as an inverter for simplification, can introduce power or energy from the electrical power grid into the DC intermediate circuit. Appropriate energy can then be removed from the relevant consumers by this DC intermediate circuit. Indeed, there is advantageously a command signal for removing such power at relevant consumers from a central point in the wind turbine or even in the wind farm, however the subsequent implementation is performed by the respective consumer. Lastly, the relevant consumer also otherwise operates independently, specifically when it is not used for power consumption, but for regular operation of the consumer function thereof.
[0023] In the case of the proposed method, a number of wind turbines are preferably used, which form a wind farm and feed into the electrical power grid via a grid point of common coupling. The aforementioned effects and the aforementioned behavior can be combined as a result. Such a wind farm, which feeds into the grid point of common coupling, thus also regularly has a significant quantity in terms of the amount of feedable and removable power (both reactive power and active power) compared with an individual wind turbine. Such a wind farm is thus preferably operated in the described 4-quadrant operation and thus constitutes a significant quantity from the viewpoint of the electrical power grid, not only for the provision of energy, but also for the potential of the controllability. It can cater in a significant measure to the supply of power, inclusive of the usual power demand. Inter alia, it can thus also favorably influence situations in which, in the past, payment of a sum would have been necessary in order to remove power in certain cases.
[0024] A wind turbine is preferably proposed which is set up to use a method according to at least one of the above-described embodiments.
[0025] More preferably, a wind farm is proposed that uses a number of wind turbines and is set up to use a method according to at least one above-described embodiment.
[0026] Such a wind farm preferably has a central controller for controlling the wind turbines, which also controls the described 4-quadrant operation, such that the wind farm can act at the grid coupling point as an efficient feed and control unit.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0027] The invention will be explained in greater detail hereinafter by way of example with reference to the accompanying figures.
[0028] FIG. 1 schematically shows a wind turbine in a perspective view.
[0029] FIG. 2 schematically shows a wind farm.
[0030] FIG. 3 illustrates the proposed 4-quadrant operation on the basis of a symbolic diagram.
DETAILED DESCRIPTION
[0031] FIG. 1 shows a wind turbine 100 with a tower 102 and a nacelle 104 . A rotor 106 having three rotor blades 108 and a spinner 110 is arranged on the nacelle 104 . During operation, the rotor 106 is set in a rotary motion by the wind and thus drives a generator in the nacelle 104 .
[0032] FIG. 2 shows a wind farm 112 comprising, by way of example, three wind turbines 100 , which may be the same or different. The three wind turbines 100 are thus representative of, in principle, any number of wind turbines of a wind farm 112 . The wind turbines 100 provide their power, specifically in particular the produced current, via an electrical farm grid 114 . Here, the produced currents or powers of the individual wind turbines 100 are added and a transformer 116 is usually provided, which performs an upward transformation of the voltage in the farm so as to then feed this into the power grid 120 at the feed point 118 , which is also referred to generally as the grid point of common coupling or PCC for short. FIG. 2 is merely a simplified illustration of a wind farm 112 , which for example does not show any controller, although a controller is of course provided. By way of example, the farm grid 114 can also be formed differently, in which for example a transformer is also provided at the output of each wind turbine 100 , so as to specify just one other exemplary embodiment.
[0033] FIG. 3 illustrates the proposed 4-quadrant drive in accordance with an illustration in the form of a diagram in the complex plane, which specifically represents active power in the abscissa direction and reactive power Q in the ordinate direction. In this diagram, the angle c o is thus also plotted, which in this regard represents the phase angle between fed current and voltage. Here, the four regions each showing one quadrant are graphically shown separately from this diagram of the complex plane for the purpose of illustration, since a spacing is plotted in the region of the coordinate system. The diagram thus shows the four quadrants, which are denoted by QI to QIV. The four quadrants are named thus in this context, wherein Q otherwise denotes the reactive power.
[0034] The first quadrant QI according to FIG. 3 shows the case in which active power and reactive power are fed. The fed reactive power is referred to as Pg (generated power) and the reactive power is referred to as Qig (generated inductive reactive power). The fed active power Pg and the fed inductive reactive power Qig give the apparent power {right arrow over (S)}.
[0035] This first quadrant may also represent the normal feed case. So as to further illustrate that inductive reactive power is fed, which leads precisely to the vector diagram of Pg, Qig and {right arrow over (S)}, the symbol of an inductance is also shown in the first quadrant. Due to the term “lag” used by a person skilled in the art, which means the same as running behind, it is additionally indicated that in this operation the fed current lags behind the voltage, specifically precisely by the shown angle φ. In the second quadrant QII, active power is removed from the electrical power grid, that is to say is consumed and not generated, which is indicated by the symbol Pc (power consumed). The reactive power component Qcc is positively illustrated. Since, however, active power is removed, the reactive power is also referred to here as removed (consumed), however is used as capacitive reactive power, which is why the naming Qcc is used. The current here runs ahead of the voltage, which is referred to here as “lead” and is illustrated by the symbol of the capacitance (of the capacitor) in the second quadrant QII.
[0036] The removed capacitive reactive power Qcc could at least theoretically also be referred to as produced inductive reactive power Qig, which from a technical viewpoint however would be confusing, at least in accordance with the selected illustration, because the leading current and accordingly the shown angle φ, denotes capacitive reactive power.
[0037] For the rest, two resistors are indicated parallel to the abscissa and thus symbolize the actual axis of this complex illustration.
[0038] In the third quadrant QIII, active power Pc is also removed, that is to say consumed. However, the proportion of reactive power Qic is negative here. Inductive reactive power is thus consumed and the current runs behind the voltage (lag), which is why the symbol of the shown inductance is also used again here.
[0039] The fourth quadrant QIV lastly shows the case that active power Pg is fed and (inductive) reactive power Qcg is removed, which corresponds to the feed (generation) of capacitive reactive power Qcg, such that the naming Qcg is selected, because here the current again runs ahead of the voltage. This is also illustrated here by the capacitance.
[0040] A solution is thus created that proposes a 4-quadrant operation of a wind turbine or of a wind farm and this behavior is illustrated by FIG. 3 .
[0041] Here, the underlying reasoning is that, in the case of the energy revolution in Germany, wind energy is one of the central pillars, if not the central pillar. In terms of technical content, the proposals of course are not limited to Germany. By means of the solution presented here, topics such as direct marketing, control reserve and minute reserve are also taken into consideration and form components for constructing what are known as green power plants. It is proposed for the provided energy to be organized such that conventional power plants, in particular nuclear power plants, can be switched off. Nevertheless, it must be possible to create and operate a stable grid without these large and partially leading and grid-stabilizing power plants. It has been identified that a key point here is the load flow control in the distributor grid and also at a higher level in the transmission grid, which both form parts of the electrical power grid. This load flow control is a parameter for stability of the electric power grid.
[0042] A conventional power plant is generally designed to provide energy. The system service powers of such a conventional power plant are limited only to the provision of the required energy, supply of reactive power for voltage preservation and control of the load flow in the electric power grid. Such a power plant provides this service only during production operation (also referred to as “generation operation”), that is to say with the delivery of energy.
[0043] In the case of the specific proposed 4-quadrant power plant, that is to say in the case of the wind turbine or the wind farm which can be operated in 4-quadrant operation, it is also possible to provide system services during consuming operation (“consumption operation”), that is to say also when energy is drawn from the electrical power grid. To this end, the possibility of load flow control by the consumption of energy is proposed.
[0044] In addition to the feed reduction to 0, power can also be removed from the electrical power grid.
[0045] So as to name one example, reference is made to the fact that the North of Germany is very windy and therefore a lot of wind energy is provided in order to be fed into the electrical power grid, and therefore specifically also into the European integrated network. An excess supply hereby produced would significantly increase the load flow from North to South Germany, which could lead to problems in the integrated network. In order to control the load flow in the integrated network such that no problems can occur, numerous large consumers (for example thermal consumers) are connected in a controlled manner into the numerous distributed wind turbines in Germany. The consumers could be generator heaters, blade heaters and generators operated in motor operation. Besides the regulated reference power, services such as reactive power for load flow control can also be introduced. This method may indeed have advantages in terms of a global energy balance, but also has an advantage in the numerous widely distributed actuators, specifically wind turbines, which can be activated and deactivated at relatively short notice. Processes in the grid can thus be responded to quickly, wherein the present invention additionally proposes this for the described 4-quadrant operation.
[0046] As a further example for illustration, reference is made to the fact that energy is traded on the spot market. There are times at which the current price can fall up to minus 3,000 euros/MWh. This regional excess supply of energy and the resultant negative price can now be controlled by reducing or even completely destroying in the regional wind turbines the excess energy responsible for such a described price behavior by switching on the large consumers, in particular thermal consumers. | A method for controlling at least one wind turbine, wherein the at least one wind turbine is set up to feed electrical power into an electrical power grid, and, depending on an amount of power of the electrical power grid, electrical active power is fed into the electrical power grid or electrical active power is removed from the electrical power grid and is supplied to at least one electrical consumer of the at least one wind turbine, and, depending on a further state variable of the electrical power grid, electrical reactive power is fed into the electrical power grid or electrical reactive power is removed from the electrical power grid. | 8 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] There are no related applications.
STATEMENT OF FEDERALLY SPONSORED RESEARCH/DEVELOPMENT (IF ANY)
[0002] Not Applicable.
REFERENCE TO A SEQUENCE LISTING
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] The Compact Interior Safe Room is an indoor storm shelter and safe room. As such the Compact Interior Safe Room may be classified under Class 109: Safes, Bank Protection, Or Related Device: Class (A) Safes; which includes all buildings and receptacles which feature the means for repelling or protecting their contents (including living beings) from explosions, penetration of missiles, other attacks by force or stealth, (including burglary or larceny), or for any other protective, or safeguarding purpose not elsewhere provided for.
[0005] The Compact Interior Safe Room is an innovation in the field of storm shelters in as much as it is readily available for installation in existing buildings, compared to many of the current versions which are restricted to installation in new buildings prior to occupancy. The Rigid Schedule 40 PVC Pipe that the Compact Interior Safe Room is comprised of is much lighter and easier to handle than the metal and concrete materials that are more common in the field to date, while the Rigid Schedule 40 PVC features considerable sturdiness and strength that provides more convenient and economical protection to the consumers.
[0006] The Compact Interior Safe Room is the invention featured in the Provisional Patent Application No. 60/819,886 filed Jul. 12, 2006, confirmation #7447.
BRIEF SUMMARY OF THE INVENTION
[0007] The general idea of the Compact Interior Safe Room is to provide substantial protection against injuries from wind-born debris during tornadoes, and to provide a safe room inside a building. The Compact Interior Safe Room will provide a readily accessible refuge without exposing the consumers to wind-blown debris, hail, and/or lightning while seeking to access the shelter. Exterior shelters expose the consumers to these risks.
[0008] The object of the Compact Interior Safe Room is to provide a reasonably strong and secure storm shelter and safe room at a more affordable price than those currently on the market. Due to the light weight and adaptability of the Rigid Schedule 40 PVC Pipe, while its strength, durability, and sturdiness provide reasonable protection, the Compact Interior Safe Room can be more economically assembled and installed in an existing building than previous products in the field of interior storm shelters and safe rooms. Due the adaptability of the Rigid Schedule 40 PVC Pipe, the Compact Interior Safe Room can be assembled in a room in an existing building with a minimum of inconvenience to the consumer, and with minimal alterations to the chosen room.
[0009] The Compact Interior Safe Room can be installed to conform to the dimensions of an existing room, or to meet the specifications of the consumer. While previous and current shelters and safe rooms are designed exclusively to provide shelter in an emergency situation, and are often inconvenient to access for use, the Compact Interior Safe Room can be furnished with a bed and accessories to allow the consumer to sleep inside the Compact Interior Safe Room overnight when there is a threat of stormy weather. The consumer won't have to wait for a tornado sighting or a weather service's warning to take shelter when severe weather strikes. The risk of not being able to access the shelter safely during a storm is eliminated in this way.
[0010] The Compact Interior Safe Room can be assembled to meet the consumer's specifications, which can provide an option to utilize the safe room for other purposes when it is not required for use as a storm shelter. Previous and current storm shelters and safe rooms in that field are designed to be used only for that primary purpose. Therefore, the consumer is denied other use of the space occupied by the shelter. The Compact Interior Safe Room provides a practical alternative for the consumer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] FIG. 1 shows the frontal view of the Compact Interior Safe Room. This view shows the wall featuring the entry, the top, the bottom, two corner-post units, and the way these units appear after being assembled.
[0012] FIG. 2A shows a view of the Compact Interior Safe Room wall that features the entry door opening into the Compact Interior Safe Room. The dimensions of the structure of this wall will conform to the dimensions of the existing room into which the Compact Interior Safe Room will be assembled, or to the consumer's specifications.
[0013] FIG. 2B shows a view of the door assembly for the Compact Interior Safe Room. The door will be assembled in conjunction with the door-way into the existing room in which the Compact Interior Safe room will be assembled. The dimensions of the door will conform to the dimensions of the door-way into the existing room.
[0014] FIG. 2C shows a view of the bar-and-brackets assembly that will firmly and securely close the door from the interior of the Compact Interior Safe Room. The brackets will be securely attached to PVC lengths in the door. The bar will be connected to a PVC length in the wall assembly by a swiveling connection that will allow the bar to be easily rotated into the brackets to securely close the door into the Compact Interior Safe Room and secure it from inside the Compact Interior Safe Room. (This same bar-and-brackets assembly will be used to secure the covering for the window/emergency exit that will be an optional part of another wall that may be assembled in line with an exterior window in the existing room into which the Compact Interior Safe Room is assembled.)
[0015] FIG. 3A shows a view of the wall of the Compact Interior Safe Room that features an opening which will be in line with an exterior window in the room into which the Compact Interior Safe Room will be installed. The purpose for this opening is to provide an alternative exit from the Compact Interior Safe Room to be used in the event that the door-way into the Compact Interior Safe Room cannot be opened from inside the Compact Interior Safe Room.
[0016] FIG. 3B shows the small door that will be used to cover the opening in the wall of the Compact Interior Safe Room that is lined up with an exterior window in the existing room. (When the Compact Interior Safe Room is occupied, this small door will be secured from inside using the bar-and-brackets assembly shown in FIG. 2C .)
[0017] FIG. 4A shows a view of one of the solid walls of the Compact Interior Safe Room. At least two of the walls will be solid, with the window/exit opening in a third wall being optional.
[0018] FIG. 4B shows a view of a length of 3″ Rigid Schedule 40 PVC Pipe that has been split length-wise, and reinforced for added strength and sturdiness by the insertion of a 2″ Rigid Schedule 40 PVC Pipe length, as depicted by the broken lines in the diagram. These reinforced lengths will be used to assemble the walls, and as the 3 horizontal bracing lengths across the top assembly.
[0019] FIG. 5 shows a view of the top assembly of the Compact Interior Safe Room. The top assembly is comprised of intact lengths of Rigid Schedule 40 PVC Pipe that has not been split length-wise, and three lengths of reinforced 3″ Rigid Schedule 40 PVC Pipe positioned across the assembly of the intact lengths for added strength, durability, and security.
[0020] FIG. 6A shows a view of two of the intact lengths of Rigid Schedule 40 PVC Pipe that have not been split length-wise. Each end of these lengths will be connected to a corner-post using a Rigid Schedule 40 double-elbow with outlet fitting joint. Four of these intact lengths will comprise the means to firmly secure the top assembly of the Compact Interior Safe Room to the wall assembly. Another four of these lengths will comprise the means to securely anchor the Compact Interior Safe Room to the floor of the building in which the Compact Interior Safe Room is installed.
[0021] FIG. 6B shows a view of four of the intact lengths of Rigid Schedule 40 PVC Pipe that will be used to comprise the corner-posts of the Compact Interior Safe Room. The corner-posts will comprise the means to securely connect the walls together and to comprise the means to firmly frame and secure the top assembly to the walls of the Compact Interior Safe Room. In addition, the corner-posts will comprise the means to frame the base of the Compact Interior Safe Room and securely anchor it to the floor of the building in which it is assembled.
[0022] FIG. 6C shows a view of the Rigid Schedule 40 PVC Pipe fitting joint that will be used to connect the corner-posts to the four intact lengths of Rigid Schedule 40 PVC Pipe that will comprise the horizontal frame that will secure the top assembly to the walls of the Compact Interior Safe Room. To secure the top, the double-elbow with outlet will be used with the outlet pointing down, extending into the opening at the top of a corner-post. Each end will be joined to an end of an intact length of Rigid Schedule 40 PVC Pipe to form a four-length frame over the top assembly. To securely anchor the Compact Interior Safe Room to the floor of the building in which it is installed, the double-elbow with outlet fitting joint will be turned so that the outlet is pointing upward and extended into the corner-post. Each end of the fitting will be connected to an end of an intact Rigid Schedule 40 PVC length in a way that comprises a four-length frame beneath the floor of the room in which the Compact Interior Safe Room is assembled.
[0023] FIG. 6D shows a view of a length of Rigid Schedule 40 PVC Pipe that has been split length-wise. This length will not be reinforced by the insertion of a length of 2″ Rigid Schedule 40 PVC Pipe. This length will be used to directly connect the top and the walls together. The split length will be used to make the connection by being placed in position between the top assembly and the wall assembly. The length will be rotated to position it so that there is adequate contact with the top of the wall and the surface of the abutting intact length of Rigid Schedule 40 PVC Pipe. Metal screws will then be drilled through the upper part of this rotated connecting length, into the intact lengths of PVC comprising the edge of the top assembly. Metal screws will then be drilled through the lower part of this rotated length, into the top lengths of Rigid Schedule 40 PVC Pipe comprising the wall assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The Compact Interior Safe Room is an interior storm shelter and safe room that is comprised of Rigid Schedule 40 PVC Pipe, which is a new and innovative concept in the field of storm shelters and safe rooms. The Compact Interior Safe Room will provide protection from dangers associated with tornadoes, other types of wind storms, and refuge from intruders. The Compact Interior Safe Room offers the advantage of an easily accessed storm shelter without exposure to lightning, hail, and wind-born debris that a person might otherwise be exposed to when one's shelter is located outdoors.
[0025] The Rigid Schedule 40 PVC Pipe used in the construction of the Compact Interior Safe Room is an improvement in the field of storm shelters and safe rooms because the light weight of the rigid PVC Pipe with its quality of rigidity, sturdiness, and strength is an advantage over such materials as metals and concrete previously used in the construction of interior storm shelters. The properties of the Rigid Schedule 40 PVC Pipe more effectively allow a flexible degree of pre-assembly of some of the component parts of the Compact Interior Safe Room at an established production location, and will allow easier assembly at the construction site.
[0026] The Rigid Schedule 40 PVC Pipe lengths will be pre-cut to the length desired, and the necessary pre-drilled holes in the PVC Pipe will be drilled at the production location. Varying degrees of pre-assembly will be completed at the production location, while the remaining components will be assembled at the installation site, per the consumer's specifications. Due to its lighter weight, compared to metal and concrete materials, the PVC component parts will be easier to maneuver into the chosen room for the assembly of the Compact Interior Safe Room and, therefore, the assembly will be more efficient, with minimal inconvenience to the consumer, and minimal alterations to the room in which the Compact Interior Safe Room is installed.
[0027] The dimensions of the Compact Interior Safe Room can be arranged in such a manner that the room containing the Compact Interior Safe Room can be utilized for other purposes when not being used for protection during a storm. The Compact Interior Safe Room can be furnished with a bed, which will not only allow the consumer to sleep in the Compact Interior Safe Room on nights when stormy weather threatens without waiting for a tornado sighting before seeking shelter, but the consumer will have the option of using that room as a bedroom when it is not needed for shelter.
[0028] The primary component parts of the Compact Interior Safe Room are: 4 walls comprised of 3″ Rigid Schedule 40 PVC Pipe lengths which are split length-wise; 4 corner-posts comprised of 3″ Rigid Schedule 40 PVC Pipe lengths that have not been split; a top frame comprised of 4 lengths of Rigid Schedule 40 PVC Pipe lengths that have not been split; a top assembly comprised of intact lengths of Rigid Schedule 40 PVC which have not been split; and 3 lengths of reinforced 3″ Rigid Schedule 40 PVC Pipe; and a bottom frame comprised of 4 intact lengths of 3″ Rigid Schedule 40 PVC Pipe that have not been split.
[0029] The walls of the Compact Interior Safe Room are comprised of the split lengths of Rigid Schedule 40 PVC Pipe which are connected together in a vertical position by metal bolts placed into pre-drilled holes in the PVC Pipe, spaced 12 inches apart. Each of the metal bolt connections are comprised of the metal bolt, a washer on each side of the hole in the PVC Pipe, a lock washer, and a metal nut securely tightened in place against the PVC Pipe. All but 8 of the split PVC lengths in the walls will be reinforced by the insertion of a 2″ PVC Pipe length that has been split length-wise. This 2″ PVC Pipe insertion will first be glued into place inside the 3″ PVC length at the production location. At the assembly site the 2″ insertion will be further secured by metal bolts placed into pre-drilled holes in the PVC Pipe. These bolts will also be secured by a metal washer on each side of the PVC Pipe, a lock washer next to the second washer, and a metal nut, which will be firmly tightened into place against the lock washer. These bolts will be placed in line with the bolts that connect the 3″ PVC lengths together at 12 inch intervals.
[0030] The dimensions of the walls will conform to the dimensions of the walls in the existing room into which the Compact Interior Safe Room will be installed, or to the consumer's specification. (The shorter the height of the Compact Interior Safe Room, the stronger and sturdier the Compact Interior Safe Room will be.)
[0031] Two walls of the Compact Interior Safe Room will be of solid construction. One of the other walls will feature an opening for a door that will be aligned with the door that opens into the room into which the Compact Interior Safe Room is installed. The door will be hinged in a manner that will allow it to open toward the interior of the Compact Interior Safe Room. It will be secured from the inside of the Compact Interior Safe Room by a metal bar firmly attached to a PVC length by a swiveling connection. This will allow the bar to be easily swung into position in two metal brackets attached to the PVC lengths on each side of the doorway for maximum security.
[0032] As an available option, the fourth wall may be constructed to allow an opening aligned with an existing exterior window in the existing room into which the Compact Interior Safe Room is installed. This opening will feature a smaller door than the entry door, and it will be hinged and secured by a bar and brackets in the same way. This will provide an alternative exit from the Compact Interior Safe Room if the entry door should be blocked. When secured from inside by the bar placed in the brackets, it will also provide protection from wind-born debris and from intrusion from outside of the building at other times.
[0033] The 4 corner-posts will primarily serve to connect the bottom frame to the top frame, to secure the top in position, and to connect the 4 walls together. The bordering length at each end of the walls will be comprised of a split length of Rigid Schedule 40 PVC Pipe that has not been reinforced by the insertion of a length of 2″ PVC Pipe. One side of each bordering length will be connected to an adjoining split length in the wall. The other side of that length will be attached to a corner-post by metal screws drilled through the split length of PVC Pipe into the corner-post. This procedure will be repeated until all four walls are securely connected to the four corner-posts.
[0034] The corner-posts will extend in height slightly above the height of the lengths in the walls. At the top of each corner-post a Rigid Schedule 40 double-elbow with side outlet fitting joint will be connected to the corner-post. The side-outlet will extend downward into the top of the corner-post. Each end of the double-elbow will be connected to an intact length of Rigid Schedule 40 PVC Pipe that has not been split, and these lengths will be securely placed over the top unit of the Compact Interior Safe Room to secure the top in place. Metal screws will be drilled into the fittings to securely connect the fittings, the PVC lengths, and the corner-posts together.
[0035] The bottom of the corner-posts will extend below the floor of the room into which the Compact Interior Safe Room will be installed. A Rigid Schedule 40 double-elbow with side outlet fitting joint will be attached to the bottom of the corner-post. The side outlet will be pointed upward to fit into the corner-post. Each end of the double-elbow fitting will be connected to one of the intact 3″ Rigid Schedule 40 PVC Pipe lengths that have not been split. These lengths will then be firmly secured against the floor of the existing room into which the Compact Interior Safe Room is assembled to provide a secure anchor for the Compact Interior Safe Room. The connections that connect the corner-posts, the lengths, and the fittings together will be secured in place by metal screws drilled into the PVC Pipe.
[0036] The top assembly is comprised of intact lengths of 3″ Rigid Schedule 40 PVC Pipe that have not been split length-wise. Every length will be connected to an adjoining length by metal bolts inserted at the end of the lengths. Each bolt connection will be comprised of a metal bolt, a washer on each side of the PVC Pipe, a lock washer, and a metal nut firmly tightened against the lock washer. The top assembly will be further strengthened by placing 3 lengths of 3″ Rigid Schedule 40 PVC Pipe, which has been split and reinforced, horizontally across the intact lengths of the top unit. (The 2″ PVC inserts will be glued and bolted to the 3″ PVC like the procedure used in the walls.) These reinforced units will be secured in place by drilling metal screws upward through the split PVC lengths into the intact PVC lengths of the top assembly.
[0037] 4 lengths of 3″ Rigid Schedule 40 PVC Pipe that have been split length-wise, but not reinforced, will be used around the sides of the Compact Interior Safe Room to connect the top assembly to the upper edge of the walls. These lengths will serve as a border link between the top assembly and the walls. These split lengths will be placed up between the walls and the top with the open interior of the split length facing into the Compact Interior Safe Room. The length will be rotated so that the top part of it will make adequate contact with an intact length in the top assembly to allow metal screws to be driven into the PVC lengths and firmly connect them together. Then metal screws will be driven through the bottom part of the split length of PVC Pipe into the lengths of PVC Pipe in the walls. This procedure will be repeated all around the perimeter of the Compact Interior Safe Room.
[0038] The bottom frame will be comprised of 4 lengths of intact 3″ Rigid Schedule 40 PVC Pipe lengths that have not been split. In addition to the connections at the corner-posts, the PVC lengths in the bottom frame will be secured in place by straps attached to the floor under the room in which the Compact Interior Safe Room is assembled. The straps will be placed at three feet intervals to securely anchor the Compact Interior Safe Room.
[0039] The intended order of assembly of the Compact Interior Safe Room is: 1.) The frame beneath the floor is secured in position; 2.) The corner-posts are erected; 3.) The upper frame is secured in position, with the downward pointing bolts ready for connecting to the frame lengths to the top assembly; 4.) The top assembly will be secured in place; 5.) The walls will be assembled; 6.) The entry door will be installed, with the swiveling bar and brackets; 7.) The small door covering the window opening, if that option is chosen, will be installed last. | The Compact Interior Safe Room is a new concept in the field of interior storm shelters and safe rooms. It offers the public a convenient and economical means to install a relatively strong, sturdy, and dependable interior storm shelter and safe room refuge in an existing building. While many manufacturers of current interior storm shelters require the installation of their interior storm shelter at the time of construction of the building that will house the shelter, the Compact Interior Safe Room is designed to be assembled inside the consumer's existing home in an economical manner, with a minimum of inconvenience to the consumer, and with minimal alterations to the existing room. The economic price of the Compact Interior Safe Room will make an interior storm shelter and safe room available to consumers who may not be able to afford the more expensive storm shelters. | 4 |
BACKGROUND OF INVENTION
[0001] The present invention relates to protective equipment, and, in particular, relates to protective equipment for human teeth.
[0002] Mouthguards and related teeth protective equipment have been known since approximately the year 1900. (Scott, J., Burke, F. J. T. and Watts, D. C.; Br Dent J. 1994; 176: 310-314). In general, known mouthguards share characteristic deficiencies in comfort afforded a wearer. (DeYoung, Amy Kay, Robinson, Emerson and Goodwin, William C. JADA, v. 125, August, 1994, pp. 1112-1117. Woodmansey, Karl F. General Dentistry, January-February 1999, pp. 64-69.) Known mouthguards typically degrade or impede a wearer's breathing and/or speech. Moreover, known mouthguards are often subjectively considered detrimental to the appearance of wearers.
[0003] One consequence of these characteristic shortcomings is a nearly universal disdain and avoidance of use by those potential wearers who are most likely to benefit from such protective equipment. While those potential wearers may be temporarily compelled to wear such protective equipment when under the supervision of an authority figure, they often discard, lose, hide or otherwise avoid wearing such protective equipment within moments after their supervision is relaxed or terminated. Unfortunately, the dangers remain and too often, teeth are then damaged or lost. (Ibid)
[0004] Thus, there remains a need for a mouthguard that is protective, comfortable, does not interfere with breathing, and allows speech by a wearer. Preferrably, such a mouthguard would not render the wearer less attractive. Such a device would eliminate much of the motivation to avoid wearing mouthguards and thereby increase comfort and pleasure while affording wearers a longer period of time during which they are protected from danger. Moreover, if the protective characteristics of such a device, when actually worn, were to exceed the protection afforded by known mouthguards, when actually worn, then a substantial increase in safety would occur. In other words, a substantially safer mouthguard would be relatively more effective in protecting teeth against a given blow and would be worn for a greater proportion of the time when danger is present. A wearer of a substantially safer mouthguard would enjoy a greater level of safety over a longer time frame with greater comfort, unimpeded open-mouth breathing, still able to speak and not become less attractive. Thus, a recognition and appreciation of a variety of significant mouthguard characteristics must be incorporated to develop a substantially safer mouthguard.
[0005] Some known mouthguards also claim an ability to improve protection of body structures other than teeth, e.g. the temporomandibular joints and brain. There remains an opportunity and need for a more critical consideration of the protection afforded by these known mouthguards. A better understanding of such protection might allow advances in protection to be considered and incorporated into the earlier mentioned substantially safer mouthguard.
[0006] There have been a number of studies and articles in relevant literature that, although not reaching the present invention may warrant review as background in understanding the present invention:
[0007] 1. DeYoung, Amy Kay, Robinson, Emerson and Goodwin, William C. Journal of the American Dental Association, v. 125, pp. 1112-1117, August, 1994.
[0008] 2. Gilboe, Dennis B., Centric Relation as the Treatment Position, Journal of Prosthetic Dentistry, 50:5, pp. 685-689, 1983.
[0009] 3. Gilboe, Dennis B., Posterior Condylar Displacement: Prosthetic Therapy, Journal of Prosthetic Dentistry, 49:4, pp. 549-553, 1983.
[0010] 4. Hickey, Judson C., Morris, Alvin L., Carison, Loren D., Seward, Thomas E., The Relation of Mouth Protectors to Cranial Pressure and Deformation, Journal of the American Dental Association, v. 74, pp. 735-740, March, 1967.
[0011] 5. Keith, David A., Orden, Adam L., Orofacial Athletic Injuiries and Involvement of the Temporomandibular Joint, Journal of the Massachusetts Dental Society, v. 43: 4, 11-15, 1986.
[0012] 6. Scott, J, Burke, F. J. T. and Watts, D. C., A Review of Dental Injuries and the Use of Mouthguards in Contact Team Sports; Br Dent J.; 176: 310-314, 1994.
[0013] 7. Westerman B, Stringfellow P M, Eccleston J A. EVA Mouthguards: How Thick Should They be? Dental Traumatology: 18, 24-27, 2002.
[0014] 8. Woodmansey, Karl F., Athletic Mouth Guards Prevent Orofacial Injuries: A Review General Dentistry, January-February, pp. 64-69, 1999.
[0015] The present invention, disclosed subsequently, addresses these many issues and challenges by applying critical and innovative thinking to the functions and mechanisms through which mouthguards protect a wearer. Additionally, the present invention, disclosed subsequently, includes innovative methods of making and using such mouthguards.
SUMMARY OF THE INVENTION
[0016] The present invention, in a first embodiment, is a heat and pressure formed custom mouthguard that protects maxillary and mandibular teeth, stabilizes temporomandibular joints, maximizes jaw muscle comfort and facilitates speech and breathing.
[0017] A mouthguard, according to the present invention, allows individuals wearing the mouthguard to speak easily and relatively naturally while still protecting their teeth and jaws and jaw joints. The ability to speak while wearing this mouthguard is due, in one aspect, to the relatively small size of the new mouthguard in comparison to known mouthguards. By using anatomical relationships heretofore ignored or discarded in known mouthguards, the mouthguard of the present invention allows for greater retention, stabilizes the temporomandibular joints, maximizes jaw muscle comfort and allows a wearer to speak easily. The upper anterior extent of the inventive mouthguard is matched with or generally level with the upper posterior extent. This anatomically matching relationship serves to maximize retentive fit on the teeth and soft tissue.
[0018] The mouthguard of the present invention is formed, in a preferred embodiment, through a combined use of heat and pressure about a dental cast or form that is largely representative of the maxillary anatomical structures that are to be protected. One preferred method of formation involves use of a machine such as a BioStar machine (available from Great Lakes Orthodontics of Buffalo, N.Y.) which machine heats a sheet of laminate thermoplastic material and pressure forms the heated sheet over a dental cast and into a close molded conformance therewith. Prior to such molding, the dental cast is modified to alter the resulting shape of the sheet being molded or formed. The sheet is subsequently trimmed to discard unwanted portions, thereby leaving a mouthguard of the present invention. The resultant mouthguard is extremely close fitting or conforming to certain teeth and portions of the maxilla. This close fit, in turn, renders the mouthguard of the present invention extremely retentive. One modification of the dental cast creates a significant or key structure of the mouthguard that further enhances its retentive property once fitted to the wearer. The dental cast is made of dental stone material. The modification of the dental cast removes a small portion of dental stone material in certain regions of the dental cast. In turn, this small portion of removed material eventually results in a mouthguard that is functionally and effectively more closely in contact with portions or regions of the wearer's mouth. That is, the resulting mouthguard is resiliently contacting the tissue within the wearer's mouth; and most specifically the mouthguard is resiliently contacting the wearer's mouth, including intaglio surfaces, with portions of the mouthguard that are the direct result of the modification to the dental cast. This added retention makes speaking and/or breathing easy and relatively natural for a wearer of the inventive mouthguard. A second modification alters the shape of the dental cast by removing a portion of the dental cast corresponding to the hard palate; in particular a portion posterior to the section that will be used to form or mold the sheet material to form the inventive mouthguard is removed.
[0019] In another embodiment of the present invention, the inventive mouthguard also includes an anterior stop for the lower teeth of the wearer. By providing an anterior stop for the lower teeth against the posterior surface of the mouthguard while upon the upper teeth, the wearer's molars do not touch. As a result, in turn, molar prematurities are avoided. The closing masticatory muscles help seat the condylar heads in the condyle-disk assembly and stabilize the temporomandibular joints for any impact to the mandible. (Gilboe, Dennis B., J. Pros. D., 49:4, pp. 549-553) The inventive mouthguard allows such seating of the condylar heads to occur while the mouthguard is in place.
[0020] The present invention is particularly useful due to the increased compliance by athletes. The inventor has informally observed that athletes afforded an opportunity to wear a mouthguards of the present invention, are far more likely to continue wearing the mouthguards without enforced monitoring of required wearing because of the comfort associated with the inventive mouthguard and because of low impact on speech and/or breathing. On a wider scale, the availability of such an inventive mouthguard would allow athletes to benefit from the general health and safety benefits generally associated with mouthguards while simultaneously avoiding some of the most notorious and least desirable side effects. Examples of such avoidable effects include bulkiness, pinching of gum tissue, gagging, looseness, bad taste, soreness of masticatory muscles, and restricting breathing.
[0021] Other known mouthguards exist but the present invention is believed distinct and superior because: First, the present inventive mouthguard maximizes retention using and innovatively exploiting naturally present anatomy of the anterior upper jaw. Second, the inventive mouthguard is specially shaped to substantially avoid facial and jaw muscle soreness, which soreness is believed to result from a condition of extended periods of enduring molar occlusal prematurities (or poor bite) associated with known mouthguards. Third, the present inventive mouthguard is not subject to shredding, flattening, or similar deterioration between the wearer's back teeth. Fourth, the present inventive mouthguard does not loosen up or otherwise detrimentally change shape with extended use. Moreover, the present inventive mouthguard stabilizes the wearer's temporomandibular joints in a position that optimally or nearly optimally resists a potentially damaging force. Further, the present inventive mouthguard contributes to stabilizing the lower jaw from lateral blows. In addition, the present invention decreases the amount of force transmitted to the cranium from blows to the lower jaw by serving as a damper to such undesireable force.
[0022] Perhaps most significantly from a health and safety view point, the present invention allows easy breathing so as to encourage compliance, thereby increasing the probability the wearer will benefit from the incorporated protection features. Comfort and thereby compliance, and in turn overall probability of protection, is also increased by the general lack of distortion of the wearer's upper lip. Moreover, the lack of distortion in the wearer's upper lip is not detrimental to the wearer's appearance, thereby reducing objections based upon the wearer's vanity and again, in turn, increasing the probability that the inventive mouthguard's protective capabilities will be available to a potential wearer when actually needed.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG. 1 is an isometric view showing the top of the mouthguard, the present invention, and also showing the post dam element of the mouthguard;
[0024] FIG. 2 is a rear view of the mouthguard of FIG. 1 ;
[0025] FIG. 3 is a sectional view at 3 - 3 of FIG. 1 and additionally schematically showing certain anatomical structures being protected within the mouthguard;
[0026] FIG. 4 is a buccal view of the mouthguard upon a dental cast;
[0027] FIG. 5 is an occlusal view of the finished mouthguard upon a dental cast;
[0028] FIG. 6 is an occlusal view of a maxillary dental cast showing palatal reference points;
[0029] FIG. 7 is an occlusal view of the maxillary dental cast modified to allow molding of the mouthguard and showing the positioning of the post dam modification machining;
[0030] FIG. 8 is a cross-sectional view of a maxillary dental cast at 8 - 8 of FIG. 7 and showing post dam machining;
[0031] FIG. 9 is a buccal view of the dental cast and showing the anterior outline of the height of the muccobuccal fold marked to show the anterior upper extent where the mouthguard is to be trimmed; and,
[0032] FIG. 10 is a sectional view at 8 - 8 of FIG. 7 and the just formed mouthguard, trimmed and re-installed upon the modified maxillary dental cast.
DETAILED DESCRIPTION OF THE INVENTION
[0033] In a first embodiment, the present invention is a mouthguard 20 , as shown in FIG. 1 . The mouthguard 20 includes an anterior portion or wall 22 and a posterior portion or wall 24 . The anterior wall 22 has an upper edge or extent 26 and a lower portion 28 . A slight dip or notch 27 is centered on the upper extent 26 of anterior wall 22 . The notch 27 accommodates the frenum (or frenulum) of the wearer, thereby allowing portions of the anterior wall 22 to reach higher on the gum 60 (as shown in FIG. 3 ). The anterior wall 22 has a curved shape and is adapted and custom fit and shaped for close conformance to the forward surfaces of the maxillary anterior teeth and gingival tissue of a wearer of the mouthguard 20 . In particular, the anterior wall 22 has an inwardly directed surface 32 (perhaps best viewed in FIG. 2 ) which is adapted and shaped to contact the forward surfaces of the wearer's anterior teeth and gingiva and gums. The anterior wall 22 also has an outwardly directed surface 34 which may be contacted by the wearer's upper lip. For a typical wearer, the frontward or outwardly directed surfaces of the following teeth are typically fit to the anterior wall surface 32 : the four incisor teeth, the two canine or cuspid teeth and the two premolar teeth on each side, and/or the forward most molar if a premolar is missing. In other words, the mouthguard 20 is generally centered on the midline of the upper or maxillary jaw and encloses only the front ten teeth, i.e. the first five teeth on each side of the midline of the maxillary jaw. The outwardly directed surface 34 typically reflects the general shape and contour of the forward surfaces of the above-mentioned wearer's anterior teeth.
[0034] The posterior wall 24 of mouthguard 20 is connected to the lower portion 28 of the anterior wall 22 by a lower portion 42 , together lower portions 28 and 42 define a bottom 43 of the mouthguard 20 which bottom 43 generally has an overall U-shape, when viewed from above or below. The posterior wall 24 also has an upper edge or extent 44 . The inwardly directed surface 46 of the posterior wall 24 is adapted and shaped to closely conform to the posterior surfaces of the anterior teeth of a wearer, most typically the foremost ten teeth, as well as adjoining regions of the wearer's palate. The inwardly directed surface 46 of the posterior wall 24 is generally facing toward the inwardly directed surface 32 of the anterior wall 22 . The posterior wall 24 also has an outwardly directed surface 48 (perhaps best shown in FIG. 2 .) The outwardly directed surface 48 typically is in intermittent contact with the wearer's tongue and has a shape generally reflective of the wearer's underlying teeth and palate. The posterior wall 24 and inwardly directed surface 46 thereof is also slightly inclined as well as having a general U-shape.
[0035] Situated on the inwardly directed surface 46 adjacent the upper edge 44 is a post dam 50 . The post dam 50 is an exception to the conformity of the interior surface 46 . The post dam 50 is a generally continuous ridge upon the inwardly directed surface 46 . The purpose and function of the post dam 50 is to bear against the palatal tissue of the wearer. Such bearing against the palatal tissue, in turn, tends to resiliently seal the mouthguard 20 to the wearer's palate.
[0036] As shown in FIG. 2 , inwardly directed surface 32 of the anterior wall 22 is directed toward the front surface of a wearer's teeth and a wearer's anterior gum 60 and conforms thereto. Rearward surface 48 of posterior wall 24 is directed for intermittent contact with a wearer's tongue. Notch 27 is situated to accommodate a wearer's frenum (or frenulum.)
[0037] The mouthguard 20 serves a protective role with respect to a wear's teeth as perhaps most easily comprehended with reference to FIG. 3 , a cross-sectional view near midline of the maxillary jaw and showing schematically an incisor 52 having a crown 54 in the bottom 43 of mouthguard 20 and a root 56 generally above crown 54 . The root 56 is anchored in bone 58 and protrudes downwardly through the gingiva, or gum 60 . This incisor 52 may be considered exemplary of the other nine teeth protected by the mouthguard 20 . Each of the ten teeth is prone to damage, for example, by blows hitting one or more of the teeth and potentially either fracturing, breaking, and/or displacing one or more of the teeth. The mouthguard 20 protects the ten teeth by cushioning them, by linking them together, (particularly in the areas about their crowns, because for example crown 54 has great leverage relative to root 56 ) and by linking them to the gum 60 and palate 62 . One of the benefits of the present invention mouthguard 20 is that the mouthguard is remarkably comfortable to wear. In particular, the back extent of the guard comes up behind the anterior teeth, particularly in the area of the rugae, i.e. the rough spots on the front of the palate or roof of the mouth. This configuration means, in turn, that the ridge formed at the edge of the mouthguard 20 is in a position where the wearer's tongue is normally used to feeling roughness or texture, and, consequently, the wearing of the guard has a more natural feel to the wearer. If the back edge/ridge of the guard were to be placed higher up in the roof of the mouth, for example, as in the prior art U.S. Pat. No. 4,672,959 Robert May mouthguard, the wearer's tongue would feel it as something not natural, and there may be the discomfort of the feeling of a foreign object in the mouth, or possibly a tendency to work it with the tongue to possibly dislodge the guard unintentionally. Additional comfort and “natural” feeling of the mouthguard in a wearer's mouth increases compliance.
METHOD OF MAKING THE MOUTHGUARD OF THE PRESENT INVENTION
[0038] In a preferred embodiment, the mouthguard 20 is made as follows: First, an alginate impression is made of the maxillary teeth of a potential wearer. Other alternative impression materials include silicones, vinylpolysiloxanes, polyethers, however, alginate impressions are believed to be the most appropriate for the present invention.
[0039] The alginate impression preferably is made within a “shorter than usual impression tray.” By “shorter than usual impression tray” herein is meant an impression tray which is shorter than a typical dental impression tray in that it does not extend posteriorly as far as conventional impression trays. The “shorter than usual impression tray” tends to minimize the amount of unhardened alginate impression material necessary to make an alginate impression in the limited dental region of interest and to significantly reduce the probability that the unhardened alginate impression material would inadvertently escape in a posterior direction within the potential wearer's mouth and gag or otherwise compromise a potential wearer. Note that the preferred “shorter than usual impression tray” does not extend as far back into a potential wearer's mouth so that the gag reflex is also less likely to be triggered. The “shorter than usual impression tray” of this invention was invented and developed for use in the method of making the mouthguard 20 of the present invention. To make the “shorter than usual impression tray” from a standard impression tray of the dental trade, the posterior border of the shortened tray is sealed off with either a periphery wax or other suitable material. Preferably, the “shorter than usual impression tray” accomodates the potential wearer's first five teeth on either side, for a total of ten teeth. However, a “shorter than usual impression tray” need, at minimum, only accommodate only the first ten teeth and, at maximum, would not extend to accommodate a full set of teeth. While the mouthguard 20 of the present invention could, alternatively but less desirably, be made using a standard impression tray, the comfort to the future wearer is promoted and enhanced by use of the “shorter than usual impression tray” in this step.
[0040] The resulting alginate impression is used to pour up a cast of the maxilla structure of the potential wearer. The cast 61 resulting is made of dental stone. After the dental stone has set, the cast of the maxilla is trimmed to a “horseshoe” shape and so that the palate is partially removed as shown in FIG. 6 . The partial removal of palate in the dental cast is preferably accomplished using a model trimmer or a bench top model former. A portion of the hard palate is removed posterior to the first molars. More specifically, the dental cast portion representative of the hard palate from approximately the mesial of the first molars and anteriorly is necessary to prepare the mouthguard of this invention. Thus, this portion of the dental cast should be preserved and not removed. However, for ease of explanation and understanding, the production of a mouthguard 20 is illustrated herein with full maxillary dental cast of a mouth wherein wisdom teeth are either not yet present, or have been removed.
[0041] Next, reference lines 64 on FIG. 6 for establishing the anterior and posterior extents of the mouthguard are made on the dental cast. From these reference lines 64 , the position corresponding to the post dam 50 of the mouthguard 20 can be defined upon the dental cast 61 . Significant in locating the position of the post dam 50 are reference points 67 on the palate. The first line drawn upon the dental cast 61 is from the interproximal area between the first molar and the next mesial tooth superiorly to the height of the roof of the palate. The second line has the same origin, moves superiorly but is angled further towards the anterior to intersect a point that is even with a point 67 marking the most superior extent of the muccobuccal fold. With the outline of the post dam 50 of the mouthguard 20 established, the initial cut for the post dam, or posterior palatal seal, is performed. This step is preferably accomplished with a lab hand piece and a #8 or #10 round bur. The resulting groove 68 is shown sectionally and across remaining surface structure of the dental cast in FIG. 8 . Preferably, the groove 68 is formed in two successive steps. First, the lab hand piece and #8 or #10 bur are applied to the desired line. Second, subsequent to the initial cut, a second cut is performed that bevels 69 the anterior edge of the post dam 50 approximately forty-five degrees. A cylindrical lab bur works well for this procedure.
[0042] The advantage of this system of retention is that the anterior and posterior walls form an approximate “U”. In some cases, the anterior extent of the mouth guard engages undercuts formed by the alveolar ridge (see FIGS. 7 and 8 .) This “U” shaped design is one of the most important unique features of mouthguard of the present invention. By way of expanded explanation, retention in dental restorations such as crowns is dependent on the relative parallelism of the walls of the preparation. This aspect of preparation design is referred to as the “retention form.” Considering analogously, stacked dispensible paper cups, such as “Dixie brand paper cups,” will stack on each other and be retentive relative to each other due to the closeness of fit and parallelism of the walls of the paper cups. Similarly, so too the present invention mouthguard has greater retention in the wearer's mouth because the front and the back walls are more parallel than known prior art mouth guard designs. The present invention mouthguard cannot be ejected by the wearer's tongue. Forced removal by fingers is the only way to remove the present invention mouthguard from the wearer's mouth.
[0043] The dental cast 61 , having a groove 68 prepared for the post darn, is now ready for the mouthguard material to be formed or conformed to the modified shape. This step is preferably performed with use of a heat and pressure-forming device. One such suitable device is a Biostar machine (available from Great Lakes Orthodontics, of Buffalo, N.Y.). Following the heat and pressure forming of the sheet into a mouthguard-like shape, it is trimmed to its final form using dental lab shears and a lab bur and lab polishing stone in a lab hand piece. This results in a mouthguard 20 .
[0044] Once formed, the mouthguard is checked for fit in the wearer's mouth. Then, the occlusal or biting surface of the mouthguard 20 is softened with a hand torch or other heating means for example, IR lamp, radiant heat source, Cal-Rod heater, and similar localized heating means, placed back into the mouth, and the wearer will close lightly to indent the chewing surface of the mouthguard 20 with the cusps of the lower jaw to a depth of approximately ½ mm-2 mm, preferably 1 mm-2 mm; this process is called “indexing.”
[0045] Indexing a mouthguard 20 with the anterior mandibular teeth is unique to the present invention mouthguard 20 . Indexing has a distinct advantage in that during the indexing process the closing muscles of the mouth engage only the front of the mouth (where the mouthguard is positioned upon the wearer's teeth) and help seat the temporomandibular joints into their medially braced positions against the petrous portions of the temporal bone where the condyle-disk assembly is best positioned to withstand force. In this position, the condyle rotates. With the mouth closed and the mouthguard 20 in place, any trauma to the mandible will only rotate the mandible into the mouthguard 20 which will dampen the movement of the mandible and decrease the magnitude of the force transmitted to the cranium as the mouthguard 20 absorbs energy as it is deformed during the trauma. It is also possible to make a mouthguard 20 of the present invention by other methods. One alternative method is to first digitally scan the maxilla in the area where the mouthguard 20 would fit. This digital scan represents a virtual cast of the maxilla. The digital scan, as a virtual cast, includes three-dimensional information of the maxilla, much as the physical cast 61 includes analog and physical information of the maxilla. Next, a cast of the teeth and associated maxilla is reproduced from the three dimensional digital information of the digital scan. This reproduced cast is then used to complete production of the mouthguard 20 . The groove is either subsequently machined or cut into the cast or alternatively, the groove is added digitally, such that a separate machining or cutting step is not needed. Note that one advantage of this digital method is that no “traditional impression technique” would be necessary. It is further envisioned, that virtual imaging technique might also be employed to provide a three-dimensional model. Examples of techniques and equipment might be a CAT scan or an MRI dataset. These approaches could be subsequently digitized and then a physical model built up using rapid prototype methods for making the mouthguard or the model dental cast or the modified dental cast for use in molding a mouthguard. Alternatively, a mouthguard could be made by rapid prototype techniques if the materials were sufficiently developed to get appropriate mechanical properties and have the safety/toxicity guidelines for the materials established. Further, it should be noted that the modification, leading to the post dam being molded integrally, as part of the mouthguard, may be the product of human intervention in prescribing the appropriate modification, or alternatively, a digital three-dimensional model could be automatically prescribed a modification leading to the correct post dam. Further, transmission of the digital information/three-dimensional model information, before or after modification could be via the Internet or telephone lines, or other electronic or photonic transmission systems.
[0046] Another alternative method is to use a molded shell, using the general anatomical relationships described in this embodiment, to hold a second stage “lining material” in the shell intraorally to further refine the fit and retention of the mouthguard.
[0047] Another method is to place a material in the groove or machining for the post dam prior to use of the Biostar machine. This material may be the same as the sheet or alternatively a different material, different either in color or in physical properties or both. Subsequently, the heated softened sheet is pressure formed and the added material incorporated at the post dam 50 that serves to form a seal.
METHOD OF USING THE MOUTHGUARD OF THE PRESENT INVENTION
[0048] The mouthguard 20 of the present invention is used by first inserting the mouthguard into the mouth of a wearer for whom it has been custom prepared. During insertion, the mouthguard 20 is oriented such that the upper edges 26 and 44 are above the lower connected portions 28 and 42 at bottom 43 . The mouthguard 20 is then positioned beneath the maxillary anterior ten teeth and raised or lifted. Next, the mouthguard 20 is lifted into a fitted position against and enclosing the maxillary anterior teeth. During this fitting, the mouthguard 20 is preferably seated with the wearer's tongue, mandibular teeth and optionally, the wearer's fingers. Simultaneously with the final movement of this upward directed seating, air and/or saliva previously residing upon or trapped between the inwardly directed surfaces 32 and 46 of the mouthguard 20 and the corresponding surfaces on the teeth, gums, and palate is expelled. Once completely fitted, there is at most a minimal space (or alternatively a thin film ) 51 between the mouthguard 20 and the teeth and palate. (In order to facilitate understanding, the film or space 51 is shown with exaggerated thickness in FIG. 3 .) The post dam 50 may be understood as resiliently sealing minimal space/thin film 51 . While not wishing to be bound by theory, the inability of air and or saliva to easily re-enter space 51 tends to hold the mouthguard 20 in position using van der Waals forces while allowing the wearer to temporarily cease application of the upward seating pressure, similar in direction but not extent, initially used to install the mouthguard 20 into such a “fitted” or desired wearing position. (It may be that further substitution or modification of the fluid in the thin film minimal space might afford even more extreme retention of the mouthguard in the wearer's mouth. In this alternative, the expanded group of fluids includes not only saliva, water, and/or air, but also a sports beverage and perhaps fluid choices employed to help further maintain adhesion such as a denture adhesive-like material. However, it should be emphasized that the basic mouthguard of the present invention demonstrates remarkably useful retention without specialized fluids.) During this temporary cessation of upward seating pressure, the wearer can speak or breathe with an open mouth. Furthermore, the mouthguard 20 is comfortable in this installed position. The comfort afforded the wearer, as will be explained subsequently, is the result of a number of characteristics of the present invention mouthguard. In particular, comfort generating characteristics of the inventive mouthguard include: reduced size of the mouthguard of the present invention relative to known prior art mouthguards, limited extent of the mouthguard of the present invention into the posterior of the mouth, and reduced strain on the jaw muscles due to the elimination of molar occlusal interferences which, if present, would compromise normal closing muscle function.
[0049] When installed, the mouthguard is also highly protective of the wearer's teeth and the relationship between the teeth and gums because the mouthguard has a thickness of from about two to about four millimeters. Alternatively, the preferred mouthguard has a separation between teeth, subsequent to indexing, of about 2.5 mm-3.0 mm. This thickness originates in the blank sheet used to form or mold the mouthguard over the dental cast 61 . Suitable blank sheets are available from dental supply houses, such as Dental Resources, Delano, Minn. which carries the ProForm brand of blank sheets. Preferred blank sheets are laminated blanks sheets, such sheets being known in the industry. Further, the subsequent indexing step allows the wearer to bite against the mouthguard with his mandibular anterior teeth. The indexing region thereafter further stabilizes the maxillary anterior teeth, as well as stabilizing the mandibular anterior teeth and, in turn, stabilizes the mandible as well. The wearer is therefore relatively substantially better protected from the following types of often-dreaded injuries. (1) A blow to the maxillary anterior teeth. The mouthguard of the present invention provides better protection than known prior art mouthguards against such blows because of the substantial thickness of mouthguard material on the outside or buccal side of the maxillary teeth, and because of the thickness of mouthguard material between the maxillary and mandibular teeth, and because of the supporting resistance of the braced mandibular anterior teeth. (2) A blow to the mandibular anterior teeth. The mouthguard of the present invention provides better protection than known prior art mouthguards against such blows because of the thickness of mouthguard material between the mandibular and maxillary teeth. (3) A lateral blow to the mandible. The mouthguard of the present invention provides better protection than known prior art mouthguards against such blows because the indexing of the mandibular teeth into the mouthguard solidly locates and solidly secures the mandible, by way of the mandibular teeth, to the mandible while providing shock absorption or dampening in relation to the thickness of the mouthguard. (4) An upwardly directed blow to the mandible. The mouthguard of the present invention provides better protection than known prior art mouthguards against such blows because of the thickness of the mouthguard material between the mandibular and maxillary teeth, and the stabilizing influence of the inventive mouthguard. Together, these factors allow the condylar heads of the temporomandibular joints to seat in the medially braced position of the glenoid fossae. Moreover, should the wearer of the mouthguard 20 of the present invention be struck in the mandible from a direction such that the blow might tend to inflict damage to the wearer's skull or the wearer's brain contained therein, the mouthguard 20 reduces a substantial portion of the force transmitted. The mouthguard of the present invention provides better protection than known prior art mouthguards against such blows because of the energy absorbing or dampening ability of the thickness of the mouthguard portions separating teeth carried by the mandible and the maxilla between about 2 mm and about 6 mm due to the mouthguard material between the mandibular and maxillary teeth.
[0050] Subsequently, when the wearer wishes to remove the mouthguard 20 , the wearer will typically observe that the mouthguard 20 cannot easily be removed by manipulation with the wearer's tongue. Rather, the wearer will typically be required to employ at least one or more fingers to deform an edge of the mouthguard 20 and thereby release the seal associated with post dam 50 . Once the seal is released, air and/or saliva can easily re-enter the space 51 between the wearer's teeth and palate. This, in turn, allows the mouthguard 20 to be lowered from the maxillary teeth and subsequently expelling forwardly between the maxillary and mandibular teeth.
[0051] While not wishing to be bound by theory, the remarkable retention of the inventive mouthguard 20 in a wearer's mouth that allows a wearer to experience open-mouth breathing and speech may be more readily understood by reference and analogy to an effect hereinafter referred to as the “paper cup effect” or “Dixie® cup effect.” This effect may be understood to result from the close fit and the near parallel walls of the well known nestable paper cups. When one cup is stacked upon another, they fit together closely, almost adhering to one another. The more parallel the walls of the paper cups, the more retention which can be observed between the members of the stack. In dentistry, this effect is useful in restoration design and is referred to as “retention form.” Analogously, the mouthguard 20 of the present invention, in cross section, approximates two surfaces that may be considered, only for the purposes of analogy, as near parallel. The analogous effect is maximized in the present invention by extending the anterior wall upward and into the muccobuccal fold and matching that dimension (i.e. the height of extension into the muccobuccal fold) on the palatal side or posterior wall of the mouthguard 20 . No other known prior art mouthguard is believed to recognize and take advantage of this analogous principle, in order to maximize retention. In another analogy, the strong retention effect may be viewed as similar to that effect which holds two sheets of glass together, particularly when water is present between the sheets of glass. Van der Waals forces or London forces account for the adhesion of the two sheets of glass.
[0052] A further possible explanation may be that capillary action due to the proximity of the surfaces of the mouth structures and the interior of the mouthguard, with a thin film of a fluid therebetween, may in part account for the strong retention characteristics of the inventive mouthguard 20 .
[0053] Yet another possible analogous explanation is that “Dixie® cup effect” relates to initially small volume space 51 and an initially small (sealed or nearly sealed) opening to the small volume. Until the opening increases, the volume cannot easily be filled. The mouthguard 20 is more resilient than a paper cup such as a “Dixie® cup” and functions even better in temporarily retaining a seal. Moreover, saliva is more viscous than air and is thought to help initially and temporarily retain the seal formed by the post dam 50 .
[0054] Those of ordinary skill will further recognize that various modifications can be made to the present invention without departing from the spirit of the invention. | A custom mouthguard has a resilient U-shaped body with an anterior wall and a posterior wall. A post dam on the posterior wall forms a seal with palatal tissue to increase retention of the mouthguard in a wearer's mouth. The increased retention allows a wearer to speak and open mouth breath while wearing the mouthguarrd. The mouth guard also has an indexed region that serves to mutually stabilize maxillary teeth, mandibular teeth, mandible and TMJ components. Mouthguard methods and processes are also disclosed. | 0 |
BACKGROUND OF THE INVENTION
(a) Field of the Invention
[0001] This application claims the benefit of Korean Patent Application No. 10-2015-0016887 filed on Feb. 3, 2015 and Korean Patent Application No. 10-2016-0013073 filed on Feb. 2, 2016 with the Korean Intellectual Property Office, the disclosures of which are herein incorporated by reference in their entirety.
[0002] The present invention relates to a composition for forming a self-healing coating layer, a coating layer and a coating film, more specifically, to a composition for forming a self-healing coating layer, a coating layer and a coating film that are applied to the exterior of various home electronics or display devices, etc., to enable the provision of a laminated film exhibiting more improved mechanical properties as well as excellent self-healing.
(b) Description of the Related Art
[0003] Various coating layers or coating films are applied on the surface of electrical and electronic devices such as a mobile phone, electronic components, home electronics, automobile interior and exterior, and plastic molded articles so as to protect from damage of the products due to mechanical, physical and chemical influences from the outside. However, since surface scratch of a product coating or crack due to external impact deteriorates the appearance, main performances and durability of products, various studies are being progressed so as to protect the product surface and maintain product quality.
[0004] Particularly, studies and attentions on self-healing coating material are recently rapidly increasing. The self-healing refers to a characteristic wherein, when an external physical force or stimulus is applied to a coating layer to generate damage such as a scratch, etc. the damage such as a scratch, etc. is autonomously healed gradually, or decreased. Although various self-healing coating materials or self-healing methods are known, a method of using elastic coating material is widely known. That is, using such coating material, even if physical damage such as a scratch, etc. is applied on a coating layer, the damaged region is gradually filled due to the elasticity of the coating material itself, thus exhibiting the above explained self-healing.
[0005] However, the conventional self-healing coating layer has a disadvantage in that mechanical properties such as hardness, abrasion resistance or coating strength, etc. are insufficient, since elastic materials are mostly used as contents of the self-healing coating layer. Particularly, in case a self-healing coating layer is to be applied on the exterior of various home electronics such as a refrigerator or washing machine, etc., high levels of mechanical properties of the coating layer are required, but most of the existing self-healing coating layers cannot fulfill such high mechanical properties. Thus, if a strong external stimulus is applied to the existing coating layer, the coating layer itself may be permanently damaged and even lose the self-healing characteristic.
[0006] Due to the problem of the prior art, there is a continued demand for the development of technology enabling the provision of a coating layer or laminated film exhibiting more improved mechanical properties as well as excellent self-healing.
RELATED ART
[0007] International Patent Publication WO2014-144539 (Publication date: Sep. 18, 2014)
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a composition for forming a self-healing coating layer that is applied to the exterior of various home electronics or display devices, etc., to enable the provision of a laminated film exhibiting more improved mechanical properties as well as excellent self-healing.
[0009] It is another object of the present invention to provide a self-healing coating layer formed using the composition for forming a coating layer, and a coating film comprising the same.
[0010] A composition for forming a self-healing coating layer, comprising a reversible covalent compound containing a (thio)urea functional group comprising one or more sterically hindered thio(urea) bonds and a (meth)acrylate-based or vinyl-based functional group bonded to the (thio)urea functional group; a photoinitiator; and an organic solvent, is provided herein.
[0011] As used herein, a (thio)urea bond includes both an urea bond and a thio urea bond. And, (meth)acrylate includes both acrylate and methacrylate.
[0012] Using the composition for forming a coating layer comprising a reversible covalent compound containing a (thio)urea functional group, the sterically hindered (thio)urea bond can be introduced into the cross link structure of the finally prepared coating layer. As such a sterically hindered (thio)urea bond is introduced into the cross link structure of the finally prepared coating layer, when an external force is applied to the coating layer, in the sterically hindered (thio)urea bond having relatively low bonding strength, at the sterically hindered nitrogen part, a bond is preferentially broken and recombined after time elapses, and thus the initial properties are recovered, or during the recovery process, the bonding structure is generally rearranged and thus the bonding strength further increases. Moreover, by the reversible covalent bond, additional stress can be absorbed, thus exhibiting more improved impact resistance compared to other coating layers having the same surface hardness.
[0013] Thus, using the composition for forming a coating layer, a high hardness coating layer that has a self-healing characteristic and has high crack resistance, bend resistance and impact resistance, etc. can be provided.
[0014] And, the coating film prepared from the composition for forming a self-healing coating layer can secure flexibility as well as high hardness, and thus, can be applied to a display device, etc. to realize improved performance.
[0015] And, the coating film prepared from the composition for forming a self-healing coating layer may exhibit recovery property wherein, when the coating film is cut and the cut sides are adhered again, the cut sides are joined while the cross link structure is recombined.
[0016] In the sterically hindered (thio)urea bond, at least one nitrogen atom may be substituted by a bulky functional group selected from the group consisting of a C2-C30 linear or branched alkyl group, a C2-C30 linear or branched alkenyl group, a C4-C30 cycloalkyl group, a C6-C30 aryl group, a heteroalkyl group, a cycloheteralkyl group, and a heteroaryl group.
[0017] The reversible covalent compound may comprise a compound of the following Chemical Formula 1:
[0000]
[0018] in the Chemical Formula 1,
[0019] L is an n-valent functional group derived from aliphatic, alicyclic or aromatic compounds;
[0020] n denotes the number of substitution of L, and is an integer of 1 to 20;
[0021] X is oxygen or sulfur;
[0022] Y is a direct bond, a C1-C30 linear or branched alkylene group, a C2-C30 linear or branched alkenylene group, a C4-C30 cycloalkylene group, a C6-C30 arylene group;
[0023] Z is a (meth)acrylate group or vinyl group;
[0024] R 1 is a bulky group selected from the group consisting of a C2-C30 linear or branched alkyl group, a C2-C30 linear or branched alkenyl group, a C4-C30 cycloalkyl group, a C6-C30 aryl group, a heteroalkyl group, a cycloheteralkyl group, and a heteroaryl group.
[0025] And, in the Chemical Formula 1, L may be a 2 to 10 valent functional group derived from a C1-C20 linear or branched alkane, a C4-C20 cycloalkane, or a C6-C20 arene.
[0026] Meanwhile, a method for synthesizing the reversible covalent compound containing a (thio)urea functional group comprising one or more sterically hindered thio(urea) bonds and a (meth)acrylate-based or vinyl-based functional group bonded to the (thio)urea functional group is not significantly limited, and for example, reversible covalent compounds having various properties can be synthesized by reacting (bulky alkylamino)alkyl (meth)acrylate with multivalent isocyanate compounds [poly(NCO)] of various structures.
[0027] The multivalent isocyanate compound may be one or more kinds selected from the group consisting of oligomer of diisocynate compounds, polymer of diisocynate compounds, cyclic polymer diisocyanate compounds, hexamethylene diisocyanate isocyanurate, isophorone diisocyanate isocyanurate, toluene 2,6-diisocyanate isocyanurate, triisocyanate compounds and isomers thereof, and besides, various multivalent isocyanate compounds having a functionality of 3 or more may be used to form the above explained binder.
[0028] Among the specific examples of the multivalent isocyanate compounds, oligomer, polymer, cyclic polymer or isocyanurate of diisocynate compounds may be formed from common aliphatic or aromatic diisocyanate compounds, or commercialized oligomer of diisocynate compounds, etc. (for example, trimer of HDI, DN980S from Aekyung Chemical Co., Ltd., etc.) may be acquired and used. More specific examples of the diisocyanate compounds may include ethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate (HDI), 1,12-dodecane diisocyanate, cyclobutane-1,3-diisocyanate, cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane, 2,4-hexahydrotoluene diisocyanate, 2,6-hexahydrotoluene diisocyanate, hexahydro-1,3-phenylene diisocyanate, hexahydro-1,4-phenylene diisocyanate, perhydro-2,4′-diphenylmethane diisocyanate, perhydro-4,4′-diphenylmethane diisocyanate, 1,3-phenylene diisocyanate, 1,4-phenylene diisocyanate, 4,4′-stilbene diisocyanate, 3,3′-dimethyl-4,4′-biphenylene diisocyanate (TODI), toluene 2,4-diisocyanate, toluene 2,6-diisocyanate (TDI), diphenylmethane-2,4′-diisocyanate (MDI), 2,2′-diphenylmethane diisocyanate (MDI), diphenylmethane-4,4′-diisocyanate (MDI), isophorone diisocyanate (IPDI), etc.
[0029] The composition for forming a self-healing coating layer may further comprise one or more kinds of compounds selected from the group consisting of (meth)acrylate-based monomers, vinyl-based monomers and multifunctional (meth)acrylate-based compounds.
[0030] The multifunctional (meth)acrylate-based compound may be one or more selected from the group consisting of multifunctional urethane acrylate, 9-ethyleneglycol diacrylate (9-EGDA), bisphenol A epoxy acrylate, polyether triacrylate, pentaerythritol tri/tetraacrylate (PETA), dipentaerythritol hexa-acrylate (DPHA), trimethylolpropane triacrylate (TMPTA) and (hexamethylene diacrylate (HDDA).
[0031] In the composition for forming a self-healing coating layer, the weight ratio of the reversible covalent compound to the total weight of the reversible covalent compound and one or more compounds selected from the group consisting of (meth)acrylate-based monomers, vinyl-based monomers and multifunctional (meth)acylate-based compounds may be about 5 wt % to about 99 wt %, or about 20 to about 95 wt %, or about 25 to about 95 wt %, or about 50 to about 95 wt %. When the weight ratio of the reversible covalent compound is within the above range, the coating layer may exhibit sufficient self-healing.
[0032] The composition for forming a self-healing coating layer may further comprise one or more polymer resin selected from the group consisting of urethane (meth)acrylate resin and hydroxyalkyl (meth)acrylate resin.
[0033] The photoinitiator may comprise one or more compounds selected from the group consisting of an acetophenone-based compound, a biimidazole-based compound, a triazine-based compound and an oxime-based compound.
[0034] The composition for forming a self-healing coating layer may further comprise inorganic filler.
[0035] The composition for forming a self-healing coating layer, besides the above explained components, may further comprise one or more additives selected from the group consisting of a surfactant for dissolving or dispersing these components, a leveling agent and a dispersion stabilizer.
[0036] As the organic solvent, those known to be usable in a coating composition in the technical field can be used without specific limitations. For example, ketone based organic solvents such as methyl isobutyl ketone, methyl ethyl ketone, dimethyl ketone, etc.; alcohol organic solvents such as isopropyl alcohol, isobutyl alcohol or normal butyl alcohol, etc.; acetate organic solvents such as ethyl acetate or normal butyl acetate, etc.; cellusolve organic solvents such as ethyl cellusolve or butyl cellusolve, etc. may be used, but the organic solvents are not limited to the above described examples.
[0037] The composition for forming a self-healing coating layer may further comprise an inorganic compound in which a (meth)acrylate-based functional group or a vinyl-based functional group is bonded through a (thio)urea functional group comprising a sterically hindered urea bond. The inorganic compound is also capable of reversible covalent bonding, and by further comprising the inorganic compound, the properties of the coating layer, such as hardness, flexibility, impact resistance, etc. can be further improved.
[0038] The inorganic compound in which a (meth)acrylate-based functional group or a vinyl-based functional group is bonded through a (thio)urea functional group comprising a sterically hindered urea bond, may comprise a silicon-based compound in which a (meth)acrylate-based functional group or a vinyl-based functional group is bonded through a (thio)urea functional group comprising a sterically hindered urea bond.
[0039] The inorganic compound in which a (meth)acrylate-based functional group or a vinyl-based functional group is bonded through a (thio)urea functional group comprising a sterically hindered urea bond, may comprise a compound of the following Chemical Formula 2.
[0000]
[0040] in the Chemical Formula 2,
[0041] X is oxygen or sulfur;
[0042] L and Y are respectively a direct bond, a C1-C30 linear or branched alkylene group, a C2-C30 linear or branched alkenylene group, a C4-C30 cycloalkylene group, a C6-C30 arylene group;
[0043] Z is a (meth)acrylate group or a vinyl group;
[0044] R 1 is a bulky group selected from the group consisting of a C2-C30 linear or branched alkyl group, a C2-C30 linear or branched alkenyl group, a C4-C30 cycloalkyl group, a C6-C30 aryl group, a heteroalkyl group, a cycloheteralkyl group, and a heteroaryl group;
[0045] R 2 is a C1-C10 linear or branched alkyl group, or a C1-C10 linear or branched alkoxy group;
[0046] p is an integer of 1 to 4, and p+q is 4.
[0047] The compound of the Chemical Formula 2 may be obtained, for example, by reacting (bulky alkylamino)alkyl (meth)acrylate with an alkoxy silane compound having an isocyanate functional group, but the present invention is not limited thereto. And, the compound of the Chemical Formula 2 may react with the surface of silica material to modify the silica material.
[0048] Meanwhile, a coating film comprising a cured product of the composition for forming a self-healing coating layer is provided herein.
[0049] Specific preparation method of the coating film is not significantly limited, and for example, the coating film may be prepared by applying the composition for forming a self-healing coating layer on a substrate and then photocuring.
[0050] In the step of applying the composition for forming a self-healing coating layer on a substrate, for example, common coating methods such as a Meyer bar coating method, an applicator coating method, a roll coating method, etc. may be used without specific limitations to apply the composition on a resin substrate. Thereafter, it may be dried at a temperature of about 20 to about 80° C. for about 1 to about 30 minutes to remove substantially all the organic solvents included in the composition.
[0051] And, in the subsequent UV curing step, UV (for example, UV having a wavelength of about 200 to 400 nm) may be irradiated at a light quantity of about 50 to about 2,000 mJ/cm 2 , to UV cure the composition for forming a self-healing coating layer, thereby forming a self-healing coating layer according to another embodiment.
[0052] And, a coating film comprising polymer resin in which a (meth)acrylate-based or vinyl-based main chain forms a cross link through a (thio)urea functional group comprising one or more sterically hindered (thio)urea bonds, is provided herein.
[0053] The polymer resin may further comprise polyurethane, urethane (meth)acrylate resin and hydroxyalkyl (meth)acrylate resin.
[0054] The coating film may further comprise inorganic filler dispersed in the polymer resin.
[0055] The coating film may further comprise an inorganic compound in which a (meth)acrylate-based functional group or a vinyl-based functional group is bonded through a (thio)urea functional group comprising a sterically hindered urea bond, dispersed in the polymer resin.
[0056] Meanwhile, a coating film comprising a polymer resin substrate; a coating layer formed on one side of the polymer resin substrate, and comprising the above explained coating film, is provided herein.
[0057] And, home electronics comprising the coating film attached thereto, are provided herein.
[0058] And, a display device comprising the coating film attached to the exterior, is provided herein.
[0059] The coating film may be applied to the exterior of various home electronics such as a refrigerator or washing machine, etc. or decorative molded articles, or applied to the exterior of display devices, and it may be preferably applied in the field of exterior molding of various products or exterior material (for example, a back cover) for protecting the screen of a mobile phone display device, and thereby, even if damage such as a scratch, etc. is generated due to external stimulus, it may exhibit excellent self-healing, while exhibiting excellent mechanical property, thus performing a function for appropriately protecting the exterior of various home electronics, display devices or molded articles.
[0060] According to the present invention, a composition for forming a self-healing coating layer that is applied to the exterior of various home electronics or display devices, etc., to enable the provision of a coating film exhibiting improved mechanical properties as well as excellent self-healing, a coating film prepared from the composition, a coating film comprising the coating film, home electronics and display devices comprising the coating film are provided.
[0061] Using the composition for forming a coating layer, a high hardness coating layer having self-healing characteristic and having high crack resistance, bend resistance and impact resistance, etc. may be provided. And, the coating film prepared from the composition for forming a self-healing coating layer may secure flexibility as well as high hardness, and thus, may be applied to flexible display devices, etc. to realize improved performance.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0062] The present invention will be explained in detail in the following examples. However, these examples are presented only to illustrate the present invention, and the scope of the present invention is not limited thereby.
Preparation Example: Preparation of Reversible Covalent Compounds
Preparation Example 1
[0063] 25 g of methylethyl ketone and 59.23 g of urethane-based isocyanate Duranate E402-90T (Asahi Kasei) were mixed, and then, stirred to make into a homogeneous state. While stirring the homogeneous solution, 21.69 g of tert-butylaminoethyl methacrylate (TBAEMA) was added dropwise. After completing the addition, the solution was additionally stirred at room temperature for 1 day, and it was confirmed that the isocyanate peak (wavenumber ˜2270 cm −1 ) disappeared in the IR spectrum.
Preparation Example 2
[0064] 25 g of methylethyl ketone and 48.45 g of hexamethylenediisocyanate/isophoronediisocyanate-based isocyanate Duranate MHG-80B (Asahi Kasei) were mixed, and then, stirred to make into a homogeneous state. While stirring the homogeneous solution, 36.24 g of TBAEMA was added dropwise. After completing the addition, the solution was additionally stirred at room temperature for 1 day, and it was confirmed that the isocyanate peak (wavenumber ˜2270 cm −1 ) disappeared in the IR spectrum.
Preparation Example 3
[0065] To 57.18 g of KBE-9007 (3-isocyanatopropyltriethoxysilane, Shin-Etsu), 42.82 g of TBAEMA was added dropwise with stirring. The solution was additionally stirred at room temperature for 1 day, and it was confirmed that the isocyanate peak (wavenumber ˜2270 cm −1 ) disappeared in the IR spectrum. 1.48 g of the prepared solution was added to 98.52 g of a silica particle dispersion IPA-ST (Nissan Chemical), and the solution was stirred for 3 days.
Comparative Preparation Example 1
[0066] 25 g of methylethyl ketone, 64.79 g of urethane-based isocyanate Duranate E402-90T (Asahi Kasei), and 16.67 g of hydroxyethylmethacrylate (HEMA) were mixed and stirred to make into a homogeneous state. To the homogeneous solution, 0.02 g of s dibutyltin dilaurate solution (methylethyl ketone solvent, 1 wt %) was added, and then, the solution was additionally stirred at room temperature for 1 day, and it was confirmed that the isocyanate peak (wavenumber ˜2270 cm −1 ) disappeared in the IR spectrum.
Comparative Preparation Example 2
[0067] 25 g of methylethyl ketone, 59.65 g of allophanate hexamethylenediisocyanate/isophoronediisocyanate-based isocyanate Duranate MHG-80B (Asahi Kasei), and 27.26 g of HEMA were mixed and stirred to make into a homogeneous state. To the homogeneous solution, 0.03 g of a dibutyltin dilaurate solution (methylethyl ketone solvent, 1 wt %) was added, and then, the solution was additionally stirred at room temperature for 1 day, and it was confirmed that the isocyanate peak (wavenumber ˜2270 cm −1 ) disappeared in the IR spectrum.
Comparative Preparation Example 3
[0068] 63.62 g of KBE-9007 (3-isocyanatopropyltriethoxysilane, Shin-Etsu) and 33.47 g of HEMA were mixed and then stirred. To the solution, 0.03 g of a dibutyltin dilaurate solution (methylethyl ketone solvent, 1 wt %) was added, and then, the solution was additionally stirred at room temperature for 1 day, and it was confirmed that the isocyanate peak (wavenumber ˜2270 cm −1 ) disappeared in the IR spectrum. 1.48 g of the prepared solution was added to 98.52 g of a silica particle dispersion IPA-ST (Nissan Chemical), and the solution was stirred for 3 days.
Example: Preparation of a Composition for Forming a Self-Healing Coating Layer and a Self-Healing Coating Film
Example 1
[0069] 83.55 g of the composition of Preparation Example 1, 6.96 g of trimethylolpropane triacrylate, 3.48 g of a diluted solution of photosensitive polymerization initiator Esacure KIP 100 F (Lamberti) (methylethyl ketone solvent, 10 wt %), 5.69 g of a methylethyl ketone, 0.32 g of a diluted solution of surfactant Tego Glide 432 (Evonik) (methylethyl ketone solvent, 10 wt %) were mixed to prepare a photocurable coating composition. The composition was coated on a polyethylene terephthalate film (Toray, 250 μm) with Meyer bar #70, and dried in a convection oven at 60° C. for 2 minutes, and then, UV of 500 mJ/cm 2 was irradiated under nitrogen atmosphere to complete a film having a self-healing coating layer.
Example 2
[0070] A film having a self-healing coating layer was completed by the same method as Example 1, except replacing the composition of Preparation Example 1 with the composition of Preparation Example 2.
Example 3
[0071] 16.58 g of Kayarad DPCA 60 (Nippon Kayaku), 22.10 g of the composition of Preparation Example 2, 53.43 g of the composition of Preparation Example 3, 2.49 g of a diluted solution of photosensitive photoinitiator Esacure KIP 100 F (Lamberti) (methylethyl ketone solvent, 10 wt %), 5.25 g of methylethyl ketone, 0.15 g of a diluted solution of surfactant Tego Glide 432 (Evonik) (methylethyl ketone solvent, 10 wt %) were mixed to prepare a photocurable coating composition. The composition was coated on a polyethylene terephthalate film (Toray, 250 μm) with Meyer bar #70, and dried in a convection oven at 60° C. for 2 minutes, and then, UV of 500 mJ/cm 2 was irradiated under nitrogen atmosphere to complete a film having a self-healing coating layer.
Example 4
[0072] 2 mL of the coating composition of Example 1 was put in an aluminum dish (diameter about 43 mm), and then, dried in a convection oven at 60° C. for 30 minutes. And then, UV of 500 mJ/cm 2 was irradiated using black light as a light source to complete a self-healing film.
Comparative Example 1
[0073] A film having an urethane-based coating layer was completed by the same method as Example 1, except replacing the composition of Preparation Example 1 with the composition of Comparative Preparation Example 1.
Comparative Example 2
[0074] A film having an urethane-based coating layer was completed by the same method as Example 1, except replacing the composition of Preparation Example 2 with the composition of Comparative Preparation Example 2.
Comparative Example 3
[0075] A film having an urethane-based coating layer was completed by the same method as Example 1, except replacing the composition of Preparation Example 2 with the composition of Comparative Preparation Example 2, and the composition of Preparation Example 3 with the composition of Comparative Preparation Example 3.
Comparative Example 4
[0076] A film having an urethane-based coating layer was completed by the same method as Example 4, except replacing the composition of Preparation Example 1 with the composition of Comparative Preparation Example 1.
Experimental Example: Formation of a Coating Layer and a Coating Film, and Property Evaluation
[0077] The properties of the coating layers obtained in Examples and Comparative Examples were measured and evaluated by the following methods, and shown in Tables 1 and 2, respectively.
[0078] 1. Initial pencil hardness: The pencil hardness of the coating layer was measured under a load of 500 g according to JIS K5400. Immediately after the evaluation, acceptable maximum pencil hardness was taken.
[0079] 2. Surface scratch healing: When the coating layer was left for 1 hour after the evaluation of pencil hardness, the maximum pencil hardness and the lowest temperature condition at which scratch can be healed were marked. If the surface scratch is not healed regardless of the temperature, it was marked as X.
[0080] 3. Bend resistance: A coating layer was wound on a steel bar of which cross section has a specific diameter, such that the coated side faces outward, and the minimum diameter value at which fracture of the coating layer was not generated was taken.
[0081] 4. Transmittance and haze: Transmittance and haze were measured using a spectrophotometer (COH-400, Nippon Denshoku), and if the conditions of transmittance>90%, haze<1.5% are fulfilled, it was marked as OK, and if not fulfilled, marked as NG.
[0082] 5. Impact resistance: A specimen was fixed on a zig having an inner diameter of 76 mm, and then, 21.7 g of spherical balance weights were dropped at an interval of 10 cm while varying the height, and the maximum height at which cracks and other defects were not generated was marked.
[0083] 6. Joining and recovery of cut sides: The specimen was cut, and the cut sides were adhered and attached with a tape, and then, stored at 60° C. for 3 hours, and joining of the cut sides and tensile properties (modulus of elasticity, fracture elongation, tensile strength) before and after recovery were compared.
[0000]
TABLE 1
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 1
Example 2
Example 3
Initial pencil hardness
4B
H
3H
B
H
3H
Surface scratch healing
HB,
2H,
4H,
HB,
X
X
(pencil hardness and
25° C.
120° C.
90° C.
25° C.
temperature at which
scratch can be healed)
Transmittance
OK
OK
OK
OK
OK
OK
Haze
OK
OK
OK
OK
OK
OK
Bend resistance (Φ)
2
4
10
2
6
12
Impact resistance
90
90
70
90
80
50
(cm)
[0000]
TABLE 2
Example 4
Comparative Example 4
Before
After
Before
After
cut
recovery
cut
recovery
Modulus of
16
66
13
No healing property
elasticity (MPa)
Fracture
44
22
42
No healing property
elongation (%)
Tensile
7
4.5
5
No healing property
strength (MPa)
[0084] Referring to Tables 1 and 2, the coating layer or coating film formed using the composition for forming a coating layer of the present invention exhibited excellent surface hardness, bend resistance and impact resistance as well as scratch self-healing or cut side recovery. Compared with Comparative Examples 2 and 3 having the same pencil hardness as Examples 2 and 3, respectively, the coating films of Examples 2 and 3 exhibited surface scratch self-healing, while Comparative Examples 2 and 3 did not have such a self-healing characteristic, and had inferior bend resistance and impact resistance to Examples 2 and 3. And, although Comparative Example 1 had scratch self-healing characteristic, Comparative Example 4 prepared in the form of a monolayer film using the same coating layer did not exhibit cut side recovery as in Example 4 of the present invention, and thus, it can be seen that a sterically hindered (thio)urea bond performs an important function in the mechanism of joining cut sides.
[0085] And, Example 1 exhibited rather low pencil hardness but had a scratch self-healing characteristic even at room temperature, and Examples 2 and 3 had a scratch self-healing temperature higher than room temperature but exhibited high pencil hardness, and thus, it appears that the coating composition of the present invention may be used to control the applications and properties.
[0086] Meanwhile, in Example 4, as the cut sides were recovered after cutting, modulus of elasticity increased, which appears to result from the general rearrangement of the cross link structure. | The present invention relates to a composition for forming a self-healing coating layer, comprising a reversible covalent compound containing a (thio)urea functional group comprising one or more sterically hindered thio(urea) bonds and a (meth)acrylate-based or vinyl-based functional group bonded to the (thio)urea functional group; a photoinitiator; and an organic solvent, a coating film prepared from the composition, a coating film comprising the coating film, and home electronics and display devices comprising the coating film. | 2 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/279,398, filed on Oct. 19, 2009 which is a national phase application under 35 U.S.C. §371 of PCT International Application No. PCT/US2007/062152, filed on Feb. 14, 2007, which claims priority under 35 U.S.C. §119(e) to U.S. provisional patent application, U.S. Ser. No. 60/773,172, filed Feb. 14, 2006. Each of these prior applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The identification of small organic molecules that affect specific biological functions is an endeavor that impacts both biology and medicine. Such molecules are useful as therapeutic agents and as probes of biological function. In but one example from the emerging field of chemical genetics, in which small molecules can be used to alter the function of biological molecules to which they bind, these molecules have been useful at elucidating signal transduction pathways by acting as chemical protein knockouts, thereby causing a loss of protein function (Schreiber et al., J. Am. Chem. Soc., 1990, 112, 5583; Mitchison, Chem. and Biol., 1994, 1, 3). Additionally, due to the interaction of these small molecules with particular biological targets and their ability to affect specific biological function, they may also serve as candidates for the development of therapeutics. One important class of small molecules, natural products, which are small molecules obtained from nature, clearly have played an important role in the development of biology and medicine, serving as pharmaceutical leads, drugs (Newman et al., Nat. Prod. Rep. 2000, 17, 215-234), and powerful reagents for studying cell biology (Schreiber, S. L. Chem. and Eng. News 1992 (October 26), 22-32).
[0003] Because it is difficult to predict which small molecules will interact with a biological target, and it is oftent difficult to obtain and synthesize efficiently small molecules found in nature, intense efforts have been directed towards the generation of large numbers, or libraries, of small organic compounds, often “natural product-like” libraries. These libraries can then be linked to sensitive screens for a particular biological target of interest to identify the active molecules.
[0004] One biological target of recent interest is histone deacetylase (see, for example, a discussion of the use of inhibitors of histone deacetylases for the treatment of cancer: Marks et al. Nature Reviews Cancer 2001, 1, 194; Johnstone et al. Nature Reviews Drug Discovery 2002, 1, 287). Post-translational modification of proteins through acetylation and deacetylation of lysine residues has a critical role in regulating their cellular functions. HDACs are zinc hydrolases that modulate gene expression through deacetylation of the N-acetyl-lysine residues of histone proteins and other transcriptional regulators (Hassig et al. Curr. Opin. Chem. Biol. 1997, 1, 300-308). HDACs participate in cellular pathways that control cell shape and differentiation, and an HDAC inhibitor has been shown effective in treating an otherwise recalcitrant cancer (Warrell et al. J. Natl. Cancer Inst. 1998, 90, 1621-1625). Eleven human HDACs, which use Zn as a cofactor, have been characterized (Taunton et al. Science 1996, 272, 408-411; Yang et al. J. Biol. Chem. 1997, 272, 28001-28007; Grozinger et al. Proc. Natl. Acad. Sci. U.S.A. 1999, 96, 4868-4873; Kao et al. Genes Dev. 2000, 14, 55-66; Hu et al. J. Biol. Chem. 2000, 275, 15254-15264; Zhou et al. Proc. Natl. Acad. Sci. U.S.A. 2001, 98, 10572-10577; Venter et al. Science 2001, 291, 1304-1351). These members fall into three related classes (class I, II, and III). An additional seven HDACs have been identified which use NAD as a confactor. To date, no small molecules are known that selectively target either the two classes or individual members of this family ((for example ortholog-selective HDAC inhibitors have been reported: (a) Meinke et al. J. Med. Chem. 2000, 14, 4919-4922; (b) Meinke, et al. Curr. Med. Chem. 2001, 8, 211-235).
SUMMARY OF THE INVENTION
[0005] The present invention provides novel histone deacetylase inhibitors and methods of preparing and using these compounds. The inventive HDAC inhibitors comprise an esterase-sensitive ester linakge, thereby when the compound is exposed to an esterase such as in the bloodstream the compound is inactivated. The compounds are particularly useful in the treatment of skin disorders such as cutaneous T-cell lymphoma, neurofibromatosis, psoriasis, hair loss, dermatitis, baldness, and skin pigmentation. The inventive compound is adminitered topically to the skin of the patient where it is clinically active. Once the compound is absorbed into the body, it is quickly inactivated by esterases which cleave the compound into two or more biologically inactive fragments. Thus, allowing for high local concentrations (e.g., in the skin) and reduced systemic toxicity. In certain embodiments, the compound is fully cleaved upon exposure to serum in less than 5 min., preferably less than 1 min.
[0006] The present invention provides novel compounds of general formula (I),
[0000]
[0000] and pharmaceutical compositions thereof, as described generally and in subclasses herein, which compounds are useful as inhibitors of histone deacetylases or other deacetylases, and thus are useful for the treatment of proliferative diseases. The inventive compounds are additionally useful as tools to probe biological function. In certain embodiments, the compounds of the ivention are particularly useful in the treatment of skin disorders. The ester linkage is susceptible to esterase cleavage, particularly esterases found in the blood. Therefore, these compounds may be administered topically to treat skin disorders, such as cutaneous T-cell lymphoma, psoriasis, hair loss, dermatitis, etc., without the risk of systemic effects. Once the compound enters the bloodstream it is quickly degraded by serum esterases. Preferably, the compound is degraded into non-toxic, biologically inactive by-products.
[0007] In another aspect, the present invention provides methods for inhibiting histone deacetylase activity or other deacetylase activity in a patient or a biological sample, comprising administering to said patient, or contacting said biological sample with an effective inhibitory amount of a compound of the invention. In certain embodiments, the compounds specifically inhibit a particular HDAC (e.g., HDAC1, HDAC2, HDAC3, HDAC4, HDAC4, HDAC5, HDAC6, HDAC7, HDAC8, HDAC9, HDAC10, HDAC11) or class of HDACs (e.g., Class I, II, or III). In certain embodiments, the compounds specifically inhibit HDAC6. In still another aspect, the present invention provides methods for treating skin disorders involving histone deacetylase activity, comprising administering to a subject in need thereof a therapeutically effective amount of a compound of the invention. The compounds may be administered by any method known in the art. In certain embodiments, the compounds are administered topically (e.g., in a cream, lotion, ointment, spray, gel, powder, etc.). In certain embodiments, the compound is administered to skin. In other certain embodiments, the compound is administered to hair. The compounds may also be administered intravenously or orally. The invention also provides pharmaceutical compositions of the compounds wherein the compound is combined with a pharmaceutically acceptable excipient.
[0008] In yet another aspect, the present invention provides methods for preparing compounds of the invention and intermediates thereof.
DEFINITIONS
[0009] Certain compounds of the present invention, and definitions of specific functional groups are also described in more detail below. For purposes of this invention, the chemical elements are identified in accordance with the Periodic Table of the Elements, CAS version, Handbook of Chemistry and Physics, 75 th Ed., inside cover, and specific functional groups are generally defined as described therein. Additionally, general principles of organic chemistry, as well as specific functional moieties and reactivity, are described in Organic Chemistry , Thomas Sorrell, University Science Books, Sausalito: 1999, the entire contents of which are incorporated herein by reference. Furthermore, it will be appreciated by one of ordinary skill in the art that the synthetic methods, as described herein, utilize a variety of protecting groups. By the term “protecting group,” has used herein, it is meant that a particular functional moiety, e.g., C, O, S, or N, is temporarily blocked so that a reaction can be carried out selectively at another reactive site in a multifunctional compound. In preferred embodiments, a protecting group reacts selectively in good yield to give a protected substrate that is stable to the projected reactions; the protecting group must be selectively removed in good yield by readily available, preferably nontoxic reagents that do not attack the other functional groups; the protecting group forms an easily separable derivative (more preferably without the generation of new stereogenic centers); and the protecting group has a minimum of additional functionality to avoid further sites of reaction. As detailed herein, oxygen, sulfur, nitrogen and carbon protecting groups may be utilized. Exemplary protecting groups are detailed herein, however, it will be appreciated that the present invention is not intended to be limited to these protecting groups; rather, a variety of additional equivalent protecting groups can be readily identified using the above criteria and utilized in the method of the present invention. Additionally, a variety of protecting groups are described in Protective Groups in Organic Synthesis , Third Ed. Greene, T. W. and Wuts, P.G., Eds., John Wiley & Sons, New York: 1999, the entire contents of which are hereby incorporated by reference. Furthermore, a variety of carbon protecting groups are described in Myers, A.; Kung, D. W.; Zhong, B.; Movassaghi, M.; Kwon, S. J. Am. Chem. Soc. 1999, 121, 8401-8402, the entire contents of which are hereby incorporated by reference.
[0010] It will be appreciated that the compounds, as described herein, may be substituted with any number of substituents or functional moieties. In general, the term “substituted” whether preceded by the term “optionally” or not, and substituents contained in formulas of this invention, refer to the replacement of hydrogen radicals in a given structure with the radical of a specified substituent. When more than one position in any given structure may be substituted with more than one substituent selected from a specified group, the substituent may be either the same or different at every position. As used herein, the term “substituted” is contemplated to include all permissible substituents of organic compounds. In a broad aspect, the permissible substituents include acyclic and cyclic, branched and unbranched, carbocyclic and heterocyclic, aromatic and nonaromatic substituents of organic compounds. For purposes of this invention, heteroatoms such as nitrogen may have hydrogen substituents and/or any permissible substituents of organic compounds described herein which satisfy the valencies of the heteroatoms. Furthermore, this invention is not intended to be limited in any manner by the permissible substituents of organic compounds. Combinations of substituents and variables envisioned by this invention are preferably those that result in the formation of stable compounds useful in the treatment, for example of proliferative disorders, including, but not limited to cancer. The term “stable”, as used herein, preferably refers to compounds which possess stability sufficient to allow manufacture and which maintain the integrity of the compound for a sufficient period of time to be detected and preferably for a sufficient period of time to be useful for the purposes detailed herein.
[0011] The term “acyl”, as used herein, refers to a carbonyl-containing functionality, e.g., —C(═O)R′ wherein R′ is an aliphatic, alycyclic, heteroaliphatic, heterocyclic, aryl, heteroaryl, (aliphatic)aryl, (heteroaliphatic)aryl, heteroaliphatic(aryl) or heteroaliphatic(heteroaryl) moiety, whereby each of the aliphatic, heteroaliphatic, aryl, or heteroaryl moieties is substituted or unsubstituted, or is a substituted (e.g., hydrogen or aliphatic, heteroaliphatic, aryl, or heteroaryl moieties) oxygen or nitrogen containing functionality (e.g., forming a carboxylic acid, ester, or amide functionality).
[0012] The term “aliphatic”, as used herein, includes both saturated and unsaturated, straight chain (i.e., unbranched) or branched aliphatic hydrocarbons, which are optionally substituted with one or more functional groups. As will be appreciated by one of ordinary skill in the art, “aliphatic” is intended herein to include, but is not limited to, alkyl, alkenyl, alkynyl moieties. Thus, as used herein, the term “alkyl” includes straight and branched alkyl groups. An analogous convention applies to other generic terms such as “alkenyl”, “alkynyl” and the like. Furthermore, as used herein, the terms “alkyl”, “alkenyl”, “alkynyl” and the like encompass both substituted and unsubstituted groups. In certain embodiments, as used herein, “lower alkyl” is used to indicate those alkyl groups (substituted, unsubstituted, branched or unbranched) having 1-6 carbon atoms.
[0013] In certain embodiments, the alkyl, alkenyl and alkynyl groups employed in the invention contain 1-20 aliphatic carbon atoms. In certain other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-10 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-8 aliphatic carbon atoms. In still other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-6 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-4 carbon atoms. Illustrative aliphatic groups thus include, but are not limited to, for example, methyl, ethyl, n-propyl, isopropyl, allyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, sec-pentyl, isopentyl, tert-pentyl, n-hexyl, sec-hexyl, moieties and the like, which again, may bear one or more substituents. Alkenyl groups include, but are not limited to, for example, ethenyl, propenyl, butenyl, 1-methyl-2-buten-1-yl, and the like. Representative alkynyl groups include, but are not limited to, ethynyl, 2-propynyl (propargy1), 1-propynyl and the like.
[0014] The term “alicyclic”, as used herein, refers to compounds which combine the properties of aliphatic and cyclic compounds and include but are not limited to cyclic, or polycyclic aliphatic hydrocarbons and bridged cycloalkyl compounds, which are optionally substituted with one or more functional groups. As will be appreciated by one of ordinary skill in the art, “alicyclic” is intended herein to include, but is not limited to, cycloalkyl, cycloalkenyl, and cycloalkynyl moieties, which are optionally substituted with one or more functional groups. Illustrative alicyclic groups thus include, but are not limited to, for example, cyclopropyl, —CH 2 -cyclopropyl, cyclobutyl, —CH 2 -cyclobutyl, cyclopentyl, —CH 2 -cyclopentyl-n, cyclohexyl, —CH 2 -cyclohexyl, cyclohexenylethyl, cyclohexanylethyl, norborbyl moieties and the like, which again, may bear one or more substituents.
[0015] The term “alkoxy” (or “alkyloxy”), or “thioalkyl” as used herein refers to an alkyl group, as previously defined, attached to the parent molecular moiety through an oxygen atom or through a sulfur atom. In certain embodiments, the alkyl group contains 1-20 aliphatic carbon atoms. In certain other embodiments, the alkyl group contains 1-10 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-8 aliphatic carbon atoms. In still other embodiments, the alkyl group contains 1-6 aliphatic carbon atoms. In yet other embodiments, the alkyl group contains 1-4 aliphatic carbon atoms. Examples of alkoxy, include but are not limited to, methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, tert-butoxy, neopentoxy and n-hexoxy. Examples of thioalkyl include, but are not limited to, methylthio, ethylthio, propylthio, isopropylthio, n-butylthio, and the like.
[0016] The term “alkylamino” refers to a group having the structure —NHR′ wherein R′ is alkyl, as defined herein. The term “aminoalkyl” refers to a group having the structure NH 2 R′—, wherein R′ is alkyl, as defined herein. In certain embodiments, the alkyl group contains 1-20 aliphatic carbon atoms. In certain other embodiments, the alkyl group contains 1-10 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-8 aliphatic carbon atoms. In still other embodiments, the alkyl group contains 1-6 aliphatic carbon atoms. In yet other embodiments, the alkyl group contains 1-4 aliphatic carbon atoms. Examples of alkylamino include, but are not limited to, methylamino, ethylamino, iso-propylamino and the like.
[0017] Some examples of substituents of the above-described aliphatic (and other) moieties of compounds of the invention include, but are not limited to aliphatic; heteroaliphatic; aryl; heteroaryl; alkylaryl; alkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alycyclic, heteroaliphatic, heterocyclic, aryl, heteroaryl, alkylaryl, or alkylheteroaryl, wherein any of the aliphatic, heteroaliphatic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, cyclic or acyclic, and wherein any of the aryl or heteroaryl substituents described above and herein may be substituted or unsubstituted. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0018] In general, the term “aromatic moiety”, as used herein, refers to a stable mono- or polycyclic, unsaturated moiety having preferably 3-14 carbon atoms, each of which may be substituted or unsubstituted. In certain embodiments, the term “aromatic moiety” refers to a planar ring having p-orbitals perpendicular to the plane of the ring at each ring atom and satisfying the Huckel rule where the number of pi electrons in the ring is (4n+2) wherein n is an integer. A mono- or polycyclic, unsaturated moiety that does not satisfy one or all of these criteria for aromaticity is defined herein as “non-aromatic”, and is encompassed by the term “alicyclic”.
[0019] In general, the term “heteroaromatic moiety”, as used herein, refers to a stable mono- or polycyclic, unsaturated moiety having preferably 3-14 carbon atoms, each of which may be substituted or unsubstituted; and comprising at least one heteroatom selected from O, S and N within the ring (i.e., in place of a ring carbon atom). In certain embodiments, the term “heteroaromatic moiety” refers to a planar ring comprising at least on heteroatom, having p-orbitals perpendicular to the plane of the ring at each ring atom, and satisfying the Huckel rule where the number of pi electrons in the ring is (4n+2) wherein n is an integer.
[0020] It will also be appreciated that aromatic and heteroaromatic moieties, as defined herein may be attached via an alkyl or heteroalkyl moiety and thus also include -(alkyl)aromatic, -(heteroalkyl)aromatic, -(heteroalkyl)heteroaromatic, and -(heteroalkyl)heteroaromatic moieties. Thus, as used herein, the phrases “aromatic or heteroaromatic moieties” and “aromatic, heteroaromatic, -(alkyl)aromatic, -(heteroalkyl)aromatic, -(heteroalkyl)heteroaromatic, and -(heteroalkyl)heteroaromatic” are interchangeable. Substituents include, but are not limited to, any of the previously mentioned substituents, i.e., the substituents recited for aliphatic moieties, or for other moieties as disclosed herein, resulting in the formation of a stable compound.
[0021] The term “aryl”, as used herein, does not differ significantly from the common meaning of the term in the art, and refers to an unsaturated cyclic moiety comprising at least one aromatic ring. In certain embodiments, “aryl” refers to a mono- or bicyclic carbocyclic ring system having one or two aromatic rings including, but not limited to, phenyl, naphthyl, tetrahydronaphthyl, indanyl, indenyl and the like.
[0022] The term “heteroaryl”, as used herein, does not differ significantly from the common meaning of the term in the art, and refers to a cyclic aromatic radical having from five to ten ring atoms of which one ring atom is selected from S, O and N; zero, one or two ring atoms are additional heteroatoms independently selected from S, O and N; and the remaining ring atoms are carbon, the radical being joined to the rest of the molecule via any of the ring atoms, such as, for example, pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl, imidazolyl, thiazolyl, oxazolyl, isooxazolyl, thiadiazolyl, oxadiazolyl, thiophenyl, furanyl, quinolinyl, isoquinolinyl, and the like.
[0023] It will be appreciated that aryl and heteroaryl groups (including bicyclic aryl groups) can be unsubstituted or substituted, wherein substitution includes replacement of one or more of the hydrogen atoms thereon independently with any one or more of the following moieties including, but not limited to: aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; heteroalkylaryl; alkylheteroaryl; heteroalkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O)R x ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or unsaturated, and wherein any of the aromatic, heteroaromatic, aryl, heteroaryl, -(alkyl)aryl or -(alkyl)heteroaryl substituents described above and herein may be substituted or unsubstituted. Additionally, it will be appreciated, that any two adjacent groups taken together may represent a 4, 5, 6, or 7-membered substituted or unsubstituted alicyclic or heterocyclic moiety. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0024] The term “cycloalkyl”, as used herein, refers specifically to groups having three to seven, preferably three to ten carbon atoms. Suitable cycloalkyls include, but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and the like, which, as in the case of aliphatic, alicyclic, heteroaliphatic or heterocyclic moieties, may optionally be substituted with substituents including, but not limited to aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; heteroalkylaryl; alkylheteroaryl; heteroalkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or usaturated, and wherein any of the aromatic, heteroaromatic, aryl or heteroaryl substituents described above and herein may be substituted or unsubstituted. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0025] The term “heteroaliphatic”, as used herein, refers to aliphatic moieties in which one or more carbon atoms in the main chain have been substituted with a heteroatom. Thus, a heteroaliphatic group refers to an aliphatic chain which contains one or more oxygen, sulfur, nitrogen, phosphorus or silicon atoms, e.g., in place of carbon atoms. Heteroaliphatic moieties may be linear or branched, and saturated o runsaturated. In certain embodiments, heteroaliphatic moieties are substituted by independent replacement of one or more of the hydrogen atoms thereon with one or more moieties including, but not limited to aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; alkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or unsaturated, and wherein any of the aromatic, heteroaromatic, aryl or heteroaryl substituents described above and herein may be substituted or unsubstituted. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0026] The term “heterocycloalkyl”, “heterocycle” or “heterocyclic”, as used herein, refers to compounds which combine the properties of heteroaliphatic and cyclic compounds and include, but are not limited to, saturated and unsaturated mono- or polycyclic cyclic ring systems having 5-16 atoms wherein at least one ring atom is a heteroatom selected from O, S and N (wherein the nitrogen and sulfur heteroatoms may be optionally be oxidized), wherein the ring systems are optionally substituted with one or more functional groups, as defined herein. In certain embodiments, the term “heterocycloalkyl”, “heterocycle” or “heterocyclic” refers to a non-aromatic 5-, 6-, or 7-membered ring or a polycyclic group wherein at least one ring atom is a heteroatom selected from O, S and N (wherein the nitrogen and sulfur heteroatoms may be optionally be oxidized), including, but not limited to, a bi- or tri-cyclic group, comprising fused six-membered rings having between one and three heteroatoms independently selected from oxygen, sulfur and nitrogen, wherein (i) each 5-membered ring has 0 to 2 double bonds, each 6-membered ring has 0 to 2 double bonds and each 7-membered ring has 0 to 3 double bonds, (ii) the nitrogen and sulfur heteroatoms may be optionally be oxidized, (iii) the nitrogen heteroatom may optionally be quaternized, and (iv) any of the above heterocyclic rings may be fused to an aryl or heteroaryl ring. Representative heterocycles include, but are not limited to, heterocycles such as furanyl, thiofuranyl, pyranyl, pyrrolyl, thienyl, pyrrolidinyl, pyrazolinyl, pyrazolidinyl, imidazolinyl, imidazolidinyl, piperidinyl, piperazinyl, oxazolyl, oxazolidinyl, isooxazolyl, isoxazolidinyl, dioxazolyl, thiadiazolyl, oxadiazolyl, tetrazolyl, triazolyl, thiatriazolyl, oxatriazolyl, thiadiazolyl, oxadiazolyl, morpholinyl, thiazolyl, thiazolidinyl, isothiazolyl, isothiazolidinyl, dithiazolyl, dithiazolidinyl, tetrahydrofuryl, and benzofused derivatives thereof. In certain embodiments, a “substituted heterocycle, or heterocycloalkyl or heterocyclic” group is utilized and as used herein, refers to a heterocycle, or heterocycloalkyl or heterocyclic group, as defined above, substituted by the independent replacement of one, two or three of the hydrogen atoms thereon with but are not limited to aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; heteroalkylaryl; alkylheteroaryl; heteroalkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or unsaturated, and wherein any of the aromatic, heteroaromatic, aryl or heteroaryl substitutents described above and herein may be substituted or unsubstituted. Additional examples or generally applicable substituents are illustrated by the specific embodiments shown in the Examples, which are described herein.
[0027] Additionally, it will be appreciated that any of the alicyclic or heterocyclic moieties described above and herein may comprise an aryl or heteroaryl moiety fused thereto. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein. The terms “halo” and “halogen” as used herein refer to an atom selected from fluorine, chlorine, bromine and iodine.
[0028] The terms “halo” and “halogen” as used herein refer to an atom selected from fluorine, chlorine, bromine, and iodine.
[0029] The term “haloalkyl” denotes an alkyl group, as defined above, having one, two, or three halogen atoms attached thereto and is exemplified by such groups as chloromethyl, bromoethyl, trifluoromethyl, and the like.
[0030] The term “amino”, as used herein, refers to a primary (—NH 2 ), secondary (—NHR x ), tertiary (—NR x R y ) or quaternary (—N + R x R y R z ) amine, where R x , R y and R z are independently an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety, as defined herein. Examples of amino groups include, but are not limited to, methylamino, dimethylamino, ethylamino, diethylamino, diethylaminocarbonyl, methylethylamino, iso-propylamino, piperidino, trimethylamino, and propylamino.
[0031] The term “alkylidene”, as used herein, refers to a substituted or unsubstituted, linear or branched saturated divalent radical consisting solely of carbon and hydrogen atoms, having from one to n carbon atoms, having a free valence “-” at both ends of the radical.
[0032] The term “alkenylidene”, as used herein, refers to a substituted or unsubstituted, linear or branched unsaturated divalent radical consisting solely of carbon and hydrogen atoms, having from two to n carbon atoms, having a free valence “-” at both ends of the radical, and wherein the unsaturation is present only as double bonds and wherein a double bond can exist between the first carbon of the chain and the rest of the molecule.
[0033] The term “alkynylidene”, as used herein, refers to a substituted or unsubstituted, linear or branched unsaturated divalent radical consisting solely of carbon and hydrogen atoms, having from two to n carbon atoms, having a free valence “-” at both ends of the radical, and wherein the unsaturation is present only as triple bonds and wherein a triple bond can exist between the first carbon of the chain and the rest of the molecule.
[0034] Unless otherwise indicated, as used herein, the terms “alkyl”, “alkenyl”, “alkynyl”, “heteroalkyl”, “heteroalkenyl”, “heteroalkynyl”, “alkylidene”, alkenylidene”, -(alkyl)aryl, -(heteroalkyl)aryl, -(heteroalkyl)aryl, -(heteroalkyl)heteroaryl, and the like encompass substituted and unsubstituted, and linear and branched groups. Similarly, the terms “aliphatic”, “heteroaliphatic”, and the like encompass substituted and unsubstituted, saturated and unsaturated, and linear and branched groups. Similarly, the terms “cycloalkyl”, “heterocycle”, “heterocyclic”, and the like encompass substituted and unsubstituted, and saturated and unsaturated groups. Additionally, the terms “cycloalkenyl”, “cycloalkynyl”, “heterocycloalkenyl”, “heterocycloalkynyl”, “aromatic”, “heteroaromatic, “aryl”, “heteroaryl” and the like encompass both substituted and unsubstituted groups.
[0035] The phrase, “pharmaceutically acceptable derivative”, as used herein, denotes any pharmaceutically acceptable salt, ester, or salt of such ester, of such compound, or any other adduct or derivative which, upon administration to a patient, is capable of providing (directly or indirectly) a compound as otherwise described herein, or a metabolite or residue thereof. Pharmaceutically acceptable derivatives thus include among others pro-drugs. A pro-drug is a derivative of a compound, usually with significantly reduced pharmacological activity, which contains an additional moiety, which is susceptible to removal in vivo yielding the parent molecule as the pharmacologically active species. An example of a pro-drug is an ester, which is cleaved in vivo to yield a compound of interest. Pro-drugs of a variety of compounds, and materials and methods for derivatizing the parent compounds to create the pro-drugs, are known and may be adapted to the present invention. Pharmaceutically acceptable derivatives also include “reverse pro-drugs.” Reverse pro-drugs, rather than being activated, are inactivated upon absorption. For example, as discussed herein, many of the ester-containing compounds of the invention are biologically active but are inactivated upon exposure to certain physiological environments such as a blood, lymph, serum, extracellular fluid, etc. which contain esterase activity. The biological activity of reverse pro-drugs and pro-drugs may also be altered by appending a functionality onto the compound, which may be catalyzed by an enzyme. Also, included are oxidation and reduction reactions, including enzyme-catalyzed oxidation and reduction reactions. Certain exemplary pharmaceutical compositions and pharmaceutically acceptable derivatives will be discussed in more detail herein below.
[0036] The term “linker,” as used herein, refers to a chemical moiety utilized to attach one part of a compound of interest to another part of the compound. Exemplary linkers are described herein.
[0037] Unless indicated otherwise, the terms defined below have the following meanings:
[0038] “Compound”: The term “compound” or “chemical compound” as used herein can include organometallic compounds, organic compounds, metals, transitional metal complexes, and small molecules. In certain preferred embodiments, polynucleotides are excluded from the definition of compounds. In other preferred embodiments, polynucleotides and peptides are excluded from the definition of compounds. In a particularly preferred embodiment, the term compounds refers to small molecules (e.g., preferably, non-peptidic and non-oligomeric) and excludes peptides, polynucleotides, transition metal complexes, metals, and organometallic compounds.
[0039] “Small Molecule”: As used herein, the term “small molecule” refers to a non-peptidic, non-oligomeric organic compound either synthesized in the laboratory or found in nature. Small molecules, as used herein, can refer to compounds that are “natural product-like”, however, the term “small molecule” is not limited to “natural product-like” compounds. Rather, a small molecule is typically characterized in that it contains several carbon-carbon bonds, and has a molecular weight of less than 2000 g/mol, preferably less than 1500 g/mol, although this characterization is not intended to be limiting for the purposes of the present invention. Examples of “small molecules” that occur in nature include, but are not limited to, taxol, dynemicin, and rapamycin. Examples of “small molecules” that are synthesized in the laboratory include, but are not limited to, compounds described in Tan et al., (“Stereoselective Synthesis of over Two Million Compounds Having Structural Features Both Reminiscent of Natural Products and Compatible with Miniaturized Cell-Based Assays” J. Am. Chem. Soc. 120:8565, 1998; incorporated herein by reference). In certain other preferred embodiments, natural-product-like small molecules are utilized.
[0040] “Natural Product-Like Compound”: As used herein, the term “natural product-like compound” refers to compounds that are similar to complex natural products which nature has selected through evolution. Typically, these compounds contain one or more stereocenters, a high density and diversity of functionality, and a diverse selection of atoms within one structure. In this context, diversity of functionality can be defined as varying the topology, charge, size, hydrophilicity, hydrophobicity, and reactivity to name a few, of the functional groups present in the compounds. The term, “high density of functionality”, as used herein, can preferably be used to define any molecule that contains preferably three or more latent or active diversifiable functional moieties. These structural characteristics may additionally render the inventive compounds functionally reminiscent of complex natural products, in that they may interact specifically with a particular biological receptor, and thus may also be functionally natural product-like.
[0041] “Metal chelator”: As used herein, the term “metal chelator” refers to any molecule or moiety that is capable of forming a complex (i.e., “chelates”) with a metal ion. In certain exemplary embodiments, a metal chelator refers to to any molecule or moiety that “binds” to a metal ion, in solution, making it unavailable for use in chemical/enzymatic reactions. In certain embodiments, the solution comprises aqueous environments under physiological conditions. Examples of metal ions include, but are not limited to, Ca 2+ , Fe 3+ , Zn 2+ , Na + , etc. In certain embodiments, the metal chelator binds Zn 2+ . In certain embodiments, molecules of moieties that precipitate metal ions are not considered to be metal chelators.
[0042] As used herein the term “biological sample” includes, without limitation, cell cultures or extracts thereof; biopsied material obtained from an animal (e.g., mammal) or extracts thereof; and blood, saliva, urine, feces, semen, tears, or other body fluids or extracts thereof. For example, the term “biological sample” refers to any solid or fluid sample obtained from, excreted by or secreted by any living organism, including single-celled micro-organisms (such as bacteria and yeasts) and multicellular organisms (such as plants and animals, for instance a vertebrate or a mammal, and in particular a healthy or apparently healthy human subject or a human patient affected by a condition or disease to be diagnosed or investigated). The biological sample can be in any form, including a solid material such as a tissue, cells, a cell pellet, a cell extract, cell homogenates, or cell fractions; or a biopsy, or a biological fluid. The biological fluid may be obtained from any site (e.g., blood, saliva (or a mouth wash containing buccal cells), tears, plasma, serum, urine, bile, cerebrospinal fluid, amniotic fluid, peritoneal fluid, and pleural fluid, or cells therefrom, aqueous or vitreous humor, or any bodily secretion), a transudate, an exudate (e.g. fluid obtained from an abscess or any other site of infection or inflammation), or fluid obtained from a joint (e.g. a normal joint or a joint affected by disease such as rheumatoid arthritis, osteoarthritis, gout or septic arthritis). The biological sample can be obtained from any organ or tissue (including a biopsy or autopsy specimen) or may comprise cells (whether primary cells or cultured cells) or medium conditioned by any cell, tissue or organ. Biological samples may also include sections of tissues such as frozen sections taken for histological purposes. Biological samples also include mixtures of biological molecules including proteins, lipids, carbohydrates and nucleic acids generated by partial or complete fractionation of cell or tissue homogenates. Although the sample is preferably taken from a human subject, biological samples may be from any animal, plant, bacteria, virus, yeast, etc. The term animal, as used herein, refers to humans as well as non-human animals, at any stage of development, including, for example, mammals, birds, reptiles, amphibians, fish, worms and single cells. Cell cultures and live tissue samples are considered to be pluralities of animals. In certain exemplary embodiments, the non-human animal is a mammal (e.g., a rodent, a mouse, a rat, a rabbit, a monkey, a dog, a cat, a sheep, cattle, a primate, or a pig). An animal may be a transgenic animal or a human clone. If desired, the biological sample may be subjected to preliminary processing, including preliminary separation techniques.
BRIEF DESCRIPTION OF THE DRAWING
[0043] FIG. 1 includes a table of esterases found in human and mouse plasma.
[0044] FIG. 2 shows the design of a reverse pro-drug version of SAHA-SAHP.
[0045] FIG. 3 illustrates the stability of SAHA (with an amide) in PBS.
[0046] FIG. 4 illustrates the stability of SAHA in serum.
[0047] FIG. 5 shows the stability of SAHP (ester instead of amdie) in PBS.
[0048] FIG. 6 shows the degradation of SAHP in serum. In less than 15 minutes, SAHP is completely degraded.
[0049] FIG. 7 shows a more detailed study of the degradation of SAHP in serum. In less than 2 minutes, SAHP is completely degraded into phenol and the corresponding carboxylic acid.
[0050] FIG. 8 shows the degradation of SAHP by human serum under various conditions.
[0051] FIG. 9 shows the degradation of SAHP by recombinant paraoxonase.
[0052] FIG. 10 shows the degradation of SAHP in RPMI media with 10% FBS.
[0053] FIG. 11 shows the effect of SAHA v. SAHP on lysine acetylation.
[0054] FIG. 12 shows the stability of SAHP in an olive oil/acetone formulation for murine model.
[0055] FIG. 13 is an exemplary synthetic scheme for preparing SAHP.
[0056] FIG. 14 . Interleukin-7 is a growth factor for T-cell development, in particular the gamma-delta subset. Transgenic mice overexpressing IL-7 in keratinocytes were developed by the laboratories of Thomas Kupper and Benjamin Rich, using a tissue-specific keratin-14 promoter element. These mice have been reported to develop a characteristic lymphoproliferative skin disease grossly and histologically similar to human cutaneous T-cell lymphoma (CTCL). Transformed lymphocytes derived from involved skin were passaged ex vivo and injected into syngeneic (non-transgenic) mice. After fourteen days, these mice develop a homogeneous lymphoproliferative disease. Two cohorts of five mice were included in a prospective study of topical, daily suberoyl hydroxamic acid phenyl ester (SAHP, also known as SHAPE) versus vehicle control. After fourteen days of therapy, mice were sacrificed and the treated region was dissected for histopathologic examination. In SHAPE-treated mice, hematoxylin-eosin staining demonstrates a marked reduction in lymphomatous infiltration within the treated window. Vehicle control mice failed to demonstrate a cytotoxic response.
[0057] FIG. 15 shows the pharmacodynamic effect of SAHP treatment as assessed using immunohistochemical staining for acetylated histones compared to vehicle treated controls. In SAHP-treated mice, AcH3K18 staining demonstrates hyperacetylated histone staining at the margin of compound treatment, with absent nuclear staining in the region of drug response. Vehicle control mice failed to demonstrate an increase in histone hyperacetylation.
DETAILED DESCRIPTION OF THE INVENTION
[0058] As discussed above, there remains a need for the development of novel histone deacetylase inhibitors. The present invention provides novel compounds of general formula (I), and methods for the synthesis thereof, which compounds are useful as inhibitors of histone deacetylases, and thus are useful for the treatment of proliferative diseases, particularly proliferative or other disorders associated with the skin and/or hair. In particular, the inventive compounds comprise an ester linkage. The ester linkage is preferably sensitive to esterase cleavage; therefore, when the compound is contacted with an esterase it is deactivated.
Compounds of the Invention
[0059] As discussed above, the present invention provides a novel class of compounds useful for the treatment of cancer and other proliferative conditions related thereto. In certain embodiments, the compounds of the present invention are useful as inhibitors of histone deacetylases and thus are useful as anticancer agents, and thus may be useful in the treatment of cancer, by effecting tumor cell death or inhibiting the growth of tumor cells. In certain exemplary embodiments, the inventive anticancer agents are useful in the treatment of cancers and other proliferative disorders, including, but not limited to breast cancer, cervical cancer, colon and rectal cancer, leukemia, lung cancer, melanoma, multiple myeloma, non-Hodgkin's lymphoma, ovarian cancer, pancreatic cancer, prostate cancer, and gastric cancer, to name a few. In certain embodiments, the inventive anticancer agents are active against leukemia cells and melanoma cells, and thus are useful for the treatment of leukemias (e.g., myeloid, lymphocytic, myelocytic and lymphoblastic leukemias) and malignant melanomas. In certain embodiments, the inventive compounds are active against cutaneous T-cell lymphoma. Additionally, as described above and in the exemplification, the inventive compounds may also be useful in the treatment of protozoal infections. In certain exemplary embodiments, the compounds of the invention are useful for disorders resulting from histone deacetylation activity. In certain embodiments, the compounds are useful for skin disorders. Examplary skin disorders that may be treated using the inventive compounds include cutaneous T-cell lymphoma (CTCL), skin cancers (e.g., squamous cell carcinoma, basal cell carcinoma, malignant melanoma, etc.), psoriasis, hair loss, dermatitis, neurofibromatosis, disorders asscoiated with skin hyperpigmentation, etc.
[0060] Compounds of this invention comprise those, as set forth above and described herein, and are illustrated in part by the various classes, subgenera and species disclosed elsewhere herein.
[0061] In general, the present invention provides compounds having the general structure (I):
[0000]
[0000] and pharmaceutically acceptable salts and derivatives thereof;
wherein
[0062] A comprises a functional group that inhibits histone deacetylase;
[0063] L is a linker moiety; and
[0064] Ar is a substituted or unsubstituted aryl or heteroaryl moiety; substituted or unsustituted, branched or unbranched arylaliphatic or heteroarylaliphatic moiety; a substituted or unsubstituted cyclic or heterocyclic moiety; substituted or unsustituted, branched or unbranched cyclicaliphatic or heterocyclicaliphatic moiety.
[0065] In certain embodiments, A comprises a metal chelating functional group. For example, A comprises a Zn 2+ chelating group. In certain embodiments, A comprises a functional group selected group consisting of:
[0000]
[0000] In certain embodiments, A comprises hydroxamic acid
[0000]
[0000] or a salt thereof. In other embodiments, A comprises the formula:
[0000]
[0000] In certain particular embodiments, A comprises the formula:
[0000]
[0000] In other embodiments, A comprises a carboxylic acid (—CO 2 H). In other embodiments, A comprises an o-aminoanilide
[0000]
[0000] In other embodiments, A comprises an o-hydroxyanilide
[0000]
[0000] In yet other embodiments, A comprises a thiol (—SH).
[0066] In certain embodiments, Ar is arylaliphatic. In other embodiments, Ar is heteroarylaliphatic. In certain embodiments, Ar is a substituted or unsubstituted aryl moiety. In certain embodiments, Ar is a monocylic, substituted or unsubstituted aryl moiety, preferably a five- or six-membered aryl moiety. In other embodiments, Ar is a bicyclic, substituted or unsubstituted aryl moiety. In still other embodiments, Ar is a tricyclic, substituted or unsubstituted aryl moiety. In certain embodiments, Ar is a susbstituted or unsubstituted phenyl moiety. In certain embodiments, Ar is an unsubstituted phenyl moiety. In other embodiments, Ar is a substituted phenyl moiety. In certain embodiments, Ar is a monosubstituted phenyl moiety. In certain particular embodiments, Ar is an ortho-substituted Ar moiety. In certain particular embodiments, Ar is an meta-substituted Ar moiety. In certain particular embodiments, Ar is an para-substituted Ar moiety. In certain embodiments, Ar is a disubstituted phenyl moiety. In certain embodiments, Ar is a trisubstituted phenyl moiety. In certain embodiments, Ar is a tetrasubstituted phenyl moiety. In certain embodiments, Ar is a substituted or unsubstituted cyclic or heterocyclic.
[0067] In certain embodiments, Ar is a substituted or unsubstituted heteroaryl moiety. In certain embodiments, Ar is a monocylic, substituted or unsubstituted heteroaryl moiety, preferably a five- or six-membered heteroaryl moiety. In other embodiments, Ar is a bicyclic, substituted or unsubstituted heteroaryl moiety. In still other embodiments, Ar is a tricyclic, substituted or unsubstituted heteroaryl moiety. In certain embodiments, Ar comprises N, S, or O. In certain embodiments, Ar comprises at least one N. In certain embodiments, Ar comprises at least two N.
[0068] In certain embodiments, Ar is:
[0000]
[0000] wherein
[0069] n is an integer between 1 and 5, inclusive; preferably, between 1 and 3, inclusive; more preferably, 1 or 2;
[0070] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ;; —NHR A ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, Ar is
[0000]
[0000] In other embodiments, Ar is
[0000]
[0000] In yet other embodiments, Ar is
[0000]
[0000] In certain embodiments, R 1 is —N(R A ) 2 , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain embodiments, R 1 is —OR A , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain particular embodiments, R 1 is —OMe. In certain embodiments, R 1 is branched or unbranched acyl. In certain embodiments, R 1 is —O(═O)OR A . In certain embodiments, R 1 is —C(═O)OR A , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain embodiments, R 1 is —C(═O)NH 2 . In certain embodiments, R 1 is —NHC(═O)R A . In certain embodiments, R 1 is —NHC(═O)R A , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain embodiments, R 1 is halogen. In certain embodiments, R 1 is C 1 -C 6 alkyl.
[0071] In certain particular embodiments, Ar is a substituted phenyl moiety of formula:
[0000]
[0072] In certain embodiments, Ar is chosen from one of the following:
[0000]
[0000] wherein
[0073] n is an integer between 1 and 4, inclusive; preferably, between 1 and 3, inclusive; more preferably, 1 or 2;
[0074] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ;; —NHR A ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0075] In certain embodiments, Ar is chosen from one of the following:
[0000]
[0000] Any of the above bicyclic ring system may be substituted with up to seven R 1 susbstituents as defined above.
[0076] In certain embodiments, L is a substituted or unsubstituted, cyclic or acyclic, branched or unbranched aliphatic moiety; a substituted or unsubstituted, cyclic or acyclic, branched or unbranched heteroaliphatic moiety; a substituted or unsubstituted aryl moiety; a substituted or unsubstituted heteroaryl moiety. In certain embodiments, L is a substituted or unsubstituted, cyclic or acyclic, branched or unbranched aliphatic moiety. In certain embodiments, L is C 1 -C 20 alkylidene, preferably C 1 to C 12 alkylidene, more preferably C 4 -C 7 alkylidene. In certain embodiments, L is C 1 -C 20 alkenylidene, preferably C 1 to C 12 alkenylidene, more preferably C 4 -C 7 alkenylidene. In certain embodiments, L is C 1 -C 20 alkynylidene, preferably C 1 to C 12 alkynylidene, more preferably C 4 -C 7 alkynylidene. In certain embodiments, L is a a substituted or unsubstituted, cyclic or acyclic, branched or unbranched heteroaliphatic moiety. In certain embodiments, L comprises a cyclic ring system, wherein the rings may be aryl, heteroaryl, non-aromatic carbocyclic, or non-aromatic heterocyclic. In still other embodiments, L comprises a substituted or unsubstituted heteroaryl moiety. In certain particular embodiments, L comprises a phenyl ring. In certain embodiments, L comprises multiple phenyl rings (e.g., one, two, three, or four phenyl rings).
[0077] In certain embodiments, L is
[0000]
[0000] wherein n is an integer between 1 and 4, inclusive; preferably, between 1 and 3, inclusive; more preferably, 1 or 2; and R 1 is is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ;; —NHR A ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, L is
[0000]
[0078] In certain embodiments, L is
[0000]
[0079] In certain embodiments, L is an unbranched, unsubstituted, acyclic alkyl chain. In certain embodiments, L is
[0000]
[0000] In other embodiments, L is
[0000]
[0000] In certain other embodiments, L is
[0000]
[0000] In other embodiments, L is
[0000]
[0000] In yet other embodiments, L is
[0000]
[0080] In certain embodiments, L is a substituted, acyclic aliphatic chain. In certain embodiments, L is
[0000]
[0081] In certain embodiments, L is an unbranched, unsubstituted, acyclic heteroaliphatic chain. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and R′ is hydrogen, C 1 -C 6 aliphatic, heteroaliphatic, aryl, heteroaryl, or acyl. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive.
[0082] In certain embodiments of the invention, compounds of formula (I) have the following structure as shown in formula (Ia):
[0000]
[0000] wherein
[0083] n is an integer between 0 and 15, inclusive; preferably, between 0 and 10, inclusive; more preferably, between 1 and 8, inclusive; even more preferably, 4, 5, 6, 7, or 8; and
[0084] Ar is defined as above. In certain embodiments, n is 5. In other embodiments, n is 6. In still other embodiments, n is 7.
[0085] In certain embodiments of the invention, compounds of formula (I) have the following structure as shown in formula (Ib):
[0000]
[0000] wherein
[0086] n is an integer between 0 and 15, inclusive; preferably, between 0 and 10, inclusive; more preferably, between 1 and 8, inclusive; even more preferably, 4, 5, 6, 7, or 8;
[0087] m is an integer between 1 and 5, inclusive; preferably, m is 1, 2, or 3; and
[0088] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, R 1 is hydrogen, halogen, hydroxy, amino, alkylamino, dialkylamino, nitroso, acyl, or C 1 -C 6 alkyl. In certain embodiments, R 1 is aryl. In certain embodiments, R 1 is a multicyclic aryl moiety. In other embodiments, R 1 is heteroaryl. In certain embodiments, R 1 is carbocyclic. In other embodiments, R 1 is heterocyclic. In certain embodiments R 1 comprises a 1,3-dioxane ring optionally substituted. In certain embodiments, n is 5. In other embodiments, n is 6. In still other embodiments, n is 7. In certain embodiments, m is 0. In other embodiments, m is 1. In still other embodiments, m is 2.
[0089] In certain embodiments of the invention, compounds of formula (I) are of the formula (Ic):
[0000]
[0000] wherein
[0090] n is an integer between 0 and 15, inclusive; preferably, between 0 and 10, inclusive; more preferably, between 1 and 8, inclusive; even more preferably, 4, 5, 6, 7, or 8; and
[0091] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, R 1 is hydrogen, halogen, hydroxy, amino, alkylamino, dialkylamino, nitroso, acyl, or C 1 -C 6 alkyl. In certain embodiments, R 1 is aryl. In other embodiments, R 1 is heteroaryl. In certain embodiments, R 1 is carbocyclic. In other embodiments, R 1 is heterocyclic. In certain embodiments, n is 5. In other embodiments, n is 6. In still other embodiments, n is 7.
[0092] In certain embodiments of the invention, compounds of formula (I) are of the formula (Id):
[0000]
[0000] wherein
[0093] n is an integer between 1 and 5, inclusive; preferably, between 1 and 3; more preferably, 1 or 2; and
[0094] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, R 1 is hydrogen, halogen, hydroxy, amino, alkylamino, dialkylamino, nitroso, acyl, or C 1 -C 6 alkyl. In certain embodiments, R 1 is aryl. In other embodiments, R 1 is heteroaryl. In certain embodiments, R 1 is carbocyclic. In other embodiments, R 1 is heterocyclic. In certain embodiments, n is 1. In other embodiments, n is 2.
[0095] In certain embodiments of the invention, compounds of formula (I) are of the formula (Ie):
[0000]
[0000] wherein R1 is defined as above.
[0096] In certain embodiments of the invention, compounds of formula (I) have the following stereochemistry and structure as shown in formula (If):
[0000]
[0000] wherein A, L and Ar are defined as above; and
[0097] n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; even more preferably, 0, 1, 2, or 3. In certain embodiments, Ar is phenyl.
[0098] In certain embodiments, compounds of formula (I) are of the formula (Ig):
[0000]
[0000] wherein
[0099] A and L are defined as above;
[0100] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0101] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0102] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n , wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0103] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0104] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0105] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0106] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0000] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0107] In certain embodiments, the stereochemistry of formula (Ig) is defined as follows:
[0000]
[0108] In certain embodiments of the invention, compounds of formula (I) are of the formula (Ih):
[0000]
[0000] wherein
[0109] A and L are defined as above;
[0110] n is an integer between 0 and 10, inclusive; preferably, between 1 and 6, inclusive; more preferably, between 1 and 3, inclusive; and even more preferably, 0, 1, 2, or 3;
[0111] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0112] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0113] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n , wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0114] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0115] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0116] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0117] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0118] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0119] In certain embodiments, the stereochemistry of formula (Ih) is defined as follows:
[0000]
[0120] In certain embodiments of the invention, compounds of formula (I) have structure as shown in formula (Ii):
[0000]
[0000] wherein
[0121] A and L are defined as above;
[0122] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0123] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0124] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n , wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0125] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0126] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0127] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0128] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0000] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0129] In certain embodiments, the stereochemistry of formula (II) is defined as follows:
[0000]
[0130] In certain embodiments of the invention, compounds of formula (I) have the following stereochemistry and structure as shown in formula (Ij):
[0000]
[0000] wherein
[0131] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0132] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstitued, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0133] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n , wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0134] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0135] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0136] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0137] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0000] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0138] Another class of compounds of special interest includes those compounds of the invention as described above and in certain subclasses herein, wherein R 3 is a substituted phenyl moiety and the compounds have the formula (Il):
[0000]
[0000] wherein
[0139] L, A, X, and R B are defined as above;
[0140] n is an integer between 0 and 5, inclusive; preferably, between, 1 and 3; more preferably, 2; and
[0141] Z is hydrogen, —(CH 2 ) q OR Z , —(CH 2 ) q SR Z , —(CH 2 ) q N(R Z ) 2 , —C(═O)R Z , —C(═O)N(R Z ) 2 , or an alkyl, heteroalkyl, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety, wherein q is 0-4, and wherein each occurrence of R Z is independently hydrogen, a protecting group, a solid support unit, or an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R Z is hydrogen. In other embodiments, R Z is C 1 -C 6 alkyl. In certain embodiments, R Z is an oxygen-protecting group.
[0142] Another class of compounds includes those compounds of formula (II), wherein Z is —CH 2 OR Z , and the compounds have the general structure (Im):
[0000]
[0000] wherein
[0143] R B , R Z , X, L, n, and A are defined generally above and in classes and subclasses herein. In certain embodiments, X is S. In other embodiments, X is O.
[0144] Yet another class of compounds of particular interest includes those compounds of formula (Ii), wherein X is S and the compounds have the general structure (In):
[0000]
[0000] wherein
[0145] R B , X, L, n, and A are defined as above; and
[0146] R Z is as defined generally above and in classes and subclasses herein.
[0147] Yet another class of compounds of special interest includes those compounds of formula (Ii), wherein X is —NR 2A and the compounds have the general structure (Io):
[0000]
[0000] wherein
[0148] R B , R Z , X, L, n, and A are defined generally above and in classes and subclasses herein.
[0149] Yet another class of compounds of special interest includes those compounds of formula (Ii), wherein X is O and the compounds have the general structure (Ip):
[0000]
[0000] wherein
[0150] R B , R Z , X, L, n, and A are defined generally above and in classes and subclasses herein.
[0151] Exemplary compounds of the invention are shown:
[0000]
[0152] Some of the foregoing compounds can comprise one or more asymmetric centers, and thus can exist in various isomeric forms, e.g., stereoisomers and/or diastereomers. Thus, inventive compounds and pharmaceutical compositions thereof may be in the form of an individual enantiomer, diastereomer or geometric isomer, or may be in the form of a mixture of stereoisomers. In certain embodiments, the compounds of the invention are enantiopure compounds. In certain other embodiments, mixtures of stereoisomers or diastereomers are provided.
[0153] Furthermore, certain compounds, as described herein may have one or more double bonds that can exist as either the Z or E isomer, unless otherwise indicated. The invention additionally encompasses the compounds as individual isomers substantially free of other isomers and alternatively, as mixtures of various isomers, e.g., racemic mixtures of stereoisomers. In addition to the above-mentioned compounds per se, this invention also encompasses pharmaceutically acceptable derivatives of these compounds and compositions comprising one or more compounds of the invention and one or more pharmaceutically acceptable excipients or additives.
[0154] Compounds of the invention may be prepared by crystallization of the compound under different conditions and may exist as one or a combination of polymorphs of the compound forming part of this invention. For example, different polymorphs may be identified and/or prepared using different solvents, or different mixtures of solvents for recrystallization; by performing crystallizations at different temperatures; or by using various modes of cooling, ranging from very fast to very slow cooling during crystallizations. Polymorphs may also be obtained by heating or melting the compound followed by gradual or fast cooling. The presence of polymorphs may be determined by solid probe NMR spectroscopy, IR spectroscopy, differential scanning calorimetry, powder X-ray diffractogram and/or other techniques. Thus, the present invention encompasses inventive compounds, their derivatives, their tautomeric forms, their stereoisomers, their polymorphs, their pharmaceutically acceptable salts their pharmaceutically acceptable solvates and pharmaceutically acceptable compositions containing them.
Synthetic Overview
[0155] The synthesis of the various monomeric compounds used to prepare the dimeric, multimeric, and polymeric compounds of the invention are known in the art. These published syntheses may be utilized to prepare the compounds of the invention. Exemplary synthesic methods for preparing compounds of the invention are described in U.S. Pat. No. 6,960,685; U.S. Pat. No. 6,897,220; U.S. Pat. No. 6,541,661; U.S. Pat. No. 6,512,123; U.S. Pat. No. 6,495,719; US 2006/0020131; US 2004/087631; US 2004/127522; US 2004/0072849; US 2003/0187027; WO 2005/018578; WO 2005/007091; WO 2005/007091; WO 2005/018578; WO 2004/046104; WO 2002/89782; each of which is incorporated herein by reference. In many cases, an amide moiety is changed to an ester moiety to prepare the inventive compounds.
[0156] An exemplary synthetic scheme for preparing SAHP is showin in FIG. 13 . Those of skill in the art will realize that based on this teaching and those in the art as referenced above one could prepare any of the esterase-sensitive compounds of the invention.
[0157] In yet another aspect of the invention, methods for producing intermediates useful for the preparation of certain compounds of the invention are provided.
[0158] In one aspect of the invention, a method for the synthesis of the core structure of certain compounds is provided, one method comprising steps of:
[0159] providing an epoxy alcohol having the structure:
[0000]
[0160] reacting the epoxy alcohol with a reagent having the structure R 2 XH under suitable conditions to generate a diol having the core structure:
[0000]
[0161] reacting the diol with a reagent having the structure R 3 CH(OMe) 2 under suitable conditions to generate a scaffold having the core structure:
[0000]
[0162] wherein R 1 is hydrogen, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0163] R 2 is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0164] X is —O—, —C(R 2A ) 2 —, —S—, or —NR 2A —, wherein R 2A is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0165] or wherein two or more occurrences of R 2 and R 2A , taken together, form an alicyclic or heterocyclic moiety, or an aryl or heteroaryl moiety;
[0166] R 3 is an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety; and
[0167] R Z is an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety and is optionally attached to a solid support.
[0168] In certain exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0169] the diol has the structure:
[0000]
[0170] and the core scaffold has the structure:
[0000]
[0171] In certain other exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0172] the diol has the structure:
[0000]
[0173] and the core scaffold has the structure:
[0000]
[0174] In certain embodiments, R 3 has the following structure:
[0000]
and the method described above generates the structure:
[0000]
[0176] In another aspect of the invention, a method for the synthesis of the core structure of certain compounds of the invention is provided, one method comprising steps of:
[0177] providing an epoxy alcohol having the structure:
[0000]
[0178] reacting the epoxy alcohol with a reagent having the structure R 2 XH under suitable conditions to generate a diol having the core structure:
[0000]
[0179] subjecting the diol to a reagent having the structure:
[0000]
[0000] wherein R 4C is a nitrogen protecting group; to suitable conditions to generate an amine having the structure:
[0000]
[0180] reacting the amine with a reagent having the structure:
[0000]
[0000] under suitable conditions to generate a scaffold having the core structure:
[0000]
[0181] wherein R 1 is hydrogen, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0182] R 2 is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0183] X is —O—, —C(R 2A ) 2 —, —S—, or —NR 2A —, wherein R 2A is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0184] or wherein two or more occurrences of R 2 and R 2A , taken together, form an alicyclic or heterocyclic moiety, or an aryl or heteroaryl moiety;
[0185] r is 0 or 1;
[0186] s is an integer from 2-5;
[0187] w is an integer from 0-4;
[0188] R 4A comprises a metal chelator;
[0189] each occurrence of R 4D is independently hydrogen, alkyl, heteroalkyl, cycloalkyl, heterocyclic, alkenyl, alkynyl, aryl, heteroaryl, halogen, CN, NO 2 , or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety; and
[0190] R Z is an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety and is optionally attached to a solid support.
[0191] In certain exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0192] the diol has the structure:
[0000]
[0193] the amine has the structure:
[0000]
[0194] and the core scaffold has the structure:
[0000]
[0195] In certain exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0196] the diol has the structure:
[0000]
[0197] the amine has the structure:
[0000]
[0198] and the core scaffold has the structure:
[0000]
[0199] In certain embodiments, the methods described above are carried out in solution phase. In certain other embodiments, the methods described above are carried out on a solid phase. In certain embodiments, the synthetic method is amenable to high-throughput techniques or to techniques commonly used in combinatorial chemistry.
Pharmaceutical Compositions
[0200] As discussed above, the present invention provides novel compounds having antitumor and antiproliferative activity, and thus the inventive compounds are useful for the treatment of cancer (e.g., cutaneous T-cell lymphoma). Benign proliferative diseases may also be treated using the inventive compounds. The compounds are also useful in the treatment of other diseases or condition that benefit from inhibtion of deacetylation activity (e.g. HDAC inhibition). In certain embodiments, the compounds are useful in the treatment of baldness based on the discovery that HDAC inhibition (particularly, HDAC6 inhibition) blocks androgen signaling vis hsp90. HDAC inhibition has also been shown to inhibit estrogen signaling. In certain embodiments, the compounds are useful in blocking the hyperpigmentation of skin by HDAC inhibition.
[0201] Accordingly, in another aspect of the present invention, pharmaceutical compositions are provided, which comprise any one of the compounds described herein (or a prodrug, pharmaceutically acceptable salt or other pharmaceutically acceptable derivative thereof), and optionally comprise a pharmaceutically acceptable carrier. In certain embodiments, these compositions optionally further comprise one or more additional therapeutic agents. Alternatively, a compound of this invention may be administered to a patient in need thereof in combination with the administration of one or more other therapeutic agents. For example, additional therapeutic agents for conjoint administration or inclusion in a pharmaceutical composition with a compound of this invention may be an approved chemotherapeutic agent, or it may be any one of a number of agents undergoing approval in the Food and Drug Administration that ultimately obtain approval for the treatment of hair loss, skin hyperpigmentation, protozoal infections, and/or any disorder associated with cellular hyperproliferation. In certain other embodiments, the additional therapeutic agent is an anticancer agent, as discussed in more detail herein. In certain other embodiments, the compositions of the invention are useful for the treatment of protozoal infections.
[0202] It will also be appreciated that certain of the compounds of present invention can exist in free form for treatment, or where appropriate, as a pharmaceutically acceptable derivative thereof. According to the present invention, a pharmaceutically acceptable derivative includes, but is not limited to, pharmaceutically acceptable salts, esters, salts of such esters, or a pro-drug or other adduct or derivative of a compound of this invention which upon administration to a patient in need is capable of providing, directly or indirectly, a compound as otherwise described herein, or a metabolite or residue thereof.
[0203] As used herein, the term “pharmaceutically acceptable salt” refers to those salts which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of humans and lower animals without undue toxicity, irritation, allergic response and the like, and are commensurate with a reasonable benefit/risk ratio. Pharmaceutically acceptable salts of amines, carboxylic acids, and other types of compounds, are well known in the art. For example, S. M. Berge, et al. describe pharmaceutically acceptable salts in detail in J. Pharmaceutical Sciences, 66: 1-19 (1977), incorporated herein by reference. The salts can be prepared in situ during the final isolation and purification of the compounds of the invention, or separately by reacting a free base or free acid function with a suitable reagent, as described generally below. For example, a free base function can be reacted with a suitable acid. Furthermore, where the compounds of the invention carry an acidic moiety, suitable pharmaceutically acceptable salts thereof may, include metal salts such as alkali metal salts, e.g. sodium or potassium salts; and alkaline earth metal salts, e.g. calcium or magnesium salts. Examples of pharmaceutically acceptable, nontoxic acid addition salts are salts of an amino group formed with inorganic acids such as hydrochloric acid, hydrobromic acid, phosphoric acid, sulfuric acid and perchloric acid or with organic acids such as acetic acid, oxalic acid, maleic acid, tartaric acid, citric acid, succinic acid or malonic acid or by using other methods used in the art such as ion exchange. Other pharmaceutically acceptable salts include adipate, alginate, ascorbate, aspartate, benzenesulfonate, benzoate, bisulfate, borate, butyrate, camphorate, camphorsulfonate, citrate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, formate, fumarate, glucoheptonate, glycerophosphate, gluconate, hernisulfate, heptanoate, hexanoate, hydroiodide, 2-hydroxy-ethanesulfonate, lactobionate, lactate, laurate, lauryl sulfate, malate, maleate, malonate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, nitrate, oleate, oxalate, palmitate, pamoate, pectinate, persulfate, 3-phenylpropionate, phosphate, picrate, pivalate, propionate, stearate, succinate, sulfate, tartrate, thiocyanate, p-toluenesulfonate, undecanoate, valerate salts, and the like. Representative alkali or alkaline earth metal salts include sodium, lithium, potassium, calcium, magnesium, and the like. Further pharmaceutically acceptable salts include, when appropriate, nontoxic ammonium, quaternary ammonium, and amine cations formed using counterions such as halide, hydroxide, carboxylate, sulfate, phosphate, nitrate, loweralkyl sulfonate and aryl sulfonate.
[0204] Additionally, as used herein, the term “pharmaceutically acceptable ester” refers to esters that hydrolyze in vivo and include those that break down readily in the human body to leave the parent compound or a salt thereof. Suitable ester groups include, for example, those derived from pharmaceutically acceptable aliphatic carboxylic acids, particularly alkanoic, alkenoic, cycloalkanoic and alkanedioic acids, in which each alkyl or alkenyl moeity advantageously has not more than 6 carbon atoms. Examples of particular esters include formates, acetates, propionates, butyrates, acrylates and ethylsuccinates.
[0205] Furthermore, the term “pharmaceutically acceptable prodrugs” as used herein refers to those prodrugs of the compounds of the present invention which are, within the scope of sound medical judgment, suitable for use in contact with the issues of humans and lower animals with undue toxicity, irritation, allergic response, and the like, commensurate with a reasonable benefit/risk ratio, and effective for their intended use, as well as the zwitterionic forms, where possible, of the compounds of the invention. The term “prodrug” refers to compounds that are rapidly transformed in vivo to yield the parent compound of the above formula, for example by hydrolysis in blood. A thorough discussion is provided in T. Higuchi and V. Stella, Pro-drugs as Novel Delivery Systems, Vol. 14 of the A.C.S. Symposium Series, and in Edward B. Roche, ed., Bioreversible Carriers in Drug Design, American Pharmaceutical Association and Pergamon Press, 1987, both of which are incorporated herein by reference.
[0206] As described above, the pharmaceutical compositions of the present invention additionally comprise a pharmaceutically acceptable carrier, which, as used herein, includes any and all solvents, diluents, or other liquid vehicle, dispersion or suspension aids, surface active agents, isotonic agents, thickening or emulsifying agents, preservatives, solid binders, lubricants and the like, as suited to the particular dosage form desired. Remington's Pharmaceutical Sciences, Sixteenth Edition, E. W. Martin (Mack Publishing Co., Easton, Pa., 1980) discloses various carriers used in formulating pharmaceutical compositions and known techniques for the preparation thereof. Except insofar as any conventional carrier medium is incompatible with the compounds of the invention, such as by producing any undesirable biological effect or otherwise interacting in a deleterious manner with any other component(s) of the pharmaceutical composition, its use is contemplated to be within the scope of this invention. Some examples of materials which can serve as pharmaceutically acceptable carriers include, but are not limited to, sugars such as lactose, glucose and sucrose; starches such as corn starch and potato starch; cellulose and its derivatives such as sodium carboxymethyl cellulose, ethyl cellulose and cellulose acetate; powdered tragacanth; malt; gelatine; talc; excipients such as cocoa butter and suppository waxes; oils such as peanut oil, cottonseed oil; safflower oil, sesame oil; olive oil; corn oil and soybean oil; glycols; such as propylene glycol; esters such as ethyl oleate and ethyl laurate; agar; buffering agents such as magnesium hydroxide and aluminum hydroxide; alginic acid; pyrogenfree water; isotonic saline; Ringer's solution; ethyl alcohol, and phosphate buffer solutions, as well as other non-toxic compatible lubricants such as sodium lauryl sulfate and magnesium stearate, as well as coloring agents, releasing agents, coating agents, sweetening, flavoring and perfuming agents, preservatives and antioxidants can also be present in the composition, according to the judgment of the formulator.
[0207] Liquid dosage forms for oral administration include, but are not limited to, pharmaceutically acceptable emulsions, microemulsions, solutions, suspensions, syrups and elixirs. In addition to the active compounds, the liquid dosage forms may contain inert diluents commonly used in the art such as, for example, water or other solvents, solubilizing agents and emulsifiers such as ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethylformamide, oils (in particular, cottonseed, groundnut, corn, germ, olive, castor, and sesame oils), glycerol, tetrahydrofurfuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan, and mixtures thereof. Besides inert diluents, the oral compositions can also include adjuvants such as wetting agents, emulsifying and suspending agents, sweetening, flavoring, and perfuming agents.
[0208] Injectable preparations, for example, sterile injectable aqueous or oleaginous suspensions may be formulated according to the known art using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution, suspension or emulsion in a nontoxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution, U.S.P. and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil can be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid are used in the preparation of injectables.
[0209] The injectable formulations can be sterilized, for example, by filtration through a bacterial-retaining filter, or by incorporating sterilizing agents in the form of sterile solid compositions which can be dissolved or dispersed in sterile water or other sterile injectable medium prior to use.
[0210] In order to prolong the effect of a drug, it is often desirable to slow the absorption of the drug from subcutaneous or intramuscular injection. This may be accomplished by the use of a liquid suspension or crystalline or amorphous material with poor water solubility. The rate of absorption of the drug then depends upon its rate of dissolution that, in turn, may depend upon crystal size and crystalline form. Alternatively, delayed absorption of a parenterally administered drug form is accomplished by dissolving or suspending the drug in an oil vehicle. Injectable depot forms are made by forming microencapsule matrices of the drug in biodegradable polymers such as polylactide-polyglycolide. Depending upon the ratio of drug to polymer and the nature of the particular polymer employed, the rate of drug release can be controlled. Examples of other biodegradable polymers include (poly(orthoesters) and poly(anhydrides). Depot injectable formulations are also prepared by entrapping the drug in liposomes or microemulsions which are compatible with body tissues.
[0211] Compositions for rectal or vaginal administration are preferably suppositories which can be prepared by mixing the compounds of this invention with suitable non-irritating excipients or carriers such as cocoa butter, polyethylene glycol or a suppository wax which are solid at ambient temperature but liquid at body temperature and therefore melt in the rectum or vaginal cavity and release the active compound.
[0212] Solid dosage forms for oral administration include capsules, tablets, pills, powders, and granules. In such solid dosage forms, the active compound is mixed with at least one inert, pharmaceutically acceptable excipient or carrier such as sodium citrate or dicalcium phosphate and/or a) fillers or extenders such as starches, lactose, sucrose, glucose, mannitol, and silicic acid, b) binders such as, for example, carboxymethylcellulose, alginates, gelatin, polyvinylpyrrolidinone, sucrose, and acacia, c) humectants such as glycerol, d) disintegrating agents such as agar--agar, calcium carbonate, potato or tapioca starch, alginic acid, certain silicates, and sodium carbonate, e) solution retarding agents such as paraffin, f) absorption accelerators such as quaternary ammonium compounds, g) wetting agents such as, for example, cetyl alcohol and glycerol monostearate, h) absorbents such as kaolin and bentonite clay, and i) lubricants such as talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate, and mixtures thereof. In the case of capsules, tablets and pills, the dosage form may also comprise buffering agents.
[0213] Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polyethylene glycols and the like. The solid dosage forms of tablets, dragees, capsules, pills, and granules can be prepared with coatings and shells such as enteric coatings and other coatings well known in the pharmaceutical formulating art. They may optionally contain opacifying agents and can also be of a composition that they release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, optionally, in a delayed manner. Examples of embedding compositions that can be used include polymeric substances and waxes. Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polethylene glycols and the like.
[0214] The active compounds can also be in micro-encapsulated form with one or more excipients as noted above. The solid dosage forms of tablets, dragees, capsules, pills, and granules can be prepared with coatings and shells such as enteric coatings, release controlling coatings and other coatings well known in the pharmaceutical formulating art. In such solid dosage forms the active compound may be admixed with at least one inert diluent such as sucrose, lactose and starch. Such dosage forms may also comprise, as in normal practice, additional substances other than inert diluents, e.g., tableting lubricants and other tableting aids such as magnesium stearate and microcrystalline cellulose. In the case of capsules, tablets and pills, the dosage forms may also comprise buffering agents. They may optionally contain opacifying agents and can also be of a composition that they release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, optionally, in a delayed manner. Examples of embedding compositions which can be used include polymeric substances and waxes.
[0215] The present invention encompasses pharmaceutically acceptable topical formulations of inventive compounds. The term “pharmaceutically acceptable topical formulation”, as used herein, means any formulation which is pharmaceutically acceptable for intradermal administration of a compound of the invention by application of the formulation to the epidermis. In certain embodiments of the invention, the topical formulation comprises a carrier system. Pharmaceutically effective carriers include, but are not limited to, solvents (e.g., alcohols, poly alcohols, water), creams, lotions, ointments, oils, plasters, liposomes, powders, emulsions, microemulsions, and buffered solutions (e.g., hypotonic or buffered saline) or any other carrier known in the art for topically administering pharmaceuticals. A more complete listing of art-known carriers is provided by reference texts that are standard in the art, for example, Remington's Pharmaceutical Sciences, 16th Edition, 1980 and 17th Edition, 1985, both published by Mack Publishing Company, Easton, Pa., the disclosures of which are incorporated herein by reference in their entireties. In certain other embodiments, the topical formulations of the invention may comprise excipients. Any pharmaceutically acceptable excipient known in the art may be used to prepare the inventive pharmaceutically acceptable topical formulations. Examples of excipients that can be included in the topical formulations of the invention include, but are not limited to, preservatives, antioxidants, moisturizers, emollients, buffering agents, solubilizing agents, other penetration agents, skin protectants, surfactants, and propellants, and/or additional therapeutic agents used in combination to the inventive compound. Suitable preservatives include, but are not limited to, alcohols, quaternary amines, organic acids, parabens, and phenols. Suitable antioxidants include, but are not limited to, ascorbic acid and its esters, sodium bisulfite, butylated hydroxytoluene, butylated hydroxyanisole, tocopherols, and chelating agents like EDTA and citric acid. Suitable moisturizers include, but are not limited to, glycerine, sorbitol, polyethylene glycols, urea, and propylene glycol. Suitable buffering agents for use with the invention include, but are not limited to, citric, hydrochloric, and lactic acid buffers. Suitable solubilizing agents include, but are not limited to, quaternary ammonium chlorides, cyclodextrins, benzyl benzoate, lecithin, and polysorbates. Suitable skin protectants that can be used in the topical formulations of the invention include, but are not limited to, vitamin E oil, allatoin, dimethicone, glycerin, petrolatum, and zinc oxide.
[0216] In certain embodiments, the pharmaceutically acceptable topical formulations of the invention comprise at least a compound of the invention and a penetration enhancing agent. The choice of topical formulation will depend or several factors, including the condition to be treated, the physicochemical characteristics of the inventive compound and other excipients present, their stability in the formulation, available manufacturing equipment, and costs constraints. As used herein the term “penetration enhancing agent” means an agent capable of transporting a pharmacologically active compound through the stratum corneum and into the epidermis or dermis, preferably, with little or no systemic absorption. A wide variety of compounds have been evaluated as to their effectiveness in enhancing the rate of penetration of drugs through the skin. See, for example, Percutaneous Penetration Enhancers , Maibach H. I. and Smith H. E. (eds.), CRC Press, Inc., Boca Raton, Fla. (1995), which surveys the use and testing of various skin penetration enhancers, and Buyuktimkin et al., Chemical Means of Transdermal Drug Permeation Enhancement in Transdermal and Topical Drug Delivery Systems, Gosh T. K., Pfister W. R., Yum S. I. (Eds.), Interpharm Press Inc., Buffalo Grove, Ill. (1997). In certain exemplary embodiments, penetration agents for use with the invention include, but are not limited to, triglycerides (e.g., soybean oil), aloe compositions (e.g., aloe-vera gel), ethyl alcohol, isopropyl alcohol, octolyphenylpolyethylene glycol, oleic acid, polyethylene glycol 400, propylene glycol, N-decylmethylsulfoxide, fatty acid esters (e.g., isopropyl myristate, methyl laurate, glycerol monooleate, and propylene glycol monooleate), and N-methylpyrrolidone.
[0217] In certain embodiments, the compositions may be in the form of ointments, pastes, creams, lotions, gels, powders, solutions, sprays, inhalants or patches. In certain exemplary embodiments, formulations of the compositions according to the invention are creams, which may further contain saturated or unsaturated fatty acids such as stearic acid, palmitic acid, oleic acid, palmito-oleic acid, cetyl or oleyl alcohols, stearic acid being particularly preferred. Creams of the invention may also contain a non-ionic surfactant, for example, polyoxy-40-stearate. In certain embodiments, the active component is admixed under sterile conditions with a pharmaceutically acceptable carrier and any needed preservatives or buffers as may be required. Ophthalmic formulation, eardrops, and eye drops are also contemplated as being within the scope of this invention. Additionally, the present invention contemplates the use of transdermal patches, which have the added advantage of providing controlled delivery of a compound to the body. Such dosage forms are made by dissolving or dispensing the compound in the proper medium. As discussed above, penetration enhancing agents can also be used to increase the flux of the compound across the skin. The rate can be controlled by either providing a rate controlling membrane or by dispersing the compound in a polymer matrix or gel.
[0218] It will also be appreciated that the compounds and pharmaceutical compositions of the present invention can be formulated and employed in combination therapies, that is, the compounds and pharmaceutical compositions can be formulated with or administered concurrently with, prior to, or subsequent to, one or more other desired therapeutics or medical procedures. The particular combination of therapies (therapeutics or procedures) to employ in a combination regimen will take into account compatibility of the desired therapeutics and/or procedures and the desired therapeutic effect to be achieved. It will also be appreciated that the therapies employed may achieve a desired effect for the same disorder (for example, an inventive compound may be administered concurrently with another immunomodulatory agent, anticancer agent or agent useful for the treatment of psoriasis), or they may achieve different effects (e.g., control of any adverse effects).
[0219] For example, other therapies or anticancer agents that may be used in combination with the inventive compounds of the present invention include surgery, radiotherapy (in but a few examples, γ-radiation, neutron beam radiotherapy, electron beam radiotherapy, proton therapy, brachytherapy, and systemic radioactive isotopes, to name a few), endocrine therapy, biologic response modifiers (interferons, interleukins, and tumor necrosis factor (TNF) to name a few), hyperthermia and cryotherapy, agents to attenuate any adverse effects (e.g., antiemetics), and other approved chemotherapeutic drugs, including, but not limited to, alkylating drugs (mechlorethamine, chlorambucil, Cyclophosphamide, Melphalan, Ifosfamide), antimetabolites (Methotrexate), purine antagonists and pyrimidine antagonists (6-Mercaptopurine, 5-Fluorouracil, Cytarabile, Gemcitabine), spindle poisons (Vinblastine, Vincristine, Vinorelbine, Paclitaxel), podophyllotoxins (Etoposide, Irinotecan, Topotecan), antibiotics (Doxorubicin, Bleomycin, Mitomycin), nitrosoureas (Carmustine, Lomustine), inorganic ions (Cisplatin, Carboplatin), enzymes (Asparaginase), and hormones (Tamoxifen, Leuprolide, Flutamide, and Megestrol), to name a few. For a more comprehensive discussion of updated cancer therapies see, The Merck Manual , Seventeenth Ed. 1999, the entire contents of which are hereby incorporated by reference. See also the National Cancer Institute (CNI) website (www.nci.nih.gov) and the Food and Drug Administration (FDA) website for a list of the FDA approved oncology drugs (www.fda.gov/cder/cancer/druglistframe).
[0220] In certain embodiments, the pharmaceutical compositions of the present invention further comprise one or more additional therapeutically active ingredients (e.g., chemotherapeutic and/or palliative). For purposes of the invention, the term “palliative” refers to treatment that is focused on the relief of symptoms of a disease and/or side effects of a therapeutic regimen, but is not curative. For example, palliative treatment encompasses painkillers, antinausea medications and anti-sickness drugs. In addition, chemotherapy, radiotherapy and surgery can all be used palliatively (that is, to reduce symptoms without going for cure; e.g., for shrinking tumors and reducing pressure, bleeding, pain and other symptoms of cancer).
[0221] Additionally, the present invention provides pharmaceutically acceptable derivatives of the inventive compounds, and methods of treating a subject using these compounds, pharmaceutical compositions thereof, or either of these in combination with one or more additional therapeutic agents.
[0222] It will also be appreciated that certain of the compounds of present invention can exist in free form for treatment, or where appropriate, as a pharmaceutically acceptable derivative thereof. According to the present invention, a pharmaceutically acceptable derivative includes, but is not limited to, pharmaceutically acceptable salts, esters, salts of such esters, or a prodrug or other adduct or derivative of a compound of this invention which upon administration to a patient in need is capable of providing, directly or indirectly, a compound as otherwise described herein, or a metabolite or residue thereof.
Research Uses, Pharmaceutical Uses and Methods of Treatment
Research Uses
[0223] According to the present invention, the inventive compounds may be assayed in any of the available assays known in the art for identifying compounds having antiprotozoal, HDAC inhibitory, hair growth, androgen signalling inhibitory, estogen singaling inhibitory, and/or antiproliferative activity. For example, the assay may be cellular or non-cellular, in vivo or in vitro, high- or low-throughput format, etc.
[0224] Thus, in one aspect, compounds of this invention which are of particular interest include those which:
exhibit HDAC-inhibitory activity; exhibit HDAC Class I inhbitiory activity (e.g., HDAC1, HDAC2, HDAC3, HDAC8); exhibit HDAC Class II inhibitory activity (e.g., HDAC4, HDAC5, HDAC6, HDAC7, HDAC9a, HDAC9b, HDRP/HDAC9c, HDAC10); exhibit the ability to inhibit HDAC1 (Genbank Accession No. NP — 004955, incorporated herein by reference); exhibit the ability to inhibit HDAC2 (Genbank Accession No. NP — 001518, incorporated herein by reference); exhibit the ability to inhibit HDAC3 (Genbank Accession No. O15739, incorporated herein by reference); exhibit the ability to inhibit HDAC4 (Genbank Accession No. AAD29046, incorporated herein by reference); exhibit the ability to inhibit HDAC5 (Genbank Accession No. NP — 005465, incorporated herein by reference); exhibit the ability to inhibit HDAC6 (Genbank Accession No. NP — 006035, incorporated herein by reference); exhibit the ability to inhibit HDAC7 (Genbank Accession No. AAP63491, incorporated herein by reference); exhibit the ability to inhibit HDAC8 (Genbank Accession No. AAF73428, NM — 018486, AF245664, AF230097, each of which is incorporated herein by reference); exhibit the ability to inhibit HDAC9 (Genbank Accession No. NM — 178425, NM — 178423, NM — 058176, NM — 014707, BC111735, NM — 058177, each of which is incorporated herein by reference) exhibit the ability to inhibit HDAC10 (Genbank Accession No. NM — 032019, incorporated herein by reference) exhibit the ability to inhibit HDAC11 (Genbank Accession No. BC009676, incorporated herein by reference); exhibit the ability to inhibit tubulin deactetylation (TDAC); exhibit the ability to modulate the glucose-sensitive subset of genes downstream of Ure2p; exhibit cytotoxic or growth inhibitory effect on cancer cell lines maintained in vitro or in animal studies using a scientifically acceptable cancer cell xenograft model; and/or exhibit a therapeutic profile (e.g., optimum safety and curative effect) that is superior to existing chemotherapeutic agents.
[0243] As detailed in the exemplification herein, in assays to determine the ability of compounds to inhibit cancer cell growth certain inventive compounds may exhibit IC 50 values ≦100 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦50 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦40 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦30 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦20 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦10 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦7.5 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦5 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦2.5 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦1 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.75 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.5 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.25 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.1 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦75 nM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦50 nM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦25 nM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦10 nM. In other embodiments, exemplary compounds exhibited IC 50 values ≦7.5 nM. In other embodiments, exemplary compounds exhibited IC 50 values ≦5 nM.
Pharmaceutical Uses and Methods of Treatment
[0244] In general, methods of using the compounds of the present invention comprise administering to a subject in need thereof a therapeutically effective amount of a compound of the present invention. The compounds of the invention are generally inhibitors of deacetyalse activity. As discussed above, the compounds of the invention are typically inhibitors of histone deacetylases and, as such, are useful in the treatment of disorders modulated by histone deacetylases. Other deacetylase such as tubulin deacetylases may also be inhibited by the inventive compounds.
[0245] In certain embodiments, compounds of the invention are useful in the treatment of proliferative diseases (e.g., cancer, benign neoplasms, inflammatory disease, autoimmune diseases). In certain embodiments, given the esterase sensitive ester linkage in the compounds of the invention, they are particularly useful in treating skin disorders modulated by histone deacetyalses where systemic effects of the drug are to be avoided or at least minimized. This feature of the inventive compounds may allow the use of compounds normally too toxic for administration to a subject systemically. In certain embodiments, these skin disorders are proliferative disorders. For example, the inventive compounds are particularly useful in the treatment of skin cancer and benign skin tumors. In certain embodiments, the compounds are useful in the treatment of cutaneous T-cell lymphoma. In certain embodiments, the compounds are useful in the treatment of neurofibromatosis. Accordingly, in yet another aspect, according to the methods of treatment of the present invention, tumor cells are killed, or their growth is inhibited by contacting said tumor cells with an inventive compound or composition, as described herein. In other embodiments, the compounds are useful in treating inflammatory diseases of the skin such as psoriasis or dermatitis. In other embodiments, the compounds are useful in the treatment or prevention of hair loss. In certain embodiments, the compounds are useful in the treatment of diseases associated with skin pigmentation. For example, the compounds may be used to prevent the hyperpigmentation of skin.
[0246] Thus, in another aspect of the invention, methods for the treatment of cancer are provided comprising administering a therapeutically effective amount of an inventive compound, as described herein, to a subject in need thereof. In certain embodiments, a method for the treatment of cancer is provided comprising administering a therapeutically effective amount of an inventive compound, or a pharmaceutical composition comprising an inventive compound to a subject in need thereof, in such amounts and for such time as is necessary to achieve the desired result. Preferably, the inventive compounds is administered topically. In certain embodiments of the present invention a “therapeutically effective amount” of the inventive compound or pharmaceutical composition is that amount effective for killing or inhibiting the growth of tumor cells. The compounds and compositions, according to the method of the present invention, may be administered using any amount and any route of administration effective for killing or inhibiting the growth of tumor cells. Thus, the expression “amount effective to kill or inhibit the growth of tumor cells,” as used herein, refers to a sufficient amount of agent to kill or inhibit the growth of tumor cells. The exact amount required will vary from subject to subject, depending on the species, age, and general condition of the subject, the severity of the infection, the particular anticancer agent, its mode of administration, and the like. In certain embodiments of the present invention a “therapeutically effective amount” of the inventive compound or pharmaceutical composition is that amount effective for inhibiting deacetylase activity (in particular, HDAC activity) in skin cells. In certain embodiments of the present invention a “therapeutically effective amount” of the inventive compound or pharmaceutical composition is that amount effective to kill or inhibit the growth of skin cells.
[0247] In certain embodiments, the method involves the administration of a therapeutically effective amount of the compound or a pharmaceutically acceptable derivative thereof to a subject (including, but not limited to a human or animal) in need of it. In certain embodiments, the inventive compounds as useful for the treatment of cancer (including, but not limited to, glioblastoma, retinoblastoma, breast cancer, cervical cancer, colon and rectal cancer, leukemia, lymphoma, lung cancer (including, but not limited to small cell lung cancer), melanoma and/or skin cancer, multiple myeloma, non-Hodgkin's lymphoma, ovarian cancer, pancreatic cancer, prostate cancer and gastric cancer, bladder cancer, uterine cancer, kidney cancer, testicular cancer, stomach cancer, brain cancer, liver cancer, or esophageal cancer).
[0248] In certain embodiments, the inventive anticancer agents are useful in the treatment of cancers and other proliferative disorders, including, but not limited to breast cancer, cervical cancer, colon and rectal cancer, leukemia, lung cancer, melanoma, multiple myeloma, non-Hodgkin's lymphoma, ovarian cancer, pancreatic cancer, prostate cancer, and gastric cancer, to name a few. In certain embodiments, the inventive anticancer agents are active against leukemia cells and melanoma cells, and thus are useful for the treatment of leukemias (e.g., myeloid, lymphocytic, myelocytic and lymphoblastic leukemias) and malignant melanomas. In still other embodiments, the inventive anticancer agents are active against solid tumors.
[0249] In certain embodiments, the inventive compounds also find use in the prevention of restenosis of blood vessels subject to traumas such as angioplasty and stenting. For example, it is contemplated that the compounds of the invention will be useful as a coating for implanted medical devices, such as tubings, shunts, catheters, artificial implants, pins, electrical implants such as pacemakers, and especially for arterial or venous stents, including balloon-expandable stents. In certain embodiments inventive compounds may be bound to an implantable medical device, or alternatively, may be passively adsorbed to the surface of the implantable device. In certain other embodiments, the inventive compounds may be formulated to be contained within, or, adapted to release by a surgical or medical device or implant, such as, for example, stents, sutures, indwelling catheters, prosthesis, and the like. For example, drugs having antiproliferative and anti-inflammatory activities have been evaluated as stent coatings, and have shown promise in preventing retenosis (See, for example, Presbitero P. et al., “Drug eluting stents do they make the difference?”, Minerva Cardioangiol, 2002, 50(5):431-442; Ruygrok P. N. et al., “Rapamycin in cardiovascular medicine”, Intern. Med. J., 2003, 33(3):103-109; and Marx S. O. et al., “Bench to bedside: the development of rapamycin and its application to stent restenosis”, Circulation, 2001, 104(8):852-855, each of these references is incorporated herein by reference in its entirety). Accordingly, without wishing to be bound to any particular theory, Applicant proposes that inventive compounds having antiproliferative effects can be used as stent coatings and/or in stent drug delivery devices, inter alia for the prevention of restenosis or reduction of restenosis rate. Suitable coatings and the general preparation of coated implantable devices are described in U.S. Pat. Nos. 6,099,562; 5,886,026; and 5,304,121. The coatings are typically biocompatible polymeric materials such as a hydrogel polymer, polymethyldisiloxane, polycaprolactone, polyethylene glycol, polylactic acid, ethylene vinyl acetate, and mixtures thereof. The coatings may optionally be further covered by a suitable topcoat of fluorosilicone, polysaccarides, polyethylene glycol, phospholipids or combinations thereof to impart controlled release characteristics in the composition. A variety of compositions and methods related to stent coating and/or local stent drug delivery for preventing restenosis are known in the art (see, for example, U.S. Pat. Nos. 6,517,889; 6,273,913; 6,258,121; 6,251,136; 6,248,127; 6,231,600; 6,203,551; 6,153,252; 6,071,305; 5,891,507; 5,837,313 and published U.S. patent application No.: US2001/0027340, each of which is incorporated herein by reference in its entirety). For example, stents may be coated with polymer-drug conjugates by dipping the stent in polymer-drug solution or spraying the stent with such a solution. In certain embodiment, suitable materials for the implantable device include biocompatible and nontoxic materials, and may be chosen from the metals such as nickel-titanium alloys, steel, or biocompatible polymers, hydrogels, polyurethanes, polyethylenes, ethylenevinyl acetate copolymers, etc. In certain embodiments, the inventive compound is coated onto a stent for insertion into an artery or vein following balloon angioplasty.
[0250] The compounds of this invention or pharmaceutically acceptable compositions thereof may also be incorporated into compositions for coating implantable medical devices, such as prostheses, artificial valves, vascular grafts, stents and catheters. Accordingly, the present invention, in another aspect, includes a composition for coating an implantable device comprising a compound of the present invention as described generally above, and in classes and subclasses herein, and a carrier suitable for coating said implantable device. In still another aspect, the present invention includes an implantable device coated with a composition comprising a compound of the present invention as described generally above, and in classes and subclasses herein, and a carrier suitable for coating said implantable device.
[0251] Within other aspects of the present invention, methods are provided for expanding the lumen of a body passageway, comprising inserting a stent into the passageway, the stent having a generally tubular structure, the surface of the structure being coated with (or otherwise adapted to release) an inventive compound or composition, such that the passageway is expanded. In certain embodiments, the lumen of a body passageway is expanded in order to eliminate a biliary, gastrointestinal, esophageal, tracheal/bronchial, urethral and/or vascular obstruction.
[0252] Methods for eliminating biliary, gastrointestinal, esophageal, tracheal/bronchial, urethral and/or vascular obstructions using stents are known in the art. The skilled practitioner will know how to adapt these methods in practicing the present invention. For example, guidance can be found in U.S. Patent Application Publication No.: 2003/0004209 in paragraphs [0146]-[0155], which paragraphs are hereby incorporated herein by reference.
[0253] Another aspect of the invention relates to a method for inhibiting the growth of multidrug resistant cells in a biological sample or a patient, which method comprises administering to the patient, or contacting said biological sample with a compound of formula I or a composition comprising said compound.
[0254] Additionally, the present invention provides pharmaceutically acceptable derivatives of the inventive compounds, and methods of treating a subject using these compounds, pharmaceutical compositions thereof, or either of these in combination with one or more additional therapeutic agents.
[0255] Another aspect of the invention relates to a method of treating or lessening the severity of a disease or condition associated with a proliferation disorder in a patient, said method comprising a step of administering to said patient, a compound of formula I or a composition comprising said compound.
[0256] It will be appreciated that the compounds and compositions, according to the method of the present invention, may be administered using any amount and any route of administration effective for the treatment of cancer and/or disorders associated with cell hyperproliferation. For example, when using the inventive compounds for the treatment of cancer, the expression “effective amount” as used herein, refers to a sufficient amount of agent to inhibit cell proliferation, or refers to a sufficient amount to reduce the effects of cancer. The exact amount required will vary from subject to subject, depending on the species, age, and general condition of the subject, the severity of the diseases, the particular anticancer agent, its mode of administration, and the like.
[0257] The compounds of the invention are preferably formulated in dosage unit form for ease of administration and uniformity of dosage. The expression “dosage unit form” as used herein refers to a physically discrete unit of therapeutic agent appropriate for the patient to be treated. It will be understood, however, that the total daily usage of the compounds and compositions of the present invention will be decided by the attending physician within the scope of sound medical judgment. The specific therapeutically effective dose level for any particular patient or organism will depend upon a variety of factors including the disorder being treated and the severity of the disorder; the activity of the specific compound employed; the specific composition employed; the age, body weight, general health, sex and diet of the patient; the time of administration, route of administration, and rate of excretion of the specific compound employed; the duration of the treatment; drugs used in combination or coincidental with the specific compound employed; and like factors well known in the medical arts (see, for example, Goodman and Gilman's, “The Pharmacological Basis of Therapeutics”, Tenth Edition, A. Gilman, J. Hardman and L. Limbird, eds., McGraw-Hill Press, 155-173, 2001, which is incorporated herein by reference in its entirety).
[0258] Another aspect of the invention relates to a method for inhibiting histone deacetylase activity in a biological sample or a patient, which method comprises administering to the patient, or contacting said biological sample with an inventive compound or a composition comprising said compound.
[0259] Furthermore, after formulation with an appropriate pharmaceutically acceptable carrier in a desired dosage, the pharmaceutical compositions of this invention can be administered to humans and other animals orally, rectally, parenterally, intracisternally, intravaginally, intraperitoneally, topically (as by powders, ointments, creams or drops), bucally, as an oral or nasal spray, or the like, depending on the severity of the infection being treated. In certain embodiments, the compounds of the invention may be administered at dosage levels of about 0.001 mg/kg to about 50 mg/kg, from about 0.01 mg/kg to about 25 mg/kg, or from about 0.1 mg/kg to about 10 mg/kg of subject body weight per day, one or more times a day, to obtain the desired therapeutic effect. It will also be appreciated that dosages smaller than 0.001 mg/kg or greater than 50 mg/kg (for example 50-100 mg/kg) can be administered to a subject. In certain embodiments, compounds are administered orally or parenterally.
Treatment Kit
[0260] In other embodiments, the present invention relates to a kit for conveniently and effectively carrying out the methods in accordance with the present invention. In general, the pharmaceutical pack or kit comprises one or more containers filled with one or more of the ingredients of the pharmaceutical compositions of the invention. Such kits are especially suited for the topical delivery of the inventive compounds. Optionally associated with such container(s) can be a notice in the form prescribed by a governmental agency regulating the manufacture, use or sale of pharmaceutical products, which notice reflects approval by the agency of manufacture, use or sale for human administration.
EQUIVALENTS
[0261] The representative examples which follow are intended to help illustrate the invention, and are not intended to, nor should they be construed to, limit the scope of the invention. Indeed, various modifications of the invention and many further embodiments thereof, in addition to those shown and described herein, will become apparent to those skilled in the art from the full contents of this document, including the examples which follow and the references to the scientific and patent literature cited herein. It should further be appreciated that, unless otherwise indicated, the entire contents of each of the references cited herein are incorporated herein by reference to help illustrate the state of the art. The following examples contain important additional information, exemplification and guidance which can be adapted to the practice of this invention in its various embodiments and the equivalents thereof.
[0262] These and other aspects of the present invention will be further appreciated upon consideration of the following Examples, which are intended to illustrate certain particular embodiments of the invention but are not intended to limit its scope, as defined by the claims.
EXAMPLES
[0263] The compounds of this invention and their preparation can be understood further by the examples that illustrate some of the processes by which these compounds are prepared or used. It will be appreciated, however, that these examples do not limit the invention. Variations of the invention, now known or further developed, are considered to fall within the scope of the present invention as described herein and as hereinafter claimed.
General Description of Synthetic Methods
[0264] The various references cited herein provide helpful background information on preparing compounds similar to the inventive compounds described herein or relevant intermediates, as well as information on formulation, uses, and administration of such compounds which may be of interest.
[0265] Moreover, the practitioner is directed to the specific guidance and examples provided in this document relating to various exemplary compounds and intermediates thereof.
[0266] The compounds of this invention and their preparation can be understood further by the examples that illustrate some of the processes by which these compounds are prepared or used. It will be appreciated, however, that these examples do not limit the invention. Variations of the invention, now known or further developed, are considered to fall within the scope of the present invention as described herein and as hereinafter claimed.
[0267] According to the present invention, any available techniques can be used to make or prepare the inventive compounds or compositions including them. For example, a variety of a variety combinatorial techniques, parallel synthesis and/or solid phase synthetic methods such as those discussed in detail below may be used. Alternatively or additionally, the inventive compounds may be prepared using any of a variety of solution phase synthetic methods known in the art.
[0268] It will be appreciated as described below, that a variety of inventive compounds can be synthesized according to the methods described herein. The starting materials and reagents used in preparing these compounds are either available from commercial suppliers such as Aldrich Chemical Company (Milwaukee, Wis.), Bachem (Torrance, Calif.), Sigma (St. Louis, Mo.), or are prepared by methods well known to a person of ordinary skill in the art following procedures described in such references as Fieser and Fieser 1991, “Reagents for Organic Synthesis”, vols 1-17, John Wiley and Sons, New York, N.Y., 1991; Rodd 1989 “Chemistry of Carbon Compounds”, vols. 1-5 and supps, Elsevier Science Publishers, 1989; “Organic Reactions”, vols 1-40, John Wiley and Sons, New York, N.Y., 1991; March 2001, “Advanced Organic Chemistry”, 5th ed. John Wiley and Sons, New York, N.Y.; and Larock 1990, “Comprehensive Organic Transformations: A Guide to Functional Group Preparations”, 2 nd ed. VCH Publishers. These schemes are merely illustrative of some methods by which the compounds of this invention can be synthesized, and various modifications to these schemes can be made and will be suggested to a person of ordinary skill in the art having regard to this disclosure.
[0269] The starting materials, intermediates, and compounds of this invention may be isolated and purified using conventional techniques, including filtration, distillation, crystallization, chromatography, and the like. They may be characterized using conventional methods, including physical constants and spectral data.
Synthesis of Exemplary Compounds
[0270] Unless otherwise indicated, starting materials are either commercially available or readily accessibly through laboratory synthesis by anyone reasonably familiar with the art. Described generally below, are procedures and general guidance for the synthesis of compounds as described generally and in subclasses and species herein.
Example 1
Synthesis of SAHP for Use as HDAC Inhibitors
[0271]
[0272] Described below is the synthesis of a SAHP, an ester-containing analog of SAHA (as shown in FIG. 12 ).
[0273] 3.86 g (24.2 mmol) O-benzylhydroxylamine hydrochloride and 13 mL (75 mmol) diisopropylethylamine were dissolved in 100 mL methylene chloride and cooled to 0° C. 5.00 g (24.2 mmol) methyl 8-chloro-8-oxooctanoate were dissolved in 10 mL methylene chloride and slowly added to the reaction mixture. The reaction mixture was stirred for 1 h at 0° C. and warmed to room temperature. After stirring for additional 12 h, 300 mL 0.5N HCl were added. The organic layer was separated and washed with brine and sat. bicarb. After drying over sodium sulfate, the organic solvent was removed under reduced pressure and the crude product was purified on silica (methylene chloride/methanol 12:1, rf=0.7) to yield the desired compound 1 as white solid (6.3 g, 89%).
[0274] 6.3 g (21.5 mmol) methyl ester 1 were dissolved in 200 mL methanol, followed by the addition of 50 mL 2N LiOH. The reaction mixture was heated to reflux for 1 h and cooled to room temperature. After addition of 100 mL 1N HCl and 200 mL water, the reaction mixture was extracted three times with 150 mL ethyl acetate. The combined organic layers were dried over sodium sulfate and the solvent was removed under reduced pressure to afford the carboxylic acid 2 pure and in quantitative yields as white solid
[0275] 140 mg carboxylic acid 2 (5 mmol), 56.5 mg phenol (6 mmol) and 113 mg dicyclohexylcarbodiimide (5.5 mmol) are mixed followed by the addition of 10 mL methylene chloride and 30 mg 4-Dimethylaminopyridine. The reaction mixture was stirred for 2 h and applied crude on a silica column followed by elution with haxanes/ethyl acetate (10-100% ethyl acetate). The desired phenol ester 3 was obtained as a white solid in 87% yield (155 mg).
[0276] 80 mg phenol ester 3 (0.225 mmol) are dissolved in methanol. A catalytical amount of palladium on charcoal (10%) was as added and hydrogen was bubbled through the reaction mixture. After 1 h hour no starting material was detectable by TLC. The reaction mixture was filtered through Celite and the solvent was removed under reduced pressure to yield the free hydroxamte SAHP as brownish solid in quantitative yields (59 mg). The crude product did not show any impurities as judged by LCMS and NMR.
Example 2
Biological Assay Procedures
[0277] Cell Culture and Transfections.
[0278] TAg-Jurkat cells were transfected by electroporation with 5 μg of FLAG-epitope-tagged pBJ5 constructs for expression of recombinant proteins. Cells were harvested 48 h posttransfection.
[0279] HDAC Assays.
[0280] [ 3 H]Acetate-incorporated histones were isolated from butyrate-treated HeLa cells by hydroxyapatite chromatography (as described in Tong, et al. Nature 1997, 395, 917-921.) Immunoprecipitates were incubated with 1.4 μg (10,000 dpm) histones for 3 h at 37° C. HDAC activity was determined by scintillation counting of the ethyl acetate-soluble [ 3 H]acetic acid (as described in Taunton, et al., Science 1996, 272, 408-411). Compounds were added in DMSO such that final assay concentrations were 1% DMSO. IC50s were calculated using Prism 3.0 software. Curve fitting was done without constraints using the program's Sigmoidal-Dose Response parameters. All data points were acquired in duplicate and IC50s are calculated from the composite results of at least two separate experiments.
Example 3
In Vivo Activity
[0281] Although a variety of methods can be utilized, one exemplary method by which the in vivo activity of the inventive compounds is determined is by subcutaneously transplanting a desired tumor mass in mice. Drug treatment is then initiated when tumor mass reaches approximately 100 mm 3 after transplantation of the tumor mass. A suitable composition, as described in more detail above, is then administered to the mice, preferably in saline and also preferably administered once a day at doses of 5, 10 and 25 mg/kg, although it will be appreciated that other doses can also be administered. Body weight and tumor size are then measured daily and changes in percent ratio to initial values are plotted. In cases where the transplanted tumor ulcerates, the weight loss exceeds 25-30% of control weight loss, the tumor weight reaches 10% of the body weight of the cancer-bearing mouse, or the cancer-bearing mouse is dying, the animal is sacrificed in accordance with guidelines for animal welfare.
Example 4
Assays to Identify Potential Antiprotozoal Compounds by Inhibition of Histone Deacetylase
[0282] As detailed in U.S. Pat. No. 6,068,987, inhibitors of histone deacetylases may also be useful as antiprotozoal agents. Described therein are assays for histone deacetylase activity and inhibition and describe a variety of known protozoal diseases. The entire contents of U.S. Pat. No. 6,068,987 are hereby incorporated by reference. | In recognition of the need to develop novel therapeutic agents, the present invention provides novel histone deacetylase inhibitors. These compounds include an ester bond making them sensitive to deactivation by esterases. Therefore, these compounds are particularly useful in the treatment of skin disorders. When the compounds reaches the bloodstream, an esterase or an enzyme with esterase activity cleaves the compound into biologically inactive fragments or fragments with greatly reduced activity Ideally these degradation products exhibit a short serum and/or systemic half-life and are eliminated rapidly. These compounds and pharmaceutical compositions thereof are particularly useful in treating cutaneous T-cell lymphoma, neurofibromatosis, psoriasis, hair loss, skin pigmentation, and dermatitis, for example. The present invention also provides methods for preparing compounds of the invention and intermediates thereto. | 2 |
TECHNICAL FIELD
[0001] The invention relates generally to security systems and, more particularly, to a security system concerning the validation of received messages.
BACKGROUND
[0002] In conventional processing systems, storage space in computer systems can be a concern. In computer systems implementing security protocols, the algorithm for security can occupy less space than the constants used to implement the security. For instance, the chain security algorithm can be implemented in less than 200 bytes, while 1024 publicly-known bytes are needed for the constants to run the chain algorithm. In the chain algorithm, the source and target systems both know and utilize the same secret key. Similarly, an algorithm such as the Secure Hash Algorithm (SHA) can be implemented in 512 bits, but needs 80 64-bit publicly known constants to make it work properly, although the source and target systems both know and utilize the same secret key in addition to the publicly known constants.
[0003] However, space constraints can create a problem with the target computer where the algorithms are to be implemented. The target computer might have memory space to store the algorithm and the secret key, but does not have all of the memory space necessary to store the publicly known constants. Increasing the size of the memory may not be a viable option, due to cost of implementation.
[0004] Therefore, there is a need for a method and a system for a target computer to process the publicly known security constants in a manner that accommodates the target computer's memory constraints.
SUMMARY OF THE INVENTION
[0005] The present invention provides for authenticating a message. A security function is performed upon the message. The message is sent to a target. The output of the security function is sent to the target. At least one publicly known constant is sent to the target. The received message is authenticated as a function of at least a shared key, the received publicly known constants, the security function, the received message, and the output of the security function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following Detailed Description taken in conjunction with the accompanying drawings, in which:
[0007] FIG. 1 schematically depicts a system for transferring a message, publicly known constants, and a message authentication code (MAC); and
[0008] FIG. 2 schematically depicts a system for transferring a message, publicly known constants, and a CBC-MAC value.
DETAILED DESCRIPTION
[0009] In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail. Additionally, for the most part, details concerning network communications, electromagnetic signaling techniques, and the like, have been omitted inasmuch as such details are not considered necessary to obtain a complete understanding of the present invention, and are considered to be within the understanding of persons of ordinary skill in the relevant art.
[0010] In the remainder of this description, a processing unit (PU) may be a sole processor of computations in a device. In such a situation, the PU is typically referred to as an MPU (main processing unit). The processing unit may also be one of many processing units that share the computational load according to some methodology or algorithm developed for a given computational device. For the remainder of this description, all references to processors shall use the term MPU whether the MPU is the sole computational element in the device or whether the MPU is sharing the computational element with other MPUs, unless otherwise indicated.
[0011] It is further noted that, unless indicated otherwise, all functions described herein may be performed in either hardware or software, or some combination thereof. In a preferred embodiment, however, the functions are performed by a processor, such as a computer or an electronic data processor, in accordance with code, such as computer program code, software, and/or integrated circuits that are coded to perform such functions, unless indicated otherwise.
[0012] Turning now to FIG. 1 , disclosed is a computer security system 100 . In FIG. 1 , illustrated is a source computer 110 and a target computer 120 communicating across an unsecured medium 115 . The source computer 110 and the target computer 120 share the same secret key 125 . Generally, the system 100 sends publicly known constants for a security algorithm from the source computer 110 to the target computer 120 , thereby allowing for the target computer 120 not to have these constants stored within the target computer while still allowing the target computer 120 to validate received messages. For example, SHA-512 has eighty 64-bit publicly known constants which are the first 64 bits of the fractional parts of the cube roots of the first eighty prime numbers. In the system 100 , the shared key 125 , the security algorithm 127 , the messages and the publicly known constants 129 are stored in memory of the source computer 110 , or are otherwise generated in a processor of the source computer 110 . The shared key 125 , the security algorithm 127 are stored in memory of the source computer 110 , or are otherwise generated in a processor of the target computer 120 .
[0013] In FIG. 1 , source computer 110 has a message it selects to send to target computer 120 over the insecure medium 115 in a data transfer 130 . The target computer 120 has the security algorithm 127 and the secret key 125 , but not the publicly known constants 129 necessary for proper use of the security algorithm. Therefore, the source 110 also sends the publicly known security constants 129 . This occurs as follows, and is done in associated with sending security-type information concerning the message itself to the target computer 120 over the one-way unsecured medium 115 in the data transfer 115 .
[0014] In one embodiment of the use of the security algorithm 127 in the system 100 , the message from the source is hashed, a form of the security algorithm 127 , using the secret key 125 and the publicly known constants 129 . The hashing creates a message authentication code (MAC) from the message, the secret key 125 , and the publicly known constants 129 . In other words, MAC is equal to a Hash function of the secret key 125 , public constants 127 , and the message to be hashed. The hash algorithm can be a cryptographically secure one-way hash function, such as the SHA, for the Secure Hash Algorithm (SHA).
[0015] After performing the security function, the source computer 110 then sends the Message (perhaps encrypted), the MAC value, or some other security value and the publicly known constants 129 used in the hash to the target computer 120 over the unsecured medium 115 in the data transfer 130 . The target computer 120 receives the computed MAC or other security code, the message and the publicly known constants 129 .
[0016] The target computer 120 then recomputes its own MAC value, using its secret key 125 , the received publicly-known constants 129 from the source computer 110 , the received message, the shared key 125 , and the hash function or other security algorithm 127 . If the MAC the target computer 120 calculates for the received message using the received publicly known constants 129 and the security algorithm 127 and the secret key 125 equals the MAC the target computer 120 received from the source 110 , then the message and the constants are authentic.
[0017] If the MAC calculated by the target computer 120 and the MAC received by the source computer 110 do not equal, either the message or the publicly known constants 129 have been changed, and therefore the Message is not validated as authentic.
[0018] Note that an unauthorized person could read or modify the Message, the MAC or the hash constants when these values are conveyed over the one-way unsecured medium 115 and try to “fool” the target computer 120 as to the authenticity of the communication. However, the MAC is a function of the message, the publicly known constants 129 constants, and the secret key 125 , and the security algorithm 127 . As the unauthorized will not know what the secret key 127 is, it is highly unlikely that an adversary would be able to properly change the message and the publicly known constants 129 and the message to pass authentication by the target computer 120 .
[0019] Turning now to FIG. 2 , disclosed is a computer security system 200 that employs encryption for the sent message for added security for the message. In FIG. 2 , a source computer 210 and a target computer 220 communicating across an unsecured medium 215 . The source computer 210 and the target computer 220 share the same secret key 225 . Generally, the system 200 sends publicly known constants for a security algorithm from the source computer 210 to the target computer 220 , thereby allowing for the target computer 220 not to have these constants stored within the target computer while still allowing the target computer 220 to validate received messages.
[0020] In the system 200 , the shared key 225 , the security algorithm 227 , the messages and the publicly known constants 129 are stored in memory of the source computer 210 , or are otherwise generated in a processor of the source computer 210 . The shared key 225 , and the security algorithm 227 are stored in memory of the target computer 210 , or are otherwise generated in a processor of the target computer 220 .
[0021] The target computer 220 performs an optional decryption upon the message from the source computer 110 , as well as a validation of the received message. In one embodiment, the source computer 210 uses CBM-MAC (cipher block chaining message authentication code) as its security algorithm 227 on the message before sending the encrypted message and the publicly known constants 229 to the target computer 220 .
[0022] When performing the encryption, the source computer 220 can perform the encryption substantially as follows, although those of ordinary skill in the art, other encryption algorithms are within the scope of the present Application.
[0023] First, the message to be sent is broken down into a series of blocks M=M 1 , M 2 . . . M n . Then, values useful for running the security algorithm 127 are generated. First, Y 1 =Enc(M 1 ) In other words, the value Y 1 is created from the encryption of M 1 , using the secret key value 225 , the security algorithm 227 and the publicly known constants 229 .
[0024] Furthermore, there are other Y values created, Y 2 , Y 3 , Y 4 . . . Y n . These other values are created as follows. Y i =Enc(M i XOR Y i−1 ). In other words, the Y i value is the encryption of the Mi value “Exclusive-Or”ed with the Y i−1 value. The Y i value is then used when determining the Y i+1 value, and so on, until the last Mi value is encrypted in Y n . Yn is then the CBC-MAC value.
[0025] The source computer 210 then sends the message, the CBC-MAC value and the publicly known constants 229 to the target computer 220 . The target computer then performs its own CBC-MAC check using the received publicly known constants 229 , the secret key 225 , and the received message. The message can be encrypted or unencrypted. Both options are allowed. If the computed CBC-MAC is the same as the received CBC-MAC, then the target 220 determines that the message and publicly known constants 220 are authentic, in other words, not modified. The target 220 uses the shared key 220 , the security algorithm 227 , and the received message, publicly known constants 229 and the CBC-MAC value for computing its own CBC-MAC.
[0026] Although the CBC-MAC, the message itself, and/or the constants could be altered during transmission over the insecure media, it is highly unlikely that an adversary would be able to successfully make the correct changes to the CBC-MAC, the constants and/or the message, because the adversary would not know the secret key to do this properly. Note that while the message itself can be read in the unsecured environment, it could not be altered. For some kinds of security applications, this is sufficient.
[0027] It is understood that the present invention can take many forms and embodiments. Accordingly, several variations may be made in the foregoing without departing from the spirit or the scope of the invention. The capabilities outlined herein allow for the possibility of a variety of programming models. This disclosure should not be read as preferring any particular programming model, but is instead directed to the underlying mechanisms on which these programming models can be built.
[0028] Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | The present invention provides for authenticating a message. A security function is performed upon the message. The message is sent to a target. The output of the security function is sent to the target. At least one publicly known constant is sent to the target. The received message is authenticated as a function of at least a shared key, the received publicly known constants, the security function, the received message, and the output of the security function. If the output of the security function received by the target is the same as the output generated as a function of at least the received message, the received publicly known constants, the security function, and the shared key, neither the message nor the constants have been altered. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation application of PCT Application Ser. No. PCT/IB2014/065113, filed Oct. 7, 2014, which claims priority to Great Britain Application Ser. No. 1317711.8, filed Oct. 7, 2013.
FIELD OF THE INVENTION
[0002] This invention relates to a treatment device, particularly but not exclusively for the treatment of adipose tissue, a treatment apparatus and a method of operating the treatment device.
BACKGROUND OF THE INVENTION
[0003] A known aesthetic body shaping technique is the use of ultrasound to treat fat tissue layers below the skin. A problem with known systems is that of directing or concentrating the ultrasonic energy to only affect or treat the desired volume of tissue, i.e. the fat cells, without affecting other regions of the skin. A related problem is that, for ultrasonic transducers, the power transmitted falls away with distance from the transducer. This can be addressed using high-intensity focussed ultrasound, but this is a relatively complex solution. An example of an alternative device is known from US2012/0277587 showing a treatment device which has a cavity into which skin surface tissue is drawn by applying a vacuum. The treatment device comprises two parallel ultrasonic transducers which direct energy into the tissue between them. To provide an effective treatment volume between a pair of transducers however, the power has to be raised sufficiently such that surrounding tissue may be affected and damaged. Circular transducers are also known to provide a strong focal point for the ultrasound but the focal point is relatively small and the transducers are expensive.
SUMMARY OF THE INVENTION
[0004] According a first aspect of the invention there is provided a treatment device comprising a cavity to receive body tissue, the cavity comprising a side wall, a closed end wall and an opening to admit tissue, and at least four ultrasonic transducers disposed to transmit ultrasound into the cavity.
[0005] The ultrasonic transducers may be disposed such that the beams generated by the transducers overlap to define a treatment volume within the cavity.
[0006] The treatment volume may be spaced from the end wall.
[0007] The plurality of ultrasonic transducers may comprise an opposed pair of ultrasonic transducers.
[0008] The treatment device may comprise six ultrasonic transducers arranged in a hexagonal configuration.
[0009] The treatment device may comprise three opposed pairs of ultrasonic transducers arranged in a regular hexagonal configuration.
[0010] The side wall may comprise internal walls arranged in a hexagonal configuration and the ultrasonic transducers may be disposed within the internal walls.
[0011] The treatment device according may comprise a plurality of radio frequency electrodes disposed around the cavity and disposed to transmit radio frequency energy into the cavity
[0012] The radio frequency electrodes may be disposed in the side wall.
[0013] The radio frequency electrodes may be disposed closer to the end wall than the ultrasonic transducers.
[0014] The treatment device may comprise tissue engagement means to draw tissue into the cavity.
[0015] The tissue engagement means may comprise a connection from the cavity for connection to a low-pressure source.
[0016] An auxiliary ultrasonic transducer may be disposed in the end wall of the cavity.
[0017] Additional treatment elements comprising light sources may be disposed in the end wall of the cavity.
[0018] An auxiliary radiofrequency electrode may be disposed in an upper wall of the cavity.
[0019] The treatment device may comprise a TENS electrode to provide pain relief.
[0020] According to a second aspect of the invention there is provided a treatment apparatus comprising a treatment device according to any one of the preceding claims and a control apparatus to control the ultrasonic transducers and the radiofrequency electrode.
[0021] According to a third aspect of the invention there is provided a method of operating a treatment device according to the first or second aspects of the invention, the method comprising receiving body tissue in the cavity and operating the ultrasonic transducers to transmit ultrasound into the cavity.
[0022] The method may comprise operating the ultrasonic transducers with a frequency in the range 200 kHz to 4 MHz, preferably 1 MHz to 3 MHz and most preferably 1.5 to 2.5 MHz,
[0023] The method may comprise operating the ultrasonic transducers for durations in the range 0.1 seconds to 20 minutes, preferably 0.5 to 10 minutes and most preferably 1 to 6 minutes.
[0024] The method may comprise operating the ultrasonic transducers such that the energy transmitted into the tissue is in the range 50 to 700 J cm−3, preferably in the range 75 to 250 J cm−3 and most preferably 100 to 250 J cm−3.
[0025] The method may comprise operating the transducers with duty cycle in the range 8 to 100%, preferably in the range 16.6 to 100% and most preferably in the range 33.33 to 100%.
[0026] The method may comprise performing a cooling cycle between operation of the ultrasonic transducers.
[0027] Where the treatment device comprises RF electrodes, the method may comprise operating the RF electrodes with a frequency in the range 100 to 4000 kHz, preferably 300 to 2000 kHz and most preferably 500 to 1000 kHz.
[0028] The method may comprise operating the RF electrodes for durations in the range 10 to 5000 ms, preferably 30 to 2000 ms and most preferably 50 to 750 ms.
[0029] The RF power may be in the range 5 to 100 W, preferably in the range 10 to 60 W and most preferably 20 to 40 W.
[0030] The method may comprise operating the RF electrodes with a duty cycle in the range 8 to 100%, preferably in the range 16.6 to 100% and most preferably in the range 33.33 to 100%.
[0031] Where the treatment device comprises a TENS electrode, the method may further comprise supplying an electrical signal to the TENS electrode.
[0032] The method may comprise operating the ultrasonic transducers to generate a generally even energy distribution in body tissue in the cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Embodiments of the present invention are described by way of example only with reference to the accompanying drawings, wherein;
[0034] FIG. 1 is a perspective view of the underside of a treatment device embodying the present invention.
[0035] FIG. 2 is a perspective view of the upper side of the device of FIG. 1 .
[0036] FIG. 3 is a plan view of the top of the device of FIG. 1 and FIG. 2 ,
[0037] FIG. 4 is a cross-section on line 4 - 4 of FIG. 3 .
[0038] FIG. 5 a and FIG. 5 b are graphs showing the energy distribution of pairs of opposed ultrasonic transducers.
[0039] FIG. 6 is a diagrammatic illustration of the ultrasonic beams generated by the device of FIG. 1 .
[0040] FIG. 7 is a diagrammatic illustration of the device of FIG. 1 in a first mode of operation.
[0041] FIG. 8 is a diagrammatic illustration of the device of FIG. 1 in a second mode of operation.
[0042] FIG. 9 is a graph showing temperatures of tissue layers during cooling and heating, and
[0043] FIG. 10 is a perspective view similar to FIG. 1 showing additional treatment elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
[0045] 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 the arrangement of the components set forth in the following description or illustrated n the drawings. The invention is applicable to other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
[0046] Referring now to FIG. 1 to FIG. 4 , a treatment device embodied in the present invention is generally shown at 10 . The device comprises a generally toroidal upper element 11 , a generally circular lower element 12 and a contact part 13 . The upper element 11 and lower element 12 are joined by bolts 14 passing through apertures 15 in the upper element 11 and received in threaded bores 16 in the lower element 12 . The contact part 13 is connected to the lower element 12 by screws 17 passing through apertures in an annular outer flange 18 of the contact part 13 .
[0047] The contact part 13 has a generally annular contact surface 20 , around the periphery of a cavity 21 . The cavity 21 comprises a closed cavity defined by an inwardly directly side wall 22 of the contact part 13 which extends perpendicularly or at an angle to the contact surface 20 . The closed end wall 23 of the cavity 21 is defined by a shaped surface of the lower element 12 . In the present example, the inner face 23 has a generally flat centre surface 24 joined to the wall 22 by angled surfaces 25 . As best seen in FIG. 1 , a central portion 26 of the flat face 24 is formed as a circular recess. In this example the side wall 22 is generally hexagonal and made of six internal walls, defining a cavity 21 which is a regular hexagon
[0048] A tissue engagement means is generally shown at 30 to draw tissue into the cavity 21 . In the present example, this is performed by suction. A central part of the lower element 12 defines a vacuum distribution chamber 31 , the distribution chamber having annular upstanding wall 32 . The chamber 31 is in flow communication with the cavity 21 through channels 31 a. The upper surface of the distribution chamber 31 is closed by a cap part 33 . The cap part 33 comprises a planar element 34 with annular wall 35 extending around the periphery. The dimensions of the planar element 34 and annular walls 35 are such that when the cap 33 is in position, the annular wall 35 engages the outer surface of the upstanding wall 32 . Seals 36 ensure a sealing engagement between the annular wall 35 and upstanding wall 32 . A connection nipple 37 is mounted on the cap 33 with a channel 38 extending therethrough to enable the vacuum distribution chamber 31 to be connected to a vacuum or low pressure source.
[0049] To provide for treatment, the treatment device 10 comprises ultrasonic transducers 40 and radiofrequency (RF) electrodes. As shown in FIG. 4 , the ultrasonic transducers are shown at 40 and are mounted as opposed pairs adjacent the surfaces of the side wall 22 inwardly of the contact surface 20 and spaced from the closed end wall 23 . The internal volume 27 of the contact part 13 may be filled with any appropriate material. The ultrasonic transducers 40 may alternatively be mounted elsewhere in the volume 27 and suitably angled as desired. In this example, the ultrasonic transducers comprise flat piezoelectric ultrasonic transducers, each of which generates a generally straight, unfocussed ultrasonic beam in a direction perpendicular to their surface, and hence perpendicular to walls 22 and into the cavity 21 .
[0050] Radio frequency (“RF”) transducers 41 are similarly mounted on the angled surfaces 35 . In the present example, an auxiliary RF electrode is shown at 42 disposed in the recessed area 26 of the flat face 24 of the cavity 21 . The RF transducers 41 are thus offset from the ultrasonic transducers 40 , and are located closer to the closed end wall 23 .
[0051] The ultrasonic transducers are preferably mounted in opposed pairs to overcome attenuation of the ultrasonic beams within tissue, as illustrated in the graphs of FIG. 5 a and FIG. 5 b . The higher the ultrasonic frequency, the greater the attenuation within the tissue. FIG. 5 a is a graph showing the transmitted power between two transducers separated by 3 cm, at a frequency of 2 MHz. FIG. 5 b shows the transmitted power between two plates separated by 6 cm, at a frequency of 400 kHz. In each case, the power transmitted by the separate plates is shown by red and blue lines, from the right and left respectively, and the attenuation with distance is clearly apparent. The combined power is shown in green, and it is apparent that there is a generally even energy distribution generated in the tissue between the plates. In this way, the treatment occurs across the gap between the two plates. In particular, as the tissue between the plates is heated above the treatment level across the whole of the cavity in an even manner, there is no need to ‘overheat’ tissue near an ultrasonic transducer to increase the treated area, as would be required by a single transducer.
[0052] In the present example, where there are 3 pairs of transducers arranged in a hexagonal orientation, the power generated within the cavity is shown diagrammatically in FIG. 6 . Opposed ultrasonic transducers 40 each generate a beam generally illustrated at 50 . The beams overlap in a central area 51 . By selection of the power generated by each of the ultrasonic transducers 40 , the temperature elevation in tissue can be controlled such that only tissue within the zone 51 is heated to the required temperature to remove or destroy fat cells or adipose tissue, thus defining a treatment volume. In areas affected by only a single beam 52 or a pair of beams 53 , the energy imparted to the tissue is not sufficient to cause damage. At the same time as the ultrasonic transducers 40 are operated to cause fat destruction, the radiofrequency electrodes 41 may be operated to cause tightening in the skin above the treated area of tissue.
[0053] In operation, as illustrated in FIG. 7 and FIG. 8 , tissue generally shown at 60 is drawn into the cavity 21 by applying a suitable vacuum to vacuum distribution chamber 31 . The side wall 22 can be shaped to optimise contact between the skin and side wall 22 . A suitable transmission medium such as a gel can also be applied to the skin. The skin layers in diagrammatic form have an epidermis 61 , a dermis 62 and a subdermal layer 63 containing fatty tissue. By drawing the tissue 60 into the cavity 21 , as can be seen the fatty tissue 63 is located between the transducers 40 , and only that tissue within volume 51 is affected, raising the temperature sufficiently to destroy the fat cells. As illustrated in FIG. 8 , the RF electrodes 41 may be simultaneously operated to raise the temperature in the epidermis and dermis to cause skin tightening in known manner. By offsetting the ultrasonic transducers 40 and RF electrodes 41 in this way, different layers of the skin can be treated at once.
[0054] Although the hexagonal arrangement of the cavity and ultrasonic transducers as shown herein is advantageous in terms of the volume treated, it is envisaged that other arrangements of the ultrasonic transducers may be used, such that a suitable treatment volume may be defined within the cavity 21 without the disadvantages of requiring local overheating as seen in known devices. For example, four or more transducers 40 may be arranged in a square, pentagonal or heptagonal configuration, or indeed with any number of sides. The polygonal arrangement need not be regular, as in the present example, but may comprise a compressed or irregular polygon depending on the shape and size of the desired treatment volume to be generated by the treatment device.
[0055] When included in a treatment apparatus, a suitable controller may be provided to control the ultrasonic transducers 40 and RF electrodes in accordance with an operator's instruction to provide a desired operating regime. The ultrasonic transducers may be operated with a frequency in the range 200 kHz to 4 MHz, preferably 1 MHz to 3 MHz and most preferably 1.5 to 2.5 MHz, for durations in the range 0.1 seconds to 20 minutes, preferably 0.5 to 10 minutes and most preferably 1 to 6 minutes. The energy transmitted into the tissue may be in the range 50 to 700 J cm−3, preferably in the range 75 to 500 J cm−3 and most preferably 100 to 250 J cm−3. The transducers may be operated with duty cycle in the range 8 to 100%, preferably in the range 16.6 to 100% and most preferably in the range 33.33 to 100%.
[0056] The ultrasonic transducers may be activated simultaneously or separately. For example, each pair of ultrasonic transducers may be operated in sequence, the duty cycle of each pair of transducers being controlled such that while one transducer pair is active, the other two transducer pairs are in a quiescent part of the duty cycle. Alternatively, individual transducers may be operated in any order, or groups of transducers may be operated together. In a particular cycle of operation, each individual transducer, pair of transducers or group of transducers may be operated once, or may be operated a plurality of times. Similar considerations may apply to the operation of the RF electrodes 41 . Accordingly, pairs of RF electrodes may be operated in sequence, the duty cycle of each pair of electrodes being controlled such that while one electrode pair is active, other electrode pairs are in a quiescent part of the duty cycle. It is believed this operation cycle may reduce patient discomfort. However, any other operation cycle may be used, and may be the same as, or different from, the operation cycle of the ultrasonic transducers.
[0057] The RF electrodes may be operated with a frequency in the range 100 to 4000 kHz, preferably 300 to 2000 kHz and most preferably 500 to 1000 kHz, for durations in the range 10 to 5000 ms, preferably 30 to 2000 ms and most preferably 50 to 750 ms. The RF power may be in the range 5 to 100 W, preferably in the range 10 to 60 W and most preferably 20 to 40 W. The RF electrodes may be operated with a duty cycle in the range 8 to 100%, preferably in the range 16.6 to 100% and most preferably in the range 33.33 to 100%. The operating parameters may be selected in accordance with the desired treatment or results and the characteristics of the skin or tissue.
[0058] The operating regime may include a cooling step as illustrated in FIG. 9 . In FIG. 9 , the temperature of a fatty subdermal layer (upper line) and skin or dermal layer (lower line) over time are shown. At 0s, a heating cycle has ended and a cooling period A occurs, in this example 60s. As the fatty subdermal layer is deeper, has a higher thermal capacity and a lower thermal conductivity, it cools at a much slower rate than the dermis. In a subsequent ultrasound heating cycle B, the temperatures of both the dermis and subdermal layer are increased, but because of cooling cycle A, the dermis has a lower starting temperature and is maintained below the temperature at which damage occurs. In contrast, the subdermal layer is raised above a treatment temperature, in this case about 44°. By allowing a further cooling cycle C before beginning heating, it will be apparent that the subdermal layer can be repeatedly treated without causing damage to an overlaying dermal layer.
[0059] In the present example, the hexagonal walls 22 are about 30 mm long and enable a volume of 226.1 cm3 to be treated in six minutes, substantially more efficiently than an equivalent high-intensity focused ultrasound device.
[0060] Further treatment elements are illustrated at 70 and 80 in FIG. 10 , although one or both of these elements may be omitted or included as desired.
[0061] Elements 70 are disposed on the closed end wall 23 , in such a manner that when tissue is drawn into the cavity 21 , the elements 70 can treat the skin or dermal layer which is disposed near the elements 70 . The elements 70 may be light sources or additional ultrasonic transducers, depending on the type of treatment desired. The energy delivered by the elements 70 may be delivered in a fractional manner, such that energy from each element 70 is delivered into separate, physically spaced locations on the skin, Advantageously, by treating the upper skin layers at the same time or immediately after treating the subdermal tissue layer, a skin tightening effect may be induced over the layers where fat reduction has been performed.
[0062] Elements 80 comprise electrodes disposed on the contact surface 20 to perform pain reduction using transcutaneous electrical nerve stimulation (TENS). In TENS, an electrical current is used to stimulate A13nerve fibres, associated with touch signals. According to the ‘Gate’ theory of TENS, the activation of the A13 nerve fibres causes the activation of inhibitory spinal interneurons. The inhibitory spinal interneurons then block the transmission of information from Aδ and C nerve fibres associated with pain sensation. Consequently, by applying a suitable electrical signal to electrodes 80 , a local analgesic effect can be induced, minimising subsequent discomfort caused by the ultrasound treatment.
[0063] In the above description, an embodiment is an example or implementation of the invention. The various appearances of “one embodiment”, “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiments.
[0064] Although various features of the invention may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the invention may be described herein in the context of separate embodiments for clarity, the invention may also be implemented in a single embodiment.
[0065] Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can be implemented in embodiments other than the ones outlined in the description above.
[0066] Meanings of technical and scientific terms used herein are to be commonly understood as by one of ordinary skill in the art to which the invention belong, unless otherwise defined. | A treatment device comprising a cavity to receive body tissue, the cavity comprising a side wall, a closed end wall and an opening to admit tissue, and at least four ultrasonic transducers disposed to transmit ultrasound into the cavity. | 0 |
BACKGROUND OF INVENTION
The present invention relates to a machine for retreading tires; the invention concerns, in particular, a buffer as well as a combined machine further containing means for application and rolling down of the treads.
It is known that most tires can be retreaded, that is, it is possible—after normal wear of the tread —to replace that tread and even some of the plies reinforcing the belt of the tire. Such operations are very common for truck tires; they can be carried out in factories or at relatively large shops.
Numerous machines designed to remove remains of the tread from worn tires, a “detreading” operation, have been proposed. Among them, many use a buffer to carry out that detreading.
Such a buffer consists of a series of blades containing cutting teeth on the outside and arranged side by side. Such a machine is disclosed in U.S. Pat. No. 4,116,256. Those machines often contain complex adjustments for enabling the whole variety of necessary buffing profiles to be obtained.
More or less complex machines making it possible to reduce the different detreading or buffing and retreading operations, without resorting to overly frequent adjustments or repairs, have also been imagined. For example, U.S. Pat. No. 4,036,677 and French Patent 2,271,037, based on an Italian priority of May 14, 1974, describe an “all-purpose” machine comprising a rotary chuck on which the tire to be detreaded-retreaded is mounted, carcass buffing tools, a coaxial radial expander with the chuck, which brings the new tread around the carcass in the form of a ring, and means for rolling down in order to make the new tread adhere to the carcass.
The tire treated remains on the same chuck during buffing and molding, that is, application of the new tread, but without any interaction of the different parts of the machine, which results in a redundancy of drive units, and the need to mark several times the respective positions of the carcass and of the tread of the tire in the course of the successive operations.
The new tread can also be cut to the desired length and placed continuously on the carcass and then butted, that is, its two ends, once joined, are welded; a machine of that type is described in patent EP 0,704,296, but that machines carries out only the application of the new tread on the tire, the so-called “molding” operation.
SUMMARY OF THE INVENTION
According to the invention, a machine for retreading tires comprises a rotary chuck on which the tire to be treated is mounted and buffing tools. The machine is characterized in that the chuck is mounted on a first carriage guided in rails and moved by a first motor, in that the buffing tools are borne by a second carriage guided in rails oriented parallel to the axis of rotation of said chuck and moved by a second motor, in that means are provided for precisely positioning the first carriage relative to the second carriage and in that any relative displacement between the axis of rotation of the chuck and the center of the buffing tools is contained in a single plane passing through the axis of rotation of said chuck.
Such a machine makes it possible, by the combination of two simple translational movements, to obtain buffing profiles of the surface of the crown of a tire. The fact that any relative displacement between the axis of rotation of the chuck and the center of the buffing tools is contained in a single plane passing through the axis of rotation of the chuck has the advantage of remarkably simplifying the interpretation of each displacement, since any moving closer, by five millimeters, for example, will correspond to a reduction of radius of the tire precisely equal to five millimeters. Any relative displacement can thus be directly linked to a thickness of rubber to be removed.
According to one preferred embodiment, the first carriage is guided in vertical rails and the second carriage is guided in horizontal rails. The buffing tools are also preferably placed above the tire. This arrangement makes possible a saving of floor space.
According to an additional characteristic, the machine of the invention contains means for reversing the direction of rotation of the buffing tools. It can also embody additional means for setting parameters for the number of tires treated after which the direction of rotation of the buffing tools is reversed.
This characteristic has the advantage of optimizing wear of the buffing tools and of simplifying use of the machine. In fact, it is well known that the blades of a buffer wear irregularly on operation. Consequently, on the known machines, after having detreaded a given number of tires, in the order of 15 to 20, the blades of the buffer are usually removed, they are turned 180° (and they are remounted. This operation is particularly tedious. The machine according to the invention makes it possible to accomplish this by a simple reversal of the direction of rotation of the buffer, for example, after every three to ten tires have been treated, and the reversal can be accomplished automatically.
In case the machine according to the invention has to treat only tires recapped with flat treads, the axis of rotation of the buffer can be arranged parallel to the axis of rotation of the chuck. In that case, it is advantageous to reverse the direction of rotation of the machine automatically at the same time as the direction of rotation of the buffer is reversed. Of course, the direction of rotation of the tire and that of the buffer are identical in order to obtain a tangential speed on the surface of maximum contact.
When said machine must also detread tires which are to receive treads having tapered wings, usually called “bandes a bavettes,” these wings having to cover the shoulders and the height of the sides of the tires, it is advantageous to have the direction of rotation of the buffer perpendicular to the axis of rotation of the chuck.
This arrangement has the advantage of making it possible to treat all parts of the crown and shoulders of the tires by simple combination of both vertical movement of the chuck and horizontal movement of the buffing tools in very simple fashion. In that case, it is not necessary to reverse the direction of rotation of the chuck of the tire when the direction of rotation of the buffing tools is reversed.
The invention also concerns a similar machine further equipped with means for application of a tread and means for rolling down said tread after its application. Said means for application and said means for rolling down are carried by the second carriage and can be the same means.
The machine also makes it possible to combine all the means necessary for detreading and molding of a worn tire with a very low space requirement. Use of the same carriage for moving the buffing tools as well as the means of application and rolling down of the new tread also makes it possible to use the same markings for all the retreading operations; it is not necessary to use additional means of measurement.
The machine preferably also contains means for separating the position of the application and rolling down means from the movement of said second carriage. This makes it possible, notably, to place the buffing tools axially away from the tire during the molding operations. This is very important in order to guarantee that there will be no contamination of the surface of the tire, for example, during the usual operations of rubber coating, placement of the bonding rubber or application of the new tread. Such contamination by particles coming off the blades of the buffer would be unacceptable.
The invention further concerns a machine for retreading tires comprising a rotary chuck on which the tire to be treated is mounted, means of application of a tread and means of rolling down said tread after its application, characterized in that the chuck is mounted on a first carriage guided in vertical rails and moved by a first motor, in that the means of application of a tread and the means of rolling down said tread after its applications are borne by a second carriage guided in horizontal rails oriented parallel to the axis of rotation of said chuck and moved by a second motor, and in that means are provided for precisely positioning the first carriage relative to the second carriage.
DESCRIPTION OF THE DRAWINGS
A working example of the invention, given without limitation, will be described in detail, referring to the attached drawings, in which:
FIG. 1 is a view in vertical section of a detreading-retreading machine according to the invention;
FIG. 2 is a side view in vertical section of the same machine;
FIG. 3 is a section on a larger scale of the means for application and rolling down of the new tread; and
FIG. 4 is a view similar to FIG. 1 of a another embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 to 3 show a detreading-retreading machine according to the invention. The machine includes buffing tools as well as means of application and rolling down of a new tread. Such a machine is intended for small shops for which the combination of buffing and molding operations on the same work station entails a saving of space and time. On the other hand, for larger shops, it is advantageous to have two machines, a first one with buffing tools and a second with means for application and rolling down of a new tread. In the latter case, these two machines can have identical frames and control means, as described below
As can be seen in FIG. 1, the detreading-retreading machine comprises a vertical rigid frame 1 and a horizontal bracket 2 . According to the invention, a chuck 3 is mounted on a carriage 4 guided in vertical rails 5 and moved by a step motor 6 and an endless screw 7 . The carriage 4 carries a motor 8 mounted on the same shaft 9 as the chuck 3 in order to be able to drive it in rotation.
It can be seen in the drawing that the chuck 3 has an extendible rim 10 making it possible to mount tires 11 or 12 (in dotted lines) of very different sizes, ranging from passenger car to truck tires.
At the top of the machine, on the bracket 2 , a second carriage 13 is mounted, guided in horizontal rails 14 and moved by a step motor 15 and an endless screw 16 . The carriage 13 supports a motor 17 for operating the buffing tools 18 .
In FIG. 1, the buffing tools 18 are arranged above the tire to be treated. One can also see in dotted lines the extreme positions to which the motor 17 and the tools 18 can be moved by the carriage 13 . The range of movement of the carriage makes it possible, when the tire detreading or buffing phase is completed, to retract the buffing tools 18 and thus avoid contamination of the treated surface of the tire during the following retreading phases.
FIG. 2 also shows the frame 1 and the bracket 2 , the chuck 10 and the tire 12 , as well as the carriage 13 and the buffing tools 18 . It is to be noted that the protecting cover 25 of the buffing tools 18 is symmetrical, which makes it possible to draw up the dust particles caused by buffing, whatever the direction of rotation of the tools 18 . The carriage 13 also carries molding and rolling down means 19 represented in two positions 19 and 19 1 . These means consist of two conical rollers 20 and 21 (FIG. 3) mounted on two cooperating pins forming an angle of approximately 10° and driven by a jack 22 carried by an assembly 23 mounted on the carriage 13 . The 10° angle corresponds simply to the fact that with the geometry of the rollers chosen, the surface of contact with the tire is flat. The assembly 23 can be uncoupled from the movement of the carriage, for example, during the tire detreading or buffing phase. The application pressure of the jack 22 can be changed by the operator of the machine according to the elongation of the tread necessary for it to cover the entire circumference of the tire to be retreaded with a correct distribution of its weight.
The exact profile according to which the tire must be detreaded is introduced in the machine by an electronic digital control (not shown), which precisely positions the tools and the tire in the horizontal and vertical directions by means of the step motors 15 and 6 .
The operation of the machine on buffing is as follows. After having introduced in the control of the machine the buffing profile corresponding to the type of tire to be retreaded and the application and rolling down means 19 to 23 being uncoupled from the movement of the carriage 13 :
The residual thickness of rubber at the crown of the tires 12 is determined, for example, by drilling a small hole with a flat bit, which does not damage the crown plies, and the thickness of rubber to be removed is put in memory;
a tire 12 is mounted on the expandable rim 10 , it is then inflated through an axial compressed air inlet 24 and it is rotated by the chuck 3 and the motor 8 ;
the buffing tools 18 are positioned in the center plane of the tire and they are rotated;
the tire 12 and chuck 3 of the buffing tools 18 are brought into contact together;
the distance between the buffing tools 18 and the axis of rotation of the chuck corresponding to the initial diameter of the tire on contact is placed in memory; that reference will be used during all the retreading operations;
the tire is brought up to the buffing tools one or more times in order to remove that thickness of rubber and the complementary horizontal movement of the carriage 13 and vertical movement of the tire 12 are coordinated in order to obtain the buffing profile of the tire chosen;
the operation is stopped and the tire is separated from the buffing tools;
it is removed and another tire to be treated is set in place.
After their buffing, the tires are usually repaired and prepared for the application of a new tread on one or more other known working stations
They are then ready for the molding operation on the machine of the invention, the buffing tools being moved to separate them perpendicular to the tire and thus avoid any further contamination due to the particles dropping from the buffing tools:
the tire 12 is again mounted on the rim 10 ;
preparation is finished, if necessary, by completing the usual operations of repair, rubber coating of the crown surface and application of a bonding rubber on the crown of the tire;
a tread is prepared by cutting it to the desired length, taking into account the initial diameter of the tire and the thickness of rubber removed;
the means for application and rolling down are engaged with the movement of the carriage 13 , those means are placed in the center plane of the tire and the pressure of application of the jack 22 is regulated in accordance with elongation of the tread to be obtained in order to cover the entire circumference of the crown;
a first end of the tread is set in place on the crown of the tire by engaging it under the rollers 20 and 21 ;
the entire tread is set in place by turning the chuck and it is verified, if necessary, that length of the tread is satisfactory;
the pressure of the jack 22 is adjusted to the value provided for rolling down;
the rollers 20 and 21 are firmly applied to the tread on one side and then on the other by movement of the carriage 13 and of the chuck 3 .
rotation of the tire is stopped, it is deflated and it is removed.
The machine represented in FIGS. 1 to 3 embodies buffing tools, the axis of rotation of which is parallel to the axis of rotation of the chuck 3 . In order to obtain the best buffing efficiency on treatment, the directions of rotation of the chuck and of the buffing tools 18 are the same. This ensures the highest tangential speed of contact. To optimize the wear of the buffing tools, after every three to ten tires have been treated, the directions of rotation of the chuck 3 and of the buffing tools 18 are reversed. The symmetrical cover 25 surrounding the buffing tools is also effective in removing (with suction means not shown) the dust particles created, whatever the direction of rotation of the buffing tools. The number of tires beyond which the directions of rotation are reversed is programmable. This makes it possible to reduce the wear of the buffing tools appreciably and greatly facilitates use of the machine
The means for application and rolling down comprise two conical rollers. They could also comprise a single roller. Two rollers can also be used with means provided for progressively separating them from each other symmetrically, while firmly applying them against the surface of the new tread.
The two movements, horizontal and vertical, of the two carriages 4 and 13 are driven by an electronic digital control (not represented) which ensures following of the exact profile according to which the tire is to be detreaded.
It can be seen in FIG. 2 that the detreading tools work vertically above the tire and not at nearly its height, as in the existing machines; this arrangement reduces the cost of the machine and the space required for its use.
It can also be seen that the same means are used for moving and positioning the detreading tools and the means for the application and rolling down of the new tread, which saves on reduction gear and floor space requirements.
Finally, the same precise positioning parameters are used for detreading and retreading, that is, the initial retreading dimension is appreciably identical to the final detreading dimension. Thus, the invention introduces a new judicious arrangement of the different parts of the machine in order to reduce its cost and facilitate its use.
FIG. 4 presents a variant embodiment of a machine according to the invention. In this variant, the buffing tools 26 have their axis of rotation 27 placed perpendicular to the axis of rotation 9 of the chuck 3 . The buffing tools are also carried by the carriage 13 and the end positions of movement of those tools 26 can be distinguished in FIG. 4 on both sides of the center plane of the tire 12 . This arrangement makes it possible to treat all parts of the crown and shoulders of the tires by combination of the vertical movement of the chuck 3 and horizontal movement of the buffing tools 26 . | A machine for retreading tires, including a rotary chuck on which the tire to be treated is mounted and buffing tools, in which the chuck is mounted on a first carriage guided in rails and moved by a first motor, the buffing tools are carried by a second carriage guided in rails oriented parallel to the axis of rotation of the chuck and moved by a second motor, and in which provision is made for precisely positioning the first carriage relative to the second carriage and any relative displacement between the axis of rotation of the chuck and the center of the buffing tools is contained in a single plane passing through the axis of rotation of said chuck. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of my prior U.S. Provisional Application Ser. No. 60/094,569, filed Jul. 29, 1998.
BACKGROUND
1. Field of the Invention
The present invention relates to a countertop kitchen appliance which occupies a minimum of kitchen counter space, i.e., has a small footprint, while increasing serving capacity over currently used similar appliances.
2. Description of Related Art
Toasters and toaster ovens are not new to the art. One common type of conventional toaster comprises two or four vertically-oriented heating units contained within a generally rectangular housing. Such toasters are common-place in households all over the world, and are perfectly suitable for households of one or two people. However, such toasters are do not have sufficient capacity for larger households, feeding guests, or commercial applications (such as restaurants or cafeterias) because only two or four items (toast, bagels, etc.) can be toasted at any one time. Moreover, providing a toaster having six or eight vertically-oriented toasting units is undesirable because of the excessive amount of counter space that would be required to accommodate large numbers of vertically oriented slots.
One potential solution to this problem is a toaster or toaster oven having a plurality of horizontally oriented slots which are stacked vertically. There have been attempts to design toasters and toaster ovens having such horizontally oriented toasting slots:
U.S. Pat. No. 2,578,034 to Baltzell shows a toaster having two horizontal elongated openings, each designed to accommodate a single food item in a horizontal orientation. Baltzell's toaster further includes a removable drip pan below each opening to receive butter, cheese and other materials likely to flow off of the edges of the food item being toasted. BaltzelI does not teach or suggest providing more than two openings. In addition, Baltzell's toaster appears relatively large and bulky.
U.S. Pat. No. 2,719,479 to Rodwick shows a toaster having two rectangular horizontally-oriented slots. Rodwick does not teach or suggest a toaster having more than two toasting slots. In addition, Rodwick's toaster is specifically designed with large open areas within the toaster to allow droppings from the food article(s) being toasted to fall to the bottom of the toaster.
U.S. Pat. No. 5,586,488 to Liu teaches a portable pizza oven having a horizontal cooking chamber designed to receive a removable pan assembly. As with the references discussed above, Liu does not teach or suggest providing an oven having more than one cooking chamber.
U.S. Pat. No. 5,584,231 to DeLeon shows a tortilla warmer having a plurality of food enclosures. DeLeon shows one embodiment in which the food enclosures are horizontally oriented. However, DeLeon's tortilla warmer does not teach or suggest providing food enclosures which can be individually controlled. In addition, DeLeon does not teach or suggest providing a crumb catcher or drip tray between each food enclosure.
OBJECTS AND SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a toaster which can accommodate a large number of food items simultaneously, yet takes up little counter space.
It is another object of the present invention to provide a toaster having modular toasting units, thereby enabling any number of additional toasting units to be added at any time.
It is another object of the present invention to provide a toaster having multiple horizontal toasting units, each of which is individually controlled.
It is yet another object of the present invention to provide a toaster having multiple horizontal toasting units and a crumb catcher located below each toasting unit to prevent crumbs and other material from falling on the food being toasted below.
It is yet another object of the present invention to provide a toaster that is easy and inexpensive to manufacture.
It is yet another object of the present invention to provide a toaster having an aesthetically pleasing appearance.
These and other objects are achieved by the present invention which comprises a vertically extending, cylindrical structure having a plurality of modules which may be integrally joined together in a single housing or may be separably stacked one upon the other. Each module comprises at least one individual heating unit having a horizontally oriented aperture opening into the unit. Each heating unit is separated from its vertical neighbors by a heat insulating layer and includes a food receiving grill, an upper heating element located above the grill, a lower heating element located below the grill, and a removable tray below the lower heating element for catching crumbs or other food particles which fall from the grill. The grill may also be movable and/or removable for easy access to the food thereon or for cleaning.
Master controls for all the modules and individual controls for each separate module are contemplated to provide versatile control of the cooking processes.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be fully appreciated as the same becomes understood from the following detailed description of the best mode presently contemplated for carrying out the present invention when viewed in conjunction with the accompanying drawings, in which:
FIG. 1 is a front perspective view which illustrates a preferred embodiment of the present invention;
FIG. 2 shows a side perspective view of the appliance with an electrical outlet;
FIG. 3 is a front view of one heating unit with the relative spacings exaggerated for clarity;
FIG. 4 is a front perspective view of a crumb catcher;
FIG. 5 is a top, cross-sectional view of the crumb catcher of FIG. 4;
FIG. 6 is a side view of the crumb catcher of FIG. 4;
FIGS. 7-8 are top views of two designs for the grill;
FIGS. 9-12 are top views in cross-section of variants of means for supporting and moving the grill relative to the appliance housing;
FIG. 13 is a front perspective view of a second embodiment of the invention wherein a pair of heating units are housed in an individual, stackable module;
FIG. 14 is a front perspective view of the second embodiment showing two stacked modules;
FIG. 15 is a side view, partially broken away and in cross-section, of a means for moving all of the grills simultaneously;
FIG. 16 shows in cross-section a means for moving the grills of a single module; and
FIG. 17 is a top, cross-sectional view showing a powered drive mechanism for moving the grills of FIGS. 15-16.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of this disclosure, the appliance will be described in terms of a toaster for toasting bread, although as will soon become apparent, it is not limited to this function nor to this product. It will be appreciated that the disclosed appliance comprises a central food processing system capable of defrosting, toasting, broiling, or heating a variety of food products, e.g., bread, bagels, pizzas, waffles, etc.
Further, the following disclosure emphasizes home use of the toaster, an environment of particular importance in view of the limited counterspace experienced in most home kitchens. Describing the invention in terms of home use is not intended to limit its utility thereto, however, for other cooking environs also suffer from limited counterspace and/or the need for multiple and/or simultaneous servings, e.g., commercial or institutional establishments such as restaurants, hospitals, school cafeterias, homeless shelters, etc. The modular embodiments described in FIGS. 13-17 are particularly suited for extra-domestic use, since they permit virtually unlimited expansion of the basic unit to fit the individual needs of a specific commercial or institutional establishment.
Whether at home or in a restaurant, hospital, or school, a serving of toast typically consists of two pieces of bread. Since the average family comprises more than two persons, all of whom have a reasonable expectation of being served fresh, hot toast simultaneously with the rest of the family, home toasters, which are limited to toasting only two or four pieces of bread simultaneously, are not usually up to the assignment. Commercial toasters, which extend this number to six or eight, could be purchased, and they would fill the bill, but they are usually too large for easy placement on home kitchen counters. Typically, home and commercial toasters in current use load the bread slices vertically through upwardly facing, rectangular apertures. While this is convenient for loading and unloading the toaster, it has the disadvantage of increasing the countertop area needed for the toaster proportionate to the number of slices toasted. The present invention resolves these conflicts.
Referring to FIGS. 1 and 2, a preferred embodiment of the multi-level toaster of the present invention is indicated generally by reference numeral 10 and comprises a housing 12 including a base 14, a vertical, cylindrical wall 16, and a top 18. A plurality of toaster modules 20, 22, 24 and 26, each capable of simultaneously toasting two pieces of bread, are housed within housing 12. A plurality of floors 28, 30, 32, 34, and 36, integral with housing 12, serve to separate each toaster module from its adjacent neighbor.
Each toaster module 20, 22, 24 and 26 preferably has its own heating controls 38, 40, 42, and 44, respectively, for separately and individually setting the desired degree of toasting or browning of each two-piece serving. Heating control 44 is diagrammatically illustrative of the nature of the controls. They are not per se a main feature of the present invention, so they will not be described in detail, but nonetheless can be in the form of buttons, as shown, rotary dials, swing levers, sliding rheostats, computerized touch panels, or any combination thereof. Whatever form of heating control is chosen, it is preferably illuminated when on and darker when off to clearly indicate which toaster module is being used. Only four toaster modules are shown, but it is obvious the number can be extended to whatever is desired, space permitting.
Four master controls 46, 48, 50, and 52 are preferably located in base 14. Such controls are shown as buttons, which are also preferably illuminated when in use, for selecting the type of cooking desired for the toaster modules in multi-level toaster 10. The nature of the type of cooking controlled by each master control will be chosen by the designer or manufacturer, but they would typically include defrosting, toasting, broiling, and heating, respectively. For example, the defrost setting 46 is needed for defrosting frozen foods, such as waffles, bagels, pizzas, pastries, and other frozen snack foods. The toasting setting 48 applies to English toast or muffins, bread slices, bagels, etc. The broil setting 50 is useful for English muffins, bagels, pizzas, and hor d'oeuvres. And the heating setting 52 applies anytime one wishes to simply heat a food product, e.g., left-overs, pot pies, etc.
Multi-level toaster 10 is extremely versatile and will permit a variety of embodiments while remaining within the purview of the invention. For instance, in one embodiment, master controls 46-52 can be configured to limit all the toaster modules to one type of cooking, e.g., toasting, while leaving the degree of browning to the separate control of the individual toaster modules 20-26. A group desiring different degrees of toast, even on different types of bread, can thus be served uniquely and simultaneously. In another embodiment, master controls 46-52 can be equipped with means (rotary dials, swing levers, sliding rheostats, computerized touch panels) for setting degrees of cooking applicable to all toaster modules. The master control settings would, in that case, override the settings of the individual toaster modules, possibly even setting their displays to the same setting and illuminating them to show they are on. This feature provides the time-saving advantage of only having to make one setting when desiring to toast all of the bread slices to the same degree of browning, especially important in commercial or institutional use. Of course, this universality of selection applies to the other master controls as well, so that, for example, a plurality of bagel pizzas will all be cooked uniformly. A third embodiment combines the two, providing master controls with degree settings but permitting switching of the master controls between universal and individual control of the existing toaster modules.
A side view schematic of multi-level toaster 10 is shown in FIG. 2. An electrical outlet 54 is preferably provided in wall 16. Outlet 54 is connected to the power source of multi-level toaster 10, which will allow other appliances to be plugged therein and derive power via multi-level toaster 10, thus reducing dependence on limited household outlet availability. A combination on-off switch 56 with a built-in safety or warning light may be added as desired or required by some local codes. Additional outlets 54 may be located on both sides of multi-level toaster 10.
A toaster heating unit 58 is shown in FIG. 3. Two such heating units are preferably integrally included in each of toaster modules 20-26. Heating unit 58 comprises an insulating disc 60, an upper heating element 62, a food supporting grill 64, a lower heating element 66, and a crumb catcher 68. The elements are vertically expanded to show them more clearly. In practice, their spacing would be appropriate for their functions. Placement of an insulating disc 60 between levels prevents heat from creeping from one heating unit 58 to another. The toasting integrity of each heating unit is protected by insulating discs 60. Heating elements 62 and 64 are standard heating elements well known in the art. They are collectively controlled by the master controls 46-52 to provide various heating functions. For example, only the upper elements 62 would be activated during the broiling phase of multi-level toaster 10, and all heating elements 62 and 66 would be activated for toasting bread. Grill 64 may assume different configurations as desired, as will be described hereinafter.
It is important to note that each heating unit 58 is horizontally oriented. The footprint of the appliance is thus reduced to essentially the flat dimension of the food product. It is this vertical stacking of horizontal toasters which makes the toaster so useful to home chefs, commercial eatery cooks, and institutional meal preparers, for it conserves valuable countertop space while offering increased serving capacity.
Crumb catcher 68 is shown in more detail in FIGS. 4-6. Crumb catcher 68 is shown as circular in FIGS. 4-6, but can assume any peripheral configuration as dictated by the cross-sectional shape of cylindrical wall 16 (compare FIGS. 9, 13-14, and 17 with FIGS. 10-12). Crumb catcher 68 comprises a flat plate 70 bordered by a short, raised ridge or ring 72, the front portion 74 of which in combination with vertical facia walls 76, 78 and an upper bridge 80 creates a smooth, decorative facade 82.
Portions 74, 76, 78 and 80 form an aperture 84 of sufficient width and height to provide access through facade 82 to the interior of heating unit 58 for insertion of slices of bread or other food products to be toasted, defrosted, grilled, etc., and through which grill 64 may be removed. The types of food products usable in multi-level toaster 10 is limited only by the size of plate 70, the height of ring 72, and the size of aperture 84. Facade 82 completes the exterior of multi-level toaster 10.
As an alternative, bridge 80 may be eliminated in order to reduce the height of multi-level toaster 10 while providing a comparably sized, or larger, aperture. While aperture 84 allows unobstructed removal of the grill and toast, it nonetheless protects upper and lower heating elements 62 and 66 from being exposed to inadvertent touches. Crumb catcher 68 is removable from housing 12 for cleaning. To facilitate the removal of crumb catcher 68 without disturbing lower heating element 66, the rear portion 86 of crumb catcher 68 is preferably lower than bridge 80.
FIGS. 7-12 illustrate a few of the many possible configurations for grill 64. A bordering ring 88 supports a latticework of wires 90 welded or otherwise made integral therewith. Openings 92 formed by latticework 90 allow heat to impinge upon the bread for toasting same. A concave, arcuate indentation 94 (FIG. 7) may be provided to allow the toasted bread to be removed without touching or moving grill 64, which at such time could be very hot. Alternatively, a finger grip 96 (FIGS. 9-12), possibly covered with a heat insulating guard 98, allows grill 64 to be manually moved at least partially from within housing 12 for removal of the toast.
Grills 64 may be supported within housing 12 by any convenient means, such as by resting on laterally located U-shaped shelves 100 (FIG. 11) or forcibly held in snap-fit, U-shaped grooves 102 (FIG. 12).
A means for extending grills 64 from housing 12 may be provided as shown diagrammatically in FIG. 12. A rod 104 extends through a guide aperture 106 in the back of wall 16 and is connected to grill 64. Rod 104 could be removably attached to grill 64 so that grill 64 can be removed for cleaning. Alternatively, rod 104 can be integrally connected to grill 64 and thereby act to position and support grill 64 in housing 12, eliminating the need for snap-fit grooves 102. A vertical rod 108 operatively connects an actuating means, (not shown in FIG. 12, [(e.g.,] e.g., motor driven gears or levers, or a solenoid, etc.; see FIG. 17), to rod 108 for moving same. Automatic control, such as by a thermostat or microprocessor, preferably actuates rod 104 to slide forward when the desired degree of toasting is completed, much like the way toast pops up in vertically oriented toasters. Rod 108 could also be activated manually, if desired.
The peripheral shape of grill 64 is selected to conform to the shape of wall 16, which is shown as semi-circular in FIG. 9 and as an open rectangle in FIGS. 10-12.
A second embodiment of the invention is illustrated in FIGS. 13-17. Referring first to FIG. 13, an individual module 110 is shown comprising a pair of heating units 58 housed in an arcuate vertical wall 16. As before, each heating unit 58 includes an insulating disc, an upper heating element, a food supporting grill, a lower heating element, and a crumb catcher, all unnumbered to avoid unduly complicating the figure (see FIG. 3 for details thereof). Module 110 includes a plurality of guide posts 112 spaced around and extending upwardly from the top surface 114 of wall 16 and a correspondingly located plurality of complementary shaped recesses 116 in the bottom surface 118 of wall 16. The complementary shaped posts and recesses allow similar modules to be stacked as shown in FIG. 14 to permit the user to customize a toaster to individual specifications. A top module (not shown) shaped like top 18 having recesses 116 in its lower surface and a base module (not shown) shaped like base 14 with guide posts 112 extending upwardly from its top surface would be provided to complete the multi-level toaster 10. Electrical connections between modules could be effected through posts 112 and recesses 116 which would include suitable mating contacts (not shown).
FIGS. 15-17 are diagrammatic illustrations of designs of various means similar to that introduced in FIG. 12 for moving grill 64 at the completion of toasting the slices of bread. Referring to FIG. 15, two modules 110, each comprising a pair of heating units 58, are shown broken away in a cross-sectional side view. Modules 110 may be integral, as in FIGS. 1-2, or stacked, as in FIGS. 13-14. An insulating disc 118 separates the two heating units 58 of each module 110. Extending vertically behind each module 110 is a segment of a hollow pipe 120 with rods 104 fixed thereto by any convenient means, such as by screwing into threaded apertures or by welding. Pipe segments 120 are each shown as having a length roughly commensurate with the height of its associated module, but as will be appreciated, it is only necessary that their lengths be capable of connecting the back ends of the two rods 104 in each module 110. A vertical actuating rod 122 extends through pipe segments 120. Preferably, rod 122 is not attached to pipe segments 120, but rather extends therethrough snugly enough to prevent rattling but loosely enough to be vertically slidable therein. The necessity of maintaining close tolerances as to vertical positioning of rod 122 relative to pipe segments 120, rods 108, and heating units 58 is thereby avoided. Rods 104 and their connecting pipe segment 120 form a unit 124. Rod 122 is not attached to pipe segments 120, because rod 122 does not support unit 124. Rod 122 functions only to move all of the units 124, and thereby all of the grills attached to rods 104, laterally, as indicated by arrows 126. When the toast is finished, a thermostat or computer will actuate a motor or solenoid to move rod 122 and thereby pipe segments 120 and rods 104 to the right. Grills 64 (FIG. 17) with the toast thereon will partially extend through apertures 84, so that the toast can be removed from grills 64. The FIG. 15 embodiment is the simplest structure wherein all of the grills 64 of all of the heating units 58 are moved simultaneously.
The rod structure of FIG. 16 is used where each module 110, corresponding to one of toaster modules 20-26, is used independently of the others in multi-level toaster 10. The two rods 104 of a single module are integrally connected by an actuating rod 128, forming a U-shaped unit 130 as shown in the figure. Rod 128 would be actuated independently of the others by an appropriate means, e.g., a solenoid, not shown, which is controlled by the appropriate one of controls 38-44 associated with module 110. In the aforementioned example of each person in a group receiving differently browned toast on different types of bread, the time required to toast its bread by each toaster module would be different than the time required by the others. Consequently, each toaster module must be capable of terminating toasting and popping the toasted bread out independently of the others.
A housing 132 snap-fit into projections 134 covers unit 130 for protection thereof and for aesthetic reasons. Housing 132 would be removed when actuating unit 130 manually, but it would be left in place, except for cleaning and repairs, if housing 132 contained an automatic grill-moving mechanism 136, as shown schematically in FIG. 17.
FIG. 17 shows a top, cross-sectional view of the embodiments of either FIGS. 15 or 16 where identical numbers identify identical parts. Where desired, a reinforcing rib 138 integral with the back of wall 16 may be provided to stably support rods 104, housing 132, and grill-moving mechanism 136. In this embodiment, mechanism 136 comprises an electric motor 140 which drives an oscillating member 142 and a lever 144 connecting oscillating member 142 and either rod 122 or rod 128, as the case may be. Mechanism 136 alternately extends and retracts rods 104 and grill 64, as indicated by arrows 126. A solenoid driven lever system can obviously replace mechanism 136, as can any other known oscillating means, and still be within the purview of the invention.
Numerous modifications and variations of the present invention are possible in light of the above teachings. | A vertically extending, cylindrical toaster having a plurality of modules which may be integrally joined together in a single housing or may be separably stacked one upon the other. Each module comprises at least one individual heating unit having a horizontally oriented aperture opening into the unit. Each heating unit is separated from its vertical neighbors by a heat insulating layer and includes a food receiving grill, an upper heating element located above the grill, a lower heating element located below the grill, and a removable tray below the lower heating element for catching crumbs or other food particles which fall from the grill. The grill may also be movable and/or removable for easy access to the food thereon or for cleaning. Master controls for all the modules and individual controls for each separate module are contemplated to provide versatile control of the cooking processes. | 0 |
RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/793,600, filed on Apr. 20, 2006.
The entire teachings of the above application are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Propane gas cylinders of about 50 lbs. or so are used in residential settings. A common problem of such use is the inability to visually determine whether a subject cylinder/tank is empty or full. Similarly, other types of cylinders and tanks (typically made for homeowner use) lack gauges, visual indicators, and the like indicating level of contents (e.g., empty versus full).
SUMMARY OF THE INVENTION
A cap secures over a three spoke propane tank cylinder handle. The handle is found on 50 lbs. cylinders typically used for home use of propane gas. The cap is made of a pliable product (plastics or rubber) to allow the end user the ability to remove, turn over, and then replace the cap (now in an opposite or generally in one of two orientations) as the tank becomes empty or each time the tank is refilled. Embodiments have legible printing on each side to tell the user which direction to turn the cap to close the cylinder flow of gas. One direction is marked “open” with an arrow pointing in a direction indicating how to turn the handle to open the valve and start gas flow. Likewise, the cap is marked with “close” and an arrow pointed in the opposite direction indicating the direction to turn the handle to close the flow of gas.
In particular embodiments, the cap has ribs along the outside to allow a better grip when turning off and on the valve. In an embodiment, the cap has a distinct color labeled for each side (orientation). One side, for example, is colored green and is labeled “FULL.” The other side is red and is labeled “EMPTY.”
In one embodiment, a cap for cylindrical tank has one side (orientation) that visually indicates the contents of the tank being at or near full capacity of the tank. The cap also includes an opposite side (orientation) that visually indicates the tank is empty. Each orientation of the cap is removably settable with respect to the tank, but while the cap in one orientation is removably secured to the tank, the operative side of the opposite orientation is not viewable.
In another embodiment, the user removably secures a cap to a tank. In the secured position, the cap has a front facing portion and a back facing portion. The front facing portion bears an indicator indicating the contents of the tank being at or near full capacity of the tank.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
FIG. 1 is an elevation view of a cap or handle cover embodiment of the present invention in place on a propane tank handle.
FIG. 2 is an exploded view that shows how an embodiment is placed on the handle of the propane tank.
FIG. 3 is a sectional view of the cap embodiment of FIG. 1 .
FIG. 4 is a top view of the EMPTY indicating side of the cap of FIG. 1 .
FIG. 5 is a cross section view of the FIG. 1 cap in place on a propane tank handle.
FIG. 6 is an elevated view of another embodiment as it would appear in place on a propane tank handle.
FIG. 7 is an exploded view on how the FIG. 6 embodiment snaps together to form one unit that is then placed on the propane tank handle.
FIG. 8 is a cross section of both halves of the embodiment of FIG. 7 before assembly.
FIG. 9 is a cross section of the embodiment of FIG. 7 assembled and in place on a propane tank handle.
FIG. 10 is a partially exploded view of an alternative embodiment of a cap used as a visual indicator.
FIG. 10A is a close-up view of a swivel connector.
FIG. 11 is a top-view of the FIG. 10 embodiment shows a connection of a receiving inlet and swivel connector.
FIG. 12 is a perspective view of the FIG. 10 embodiment places on a valve of the propane tank.
DETAILED DESCRIPTION OF THE INVENTION
A description of preferred embodiments of the invention follows.
FIG. 1 shows a cap 20 (e.g., a handle cover) on a propane tank handle 10 . In use, a user places the cap 20 on the propane tank handle 10 as shown. For example, a donut shaped design of the cap 20 that is placed over a three pronged propane tank handle 10 is shown in FIG. 2 . Further, the cap 20 includes ridge grips 50 around the outside circumference allowing for better gripping when rotating the cap. The cap 20 also has two visually distinct sides. More specifically, one side 30 is color-coded, preferably GREEN, and imprinted with an indicator (e.g., FULL 28 ). Moreover, the one side 30 includes the word OPEN 24 with a direction arrow and the word CLOSE 24 with an opposite direction arrow indicating how to operate a tank valve. The other side 32 (e.g., opposite side) is also color-coded, preferably RED, and is imprinted with the indicator EMPTY 26 ( FIG. 4 ). The other side 32 also includes OPEN 24 and CLOSE 24 labels with directional respective arrows. It is useful to note that the indicator 26 , 28 may also be a symbol, such as a recognized representation for FULL or EMPTY.
In a convenient embodiment, for each orientation illustrated in FIGS. 2 and 4 , the cap 20 is pressed down over the three pronged propane tank handle 10 until lower flexible fins 22 snap under each prong of the tank handle 10 . The upper and lower fins 22 hold the cap 20 in place on the tank handle 10 . In this way, a user can removably secure the cap 20 in the appropriate and desired orientation (FULL 28 indicator side up or EMPTY 26 indicator side up), and thereafter be able to visually recognize the indicator (e.g., FULL 28 or EMPTY 26 ) on the propane tank by viewing the cap 20 (i.e., at a glance).
Shown in FIGS. 3-5 is a cross section view of cap 20 ( FIG. 3 ), a top view of the EMPTY 26 indicating side 32 ( FIG. 4 ), and a cross sectional view of the cap installed on the propane tank handle 10 ( FIG. 5 ). More accurately, FIGS. 3-5 show details of the indicators OPEN 24 , CLOSE 24 , and EMPTY 26 . From the cross sectional view of FIG. 3 , one can distinguish between the EMPTY indicating side 32 (a red side in one embodiment) and the FULL indicating side 30 (a green side in one embodiment). Also shown in detail are ridges 50 allowing for a better grip for a user. Moreover, the flexible upper and lower fins 22 are seen in FIG. 3 and FIG. 5 . The flexible fins 22 secure the cap 20 to a three (or any number) pronged tank handle 10 . The relationship between the flexible fins 22 and the multi-pronged tank handle 10 is shown in FIG. 5 .
In use, the user removably secures cap 20 FULL 28 indicia side 30 up (e.g., green side 30 up) onto tank handle 10 of a full propane tank. This is accomplished by respectively orienting cap 20 (side 30 up) and snapping cap 20 over or pressing the cap 20 onto the tank handle 10 . After use of the contents of the tank, i.e., when the tank is effectively empty of its contents, the user lifts cap 20 off tank handle 10 and changes orientation of cap 20 . That is, the user flips cap 20 over to bear opposite (red) side 32 . now with EMPTY indicator 26 (red) side 32 up, the user applies (presses) cap 20 onto the tank handle 10 removably securing cap 20 in its new orientation. As a result, cap 20 now at a glance (readably visually) indicates that the subject tank is empty and the user can easily avoid attempting to use contents from the tank. Instead, the convenient cap indicators let the user know, again at a glance and without lifting the tank, that the tank needs refilling or replenishing of contents. Once the user refills the tank the user reasserts cap 20 to be removably secured on handle 10 in the orientation reading “FULL” and so on.
FIGS. 6-8 show a cap embodiment assembled in two components, where one component 300 (a green piece) indicates FULL 280 and the other component 320 (a red piece) indicates EMPTY 260 . Both components are shaped like a bowl with the FULL 280 component 300 having pencil-like prongs 42 with ridges on the ends protruding from a bottom side. Similarly, EMPTY 260 component has holes 40 having a ridge inside that receives prongs 42 . To make the cap 200 ready for use, the prongs 42 of component 300 are snapped into respective receiving holes 40 of component 320 . Once the components 300 , 320 are snapped together, both components during use in this manner, they will not separate from each other during cap 200 use. An additional benefit of snapping the components 300 , 320 together is ridges 50 are formed, by way of the cap assembly, resulting in a more comfortable grip. Further, the cap 200 also includes CLOSE 24 and OPEN 24 indicators with respective directional arrows for providing to a user operating instruction for the valve. Moreover, on the green component 300 , the indicator “FULL” 280 is imprinted on the bottom of a bowl shaped surface. On its counterpart, the red color component 320 , the indicator “EMPTY” 260 is similarly imprinted on the respective bottom of the bowl surface of component 320 .
For further convenience, each component 300 , 320 includes flexible fins 22 as shown in the cross sectional of FIGS. 8-9 . The flexible fins 22 are used to removably secure a cap 200 to a tank handle 10 , in the desired one of two orientations at a time, in the manner describe above for cap 20 in FIGS. 1-5 . For example, FIG. 9 shows how the fins 22 snap under the tank handle 10 to temporarily securely hold the cap 200 in place (i.e., in removably secure fashion).
FIG. 10 represents an alternative embodiment of a visual indicator cap 403 . In particular, the cap 403 includes a first half 410 or first portion, a second half 405 or second portion, and a receiving inlet 415 . In FIG. 12 for purposes of illustration, the first half 410 is shown forward facing and includes indicia (e.g., FULL) in proper reading orientation for a user to determine, at a glance, whether the contents of the tank are near full. The second half 405 is shown backwards facing and includes indicia (e.g., EMPTY) that is not in proper reading orientation when the cap 403 is positioned with the first half 410 facing out. As will be further described below, depending on orientation (position/placement) of cap 403 on a subject tank, one of the two halves 405 , 410 will be outward facing and in proper reading orientation to indicate respective contents level (empty or full) of the tank.
Also shown is a strap 420 , which includes a swivel connector 425 at a distal end. The swivel connector 425 is adapted to cooperate with the receiving inlet 415 so as to form a rotatable connection with cap 403 . A close-up view of the swivel connector 425 is shown in FIG. 10A . The swivel connector 425 also provides a fastened connection by using flexible fins 428 . The flexible fins 428 protrude into the receiving inlet 415 of FIG. 10 and secure the swivel connector 425 to the cap 403 . A top-view of the connection (strap 420 connected to cap 403 ) is shown in FIG. 11 . First half 405 and second half 410 are shown on either side of a ring 430 , and the ring 430 couples receiving inlet 415 to cap 403 . The receiving inlet 415 receives swivel connector 425 to form a rotatable connection.
The swivel connector 425 provides a rotational movement of about 360 degrees within receiving inlet 415 . The rotational movement allows the strap 420 and cap 403 to rotate relative to each other and to change angular position, relative to each other, about a longitudinal axis. For example, cap 403 rotates, using the swivel connector 425 , to reverse the position of the first half 410 and the second half 405 . That is, the first half 410 can be moved (repositioned) to be backwards facing and the second half 405 becomes forward facing. As a result, the indicia (e.g., EMPTY) of the second half 405 moves to a proper reading orientation and the indicia (i.e., indicator) of the first half 410 is consequently placed in a non-readable orientation as desired by the user.
FIG. 12 shows cap 403 placed over a tank valve, orifice, or other opening 455 . In a preferred embodiment, the cap 403 includes a first cup-shaped half 410 that is color-coded, preferably GREEN, and imprinted with the indicator FULL 28 . A second. cup-shaped half 405 is also color-coded, preferably RED, and is imprinted with the indicator (a word, symbol or other indicia) EMPTY 26 . At one end, strap 420 connects to the tank valve 455 . At the other end, the strap 420 attaches to receiving inlet 415 in rotational freedom fashion described above. By attaching the distal end of strap 420 to the receiving inlet 415 , the strap 420 secures (tethers) the cap 403 to the tank valve 455 and also enables the cap 403 to be rotatable by a user at the receiving inlet 415 . For example, a user may remove the cap 403 from the tank valve 455 and swivel, pivot, or rotate the cap 403 to be in the reverse direction (orientation). That is, the user rotates the first half 410 from forward facing to backwards facing (i.e., towards the stem of the tank valve 455 ) and the second half 405 from backwards facing to forward facing (i.e., away/outward from the tank). After rotating the cap 403 , the user places the cap 403 over the tank valve 455 opening where the indicia (e.g., EMPTY) of the second half 405 is in proper reading orientation. To aide a user in removably securing the cap 403 over the tank valve 455 opening, the cap 403 (cup halves 405 , 410 ) is made of internal dimensions and material that allows a comfortable loose fit over such opening. It is useful to note that the cap 403 may be two separate pieces that are snapped together in the same manner as described in FIGS. 6-8 above.
It should be understood that any of the embodiments disclosed herein, such as the cap of FIG. 1 or FIG. 10 , may be implemented without the use of sensors (e.g., sensor-less) or electronics. If implemented without the use of sensors, a user may manually position/reposition the cap.
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.
For example, in addition to the above retrofit type caps/handle covers, initial handles manufactured with the tank stem may incorporate the principles of the present invention. A releasable and reversible (top to bottom side up and vice versa) cap may incorporate the color scheme and FULL/EMPTY coordinating indicia as described above and shown in the drawings.
Although the above description refers to propane tanks, the present invention cap is useable on other tanks, refillable containers and the like of various contents. | A tank handle or cap is designed for the convenience of the consumer. One aspect of the invention cap allows the end user to determine at a glace and from a distance if the tank is full or empty based on color distinction and/or word imprints on different sides (halves) of the invention cap. The cap is removably securable to the tank in different orientations to effectively expose the telling side of the invention cap. This allows the user the ability not to have to go over to the tank and lift the tank to gauge if the tank is full or not. This will reduce the risk of possible back injury. Other design features include an easy-to-use grip and open and close directional indicators to allow clear and concise understanding and operation of tank valves. | 5 |
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without he payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
This invention relates to fluid jet valves and in particular to valves which comprise two opposing tube openings with high pressure fluid flowing out of one of the tube openings toward the other. The other tube opening may also be in the form of a fixed valve seat or orifice equipped receiver plate. In these valves one or both of the tube openings are movable so that they may be either coaxially aligned with each other or misaligned. A valve of this type is described in detail in the U.S. Pat. No. 3,939,857. In that valve, both of the opposing tube ends are laterally movable by means of piezoelectric actuators which are driven by electric signals. Many other types of electrical or mechanical actuators may also be used to move the opposing tube ends. The tube ends on the valves disclosed in that patent were cut off square so that the surface of each end was perpendicular to the longitudinal axis of the tube. If the two opposing tube ends in that valve were coaxially aligned with each other in positions so close that they were in contact, the tube ends would bind or catch each other when an attempt is made to deflect them laterally apart. Square cut tube ends of this type must be mounted with a large enough separation when they are coaxially aligned with each other so that the tube ends will not bind when they are deflected apart. Because a minimum clearance must always be maintained between the two tube ends, there will always be a considerable leakage of the pressurized fluid flowing through the tubes. The amount of this leakage will depend upon the pressure of the fluid and the amount of clearance between the two opposing tube ends. Regardless of how high the input fluid pressure to the valve may be, the output fluid pressure from the valve will be much lower as long as a great deal of the fluid is leaking out through the gap between the two tube ends. The prior art shows end surfaces on jet valve tubes which are rounded in shape so as to avoid binding when the tube ends are positioned close to another surface. However, these rounded ends are not complementary to each other (male and female) and these these valves do not allow or provide for a tight seal between the movable jet tube end and the opposing jet fluid passage. It would be desirable for the tube ends of these fluid jet valves to form a tight seal while they are coaxially aligned with each other and also to be shaped so that they can be easily deflected apart from each other when it is desired to turn the valve off. It would also be desirable to obtain the tight seal by using small lateral seating forces in such a way as to generate large axial force components which crush contaminants and press the seats together.
OBJECTS OF THE INVENTION
It is therefore an object of this invention to provide a fluid valve comprising two opposing axially fixed tubes wherein the tubes form a tight seal when they are coaxially aligned with each other.
It is also an object of this invention to provide a fluid valve comprising two opposing tubes wherein the tube ends may be deflected apart from each other without catching or binding even though the tube ends fit together to form a tight seal when they are coaxially aligned with each other.
It is also an object of this invention to provide a valve comprising two opposing, cantilevered, laterally deflectable tubes which convert and amplify anti-deflection forces or anti-deflection stresses into large axial forces along the alignment axes, whereby the axial force becomes equal to the cotangent of the average tilt angle times the anti-deflection force.
It is another object of this invention to provide a fluid valve comprising two opposing tubes with tube ends which make a relative seating motion consisting of a combination of a relatively large lateral shear motion and a relatively small axial seating motion.
It is another object of this invention to provide a fluid valve comprising two opposing tubes with tube ends performing the seating and closure motion whereby the actuator motion is approximately perpendicular to the seating force when the tubes are fully aligned so that little if any actuator force has to be maintained when the valve is closed in a fully aligned position.
It is another object of this invention to provide a fluid valve comprising two opposing tubes which minimizes the pressure loss of the fluid flowing through the valve while the tubes are aligned.
SUMMARY OF THE INVENTION
This invention provides for specially shaped end surfaces on the jet tubes of fluid transfer valves which have two opposing jet tubes. The jet tubes end surfaces are tilted so that either one or both of the two tubes may be moved sideways away from each other without binding or catching on each other even though the two tubes are in contact when coaxially aligned with each other. The shape of the surface on the end of one tube is made to be an inverted reproduction of the shape of the opposing tube end surface so that when the two tube ends are coaxially aligned with each other and pressed together they will match up and fit together. A tight seal will thus be formed which will allow very little fluid to leak through the joint between them. This tight seal will minimize the amount of pressure loss of fluid flowing through the valve when the two tube ends are coaxially aligned with each other. In the preferred embodiment, each of the tube ends will have a concave surface over half of the tube end and a convex surface with the same curvature over the other half of the tube end. The positions of the concave halves and convex halves of the surfaces on the opposing tubes are reversed so that the tube openings will match up and fit together tightly. The tube ends in the preferred embodiment will always be deflected apart sideways in opposite directions which face outward from the sides of the tubes. Alternatively, the tube ends may be cut perpendicular, as in the prior art, and forced together by supporting the base end of each cantilevered tube with an axial actuator to form a tight seal at those time when the tube ends are coaxially aligned with each other. Whenever it is desired to deflect the tube ends away from each other in this alternative embodiment, the axial pressure forcing the tube ends together must be released first. This will allow enough clearance between the tube ends so that they may move apart laterally without binding. In any of the embodiments of this invention the seal between the two ends of the tubes may be tightened by covering the end surfaces with an elastic material which is deformable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross sectional view of two fluid jet valve tube ends which are coaxially aligned with each other and which have the shape of the preferred embodiment of this invention.
FIG. 2 shows a cross section of the same valve tube ends and as in FIG. 1 but with the tube ends deflected sideways from each other.
FIG. 3 is like FIG. 2 except that the tube end surfaces have a slightly different curvature.
FIG. 4 shows a cross sectional view of another embodiment of this invention wherein the tube ends are cut off square and an axial separation actuator is used to force the tube ends together to form a tight seal.
FIG. 5 shows another embodiment of the invention wherein the tube end surfaces are tilted as in FIGS. 1, 2 and 3 but are flat instead of curved.
FIG. 6 shows a variation of the embodiment shown in FIG. 4 wherein a pile of piezoelectric discs is used as the axial separation actuator.
FIG. 7 shows another embodiment of the invention wherein the tube end surfaces are covered with a material which is relatively elastic and deformable relative to the rest of the tube.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The views in FIGS. 1, 2, 3, 4 and 7 illustrate how the novel tube end surfaces of this invention would be used on a fluid jet valve such as, for example, the valve disclosed in U.S. Pat. No. 3,939,857. In that valve, the open ends of two cantilevered tubes are deflected laterally to turn the valve on and off. The tubes are made of a laterally deflectable piezoelectric material so that when a signal is applied, the open tube ends bend laterally apart from each other.
In FIG. 1 the ends of two tubes 18 and 19 of a fluid jet valve are shown coaxially aligned with each other and in abutting contact with each other wherein their respective longitudinal axes, as represented by broken lines exending between points 11 and 16 and 12 and 15, are likewise coaxially aligned. The surfaces of the ends of the tubes may be defined as being sections of cylindrical surfaces. That part of the end surface of tube 18 which lies between points 16 and 13 is defined by the intersection between the tube 18 and a cylindrical surface whose central axis passes through pivot point 11. The radius of this cylindrical surface is equal to the distance between point 11 and point 16 which is also equal to the distance between point 11 and point 13. The opposing end surface of tube 19 between points 15 and 23 has the same radius and center of curvature as the surface between points 16 and 13 on tube 18, but is concave instead of convex. The surface on the end of tube 19 between point 15 and point 14 is defined by the intersection between the tube 19 and a cylindrical surface whose central axis passes through point 12. The radius of the cylindrical surface is equal to the distance between the points 12 and 15 which is also equal to the distance between point 12 and 14. Tube 18 is shortest at point 13 and gradually becomes longer across the end of the tube until it reaches its maximum length at point 22. Similarly tube 19 is shortest at point 14 and gradually becomes longer across the end of the tube until it reaches its maximum length at point 23. At points 15 and 16 the seating surfaces are not tilted relative to the tube axes laying along the line 11 to 12.
The arrows 20 in FIG. 2 show the direction of movement of the end of tube 18 and the arrows 21 show the directions of movement of the end of tube 19. The tube 18 has been deflected downward by an angle α and the tube 19 has been deflected upward by angle α.
The view illustrated in FIG. 2 shows the case where the end of tube 19 is being rotated in a circular path about a pivot axis represented by point 12 and the end of tube 18 is being rotated in a circular path about a pivot axis represented by point 11. This circular motion is based on the phenomena that slender cantilevered beams describe an approximately circular motion during relatively small deflections. In FIG. 1 and FIG. 2, the tube ends are rotated in approximately circular paths about points 11 and 12 which are also the points about which the circular end surfaces are curved. In this situation, as long as any portion of the two tubes are opposite each other, the tubes will be substantially in contact with each other. In FIG. 2 the point of contact is at point 17. However, the tubes will not catch each other or bind against each other and they will move freely. If the radii at the tube ends are made slightly shorter than necessary for free sliding the seats will open immediately at point 17 because of the steeper curvature. In FIG. 3, as in FIG. 2, the left tube end 33 has been laterally deflected downward by an angle α in a circular path about point 11 as shown by arrows 20. Similarly, the adjacent ends of tubes 33 and 34 in FIG. 3 are spaced apart and their respective longitudinal axes, as represented by broken lines extending between points 11 and 16 and 12 and 15, are non-aligned. However, the radius of curvature of the cylindrical surfaces on the tube ends is shorter in FIG. 3 than in FIG. 2. That is, the tube ends curvature radii are slightly shorter than the radius of the arc generated by the deflecting cantilevered beams. The surface on the end of tube 33 between the points 27 and 30 is curved about point 25 instead of point 11 as in FIG. 2. The corresponding surface between points 35 and 31 at the end of tube 34 has the same increased curvature. The surface on the end of tube 34 between points 29 and 28 is curved about point 26 in FIG. 3 instead of about point 12 as in FIG. 2. The corresponding surface at the end of tube 33 between points 30 and 24 has the same increased curvature. The effect of decreasing the radius of curvature of the end surfaces of the tubes to be less than the radius of the circular path about which the tubes are moved when deflected is to cause the two tubes to immediately lose contact with each other as soon as they are not completely aligned. Therefore, in FIG. 3, point 32 on tube 33 is not in contact with point 31 on tube 34. It can be seen from FIGS. 2 and 3 that the ends of the two opposing tubes have complementary, contoured end faces which will not bind against each other when they are laterally deflected from their contact position as long as the radius of curvature of the end surfaces is equal to or less than the radius of curvature of the path along which the ends of the tubes move when deflected. However, to avoid binding contact therebetween, the two tube ends must always be deflected away from each other by bending them about axes which are parallel to the axes defining the cylindrical curved tube end surfaces. This will result in the paths of the two tube ends always lying within a single plane surface.
In order to achieve a tight seal between the ends of the two tubes, as shown in FIG. 1, it is necessary that the surface on the end of one tube be complementary to the surface of the end of the opposing tube. The surface on the end of one tube, such as tube 19 in FIG. 1, must be an inverted reproduction of the surface on the end of the opposing tubes, such as tube 18 in FIG. 1.
In order that the two tubes should form a tight seal when they are aligned with each other it is important that the tubes be mounted in such a way that there is no positive clearance between the tube ends while they are aligned. It is desirable to mount the tubes so that there will be a very slight negative clearance between them while coaxially aligned with each other. The amount of this negative clearance should be large enough so as to create a significant amount of force pushing the tubes together while they are aligned, yet at the same time not so great as to cause the tubes to bind against each other. The negative clearance will cause an equal axial deflection of the tube ends as determined by the axial compression of the tubes and elasticity of the tube's supporting frame. This axial deflection of the tube ends will be along a line between points 11 and 12. The tube endings which are illustrated in FIG. 1, 2 and 3 would have hardened and polished surfaces so that the tube endings may easily slide across each other when in contact. However, the same tube end faces could also be made, as shown in FIG. 7, out of an elastic deformable and compressable material which has a very low sheer friction coefficient. By placing an elastic deformable material 49 on the ends of the tubes 48 and 47, a tight seal may still be obtained between the two tubes if the end surface on one is not an exact reproduction of the end surface of the other or if defects, contaminants or scratches occur on one of the end surfaces. When fluid jet valve tubes have tube endings such as illustrated in FIG. 1 through 3, small portions of the end surfaces will slide against each other for a short distance before they finally stop and make a firm seat. The length of this distance will be much shorter in FIG. 3 than in FIGS. 1 and 2. This sliding or wiping action will tend to keep the tube end surfaces cleaned of any material which might tend to hold the tube ends apart. When the tube ends deflect toward each other to close, they cannot easily over travel and pass each other since when they reach the point at which they are exactly aligned with each other, they will hit and stop each other from moving further past such predetermined aligned position. The valve can be set up to exert a continuing closing force which will hold the tube ends tightly closed. A high closing speed of the two tubes ends when they hit and seal against each other while closing will cause rapidly damped vibrations. This rapid damping is a result of low mass inertia, sliding friction at tube ends, energy absorbed by the actuators, and the hysteresis losses of axial deflections and lateral tube deflections.
FIG. 4 illustrates an embodiment of the invention whereby the two tubes of a fluid jet valve may be sealed tightly against each other while they are aligned and yet still be free to be deflected apart even though the tube ends are not tilted or slanted as are those shown in FIGS. 1, 2 and 3. In FIG. 4 the tube 55 is mounted on a block of material 52 which has a high coefficient of axial thermal expansion. The fluid flows through the channel 56 in the block 52 and the tube 55. The end surfaces 58 and 59 of the tubes 55 and 57 are flat and perpendicular to the longitudinal axes of these tubes. In FIG. 4 the tube 55 is shown in a deflected position relative to tube 57. The lead in wires 50 supply electrical current to the heater coil 51 which heats up the block 52 causing it to expand. When the current is turned off, the block 52 will contract. The tube 55 is made of a piezoelectric material which will be deflected when actuated by voltages applied to electrodes 53 and 54. While in operation, when the tube 55 is deflected so that the end surface 58 is not aligned with the end surface 59 of tube 57, there will be no current flowing through the heating coil 50 and the block 52 will be relatively cool. When the tube 55 is not deflected and thus the end surface 58 is aligned opposite the end surface 59 of tube 57, current will flow through the heating coil 51 to cause the block 52 to heat up and expand. The expansion of block 52 will exert a force through the tube 55 to force the tube end surfaces 58 and 59 together to form a tight seal. When it is desired to deflect the tube 55 again, the current through the heating coil will be turned off allowing the block 52 to cool down and contract and thus to pull the tube 55 far enough away from the tube 57 so that it may be deflected without binding against the end 59 of tube 57. Alternatively, as shown in FIG. 6 the block could be made of a stack of piezoelectric discs 43 which will exert axial forces on the tube 55 whenever the discs are activated. With this alternative, the heating coils 51 would be unnecessary. The stack of piezoelectric discs 43 are supported by the bracket 42 and flexible retaining ring 46. The piezoelectric discs are activated by way of the input leads 44 and 45.
Whereas the embodiments of the invention shown in FIGS. 1, 2 and 3 have curved surfaces, the invention could also be built with flat tube end surfaces such as shown in FIG. 5. If a continuing lateral closing force is applied between the two tubes 40 and 41, a tight seal will be formed between them. The flat end surfaces need to be tilted at a larger angle than do the curved end surfaces in order to prevent the opposing tube ends from binding against each other. The average tilt angle of the curved tube end surfaces in FIG. 3, β, may be smaller than the tilt angle α of the flat tube end surfaces shown in FIG. 5. The use of smaller tilt angles for the tube ends will result in a tighter seal and less leakage.
Obviously many modifications and variations of this invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | In fluid jet transfer valves comprising two opposing jet tube openings with high pressure fluid flowing out of one opening towards the other, the end surfaces of the jet tubes are provided with a novel shape which allows the tube ends to seal tightly together when they are coaxially aligned with each other and also to be deflected apart without binding. The shape of the end surface on one of the tubes is an inverted reproduction of the surface on the opposing tube so that when the tubes are coaxially aligned with each other and pressed together a tight seal will be formed. The end surfaces on the tubes are shaped so that the tubes may be freely moved laterally relative to each other without binding. The tilt of the end surfaces of the two tubes is minimized so that small lateral closure forces will generate much larger axial seating forces and so that the lateral opening forces created by escaping high pressure fluid are minimized. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a heat exchanger made of aluminum alloys, such as condenser, evaporator and so forth incorporated in automobile air conditioners, and more particularly relates to a corrugate fin type heat exchanger made of aluminum alloys and improved to prevent pitting corrosion of the heat exchanger tubes, and further relates to a tube material for such heat exchanger.
Conventionally, the tubes of corrugate fin type heat exchangers made of aluminum alloys are formed of an aluminum alloy generally referred to as 3003 specified in the U.S. Aluminum Association Standard (hereinafter called "AA") having compositions consisting essentially of 0.05 to 0.20 wt% of Cu, not more than 0.6 wt% of Si, not more than 0.7 wt% of Fe, 1.0 to 1.5 wt% of Mn, not more than 0.10 wt% of Zn and the balance Al, or are formed of an aluminum alloy of compositions having a slightly lower Mn content than the AA 3003 aluminum alloy. As to the material of the corrugate fin, a core material of an aluminum-zinc alloy, which has an electrochemical potential lower than the AA 3003 aluminum alloy constituting the tubes and thus exhibits a sacrificial corrosion effect to prevent the corrosion of the tubes, is used in combination with a cladding layer for brazing filler alloy.
The AA 3003 aluminum alloy used as the tube material, however, has such poor drawing or hot-extrusion characteristics (drawability or hot-extrudability) as amounts, for example, to about 1/3 of that of pure aluminum such as AA 1050. Therefore, the production of the heat exchanger tubes from the AA 3003 alloy by drawing or hot-extrusion costs much higher than the production from the pure aluminum, resulting in a raised cost of production of the heat exchanger as a whole.
SUMMARY OF THE INVENTION
Accordingly, an object of the invention is to provide a heat exchanger made of aluminum alloys, capable of eliminating the above-described problems of the prior art while maintaining the pitting corrosion resistance of the tubes equivalent to that of the tubes made from the AA 3003 aluminum alloy.
To this end, according to the invention, there is provided a heat exchanger made of aluminum alloys comprising tubes each made of an aluminum alloy consisting essentially of 0.2 to 1.0 wt% of Cu, the balance aluminum and inevitable impurities; and fins attached to the tubes, at least a part of each fin being made of another aluminum alloy which is lower in electrochemical potential than the aluminum alloy constituting the tubes thereby to bring about a sacrificial corrosion effect.
In the heat exchanger in accordance with the invention, the aluminum alloy used as the material of the tube is an alloy consisting essentially of 0.2 to 1.0 wt% of Cu, the balance aluminum and inevitable impurities in which, particularly, the amount of Fe and Si is not more than 1.0 wt%.
Hereinafter, the percentages (%) of contents of aluminum alloy compositions will be represented as weight percent (wt%).
According to the invention, an aluminum alloy consisting of 0.2 to 1.0% of Cu and the balance aluminum and inevitable impurities is used as the alloy material for the tubes of the heat exchanger. This alloy has a greater copper content than the pure aluminum (AA 1050) conventionally used as a tube material which pure aluminum consisting of not more than 0.05% of Cu, not more than 0.25% of Si, not more than 0.40% of Fe, not more than 0.05% of Mn, not more than 0.05% of Mg, not more than 0.05% of Zn, not more than 0.03% of Ti and more than 99.50% of Al. Thus, this alloy used in the present invention exhibits an electrochemical potential value approximating that of the conventional tube material, i.e. AA 3003 aluminum alloy. If the copper content in the alloy is below 0.2%, unsatisfactorily the electrochemical potential of the alloy does not become similar to that of the AA 3003 aluminum alloy. To the contrary, a copper content in excess if 1.0% makes the alloy impractically hard in hardness to decrease the characteristics of the drawing or hot-extrusion, as well as bending characteristics of the alloy, although the electrochemical potential becomes sufficiently high in value. It is a particular tendency peculiar to copper that the electrochemical potential of the aluminum alloy is increased by addition of a small amount of copper. It is also possible to obtain a drawing or hot-extrusion characteristics, as well as bending characteristics, equivalent to that of AA 1050 aluminum alloy, by maintaining the amount of addition of copper at a level not more than 1.0%. By using this tube material in combination with the fin material acting as a sacrificial anode, it is possible to obtain a pitting corrosion resistance of the tubes equivalent to that of the conventionally used AA 3003 aluminum alloy. The sacrificial anode material is constituted by a brazing sheet in which a brazing filler material of Al-Si base alloy or Al-Si-Mg base alloy acting as a cladding layer is clad to each surface of the core with a cladding ratio of 5 to 20% with respect to each side of the core material. The core material may be formed from an Al-Mn base alloy such as AA 3003, AA 3203 or the like with an addition of small amount of Zn, Sn or In. These elements may be added also to the brazing filler material. The bonding of the fins to the tube is achieved by a brazing method including flux brazing, vacuum brazing, brazing process under an inert gas atmosphere and so forth.
According to the invention, an alloy obtained by adding small amounts of Sn and Zn to the AA 3003 aluminum alloy is preferably used as the material of the core member of the sacrificial corrosion fin having lower electrochemical potential value for use in combination with the above-described tubes of heat exchanger made from aluminum alloy embodying the present invention. For instance, the core member of the fin is made of an aluminum alloy consisting of 0.05 to 0.20% of Cu, not more than 0.6% of Si, not more than 0.7% of Fe, 1.0 to 1.5% of Mn, not more than 1.0% of Zn, not more than 0.06% of Sn, and the balance aluminum and not more than 0.15% of inevitable impurities. It is also possible to use as the material of the core member of the sacrificial corrosion fin an alloy which is obtained by adding not more than 1.0% of Zn and not more than 0.06% of Sn to the AA 3203 alloy which consists of not more than 0.05 % of Cu, not more than 0.6% of Si, not more than 0.7% of Fe,, 1.0 to 1.5% of Mn, not more than 0.10% of Zn and the balance Al.
According to the invention, it is also preferred to use, as an aluminum alloy material for tubes having a pitting corrosion resistance equivalent to that of the AA 3003 aluminum alloy when combined with the sacrificial anode fin and extrusion characteristic equivalent to that of pure aluminum such as AA1050, AA1100 and the like, an alloy consisting essentially of 0.2 to 1.0% of Cu, and the balance Al and inevitable impurifies in which, particularly, the amount of Fe and Si is not more than 1.0%. Fe and Si exist unavoidably or inevitably as impurities of aluminum. Moderate cost and strength are obtainable by the presence of Fe and Si. However, if the sum of the Fe and Si contents exceeds 1.0%, the corrosion resistance of the aluminum alloy is decreased and the extrudability into tubes and the formability of tubes after extrusion is decreased undesirably. In order to reduce the Fe and Si contents, it is necessary to use aluminum metal having a high purity. Such a aluminum metal having high purity, however, is generally expensive. For reducing the cost to an acceptable level while maintaining the required mechanical strength and other requisites, the sum of Fe and Si contents is preferably in a range between 0.4 and 1.0%.
Other objects, features and advantages of the invention will become clear from the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a condenser which embodies the heat exchanger in accordance with the invention;
FIG. 2 is a perspective view of an evaporator which embodies the heat exchanger in accordance with the invention;
FIG. 3 is an enlarged view of a part of the heat exchanger in accordance with the invention showing particularly the state of jointing between the fins and tubes;
FIG. 4 is a perspective view of an extruded tube as used in the heat exchanger of the invention; and
FIG. 5 is a front elevational view of a model core similar to that of the heat exchanger in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate, respectively, a condenser and an evaporator constructed in accordance with the heat exchangers of first to fifth embodiments described hereinunder. Each heat exchanger comprises a plurality of corrugate fins 1 arranged between adjacent turns of a winding tube 2 formed by a hot-extrusion. Reference numerals 3 and 4 designate, respectively, a fluid inlet and a fluid outlet. FIG. 3 shows, in larger scale, the tube 2 and the corrugate fin 1 of the heat exchanger. It will be seen that the corrugate fin 1 is constituted by a core member 6 and a cladding 5 which is made of a brazing filler. As shown in the drawings, the corrugate fin 1 is bonded by brazing to adjacent turns of the tube 2 which is bent to have a meandering form. This brazing is made by making use of the brazing material cladding 5 which is beforehand provided on the surface of the core member 6. Pipes for the fluid inlet 3 and fluid outlet 4 are connected to both ends of the tube 2. In the drawings, the arrow indicates the direction of flow of a refrigerant.
Embodiment 1:
The tube is made of a material having a chemical composition consisting of 0.4% of Cu, and the balance Al and inevitable impurities in which, particularly, the amount of Fe and Si is 0.4%. The extrusion characteristics (extrusion rate at a billet temperature of 450° C.) of the above-mentioned aluminum alloy into the heat exchanger tube shown in FIG. 4 was 80 m/min. This extrusion rate is substantially equivalent to that of AA1050 alloy advantageously. On the other hand the AA3003 alloy material exhibits, under the same extrusion condition, a very decreased extrusion rate of 30 m/min.
As shown in FIG. 4, the tube has a rectangular cross-section with four parallel bores and a thickness of 1.0 mm. The corrugate fin for use in combination with the tubes is made of a brazing sheet having a total thickness of 0.16 mm and constituted by a core member and claddings to both surfaces of the core member at a cladding ratio of 12% with respect to each side. The material of the core member consists essentially of 0.10% of Cu, 1.1% of Mn, 0.4% of Zn, 0.06% of Sn and the balance Al, while the material of the cladding is a brazing material for vacuum brazing consisting essentially of 10% of Si, 1.5% of Mg and the balance Al.
The fin was secured to the tube by the brazing which is conducted under the vacuum of 4×10 -5 Torr and at a temperature of 610° C. for 10 minutes to form the heat exchanger as shown in FIG. 1. The tube and fins after the vacuum brazing showed electrochemical potentials of -0.79 V and -0.90 V, respectively, when measured in a 3% aqueous solution of salt (R.T.). For information, the AA1050 alloy material and AA3003 alloy material generally exhibit potentials of -0.86 V and -0.78 V, respectively. Thus, the aluminum alloy used as the tube material of the invention shows a potential close to that of the AA3003 alloy.
The corrosion resistance of the aluminum heat exchanger thus produced was evaluated by a CASS test. The test result showed that the maximum depth of the pitting in the tube is as small as 0.12 mm during the term of 700 hours after the start of the test. The same test was conducted with heat exchangers having tubes made from the AA1050 alloy and AA3003 alloy, by way of reference. The depths of the pitting in the tube were 0.70 mm and 0.12 mm, respectively. It was thus confirmed that the aluminum alloy as tube material of the invention exhibits a corrosion resistance superior to that of the AA1050 alloy and equivalent to that of the AA3003 alloy.
Heat exchangers of second to fifth embodiments were produced by extruding tubes in the same manner as the first embodiment and assembling the tubes in the same manner as in the first embodiment. The fabricating conditions and test results of these embodiments are as follows:
Embodiment 2:
______________________________________components of tube material Al--0.3% Cu--0.5% (Fe + Si)tube thickness 0.9 mmcomponents of fin materialcore member; Al--0.12% Cu--1.1% Mn--0.4% Zn--0.06% Sncladding; Al--10% Si--1.5% Mgfin thickness 0.18 mmextrusion characteristicalloy used in the invention 80 m/min.(extrusion rate)AA1050 alloy 80 m/min.AA3003 alloy 30 m/min.CASS test maximum depth of pitting in tube after 700 hrs. testalloy used in the invention 0.15 mmAA1050 alloy 0.72 mmAA3003 alloy 0.16 mmbrazing condition 6 × 10.sup.-5 Torr 600° C., 8 minutes______________________________________
Embodiment 3:
______________________________________components of tube material Al--0.5% Cu--0.45% (Fe + Si)tube thickness 0.87 mmcomponents of fin materialcore member; Al--0.15% Cu--1.1% Mn--0.4% Zn--0.01 Sncladding; Al--9.5% Si--1.3% Mgfin thickness 0.16 mmextrusion characteristicalloy used in invention 80 m/min.AA1050 alloy 80 m/min.AA3003 alloy 30 m/min.CASS test maximum depth of pitting in tube after 1000 hrs. testalloy used in invention 0.14 mmAA1050 alloy 0.78 mmAA3003 alloy 0.14 mmbrazing condition 5 × 10.sup.-5 Torr, 600° C., 12______________________________________minutes
Embodiment 4:
______________________________________components of tube material Al--0.8% Cu--0.4% (Fe + Si)tube thickness 1.0 mmcomponents of fin materialcore member; Al--0.10% Cu--1.1% Mn--1.0% Zn cladding;Al--7.5% Sifin thickness 0.16 mmextrusion characteristicalloy used in the invention 75 m/min.AA1050 alloy 80 m/min.AA3003 alloy 30 m/min.CASS test maximum depth of pitting in tube after 1000 hrs. testalloy used in invention 0.16 mmAA1050 alloy 0.80 mmAA3003 alloy 0.15 mmbrazing condition flux brazing (without Zn) 610° C., 10______________________________________minutes
Embodiment 5:
______________________________________components of tube material Al--0.6% Cu--0.8% (Fe + Si)tube thickness 1.0 mmcomponents of fin materialcore member; Al--0.12% Cu--1.1% Mn--0.9% Zn cladding;Al--10% Si--0.08% Bifin thickness 0.16 mmextrusion characteristicalloy used in invention 78 m/min.AA1050 alloy 80 m/min.AA3003 alloy 30 m/min.CASS test maximum depth of pitting in tube after 1000 hrs testalloy used in invention 0.15 mmAA1050 alloy 0.79 mmAA3003 alloy 0.15 mmbrazing condition 600 Torr in N.sub.2 gas atmosphere600° C., 10 minutes______________________________________
Embodiment 6:
Aluminum alloys of compositions of Nos. 1 to 5 in the following table were produced by water-cooled casting to have a billet form of 175 mm diameter×400 mm length. The billets of these alloys were then subjected to a soaking treatment at 250° C. for 3 hours and then to a hot-extrusion at about 450° C. into tubes having a form as shown in FIG. 4, having a wall thickness (t) of 1 mm, width (w) of 32 mm and a height (h) of 5 mm. On the other hand, the fin was formed from a brazing sheet (thickness 0.16 mm) having of a core member of an aluminum alloy consisting of 0.12% Cu 1.1% of Mn, 1.0% of Zn and the balance Al, and claddings to both sides of the core member which claddings is made of an aluminum alloy consisting of 7.5% of Si and the balance Al (AA4343). The brazing sheet was then corrugated to have fins of a height of 20 mm and a pitch of 4 mm.
After degreasing of the tube and the fin, these two members are fixed by an iron jig and were applied with a flux, and were placed in an air furnace at a temperature of 610° C. for 10 minutes for effecting brazing to fabricate a model core as shown in FIG. 5. A CASS test was conducted with these samples, and the period of time was measured until the wall thickness of 1 mm is completely penetrated by the pitting to evaluate the corrosion resistance. Also, the electrochemical potentials of the tubes and fins were measured in 5% aqueous solution of NaCl. Furthermore, the extrusion characteristics were evaluated through measurement of the extrusion rate for the aluminum alloy tube material of the invention. The results of these tests are also shown in the following table, together with the results of the same tests conducted with reference materials Nos. 6 and 7, as well as the conventional alloy.
__________________________________________________________________________ CASS test Extrusion (time till character- Cu Mn Fe + Si Potential penetra- istics (%) (%) (%) Balance mV (SCE) tion) (Hr) (m/min)__________________________________________________________________________Alloys of the No. 1 0.2 -- 0.5 AI and other -730 1400 or 80invention impurities longer No. 2 0.5 -- 0.5 AI and other -720 1500 or 80 impurities longer No. 3 1.0 -- 0.5 AI and other -720 1500 or 55 impurities longer No. 4 0.5 -- 0.2 AI and other -720 1500 or 80 impurities longer No. 5 0.5 -- 1.0 AI and other -720 1500 or 55 impurities longerReference No. 6 0.1 -- 0.5 AI and other -750 300 or 80alloys impurities longer No. 7 1.5 -- 0.5 AI and other -720 1500 or 40 impurities longerConventional A1050 -- -- 0.4 AI and other -780 300 or 80alloys impurities longer A3003 0.15 1.2 0.8 AI and other -710 1500 or 30 impurities longerElectro-chemical potential of corrugate -830 mVsacrificial fin__________________________________________________________________________
Embodiment 7:
An aluminum alloy consisting of 0.4% of Cu, 0.4% of Fe+Si and the balance aluminum was produced by watercooled casting into the form of billets (175 mm diameter×400 mm length) used as the material of the heat exchanger tube. After a soaking at 540° C. for 2 hours, the billets were subjected to a hot-extrusion at 470° C. into the form of tubes as shown in FIG. 4, having a thickness (t) of 1 mm, width (w) of 26 mm and a height (h) of 5 mm. On the other hand, the fin material was constituted by a brazing sheet (0.16 mm thick) having a core member of an aluminum alloy consisting of 0.15% of Cu, 1.1% of Mn, 0.06% of Sn, 0.6% of Zn and the balance Al, and cladding layers at both sides of the core member which cladding layers are made of an aluminum alloy containing 10% of Si, 1.5% of Mg and the balance Al. The brazing sheet was corrugated to have fins of 16 mm height and a pitch of 6 mm.
After degreasing, the tube and fin were fixed by means of an iron jig and were subjected to a vacuum brazing conducted under the vacuum of 5×10 -5 Torr at 600° C. for 3 minutes to form a model core as shown in FIG. 5. The model core was then subjected to a CASS test. The test result showed that it takes more than 1500 hours until the tube is completely perforated by corrosion. The alloy of the invention showed an extrusion rate of 80 m/min. which is equivalent to that of AA1050 alloy, as well as an electrochemical potential of -720 mV after the vacuum brazing substantially equivalent to that of A3003 alloy, while the fin serving as the sacrificial anode showed a potential of -1100 mV. By way of reference, the same CASS test was conducted with a tube made from AA1050 alloy. In this case, the tube was completely perforated by corrosion after about 500 hours.
Embodiment 8:
A tube was formed by extrusion in the same manner as the Embodiment 7, from an aluminum alloy consisting of 0.5% of Cu, 0.45% of Fe+Si and the balance Al. On the other hand, the fin was formed from a brazing sheet (0.16 mm thickness) constituted by a core member of an aluminum alloy consisting of 0.12% of Cu, 1.1% of Mn, 0.9% of Zn and the balance Al, and cladding layers clad to both side of the core member which layers are made of an aluminum alloy consisting of 10% of Si, 0.06% of Bi, 0.05% of Sn, 0.005% of Be and the balance Al. The brazing sheet was corrugated to have a plurality of fins of 18 mm height and a pitch of 4 mm.
The tube and fin were then subjected to an etching conducted for 1 minutes in a 5% NaOH solution at 60° C., and then to a pickling and rinsing by water. After a sufficient drying, these members were fixed by means of an iron jig, and were subjected to brazing conducted for 4 minutes in an N 2 gas atmosphere of 600 Torr to form a model core as shown in FIG. 5. This model core was subjected to a CASS test the result of which showed that it takes more than 1600 hours until the tube is completely perforated by corrosion. The extrusion rate of this alloy was 80 m/min which is equivalent to that of AA1050 alloy while the electrochemical potential after the brazing was -720 mV, while the fin serving as sacrificial anode showed a potential of -1050 mV.
By way of reference, the same CASS test was conducted with a tube made of AA1050 alloy. In this case, the tube was completely perforated by corrosion in about 450 hours.
In the embodiments of the invention described heretofore, aluminum alloys obtained by adding small amounts of Sn, Zn or the like to the AA3003 alloy are used as the material of the core member of the fin. This, however, is not exclusive and any aluminum alloy which exhibits an electrochemical potential value lower than that of the tube material can be used as the material of the fin.
The heat exchanger of the invention exhibits an pitting corrosion resistance of tubes equivalent to that of the conventional heat exchangers incorporating tubes made from AA3003 alloy, as well as a good drawing of extrusion characteristics of the material substantially equivalent to that of AA1050 aluminum to economically lower the cost of production of the heat exchanger as a whole. | A heat exchanger made of aluminum alloys comprising a tube made of an aluminum alloy consisting of 0.2 to 1.0 wt % of Cu and the balance Al and inevitable impurities, and fins jointed to the tube, at least a portion of each fin being formed from another aluminum alloy exhibiting and electrochemical potential value lower than that of the aluminum alloy from which the tube is made, so as to provide a sacrificial corrosion effect. Disclosed also is an aluminum alloy material having superior hot-extrusion characteristics and pitting corrosion resistance suitable for use as the material of heat exchanger tubes, the aluminum alloy material consisting of 0.2 to 1.0 wt % of Cu and the balance Al and inevitable impurities. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to a loudspeaker, comprising: an electro dynamic transducer whose diaphragm, when driven, vibrates in a rocking mode with a rocking frequency; and a bass reflex enclosure, in which said electro dynamic transducer is mounted.
[0002] The invention furthermore relates to a mobile device, comprising an inventive loudspeaker, in particular to a mobile phone, a PDA, a mobile computer, or a toy.
BACKGROUND OF THE INVENTION
[0003] A loudspeaker in the context of this patent comprises an electro dynamic transducer mounted in an enclosure. The electro dynamic transducer converts an electrical signal into sound. A purpose of the enclosure, which is also called a cabinet, is to prevent combining out-of-phase sound waves generated by the rear of the transducer with the positive phase sound waves generated by the front of the transducer, which would result in interference patterns and cancellation causing the efficiency of the loudspeaker to be compromised.
[0004] FIGS. 1 and 2 show an example of an electro dynamic transducer 1 . FIG. 1 shows the transducer 1 in a top view and FIG. 2 shows the transducer 1 in a cross-sectional view. The transducer 1 comprises a diaphragm 2 , a coil 3 attached to the diaphragm 2 , a magnet 4 interacting with the coil 3 , and a frame 5 . The frame 5 holds the magnet 4 and holds the diaphragm 2 via a surround 6 . If an electric signal is applied to the coil 3 , then the coil 3 causes the diaphragm 2 to vibrate in piston motion as indicated by a velocity vector 7 . Ideally, all points of the diaphragm 2 move uniformly relative to the velocity vector 7 as illustrated in FIG. 3 . In some circumstances, however, the diaphragm 2 may move as indicated by arrows 8 , resulting in vibratory rotational motion about an axis 9 . The non-piston motion of this type is illustrated in FIG. 4 and is also referred to as “rocking mode”, which may particularly present itself if the transducer does not comprise a spider as it is the case for the transducer 1 shown.
[0005] Rocking mode vibration is undesirable, because it may result in loss of acoustic efficiency or may distort the acoustic signal generated by the transducer 1 .
[0006] Published European application for patent 1 555 849 A2 discloses an acoustic passive radiator with rocking mode reduction. The passive radiator, which is sometimes referred to as a “drone”, comprises a diaphragm for radiating acoustic energy and a suspension. The diaphragm has a perimeter portion and a central portion which is thinner than the perimeter portion. The suspension includes a skin element encasing the diaphragm. The skin element comprises a surround for physically coupling the passive radiator to an enclosure, pneumatically sealing the diaphragm and the enclosure. A non-surround, non-spider suspension element coacts with the surround to control the motion and to support the weight of the diaphragm.
OBJECT AND SUMMARY OF THE INVENTION
[0007] It is an object of the invention to provide a loudspeaker whose enclosure at least supports reducing the rocking mode of the transducer of the loudspeaker.
[0008] The object of the invention is achieved by means of a loudspeaker, comprising an electro dynamic transducer whose diaphragm, when driven, can vibrate in a rocking mode with a rocking frequency, and a bass reflex enclosure, in which the electro dynamic transducer is mounted. The bass reflex enclosure is tuned to the rocking frequency. A bass reflex enclosure, also referred to as ported or vented enclosure, is a type of loudspeaker enclosure utilizing the sound from the rear side of the diaphragm of the transducer. Contrary to closed box loudspeakers, which are substantially airtight, the bass reflex enclosure comprises an opening, usually called a port or a vent, which may comprise a pipe or a duct, normally of rectangular or circular cross section. The opening resonates with the air inside the enclosure. The frequency, at which the bass reflex enclosure resonates is sometimes referred to as the Helmoltz resonance and depends on the size of enclosure and on the dimensions of the port. For conventional loudspeakers, a bass reflex enclosure is used to extend the frequency response of the loudspeaker below the range the transducer could reproduce in a closed enclosure. Thus, conventional bass reflex enclosures are tuned to a certain bass frequency.
[0009] The bass reflex enclosure of the inventive loudspeaker, however, is tuned to the rocking frequency of the electro dynamic transducer. Due to this inventive tuning, the excursion of the diaphragm of the transducer at the rocking frequency is at least decreased, if not completely suppressed. Therefore, if the bass reflex enclosure is tuned to the rocking frequency of the transducer, then the transducer is less prone to be excited at this frequency, resulting in less rocking of the diaphragm.
[0010] Electro dynamic transducers may comprise a spider system for improved stability of the diaphragm. Such spider systems may reduce the rocking of the transducer. Particularly for low-cost applications, transducers without such a spider system are used, such as the transducer 1 described in the introduction. The inventive tuning of the bass reflex enclosure is especially useful if a transducer without a spider is used.
[0011] Since the enclosure of the inventive loudspeaker is a bass reflex enclosure, it comprises an opening, commonly known as a port or a vent. The port has a cross-section S R of any shape and a length L R . Particularly, the cross section S R may be circular or rectangular and the enclosure has a volume V B . Then, the length L R of the port may be determined in order to tune the bass reflex enclosure to the rocking frequency f rock of the transducer, according to the following equation:
[0000]
L
R
=
S
R
·
c
2
4
·
V
B
·
π
2
·
f
rock
2
[0012] wherein c is the sound velocity in air.
[0013] The inventive loudspeaker may particularly be used for a mobile device, for instance, a mobile phone, a PDA, a mobile computer, or a toy.
[0014] The object is also achieved in accordance with the invention by means of a loudspeaker, comprising an electro dynamic transducer whose diaphragm, when driven, vibrates with a resonance frequency in free air, and a bass reflex enclosure, in which the electro dynamic transducer is mounted. The bass reflex enclosure is tuned to a frequency which equals 1.5 times the resonance frequency f res in free air. Electro dynamic transducers without a spider centering system, such as the transducer 1 described in the introduction, have often a rocking frequency of approximately 1.5 times the free air resonance frequency f res of the transducer. This is particularly true for transducers whose diaphragms are made of a material with a relative low inner damping. Such transducers are especially used for low-cost applications or for mobile devices, such as mobile phones, mobile computers, PDAs, or toys. Consequently, if the bass reflex enclosure is tuned to 1.5 times the resonance frequency f res in free air, then the corresponding bass reflex loudspeaker is likely to be tuned to the rocking frequency of the used electro dynamic transducer.
[0015] The parameters of the port of such an inventive enclosure may then be determined according to the following equation:
[0000]
L
R
=
S
R
·
c
2
9
·
V
B
·
π
2
·
f
res
2
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will be described in greater detail hereinafter by way of non-limiting examples with reference to the embodiments shown in the drawings.
[0017] FIGS. 1 to 4 , as discussed above, illustrate the rocking mode of an electro dynamic transducer;
[0018] FIG. 5 is a plot illustrating the diaphragm excursion versus frequency of an electro dynamic transducer;
[0019] FIGS. 6 and 7 are loudspeakers comprising an electro dynamic transducer and bass reflex enclosures;
[0020] FIG. 8 are plots illustrating the sound pressure levels versus frequency of the transducer and at the port of the bass reflex enclosure of FIG. 7 .
[0021] FIG. 9 is a mobile phone comprising the loudspeaker of FIG. 7 .
DESCRIPTION OF EMBODIMENTS
[0022] FIGS. 1 to 4 have been discussed in the introduction.
[0023] FIG. 5 is a plot 10 illustrating the diaphragm excursion versus frequency of a typical electro dynamic transducer without a spider centering system and in free air, i. e. if the transducer is not attached to an enclosure. For the exemplary embodiment, this transducer is the transducer 1 of FIGS. 1 to 4 . The plot 10 shows a first peak 11 at 750 Hz and a second peak 12 at about 1 kHz. The first peak 11 corresponds to the resonance frequency f res in free air of the transducer 1 at about 750 Hz and the second peak 12 corresponds to the rocking frequency f rock of the transducer 1 . The rocking frequency f rock is approximately 1000 kHz for the exemplary embodiment. Thus, the rocking frequency f rock of this transducer 1 is approximately 1.5 times the resonance frequency in free air of the transducer 1 . This is relatively often the case for electro dynamic transducers with diaphragms having a relatively low inner damping. Such transducers are used, for instance, for mobile devices, such as mobile telephones, PDAs, Laptops, or toys.
[0024] FIG. 6 shows a first exemplary embodiment of an inventive loudspeaker 13 which comprises an enclosure 14 and the transducer 1 of FIGS. 1 to 4 for the exemplary embodiment. The enclosure 14 has a volume V B,1 and is a bass reflex enclosure with an opening 15 . The opening 15 has a cross-section S R,1 and a length which corresponds to the thickness d of the walls of the enclosure 14 .
[0025] The transducer 1 has a rocking frequency f rock of approximately 1 kHz as illustrated by FIG. 5 . The enclosure 14 of the loudspeaker 13 is tuned to this rocking frequency f rock , i.e. the volume V B,1 , the cross-section S R,1 , and the thickness of the walls of the enclosure 14 are chosen so that the system comprised of the transducer 1 and the enclosure 14 resonates at the rocking frequency f rock . For the exemplary embodiment, the cross-section S R,1 of the opening 15 is rectangular and is chosen to satisfy the following equation:
[0000]
S
R
,
1
=
4
·
d
·
V
B
,
1
·
π
2
·
f
rock
2
c
2
=
4
·
(
1000
Hz
)
2
·
d
·
V
B
,
1
·
π
2
c
2
[0026] wherein c is the sound velocity in air.
[0027] Alternatively, the enclosure 14 is tuned to a frequency, which equals 1.5 times the resonance frequency f res in free air of the transducer 1 . Then, the cross-section S R,1 of the opening 15 is chosen to satisfy the following equation for the exemplary embodiment:
[0000]
S
R
,
1
=
9
·
d
·
V
B
,
1
·
π
2
·
f
res
2
c
2
=
9
·
(
750
Hz
)
2
·
d
·
V
B
,
1
·
π
2
c
2
[0028] FIG. 7 shows a second exemplary embodiment of an inventive loudspeaker 16 , which comprises the transducer 1 and a bass reflex enclosure 17 . The enclosure 17 has a volume V B,2 and comprises a reflex port 18 . The port 18 has a length L and a cross-section S R,2 . The cross-section S R,2 is circular for the exemplary embodiment.
[0029] The length L of the port 18 is dimensioned so that the system comprised of the transducer 1 and the enclosure 16 resonates at the rocking frequency f rock . For the exemplary embodiment, the length L of the port 18 is dimensioned so that the following equation is satisfied:
[0000]
L
=
S
R
,
2
·
c
2
4
·
V
b
,
2
·
π
2
·
f
rock
2
[0030] Alternatively, the enclosure 17 is tuned to a frequency, which equals 1.5 times the resonance frequency f res in free air of the transducer 1 . Then, the length L of the port 18 is chosen to satisfy the following equation for the exemplary embodiment:
[0000]
L
=
S
R
,
2
·
c
2
9
·
V
B
,
2
·
π
2
·
f
res
2
[0031] FIG. 8 shows a plot 19 illustrating the sound pressure levels L pi versus the normalized frequency ω n of the diaphragm 2 of the transducer 1 and a plot 20 illustrating the sound pressure levels versus the normalized frequency ω n at the port 18 . The frequency axis is normalized so that the frequency ω n =1 corresponds to the rocking frequency f rock of the transducer 1 . From plot 19 is obvious that the diaphragm 2 of the transducer 1 produces no or at least hardly any sound. This means that the diaphragm 2 does not move at all or at least moves very little at the rocking frequency f rock .
[0032] The loudspeakers 13 , 16 are particularly used for a mobile device, such as a mobile phone, a PDA, a mobile computer, or a toy. FIG. 9 shows a mobile phone 21 comprising the loudspeaker 13 or the loudspeaker 16 as an exemplary embodiment of a mobile device.
[0033] Finally, it should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be capable of designing many alternative embodiments without departing from the scope of the invention as defined by the appended claims. In the claims, any reference signs placed in parentheses shall not be construed as limiting the claims. The words “comprising” and “comprises”, and the like, do not exclude the presence of elements or steps other than those listed in any claim or the specification as a whole. The singular reference of an element does not exclude the plural reference of such elements and vice-versa. In a device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. | A loudspeaker ( 13, 16 ) comprises an electro dynamic transducer ( 1 ) and a bass reflex enclosure ( 14, 17 ), in which the electro dynamic transducer ( 1 ) is mounted. The diaphragm ( 2 ) of the transducer, when driven, vibrates in a rocking mode with a rocking frequency and the bass reflex enclosure ( 14, 17 ) is tuned to the rocking frequency. | 7 |
This application is a continuation of application Ser. No. 07/979,995 filed Nov. 23, 1992 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to control systems for dynamoelectric machines and, more particularly, to a method for determining the available output power of an alternator operating at a constant speed.
Dynamoelectric machines such as alternators are used in various applications to develop electric power. In an exemplary application such as a diesel-electric locomotive, an on-board alternator is driven by a diesel engine to provide electric power to traction motors coupled in driving relationship to wheels of the locomotive and to provide electric power for other electrical apparatus in the locomotive. Electric power for such other apparatus is commonly referred to as "hotel" power and may be used to power various electric appliances designed to operate on fixed frequency, typically 60 H z , alternating current (AC) power. Since the frequency of the electric power generated by the alternator is determined by the rotational speed of the alternator rotor which is driven by the diesel engine, it is desirable to operate the engine at a constant speed or RPM. In one conventional system, the engine operates at 900 RPM to produce 60 H z power from the alternator.
In locomotives, multiple alternators are coupled to an output drive shaft of the diesel engine with each alternator providing power for specific purposes. For example, one alternator may provide traction power to the traction motors, another alternator may provide power for charging batteries and still another alternator may provide the above-described hotel power. The electric power available from such alternators, given a constant RPM, is determined by the field current in field windings of the alternators. However, as additional electric power is demanded from the alternators, such demand is reflected as additional loading on the diesel engine. If the electric power demand is increased to a value which overloads the diesel engine, the engine may "bog" down. If the engine is able to maintain RPM under the overload condition, it may begin to "smoke" badly from incomplete combustion in the engine cylinders possibly damaging the engine. If the overload is such as to force a drop in engine RPM, the frequency of the hotel electric power will drop proportionately and may result in damage to the electric appliances receiving the hotel power.
In order to avoid the above disadvantages of overloading of the diesel engine/alternator power systems, such systems may include power monitors to measure the magnitude of power being drawn by such hotel loads. The diesel engine is specified to have capability of providing a maximum magnitude of electric power without overloading. Some portion of this electric power may be supplied as hotel power and the remainder supplied as propulsion power to the traction motors. In one exemplary system, the hotel power alternator may be capable of supplying up to 800 kilowatts (KW) of hotel power while the traction alternator can supply electric power to the traction motors for producing up to 2800 horsepower (HP). If the diesel engine has a maximum limit of 2800 HP, the power monitor is adapted to provide a control signal representative of the magnitude of hotel power so that the maximum available remaining power can be supplied to the traction motors, if desired, without overloading the diesel engine, thus allowing the locomotive to operate at a higher power or speed.
A disadvantage of the above described system is the requirement for a power monitor, e.g., a wattmeter, to determine the output power provided to the hotel loads. The wattmeter is relatively expensive, fragile and affected by the incessant vibration of the locomotive. Accordingly, it is desirable to provide a method for determining available traction power without use of a power monitor.
SUMMARY OF THE INVENTION
Among the several objects and advantages of the present invention may be noted the elimination of a watt meter for measuring alternator output; the use of existing voltage and current sensors to obtain data representative of alternator loading; and the use of an on-board computer on a traction vehicle for computing alternator loading. The invention is illustrated in one form as applied to a control system for a diesel-electric locomotive in which a diesel engine is connected in driving relationship to a plurality of alternators. One alternator is connected to supply electric power to at least one traction motor connected to a wheel of the locomotive. A second alternator is connected to supply constant frequency, constant voltage electric power ("hotel power") to variable loads, typically located in other train cars pulled by the locomotive. A third alternator is connected to primarily fixed loads in the locomotive, such as blowers, fans and a battery charger, such that the mechanical power to drive this alternator is determinable from pre-computed variables as a function of locomotive speed. Each of the alternators include voltage and current sensors whose outputs are connected to an on-board computer ("regulator") which regulates field current to the alternators in order to maintain a predetermined constant output voltage.
The present invention utilizes inherent characteristics of the alternators, in particular, the characteristics of the hotel power or head end alternator, to compute the load reflected by the head end alternator on the diesel engine so as to maximize the available engine power for the traction alternator without bogging down the diesel engine. To this end, the alternator characteristics are mapped to a first set of curves which plots constant power curves for constant voltage and frequency as a function of alternator field current and average phase current. The curves are converted to a set of data points which are then stored in a look-up table format in a memory of the computer. Another set of alternator characteristics which plots constant power curves for the same voltage and frequency as a function of alternator efficiency and field current are similarly stored as data points in the computer memory.
During locomotive operation, the head end alternator currents are constantly monitored and the engine power required to drive the alternator so as to maintain constant output voltage and frequency computed from the monitored currents. In particular, the computer uses the monitored field and phase currents to extract data points from memory which most nearly correspond to the monitored currents. Generally, such currents will correspond to output power values which fall between the actual stored data points. For example, data points may be stored for field current at increments of twenty amperes and for phase currents at increments of one hundred amperes. For currents between these increment values, the computer extracts values below and above the measured values and then linearly interpolates to obtain the corresponding value of power. Similarly, the efficiency characteristics are extracted based upon the interpolated power value and measured field current, again using interpolation to compute an actual or more precise efficiency.
Once the electric power output and efficiency have been computed, the horsepower required by the head end alternator is determined by dividing the computed electric power by the computed efficiency and by a watts to horsepower conversion factor of 746. The result is the actual engine power required to drive the head end alternator. This result can be subtracted from the maximum available engine horsepower to obtain the horsepower available for the traction alternator. The regulator thereafter limits the traction alternator to this available power level to avoid bogging down the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference may be had to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a simplified block diagram of a diesel-electric power system for an electric traction motor vehicle;
FIG. 2 is a set of characteristic power curves for an alternator;
FIG. 3 is a set of characteristic efficiency curves for the alternator of FIG. 2; and
FIG. 4 is a flow chart for a method for computing alternator power requirements from measured voltage and current.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a simplified block diagram of a diesel-electric power system for a traction vehicle. A diesel engine 10 is mechanically coupled by shaft 12 to multiple alternators 14,16 and 18. Each of the alternators 14 and 18 is electrically coupled to a respective one of the power rectifier blocks 20 and 24. Each rectifier block is electrically coupled to a respective one of the load circuits 26 and 30. Head end alternator 16 supplies AC power through hotel power block 22 to hotel loads indicated at block 28. Electrical power output from each alternator 14,16 and 18 is regulated by field control 32 which is responsive to regulator 34. Field control 32 incorporates separate control functions for each of the field windings associated with alternators 14, 16 and 18. Regulator 34 is a microcomputer based regulator of a type well known in the art, i.e., it is programmable to establish required levels of field current in response to signals representative of commanded and measured parameters. In the prevent invention, the measured parameters include the direct current (DC) in the alternator fields, the RMS value of the alternating voltage from each of the alternators and the RMS value of the alternating current (AC) output of each alternator. Field current may be monitored by conventional DC shunts 36, 38 and 40. Output phase currents may be monitored by conventional alternating current detectors, such as current transformers, indicated at 42,44 and 46. RMS output voltage (line-to-line) is also measured for each alternator and indicated as signals VAC1, VAC2 and VAC3 coupled to regulator 34.
In the operation of the system of FIG. 1, the diesel engine 10 is run at a constant speed, e.g., 900 RPM, in order to maintain the frequency of the AC power from head end alternator (HEA) 16 at a constant value, e.g., 60 H z . Engine 10 exhibits a characteristic which allows it to produce a predetermined shaft horsepower (HP) at such constant speed without bogging, i.e., slowing or smoking from incomplete combustion. For purposes of illustration, it will be assumed that engine 10 can produce 2800 HP at shaft 12 at 900 RPM without bogging. It will also be assumed that alternator 16 can produce a maximum of 800 kilowatts (KW) which represents a maximum load of 1072 HP. The auxiliary alternator 32 provides power to various locomotive functions such as blowers for the alternators and other equipment, a radiator fan, an air compressor and a battery charger. Power supplied to the battery charger is determined by measurement of charging current while power for the other functions is generally determined from a look-up table in regulator 34 as a function of commanded locomotive speed. The additional engine load from auxiliary alternator 18 is added to the load produced by HEA 16. The difference between the loading due to alternators 16 and 18 and the available horsepower from engine 10 represents the amount of power which can be developed by alternator 14 for use by traction motors M in load 26.
In prior art systems it has been necessary to provide on-board watt meters to measure the power supplied by HEA 16. The present invention overcomes the need for such watt meters by using existing current and voltage monitors to provide data which is used to uniquely compute the magnitude of actual hotel load. In particular, the alternator 16, as well as other alternators, is characterized by a set of curves which depict the real DC field current as a function of AC load current for constant values of kilowatt loading. FIG. 2 illustrates a set of such characteristic curves for an exemplary alternator operating at a constant output voltage and frequency. From these curves, the measure values of field current and phase current enable a determination of the magnitude of power generated by the alternator. For example, at 140 amps of DC field current and 600 amps RMS of phase current, the alternator generates about 600 KW.
Another factor which is necessary to consider in determining the available power for traction application is the efficiency of the alternator 16 at different power levels and field currents. Efficiency data for each alternator can also be developed as a family of characteristic curves plotted in the manner shown in FIG. 3 with field current on the abscissa axis and efficiency on the ordinate axis and with each curve representing a selected power output in kilowatts. These characteristic curves are also developed for the same voltage and frequency as in FIG. 2. In the illustrative example of about 600 KW at 140 amps DC field excitation, the efficiency is about 0.970 or 97 per cent.
From the data obtained from FIGS. 2 and 3, gross horsepower required for alternator 16 can be computed to be the net KW output divided by the alternator efficiency and then converted to HP by division by 746 KW/HP, i.e.,
HP=(NET KW)/EFFICIENCY/746.
For the illustrative example, the gross HP required for hotel loads is:
HP=600/0.97/0.746≃829.
The horsepower required for the auxiliary alternator 18 is determined from tables as described above based upon locomotive speed or throttle notch position in a customary manner. It will be appreciated that the power output of alternator 18 is relatively constant at each speed position and can be determined without measurement of a widely varying load current. The value of the auxiliary alternator output is also smaller than the HEA 16 output. Assuming that alternator 18 requires a constant 200 HP, the total power required for alternators 16 and 18 is 1029 HP, leaving about 1771 HP to be used by the traction alternator 14. The control electronics in regulator 34 can therefore allow field current to alternator 14 to increase to a value sufficient to generate up to 1771 HP from the alternator without bogging down the engine 10.
The curves illustrated in FIGS. 2 and 3 can be utilized visually to obtain the data necessary to compute power required by alternator 16. However, the regulator 34 requires that the data embodied in the curves be stored in discrete increments. In a preferred method, the data is stored in look-up tables in a well known manner. In order to minimize the volume of data, values of power output are stored for 16 values of field current and 16 values of average phase current, i.e., 256 data points of output power. Values of power corresponding to currents between the selected data points are obtained by linear interpolation. Table I shows a first step in deriving a power value for the case in which the alternator 16 (operating at a fixed 480 volts RMS and 60 H z ) is formed to be drawing 108 amps DC field and 860 amps phase current.
TABLE I______________________________________I PHASE = 800 A 860 A 900 A______________________________________I.sub.FLD = 100 550 KW -- 600 KWI.sub.FLD = 108 -- -- --I.sub.FLD = 120 611.11 KW -- 662.25 KW______________________________________
The power corresponding to 800 and 900 amps-phase current at field strength of 100 and 120 amps are taken from the look-up table within the microcomputer in regulator 34. The first step is to use interpolation to determine the power at a field current of 108 amps DC for each of 800 and 900 amps of phase current. From such linear interpolation, one arrives at the values shown in Table II.
TABLE II______________________________________I PHASE = 800 A 860 A 900 A______________________________________I.sub.FLD = 100 550 -- 600I.sub.FLD = 108 574.44 -- 625I.sub.FLD = 120 611.11 -- 662.5______________________________________
From Table II it is now possible to interpolate for the power output at 860 A phase current. The interpolated value is 574.44 KW plus sixty percent of the difference between 625 and 574.44 KW, for a value of 604.77 KW. This value is then used to create another table from stored data points corresponding to the curves of FIG. 3. The look-up table for FIG. 3 does not require the same number of data points as the table for FIG. 2. In practice, it has been found that a table of 9×12 data points is sufficient. Table III is a final interpolation table for the 604.77 KW loading of alternator 16 and shows the results of interpolation for the efficiency at the specified field current and power output.
TABLE III______________________________________ KW = 600 KW = 604.77 KW = 700______________________________________fld = 100 0.968 -- 0.971fld = 108 0.9676 0.9674 0.971fld = 120 0.967 -- 0.971______________________________________
From Table III, it is determined that the alternator efficiency is 0.9674 at a power output of 604.77 KW. Gross power required for alternator 16 is therefore:
Power=604.77÷0.9674÷0.746=838 HP
Assuming again a constant 200 HP for alternator 18, the remaining power available for traction alternator 14 is 2800-1038 or 1762 HP.
Turning to FIG. 4, there is shown a flow diagram of the method described above for determining available power for the traction motor alternator 14. In a first step, block 50, the operating conditions of alternator 16 are determined, i.e., the voltage, field current and phase current are obtained from the voltage and current sensors such as the sensors shown in FIG. 1. The values of field and phase current bracketing the measured values are then used to obtain from the net KW table, block 62, the values of KW power at the bracketing current values. The table values from block 62 are used in conjunction with the measured values of currents to interpolate to a more exact value of power in block 64, using the process described with regard to Tables I, II and III.
Once the value of KW power has been computed, the program then determines if the value is less or greater than 100 KW. If the value is less than 100 KW, block 64, or greater than 900 KW, block 66, the power is outside the range of the look-up table and an approximation calculation of power output is made. For values less than 100 KW, the calculation multiplies voltage by average current per phase times the square root of three to obtain KW power and then divides by 746 to convert to HP, block 68. The same equation is used for power output greater than 900 KW except that an efficiency of 0.8 is assumed, block 70. These two calculated values are then used as the actual value of power required by alternator 16.
If the value of electric power produced by alternator 16 is between 100 and 900 KW, the problem steps to block 72 to compute efficiency. Again, the values of KW power and field current are used as entries to the look-up table, block 74, to obtain the bracketing values as described with regard to Table III. These values are loaded to block 72 which uses linear interpolation to derive actual efficiency. With efficiency computed, the program steps to block 76 to compute gross power by dividing the net kilowatt value by efficiency and the KW to HP conversion factor of 746.
What is provided by the above method is a means of eliminating the costly watt meter used in the past to measure alternator output. Instead, the method uses existing voltage and current data to compute output power. In this method, alternator characteristic curves are stored in conventional look-up table format within the microcomputer in regulator 34. The microcomputer is programmed to extract the look-up table data and to compute the electric power output and required horsepower from such data. The computed horsepower is then used in the same manner as in the past to determine available power from the engine 10 which can be supplied to the traction alternator 14.
While the invention has been described in what is presently considered to be a preferred embodiment, many variations and modifications will become apparent to those skilled in the art. Accordingly, it is intended that the invention not be limited to the specific illustrative embodiment but be interpreted within the full spirit and scope of the appended claims. | A method for determining gross engine horsepower of an internal combustion engine coupled in driving relationship to an alternating current electric alternator, the alternator supplying electric power to variable loads, comprises measuring the field current and average per phase armature current supplied by the alternator; computing the magnitude of electric power supplied by the alternator from the measured values of field current and armature phase current; determining the engine efficiency at the computed magnitude of electric power; and converting the computed electric power to engine horsepower at the determined efficiency. | 8 |
CLAIM OF PRIORITY
[0001] This application claims priority to U.S. patent application Ser. No. 60/401,084, filed on Aug. 5, 2002, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to building materials, and more particularly to a metal framing member for structural and non-structural building applications.
BACKGROUND
[0003] The use of light gauge metal framing members for structural and non structural applications has grown in the residential and light commercial building industry due, in part, to volatile lumber costs and the inconsistent and unpredictable quality of wood studs. Although the use of metal in framing applications has increased over the last few years, a few issues have resulted in the rate of growth being inhibited. Exemplary issued include the relatively high cost of manufacturing the metal members and the high of the thermal conductivity. For example, metal members transmit cold and heat at a rate significantly higher than wood counterparts. While composite materials of wood and metal can help resolve the thermal conductivity issues, increased cost can result.
SUMMARY
[0004] A framing member including a series of slots along a portion of the member can be expanded during manufacture. The expansion of the slots creates an expanded region that includes voids and metal web elements in the framing member. The voids created during the expansion process can be used for running wiring, plumbing and heating ducts. The expanded slots can be designed to minimize thermal transmission from the exterior to the interior of the wall of the finished structure and can provide adequate structural properties for the application. The expanded slots can allow the dimensions of the part to enlarge without increasing the amount of raw material, which can substantially reduce the cost to manufacture the member. For example, the expanded slots can create a condition where the cost of raw material to produce the member is reduced by as much as 30 to 50%, for example, 40%, as compared to metal member technology that does not include the expanded slots, such as punching or pressing to form voids.
[0005] In one aspect, a metal framing member includes a formed sheet of metal with a series of slots created in a region of the member. The region can be expanded in the manufacturing process to create voids and web elements in the region of the member. The member can exhibit desired dimensional and structural and thermal performance based on customer requirements at a more affordable price. Framing members include both structural and non-structural member designs.
[0006] In one aspect, a metal framing member includes a formed metal sheet including a plurality of expanded web slots in a region of the formed sheet metal.
[0007] The expanded web slots can include voids and metal web elements in the region of the framing member. The formed metal sheet can include a web region and a first flange extending from the web region. The formed metal sheet can include a second flange extending from the web region in a direction substantially parallel to the first flange. In some embodiments, the formed metal sheet can includes a closing region extending the first flange to the second flange to form a substantially tubular structure. In certain embodiments, one or more of the web region, the closing region, the first flange and the second flange includes the expanded web slots.
[0008] In another aspect, a preexpanded metal framing member includes a formed metal sheet having a length and including a web region and two flanges, each flange extending from the web region, and a plurality of web slots extending along a portion of the length in the web region or at least one of the flanges. The flanges can extend from the web region in a direction substantially parallel relationship. The formed metal sheet can include a closing region extending between the flanges. The web region, each flange, the closing region, or combinations thereof, can includes the web slots.
[0009] In another aspect, a method of manufacturing a framing member includes providing a formed metal sheet having a length and a web region, and placing a plurality of slots along a portion of the length in the web region. The formed metal sheet can be provided by roll forming a metal sheet. The plurality of slots can be placed by piercing or stamping slots into the region. The method can include expanding the slots of the web region to form expanded slots having a web element and a web void, for example, by passing the formed metal sheet over a tapered block or mechanically moving sides of the region apart. The method can also include reinforcing the expanded formed metal sheet, for example, by placing a flange or dart in the web element. The method can include placing a plurality of slots along the length in each of a first flange and a second flange of the formed metal sheet, which can be expanded. The plurality of slots can be placed by arranging the slots in offset columns substantially parallel to a length of the member. The method can include heat-treating the member after expanding the slots.
[0010] In another aspect, a method of building a structure includes placing an expanded framing member in a portion of the structure. The expanded framing structure can include a plurality of expanded web slots forming a plurality of voids in a region of the framing member. The method can include installing wiring, plumbing or a heating duct through at least one void of the member.
[0011] Each slot can extend along a portion of a length of the member. For example, the plurality of slots can be arranged in offset columns substantially parallel to a length of the member, to form, e.g., three or more (e.g., 5 or more) columns of slots along the length of the member. The member can include reinforcements in the web elements, which can include flanges or darts.
[0012] Advantageously, the expanded framing member provides a design that can reduce the production costs of the of light gauge metal framing members used today in residential and commercial construction by cutting slots in the web area of the metal member and expanding the web-area through a manufacturing process. The expansion creates and openings web elements that connect the flanges of the member without forming voids or holes by cutting and scrapping the material at a substantial cost penalty. Thus, this concept substantially eliminates manufacturing scrap, creating structurally and dimensionally stable members at significantly reduced cost as compared to manufacture of nonexpanded framing members. The structure of the expanded web can be enhanced by creating dimples and flanges at strategic locations during the manufacturing process.
[0013] The expanded framing member also can have a design that can reduce the rate of heat transfer through the member by, for example, controlling the quantity, width and length of web elements of the members. For example, a thin and long web element can reduce the rate of heat transfer from one flange to the other resulting in improvement in the overall R-Value of the wall incorporating the expanded framing member. For example, a recent study performed on several alternative designs showed that large voids produced in the web area decrease of the stud can decrease the thermal transfer rate by a much as 50% when compared to a standard available metal stud.
[0014] In another advantage, the voids created during expansion in the web area can facilitate the installation of wiring and plumbing through the wall in a manner that tradespersons are accustomed to dealing with. This can be achieved by developing the shape and size of the openings created by the configuration of the web slots and web elements.
[0015] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0016] [0016]FIG. 1 is a perspective view of a portion of the member with forming complete and web created but prior to expansion into final configuration.
[0017] [0017]FIG. 1 a is a perspective view of the member of FIG. 1 with forming complete, web slots created and expanded into its expanded configuration.
[0018] [0018]FIG. 2 is a perspective view of a portion of a member with insulation strips shown attached to the flanges.
[0019] [0019]FIG. 2 a is a section view of the member of FIG. 2 with insulation strips shown attached to the flanges.
[0020] [0020]FIG. 3 is a perspective view of a portion of a member with darts and flanges shown in locations of the member.
[0021] [0021]FIG. 3 a is a section view of the member of FIG. 3 through a darted area showing a typical configuration.
[0022] [0022]FIG. 3 b is a section view of the member of FIG. 3 through a flanged area showing a typical configuration.
[0023] [0023]FIG. 4 a - 4 e are section views showing alternative flange configurations that could be used in conjunction with the expanded web.
[0024] [0024]FIG. 5 is a perspective of a portion of a member with expanded web in the flange area.
[0025] [0025]FIG. 6 is a perspective view of a portion of the member in a tubular configuration with forming complete, web slots created but prior to expansion.
[0026] [0026]FIG. 6 a is a perspective of the member of FIG. 6 with forming complete, web slots created and expanded.
[0027] [0027]FIG. 7 is a perspective of a portion of a tubular section with expanded web design on both the web area and flange area.
[0028] [0028]FIG. 8 is a perspective of a portion of a member with an alternative web slot and web element configuration.
[0029] [0029]FIG. 9 is a perspective of a portion of a member with an alternative web slot and web element configuration.
DETAILED DESCRIPTION
[0030] A framing member can be manufactured by expanding metal in a web region, a flange region, or both, during the manufacturing process. Slots can be formed in a pattern such that the region can be expanded during the manufacturing process. The expansion creates the voids and web elements that extend at least one dimension of the framing member. The voids can create thermal resistance which reduces the thermal conductivity of the member and improves R-value of the ultimate structure. Because the metal is expanded, there is little or no scrap metal produced during manufacture.
[0031] [0031]FIG. 1 is an isometric view of a portion a framing member 100 prior to expansion into the final configuration but with the web slots 103 pierced into the web area. The placement, shape and length of the web slots 103 in a region having dimension a 1 determine the width and length of the web elements 102 as well as the shape and size of the web voids. Flanges 101 extend away from the web region. The member can be manufactured in part or in whole through a roll forming process. Alternatively, a stamping process can be used to manufacture the member. The member can be manufactured from steel or aluminum, or any other suitable metal in sheet form. The sheet can have a thickness of, for example, 24 to 10 gauge.
[0032] Referring to FIG. 1 a, which depicts an expanded framing member, the typical dimension c of flange 101 can be approximately 1.5 inches, although it can be adjusted for different applications. Web area dimension a 1 in the region increases during the manufacturing process by expanding the slots to become significantly wider until the web area reaches the final dimension a 2 is shown on FIG. 1 a. The final quantity, shape and width and length of the web slots determine the size of web voids 104 and web elements 102 are selected to optimize all of the objectives and limitations of the material to be formed into the final shape. Optimization will depend upon specific customer needs. Dimension b can be 2.5 inches to 11.5 inches but can be higher if required. The final member length d can be 92 to 120 inches for wall studs and 2 feet to 20 feet for structural elements such as floor joists, although, generally, dimension d can be any length.
[0033] The framing member can be manufactured by a process, for example, that includes passing a sheet of metal from a coil through a series of form rolls that create the structural shape of the framing member. During the roll forming process, the web slots are pierced into the region to be expanded, such as center web area b. The piercing can be performed with a stamping die, a configured roll, laser or any other suitable method of creating the web slot. The web slot configuration can be adjusted to accommodate any desired shape or length in order to create a web void or web element that enhances the thermal performance, cost reduction, tradesperson access, structural enhancement or any other desired objective not currently realized.
[0034] After the web slots have been incorporated into the region of the member, the member can be expanded by moving the flanges perpendicularly opposed to one another until the desired width a 2 is obtained. The expansion process can be performed in several ways including passing the member over a tapered forming block during the roll forming process. For example, the unexpanded member can be forced over a tapered forming block that fits between the two flanges. As the flanges move down forming line and over the tapered forming block, the flanges move progressively apart until reaching the desired width a 2 shown in FIG. 1 a. An alternative to a tapered forming block can be rolls or a block including rolls attached to the forming block. An alternative method of expansion by rolling can include expanding using a mechanical or hydraulic mechanism that locks onto the flanges on the member and move them apart to the desired width a 2 . The expansion can extend a dimension by a factor of 10% to 300%, 20% to 250%, or 50% to 100%.
[0035] The final width determines the overall width of the member as well as the final configuration and dimension of the of the web voids. After expanding, the member can be heat treated to strengthen a portion of the member, for example, by heating the portion of the member for a period of time, or the entire member, and quenching the member. The member can have a yield strength of between 10 and 100 ksi, or 30 to 60 ksi, for example, 33 ksi or 50 ksi.
[0036] Referring to FIGS. 2 and 2 a an insulated strip 201 can be attached to the flange 203 by adhesive, staples, nails or other similar fasteners. The insulated strip can be made of wood, plastic, or other materials that can function as both a thermal insulated barrier fire resistant and exhibit characteristics that would allow conventional nailing. This can allow the use of nail guns and other automated tools normally used for attaching the structural members together and sheathing to flanges. This configuration can have insulated strips on either one or both flanges of the member.
[0037] [0037]FIG. 3 is perspective showing an expanded web framing member made with optional flanges 302 and darts or dimples 301 that can enhance the structural properties of the web elements, and the member. The expanded slots form regions of stress in the member, which can enhance or degrade the structural properties of the member. The darts or dimples, or flanges, can reduce stress in the member introduced during expanding, thereby strengthening the member. The flanges and darts can be incorporated, for example, during the roll forming operation of manufacture, or by stamping or rolling in to the sheet prior, to or after the shaping operation. The shape and configuration of the darts and flanges can be adjusted to any length, shape or depth in order to achieve the desired objectives. FIG. 3 a shows a cross section of the member of FIG. 3 through the flanged area of the web element and depicts flanges 302 . FIG. 3 b shows a cross section of the members of FIG. 3 through the dimpled or darted area 301 .
[0038] [0038]FIGS. 4 a - 4 e show a cross section of various members with alternative flange configurations 402 that can be applied to the expanded framing member. The effectiveness and benefits of the expanded web design can be enhanced by the different configurations of the flanges, however, any alternative flange configuration can generally be used.
[0039] [0039]FIG. 5 is a perspective of a framing member 500 that includes web slots 503 and web elements 502 within the flange 501 of the member.
[0040] [0040]FIG. 6 and FIG. 6 a depict an alternative framing member 600 made of a tubular section 610 having web region 601 , flanges 602 , and closing region 608 . FIG. 6 is the member 600 shown prior to expansion and FIG. 6 a is the member 600 shown in the final expanded form. The tubular section can exhibit improved torsional rigidity as compared to an open “C” section (see, for example, the member of FIG. 1). The improved torsional rigidity can be desirable in some structural applications.
[0041] [0041]FIG. 7 is a perspective of another member 700 similar to the one shown in FIG. 6 a, which includes web slots and web elements within the flange of the member.
[0042] [0042]FIGS. 8 and 9 depict perspective views of members 800 and 900 , respectively, that include varied web element 802 and 902 and web void 902 and 903 configurations. It is important to state that the configuration of the web slots and web elements are determined on a case-by-case basis. These alternatives shown are only examples and are not meant to be limiting.
[0043] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the concepts described above. For example, the expanded framing member concept can apply to other structural members such as floor joists, in which the web slots can be designed to create web elements capable of withstanding a structural load. If required, the web slot and web elements can have darts and flanges added to create strength. Accordingly, other embodiments are within the scope of the following claims. | A framing member incorporates a series of web slots along a portion of the member that are expanded through the process of manufacture. The expansion of the web slots creates voids and metal web elements in the webbed portion of the member, which can be a stud. The voids created during the expansion process can become the voids for running wiring, plumbing and heating ducts. The web elements can be designed to minimize thermal transmission from the exterior to the interior of a wall including the member, as well as provide adequate structure properties required from the structural member. The expanded slots allow the part to enlarge without increasing the amount of raw material and therefore substantially reducing the cost to manufacture. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 09/876,587 filed Jun. 7, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of chemical vapor deposition (CVD) in semiconductor device manufacturing, and more specifically to a method for in-situ cleaning of a throttle valve in a CVD system.
BACKGROUND OF THE INVENTION
[0003] Chemical vapor deposition (CVD) processes are used widely in the manufacture of semiconductor devices. Generally, CVD involves exposing a semiconductor wafer to a reactive gas under carefully controlled conditions including elevated temperatures, sub-ambient pressures and uniform reactant gas flow rate, resulting in the deposition of a thin, uniform layer or film on the surface of the substrate. The undesired gaseous byproducts of the reaction are then pumped out of the deposition chamber. The CVD reaction may be driven thermally or by a reactant plasma, or by a combination of heat and plasma. A typical CVD system is a single-wafer system utilizing a high-throughput CVD chamber.
[0004] A typical CVD process begins with heating of the CVD chamber to a temperature between about 250° C. and about 1,000° C. A semiconductor substrate is placed in the chamber on a receptor, typically known as a susceptor, which is generally made of ceramic or anodized aluminum. Next, reactant gases are introduced into the chamber, while regulating the chamber pressure. The chamber pressure may be controlled to as low as 1 torr up to as high as atmospheric pressure. The gases react in the chamber to form a deposition layer on the surface of the wafer.
[0005] Chamber pressure is precisely controlled by an inlet flow regulating device which regulates the flow rates of the gases into the chamber, and by an exhaust flow control apparatus attached to the exhaust gas port of the chamber. The exhaust flow control apparatus typically consists of an isolation valve, a throttle valve and a vacuum pump. The isolation valve is typically connected directly to the exhaust gas port of the reaction chamber, and the throttle valve is typically installed downstream from the isolation valve at a distance of approximately 6-10 inches away from the reaction chamber exhaust port. The vacuum pump is installed downstream from both the isolation valve and the throttle valve. During a typical deposition process, the isolation valve remains open while the throttle valve cycles between the open and closed positions to regulate the gas pressure in the chamber. The position of the throttle valve is controlled by a servo-motor which is in turn controlled by a closed-loop control system based on feed-back signals from a pressure manometer mounted in the reaction chamber.
[0006] In a typical deposition process, reactant gases enter the reaction chamber and produce films of various materials on the surface of a substrate for various purposes, such as for dielectric layers, insulation layers, etc. The various materials deposited include epitaxial silicon, polysilicon, silicon nitride, silicon oxide, and refractory metals such as titanium, tungsten and their silicides. Most of the material produced from the reactant gases is deposited on the wafer surface. However, some material also is inevitably deposited on other surfaces inside the chamber, and some material also may be deposited on the throttle valve. Deposition of unwanted film on the throttle valve is more likely during deposition of certain materials, such as silicon oxide, which require a relatively high chamber pressure. As unwanted material is deposited on the throttle valve, the precise operation of the throttle valve is diminished, thereby compromising the precise control of the reactant gas pressure inside the reaction chamber.
[0007] In a typical CVD system, after each deposition process wherein a film is deposited onto a semiconductor substrate and the substrate is removed from the chamber, a cleaning gas or mixture of cleaning gases is purged through the reaction chamber in order to clean unwanted deposits from the chamber interior surfaces, including the chamber walls and the susceptor. A typical cleaning gas system is a mixture of nitrogen trifluoride, hexafluoroethane and oxygen for cleaning unwanted silicon oxide films from the chamber interior. A plasma gas is typically ignited in the chamber to enhance the efficiency of the cleaning gas mixture. However, the reactive species of the cleaning gas cannot reach the throttle valve for effective cleaning due to the limited lifetime of the reactive species. Consequently, after multiple deposition and cleaning processes are performed in the chamber, a substantial amount of unwanted silicon oxide film is deposited and remains on the throttle valve, rendering it nonfunctional. That is, a sufficient amount of material is deposited on the interior surfaces of the throttle valve to prevent smooth motion of the throttle valve and accurate pressure control in the reaction chamber. This poor pressure control in the reaction chamber contributes to the production of semiconductor devices having insufficient reliability.
[0008] In addition, deposited material which builds up on the throttle valve may become dislodged and travel back through the isolation valve and exhaust gas port, and into the reaction chamber. Semiconductor wafers subsequently processed in the CVD chamber will be exposed to this foreign material, which will negatively impact manufacturing yield.
[0009] This problem of deposited material build-up on the throttle valve requires complete disassembly of the throttle valve assembly and manual cleaning by a wet chemistry technique. This is a very labor intensive and time consuming process which leads to poor throughput and increased cost of manufacturing. Moreover, after each manual disassembly and cleaning, the entire exhaust flow control system must be recalibrated in order to resume processing of semiconductor wafers in the reaction chamber.
[0010] Furthermore, if the reaction chamber has become contaminated with foreign material which has been dislodged from the throttle valve, the entire chamber must be opened and cleaned manually through a similarly labor intensive process. Once the chamber cleaning has been completed, the entire CVD system must be recalibrated and requalified in order to resume processing of semiconductor wafers in the reaction chamber.
[0011] An in-situ cleaning method and apparatus has been proposed by Robles et al. in U.S. Pat. No. 5,707,451. Robles et al. reposition the throttle valve assembly so that it is located upstream of the isolation valve and therefore closer to the exhaust gas port of the reaction chamber. Locating the throttle valve adjacent to the chamber increases the chance that some of the reactive species of the chamber cleaning gas may reach the throttle valve within their limited lifetime. However, this arrangement still suffers from reduced cleaning efficiency with regard to the throttle valve, because the throttle valve still is located relatively far from the plasma gas which is ignited in the chamber. Thus, most of the reactive species of the cleaning gas still do not reach the throttle valve for effective cleaning due their limited lifetime. More importantly, due to the absence of an isolation valve between the throttle valve and the reaction chamber, it is impossible in this arrangement to prevent material dislodged from the throttle valve, or any other foreign material in the CVD exhaust system, from contaminating the chamber.
SUMMARY OF THE INVENTION
[0012] The present invention eliminates the aforementioned problems by providing an in-situ apparatus and method for effectively cleaning a throttle valve in a CVD system.
[0013] In one aspect of the present invention, an exhaust flow control apparatus attached to a CVD chamber, for controlling an exhaust flow passage and for regulating gas pressure in said CVD chamber, is disclosed. The exhaust flow control apparatus comprises: an isolation valve in fluid communication with said CVD chamber, for opening and closing said exhaust flow passage; a throttle valve mounted downstream from and in fluid communication with said isolation valve, for regulating gas pressure in said CVD chamber; means for introducing a cleaning gas into said exhaust flow passage downstream of said isolation valve and upstream of said throttle valve; and a vacuum pump mounted downstream from and in fluid communication with said throttle valve, for evacuating gas from said CVD chamber. The apparatus optionally may further comprise means for applying RF power in said exhaust flow passage downstream of said isolation valve and upstream of said throttle valve, for generating a reactive plasma of said cleaning gas.
[0014] In another aspect of the present invention, an exhaust flow control apparatus attached to a CVD chamber, for controlling an exhaust flow passage and a cleaning gas flow passage, and for regulating gas pressure in said CVD chamber, is disclosed. The exhaust flow control apparatus comprises: a first isolation valve in fluid communication with said CVD chamber, for opening and closing said exhaust flow passage; a second isolation valve in fluid communication with a cleaning gas source, for opening and closing said cleaning gas flow passage; a throttle valve mounted downstream from and in fluid communication with said first isolation valve and said second isolation valve, for regulating gas pressure in said CVD chamber; and a vacuum pump mounted downstream from and in fluid communication with said throttle valve, for evacuating gas from said CVD chamber. The apparatus optionally may further comprise an RF power source for generating a reactive plasma of said cleaning gas in said exhaust flow passage downstream of said isolation valve and upstream of said throttle valve.
[0015] In yet another aspect of the present invention, a method for cleaning a throttle valve attached to a CVD chamber is disclosed. The method comprises the steps of: isolating said throttle valve from said CVD chamber; and flowing at least one cleaning gas into said throttle valve at a temperature and pressure and for a length of time such that unwanted film deposits are removed from said throttle valve. The method optionally may further comprise the step of generating a reactive plasma of said cleaning gas, prior to the step of flowing said cleaning gas into said throttle valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The drawings are for illustration purposes only and are not drawn to scale. Furthermore, like numbers represent like features in the drawings. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows, taken in conjunction with the accompanying drawings, in which:
[0017] FIG. 1A is a schematic view of a prior art exhaust flow control apparatus;
[0018] FIG. 1B is a schematic view of an exhaust flow control apparatus of the present invention; and
[0019] FIG. 2 is a process flow diagram for a CVD chamber and exhaust flow control apparatus of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] FIG. 1A shows a typical prior art exhaust flow control apparatus attached to a CVD system, such as the Precision 5000 System available from Applied Materials, Inc., Santa Clara, Calif. A CVD reaction chamber 100 for processing semiconductor wafers has an exhaust flow control apparatus attached to the side of the chamber through a flow adapter 110 . Connected to the flow adapter 110 is a chamber isolation valve 111 for the opening and closing of the flow passage therein. Throttle valve 113 is connected to and in fluid communication with the chamber isolation valve 111 via exhaust pipe 112 . Throttle valve 113 is controlled by a precision servo-motor 114 which is in turn controlled by closed-loop feedback signals received from a pressure manometer (not shown) attached to the CVD chamber 100 . The gases exhausted from the CVD chamber 100 pass through flow adapter 110 , chamber isolation valve 111 , exhaust pipe 112 and throttle valve 113 into flow passage pipe 115 to a vacuum pump (not shown).
[0021] In this prior art arrangement of the exhaust flow control apparatus, cleaning gases used in CVD chamber 100 for removing unwanted deposits from surfaces of the chamber interior must travel through flow adapter 110 , chamber isolation valve 111 and exhaust pipe 112 before reaching throttle valve 113 . A plasma gas typically is ignited in CVD chamber 100 to enhance the efficiency of the cleaning gas mixture. However, the reactive species of the cleaning gas cannot reach throttle valve 113 for effective cleaning due the limited lifetime of the reactive species. Consequently, after multiple deposition and cleaning processes are performed in chamber 100 , a substantial amount of unwanted film is deposited and remains on throttle valve 113 , rendering it nonfunctional. That is, a sufficient amount of material is deposited on the interior surfaces of throttle valve 113 to prevent smooth motion of the throttle valve and accurate pressure control in reaction chamber 100 .
[0022] FIG. 1B shows an improved exhaust flow control apparatus according to the present invention. In this embodiment, means are provided for introducing a cleaning gas downstream of chamber isolation valve 111 and upstream of throttle valve 1113 , by connecting a cleaning gas pipe 116 via a T-connection to exhaust pipe 112 , thereby forming a cleaning gas flow passage. A cleaning isolation valve 117 is installed in cleaning gas pipe 116 , for opening and closing the cleaning gas flow passage.
[0023] While gases are exhausted from CVD chamber 100 , chamber isolation valve 111 remains open, and cleaning isolation valve 117 remains closed. Throttle valve 113 cycles between the open and closed positions as in a conventional CVD system in order to regulate the chamber pressure. Throttle valve 113 is controlled by servo-motor 114 which is in turn controlled by closed loop feedback signals received from a pressure manometer (not shown) attached to the CVD chamber 100 .
[0024] When cleaning of throttle valve 113 is desired, chamber isolation valve 111 is closed, and cleaning isolation valve 117 is opened. Cleaning gases are introduced into cleaning gas pipe 116 , pass through cleaning isolation valve 117 , and enter throttle valve 113 . A plasma gas may be ignited by an RF power source (not shown) just before throttle valve 113 , for example in cleaning gas pipe 116 or in exhaust pipe 112 . Alternatively, a plasma gas may be ignited just before cleaning isolation valve 117 , so long as the distance to be traveled through cleaning isolation valve 117 , cleaning gas pipe 116 and exhaust pipe 112 is not excessive. Cleaning gases and byproducts then continue through flow passage pipe 115 to a vacuum pump (not shown).
[0025] FIG. 2 shows a process flow diagram for a CVD process in which a CVD chamber 200 is used. Reactant gases 201 flow into chamber 200 through flow control valve 203 , gas inlet 204 , and gas distribution plate 205 . Gas inlet 204 and gas distribution plate 205 also act as the upper electrode for the RF source. Gas distribution plate 205 is sometimes called a showerhead. The lower electrode or susceptor 206 is normally grounded when RF power is required. A RF generator (not shown) may provide RF power 202 through a matching network (not shown) to the upper electrode (gas inlet 204 and gas distribution plate 205 ). A pressure manometer 207 monitors the gas pressure in chamber 200 .
[0026] There are a number of different types of thin films that can be deposited using CVD. The reactant gases to be used, and the chamber pressure and temperature, vary depending on the type of thin film desired. For silicon oxide films, the reactant gases may include tetraethoxyorthosilicate (TEOS), optionally with a carrier gas such as helium, oxygen (O 2 ), and ozone (O 3 ), or silane (SiH 4 ) and nitrous oxide (N 2 O). The chamber pressure may be maintained at between about 40 torr and about 600 torr during the deposition of silicon oxide films, or may be maintained as low as about 8 torr for plasma-enhanced CVD. The temperature of the chamber is elevated to usually greater than 100° C. At this elevated temperature, and if desired, with RF applied, the gases will react and deposit a silicon oxide layer on the surface of the wafer.
[0027] During the deposition process, chamber isolation valve 211 remains open and cleaning isolation valve 217 remains closed. Gases from the reaction chamber 200 are exhausted through chamber isolation valve 211 and throttle valve 213 , to a vacuum pump (not shown). Throttle valve 213 cycles between the open and closed positions to regulate the gas pressure in chamber 200 . The position of throttle valve 213 is controlled by a servo-motor (not shown) which is in turn controlled by a closed-loop control system based on feed-back signals from pressure manometer 207 .
[0028] Reactant gases deposit a film not only on the semiconductor wafer, but also on all of the interior surfaces of chamber 200 , as well as on throttle valve 213 . When the deposition process is completed, the wafer is removed from the chamber and a cleaning process is performed to remove deposits from the walls of the chamber. For the chamber clean, cleaning gases 201 are flowed into the chamber 200 through gas inlet 204 and gas distribution plate 205 .
[0029] For cleaning following a silicon oxide film deposition, nitrogen trifluoride (NF 3 ), hexafluoroethane (C 2 F 6 ) and oxygen (O 2 ) may be used. The flow rate of the cleaning gases is controlled such that the chamber pressure can be maintained at usually less than 200 torr. The temperature inside chamber 200 is maintained between about 100° C. to about 500° C. A plasma is ignited in the cleaning gas by applying RF power 202 , thereby causing the gas to react with the deposit layers and etch the layers away. RF power of about 700 watts to about 1500 watts, usually about 900 watts, may be applied.
[0030] During the chamber cleaning process, cleaning gases are exhausted through chamber isolation valve 211 and throttle valve 213 to a vacuum pump (not shown). Chamber isolation valve 211 is in the open position, and cleaning isolation valve 217 is in the closed position.
[0031] Either before the chamber cleaning process is begun or after the chamber cleaning process is completed, the throttle valve cleaning process of the present invention may be commenced. Chamber isolation valve 211 is closed, and cleaning isolation valve 217 is opened. Before cleaning gases are introduced through cleaning isolation valve 217 , purge gases 221 may be flowed through cleaning isolation valve 217 , into the exhaust pipe upstream of throttle valve 213 , and through throttle valve 213 . Purge gases may be inert or “house” gases, such as oxygen (O 2 ) or nitrogen (N 2 ) or a mixture of these gases. Purge gases may be flowed at a rate of as much as about 5 standard liters per minute (slm), for as long as about 1 minute.
[0032] Cleaning gases 221 are then flowed through cleaning isolation valve 217 , into the exhaust pipe upstream of throttle valve 213 , and through throttle valve 213 . The same cleaning gases used to clean the chamber may be used to clean the throttle valve, or different cleaning gases may be used. For example, when cleaning a throttle valve following a silicon oxide film deposition, nitrogen trifluoride (NF 3 ), hexafluoroethane (C 2 F 6 ) and oxygen (O 2 ) may be used. Alternatively, fluorine (F 2 ) may be used, at a flowrate of about 1 slm for about 20 seconds, depending on the deposited film thickness.
[0033] The pressure in the piping between chamber isolation valve 211 and throttle valve 213 should be maintained in the range of about 20 mtorr to about 10 torr. This may be accomplished by reducing the flow of gases 221 , and/or by cycling throttle valve 213 between the open and closed positions via a servo-motor (not shown) controlled by a closed-loop control system based on feed-back signals from a pressure manometer (not shown) installed between chamber isolation valve 211 and throttle valve 213 . The pressure is preferably measured and stabilized using purge gases, prior to introducing cleaning gases.
[0034] The piping between chamber isolation valve 211 and throttle valve 213 need not be heated or cooled during the cleaning method of this invention. However, heating of the piping between chamber isolation valve 211 and throttle valve 213 may enhance the effectiveness of the cleaning gases.
[0035] While cleaning gases 221 are being introduced through cleaning isolation valve 217 , a plasma may be ignited in the cleaning gas by applying RF power 222 , thereby causing the gas to react with the deposited material and etch the material away. The plasma may be generated using any conventional means. For example, a remote RF source may be used, which would require much less power than the chamber RF source. For example, a remote RF source having a power as low as about 5 watts, up to about 1500 watts, may be used for the throttle valve cleaning process. Preferably, an inductive plasma system may be employed to generate plasma for the throttle valve cleaning process. In FIG. 2 , RF power is shown being applied in the exhaust flow passage downstream of chamber isolation valve 211 and upstream of throttle valve 213 . However, RF power may also be applied in the cleaning gas passage downstream of cleaning isolation valve 217 , or even upstream of cleaning isolation valve 217 , so long as the distance to be traveled through cleaning isolation valve 217 and to throttle valve 213 is not excessive.
[0036] Some types of throttle valves may need to be actuated or rotated while the reactive plasma is being generated. For example, certain vales, such as the MKS throttle valve or the Applied Materials (AMAT) sigma throttle valve, should be repositioned during generation of the reactive plasma in order to effectively clean all surfaces of the valve. Other types of valves, such as a C-plug valve or a dual spring valve, need not be actuated during reactive plasma generation.
[0037] After the throttle valve cleaning process is complete, the remaining cleaning gases and any cleaning byproducts are pumped out of the piping and the throttle valve. Optionally, an inert gas may be used to purge the remaining cleaning gases and cleaning byproducts.
[0038] While the present invention has been particularly described in conjunction with a preferred embodiment and other alternative embodiments, it is evident that numerous alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore intended that the appended claims embrace all such alternatives, modifications and variations as falling within the true scope and spirit of the present invention. | The present invention relates generally to the field of semiconductor device manufacturing, and more specifically to an apparatus and method for in-situ cleaning of a throttle valve in a chemical vapor deposition (CVD) system. In the exhaust flow control apparatus of the CVD system, which comprises a chamber isolation valve, throttle valve and vacuum pump, means are provided for introducing cleaning gases downstream of the chamber isolation valve and upstream of the throttle valve. Such means may include a cleaning isolation valve connected to a cleaning gas source. Means for generating a reactive plasma of the cleaning gases, just before the throttle valve, may also be provided. During cleaning of the throttle valve, the CVD chamber is isolated, by closing the chamber isolation valve, and cleaning gases are flowed into the throttle valve, by opening the cleaning isolation valve. | 1 |
This is a continuation application of U.S. application Ser. No. 08/537,918, filed Nov. 1, 1995, now U.S. Pat. No. 5,644,999, issued Jul. 8, 1997, which is a U.S. National Phase Application of International Application No. PCT/US94/08783, filed Aug. 2, 1994.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automatic transplanter. More specifically, the invention relates to a mechanism for transferring seedlings or plants from plant trays or flats ("trays" and "flats" are used interchangeably in the art and in the application) in which they have been grown or propagated onto a conveyor for delivering to means for effecting transplanting into a field.
2. Related Art
Related prior art transplanters have included indexing mechanisms that engage on the ends and sides of trays containing seedlings or which engage a single contact point on the back of such trays. Therefore, these previous transplanters require a mechanism for ejecting the seedlings from the trays that is separate from the indexing mechanism. An inherent disadvantage of these previous transplanters is the frequency of misalignment between the seedling ejection apparatus and the rows of seedlings in a particular tray. This misalignment results from variations in the center-to-center distance between rows of seedlings in a tray and the center-to-center distance between the last row of seedlings on one tray and the first row of seedlings on a second succeeding tray being fed into position for ejection of the seedlings. Previous transplanters have relied on gravity for the feeding of a second tray into contact with the indexing mechanism after a first tray has been completely emptied. Consequently, soil or foliage trapped between the two trays often causes significant misalignment of the seedling ejection mechanism with the rows of seedlings in the tray; such misalignment can result in a multitude of malfunctions, none of which are beneficial.
Previous transplanters have employed feed mechanisms which require the use of hard plastic trays rather than trays made from materials such as expanded polystyrene which is of insufficient strength to withstand the forces exerted by such feed mechanisms because of the relatively soft nature of the expanded polystyrene. However, expanded polystyrene trays are desirable to use because of their light weight and lower cost.
SUMMARY OF THE INVENTION
The transplanter of the present invention is adapted to be mounted on a supporting vehicle such as a tractor capable of movement along a row and having planting means which receives seedling plants from the present invention and inserts them in the soil in conventional manner. Disadvantages of earlier transplanters are overcome by providing an indexing mechanism and a seedling or plug ejection mechanism which are positively located relative to each other and relative to a common datum surface on the plant tray. An expanded polystyrene plant tray of the type used with the present invention is of rectangular configuration having a longer longitudinal dimension and a shorter transverse dimension. Each plant tray includes a plurality of plant or seedling cells for containing plugs of growing medium arranged in a matrix of spaced perpendicular longitudinal and transverse rows of the seedling cells. The seedling cells each have a centrally located drain hole on the bottom surface of the plant tray. These plant trays have drive grooves located between adjacent longitudinal rows of cells across a substantial part of the bottom surface of the tray (which is oriented in a vertical plane when in the apparatus of the present invention).
The indexing mechanism of the transplanter according to the present invention includes a rotary indexing drum adapted to engage with the drive grooves of the tray and actuation means arranged to index the indexing drum and hence move the plant tray in sequential steps along a predetermined vertical path perpendicular to the longitudinal rows of seedling cells. An entire longitudinal row of plants is ejected from the tray during each dwell of the indexing drum. In the preferred embodiment the drive grooves comprise parallel indexing grooves in the bottom surface of the plant tray located on either side of the longitudinal rows of cells so that a drive groove is provided between each longitudinal row of cells. The drive grooves extend upwardly from the bottom surface of the plant tray, opposite from the top side of the plant tray from which the seedlings extend.
The rotary indexing drum comprises a driven hollow cylindrical roll having a plurality of parallel longitudinally extending cylindrical rods which define its outer extent and each of which is parallel to the axis of rotation of the hollow cylindrical roll so as to be drivingly engageable with the drive grooves of the tray. This configuration maximizes the contact area between the drive means and the grooves and spreads the resulting mechanical forces created by the indexing roll over a large area of plant tray surface. Therefore, the pressure load that must be withstood by the plant tray during indexing is spread over a large area and reduced so that materials such as expanded polystyrene can be used without damage to the tray surface.
Thus, the preferred embodiment of the indexing drum includes a plurality of indexing rods arranged in spaced, parallel relationship around the circumference of a circle to form a cylindrical indexing drum having an interior cavity and a central axis along which the drum rotates. The indexing drum is rotatably supported by rollers mounted on a drum support frame and located at each end of the drum to engage the outer periphery of the drum to maintain proper radial and linear positioning of the drum at all times. The drum support frame also allows for quick and efficient replacement of an indexing drum in order to accommodate plant trays of different dimensions. The support frame also supports a plug ejection mechanism which comprises a linear row of plug ejecting pins mounted on a pin mounting beam that is parallel to the axis of the indexing drum and which is positioned within the interior cavity of the indexing drum. The plug ejecting pins can be moved into contact with the lower ends of the soil plugs of a longitudinal row of seedlings located in between two adjacent indexing grooves of a tray so as to eject the seedlings outwardly from the tray for deposit onto a conveyer which carries the seedlings to conventional planting means which plants them in a row as the supporting vehicle moves along the row.
The plant tray of the present invention also includes a centrally located transverse alignment groove in the bottom surface of the plant tray which is perpendicular to the indexing grooves and is configured to mate with the outer circumference of a circular mid ring on the indexing drum. This alignment groove provides a datum surface in addition to the datum surfaces provided by the indexing grooves for maintaining the plant tray in proper position relative to the axis of the indexing drum and the plug ejection mechanism.
In the preferred embodiment, the plant trays are oriented in a vertical plane and the indexing mechanism is adapted to index the plant trays downwardly in a vertically configured tray support assembly or loading frame so that plants or seedlings are ejected horizontally from the cells of the plant trays. The above mentioned datum surfaces provided by the transverse alignment groove and the longitudinal indexing grooves on the bottom of the plant tray ensure accurate alignment between plug ejector pins and the drain holes located in the bottom center of each cell. The plug ejection mechanism is mounted to the indexing drum support frame and includes a pin mounting beam positioned parallel to the center axis of the indexing drum. The plug ejecting pins are supported by the pin mounting beam for a consistent axial entry into the bottom of each plant cell of the plant tray and for consequent accurate positioning in alignment with the center line of each row of plugs to be ejected from the plant tray.
The entire mechanism consisting of the hollow indexing drum, the plug ejection mechanism and a power source for rotating the indexing drum and activating the plug ejection mechanism is arranged to be a unit, and is attached as a unit to the plant tray loading frame by a pivotally mounted indexing drum frame and a retention device which allows for quick assembly and disassembly. Different plant tray sizes or plant trays with a different number of plant cells can be easily accommodated by changing the indexing drum and/or the plug ejection mechanism.
A greater biassing force is required than gravity alone to accurately and consistently move plant trays down from their initial loading position in the loading frame to be ready for positive engagement and location on the indexing drum. This force is provided by one or more down loader drums similar in construction to the indexing drum and located on separate pivotal support frames vertically above the indexing drum.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is better understood by reading the following Detailed Description of the Preferred Embodiments with reference to the accompanying drawing figures, in which like reference numerals refer to like elements throughout, and in which:
FIG. 1 is a front elevation of the preferred embodiment of the invention.
FIG. 1A is a left side elevation view of the preferred embodiment;
FIG. 1B is a partial rear elevation view taken in the direction of arrows B--B in FIG. 1A.
FIG. 1C is a view taken in the direction of arrows C--C in FIG. 1B.
FIG. 1D is a view similar to FIG. 1A but illustrating the support frame and index drum in a deactivated position for permitting loading or rapid unloading of plant flats from the apparatus.
FIG. 1E is a right side elevation view of the preferred embodiment showing the pneumatic cylinder and return spring mounted on the down loader drum support frame.
FIG. 2 is a vertical sectional view illustrating the relationship of the upper down loader drum to the vertical guide means for the plant flats.
FIG. 2A is a front elevation view of the transplanter showing an upper plant tray being urged vertically downwardly by the down loader drum and contacting a lower tray which is engaged with the indexing drum and from which plants are being ejected.
FIG. 2B is a front elevation view of the transplanter similar to FIG. 2A showing the relative positions of an upper and lower plant tray at the point when pneumatic locking cylinders are activated to grasp the upper plant tray prior to discharge of the lower empty tray.
FIG. 3 is a bottom plan view of a plant flat or tray employed with the present invention.
FIG. 3A is a front elevation view of the plant flat of FIG. 3.
FIG. 3B is an end elevation of the plant flat as viewed from line 3B--3B of FIG. 3A.
FIG. 4 is a rear perspective view of the preferred embodiment of the down loader drums employed in the invention and the associated drive means employed therewith.
FIG. 5 is a side elevation view of the preferred embodiment of the down loader drum engaged with the indexing grooves on the bottom surface of a plant tray.
FIG. 5A illustrates the manner in which down loader drums are mounted.
FIG. 6 is a side elevation view of the indexing drum and its associated support rollers.
FIG. 7 is a front elevation view of one end of the indexing drum and its support rollers.
FIG. 8 is a perspective view of a further embodiment of the indexing drum.
FIG. 9 is an enlarged front elevation view of a portion of the mid ring and indexing rods of the indexing drum of FIG. 8.
FIG. 10 is a front elevation view of a portion of the transplanter including the indexing drum of FIG. 10 along with means for indexing the drum and means for locking the indexing drum in successive index positions.
FIG. 11 is a side elevation view of the components shown in FIG. 10 with a pawl member engaged with the indexing drum in a first position prior to the initiation of an indexing movement of the indexing drum.
FIG. 12 is a side elevation view of the pawl member of FIG. 11 in a second position immediately following the initiation of an indexing movement.
FIG. 13 is a side elevation view of the pawl member of FIG. 11 in a third position subsequent to the FIG. 12 position.
FIG. 14 is a side elevation view of the pawl member of FIG. 11 in a fourth position subsequent to its FIG. 13 position.
FIG. 15 is a side elevation partial section view of the indexing drum and the preferred plug ejection mechanism illustrating the manner of ejecting plants from a plant tray.
FIG. 16 is a side elevation view of the indexing drum and plug ejection mechanism similar to FIG. 16 but employing different plug ejection pins.
FIG. 17 is a perspective view of a plant foliage separator comb assembly used for separating and downwardly guiding plants ejected from the plant tray.
FIG. 18 is a perspective view of a second embodiment of the plug ejection mechanism.
FIG. 19 is a perspective view of a third embodiment of the plug ejection mechanism.
FIG. 20 is a perspective view of a fourth embodiment of the plug ejection mechanism.
FIG. 21 is a front elevation view of a second embodiment of the conveyer belt;
FIG. 22 is a front elevation view similar to FIG. 21 with the second embodiment of the conveyer belt in a lowered position.
FIG. 23 is a perspective view of a second embodiment of a down loader drum mounted on a pivotal support frame.
FIG. 24 is a side elevation view of the second embodiment down loader drum of FIG. 23 engaging with the indexing grooves on the lower surface of a plant tray.
FIG. 25 is a front elevation view, partially in cross section, of a third embodiment of the down loader drum having rotatable down loader bars.
FIG. 26 is a side elevation view of the rotatable down loader bars approaching engagement with the indexing grooves on the lower surface of a plant tray.
FIG. 27 is a side elevation view of a rotatable down loader bar engaged with an indexing groove on the back surface of a plant tray.
FIG. 28 is a side elevation view of an upper and lower plant tray contacting each other along one edge.
FIG. 29 is an enlarged side elevation view of the indexing drum and plug ejection mechanism and upper and lower plant trays being fed into position for ejection of seedlings.
FIG. 30 is a side elevation view similar to FIG. 29 showing the upper plant tray locked in position while the lower plant tray is indexed downward.
FIG. 31 is a side elevation view similar to FIG. 29 showing the upper plant tray being downloaded after emptying of the lower plant tray.
FIG. 32 is a side elevation view similar to FIG. 29 showing the upper plant tray engaging with the indexing drum.
FIG. 33 is a side elevation view similar to FIG. 29 showing the ejector pins in position to eject a row of seedlings from the upper plant tray.
FIG. 34 is a front elevation view of a first embodiment of the conveyor belt in position below the comb assembly.
FIG. 35 is a front elevation view similar to FIG. 34 with the first embodiment of the conveyor belt in a lowered position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 3, 3A and 3B, an expanded polystyrene plant tray 50 similar to the tray of Todd, U.S. Pat. No. 3,667,159, as used in the automatic transplanter of the present invention is shown. However, unlike the tray of Todd, horizontal longitudinal indexing grooves 52 are formed in the bottom surface 51 of the tray between rows of tapered pyramid shaped plant cells 54 (FIG. 15). Indexing grooves 52 have a width equal the diameter of indexing rods 112 of an indexing drum 110 (FIGS. 15 and 2A) and down loader rods 58 of down loader drums 62U and 62L (FIG. 1A) and have their inner extent defined by cylindrical surfaces 55 which mate with rods 112 and 58 (FIGS. 2 and 15). Indexing grooves 52 comprise drive member receiving means for mechanically powering plant trays 50 in a vertically downward direction in a loading frame 60 (FIG. 1) and for accurately indexing the lowermost plant tray 50 to bring successive longitudinal rows R1, R2 (FIG. 3), etc. into the proper position for simultaneous ejection of all plugs from the plant cells 54 (FIG. 15) of each successive longitudinal row.
When a first plant tray 50 is placed in the upper end of loading frame 60 (FIGS. 1 and 1A) it is positioned against backwall 61, FIG. 2, and manually pushed down until it initially engages an uppermost down loader drum 62U. The tray 50 (FIG. 1) is positioned between a vertical front guide flange 59F and a vertical rear guide flange 59R, as shown in FIG. 2. The flanges 59R and 59F are provided on both the right and left side frame members 60 so that the right vertical side edge 50R and the left vertical side edge 50L of tray 50 (FIG. 3A) are each positioned between a front flange 59F and a rear flange 59R (FIG. 2) which respectively engage the edge portions of the top surface 57 and the bottom surface 51 of the tray 50 (FIG. 3A) so that the tray can only move downwardly.
Downloader drums 62U and 62L (FIGS. 1 and 2) are mounted to a pivotably mounted support frame 64 (FIG. 5A) pivotally attached to support frame 60 by pivot sleeves 65 mounted on pivots 93 on the right and left sides of frame 60, as shown in FIGS. 1A and 1E. Upper down loader drum 62U is biased toward the back side of loading frame 60, as shown in FIG. 1A, by springs 66 attached to the left and right ends of down loader drum support frame 64 (the left end springs being shown in FIG. 1A, and the right end springs 66 being shown in FIG. 1E).
As shown in FIG. 4, upper down loader drum 62U includes two circular end plates 70 and 72, one mid plate 74 and a central axial shaft 76. The outer circumference of mid plate 74 is configured to match the profile of a transverse alignment groove 53, shown in FIGS. 3 and 3A, on the bottom surface of plant tray 50. Transverse alignment groove 53 is perpendicular to longitudinal indexing grooves 52 and centrally located on the bottom surface 51 of plant tray 50 midway between the opposite sides 50L and 50R of tray 50 (FIG. 3A). The engagement of down loader drum mid plate 74 (FIG. 4) with transverse alignment groove 53 (FIG. 3A) ensures that plant tray 50 is maintained in the proper position relative to upper down loader drum 62U (FIG. 1) during the loading operation.
In a preferred embodiment of upper down loader drum 62U, as shown in FIG. 4, ten stainless steel down loader rods 58 are arranged in a circular fashion to form an open drum. One end of down loader drum shaft 76 supports a sprocket 78 that is provided with a one way clutch 79 so that shaft 76 can be driven in one direction and allowed to free wheel in the opposite direction.
Rotation of shaft 76, and therefore upper down loader drum 62U in the direction of arrow 81, is effected by the application of air pressure to the lower end of upper pneumatic cylinder 80U which tends to effect retraction of pneumatic cylinder 80U which tends to urge upper down loader drum 62U to rotate in the direction of arrow 81. Return spring 82U and chain 84 effect rotation only of sprocket 78 in the direction opposite that of arrow 81. Chain 84 is wrapped around sprocket 78 with one end being connected to piston rod 83 of pneumatic cylinder 80U and the other end connected to return spring 82U which has its opposite end attached to a pivotable extension arm 64a at connection point 69 (FIG. 1E) to which one end of cylinder 80U and 80L (FIG. 1E) is also connected. As pneumatic cylinder 80U retracts and rotates shaft 76 and down loader drum 62U in the direction of arrow 81, return spring 82U is extended. Once the desired amount of rotation of down loader drum 62U is complete, pneumatic cylinder 80U exhausts and return spring 82U retracts, keeping constant tension on chain 84. Such retraction does not exert any rotary force on down loader drum 62U due to the one way drive connection between sprocket 78 and shaft 76.
Pneumatic cylinder 80U is pivotally mounted at its uppermost end to extension arm 64a (FIG. 1E). Extension arm 64a extends upwardly from the right side of down loader drum frame 64 as shown in FIG. 1E, and is provided with a cylinder bracket 67 to which the uppermost end of pneumatic cylinder 80U and spring bracket 69 is pivotally attached providing an adjustable connection to the uppermost end of spring 82U. The lower end of extension arm 64a is connected to down loader drum support frame 64 so that 64a and 64 are mounted for unitary pivotal movement.
The chordal distance between two adjacent down loader rods 58 is equal to the linear distance between horizontal longitudinal indexing grooves 52 on the bottom surface of plant tray 50. Therefore, as plant tray 50 (FIG. 5) is moved into a position adjacent down loader drums 62U or 62L (FIG. 1E), down loader rods 58 (FIG. 5) engage with indexing grooves 52 and thereby mechanically urge plant tray 50 (FIG. 5) downwardly when air pressure is supplied to pneumatic cylinder 80U or 80L (FIG. 1E).
Down loader drum shaft 76 is supported at each end by bearings 90, as shown in FIG. 5A, which are mounted by a quick release mechanism to down loader drum support frame 64, thereby allowing a quick and efficient change of down loader drum 62U to accommodate plant trays having different dimensions or spacings of indexing grooves 52 (FIGS. 3 and 3B).
A lower down loader drum 62L (FIG. 1A) identical to the upper down loader drum 62U is provided below drum 62U and is attached to the support frame in exactly the same manner as upper drum 62U.
Each down loader drum support frame 64 is pivotally mounted at its lower right and left end by pivot sleeves 65 supported on pivot pins 93 on the loading frame 60, as shown with respect to upper most down loader drum 62U in FIG. 1A and as shown with respect to upper and lower down loader drums 62U and 62L in FIG. 1E, and is biased towards loading frame 60 and into engagement with the lower surface of a plant tray 50 in loading frame 60 by a pair of springs 66 one of which engages the right end of frame 64 as shown in FIG. 1E and the other of which engages the left end of frame 64 as shown in FIG. 1A so as to bias the frame and its associated down loader drum to engage the bottom surface of any tray positioned adjacent the down loader drum.
Down loader drums 62U and 62L urge plant tray 50 vertically downward into engagement with an indexing drum 110 (FIG. 10). Indexing drum 110 is formed from a plurality of parallel indexing rods 112 that are arranged in spaced parallel relationship into a drum shape and held together by circular end rings 114 and 116, an interior ring 117' and a mid ring 118 as shown in FIG. 8. Indexing drum 110 is supported by 8 rollers 120 (4 at each end) as shown in FIGS. 6 and 7. Rollers 120 engage in a machined slot 122 around the circumference of end rings 114 (FIG. 8) and 116 at each end of indexing drum 110 in the manner shown in FIG. 7. Rollers 120 are attached to a quick release indexing drum frame 105 which allows for quick and efficient change over of different indexing drums 110 to accommodate different plant trays 50.
Indexing drum frame 105 comprises two parallel, substantially vertical members 105a which are spaced apart by a distance slightly greater than the total transverse length of indexing drum 110 (FIG. 2A). These vertical members are pivotally attached by pivot sleeves 65 at their lower ends to main frame 60 as shown in FIG. 1A. Vertical members 105a are connected at their top ends by an upper cross member 105b' which is parallel to the central axis of indexing drum 110 and is positioned vertically above indexing drum 110 when a latch member 106, shown in FIGS. 1A and 1D, engages with a latch pin 48 attached to upper cross member 105b' to hold indexing drum frame in position as shown in FIG. 1A for driving engagement with plant tray 50.
Indexing drum frame 105 further comprises two annular roller support brackets 105c that are fixedly connected in vertical, parallel, spaced relationship at their top ends to upper cross member 105b' and at their lower ends to lower cross member 105b", best seen in FIG. 11. Annular roller support brackets 105c each rotatably support four rollers 120 with their axes of rotation horizontal and with rollers 120 engaged in the machined slots 122 around the circumference of end rings 114 and 116 at each end of indexing drum 110, as shown in FIGS. 6 and 7.
Pneumatic cylinder support bars 105d (FIG. 1A) are fixedly connected in horizontal, parallel, spaced relationship at the upper ends of vertical members 105a such that they extend perpendicular to vertical members 105a and perpendicular to the central axis of indexing drum 110. End portions 105d' of cylinder support bars 105d extend toward indexing drum 110 from the opposite ends of cylinder support bars 105d and receive therebetween a double rod pneumatic cylinder 107 at each end of indexing drum 110.
The ends of each of the cylinder rods of pneumatic cylinder 107 are connected to respective cylinder support bar end portions 105d', and the body of cylinder 107 is connected by an adjustable bracket 108 to a respective end of a pin mounting beam 142 (FIG. 1B and 16). Pin mounting beam 142 (FIG. 16) carries a plurality of plug ejector pins 144 and extends from one adjustable bracket 108 (FIG. 1A) at one end of indexing drum 110, through the central cavity of indexing drum 110 and parallel to its central axis, and terminates at an identical adjustable bracket 108 at the opposite end of indexing drum 110. Adjustable brackets 108 allow for vertical and horizontal adjustments to the position of pin mounting beam 142 relative to indexing drum frame 105 and indexing drum 110.
Supply of compressed air to one side or the other of cylinders 107 causes the cylinder body to move either towards or away from loading frame 60 and thereby drives pin mounting beam 142 and plug ejector pins 144 (FIGS. 15 & 16) either toward or away from a plant tray 50 supported in loading frame 60 (FIG. 1) and engaged with two indexing rods 112 of indexing drum 110 (FIGS. 15 and 16) positioned above and below the plane within which pin mounting beam 142 is driven.
Adjustable bracket 108 (FIG. 1B) is connected to a pinion gear support bearing 109 that rotatably supports a pinion gear 111 (FIG. 1C) with its rotational axis horizontal and parallel to the central axis of indexing drum 110. Pinion gears 111 at each end of indexing drum 110 mesh with horizontal racks 113, which are attached to annular roller support brackets 105c (FIGS. 1B and 1C) in spaced, parallel relationship below pinion gears 111 to guide pinion gears 111, and therefore adjustable brackets 108 and pin mounting beam 142 in their movement towards and away from loading frame 60.
Pinion gears 111 are connected by a torsional shaft 168, as best seen in the embodiment shown in FIG. 20, in order to ensure that each gear rotates the same amount and maintains the pin mounting beam 142 parallel to the central axis of indexing drum 110 throughout an entire plug ejection stroke. An additional stop bar 125, shown in FIG. 1A, is fixedly connected to each vertical member 105a and positioned below and parallel to each pneumatic cylinder support bar 105d in order to provide stops at each end of the path traveled by pin mounting bean 142 during a complete plug ejection stroke.
As with the mid plate 74 of down loader drum 62 (FIG. 4), mid ring 118 of indexing drum 110 has an outer circumference shaped to conform to the profile of transverse alignment groove 53 on the lower surface of plant tray 50. This configuration is shown in FIG. 9, and allows the mid ring 118 to centralize and guide plant tray 50 during its downward movement.
Pneumatic locking cylinders 115, shown in FIGS. 10, 2A and 2B, are mounted on both sides of loading frame 60 (FIG. 11) at a point vertically above the lower down loader drum 62L, and positioned to actuate press plates 117, shown in FIGS. 2A, 2B, 10 and 11, horizontally inwardly to lock an upper plant tray 50 in fixed position at a predetermined time during its down feed past down loader drums 62U and 62L. A sensor 119, shown in FIGS. 2A and 2B is mounted to look through a hole in a kick-out plate 121 positioned below indexing drum 110 as shown in FIGS. 2A and 2B. Kick out plate 121 serves the purpose of ejecting a lower plant tray 50 after it has been indexed completely past indexing drum 110 and has been completely emptied of seedlings.
Sensor 119 is positioned to detect the bottom edge 51b of lower plant tray 50 when plant tray 50 has been driven downwardly to the position where the second row of plant cells 54 down from the top edge 51a of plant tray 50 is in the same horizontal plane as pin mounting beam 142 and thereby positioned for ejection of the seedlings.
A signal generated by sensor 119 is sent to a processor (not shown) and translated into an actuation signal to pneumatic locking cylinders 115 (as represented schematically by the line 123 extending from sensor 119 to pneumatic locking cylinder 115 in FIGS. 2A and 2B).
The purpose of locking an upper plant tray 50 that is being driven downwardly by down loader drum 62 at the point when a lower plant tray being indexed downwardly by indexing drum 110 is positioned for ejection of the second row of seedlings from the top edge of the lower tray, as shown in FIG. 2B, is to compensate for the differential spacing (caused by the requirement of an expanded polystyrene tray to have a wide outer edge to retain strength) between the top row of plant cells 177 (FIG. 28) in the lower tray and the bottom row of plant cells 178 in the upper tray. The variation of this spacing from the spacing between transverse rows of plant cells 178, 179 and 180 on a single plant tray would result in a misalignment of plug ejector pins 144 with plant cells 54 (FIGS. 15 and 16) if the upper plant tray were not locked in position 181 (FIG. 29) from the time the lower plant tray was positioned to eject the second row of plants 182 until the lower plant tray had been indexed to the last row of seedlings (top row 183, FIG. 30) then completely past indexing drum 110 and emptied of all seedlings (FIG. 31).
The top two rows of seedlings in the lower plant tray being indexed downwardly by indexing drum 110 are ejected by plug ejector pins 144 while an upper plant tray is locked in position by locking cylinders 115 in order to ensure that the upper plant tray will not be driven downwardly by down loader drums 62U and 62L into engagement with indexing rods 112 until the lower plant tray has been completely emptied of seedlings. The downloader drums 62U and 62L are switched off and locking cylinders 115 prevent gravity from causing the upper plant tray to fall.
Once the lower plant tray has been indexed clear of indexing drum 110, the press plates 117 (FIGS. 2A, 2B, 10 and 11) unlock the upper plant tray and the downloader drums 62U and 62L (FIG. 1A) are switched on causing the upper tray to move downward free from obstruction in the direction of arrow 184 (FIG. 31) and remaining clear of the indexing drum rod 112 until the plant tray engages on indexing drum rod 112B (FIG. 32). The index drum is then indexed one position so that indexing drum rods 112A and 112B (FIG. 33) are spaced evenly either side of the center line of the bottom row of plant cells in the upper tray and the ejector pins 144 (FIG. 33) are on the center line of the plants to be ejected.
To ensure speed and accuracy of operation during the indexing of plant tray 50 (FIG. 15) in a downward direction from one row of plant cells 54 to an adjacent row of plant cells, it is necessary to provide for rapid indexing of the indexing rods 112 (FIGS. 15 and 16) without skipping or overrunning successive plug ejection positions. A means for intermittently rotating indexing drum 110 about its central axis and positively engaging indexing drum 110 in successive plug ejection positions is provided by the drive pawl 138 and a special indexing lock mechanism shown in FIGS. 11, 12, 13 and 14.
Indexing drum 110 is rotated in a clockwise direction as viewed by in FIG. 11 by a drive pawl 138 driven by a pneumatic cylinder 133 that is pivotally mounted at one end to vertical frame member 105a by bracket 139. Spring 131, connected between indexing drum frame 105 and drive pawl 138, biases drive pawl 138 into engagement with successive indexing rods 112 as each successive activation of pneumatic cylinder 133 results in clockwise rotation of indexing drum 110.
In a preferred embodiment, as shown in FIGS. 11-14, an index lock pawl member 128 is provided having a plurality of lock lobes 130a, 130b a plurality of cam lobes 132a, 132b, a pivot opening mounted on a pivot pin 134 on fixed frame 105, as shown in FIG. 11, and an attachment point 136 for attachment to pneumatic cylinder 124, which is mounted to an upwardly extending portion of frame 105. Cam lobes 132a, 132b are disposed in between lock lobes 130a, 130b and provide a means for allowing the rotation of indexing drum 110 to assist the oscillation of index lock pawl member 128 generated by pneumatic cylinder 124.
Referring to FIG. 11, indexing drum 110 is positively positioned in a first indexed position by the contact of indexing rod 112b against lock lobe 130a of pawl member 128 with the resultant force being transferred directly through pawl member pivot pin 134 which is fixed to the support frame 105 for indexing drum 110. Indexing drum 110 is thereby firmly positioned in a first plug ejection position. With indexing drum 110 in this first position, two adjacent indexing rods 112 are engaged with two adjacent longitudinal indexing grooves 52 located on both sides of a row of plant cells 54 on plant tray 50 (FIGS. 15 and 16). When in this first plug ejection position, the row of plant cells 54 lie in a common horizontal plane with the central axis of indexing drum 110 (FIGS. 15 and 16). This arrangement ensures the proper alignment of the plug ejection mechanism, which is mounted to the indexing drum frame, with the row of plant cells 54. The plug ejection mechanism includes pin mounting beam 142 that extends through the central cavity of indexing drum 110 and carries a series of plug ejector pins 144 (FIGS. 15 and 16) for entering drain holes at the bottom of each plant cell to eject plugs and seedlings contained within each plant cell.
When indexing drum 110 is rotated about its central axis in a clockwise direction, as shown in FIGS. 11 through 14, pawl member lock lobe 130a disengages from indexing rod 112b and cam lobe 132a rides over an adjacent indexing rod 112c, thus providing a mechanical assist to pneumatic cylinder 124 which is exerting a force at attachment point 136 to rotate pawl member 128 about pivot pin 134 in a clockwise direction as viewed in FIG. 12. Lock lobe 130b is thereby rotated into a position between adjacent indexing rods 112e and 112f as shown in FIGS. 12 and 13.
When indexing rod 112e is locked against lock lobe 130b as shown in FIG. 13, indexing drum 110 is half way to the next successive plug ejection position of indexing drum 110 after the plug ejection position shown in FIG. 11. The rotation of indexing drum 110 to the position shown in FIG. 13 is detected by a sensor 126. Sensor 126 is mounted on a bracket 127 fixed to indexing drum frame 105, as shown in FIG. 11. Sensor 126 generates a signal when indexing rod 112 passes close by one end of the sensor and this signal is input to a processor (not shown) which in turn sends an activation command to pneumatic cylinder 124 connected to attachment point 136 on pawl member 128. The activation of pneumatic cylinder 124 to drive pawl member 128 in a counterclockwise direction, as shown in FIG. 13, tends to disengage lock lobe 130b from indexing rod 112e.
The clockwise rotational force being applied to indexing drum 110 is conveyed through cam lobe 132b as shown in FIG. 14 to assist in the rotation of pawl member 128 about pivot point 134 in a counterclockwise direction as viewed in FIG. 14. Cam lobe 132b is not free from the rotational force being applied by indexing rod 112d until lock lobe 130a is fully engaged between indexing rod 112a and indexing rod 112b. Continued clockwise rotation of indexing drum 110 locks indexing rod 112a against lock lobe 130a, thereby engaging indexing drum 110 in its next successive plug ejection position. The entire cycle is repeated to advance indexing drum 110 to successive plug ejection positions, thereby providing a high speed positive locking indexing method.
A rachet bar 135, shown in FIG. 11, is pivotally mounted on pivot pin 134 and biased by spring 129 to engage indexing rods 112 after each successive plug ejection position is reached. Rachet bar 135 prevents counterclockwise rotation of indexing drum 110.
Because of slight variations in the lengths of plant trays 50, and therefore the distance between cells 54, a waisted shank 144' is provided on plug ejector pins 144 to allow for sideways deflection of pins 144, as shown in FIG. 16. The heads of pins 144 can also be provided with tapered spikes 145 that enter the bottom of a plug prior to it becoming dislodged from plant cell 54. Tapered spikes 145 ensure that the plugs will not shift relative to the ejector pins 144 during the ejection process, and will therefore be fully ejected before separating from pins 144. When pins 144 are retracted by movement of pin mounting beam 142 back away from the plant tray, tapered spikes 145 easily dislodge from the plugs while leaving the plugs in their fully ejected position.
As shown in FIG. 1A and FIG. 17, a vertical plant foliage separator comb assembly 170 is mounted to the front side of loading frame 60 opposite from indexing drum 110 and lower down loader drum 62L. Comb assembly 170 separates any entangled stems and foliage enabling clear and easy transfer from plant tray 50 onto conveyer 150 in between plug retainers 152. Comb assembly 170 is easily removed from loading frame 60 as a modular component by pulling pins 172 shown in FIG. 17 and removing comb assembly 170 for quick and efficient changes to accommodate plant trays 50 having different numbers of plant cells 54.
Angular side guides 174, shown in FIG. 21, are provided at the bottom of individual plates and in one preferred embodiment of the invention can be extended the full length of 176 making up comb assembly 170 (FIG. 1A). Plug retainers 152 mounted on conveyer 150 engage the base of angular side guides 174 during the ejection of plugs from plant trays 50 in order to ensure that any crooked plant stems are retained and guided into the correct plug retainer 152. Conveyer 150 and plug retainers 152 must be moved downwardly away from angular side guides 174 before conveyer 150 is rotated in order to convey the plant seedlings to a planting position. This ensures that any foliage of plant seedlings that have been previously separated into vertical columns by comb assembly 170 (FIG. 1A), but may still be partially engaged with plant seedlings above which could cause misalignment or damage when plant ejection occurs or when conveyer belt 150 is rotated, are clearly separated by the lowering of conveyer 150. Conveyer 150 is lowered by either pivoting about one roller 185 and lowering one end of the conveyor 186 as shown in FIGS. 34 and 35 or by the use of a parallelogram type linkage as shown in FIGS. 21 and 22.
Details of the apparatus and method for transferring seedlings along conveyor 150 and subsequently planting the seedlings in the ground are provided in PCT application # PCT/AU93/00408, which is herein incorporated by reference. These details are not essential to an understanding of the claimed invention.
The layer of foam rubber 92 in an alternative embodiment of down loader drums 62U and 62L shown in FIG. 23 deforms in order to provide a nearly constant force at the point of contact with plant tray 50. The deformation of foam rubber layer 92 causes down loader drum 62U or 62L to flatten against a number of the horizontal longitudinal indexing grooves 52 as shown in FIG. 24. In effect, foam rubber gear teeth are formed and engaged with four or more longitudinal indexing grooves 52 across the full width of plant tray 50 thereby allowing for the generation of a considerable down loading force on plant tray 50 while maintaining gentle pressure over a large area of the plant tray surface. This embodiment also allows for the accommodation of a variety of plant trays having different numbers of plant cells because of the automatic adjustment of the layer of foam rubber 92 to the spacing of longitudinal indexing grooves 52.
In another embodiment of the down loader drum, a drum 62A as shown in FIG. 25, has down loader rods 58' which are designed to be free to rotate along the lower surface of plant tray 50 until they roll into and engage with indexing grooves 52. Roller bearings 94 are provided in end plates 70 and 72, and needle roller bearings 96 are fitted inside down loader rods 58' at mid plate 74. Small stub axles 98 are secured to mid plate 74 to provide support for needle roller bearings 96 and down loader rods 58'. End plates 70 and 72 and mid plate 74 are secured by flanges 100 welded to the central down loader drum shaft 76. As a plant tray 50 is lowered into engagement with down loader drum 62A any misalignment between down loader rods 58' and longitudinal indexing grooves 52 is compensated for by pivotal movement of down loader drum support frame 64 away from loading frame 60 as rotatable down loader rods 58' roll along the bottom surface of plant tray 50 until they drop into an indexing groove 52 as shown in FIGS. 26 and 27. The rolling action of down loader rods 58' ensures that there will be no damage to plant tray 50 resulting from initial misalignment with down loader rods 58'.
In one embodiment of down loader drum 62, as shown in FIG. 23, a layer of foam rubber 92 can be provided around the spaced support down loader rods 58. The down loader rods 58 in this embodiment provide support for the application of pressure and rotational force to the layer of foam rubber. Rotational power can be provided to the down loader drum in this embodiment by a pneumatic powered gear drive assembly 95, rather than the pneumatic cylinder, spring and chain arrangement shown in FIG. 4. In this embodiment, a power output gear 91 driven by pneumatic powered gear drive assembly 95 engages with the ends of down loader rods 58 as shown in FIG. 5. The following description provides several additional embodiments for plug ejection mechanisms to be mounted to the indexing drum support frame 105 for movement relative to the indexing drum 110 and along a plane that intersects the central axis of the indexing drum. However, the invention is not intended to be limited to the specific combination of elements selected, and it is to be understood that the combination of components described for each of the embodiments can be varied to include all technical equivalents which operate in a similar manner to accomplish a similar purpose.
One embodiment consists of two double rod air cylinders 140, as shown in FIG. 18, to which a pin mounting beam 142 is attached. A plurality of plug ejector pins 144 are mounted on pin mounting beam 142. Air cylinders 140 and pin mounting beam 142 are supported on a quick release plug ejector frame 146. Quick release plug ejector frame 146 is demountably fastened to indexing drum frame 105 by means such as bolting to vertical members 105a. This plug ejector sub assembly 148 can be quickly and efficiently changed in order to accommodate plant trays 50 having different numbers of plant cells 54.
When plug ejector sub assembly 148 is mounted on indexing drum frame 105 (FIG. 1A), pin mounting beam 142 (FIGS. 15 and 16) passes through the central cavity of indexing drum 110 and is parallel to the central axis of indexing drum 110. When air cylinders 140 are activated they force pin mounting beam 142 to travel along a plane intersecting the central axis of indexing drum 110 and cause plug ejector pins 144 to enter the drain holes in plant cells 54 contained in plant tray 50 as shown in FIGS. 15 and 16.
The plugs with seedlings are ejected onto a conveyer 150 having a plurality of plug retainers 152 as shown in FIGS. 21 and 22. Air cylinders 140 are then retracted and indexing drum 110 is rotated while activating pneumatic cylinder 124 in order to release pawl member 128 (as explained in greater detail above) until the next index position is reached.
In an alternative embodiment, as shown in FIG. 19, two air cylinders 140 are attached to a linear motion device consisting of a linear bearing 154 that is slidably mounted on a hardened steel shaft 156. Pin mounting beam 142 is mounted to linear bearing 154 at one end. At the opposite end pin mounting beam 142 is connected to a polyethylene or nylon yoke 158 which fits snugly but slidably around a bar 160 having a substantially square cross section. This mechanism ensures that pin mounting beam 142 moves linearly without rotation in a plane intersecting the central axis of indexing drum 110 and the row of plant cells 54 currently positioned for plug ejection.
In another alternative embodiment of the plug ejector mechanism, as shown in FIG. 20, a gear drive 162 is mounted on quick release plug ejector frame 146 to engage with two parallel gear racks 164 mounted at each end of pin mounting beam 142. Gear drive 162 is activated by an air motor 166 or alternative drive means. Gear drive 162 drives gear racks 164 in a forward direction towards loading frame 60 and plant tray 50 in order to eject plugs contained in plant tray 50. Subsequently, gear drive 162 drives gear racks 164 and pin mounting beam 142 backwards away from loading frame 60 in order to prepare for rotating indexing drum 110 to its next planting position. Torsional shaft 168 connecting the gears 161 at both ends of gear drive 162 transfers equal rotational force to both gear racks 164 and ensures that gear racks 164 remain parallel.
In describing the disclosed embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. | The present invention relates to an automatic transplanter. More specifically, the invention relates to a mechanism for transferring seedlings or plants from plant trays or flats in which they have been grown or propagated onto a conveyor for delivering to means for effecting transplanting into a field. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a Continuation-In-Part of the prior application under the Ser. No. 09/656,919 filed on Sep. 07, 2000 now U.S. Pat. No. 6,364,575.
BACKGROUND TO THE INVENTION
The invention relates to a pile repair jacket form being useful in repairing bridge, pier or walkway supports that are submerged in a body of water or above the ground. Walkways such as piers or boardwalks are supported over a body of water or above the ground by way of piles that have been driven into the bottom of the body of water below the mud line or simply into the ground. Such piles can consist of concrete, timber and steel. It is obvious that the concrete, timber and steel piles are subject to corrosion or deterioration because of being permanently located in a water environment. Concrete piles are subject to corrosion, especially if the steel re-bars located therein are subject to rusting if they are located too close to the outer surface of the concrete pile or are exposed altogether. The timber piles are always pressure treated against corrosion or deterioration but the time span of their useful life is substantially shortened when the timber piles are located in a body of water. Steel piles are water proofed prior to their installation but over a period of time the water proofing is not durable or protective enough to protect the steel from corroding.
Most of the damage in all of the above supporting piles occurs at the water line because of the wave action. This wave action is further aggravated by the tides which are prevalent at most installations. In many installations, the high tide covers a greater height of the pile, while at a low tide, a greater length of the pile is exposed to the environment. Therefore, the piles undergo drying and wetting cycles which tend to eat away at the pilings, especially the wooden piles, thus weakening the piles mostly at their mid sections of their total length. Also, water insects like marine borers tend to accelerate the above noted deterioration and are the leading cause of timber pile deterioration. The above noted problems are not as prevalent with support piles that have been driven into the ground, mainly to support buildings or houses. It is noted that, especially at shore lines, houses or dwellings are supported on so-called stilts. These stilts are subject to some wave action, especially at high tides but are normally kept out of the water action. If not subjected to any water action, the corrosive and salty air does contribute to a corrosive action and thereby destroying action over a longer period of time. The support piles can be repaired in situ without having to remove the supported superstructure.
Many devices have been used to repair the above noted damages short of replacing the pilings altogether. This tends to substantially increase the cost of such an installation.
The DENSO™ North America Corp. teaches the use of fiber form jackets that are placed over the whole length of the pile to be repaired or over the damage at the tidal zone. The jacket is made of fiber glass and therefore has some flexure in the material, especially over greater lengths. Because of its ability to flex, the jackets can be installed at the desired location without having to disassemble the superstructure above the piles. Once in place, the jackets at their longitudinal open edges have a tongue and groove arrangement to close and seal the longitudinal edges. Bandings are placed around the jacket at about every 12″. Also standoffs between the pile and the interior surface of the jacket should be used to increase its stability. The use of fiberglass material is very expensive.
Another suggested use is demonstrated by the above noted corporation and that is the use of a fabric form jackets. The fabric form jacket is made of 100% continuous multifilament NYLON fibers and is placed around the damaged area of the pile and the top and the bottom is then closed against the pile by banding. A longitudinal zipper is then closed to complete a cylindrical enclosure. A disadvantage with this kind of an arrangement is that the cylindrical fabric form does not have a form stability in that when the concrete fill is inserted therein, it has a tendency to collect more concrete in the bottom of the cylinder and less at the top, whereby a pear-shaped form is assumed. Therefore, more concrete has to be used than is necessary. Hydraulic concrete is quite expensive. Also, the fabric form pile jacket itself is quite expensive.
A similar jacket system is disclosed by the ROCKWATER Corp. in Farmingdale N.Y. They disclose fiberglass reinforced pile jackets under the name of ROCKFORM™ F and a nylon Pile Jacket under the name of ROCKFORM™ N. As a matter of fact, there is an illustration in their brochure showing the nylon jacket installed on a pile after having been filled with concrete. This illustration clearly demonstrates the disadvantage of this type of a repair wherein more of the concrete is located in the bottom of the bag instead of being equally distributed throughout the length of the bag, as was enumerated above already.
Another form jacket is disclosed by the DESLAURIERS, Inc. company. The disclosed jacket consists of two halves that have to be bolted together at their respective flanges and therefore can be installed around existing piles without having to disturb the decking which is supported by the same. However, the assembly underwater is quite cumbersome, expensive and time consuming.
OBJECTS OF THE INVENTION
According to the invention, applicant is using a high density polyethylene HDPE pipe, which pipe has a smooth interior wall and an annular corrugated exterior for strength. This pipe is manufactured by the Advanced Drainage Systems, Inc. of Columbus, Ohio. High Density Polyethylene is an extremely tough material that can easily withstand the normal impacts involved in shipping and installation. The proposed applications for this pipe have been specified for culverts, cross drains, storm sewers, land fills and other public and private constructions. There is no proposal to use these pipes for repairing pile supports above water or below.
The pipe, as is, could be used for that purpose but only after the decking, which is supported by the pile, has been removed, and then the pipe could be slipped over and along the pile. However, this pipe cannot be used as a jacket in sections above and below water without first removing the decking or superstructure. In the inventive concept, the pipe has been modified for this purpose by cutting through the pipe longitudinally first. This cutting alone will not suffice because the annular corrugations prevent the pipe at its longitudinal cut to be opened to such an extent and size so that the jacket can easily be slipped around a damaged pile. The corrugations are of such a size and strength so as to not allow any such movement. To accommodate a proper opening, the casing or jacket has been cut in a V-shape and only through the corrugations and opposite the longitudinal cut but not into the wall itself that supports the corrugations and forms the interior smooth surface, thereby creating a live hinge. The HDPE material is flexible enough to allow repeated openings and closings of the jacket along its live hinge without breaking or separating. The corrugated pipe is readily available in diameters from 4 inches to 48 inches and therefore lends itself to many applications including in square concrete pile applications. The pipe also is available in various lengths which enhances the installation possibilities under water. If various lengths have to be assembled, the various sections can be supplied with bell- and spigot ends that fit well within each other including various seals between the sections.
As will be explained in more detail below, the pipe is normally delivered in a black color. It is also desirable to have the pipe made of a transparent material. This material allows for a view of the interior of the jacket when it is being filled with concrete. When filling a long pipe or tube with concrete, it can happen that voids form within the concrete, especially at the inner wall of the pipe. If not corrected, this will form voids in the formed concrete which would effect the quality and the performance of the installation. A transparent material allows a visual observation of the pouring of the concrete and observed flaws can immediately be corrected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the pile repair jacket;
FIG. 2 is a perspective view of the jacket installed on a pile to be repaired;
FIG. 2A is a perspective view of an alternative seal;
FIG. 2B is a perspective view of still another alternative seal;
FIG. 3 is a somewhat different embodiment of FIG. 2;
FIG. 3A shows a different seal for the edges of the jacket;
FIG. 4 illustrates a construction of closing the edges of the jacket;
FIG. 5 shows a bell and spigot arrangement of connecting two units;
FIG. 6 illustrates an installation of the jacket within a tidal zone;
FIG. 7 is a top view of a modified jacket form of FIG. 1;
FIG. 8 is a perspective view of a modified edge connection;
FIG. 9 is a detailed view of a modified connection.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates the invention of the pile repair jacket as it has been modified from what is known in the prior art. The jacket is being identified as 1 . The jacket 1 normally has a solid but somewhat resilient and circumferential wall forming a cylinder. Around the cylindrical wall a multiple of corrugations 3 are formed or molded to give the jacket a strong rigidity. The cylinder is being cut in a longitudinal direction to expose longitudinal edges 4 . Opposite from the longitudinal edge 4 a V-shaped cut is made into the corrugations but only onto the straight cylindrical to maintain its integrity. This is shown at 6 . The jacket 1 has a smooth interior wall 7 and an upper edge 2 . This way a live hinge 8 is created by virtue of the wall being somewhat flexible because of the loss of the corrugations 3 at that particular point 8 . It is now apparent that the former rigid cylinder may now be opened up so that it can be draped around a timber pile that is in need of a repair. If any larger diameter piles or supports within a body of water needs to be repaired, it is quite possible to cut at least three V-shaped cuts into the corrugations 3 down to the smooth wall so as not to over stress any individual live hinge in case that the jacket has to be opened rather wide to surround a large pile support such as could happen with square concrete piles. Once the jacket has been installed around a pile, the edges 4 have to be brought together again and sealed against each other. Therefore, a self-adhesive seal 5 has been provided between the edges 4 which will seal against water leaking into the jacket or concrete leaking out at a later time when the jacket is filled with concrete. The adhesive seal may consist of a soft foam rubber or some other flexible rubber. The seal is adhesive at least on one side so that it will firmly adhere to at least one of the edges 4 and cannot be dislodged.
FIG. 2 illustrates the jacket 1 after it is installed around a damaged area of the pile P. Like reference characters have been applied to like elements as explained in FIG. 1 . In order to stabilize the interior wall against the pile P, standoffs 9 have been provided which are merely nailed into the pile P. The standoffs have been shown as U-shaped but can take many other forms. It is also noted that the standoffs should be made of a plastic material or other non-corrosive material, because if it is too close to the surface, once the concrete is cast and is cured, the standoff if it is made of metal, could be a cause for corrosion and/or rusting. In order to bring the outer circumference of the jacket 1 back into its original circular shape, the edges 4 are pulled together by banding 10 which will settle in annular grooves between the annular corrugations 3 . The banding 10 shown in FIG. 2 is of the conventional ratchet type otherwise known as hose clamps in automobile engines, for example. The banding 10 is tightened within the groove by ratchet screw 10 a which is well known. The seal 5 is shown as self-adhering to one of the edges 4 . When the banding 10 is applied to the jacket 1 , the seal 5 may have to applied with a notch 5 a so that the banding 10 will not disturb the shape of the rectangular seal 5 .
FIG. 2A illustrates another seal 11 which is not self-adhering but instead is supplied with plugs 11 a which are formed in such a shape so that will snugly fit within the interior openings of the corrugations 3 . This type of an arrangement will assure a longer lasting fit and could be reusable, while a self-adhering seal 5 will have a one time use only.
FIG. 2B illustrates still another seal 26 which has plugs 26 a and 26 b on both sides of the rectangular seal 26 . Additionally, the rectangular is somewhat enlarged so that it will extend into the interior of the jacket form 1 . The extension into the interior of the jacket form has lateral holes 26 c therein. When the jacket form 1 is being filled with concrete, the concrete will migrate into these holes to completely fill the same. Of course, the soft rubber seal of FIG. 2A would not be practical in this type of installation. It is preferred that the same material by used in this instance as was used to manufacture the jacket form 1 such as HDPE. All other seals disclosed above could have the same interior extensions as shown in FIG. 2 B. This type of installation makes a very rigid fastening system.
Turning now to FIG. 3, there is shown a similar jacket 1 of FIG. 2 but with some preferred modifications It is clear that when installing a jacket 1 around a pile P that there always should be at least two bandings 10 . Another type of banding is shown at 13 . This banding is also well known. It is made of a plastic material and has a non-reversing or one-way buckle 14 . FIG. 3 also illustrates the use of form-fitting plugs 12 which are pressed into the interior of each of the corrugations of one of the edges and are received in the same manner in the other interiors of the other corrugations of the other edge. This will assure a rigid fit between the longitudinal edges 4 of the jacket 1 . These plugs also help in locating the edges 4 relative to each other in a self-aligning manner when the jacket is installed. After all, the assembly takes place in an underwater environment and the visibility might be hampered.
FIG. 3A shows a different seal 15 to be used between the edges 4 when they are closed. This seal 15 is a rectangular seal but having openings 15 a therein to accommodate the plugs 12 there through when the plugs 12 enter the openings in the corrugations.
Turning now to FIG. 4 which shows a different fastening system for closing the jacket onto its edges 4 . This fastening system consists of a buckle system 16 of the over center type. To this end, the buckle 16 includes two plates 17 and 19 which are riveted by rivets 17 a and 19 a , respectively, to the top or outside surfaces of the respective corrugations 3 . Plate 17 has a longitudinal hasp 18 mounted thereon which is pivotal around pivot 18 a . The other plate 19 has a pivotal handle 20 mounted thereon which is pivotal around pivot 20 a . The handle 20 also carries a hook 21 thereon. When it is desired to lock the two edges 4 of the jacket together including the seal 5 , the hasp 18 is placed within the hook 21 on handle 20 and the handle 20 is then moved to a closed position, as shown in FIG. 4, whereby the hook 21 pulls the hasp 18 and thereby the edges 4 together until the hook 21 is pulled past the pivot 20 a which position is over the center of the buckle system 16 . This assures a secure lock. Of course, two such buckle systems need to be used, one at the top of the jacket and a second one at the bottom. The advantage is this type fastening system is that it can be used repeatedly in many different installations. Another advantage resides in the fact that no tools are required to lock the edges 4 together which greatly enhances the use in an underwater assembly. Another advantage lies in the fact that this installation can be a one man operation. All of the above lessens the cost of the installation and the assembly is quicker to perform.
FIG. 5 illustrates how two jackets are connected together through the use of a bell and spigot system. Lines and arrow I denote the lower section of the upper jacket, while lines and arrow II denote the upper section of the lower jacket. The lower section of the upper jacket has an extension or bell S which overlaps the first two annular corrugations of the upper section of the lower jacket. For this purpose, the two annular corrugations 3 a and 3 b are somewhat reduced in circumferential size so that the extension S can slip over the same. The corrugation 3 a also has the seal 25 embedded in its outer surface to assure a tight seal between the two jackets.
FIG. 6 illustrates a complete installation of the jacket on a limited extent of the underwater pile P. Any installation contemplated above ground would follow the same assembly steps. In the previously described jackets, above, it was assumed that the jacket would completely cover the pile P all the way to and below the mud line of the body of the water. FIG. 6 only repairs or rehabilitates only part of the pole P. It is a well known fact that most of the damage to a timber pile occurs at the wave line W and within the tidal zone T. The corrosion has been indicated by C. To this end, a jacket 1 is installed over the deteriorated section C and is stabilized laterally by standoffs 9 . The bottom of the jacket is stabilized relative to the height of the pile P by spikes 23 driven into the pile or otherwise fastened to the pile. In order to completely close the bottom of the jacket 1 against the loss of concrete, a Nylon fabric bag 24 is installed. The bag 24 is banded within a valley of the last corrugations 3 of the jacket 1 through the use of banding 24 a and the lower end of the bag is banded against the pole P itself through the use of banding 24 b . The numeral 22 indicates a port for the entry of concrete. It is a known fact that concrete should be introduced into the interior of the jacket at a bottom thereof. This will force the water therein upwardly and furthermore avoid air bubbles from forming within the concrete.
Turning to FIG. 7, there is shown a repair jacket form having at least three V-shaped cuts 6 , 6 a and 6 b made through the corrugations 3 . In some repair undertakings, larger piles in circumference are encountered including square concrete piles that require the repair jacket form to be opened rather wide. This might overstress the material tolerance of just a single live hinge. Therefore, the presence of three live hinges 6 , 6 a and 6 b will considerably alleviate the overstressing.
FIG. 8 illustrates a different system of connecting the edges of the jacket 3 together. It has been found that when long or tall columns are being used and when they are tilled with concrete, the lower end of the column, especially at their edges does not want to stay in form because of the accumulated weight of the concrete. This problem is being alleviated through the use of the connectors 30 and 31 shown in both FIGS. 8 and 9. The connectors 30 and 31 can easily be extruded from a plastic material of the some composition from which the jackets are made. The connectors can easily be fastened to the inside surface of the jacket 3 by fasteners shown in FIG. 8 . As can be seen in FIG. 8, the female connector 30 is installed with its socket edge flush with the edge of the jacket. The male connector 31 is installed with its projecting part protruding from its base and is ready to be received within the female socket of connector 30 . In this manner, both opposing edges of the jacket will be abutting each other and will be form-fitting.
Turning now to FIG. 9, the structural details of the connectors 30 and 31 are shown. The male as well as the female are double serrated and the serrations are opposing each other. Once the serrations are inserted into each other they will form a planar surface facing at the interior of the jacket. Experiments have shown that this type of connector solves the problem of the jacket edges opening at any length or
SUMMARY OF THE INVENTION
From all of the above, it can now be seen that the repair or rehabilitation of an underwater as well as an above ground support pile has greatly been simplified with a lower cost realization. The jacket forms disclosed herein can be reused many times over or the jacket forms can be left in situ which may prolong the life of the installation indefinitely. The installation has been simplified and speeded up to thereby save cost in labor. These were the objects of the invention. | A plastic jacket that is used for repairing underwater or on ground support piles that have corroded by the wave action at the water line, by a tidal zone or natural salty air corrosion, respectively. The jacket consists of a cylindrical wall having annular corrugations on its exterior surface. The cylindrical wall has a longitudinal cut along its length to exhibit two opposing edges. A seal is placed between the opposing edges. Opposite from the longitudinal cut there is a V-shaped through the corrugations to the cylindrical wall to create a living hinge in the plastic material of the wall. Banding is provided to pull the opposing edges into a tight relationship and trapping the seal there between. The V-shaped cuts enable the jacket to be opened and placed around a damaged pile in spite of the corrugations which prevent such an opening. It is preferred that the material of the jacket be made of a transparent material. This way, when the any flaws, such as voids, develop within the poured concrete they can be observed through the transparent material and can be eliminated or corrected immediately. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a control system and method for an internal combustion engine and more particularly to an improved control system for an engine employing an electrically actuated component that provides protection in the event of a decrease in electrical power.
As is well known, internal combustion engines rely heavily on electrically operated components. Although at one time the only electrical component on an engine was its ignition system, now a number of the engine functions are controlled or monitored electrically. For example, many forms of fuel injectors employ electric solenoid operated valves which control the timing and duration of fuel injection. In addition, the ignition timing, fuel control, and a number of other portions of the engines may be controlled by electric modules.
Most engine applications employ an engine driven generator which generates electricity. Rather than providing the power directly from the generator, however, the generator is utilized to charge a storage battery and the storage battery supplies the actual electrical power to the engine components for their actuation. In this way, the voltage of the electricity supplied tends to be more stable.
However, there may be instances wherein the battery power becomes depleted. In this instance, a number of the engine controls can be adversely affected resulting in undesirable engine performance. For example, if the voltage available for energizing the solenoid of the fuel injector falls, the injector performance will deteriorate and the amount of fuel supplied will vary from that which is desired. Similar results may occur with other electrical components.
It is, therefore, a principal object of this invention to provide an improved engine and control system that employs an electrically actuated component for the engine, a battery for supplying electricity to the component and an arrangement for sensing when the battery voltage falls below a predetermined value at which the component performance may be affected and provides an additional electric power under these circumstances to maintain the performance as desired.
One example of a condition when the battery power may become depleted and wherein the generator may not supply sufficient charging to keep the battery up to the necessary voltage to correctly operate the electrical components for the engine is when the engine is idling. Engine idle is a very difficult condition under even the best circumstances and, if the available voltage varies during idle operation, then the engine performance can be further deteriorated.
It is, therefore, a still further object of this invention to provide an improved electrical system and control for an engine wherein an additional source of electrical power is made available during periods when the engine is operating at a low speed.
Another condition when the engine control may be adversely affected due to low available electric power is during starting. As is well known, many engine applications employ electric starters for starting the engines. The electric starter consumes a large amount of power and this may delete the power available for operating the other engine accessories so that engine starting can be made more difficult.
It is, therefore, a still further object of this invention to provide an improved engine control method wherein additional electric power is available on starting.
In many applications, the vehicle powered by the engine may employ an auxiliary battery for providing electric power for accessories of the vehicle which are not necessarily associated with the engine. For example, in watercraft it is frequently the practice to have one battery that serves the primary function of supplying electric power to the engine and another battery that supplies electrical power for accessories, such as lights, etc. It may be that this auxiliary battery is, at times, also charged from the engine generator. However, if this is the case, it is desirable to ensure that the batteries are electrically isolated from each other.
It is, therefore, a still further object of this invention to provide an improved system that employs a pair of batteries and wherein the batteries are isolated electrically form each other, but may be both utilized to communicate with the same source or load.
SUMMARY OF THE INVENTION
A first feature of this invention is adapted to be embodied in a method and control for an internal combustion engine having an output shaft. The engine includes at least one electrically operate component which is required for operation of the engine. A battery is provided to supply electrical power. A generator is driven by the engine output shaft and charges the battery through a charging circuit.
In accordance with a control for an engine constructed in accordance with this first feature of the invention, a voltage sensor is provided for sensing the voltage condition of the battery and an arrangement is provided for increasing the voltage available to the electrically operated component when the voltage sensor senses a battery voltage lower than a predetermined value.
In accordance with a method for practicing this feature of the invention, the battery voltage is sensed. If the sensed voltage falls below a predetermined value, the voltage available for operating the electrically operated component is increased.
A still further feature of the invention is adapted to be embodied in an engine control system that includes a first battery for operating an engine and a second battery for operating accessories other than the engine. The batteries are both connected to engine operating parts through reverse current flow preventing diodes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a composite view consisting of, at the bottom, right hand side, a partial side elevational view of an outboard motor constructed and operated in accordance with an embodiment of the invention. The lower, left hand view of this figure is a cross sectional view taken generally along the line A--A of the remaining view. This remaining, upper view is a partially schematic cross sectional view taken through a single cylinder of the engine showing the components associated with the control system.
FIG. 2 is a graphical view showing elements of the control system for the outboard motor in accordance with an embodiment of the invention.
FIG. 3 is a graphical view similar to FIG. 2 and shows another embodiment of the invention.
FIG. 4 is a graphical view showing the relationship between the voltage of a first battery of the electrical powering system and time.
FIG. 5 is a graphical view showing the relationship between the voltage of a second battery of the electrical powering system and time.
FIG. 6 is a schematic view showing the electrical powering system for the outboard motor in accordance with yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings and initially to FIG. 1, an outboard motor constructed in accordance with an embodiment of the invention is identified generally by the reference numeral 11. The invention is described in conjunction with an outboard motor because the invention deals with an internal combustion engine and the control system therefor. Therefore, an outboard motor is a typical application in which an engine constructed and operated in accordance with the invention may be utilized.
The outboard motor 11 is comprised of a power head that consists of a powering internal combustion engine, indicated generally by the reference numeral 12 and a surrounding protective cowling comprised of a main cowling portion 13 that is detachably connected to a tray portion 14.
As is typical with outboard motor practice, the engine 12 is supported within the power head so that its output shaft, a crankshaft indicated by the reference numeral 15 in the upper view of this figure, rotates about a vertically-extending axis. This output shaft or crankshaft 15 is rotatably coupled to a drive shaft (not shown) that depends into and is journaled within a drive shaft housing 16. The tray 14 encircles the upper portion of the drive shaft housing 16.
The drive shaft continues on into a lower unit 17 where it can selectively be coupled to a propeller 18 for driving the propeller 18 in selected forward or reverse direction so as to so propel an associated load, namely a watercraft. A conventional forward reverse bevel gear transmission (shown schematically in FIG. 2 and indicated by the reference numeral 20) is provided for this purpose.
A steering shaft (not shown) having a tiller 19 affixed to its upper end is affixed in a suitable manner, by means which include a lower bracket assembly 21, to the drive shaft housing 16. This steering shaft is journaled within a swivel bracket 22 for steering of the outboard motor 11 about a vertically-extending axis defined by the steering shaft.
The swivel bracket 22 is, in turn, connected to a clamping bracket 23 by means of a trim pin 24. This pivotal connection permits tilt and trim motion of the outboard motor 11 relative to the associated transom of the powered water craft. The trim adjustment through the angle β permits adjustment of the angle of the attack of the propeller 18 to obtain optimum propulsion efficiency. In addition, beyond the range defined by the angle β, the outboard motor 11 may be tilted up to and out of the water position for trailering and other purposes, as is well known in this art.
The construction of the outboard motor 11 as thus far described may be considered to be conventional and for that reason, further details of this construction are not illustrated nor are they believed necessary to permit those skilled in the art to practice the invention.
Continuing to refer to FIG. 1 but now referring primarily the lower left hand portion of this figure and the upper portion, the engine 12 is, in the illustrated embodiment, of the three-cylinder in-line type. To this end, the engine 12 is provided with a cylinder block 25 in which three horizontally extending, vertically aligned, parallel cylinder bores 26 are formed. Although the invention is described in conjunction with a three-cylinder in-line engine, it will be readily apparent to those skilled in the art how the invention may be utilized with engines having various cylinder numbers and cylinder configurations. In addition, the invention may also be employed with four stroke engines.
Pistons shown schematically at 27 in FIG. 1 are connected to connecting rods 28 by means of piston pins 29. The lower or big ends of the connecting rods 28 are journaled on respective throws 31 of the output shaft or crankshaft 15, as is well known in this art.
The crankshaft 15 is rotatably journaled within a crankcase chamber 32 formed at the lower ends of the cylinder bores 26. The crankcase chambers 32 are formed by the skirt of the cylinder block 25 and a crankcase member 33 that is affixed to the cylinder block 25 in any well known manner. As has been noted, the engine 12 operates on a two-cycle crankcase compression principal. As is typical with such engines, the crankcase chambers 32 associated with each of the cylinder bores 26 are sealed relative to each other in any suitable manner.
The ends of the cylinder bores 26 opposite the crankcase chambers 32 are closed by means of a cylinder head assembly 34 that is affixed to the cylinder block 25 in any known manner. The cylinder head 34 has recesses which cooperate with the cylinder bores 26 and the heads of the pistons 27 to form combustion chambers, indicated generally by the reference numeral 35. These combustion chambers 35 have a volume which varies cyclically during the reciprocation of the pistons 27 as is well known in this art.
An intake charge is delivered to the crankcase chambers 32 for compression therein by means of a charge forming and induction system, indicated generally by the reference numeral 36. The charge forming and induction system 36 includes an air inlet device 37 that is disposed within the protective cowling of the power head and which draws air therefrom. This air is admitted to the interior of the protective cowling by one or more air inlets formed primarily in the main cowling member 13.
A throttle valve 38 is positioned in the induction passage or intake manifold 39 that connects the air inlet device 37 to respective intake ports 41 formed in the cylinder block 25 and which communicate with the crankcase chambers 32 in a well known manner.
Reed type check valves 42 are provided in each of the intake ports 41 so as to permit a charge to flow into the crankcase chambers 32 when the pistons 27 are moving upwardly in the cylinder bores 26. On the other hand, when the pistons 27 move downwardly these valves 42 close and the charge is compressed in the crankcase chambers 32. The compressed charge is transferred to the combustion chambers 35 through one or more scavenge passages 43.
Fuel is supplied to the air charge admitted as thus far described by a charge forming system, indicated generally by the reference numeral 44. This charge forming system 44 includes one or more fuel injectors 45 that spray into each of the intake passages 39. The fuel injectors 45 are of the electrically operated type having electrically actuated solenoid valves (not shown) that control the admission or spraying of fuel into the intake passages 39 upstream of the check valves 42.
Fuel is supplied to the fuel injectors from a remotely positioned fuel tank 46. The fuel tank 46 is, most normally, positioned within the hull of the associated watercraft as is well known in this art. The fuel is drawn through a supply conduit by a pumping system including a high pressure pump 47 which discharges into a main fuel rail 48. The fuel rail 48 supplies fuel to each of the fuel injectors 45 in a known manner.
A pressure control valve 49 is provided in or adjacent the fuel rail 48 and controls the maximum pressure in the fuel rail 48 by dumping excess fuel back to the fuel tank 46 or some other place in the system upstream of the fuel rail 48 through a return conduit 51. The fuel that is mixed with the air in the induction and charge forming system 36 as thus far described will be mixed and delivered to the combustion chambers 35 through the same path already described.
Spark plugs 52 are mounted in the cylinder head 34 and have their gaps extending into the respective combustion chambers 35. These spark plugs 52 are fired by ignition coils (shown schematically in FIG. 2 and identified by the reference numeral 50) that are actuated by an ignition circuit that is controlled by a control means which includes an electronic control unit or ECU 53 which will be discussed in detail later.
When the spark plugs 52 fire, the charge in the combustion chambers 35 will ignite, burn and expand. This expanding charge drives the pistons 27 downwardly to drive the crankshaft 15 in a well known manner. The exhaust gases are then discharged through one or more exhaust ports 54 which open through the sides of the cylinder block bores 26 and communicate with an exhaust manifold 55 as shown schematically in the upper view of FIG. 1 and in more detail in the lower left side view of this figure.
Referring now primarily to the lower left hand side view of FIG. 1, the exhaust manifold 55 terminates in a downwardly facing exhaust discharge passage 56 that is formed in an exhaust guide plate upon which the engine 12 is mounted. This exhaust guide plate delivers gases to an exhaust pipe 57 that depends into the drive shaft housing 16.
The drive shaft housing 16 defines an expansion chamber 58 in which the exhaust pipe 57 terminates. From the expansion chamber 58, the exhaust gases are discharged to the atmosphere in any suitable manner such as by means of a underwater exhaust gas discharge 59 which discharges through the hub 61 of the propeller 18 in a manner well known in this art. At lower speeds when the propeller 18 is more deeply submerged, the exhaust gases may exit through and above the water atmospheric exhaust gas discharge (not shown) as also is well known in this art.
In addition to controlling the timing of the firing of the spark plugs 52, the ECU 53 also controls the timing and duration of fuel injection 6f the fuel injector 45 and may control other engine functions. For this purpose, there are provided a number of engine and ambient condition sensors. In addition, there is provided a feedback control system through which the ECU 53 controls the fuel air ratio in response to the measurement of the actual fuel air ratio by a combustion condition sensor such as an oxygen (O 2 ) sensor 62 which is positioned in a passageway 63 that interconnects two of the cylinder bores 26 at a point adjacent the point where the exhaust passages 54 are located,
In addition to the O 2 sensor, other sensors of engine and ambient conditions are provided. These include an in cylinder pressure sensor 64 and knock sensor 65 that are mounted in the cylinder head 34 and cylinder block 25, respectively. The outputs from these sensors are transmitted to the ECU 53.
Air flow to the engine may be measured in any of a variety of fashions and this may be done by sensing the pressure in the crankcase chamber 32 by means of a pressure sensor 66. As is known, actual intake air flow can be accurately measured by the measuring the pressure in the crankcase chamber 32 at a specific crank angle. A crank angle position sensor 67 is, therefore, associated with the crankshaft 15 so as to output a signal to the ECU 53 that can be utilized to calculate intake air flow and, accordingly, the necessary fuel amount so as to maintain the desired fuel air ratio. The crank angle sensor 67 may be also used as a means for measuring engine speed, as is well known in this art.
Intake air temperature is measured by a crankcase temperature sensor 68 which is also positioned in the crankcase 33 and senses the temperature in the crankcase chambers 32.
Exhaust gas back pressure is measured by a back pressure sensor 69 that is mounted in a position to sense the pressure in the expansion chamber 58 within the drive shaft housing 16.
Engine temperature is sensed by an engine temperature sensor 71 that is mounted in the cylinder block 25 and which extends into its cooling jacket. In this regard, it should be noted that the engine 12 is, as is typical with outboard motor practice, cooled by drawing water from the body of the water in which the outboard motor 11 operates. This water is circulated through the engine 12 and specifically its cooling jackets and then is returned to the body of water in any suitable return fashion.
The temperature of the intake water drawn into the engine cooling jacket is also sensed by a temperature sensor which is not illustrated but which is indicated by an arrow and legend in FIG. 1. In addition other ambient conditions such as atmospheric air pressure are transmitted to the ECU 53 by appropriate sensors and as indicated by the arrows in FIG. 1.
The condition of the transmission 20 which, as has been noted, couples the drive shaft to the propeller 18 is determined by a transmission sensor 70 as shown schematically in FIG. 2, the output of which is indicated by the arrow in FIG. 1. This sensor indicates the condition of the transmission as to whether it is in a neutral or in a driving condition.
A trim angle sensor 73 is provided adjacent the trim pin 24 so as to provide a signal indicative of the angle β.
A throttle angle position sensor 75 is also provided and outputs a signal indicative of the position of the throttle valve 38 to the ECU 53.
As previously stated, the ECU 53 controls the ignition timing for the engine 12 and the timing and duration for the fuel injectors 45. Additionally, the ECU 53 also controls the powering of various additional electrically operated engine components. The power for the electrically operated engine components, as well as for the ignition and fuel injection systems, is provided by a battery that is charged by a charging circuit that includes a flywheel magneto generator (shown later in FIG. 6) which is driven by the output shaft 15 of the engine 12.
Although the battery is charged through a regulating circuit of any known type, a problem may at times exist with this configuration and inadequate or low voltage may only be available. This can exist under conditions of lower engine speeds, such as when the engine is idling or when trolling for long time periods. Under such conditions the generator is driven by the output shaft at a rate that is insufficient for replenishing the charge in the battery. Thus, the battery power becomes depleted and the electrically operated engine components are adversely affected. An embodiment of this invention eliminates this adverse situation by ensuring that the charging circuit is fully able to replenish the charge in the battery regardless of the engine operating conditions and is described with reference to FIG. 2.
As seen in FIG. 2, a control means that is indicated by the reference numeral 76 is incorporated in the ECU 53. This includes an engine speed control circuit 77 which controls the operation of the ignition coils 50 and fuel injectors 45. In addition an electric current control circuit 78 which controls the amount of electricity available for other electrically operated engine components that are indicated collectively by the reference numeral 79. Both the engine speed control circuit 77 and the electric current control circuit 78 are powered by a battery, which is indicated by the reference numeral 81 and whose electrical charge level is monitored by a voltage sensor 82. Additionally, the transmission sensor 70 provides the engine speed control circuit 77 a signal that indicates whether the transmission is in a neutral or driving condition.
When the engine 12 is idling, the generator is not driven at a rate sufficiently high to allow the charging circuit to replenish the charge in the battery 81. Thus, the charge in the battery 81 will deplete. When the charge in the battery 81 drops below a certain predetermined voltage level, the voltage sensor 82 will signal the ECU 53. If, at the same time, transmission sensor indicates that the transmission is in a neutral condition, the engine speed control circuit 77 will increase the engine speed by advancing the ignition timing or the injection timing and duration or both.
This increase in engine speed will increase the speed at which the generator is driven and thus the charging capabilities of the charging system will now fully replenish the charge in the battery 81 and thus increase the available voltage. Thus, the above control method ensures that the battery 81 will have sufficient charge to meet the operating demands of the outboard motor 11 and its electrically operated engine components 79, even when the engine 12 is idling. The engine speed control circuit 77 will also discontinue the operation of the engine 12 at the higher engine speed whenever a signal from the transmission sensor indicates that the transmission is in a driving condition since, in this condition, the generator is normally driven by the output shaft 15 at a rate sufficient to replenish the charge in the battery 81. Additionally, this also ensures against excessive engine speed causing the watercraft driven by the outboard motor 12 to travel at a rate above the operator demand.
In addition to powering the electrically operated engine components 79, the battery 81 also powers non-engine related electrically operated components that are indicated by the reference numeral 83 such as any lighting or radio navigational equipment associated with the watercraft that is driven by the outboard motor 11, all of which deplete the battery 81 and decreases the available voltage for the electrically operated engine components 79.
A further embodiment of this invention utilizes the electric current control circuit 78 to increase the voltage available to the electrically operated engine components 79 and is described with further reference to FIG. 2.
As previously stated, the voltage sensor 82 signals the ECU 53 if the battery voltage drops below a certain predetermined level. This signal is sent to both the engine speed control circuit 77 and the electric current control circuit 78. If such a low battery voltage signal is received by the electric current control circuit 78 it will discontinue the supply of electrical power to the non-engine related electrically operated components 83 and thus reduce the power demands on the battery 81 and increase the voltage available to the engine components. This also will more readily allow the charging system to recharge the battery 81 and has an added advantage in that it may also be in operation even when the transmission is in a driving condition.
It is often the practice for outboard motors to utilize an electric starter 87 as a means by which to initiate the operation of the engine 12. These starters tend to consume a large amount of available battery power and may deplete the battery 81 such that its voltage level, indicated by V1 in FIG. 4, falls below the minimum predetermined voltage and is insufficient to properly power the engine and non-engine related electrically operated components 79 and 83 respectively.
An embodiment of this invention utilizes a further control means which includes a second battery 89, normally utilized for powering the non-engine related electrically operated components 83. If the normally utilized engine, first battery 85 is in a low voltage condition, the second battery 89 is also utilized for powering a starter to reduce the load on the first battery 85.
Referring now to FIG. 3, a control means is indicated by the reference numeral 84 and consists of the first battery 85 which powers an engine start circuit 86 that is incorporated within the ECU 53. The engine start circuit 86 actuates the starter 87 and controls the operation of the electrically operated engine components 79. The charge in the first battery 85 is monitored by the voltage sensor 82 which outputs a signal to a switch 88.
The second battery 89 powers the non-engine related electrically operated components 83 through the switch 88 and may also be used to power the starter 87 in a manner now described. When the voltage in the first battery 85 is below a predetermined level, the voltage sensor 82 will signal the switch 88 which will, in turn, open a circuit that enables the second battery 89 whose voltage V2, as shown in FIG. 5, is above the desired predetermined level to be used for powering the starter 87 and the electrically operated engine components 79 during start-up.
Thus, adequate charge is provided by the control means 84 to ensure that the engine 12 can be started even in circumstances where the charge in the first battery 85 is depleted. In addition, the engine electrical components will have available adequate voltage to operate correctly.
FIG. 6 illustrates a further embodiment of the invention where the control means 84 of the previous embodiment has been modified in order to ensure that the first and second batteries 85 and 89, respectively, are electrically isolated from one another so that one will not deplete the charge in the other.
The engine driven flywheel magneto includes a three coil power source, indicated by the reference numeral 91. This is utilized, as previously noted as the powering agent or generator for charging the batteries 85 and 89. A voltage regulator 92 regulates the charge from the three-way coil 91 to the batteries 85 and 89, while fuses 93 safeguard the batteries in the event of an excessive power surge.
The first battery 85 supplies electrical power to the starter 87 and the electrically operated engine components 79 through a diode 94 while the second battery 88 supplies power to the other non-engine related electrically operated components 83 and, when the voltage in the first battery 85 is below the predetermined level, to the electrically operated engine components 79 through a further diode 95.
In the situation where both batteries 85 and 89 are powering the electrically operated engine components 79, the batteries 85 and 89 are kept electrically isolated from each other by the diodes 94 and 95 which preclude electric charge flow from one battery to the other.
From the foregoing description, it should be readily apparent that the described embodiments are very effective in providing adequate power for the electrical components of an engine and its accessories under substantially all conditions without deterioration in performance due to low voltage. Of course, the foregoing description is that of preferred embodiments of the invention and various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims. | An internal combustion engine particularly adapted for driving a vehicle, such as a watercraft, that includes accessories and an engine management system for controlling certain functions of the engine electrically. In order to prevent misadjustment in the event of low available battery voltage, a number of arrangements are depicted for maintaining battery voltage when the normal battery voltage falls. This may be done by increasing engine speed when operating in neutral, discontinuing the operation of other accessories and/or switching a second battery into the power circuit. In addition, an arrangement is provided wherein a battery may be supplied for utilization in starting of the engine to avoid depletion of the main battery's voltage so that the engine control can be maintained even during starting. | 5 |
BACKGROUND OF INVENTION
[0001] The purpose of a railroad tie is to connect the earth, or other intermediate supporting base, to plates which connect to rails. They also provide for the proper spacing (gauge) between rails. In turn the rails support locomotives, passenger, freight or service cars as they transit or park.
[0002] FIG. 1 shows the cross section of a treated timber tie 10 in a common cross section of seven inches (7″) tall and nine inches (9″) wide. Common lengths for cross ties are eight feet (8′), eight foot and six inches (8′-6″) and nine feet (9′). Switch ties are longer. In this drawing the pressured applied preservative 20 does not penetrate through the entire tie. There is a core 30 that may remain untreated.
[0003] Railroad ties are traditionally made of wood, though some are of concrete or all-plastic or plastic-composite. There are several standard sizes, one common size being seven inches tall by nine inches wide by nine feet long. Other standards include cross sections of 6″×8″, 6″×9″ and lengths of 8′-0″ and 8′-6″.
[0004] Ties must be strong enough to maintain support and gauge under lateral loads, static vertical loads, and dynamic vertical loads. The tie must be resistant to the dynamic load which can cause the tie plate to move and abrade the tie. The tie must be able to function despite environmental stresses of thermal expansion, ultraviolet (UV) radiation, attack from microorganisms, fungi, insects and other life forms. It is highly preferable that ties be installable using the existing base of standardized installation equipment and fasteners. Some rail systems use a “third rail” to conduct power to trains. For this and other reasons, railroad ties should not be conductors of electricity.
[0005] The predominant tie in service is a hardwood timber treated with creosote, coal tar, chromated copper arsenate or other preservative. Over time these preservatives leach from the tie to the surrounding earth and eventually migrate to the surrounding areas, including water tables. There are few safe methods for disposing of treated timber ties. Stacking them in landfills does little to retard leaching. Open air burning releases the toxins into the atmosphere. Closed effluent burning with contaminant capture is expensive.
[0006] Because concrete and reinforced concrete ties are highly inflexible they do not allow a flex-and-resume support of the rails. More concrete ties are required per mile of track which increases the cost per mile. The cost per tie is also higher. Further, the increased weight of concrete requires changes to installation equipment and procedures.
[0007] Both timber and concrete ties can accept water into cracks or grain separations. As water freezes it expands and can force the cracks wider, leading to a reduction in tie strength. For reinforced concrete ties this crack expansion can also expose the metallic reinforcing material to air, thereby initiating the deleterious effects of rust, further reducing tie strength.
[0008] More than ten million ties were installed as new or replacements during each of 2003-2006. With thousands of ties per mile, the introduction of a functionally equivalent or superior, longer lived, and lower life cycle cost tie is materially beneficial to rail operators, maintains or improves rail system safety, and is ecologically beneficial.
[0009] Thus, there is a need for a tie with a combination of lower manufacturing times, better spike retention, increased resistance to abrasion, lighter weight, and lower cost than existing concrete, plastic or composite ties.
[0010] There is a further need for processes for manufacturing a tie having the above characteristics in an efficient and environmentally sensitive manner.
SUMMARY OF THE INVENTION
[0011] A railroad tie according to embodiments of the present invention uses a wood, composite wood, wood-plastic or engineered plastic core and is encapsulated in one to many layers of plastic, or plastic-composite materials. A complete encapsulation is also referred to as a sleeve or a jacket. Only the outer-most encapsulating layer is exposed to the elements. A single plastic layer is, or multiple layers are, applied in a high pressure mold to promote adhesion between the core and adjacent plastic layer as well as between layers to increase strength. High pressure also helps the plastic or plastic-composite material to displace voids in the core with the result being a stronger and longer lasting product than natural wood could provide.
[0012] The core may be an old tie removed from service, but is still adequately strong. It may be trimmed to size and encapsulated. The encapsulation retards leaching of preservatives in the core.
[0013] Alternatively, the core may start as an unusable treated timber tie rendered into fibers. Rotten or otherwise undesirable fibers are separated from reusable fibers and disposed of. The reusable fibers may be mixed with a binder and formed into cores of the appropriate size. Again, the encapsulation retards leaching of any fiber-borne preservative to the environment.
[0014] The core may be an engineered wood, structured wood, wood by-product, plastic/wood beam or plastic composite.
[0015] The encapsulation may be an engineered plastic or plastic-composite section.
[0016] The top side of the outermost encapsulation may be textured or pigmented to reduce glare or provide another aesthetically pleasing or functional appearance. The underside may be patterned to increase friction with ballast or other bed material, so as to retard lateral movement. The encapsulation(s) may be colored for an aesthetic or functional purpose. Other functional or decorative moldings may be added. These include, but are not limited to, owner identification, date of manufacturing, location of manufacturing facility, mold number, lot number etc.
BRIEF DESCRIPTION OF DRAWINGS
[0017] Aspects, features, benefits and advantages of the embodiments of the present invention will be apparent with regard to the following description, appended claims and accompanying drawings where:
[0018] FIG. 1 , a cross section of a traditional timber tie showing irregular penetration of preservative;
[0019] FIG. 2 , a cross section of an embodiment of the invention showing a single layer encapsulation;
[0020] FIG. 3 , a cross section of an embodiment of the invention showing a double layer encapsulation;
[0021] FIGS. 4A-4C illustrate pattern elements for a tie in ballast;
[0022] FIG. 5 , the bottom of an embodiment of the showing pattern elements in pattern A;
[0023] FIG. 6 , the bottom of an embodiment of the showing pattern elements in pattern B;
[0024] FIG. 7 , the bottom of an embodiment of the showing pattern elements in pattern C;
[0025] FIG. 8 , a bottom view of an embodiment of the showing pattern element suitable for a tunnel;
[0026] FIG. 9 , a side view of an embodiment of the invention showing pattern element suitable for a tunnel;
[0027] FIG. 10 , a cross sectional view of the core and the inner sleeve during manufacture in an embodiment; and
[0028] FIG. 11 , a cross sectional view of the core, inner sleeve, and outer sleeve according to an embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIG. 2 shows a railroad tie 40 according to an embodiment of the present invention. Railroad tie 40 has a cross section of 7″×9″ with a core 60 of cross section 6.5″×8.5″ encapsulated in a single sleeve 50 0.25″ inches thick.
[0030] FIG. 3 shows a railroad tie 70 according to another embodiment of the present invention. Railroad tie 70 has a common cross section of 7″×9″ with a of 6″×8″ core 100 , an inner sleeve 90 , 0.25″ in thickness, and an outer sleeve 80 , 0.25″ in thickness. Railroad tie 30 , encapsulated in two sleeves, holds several advantages over the railroad tie 40 , having only a single layer of encapsulation. First, plastic cools at a near-logarithmic rate. During the manufacturing process, a 0.25″ layer may cool sufficiently after only thirty seconds. A 0.5″ layer may, however, take two minutes to cool. Thus, using two layers may result in a lower manufacturing time, given the same desired final thickness. Second, using multiple sleeves allows different materials to be used for each sleeve. Third, using multiple sleeves allow the interface between the sleeves to be molded in an interlocking form, resulting in increased strength. However, it is to be understood that single, dual, or even greater levels of encapsulation are within the scope of this invention.
[0031] The cores 60 and 100 may be new treated timber ties reduced to the 6.5″×8.5″ and 6″×8″, respectively. Because the cores 60 and 100 are encapsulated by the sleeve 50 and sleeves 80 and 90 , respectively, the preservative in the cores 60 and 100 is retarded from leaching into the surrounding environment. Further, the cores 60 and 100 are protected from the elements. Alternatively, the cores 60 and 100 may be used treated timber ties that are structurally sound, but worn towards the outer edges. The outer edges are removed in sufficient quantity to result in the cores 60 and 100 shown in FIGS. 2 and 3 , respectively.
[0032] The cores 60 and 100 may alternatively be constructed from used timber ties that are no longer structurally sound, but contain sound fibers and strands.
[0033] The sleeves 50 , 80 and 90 may be constructed from any number of non-plastic polymers, plastics or plastic-composites. Preferably, inner sleeve 80 is constructed from a polyester, such as poly ethylene terephthalate, or PET. The PET may be additionally be mixed with a fine rubber, such as a rubber dust, and a stabilizer. Rubber dust performs two functions. First, one of the elements in rubber dust is carbon black, which assists in adding UV resistance to the sleeves. Second, the rubber dust consumes volume and is cheaper than plastic, i.e., a filler. The stabilizer may be, for instance, FUSABOND co-polymer, manufactured by DuPont. The stabilizer may improve the compatibility between the base plastic, such as PET, and any additives, fillers, or reinforcing agents, such as the rubber dust. Sleeves 50 and 90 are preferably constructed from a polyolefin such as high density poly ethylene, or HDPE. The HDPE may be mixed with a fine rubber dust and a stabilizer, as discussed above with respect to PET. As sleeves 50 and 90 are externally visible, a colorant may be added to the HDPE to attain the desired color. Additional additives, such as scents, may be added to the HDPE. Inner sleeve 80 and outer sleeve 90 are preferably greater than 75%, by weight, of PET and HDPE, respectively.
[0034] Although not shown in FIGS. 2 and 3 , the end surfaces of railroad ties 40 and 70 are also covered by the sleeves 50 , and 80 and 90 , respectively. The end surfaces may be unadorned, or they may be impressed with information, such as the identity of the manufacturer.
[0035] The side surfaces of railroad ties 40 and 70 are preferably smooth to reduce friction during material handing.
[0036] The upper surface railroad ties 40 and 70 may be patterned in either a decorative or functional pattern. Such functional patterns include, but are not limited to, those patterns resulting in increased friction or glare reduction.
[0037] The bottom surface of the railroad ties 40 and 70 is preferably patterned depending on the surface upon which the railroad ties 40 and 70 are intended to be placed. For instance, the railroad ties 40 and 70 may be placed in ballast, requiring one type of patterning, or on a smooth surface such as those found in smooth floored tunnels, requiring different patterning.
[0038] For ties that are to be placed on ballast, the tread patterns should capture the ballast material (e.g., gravel rock) to increase friction. In FIGS. 4A-4C and FIGS. 5-7 , the lines indicate ridges that protrude from the surrounding surface. The ridges need not be squared, but may instead be chamfered with a draft angle. FIGS. 4A , 4 B and 4 C each show an embodiment of a tread pattern section. FIG. 4A is a right pointing chevron section 110 , and shows two parallel chevrons each of which is bounded by three triangles. In this embodiment, the chevron section contains all 90-45-45 degree triangles, though one of ordinary skill would understand that the angles may be modified while still staying within the scope of the present invention. The chevrons are 90-degrees at the apex and 135-degrees at the sides. In this embodiment, the end result is a two square pattern. The left pointing chevron 120 , shown in FIG. 4B , is a mirror image of the right pointing 110 chevron. FIG. 4C shows another section 130 composed of eight triangles (8T) where the triangles are at angles other than 90-degrees or 45-degrees. The mix of differing angles increases the probability of a rock capture and increased friction. The three patterns illustrated in FIGS. 4A , 4 B and 4 C may be combined in many ways to achieve a bottom surface with higher friction in ballast than a smooth bottom surface.
[0039] FIGS. 5 , 6 and 7 show various combinations of the sections shown in FIGS. 4A , 4 B and 4 C. FIG. 5 shows a combination 140 comprising one 8T section 130 placed between left pointing 120 and right pointing 110 chevron patterns. FIG. 6 shows a combination 150 comprising one 8T section 130 placed between alternating left pointing 120 and right pointing 110 chevron patterns. FIG. 7 shows a combination 160 one 8T section 130 placed before and after each pair of left pointing 120 and right pointing 110 chevron patterns. The combinations 140 , 150 and 160 may be repeated over the length of the bottom surface of the tie.
[0040] The bearing surfaces of ties according to an embodiment of the present invention having a patterned bottom surface may range in width from near-zero for a knife edge to two inches (2″) wide. The molding draft angle of the raised tread to the relieved section may range between 0.01-degrees (near vertical) to 89.99-degrees (near flat).
[0041] Not all ties are placed in ballast. To improve performance in tunnels, or other smooth bottomed surfaces, FIG. 8 shows a bottom surface 180 of a tie section showing one inch (1″) diameter channels 174 at five inch (5″) intervals. These channels are over the length of the tie. FIG. 9 shows a side surface 180 of a tie section showing the same spacing and channels 174 . Although the 5″ spacing and 1″ diameter are shown here, other combinations of spacing, diameter, and shape are possible. The channels allow for drainage.
[0042] Hereinafter, a preferred method of manufacturing the tie shown in FIG. 3 will be described. As shown in FIG. 3 , the completed tie 70 according to an embodiment of the present invention comprises three elements, the core 100 , inner sleeve 90 and outer sleeve 80 . To construct the core 100 , a whole railroad tie in a 7″×9″×8′-6″ size is first obtained. The whole railroad tie is then cut to the desired length, and then cut in half longitudinally to make two cores 100 , nominally 4.5″ tall and 7″ wide. One core 100 is set aside for later use. For the inner sleeve 90 , PET regrind is first obtained. Regrind refers to plastic feed stock that has been sorted, ground, cleaned, and otherwise processed to be ready to be used immediately. The PET regrind is then preferably mixed with a fine virgin rubber dust. A stabilizer is also preferably added to the PET regrind. The PET, rubber dust and stabilizer are placed in a blender and blended. The PET mixture is then transferred to an injection molding machine. For the outer sleeve 80 , HDPE regrind is first obtained. The HDPE regrind is then preferably mixed with a fine rubber dust, either de-vulcanized, recycled rubber or virgin rubber. A stabilizer is also preferably added to the HDPE regrind. The HDPE, rubber dust and stabilizer are placed in a blender and blended. The HDPE mixture is then transferred to an injection molding machine.
[0043] A mold is formed in the desired shape of the final product. If two layers of sleeves are desired, two molds may be necessary. Alternatively, molds are available that may reconfigure themselves, allowing both layers to be formed in a single mold. The core 100 may be suspended in the mold in various ways, such as by a rod. The hole in the sleeves resulting therefrom may be filled in at a later time.
[0044] The 4.5″×7″ core 100 is placed in the mold. Then, the PET injection molding machine supplies the PET mixture into the mold to form the inner sleeve 90 . After the inner sleeve 90 is formed, the HDPE injection molding machine supplies the HDPE mixture in the mold to form the outer sleeve 80 . Alternatively, if a single mold is used for both layers, PET is first injected, then allowed to cool. Then, the mold may be reconfigured, and the HDPE may be injected into the mold.
[0045] In a preferred embodiment and referring to FIG. 10 , the inner sleeve 290 is molded so as to have a solid base layer in contact with the core 270 , with fingers protruding therefrom. These fingers give inner sleeve 290 a ridged surface. FIG. 11 shows a cross-section of a portion of a completed tie. It shows inner sleeve 290 , including fingers, as well as the outer sleeve 280 having opposite, interlocking fingers, and a solid layer. In a preferred embodiment, the sides and top of the tie comprise an inner sleeve 290 having a 0.25″ thick solid layer and 0.5″ fingers, as well as an outer sleeve 280 having 0.5″ fingers and a 0.25″ solid layer, resulting a total thickness of 1.0″ because the fingers interlock. Given a 7″ wide core 270 , this results in the desired final width of 9″. The bottom of the tie is preferably formed in a similar fashion, only differing in that the outer sleeve 280 additionally includes 0.5″ of high friction ridges. By forming the first and second sleeves in the above fashion, the sleeves may be formed and cooled quicker than if, for instance, each of the two sleeves were a 0.5″ solid layer. This is because two sleeves, each having a 0.25″ solid layer with 0.5″ interlocking fingers, will cool quicker than two sleeves, each a 0.5″ solid layer, even though both result in a total encapsulation of 1.0″.
[0046] In an alternate embodiment, rather than obtaining PET and HDPE regrind, PET and HDPE recyclate may instead be obtained. Recyclate refers to plastic feed stock that has been sorted by type but requires further processing to remove contaminants, such as labels and traces of previous contents, and grinding before being ready for use. Before being introduced to the respective mixers and if the PET or HDPE recyclate is obtained in baled form, the PET or HDPE bales are placed in a debater, wherein the bales of PET or HDPE recylate are broken apart into a more manageable stream of recyclate. PET or HDPE recyclate from the debater is then forwarded to a shredder, wherein the large pieces of PET or HDPE recylate are reduced into smaller shreds of plastic. The shreds of PET or HDPE are then forwarded to a separator, which separates the PET or HDPE from non-plastic elements such as labels. The non-plastic elements may be removed to a closed effluent furnace where they can be burned as fuel to generate some electricity. The separated shreds of PET or HDPE may used identically to the PET or HDPE regrind above.
[0047] In another embodiment, old and scrap ties may be recycled to obtain new cores 100 . First, remaining metal, such as plates and spikes, are removed from the old and/or scrap ties. The ties are then rendered into fibers and strands which are sorted. Rotten, overly short, or otherwise undesirable fibers may be disposed of by sending them to a closed effluent furnace to be burned to generate electricity. The remaining fibers may then be mixed with a binder such as, for instance, an iso-cyanate resin, heated and pressed to form a large sheet or billet. The large sheet or billet may then be processed to create ready-to-use cores of a desired size, which may be used identically to the 4.5″×7″ cores 100 in the process described above. The core 100 produced by the this method is greater than 80% wood fibers, by weight.
[0048] In another embodiment, scrap tires may be recycled to obtain rubber dust. Scrap tires may first be subject to a gross shred which turns the tires into crumbs. At this stage, the tire crumbs still contain metal fibers, such as remnants of steel belting and valves, and the rubber in the tire crumbs is vulcanized. Tire crumbs may be used as fuel in a closed effluent furnace. Alternatively, the tire crumbs may be finely shredded to de-vulcanize the rubber. The resulting finely shredded rubber dust may be used instead of the virgin rubber dust in the process described above. The shredding process also separates the metal from the shredded rubber dust. The metal may then be sold to a recycler.
[0049] While we have shown illustrative embodiments of the invention, it will be apparent to those skilled in the art that the invention may be embodied still otherwise without departing from the spirit and scope of the claimed invention. For instance, although the exemplary embodiments disclosed above have been generally limited to the traditional rectangular-shaped tie, non-rectangular embodiments also lie within the scope of the present invention. | Disclosed herein is a railroad tie comprising a core comprising wood or a wood product, and a first sleeve encapsulating the core, wherein the first sleeve comprises at least one of the group consisting of plastic, plastic-composite, or non-plastic polymers. A second sleeve may additionally encapsulate the first. In a preferred embodiment, the first sleeve is comprised primarily of poly ethylene terephthalate, and the second sleeve is comprised primarily of high density poly ethylene. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to the handling of articles and material including the identification and correct sorting of the articles.
BACKGROUND
[0002] An industrial scale conveyor, handling articles for washing and subsequent sorting, needs to maintain an economic rate, based upon the required number of articles per second on the conveyor. To manage this manually requires a sufficient number of operators, proportional to the rate of articles requiring sorting.
[0003] One method of managing the rate of articles is to automatically sort the articles as they reach a particular zone either robotically or through mechanical sorting means.
[0004] However, this is not effective if the articles are different with the number of categories of articles progressively increasing the complexity of the sorting process.
[0005] One such application is for an industrial dish washer whereby the articles may be normal crockery (e.g plates, cups, sauces and bowls) and cutlery (e.g fork, knife, spoon, chopsticks etc). A further complexity includes sourcing said articles from different locations. Using the dishwasher analogy further, a bowl from one source may be completely different from a bowl from another source and in fact each source may have several different types of bowls.
[0006] Accordingly, mechanical sorting based on shape is not viable and so opportunities for automatic sorting and so operating the conveyor at an economic rate according to the prior art is unavailable.
SUMMARY OF INVENTION
[0007] In one aspect the invention provides a material handling system comprising: a platform for receiving a plurality of articles; a plurality of sorting bins, each bin in corresponding to an article type; an object recognition system for identifying an article on the platform and categorizing said article by specific article type; said 3D object recognition system including a 3D detector for detecting said article and a database containing data on characteristics of article types; an article engagement assembly for engaging and delivering said article to said corresponding sorting bin; wherein the object recognition system is arranged to identify the article based upon the data within said database and instructs the article engagement assembly to engage and place the article in said sorting bin.
[0008] In a second aspect the invention provides a method for identifying and sorting an article, said method comprising the steps of: detecting the presence of the article by a 3D detector; comparing detected article with data contained in a database; locating the position and orientation of the article from the 3D image and transformed such information into robot coordinate frame; categorizing said article as a specific article type based upon said comparison.
[0009] Accordingly, by using an object recognition system in communication with a database identifying articles by category, the invention provides a robotic and therefore automatic sorting system.
[0010] In one embodiment, the platform may be a carriage, tray or crate. Alternatively, the platform may be located on a conveyor, such as the surface of the conveyor or a carriage moved by said conveyor. This arrangement may provide the advantage of operating the conveyor at an economic rate possibly beyond that of multiple operators sorting manually.
[0011] For the platform being a tray or crate, said platform may be part of a set of shelves delivered within a movable array of said trays or crates, with said system directed to handle the articles from said trays or crates.
[0012] For the purpose of simplifying the description, reference to the platform being part of a conveyor will be used, on the understanding that the platform is not limited to a conveyor, but may also refer to the platform being a tray, crate or carriage.
[0013] The database may list articles by image with each article determined by a range of perimeters which may include category (e.g bowl), source (e.g specific restaurant) and/or type (e.g soup bowl). The database may further include other perimeters based upon a range of criteria which may be by manufacturing brand or merely by external dimensions.
[0014] The database may contain the article information which may include at least one image of the article. Preferably, there may be several images of the article taken from different angles so as to facilitate the object recognition system correctly identifying the articles irrespective of the orientation on the conveyor.
[0015] To this end, the object recognition system may include a camera which may be a 3D camera providing depth information on the article. Alternatively, or in combination with a camera derived system, the object recognition system may include an electronic or digital tagging system such as an RFID tag, a barcode or a QR code system placed upon each article. The system according to the present invention may therefore have an ID recognition system such as a barcode reader, RFID reader etc located adjacent to the conveyor for identifying the ID information on the targeted article. When used in combination with a camera, the two systems may be used to confirm an identity and/or act as a redundancy system. Having the two systems in combination may also act to reduce the margin of error which may allow the operator to increase the speed of the conveyor within a wider confidence margin.
BRIEF DESCRIPTION OF DRAWINGS
[0016] It will be convenient to further describe the present invention with respect to the accompanying drawings that illustrate possible arrangements of the invention. Other arrangements of the invention are possible and consequently, the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention.
[0017] FIG. 1 is a schematic view of the system having a conveyor according to one embodiment of the present invention;
[0018] FIG. 2A is a photographic image captured by the conveyor system;
[0019] FIG. 2B is a raw depth image captured by the conveyor system according to a further embodiment of the present invention;
[0020] FIG. 3 is an isometric view of a sorting system according to one embodiment of the present invention;
[0021] FIG. 4 is an elevation view of an end-effector of the sorting system according to one embodiment of the present invention;
[0022] FIG. 5 is a flow diagram of the object recognition system logic according to one embodiment of the present invention, and;
[0023] FIGS. 6A to 6C are images from the object recognition system for progressive recognition of an article.
[0024] FIG. 7 is an isometric view of an end effector assembly according to a further embodiment of the present invention.
DETAILED DESCRIPTION
[0025] For the purpose of simplifying the following examples, reference is made to a conveyor, which in this case will be the conveyor. It will be appreciated that the platform is not limited to a conveyor, but may also refer to the platform being a tray, crate or carriage either in association with a conveyor or used distinctly from a conveyor.
[0026] FIG. 1 shows a material handling system, which in this case is a conveyor system 5 . In general, the platform upon which the articles are received may be the surface of the conveyor 15 , a carriage upon the conveyor or a crate/tray placed on the conveyor.
[0027] Articles 10 are loaded onto the conveyor 15 . For this particular example, the conveyor system 5 is arranged with an industrial dishwasher and so includes a washing station 20 and drying station 25 through which the article 10 passes. Central to the invention is an object recognition system 32 comprising a detector 30 , in this case a 3D camera for targeting an article 45 . The camera 30 is connected to a control system and database 34 which compares the article 45 to a database of images in order to identify the type of article.
[0028] The control system 34 then engages an end-effector 35 which in this case is engaged with a linear slide 40 . It will be appreciated that movement of the end-effector 35 may vary with FIG. 3 showing a further embodiment of the drive system for the end-effector.
[0029] The end-effector engages the article 45 and moves 50 whereupon the article 45 is placed within one of a series of sorting bins 55 with the sorting bin corresponding to the article type as determined by the control system 34 .
[0030] The sorting bins may be basket-like containers placed on sliding base with security fences covered around. This security fences may be locked by electro-magnet lock controlled by system digital I/O output. In addition, each sorting bin may be mounted with manual push button and proximity sensors to detect the loads of placed articles.
[0031] Either push buttons may be pressed or the proximity sensor senses that the sorting bin is full, the robot will not place additional articles into this bin any more while the security lock will be released so that operators can pull the full-loaded sorting bin from the security fences. After the empty sorting bin is replaced and the security lock is locked again, the robot arm will start placing articles into this sorting bin again. This design protects operators and robot arms so that operators can safely remove full-loaded sorting bin from the system.
[0032] In a further embodiment the object recognition system may be visual whereby the detector is a camera such as a 3D camera. FIGS. 2A and 2B show images captured by a 3D camera for an object recognition system. In particular, there is shown a crate 60 in which the articles are placed on the conveyor. Within the crate is a cup 65 , a type of bowl 70 and a further type of bowl 75 . The control system according to this embodiment takes the image taken from the 3D camera and conducts a depth analysis.
[0033] Articles handled by such a conveyor system will have both an image taken as shown in FIG. 2A and a depth image as shown in FIG. 2B whereas traditional vision recognition is achieved by template matching. This is not appropriate for the present invention. As objects are not flat and may fall onto the conveyor in any orientation, a template matching approach using a two dimensional camera is unreliable. Further, in order for the control system to engage the end-effector, some information on the height of the article is required. A two dimensional camera cannot provide this. The object recognition system according to the present invention in this embodiment therefore uses a “background subtraction” process in order for the article to be detected.
[0034] FIG. 3 shows a further arrangement of the system according to one embodiment of the present invention. Here a pick and place system 90 comprising a drive system 95 operating an end-effector 100 to remove articles from the conveyor 88 and place them in one of two respective bins 105 , 110 . Thus, the means of driving the end-effector may vary according to design parameters and still fall within the present invention.
[0035] The pick and place system of FIG. 3 shows an articulated robotic arm 95 which is rotatable so as to engage an article from the conveyor 88 , lift the article into a particular position and rotate to the appropriate bin 105 , 110 .
[0036] FIG. 4 shows one example of an end-effector 115 , in this case, operated through a suction cup 120 . The end-effector according to this embodiment is designed to pick and place a variety of articles including bowls and dishes. As the articles are very different in terms of size, shape and material (for instance plastic, glass or ceramic) the means of engaging these articles must be able to accommodate a wide range of variation. Because all of these items will be mixed on the conveyor, the end-effector must be able to achieve this result without having to change the nature of the end-effector and therefore will need to be selected in order to be as flexible as possible. In terms of the industrial dishwasher application in this embodiment, the suction cup 120 design is particularly useful.
[0037] When used with a 3-dimensional camera, the moving conveyor belt makes estimation of the precise pick-up position of the article very difficult. Therefore, the tolerance required for the end-effector may be relatively large both in terms of selecting the most appropriate engagement point on the article as well as managing the positioning of the end-effector where the article is relatively small. To this end, the designer for a particular application may use a grip such as articulated clamps which can emulate an operator's hand. Alternatively, the suction cup as shown in FIG. 4 may also be appropriate.
[0038] A suction cup has a degree of advantage in that it can pick up an article from the centre of the article regardless of the size of the object whereas a gripper must encompass the article in order to engage it sufficiently. Secondly, the pick-up point on the object is relatively in material. As once it is engaged on lifting, it will achieve a natural position.
[0039] The suction cup 120 may have several layers 130 , 135 . This provides a larger tolerance of operational angle to the object surface. Further, the end-effector 115 may provide a spring so as to provide a tolerance in the vertical direction such as 2 cm subject to the type of article being engaged. This tolerance 133 also provides protection to prevent the end-effector 115 contacting the articles in a manner which may crush the article if the location position is miscalculated by the control system. Thus, the tolerance will be a function of the margin for error in detecting the article by the control system.
[0040] FIG. 5 shows the process flow for the identification of the article. The process starts 140 from 3D camera. When 3D camera detects 145 some articles on the moving conveyor belt, it will identify its position 150 and article type 165 . This information is then passed to software to plan the motion of industrial robot 170 . The industrial robot picks up 175 the article from expected position and places it down to the corresponding sorting bin. After that, industrial robot returns to its idle position and wait for the next article.
[0041] Traditional pick and place robots may only pick up and place down articles from known and fixed positions, following pre-programmed sequential paths to complete the tasks. For such applications, the challenges are usually the end-effector design and workspace arrangement.
[0042] However, for the present invention, such repetitive robot cannot fulfill the tasks required given the diversity of articles and speed of the conveyor. The position of dishes and bowls on the conveyor belt is almost random and cannot be predicted. To pick up dishes and bowls from moving conveyor belt, the robotic system has to detect and identify each items on the conveyor belt.
[0043] There are several challenges of developing the perception system and a good perception system is the key function for the intelligent robotic material handling system. The dishes and bowls have a large variety of types, each with different sizes and shapes. The requirement is to pick up dishes and bowls and stack up them of same type nicely. In another word, the robot has to perform sorting operation. Without knowing the type of the item, the robot cannot determine the place to drop the item. Therefore, perception system has to perform three tasks: detection, recognition and positioning.
[0044] Conventional vision guided robots use 2D camera mounting on top of the conveyor belts and detect anything which is not a part of the conveyor. This approach is based on the assumption that the color of conveyor belt is known and the color of object is significantly different from the conveyor. However, for this project, the color of dishes and bowls are unknown. Each source may have their own preferences of color and design their bowls or dishes with any patterns. In addition, there might be dirt or waste falling on the conveyor belt to ‘change’ its color. This could annoy detection system as well. As a result, detecting objects relying on 2D vision may not be reliable.
[0045] The object recognition system used to identify the article may be any one of a number of standard commercially available machine vision systems used for the identification of objects using automated image analysis. The characteristic shape of the article may be sufficient for the machine vision systems used. The detector for the object recognition system may include camera, which may be a 3 dimensional camera in order to identify the object through depth perception. Which category of camera used, and the object recognition system adopted, will be at the discretion of the operator when designing a system falling within the scope of the present invention.
[0046] In this regard, two approaches may be used, being pattern recognition and feature-based geometric recognition. With the former, stored images of objects may be identified as representing patterns within a more complex. For feature-based geometric recognition, an object may be identified from a range of images of the object taken from different perspectives such that the comparison is made with each different view. Given the view of the articles may be from a wide variety of orientations, it is likely the database will require a large number of images in order to adequate allow for such variation. The actual number of images will be a matter of design for each individual application of the invention. For instance, the use of crates to hold the articles, which may also include racks may limit the variable positions of the articles which may also limit the number of images required for the database.
[0047] FIGS. 6A to 6C show a result of a process according to a further embodiment of the present invention. FIG. 6A shows an image of an article 185 , in this case a cup, within a complex environment. Using a depth perception camera, the image may be modified so as to define a “background” 195 and the article 190 . By then eliminating the background 205 from the image, the remaining article 200 can be readily identified for engagement by the end-effector. FIG. 7 demonstrates the use of multi-suction-cup end-effector assembly 210 . The end-effector assembly 210 has an arm 215 to which is mounted two branches 220 , 225 . The branches 220 , 225 each have two suction cups 230 , 235 , 240 mounted thereto. Each branch 220 , 225 can capture one individual article. For instance, for the large plate 245 , the end effectors 230 , 235 have engaged the plate providing a stable and redundant engagement ensuring the article is securely held prior to placement in a sorting bin. The end effector assembly 210 , having two branches, also allows a second article, in this case a smaller plate 250 , to be engaged by the second branch 225 without disruption to the first branch 220 .
[0048] A possible sequence of engagement could therefore include:
1. Pick article A 2. Pick article B 3. Move to sorting bin area 4. Place article A to sorting bin A 5. Place article B to sorting bin B 6. Move back to conveyor area
[0055] An advantage of the two branch end effector assembly includes further reducing the cycle time of pick-and-place action of moving each article. The area of picking may be relatively far from the area of sorting bins. Since the cycle time may be a function of the travel distance of the robot arm and articles are very near to each other on the conveyor, it is easier for the robot arm to travel in short distance but not in long distance. The two branch end effector assembly only requires two short distance movements and two long distance movements to place two articles, while it takes four long distance movement to place two articles one by one. Therefore, it is more efficient of moving multiple articles at once, rather than moving them one by one.
[0056] It will be appreciated, in achieving further benefits that the end effector assembly may include more than two branches. To this end the assembly could include three or four branches, depending on the size of articles. As a non-exhaustive list, the optimum number of branches may then be a function of any one or a combination of:
Article size; Distance from conveyor to sorting bin; Speed of conveyor; Density of articles on conveyor. | A material handling system comprising: a platform for receiving a plurality of articles; a plurality of sorting bins, each bin in corresponding to an article type; an object recognition system for identifying an article on the platform and categorizing said article by specific article type; said 3D object recognition system including a 3D detector for detecting said article and a database containing data on characteristics of article types; an article engagement assembly for engaging and delivering said article to said corresponding sorting bin; wherein the object recognition system is arranged to identify the article based upon the data within said database and instructs the article engagement assembly to engage and place the article in said sorting bin. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to the field of treatment or prevention of diseases in which integrin α4 and integrin α9 are involved. More specifically, the present invention relates to a method for treatment or prevention of diseases in which integrin α4 and integrin α9 are involved which uses a soluble integrin α4 mutant.
BACKGROUND ART
[0002] Integrin (hereinafter referred to as the “ITG”) is a transmembrane receptor protein in which an α-chain and a β-chain form a heterodimer at 1:1. It is known that integrin α4 (hereinafter referred to as the “ITG-α4”) is principally expressed on lymphocytes and tumor cells, and binds to ligands such as vascular cell adhesion molecule-1 (VCAM1), fibronectin (Fn), junction adhesion molecule-2 (JAM2), mucosal vascular addressin cell adhesion molecule-1 (MAdCAM1), human lymphocyte expression metalloproteinase-like disintegrin-like cysteine rich protein family member (MDC-L; disintegrin and metalloprotease 28 (ADAM28)), von Willebrand factor (pp-vWF) and osteopontin (OPN) (Non Patent Literatures 1 and 2). It is regarded that ITG-α4 binds to such a ligand so as to exhibit various functions such as cell adhesion, migration (for example, migration of lymphocytes, monocytes or eosinocytes to an inflammation site), and homing of lymphocytes. It has been found that ITG-α4 is involved in cancer metastasis (Non Patent Literature 3), multiple myeloma (Patent Literature 1), inflammatory diseases such as rheumatoid arthritis, bronchitis, inflammatory bowel disease, Crohn disease and multiple sclerosis (Non Patent Literature 4), acute central nervous system damage (Patent Literature 2), and HIV (Patent Literature 3). It has been reported that an anti-ITG-α4 antibody shows a certain effect in models of T cell dependent autoimmune diseases such as experimental allergic encephalomyelitis, hypersensitivity and type I diabetes. Furthermore, it is also known that an anti-ITG-α4 antibody is effective for suppressing allergic pneumonia, immunocomplex-mediated pneumonopathy, acute nephrotoxic nephritis, and sclerema and deposition of fibrin in delayed hypersensitivity, and suppresses rejection occurring in vascularized heart allograft (Non Patent Literature 1).
[0003] Since ITG-α4 is thus involved in the diseases, it is expected to use an inhibitor of ITG-α4 for a medicine. Actually, substances to inhibit the functions of ITG-α4, such as an anti-ITG-α4 antibody, an ITG-α4 antagonist (Patent Literature 4 and the like), and an ITG-α4 receptor antagonist (Patent Literature 5 and the like) have been examined, and an anti-ITG-α4 antibody Tysabri has already been approved as a therapeutic agent for multiple sclerosis and Crohn disease. Furthermore, a treatment method targeting a functional motif in an intracytoplasmic domain of ITG-α4 (Patent Literature 6) has been reported.
[0004] In using an antibody is used as a pharmaceutical, its effect varies according to its epitope. It is known that α4β1ITG strongly binds to its ligand on a sequence (LDV sequence (SEQ ID NO: 2) or QIDSPL sequence (SEQ ID NO: 3) which is different from a RGD sequence (SEQ ID NO: 1) to which ITG-α5β1 binds (Non Patent Literatures 1 and 2). It was known that each binding of ITG-α4 to its ligand has different characteristics depending on the ligand. For example, although a binding sites of ITG-α4 to Fn and VCAM1 mutually overlap, binding of ITG-α4 to VCAM1 requires a help of a calcium ion whereas binding to Fn does not require such ion, and some antibodies only inhibit binding of ITG-α4 to Fn. Moreover, it was known that three kinds of epitopes not overlapping one another exist as principal epitopes of anti-ITG-α4 antibodies (Non Patent Literature 1).
[0005] On the other hand, integrin α9 (hereinafter referred to as “ITG-α9”) is known as an ITG having common ligands with ITG-α4. It has been reported that ITG-α9 is involved in exacerbation of experimental autoimmune encephalomyelitis (EAE), a mouse model of multiple sclerosis (Non Patent Literature 5). The present inventors produced an antibody against ITG-α9 and found a treatment effect for rheumatoid arthritis (Non Patent Literature 6 and Patent Literature 7).
[0006] Since ITG-α9 has common ligands with ITG-α4, ITG-α9 is regarded to have functions similar to those of ITG-α4. Furthermore, an amino acid sequence of ITG-α9 has 39% homology to that of ITG-α4, which are known as the highest homology among ITGs (Non Patent Literature 7).
[0007] The present inventors have discovered that an α9 mutant (SFα9), an alternative splicing variant of ITG-α9 consisting a part of an extracellular region of ITG-α9 and a novel C-terminal amino acid, is present in vivo, and reported the result of analysis of the structure and functions of the SFα9 (Non Patent Literature 8). On the other hand, relating to ITG-α4 mutant, only polymorph of ITG-α4 was reported (Patent Literature 8), however no report has been made on an alternative splicing variant.
CITATION LIST
Patent Literatures
[0000]
Patent Literature 1: International Publication No. WO00/15247
Patent Literature 2: International Publication No. WO01/43774
Patent Literature 3: International Publication No. WO2008/140602
Patent Literature 4: International Publication No. 2010/126914
Patent Literature 5: International Publication No. 2006/096807
Patent Literature 6: International Publication No. WO2006/112738
Patent Literature 7: International Publication No. WO2008/007804
Patent Literature 8: International Publication No. WO00/17394
Non Patent Literatures
[0000]
Non Patent Literature 1: Roy R. Lobb., et al. (1994) J. Clin. Invest., 94: 1722-1728
Non Patent Literature 2: Roberto Gonzalez-Amaro, et al. (2005) Immunology, 116: 289-296
Non Patent Literature 3: Holzmann, B., et al. (1998) Curr. Top. Microbiol. Immunol., 231: 125-141
Non Patent Literature 4: Jackson, D. Y. (2002) Curr. Pharm. Des., 8: 1229-1253
Non Patent Literature 5: Kanayama, M., et al. (2009) J. Immunol., 182: 8015-8025
Non Patent Literature 6: Palmer, E. L., et al. (1993) J. Cell. Biol., 123: 1289-1297
Non Patent Literature 7: International Immunology Meeting, PP-038-31
Non Patent Literature 8: Kon, S., et al. (2011) Exp. Cell. Res. 317: 1774-84
SUMMARY OF INVENTION
[0024] Since ITG-α4 and ITG-α9 have common ligands and are regarded to be involved in the onset of similar diseases such as EAE, a substance capable of simultaneously inhibiting ITG-α4 and ITG-α9 is expected to be an effective therapeutic agent for the diseases relating to ITG-α4 and ITG-α9. Furthermore, it is known that cancer cells of melanoma and the like express both ITG-α4 and ITG-α9 (J Cell Physiol. (2007) 212: 368-74; Exp Cell Res. (2009) 315: 3312-24). A cancer metastasis is known to involve steps of rolling in blood vessels, adhesion, and transmigration out of the blood vessels. ITG is regarded to play a significant function in the adhesion. When a common ligand of ITG-α4 and ITG-α9 is expressed on vascular endothelial cells, it is regarded that inhibition of binding between one of the integrins and said ligand by using an antibody or the like cannot block metastasis, and it is necessary to use an antibody against both of ITG-α4 and ITG-α9 in order to block such binding. Actually, it has been reported that the von Willebrand factor (vWF), a common ligand of ITG-α4 and ITG-α9, is produced from vascular endothelial cells (J Clin Invest. 1978 June, 61(6): 1498-507). It is reported that both of ITG-α4 and ITG-α9 are expressed in lymphatic vessels (Nat Rev Cancer. (2008) 8: 604-17). Accordingly, a substance capable of simultaneously inhibiting ITG-α4 and ITG-α9 is regarded to be an effective antimetastatic agent. Furthermore, influence of ITG-α4 inhibition and ITG-α9 inhibition on lymphangiogenesis and the function of lymphatic vessels has been reported (Cancer Res. (2010) 70: 3042-51, EMBO J. (2005) 24: 2885-95), and it is expected that a novel efficient lymphangiogenesis inhibitor can be provided by simultaneously inhibiting ITG-α4 and ITG-α9.
[0025] The present inventors tried to search for an effective inhibitor for ITG-α4 and identified novel alternative splicing variants of ITG-α4. As a result, the present inventors have succeeded in identifying six novel alternative splicing variants ( FIGS. 1 to 3 and SEQ ID NOs: 4 to 9). Surprisingly, analysis of the structures of the obtained alternative splicing variants of ITG-α4 revealed that five of six obtained alternative splicing variants unexpectedly have novel and peculiar amino acid sequences at the C-terminal which are derived from introns but not derived from human ITG-α4 (SEQ ID NO: 10) (said novel amino acid sequence at the C-terminal of the each ITG-α4 alternative splicing variant is shown in FIG. 3 ).
[0026] From analysis of the functions of the obtained ITG-α4 alternative splicing variants, the present inventors have found that these alternative splicing variants can inhibit bindings of ITG-α4 to a plurality of different ligands. Furthermore, the present inventors have found that the obtained ITG-α4 alternative splicing variants can inhibit bindings of ITG-α9 to its ligands in addition to bindings of ITG-α4 to its ligands.
[0027] An object of the present invention is to provide a novel substance capable of inhibiting various functions of ITG-α4 and/or to provide a novel substance capable of inhibiting both of ITG-α4 and ITG-α9. The present invention is on the basis of finding of novel alternative splicing variants of ITG-α4. Specifically, the present invention relates to the following inventions (1) to (17):
[0028] (1) An integrin α4 mutant peptide comprising a part of an extracellular region of human integrin α4 (SEQ ID NO: 10);
[0029] (2) The peptide of (1), wherein the extracellular region of human integrin α4 (SEQ ID NO: 10) includes an amino acid sequence derived from a β-propeller domain of human integrin α4 (SEQ ID NO: 10);
[0030] (3) The peptide of (1), wherein the extracellular region of human integrin α4 (SEQ ID NO: 10) consist of a sequence selected from SEQ ID NO: 9 and SEQ ID NOs: 11 to 14;
[0031] (4) The peptide of any one of (1) to (3), wherein a sequence selected from SEQ ID NOs: 15 to 19 is bonded to a C-terminal of the extracellular region of human integrin α4 (SEQ ID NO: 10);
[0032] (5) A peptide comprising a sequence selected from SEQ ID NOs: 4 to 9;
[0033] (6) The peptide of any one of (1) to (5), which binds to a ligand of integrin α4 and/or inhibits binding of integrin α4 to said ligand;
[0034] (7) The peptide of (6), wherein the ligand of integrin α4 is a substance selected from the group consisting of VCAM1, Fn, JAM2, MAdCAM1, MDC-L (ADAM28), pp-vWF and OPN;
[0035] (8) The peptide of (6), wherein the ligand of integrin α4 is pp-vWF or OPN;
[0036] (9) The peptide of (6), wherein the ligand of integrin α4 is a peptide comprising an amino acid sequence of SEQ ID NO: 20 or 21;
[0037] (10) The peptide of any one of (1) to (9), which further binds to a ligand of integrin α9 and/or inhibits binding of integrin α9 to said ligand;
[0038] (11) The peptide of (10), wherein the ligand of integrin α9 is a substance selected from the group consisting of VCAM1, Fn, JAM2, MAdCAM1, MDC-L (ADAM28), pp-vWF and OPN;
[0039] (12) The peptide of (10), wherein the ligand of integrin α9 is pp-vWF or OPN;
[0040] (13) The peptide of (10), wherein the ligand of integrin α9 is a peptide comprising an amino acid sequence of SEQ ID NO: 20 or 21;
[0041] (14) The peptide of any one of (1) to (13), which is a soluble peptide;
[0042] (15) A pharmaceutical composition containing the peptide of any one of (1) to (14) as an active ingredient;
[0043] (16) An antibody that specifically recognizes (or binds to) the peptide of any one of (1) to (14); and (17) The antibody of (16) that does not recognize (or does not bind to) integrin α4.
[0044] In the present invention, “integrin α4 mutant” and “ITG-α4 mutant” mean the same, that is an alternative splicing variant peptide of ITG-α4 which are derived from the genome of ITG-α4 but produced through different splicing from ITG-α4, or a peptide having substantially the same amino acid sequence as said alternative splicing variant peptide of ITG-α4. The “integrin α4 mutant” herein includes a part of an extracellular region of human ITG-α4 (corresponding to a portion of the 1st to 977th amino acid sequence of SEQ ID NO: 10) but includes neither a transmembrane region nor an intracellular region. The presumed domains of ITG-α4 were reported as that obtained by homology analysis of the amino acid sequence of ITG-α4 comparing with that of integrin αv which was already analyzed for steric structure (Science (2001), 294. 339-345) (Proc Natl Acad Sci USA. (1997) 94: 65-72). Specifically, ITG-α4 extracellular region is known to have domains designated as: a signal sequence (corresponding to a portion of amino acid sequence positions from 1 to 33 of SEQ ID NO: 10); β-propeller (corresponding to a portion of amino acid sequence positions from 34 to 465 of SEQ ID NO: 10); Thigh (corresponding to a portion of amino acid sequence positions from 466 to 618 of SEQ ID NO: 10); Genu (corresponding to a portion of amino acid sequence positions from 619 to 626 of SEQ ID NO: 10); Calf1 (corresponding to a portion of amino acid sequence positions from 627 to 770 of SEQ ID NO: 10); and Calf2 (corresponding to a portion of amino acid sequence positions from 771 to 977 of SEQ ID NO: 10). As the part of the extracellular region of human ITG-α4 of the present invention, it preferably is the β-propeller domain and/or the Thigh domain. The part of the extracellular region of human ITG-α4 herein has, for example, an amino acid sequence derived from the β-propeller domain of human ITG-α4. Here, the amino acid sequence derived from the β-propeller domain may be a sequence of any site as long as it is a part of the amino acid sequence of the β-propeller domain positioned at the N-terminal of ITG-α4. The part of the extracellular region of human ITG-α4 may have, for example, 50 or more, 100 or more, 150 or more, 180 or more, or 185 or more amino acids, derived from the amino acid sequence of the β-propeller domain (consisting of 432 amino acids). Furthermore, the amino acid sequence derived from the β-propeller domain of human ITG-α4 preferably contains the amino acid at position 34 sequence of SEQ ID NO: 10. Moreover, the part of the extracellular region of human ITG-α4 having an amino acid sequence derived from the β-propeller domain of human ITG-α4 may consisting of merely an amino acid sequence derived from the β-propeller domain, or may have, in addition to an amino acid sequence derived from the β-propeller domain, an amino acid sequence derived from the extracellular region of human ITG-α4 other than the β-propeller domain. More specifically, the part of the extracellular region of human ITG-α4 herein may include any one of the amino acid sequence of SEQ ID NOs: 11 to 14 (or any one of the amino acid sequences which lack a signal sequence consisting of the positions from 1 to 33 of said amino acid sequence), or may include any one of amino acid sequences of the positions from 1 to 185, the positions from 1 to 384, the positions from 1 to 513, and the positions from 1 to 640 of SEQ ID NO: 10 (or any one of the amino acid sequences of the positions from 34 to 185, the positions from 34 to 384, the positions from 34 to 513, and the positions from 34 to 640 of SEQ ID NO: 10).
[0045] In the present application, the “integrin α4 mutant” may contain an amino acid sequence which is not derived from ITG-α4 (hereinafter referred to as the “ITG-α4 mutant specific amino acid sequence”). The “ITG-α4 mutant specific amino acid sequence” preferably is a sequence derived from intron of ITG-α4, and specifically can be an amino acid sequence represented by any one of SEQ ID NOs: 15 to 19.
[0046] In other words, in one aspect, an “integrin α4 mutant” herein is a peptide consisting of a part of the extracellular region of human ITG-α4 alone or a peptide consisting of a part of the extracellular region of human ITG-α4 and the ITG-α4 mutant specific amino acid sequence (hereinafter collectively designated as an “alternative splicing variant of ITG-α4”). Specifically, the ITG-α4 mutant herein may be a peptide comprising of an amino acid sequence of any one of SEQ ID NOs: 4 to 9 (designated as a “1-2-1 mutant” (SEQ ID NO: 4), a “1-1-2 mutant” (SEQ ID NO: 5), a “7-3-2 mutant” (SEQ ID NO: 6), a “10-7-3 mutant” (SEQ ID NO: 7), a “10-7-2 mutant” (SEQ ID NO: 8) and a “9-5-4 mutant” (SEQ ID NO: 9), respectively). Furthermore, the alternative splicing variant of ITG-α4 herein has an activity to bind to a ligand of ITG-α4 and/or to inhibit binding of ITG-α4 to its ligand, and/or has an activity to bind to a ligand of ITG-α9 and/or to inhibit binding of ITG-α9 to its ligand.
[0047] In another aspect, an “integrin α4 mutant comprising a part of an extracellular region of human integrin α4” herein includes a peptide which is substantially the same as the alternative splicing variant of ITG-α4. Here, the peptide which is substantially the same means a peptide which has highly homologous amino acid sequence to said alternative splicing variant of ITG-α4, a peptide which is encoded by a DNA capable of hybridizing with a DNA encoding said alternative splicing variant of ITG-α4 under stringent conditions, and/or a peptide in which a small number of amino acid residues are substituted, deleted, added and/or inserted. These peptides which are substantially the same as the alternative splicing variant of ITG-α4 has biological activity equivalent to that of the alternative splicing variant of ITG-α4 of the present specification.
[0048] Herein, highly homologous amino acid sequence means to have an amino acid sequence with homology of 80%, 85%, 90%, 95%, 98% or 99% to the alternative splicing variant of ITG-α4. For example, a peptide which has highly homologous amino acid sequence to the alternative splicing variant of ITG-α4 may be a peptide having an amino acid sequence with homology of 80%, 85%, 90%, 95%, 98% or 99% to any one of the amino acid sequences of SEQ ID NOs: 4 to 9. Here, the homology of an amino acid sequence can be determined by a method usually employed by those skilled in the art using a known program such as BLAST or FASTA.
[0049] Herein, a DNA capable of hybridizing with a DNA encoding the alternative splicing variant of ITG-α4 under stringent conditions means a DNA which hybridizes with the DNA encoding the alternative splicing variant of ITG-α4 under hybridization conditions usually employed by those skilled in the art. For example, a DNA which hybridizes with a DNA encoding the alternative splicing variant of ITG-α4 under stringent conditions may be a DNA which hybridizes with a DNA encoding any one of the amino acid sequences of SEQ ID NOs: 4 to 9 under stringent conditions. Whether the candidate DNA can hybridize under stringent conditions can be determined as whether it hybridizes by a method described in Molecular Cloning, A Laboratory Manual, Second Edition, Cold Spring Harbor Laboratory Press (1989). For example, the stringent hybridization conditions may be conditions in which the hybridization is performed in 6×SSC (0.9 M NaCl, 0.09 M trisodium citrate) or 6×SSPE (3M NaCl, 0.2 M NaH 2 PO 4 , 20 mM EDTA.2Na, pH 7.4) at 42° C., and the resultant is washed with 0.5×SSC at 42° C.
[0050] Herein, the peptide in which a small number of amino acid residues are substituted with, deleted from, added to and/or inserted into the alternative splicing variant of ITG-α4 means a peptide in which some amino acids of the amino acid sequence constituting the alternative splicing variant of ITG-α4 are substituted by other amino acids and/or deleted, and/or a peptide in which another amino acid sequence is added to the C-terminal or the N-terminal of the amino acid sequence constituting the alternative splicing variant of ITG-α4, and/or a peptide in which another amino acid is inserted into the amino acid sequence constituting the alternative splicing variant of ITG-α4. The peptide in which a small number of amino acid residues are substituted with, deleted from, added to and/or inserted into the alternative splicing variant of ITG-α4 can be, for example, a peptide in which a small number of amino acid residues are substituted with, deleted from, added to and/or inserted into a peptide consisting of any one of the amino acid sequences of SEQ ID NOs: 4 to 9. The number of amino acids to be substituted, deleted, added and/or inserted is not especially limited as long as the biological activity of the alternative splicing variant of ITG-α4 is not affected, and can be, for example, the number can be 1 to 10, 1 to 5, 1 to 4, or 1 to 3.
[0051] As described above, a peptide which is substantially the same as the alternative splicing variant of ITG-α4 has the biological activity equivalent to that of the alternative splicing variant of ITG-α4. Here, the “biological activity equivalent to that of the alternative splicing variant of ITG-α4” means an activity to bind to a ligand of ITG-α4 and/or to inhibit binding of integrin α4 to its ligand. Here, a ligand of ITG-α4 is not especially limited as long as it is a protein or a peptide already known as a ligand of ITG-α4, and is preferably VCAM1, Fn (fibronectin EIIIA (Fn-EIIIA) in particular), JAM2, MAdCAM1, MDC-L (ADAM28), pp-vWF or OPN, more preferably Fn-EIIIA, pp-vWF or OPN, and even more preferably a peptide having an amino acid sequence of SEQ ID NO: 20 or 21. In the meaning of the binding to a ligand of ITG-α4 and/or the inhibition of binding of integrin α4 to its ligand, said ligands need not to be all types of ligands of ITG-α4, but for example, it can be binding to some of the aforementioned ligands and/or can be the inhibition of binding of integrin α4 to some of the aforementioned ligands. Preferably, the peptide of the present invention binds to two or more ligands, and/or inhibits binding of integrin α4 to said ligands, and preferably said two or more ligands include Fn-EIIIA, pp-vWF and OPN, and more preferably include a peptide having an amino acid sequence of SEQ ID NO: 20 and a peptide having an amino acid sequence of SEQ ID NO: 21.
[0052] Preferably, the “biological activity equivalent to that of the alternative splicing variant of ITG-α4” means an activity to bind to a ligand of ITG-α9 and/or to inhibit binding of ITG-α9 to its ligand in addition to the activity to bind to a ligand of ITG-α4 and/or to inhibit binding of ITG-α4 to its ligand. Here, a ligand of ITG-α9 is not especially limited as long as it is a protein or a peptide already known as a ligand of ITG-α9, and is preferably VCAM1, Fn (fibronectin EIIIA (Fn-EIIIA) in particular), JAM2, MDC-L (ADAM28), pp-vWF or OPN, more preferably Fn-EIIIA, pp-vWF or OPN, and even more preferably a peptide having an amino acid sequence of SEQ ID NO: 20 or 21. In the meaning of the binding to a ligand of ITG-α9 and/or inhibiting binding of integrin α9 and its ligand, said ligands need not to be all types of ligands of ITG-α9, but for example, it can be binding to some of the aforementioned ligands and/or can be inhibition of binding of integrin α9 to some of the aforementioned ligands. Preferably, the peptide of the present invention binds to two or more ligands, and/or inhibits binding of integrin α9 to said ligands, and preferably said two or more ligands include Fn-EIIIA, pp-vWF and OPN, and more preferably include a peptide having an amino acid sequence of SEQ ID NO: 20 and a peptide having an amino acid sequence of SEQ ID NO: 21.
[0053] Herein, the activity to inhibit binding of ITG-α4 and its ligand and the activity to inhibit binding of ITG-α9 to its ligand can be replaced with an activity to inhibit binding of ITG-α4 expressing cells to an ITG-α4 ligand (cell adhesion of ITG-α4 expressing cells to an ITG-α4 ligand) and an activity to inhibit binding of ITG-α9 expressing cells expressing to an ITG-α9 ligand (cell adhesion of ITG-α9 expressing cells to an ITG-α9 ligand).
[0054] As described above, the ITG-α4 mutant of the present invention has the activity to bind to a ligand of ITG-α4 and/or to inhibit binding of ITG-α4 to its ligand, and/or the activity to bind to a ligand of ITG-α9 and/or to inhibit binding of ITG-α9 to its ligand. Preferably, the ITG-α4 mutant of the present invention has an activity to bind to a ligand of ITG-α4 and/or to inhibit binding of ITG-α4 to its ligand as well as an activity to bind to a ligand of ITG-α9 and/or to inhibit binding of ITG-α9 to its ligand. More preferably, the ITG-α4 mutant of the present invention binds to a common ligand for ITG-α4 and ITG-α9, or inhibits bindings of ITG-α4 and ITG-α9 to the common ligand for ITG-α4 and ITG-α9. Examples of the common ligand for ITG-α4 and ITG-α9 include Fn-EIIIA, pp-vWF and OPN.
[0055] Even more preferably, the “biological activity equivalent to that of the alternative splicing variant of ITG-α4” may include, in addition to the aforementioned activities, to be soluble. It can be determined whether a peptide of interest is soluble, for example, as follows: recombining a DNA encoding the peptide modified with FLAG or the like with host cells, culturing the resulting cells, and subsequently confirming the presence of the peptide in a culture supernatant by using an anti-FLAG antibody or the like. If the peptide has been released into the culture supernatant, it can be determined that the peptide is soluble. Herein, to be “soluble” means that most (more than half) of produced peptides are released into a culture medium and do not remain in cells or on cell surfaces, and it is not required that the produced peptides are entirely released into a culture medium.
[0056] Herein, the “biological activity equivalent to that of the alternative splicing variant of ITG-α4” basically means a qualitative property and the amplitude of the activity is not required as long as there is the aforementioned activity, but the amplitude is preferably equivalent (to have, for example, an active value within a range of ±25%, ±20%, ±15% or ±10%) to that of the alternative splicing variant of ITG-α4 (preferably, those of the peptides containing the amino acid sequences represented by SEQ ID NOs: 4 to 9).
[0057] Furthermore, an amino acid contained in the “integrin α4 mutant” herein may be appropriately chemically modified as appropriate. Moreover, the “integrin α4 mutant” of the present application may be a peptide that do not bind to the RGD sequence (SEQ ID NO: 1) and/or a peptide that do not inhibit binding of ITG (particularly, ITG-α4 and/or ITG-α9) to the RDG sequence (SEQ ID NO: 1).
[0058] In still another aspect, the present invention relates to an antibody which specifically recognizes the ITG-α4 mutant. The antibody of the present invention may be a polyclonal antibody or a monoclonal antibody, and is preferably a monoclonal antibody. In the present invention, a “monoclonal antibody” is one highly specific to an antigen and recognizing a single antigen. Furthermore, the antibody of the present invention includes a non-human animal antibody, an antibody having both of an amino acid sequence of a non-human animal antibody and an amino acid sequence of a human-derived antibody, and a human antibody. Examples of the non-human animal antibody include antibodies of a mouse, a rat, a hamster, a guinea pig, a rabbit, a dog, a monkey, a sheep, a goat, a chicken and a duck, and it is preferably an antibody of an animal from which a hybridoma can be prepared, and more preferably a mouse antibody. Examples of the antibody having both of an amino acid sequence of a non-human animal antibody and an amino acid sequence of a human-derived antibody include a human-type chimeric antibody and a humanized antibody. In the above, a “chimeric antibody” refers to an antibody in which a constant region of a non-human animal-derived antibody that specifically binds to an ITG-α4 mutant is altered by genetic engineering technique to have the same constant region of a human antibody, and is preferably a human-mouse chimeric antibody (see EP Patent Publication No. EP 0125023). A “humanized antibody” refers to an antibody in which a primary structure of a non-human animal-derived antibody that specifically binds to an ITG-α4 mutant other than the complementarity determining region (CDR) of an H chain and an L chain is altered, by genetic engineering technique, with a corresponding primary structure of a human antibody. Here, a CDR may be defined by either of Kabat et al. (“Sequences of Proteins of Immunological Interest”, Kabat, E. et al., U.S. Department of Health and Human Services, 1983) or Chothia et al. (Chothia & Lesk (1987) J. Mol. Biol., 196: 901-917). A “human antibody” refers to a human antibody as an expression product of an antibody gene that is completely derived from human, and an example includes a monoclonal antibody produced by using a transgenic animal in which a gene relating to human antibody production has been introduced (see EP Patent Publication No. EP 0546073).
Advantageous Effects of Invention
[0059] Since the ITG-α4 mutant of the present invention can inhibit various functions of ITG-α4, the ITG-α4 mutant can be used for treatment or prevention of various diseases which onset or exacerbation involve ITG-α4. In particular, since the ITG-α4 mutant of the present invention can inhibit not only binding of ITG-α4 to its ligand but also binding of ITG-α9 to its ligand, the ITG-α4 mutant can be used for treatment or prevention of various diseases which onset or exacerbation involve ITG-α4 and ITG-α9.
BRIEF DESCRIPTION OF DRAWINGS
[0060] FIG. 1 shows amino acid sequences of alternative splicing variants of ITG-α4, a 1-2-1 mutant, a 1-1-2 mutant, a 7-3-2 mutant and a 10-7-3 mutant.
[0061] FIG. 2 shows amino acid sequences of alternative splicing variants of ITG-α4, a 10-7-2 mutant and a 9-5-4 mutant.
[0062] FIG. 3 is a schematic diagram illustrating sequences of the alternative splicing variants of ITG-α4.
[0063] FIG. 4 is a diagram illustrating genomic structures on chromosome 2 of the alternative splicing variants of ITG-α4.
[0064] FIG. 5 is a picture of Western blotting as a result of confirming expression of each mutant in a culture supernatant of COS cells in which each of the six alternative splicing variants of ITG-α4 (the 1-1-2 mutant, the 1-2-1 mutant, the 7-3-2 mutant, the 10-7-3 mutant, the 10-7-2 mutant and the 9-5-4 mutant) was forcibly expressed.
[0065] FIG. 6 shows a graph of a result of ligand solid phase ELISA, which was conducted to investigate binding of each alternative splicing variant of ITG-α4 in a culture supernatant to human OPN RAA Nhalf protein that is a ligand of integrin α4 (Kon, S., et al., (2002) J. Cell. Biochem., 84: 420-432) or to a negative control (bovine serum albumin: BSA). The vertical axis indicates absorbance at 450 nm of a labeled antibody to be an index of the amount of the integrin α4 mutant bound to the ligand, and the horizontal axis indicates each alternative splicing variant of ITG-α4 used. Black bars indicate the bound of the alternative splicing variants of ITG-α4 to the human OPN RAA Nhalf protein, and gray bars indicate the bound of the alternative splicing variants of ITG-α4 to BSA.
[0066] FIG. 7 shows a picture of Western blotting as a result of analyzing expression of endogenous 1-2-1 mutant. Each numerical value on the left of the picture indicates the molecular weight (kDa) of the protein. On above the photograph, “1-2-1/COS posi-con” indicates a culture supernatant of COS1 cells in which the 1-2-1 mutant was forcibly expressed, “Jurkat sup” indicates a culture supernatant of Jurkat cells, and “Rec-1 sup” indicates a culture supernatant of Rec-1 cells.
[0067] FIG. 8 shows a graph of a result of investigation of a integrin α4 and integrin α9 mediated cell adhesion inhibitory function of the 1-2-1 mutant. The vertical axis indicates absorbance at 595 nm to be an index of the number of cells bound to a ligand, and the horizontal axis indicates each ligands used. “mα4/CHO” means that CHO cells expressing mouse integrin α4 were used, and “mα9/CHO” means that CHO cells expressing mouse integrin α9 were used. White bars indicate no addition of the 1-2-1 mutant (-). Black bars, dotted bars, and shaded bars indicate addition of the 1-2-1 mutant in an amount of 6.25 μg/mL, 12.5 μg/mL, and 25 μg/mL, respectively.
[0068] FIG. 9 is a diagram of a schedule for examining influence of 1-2-1 mutant/GST protein on EAE.
[0069] FIG. 10 is a graph of a result of examining inhibitory effect of 1-2-1 mutant protein on an EAE. The vertical axis indicates an EAE score, and the horizontal axis indicates the number of days after administration of the 1-2-1 mutant.
DESCRIPTION OF EMBODIMENTS
(ITG-α4 Mutant)
[0070] An ITG-α4 mutant of the present invention can be obtained by referring to the structure (shown in FIG. 3 ) and the sequence (SEQ ID NO: 10) of ITG-α4 and by employing a method known to those skilled in the art, referring to the description of the present application. For example, an ITG-α4 mutant can be obtained by the 3′-race method using a cDNA of cells which are known to express ITG-α4 (for example, T cells such as Jurkat cells, or Rec-1 cells, or the like). It has been reported that ITG-α4 is expressed in bowel, T cells, IgA-producing B cells, (mononuclear) leucocytes and the like. Specifically, a total RNA obtained from cells which are known to express ITG-α4 is extracted by using a QIAGEN RNeasy kit (QIAGEN). From the total RNA, cDNA for the 3′-race method can be synthesized by using Firststrand cDNA synthesis kit (Roche). Specifically, a cDNA for the 3′-race method is synthesized by using a QT primer for the 3′-race method as a primer for reverse transcription (for example, SEQ ID NO: 22). With the obtained cDNA as a template, 1st PCR is performed by using a Q0 primer (for example, SEQ ID NO: 23) and a primer for various regions of ITG-α4 described below (for example, SEQ ID NO: 24, 25, 26 or the like for human ITG-α4). The obtained PCR product is 20 fold diluted and 1 μL of which is used as a template in 2nd PCR, which is performed by using a Q1 primer (for example, SEQ ID NO: 27) and an ITG-α4 primer (for example, SEQ ID NO: 25, 26, 28 or the like for human ITG-α4). The obtained band is purified by gel extraction, the resultant is cloned, and thus, an ITG-α4 mutant can be obtained.
[0071] Alternatively, the ITG-α4 mutant of the present invention can be obtained directly as or appropriately modifying a 1-2-1 mutant, a 1-1-2 mutant, a 7-3-2 mutant, a 10-7-3 mutant, a 10-7-2 mutant, or a 9-5-4 mutant. If the 1-2-1 mutant, the 1-1-2 mutant, the 7-3-2 mutant, the 10-7-3 mutant, the 10-7-2 mutant or the 9-5-4 mutant is directly used as the ITG-α4 mutant, it can be prepared in accordance with a method described in Example 2 of the present specification. Furthermore, the modification can be performed by appropriately modifying an amino acid by, for example, substituting, deleting, adding or inserting an amino acid by using a technique usually employed in the field of protein engineering.
[0072] Specifically, the ITG-α4 mutant of the present invention can be manufactured by the following method: carrying out PCR with using a cDNA of cells from which the mutant has been obtained as a template, and appropriately designing a primer for amplifying a DNA encoding a desired mutant. The resulting PCR product is digested with restriction enzymes appropriately selected, and then integrated into an expression vector, which is introduced into host cells by using Lipofectamine 2000 (Invitrogen) or the like, and the culture supernatant is purified if necessary. Alternatively, a DNA sequence can be designed from the amino acid sequence and produced by synthesis to be integrated into an expression vector by using a method known to those skilled in the art. Alternatively, a short mutant like the 1-2-1 mutant may be directly manufactured by peptide synthesis.
(Method for Measuring Binding Activity)
[0073] It can be determined whether the ITG-α4 mutant has binding ability to a ligand of ITG-α4 or ITG-α9 by employing a method known to those skilled in the art with referring to the description of the present application. Specifically, it can be determined by using the ligand solid phase ELISA as follows: a ligand of ITG-α4 or ITG-α9 is immobilized, and after blocking with BSA/PBS, a solution containing a test ITG-α4 mutant labeled with FLAG is added thereto. After performing a reaction for 1 hour at 40° C., a mixture of anti-FLAG antibodies and anti-mouse IgGs is added to the resulting solution. Thereafter, a reaction is performed for 30 minutes at 4° C., and the resultant is washed and then color-developed with a TMB solution to analyze the binding ability.
(Method for Measuring Activity of Binding Inhibition)
[0074] Whether the ITG-α4 mutant has an activity to inhibit binding of ITG-α4 to its ligand or binding of ITG-α9 to its ligand can be determined by examining whether the ITG-α4 mutant can inhibit binding (cell adhesion) of cells expressing ITG-α4 or ITG-α9 to the ligand thereof. Specifically, BSA is coupled with a ligand of ITG-α4 or a ligand of ITG-α9, and the resultant is incubated overnight at 4° C. to immobilize. After blocking for 1 hour with a DMEM medium containing BSA, a mixture of cells (such as CHO cells) expressing integrin α4 or integrin α9 and a GST-fused test ITG-α4 mutant is added thereto, and then cultured in a CO 2 incubator at 37° C. for 1 hour. Non-adherent cells were removed by using PBS, and adherent cells are fixed and stained with 20% methanol containing 0.5% crystal violet. The fixed and stained cells are solubilized with 20% acetic acid, and then a cell adhesion inhibitory effect can be measured and quantitatively determined in accordance with absorbance at 595 nm.
(Pharmaceutical Composition)
[0075] The ITG-α4 mutant of the present invention can be used as a pharmaceutical composition according to general knowledge in the field of protein medicines which those skilled in the art usually employ. Accordingly, in one aspect, the present invention relates to a pharmaceutical composition containing the ITG-α4 mutant of the present invention as an active ingredient. Specifically, the pharmaceutical composition of the present invention can be used as a therapeutic agent or a preventive agent for cancer, cancer metastasis, multiple myeloma, inflammatory diseases such as rheumatoid arthritis, bronchitis, inflammatory bowel disease, Crohn disease, and multiple sclerosis, or autoimmune disease, acute central nervous system damage, immune disorder such as HIV, allergic encephalomyelitis, hypersensitivity, T cell dependent autoimmune diseases such as type I diabetes, allergic pneumonia, immunocomplex-mediated pneumonopathy, acute nephrotoxic nephritis, delayed hypersensitivity (sclerema and deposition of fibrin), arterial sclerosis and cardiac infarction, or can be used as an inhibitor for rejection in transplantation, such as rejection occurring in vascularized heart allograft.
[0076] In using the ITG-α4 mutant of the present invention as a pharmaceutical composition, the administration route can be, for example, oral administration, buccal administration, intratracheal administration, subcutaneous administration, intramuscular administration, intravascular (intravenous) administration or dermal administration. Furthermore, the pharmaceutical composition can be formulated as, for example, injections, capsules, tablets, syrups, granules, and embrocation such as ointments. The ITG-α4 mutant of the present invention can be singly administered, or administered together with a pharmacologically acceptable carrier.
(Antibody)
[0077] An antibody of the present invention can be obtained by the following method: first, an immunogen used for preparing an antibody of the present invention is obtained by transforming an expression vector (such as pGEX (for E. coli ) or pcDNA3.1 (for expression in animal cells)) containing a DNA encoding a polypeptide having the whole or a part of the ITG-α4 mutant (preferably an ITG-α4 mutant specific amino acid sequence not present in ITG-α4, such as SEQ ID NOs: 15 to 19) into E. coli , yeast, insect cells, animal cells or the like, and by culturing the transformed host microorganism or culture cells such as E. coli or the like in a suitable medium (such as an LB medium) to express said polypeptide. Alternatively, a peptide chemically synthesized to have such a sequence may be used.
[0078] Immunization of an animal by using the above obtained antigen is performed as follows: the above obtained antigen is dissolved in a sodium phosphate buffer solution (PBS), and non-human mammal or bird is immunized with the dissolved solution optionally with an immunostimulant (such as a mineral oil or an aluminum precipitate and heat-killed bacterium or lipopolysaccharide, Freund's complete adjuvant, or Freund's incomplete adjuvant). The immunogen can be administered to an animal, for example, by subcutaneous injection, intraperitoneal injection, intravenous injection, intramuscular injection or sole injection. The amount of immunogen to be used is not especially limited as long as an antibody can be produced, and is preferably 0.1 to 1000 μg, more preferably 1 to 500 μg and even more preferably 10 to 100 μg. The immunization can be performed once or several times at appropriate intervals. Preferably, the immunization can be performed a plurality of times (preferably, 2 to 5 times in total) every 1 to 5 weeks. A polyclonal antibody can be obtained by purification from a serum of an animal showing sufficient antibody titer.
[0079] For producing a monoclonal antibody, it can be prepared by fusing antibody producing cells originated from a spleen or the like of an immunologically sensitized animal immunized by the aforementioned method with myeloma cells to obtain hybridoma, and then culturing said hybridoma. The fusion method can be, for example, Milstein's method (Galfre, G. & Milstein, C., Methods Enzymol. 73: 3-46, 1981). The antibody can be obtained by culturing the hybridoma in vitro and purifying the resulting culture medium.
(Production of Human-Type Chimeric Antibody)
[0080] When the antibody of the present invention is a human-type chimeric antibody, it can be obtained by following steps: preparing DNAs encoding VH and VL of a nonhuman animal monoclonal antibody capable to bind to the ITG-α4 mutant, connecting the DNAs to a constant region cDNA of human immunoglobulin, inserting the connected DNA into an expression vector, transforming a suitable host cell with the vector, and having the human-type chimeric antibody to be expressed (Morrison, S. L. et al., Proc. Natl. Acad. Sci. USA, 81, 6851-6855, 1984).
(Production of Humanized Antibody)
[0081] When the antibody of the present invention is a humanized antibody, it can be obtained by following steps: constructing a DNA encoding a V region in which amino acid sequences encoding CDRs of VH and VL of a nonhuman animal monoclonal antibody capable to bind to the ITG-α4 mutant are transplanted into FRs of VH and VL of a human antibody, connecting the constructed DNA to a constant region cDNA of human-derived immunoglobulin, inserting the connected DNA into an expression vector, transforming a suitable host cell with the vector, and having the humanized antibody to be expressed (see L. Rieohmann et al., Nature, 332, 323, 1988: Kettleborough, C. A. et al., Protein Eng., 4, 773-783, 1991: and Clark M., Immunol. Today., 21, 397-402, 2000). CDRs of the non-human animal monoclonal antibody can be determined by comparing an amino acid sequence predicted from the DNA sequence encoding VH and VL of said non-human animal monoclonal antibody obtained as described above with the whole amino acid sequences of VH and VL of a known antibody. Amino acid sequences of the known antibody can be obtained, for example, as amino acid sequences of antibodies registered in database such as Protein Data Bank. The FRs used for the humanized antibody are not especially limited as long as transplanted humanized antibody exerts the effect of the present invention, and are preferably human antibody FRs which give a steric structure of variable region (hereinafter referred to as the “V region”) to the humanized antibody that is similar to the steric structure of V region of the non-human animal monoclonal antibody to which CDRs originated, or human antibody FRs having high homology in amino acid sequence to FRs of the non-human animal monoclonal antibody used. A DNA sequence encoding the V region of the humanized antibody used is designed as a DNA sequence corresponding to the amino acid sequence wherein the amino acid sequences of the CDRs of the non-human animal monoclonal antibody are connected to the amino acid sequences of a human antibody FRs. The DNA encoding the V region of the humanized antibody can be prepared based on the designed DNA sequence by using a method known to those skilled in the art.
(Human Antibody)
[0082] A human antibody can be obtained by, for example, utilizing a human antibody phage library or a human antibody producing transgenic mouse (Tomizuka et al., Nature Genet., 15, 146-156 (1997)). In using a human antibody phage library, for example, the ITG-α4 mutant or a peptide having an epitope sequence recognized by the antibody of the present invention is immobilized on a solid phase, to which a phage antibody library is reacted, and unbound phages are removed by washing, and then, bound phages are recovered, so as to obtain a desired clone (panning). Furthermore, the obtained phages may be amplified so as to repeatedly perform panning on a library of the amplified phages to improve the accuracy of obtained clone. By analyzing a VH gene and a VL gene of the obtained clone, a complete human antibody having these gene sequences can be produced.
[0083] A human antibody producing transgenic mouse is a mouse in which an endogenous immunoglobulin (Ig) gene is knocked out and an Ig gene of a human antibody is introduced. The human antibody producing transgenic mouse can be obtained, for example, by the following method: treating a human-mouse hybrid cell with colcemid (a spindle fiber formation inhibitor) for 48 hours to form a microcell, a structure in which one to a few chromosomes are wrapped with a nuclear membrane, fusing the isolated microcell with a chromosome receiving cell (a mouse ES cell) by using polyethylene glycol in the presence of cytochalasin B to produce a microcell hybrid ES cell, injecting the hybrid ES cell into a mouse germ, immunizing a human antibody producing transgenic mouse with an antigen (preferably, a peptide having an epitope sequence recognized by the antibody of the present invention) according to the above-described method for preparing an anti-ITG-α4 mutant antibody to obtain an anti-ITG-α4 mutant human antibody.
(Production of Antibody Fragment)
[0084] An F(ab′) 2 fragment (an antibody fragment having antigen binding activity and a molecular weight of approximately 100 thousands) can be obtained by treating an IgG antibody of the present invention with pepsin so as to cut at the 234th amino acid residue of an H chain. An Fab′ fragment can be obtained by treating the F(ab′) 2 fragment obtained as described above with dithiothreitol. Alternatively, an Fab′ fragment of the present invention can be obtained from a DNA encoding an Fab′ of the antibody of the present invention. An Fab fragment (an antibody fragment having antigen binding activity and a molecular weight of approximately 50 thousands, in which an about half region on the N-terminal side of an H chain and the entire region of an L chain are bound through a disulfide bond) can be obtained by treating the antibody of the present invention with papain so as to cut at the 224th amino acid residue of an H chain. Alternatively, an Fab fragment of the present invention can be obtained from a DNA encoding an Fab of the antibody of the present invention. A scFv can be obtained by inserting a DNA encoding a linker sequence between cDNAs encoding VH and VL of the antibody of the present invention, so as to construct a DNA encoding the scFv. The length of the linker is not especially limited as long as the length is sufficient for associating VH and VL, and is preferably 10 to 20 residues, and more preferably 15 residues. A sequence of the linker is not especially limited as long as it does not inhibit folding of a polypeptide chain of two domains VH and VL, and is preferably a linker consisting of glycine and/or serine, and more preferably GGGGS (G: glycine, S-serine) or a repeat sequence thereof. A dsFv can be obtained by substituting one amino acid residue in each of VH and VL with a cysteine residue, and binding these cysteine residues through a disulfide bond. A diabody can be obtained by constructing a DNA encoding the above-described scFV to have a linker with 8 or less (preferably, 5 residues) amino acid residues. A bispecific diabody can be obtained by producing a scFv by combining DNAs of VHs and VLs of different two scFvs. A peptide containing a CDR of the present invention can be obtained by designing a peptide having an amino acid sequence of a CDR of VH or VL of the antibody of the present invention.
[0085] In order to illustrate the present invention in more details, examples are described below, however the present invention is not limited to those in the examples. All literatures cited herein are incorporated by reference in their entirety.
Example 1
Identification of Integrin α4 Mutants
[0086] Novel human α4 integrin mutants were identified by the 3′-race method using cDNAs originated from Jurkat cells and Rec-1 cells. A total RNA obtained from human T cell Jurkat cell line (ATCC, TIB-152) and human mantle cell lymphoma Rec-1 cell line (ATCC, CRL-3004) was extracted by using a QIAGEN RNeasy kit (QIAGEN). Specifically, a cDNA for the 3′-race method was synthesized by using a primer for the 3′-race method, a QT primer (5′-CCAGTGAGCAGAGTGACGAGGACTCGAGCTCAAGCTTTTTTTTTTTTTTTTT-3′: SEQ ID NO: 22) as a primer for reverse transcription. With the obtained cDNA used as a template, 1st PCR was performed by using a Q0 primer (5′-CCAGTGAGCAGAGTGACG-3′: SEQ ID NO: 23) and the following three primers for various regions of human integrin α4 (α4-N: 5′-TGTCTCGAGTGGCCGTTTAGTGTTGAATGT-3′: SEQ ID NO: 24; α4-1246: 5′-ACTGGTGGTTGCTATGGAGTA-3′: SEQ ID NO: 25; α4-2118: 5′-CTTTTCGGTCTGATTCTGCTG-3′: SEQ ID NO: 26). The obtained PCR product was diluted by 20 times, and 2nd PCR was performed using 1 μL of said diluted first PCR product as a template. As a primer set for the 2nd PCR, a Q1 primer (5′-GAGGACTCGAGCTCAAGC-3′: SEQ ID NO: 27) and three human integrin α4 primers (α4-1246: 5′-ACTGGTGGTTGCTATGGAGTA-3′: SEQ ID NO: 25; α4-2118: 5′-CTTTTCGGTCTGATTCTGCTG-3′: SEQ ID NO: 26; α4-2556: 5′-CACTTCAGCCAATTCTTCAGC-3′: SEQ ID NO: 28) were used. The obtained plural bands were purified by gel extraction, and cloned by using a TOPO cloning kit (Invitrogen), and nucleotide sequences were determined by sequencing.
[0087] As a result, six novel integrin α4 mutants were successfully identified. The identified novel mutants were respectively designated as the 1-1-2 mutant, the 1-2-1 mutant, the 7-3-2 mutant, the 10-7-3 mutant, the 10-7-2 mutant and the 9-5-4 mutant. Amino acid sequences of the identified six integrin α4 mutants, the 1-2-1 mutant, the 1-1-2 mutant, the 7-3-2 mutant, the 10-7-3 mutant, the 10-7-2 mutant and the 9-5-4 mutant, are shown in FIGS. 1 and 2 . The sequences of these mutants are schematically illustrated in FIG. 3 , and genomic structures on chromosome 2 of these integrin α4 mutants are illustrated in FIG. 4 .
Example 2
Expression of Integrin α4 Mutants
[0088] All the obtained integrin α4 mutants include only extracellular regions of integrin α4, and therefore, it was presumed that they were secretory proteins. Therefore, in order to express each mutant in culture cells, a plasmid comprising a FLAG tag added to the C-terminal of each mutant was constructed. Expression vectors for the six integrin α4 mutants (the 1-1-2 mutant, the 1-2-1 mutant, the 7-3-2 mutant, the 10-7-3 mutant, the 10-7-2 mutant and the 9-5-4 mutant) were constructed as follows: using cDNAs obtained from Jurkat cells (ATCC, TIB-152) and Rec-1 cells (ATCC, CRL-3004) as templates, PCR was performed with an α4-N primer and an each mutant specific 3′-end primer. The 3′-end primers used are shown below. To each primer, a FLAG tag sequence was added for expression analysis.
[0000] ha4-1-1-2-FLAG-RV primer: (SEQ ID NO: 29) 5′-TTACTCTAGACTATTTATCGTCATCATCTTTGTAGTCATTACCTTCAAAGCCATCATT-3′; ha4-1-2-1-FLAG-RV primer: (SEQ ID NO: 30) 5′-TCGTTCTAGACTATTTATCGTCATCATCTTTGTAGTCTGTCCTAGCTCTGTACTTGCT-3 ; ha4-7-3-2-FLAG-RV primer: (SEQ ID NO: 31) 5′-CCACTCTAGACTATTTATCGTCATCATCTTTGTAGTCATATTGTAGGGCATACCCACC-3′; ha4-10-6-3-FLAG-RV primer: (SEQ ID NO: 32) 5′-TTGATCTAGACTATTTATCGTCATCATCTTTGTAGTCTGAGGAAAAGCTGAGAGAGTT-3′; ha4-10-7-2-FLAG-RV primer: (SEQ ID NO: 33) 5′-CCCATCTAGACTATTTATCGTCATCATCTTTGTAGTCGAGACAACACTTCAAAAACCC-3′; ha4-9-5-4-FLAG-RV primer: (SEQ ID NO: 34) 5′-CGTTTCTAGACTATTTATCGTCATCATCTTTGTAGTCCTTCAAAAACCCAATCTTTGC-3′.
Each PCR product was digested with Xhol and Xbal restriction enzymes, and inserted into a pcDNA3.1 expression vector (Invitrogen), and the sequence was determined by sequencing.
[0089] The produced expression vector was introduced into COS1 cells (ATCC, CRL-1650) by using Lipofectamine 2000 (Invitrogen), and after 2 days a culture supernatant was concentrated by 10 times with Vivaspin (GE), which was used for performing Western blotting with an anti-FLAG antibody (Wako Pure Chemical Industries, Ltd.).
[0090] The results of the Western blotting are shown in FIG. 5 . As illustrated in the picture, it was confirmed that each integrin α4 mutant is secreted into a culture supernatant.
Example 3
Binding Capacity of Integrin α4 Mutant to Integrin α4 Ligand
[0091] The binding ability of integrin α4 mutant contained in the supernatant to a ligand of integrin α4 was examined by the ligand solid phase ELISA. 10 μg/mL of a human OPN RAA Nhalf protein as a ligand of integrin α4 (Kon, S., et al., (2002) J. Cell. Biochem., 84: 420-432) or BSA as a control was immobilized at 4° C. overnight, and after blocking with 1% BSA/PBS, the same culture supernatant concentrated by 10 times as in Example 2 was added thereto. After incubating at 4° C. for 1 hour, a mixture of an anti-FLAG antibody (Wako Pure Chemical Industries, Ltd.) and an anti-mouse IgG (Immuno-biological Laboratories Co., Ltd.) was added, and incubated at 4° C. for 30 minutes. After washing, a TMB solution (DAKO) was added to develop color for analyzing binding capacity.
[0092] The result is shown in FIG. 6 . All the mutants other than the 9-5-4 mutant had binding ability to the human OPN RAA Nhalf protein, a ligand of integrin α4. From the result of the Western blotting, it is presumed that this result of the 9-5-4 mutant was not due to lack of its binding ability but due to small amount secreted into the culture medium.
Example 4
Analysis of Expression of Endogenous 1-2-1 Mutant
(1) Production of Anti-1-2-1 Mutant Antibody
[0093] A rabbit polyclonal antibody was prepared by using a 1-2-1 mutant specific amino acid sequence GSISKYRART (SEQ ID NO: 15) as an antigen, which was used for analysis of endogenous expression of the 1-2-1 mutant. Specifically, bovine thyroglobulin was introduced as a carrier into the 1-2-1 mutant specific amino acid sequence GSISKYRART (SEQ ID NO: 15), which was immunized a rabbit. The resultant antiserum was purified by using thiol Sepharose beads (GE) to which the GSISKYRART peptide (SEQ ID NO: 15) was bound, so as to obtain an anti-1-2-1 mutant antibody.
(2) Preparation of Culture Supernatant
[0094] The α4 integrin mutant (1-2-1 mutant) in COS1 cells (ATCC, CRL-1650) was transiently overexpressed by introducing the expression vector of the 1-2-1 mutant prepared in Example 2 into COS1 cells (ATCC, CRL-1650) with Lipofectamine 2000 (Invitrogen). The obtained cells were cultured in a DMEM medium (containing no serum) for 2 days, and a culture supernatant and cells were recovered. The culture supernatant was concentrated by 10 times with Vivaspin (GE), which was used for Western blotting. Jurkat cells (ATCC, TIB-152) and Rec-1 cells (ATCC, CRL-3004) were cultured without a serum in a TIL medium (Immuno-biological Laboratories Co., Ltd.), and a culture supernatant at 3 days was concentrated by 20 times with Vivaspin, which was used for Western blotting.
(3) Confirmation of Expression by Western Blotting
[0095] The Western blotting was performed, after SDS-PAGE, through transfer to immobilon-P membrane (Millipore Inc.). Since the FLAG tag was added to all the α4 mutants, the expression of the integrin α4 mutant (the 1-2-1 mutant) in COS cells was blotted with an anti-FLAG antibody (Wako Pure Chemical Industries, Ltd.). Expression of the endogenous integrin α4 mutant (1-2-1 mutant) was blotted with the anti-1-2-1 mutant antibody prepared in the aforementioned manner. The luminescence detection was carried out by using ECL-plus (Perkin-Elmer).
[0096] From the results of the Western blotting, it was observed that the Rec-1 cells (ATCC, CRL-3004) sample showed a band at the same position as the culture supernatant of the 1-2-1 mutant transformed COS cells ( FIG. 7 ). In other words, it was revealed that the 1-2-1 mutant was endogenously expressed and secreted at a level of protein in the Rec-1 cells.
Example 5
Cell Adhesion Inhibitory Function of 1-2-1 Mutant Via Integrin α4 and Integrin α9
(1) Production of GST-Fused 1-2-1 Mutant Protein
[0097] In order to analyze the function of the 1-2-1 mutant, the 1-2-1 mutant was expressed as a GST-fused protein in E. coli , and purified by a general method using glutathione Sepharose. For prepare integrin α4 mutant (1-2-1 mutant) protein in E. coli , the 1-2-1 mutant was recombined into pGEX6P-1 (GE). PCR was performed with a 1-2-1 mutant expression vector as a template, and a 5′-end primer (5′-GAGGAATTCTACAACGTGGACACTGAGAG-3′: SEQ ID NO: 35) designed to delete an N-terminal signal sequence of the 1-2-1 mutant and a 3′-end primer (5′-CGTCTCGAGTTATGTCCTAGCTCTGTACTTGC-3′: SEQ ID NO: 36). The obtained PCR product was digested with EcoRl and Xhol restriction enzymes, and the resultant was inserted into a pGEX6P-1 vector to match a frame of the GST portion. The sequence was confirmed by sequencing. This plasmid was transformed into E. coli , which was grown in an LB medium containing ampicillin at 37° C. During logarithmic growth phase, the E. coli was cultured at 20° C. for 1 hour, and then added isopropyl-β-D-1-thiogalactopyranoside (IPTG) to be a final concentration of 0.3 mM, which was cultured at 20° C. overnight. The E. coli was recovered and suspended in NETN 150 (20 mM Tris-HCl (pH 8.0), 150 mM NaCl, 1 mM EDTA, 0.5% (v/v) NP-40), and then sonicated by using an ultrasonic grinder. The supernatant after centrifugation was added with glutathione beads (GE, and then rotated at 4° C. overnight. After collecting the beads by centrifugation, the resultant was washed with NETN 100 (20 mM Tris-HCl (pH 8.0), 100 mM NaCl, 1 mM EDTA, 0.5% (v/v) NP-40) three times, and eluted with an eluent (20 mM reduced glutathione (Sigma), 100 mM Tris-HCl (pH 8.8)). The obtained GST-fused 1-2-1 mutant protein was dialyzed against PBS and quantitatively determined by using a protein assay kit (Bio-Rad).
[0000] (2) Preparation for CHO Cells Expressing Integrin α4 or Integrin α9 (Designated as “mα4/CHO” or “mα9/CHO”, Respectively)
[0098] A mouse α4 integrin (herein, designated as “mα4”) expression vector was prepared as follows: PCR was performed with a mouse melanoma cell line B16-F10 (ATCC, CRL-6475) as a template and an mα4-Fw primer (5′-CGAGGATCCTGAATGTTCTCCACCAAGAGC-3′: SEQ ID NO: 37) and an mα4-RV primer (5′-TTACTCGAGACGGGTCTTCTGAACAGGATT-3′: SEQ ID NO: 38), and the obtained PCR product was digested with BamHl and Xhol restriction enzymes, and cloned into a pcDNA3.1 vector (Invitrogen).
[0099] A mouse α9 integrin (herein, designated as “mα9”) expression vector was constructed as follows: PCR was performed with a cDNA prepared from a mouse placenta as a template and an mα9-Fw primer (5′-GCTAAGCTTCTCTCGACTGTAGCCCATCG-3′: SEQ ID NO: 39) and an mα-RV primer (5′-CCATCTAGAGCAACTGCTGAGAGGAAAC-3′: SEQ ID NO: 40), and cloned by using a TOPO cloning kit (Invitrogen) (mα9/TOPO). After confirming the sequence of the mouse α9 integrin by sequencing, an mα9 integrin expression vector added with a FLAG tag was prepared by PCR with the mα9/TOPO as a template and the mα9-Fw primer and an mα-FLAG-RV primer (5′-CTGTCTAGATTACTTGTCATCGTCATCCTTGTAGTCCTGGTTTTTCTGGACCCAGTC-3′: SEQ ID NO: 41). The obtained PCR product was digested with Hind III and Xbal restriction enzymes, and integrated into a pcDNA 3.1 vector (Invitrogen).
[0100] The sequences of the vectors constructed for mouse α4 integrin and α9 integrin were confirmed by sequencing. Respective genes were introduced into CHO-K1 cells (ATCC, CCL-61) by using Lipofectamine 2000 (Invitrogen), and after selection with 10% FCS in a DMEM medium containing 1 mg/mL G418 (PAA) as an antibiotic, the CHO-K1 cells were limiting diluted to confirm expression of mouse α4 integrin and mouse α9 integrin in single colonies. The expression of mouse α4 integrin was confirmed by flow cytometry analysis using an anti-mouse α4 integrin antibody (R1-2) (Biolegend). The expression of mouse α9 integrin was confirmed by Western blotting using an anti-FLAG antibody (Wako Pure Chemical Industries, Ltd.). The clone having the highest level of expression was used for a cell adhesion inhibitory activity test.
(3) Cell Adhesion Inhibitory Activity Test
[0101] The obtained purified GST-fused 1-2-1 mutant protein (1-2-1/GST) was used for a cell adhesion inhibitory test. In the cell adhesion test, peptides of functional site of various extracellular matrix proteins, specifically the following peptides, were bound to BSA and were used as various integrin ligands: 5 μg/mL GRGDS (SEQ ID NO: 42) peptide (a peptide for cell adhesion via RGD-dependent integrin such as αv integrin: negative control); 10 μg/mL SVVYGLR (SEQ ID NO: 20) peptide (functional peptide of OPN which exerts cell adhesion activity through binding to integrin α4 and integrin α9); and 10 μg/mL QDHSFSIVIETVQ (SEQ ID NO: 21) peptide (functional peptide of pp-vWF which exerts cell adhesion ability through binding to integrin α4 and integrin α9).
[0102] Each functional site peptide of extracellular matrix proteins coupled to BSA was incubated at 4° C. overnight for immobilization. After blocking with a DMEM medium containing 0.5% BSA for 1 hour, a mixture of CHO cells expressing either of α4 integrin or α9 integrin and 1-2-1/GST protein (in a final concentration of 6.25 μg/mL, 12.5 μg/mL or 25 μg/mL) was added, which is cultured in a CO 2 incubator at 37° C. for 1 hour. Non-adherent cells were removed with PBS. Adherent cells were fixed and stained with 20% methanol containing 0.5% crystal violet, which were solubilized with 20% acetic acid, and absorbance at 595 nm was measured with an immunoreader, so as to examine the cell adhesion inhibitory effect.
(4) Results
[0103] It was observed that the 1-2-1/GST protein did not inhibit RGD-dependent cell adhesion, but concentration dependently inhibited cell adhesion dependent on the SVVYGLR (SEQ ID NO: 20) peptide or the QDHSFSIVIETVQ (SEQ ID NO: 21) peptide which are capable to bind integrin α4 and integrin α9 ( FIG. 8 ). In other words, it was found that the 1-2-1/GST protein has a function to simultaneously inhibit cell adhesion via integrin α4 and integrin α9. In addition, the adhesion inhibitory activity against fibronectin EIIIA was measured similarly, and the 1-2-1/GST protein has a function to simultaneously inhibit cell adhesion via integrin α4 and integrin α9 (data not shown). OPN is known to be involved in arterial sclerosis, cardiac infarction, cancer metastasis, and inflammatory diseases. Since the ITG-α4 mutant of the present invention can inhibit OPN mediated adhesions via integrin α4 and integrin α9, it was indicated that the ITG-α4 mutant can be a more effective therapeutic agent for these diseases. A pp-vWF is known to be involved in thrombus, blood platelet function, inflammation and the like. Since the ITG-α4 mutant of the present invention can inhibit pp-vWF mediated adhesion via integrin α4 and integrin α9, it was indicated that the ITG-α4 mutant can be a more effective therapeutic agent for inflammatory diseases (Japanese Patent Laid-Open No. 2005-298336) and the like. A fibronectin EIIIA (also known as EDA) is known to be involved in cancer (Clin. Chim. Acta. (2006) 372: 83-93). Since the ITG-α4 mutant of the present invention can inhibit fibronectin EIIIA mediated adhesion via integrin α4 and integrin α9, it was indicated that the ITG-α4 mutant can be a more effective therapeutic agent for cancer or antimetastatic agent.
Example 6
EAE Inhibitory Effect by Integrin α4 Mutant 1-2-1 Protein
[0104] An inhibitory effect for disease exacerbation of the 1-2-1/GST protein was examined by using an EAE model. The EAE was developed as follows: an emulsion of 200 μg of PLP139-151 peptide (sequence: HSLGKWLGHPDKF: SEQ ID NO: 43) and CFA was subcutaneously administered via a tail root of an SJL/J mouse (Charles River Laboratories Japan Inc.), on the same day, pertussis toxin (List Biological Laboratories Inc.) (400 ng) was intravenously injected, after 2 days, pertussis toxin (400 ng) was intravenously injected again. On the day before administering PLP139-151 peptide, the 1-2-1/GST protein or 50 μg of GST protein (as a negative control) was intraperitoneally administered. A clinical score for EAE was determined as follows: 0: no symptom; 1: paralyzed tail; 2: ataxia; 3: mild paralysis of hind legs; 4: paralysis of hind legs; 5: paralysis in extremities and urinary incontinence; 6: moribund; and 7: death. A schedule for examining the influence of the 1-2-1/GST protein on EAE is shown in FIG. 9 .
[0105] As a result of the examination, it was found that the 1-2-1/GST protein delays the day of onset (onset), and furthermore, drastically suppresses the EAE score ( FIG. 9 ). Since the EAE model is a model of multiple sclerosis, the result of this experiment indicates that the ITG-α4 mutant of the present invention can be used as a therapeutic agent or preventive agent for multiple sclerosis. | The present invention addresses the problem of providing a novel substance capable of interfering with various functions of integrin α4, and/or providing a novel substance capable of interfering with both integrin α4 and integrin α9. The present invention provides an integrin α4 mutant peptide having one portion of the extracellular domain of human integrin α4, and the like, and in concrete terms relates to a peptide and the like having the amino acid sequence of Sequence No. 4 through 9, and a pharmaceutical composition comprising as the active ingredient the same peptide. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for preventing backlash on a fishing reel in which a spool is braked by magnetic induction.
In a conventional device for preventing such backlash, a magnetic member has, on at least one side, a nonmagnetic electroconductive member which is rotated with the spool. The relative movement between the two members causes an eddy current in the nonmagnetic electroconductive member by the magnetic force of the magnetic member to magnetically brake the rotating spool thereby preventing backlash from being caused by the excessive rotation of the spool at the time of casting of a fishhook, fishline and so forth. Since the magnetic member cannot be adjusted during casting, the rotation of the spool is magnetically braked even before casting. For that reason, such a conventional device has a problem that the fishhook, fishline and so forth cannot be cast far enough.
In order to solve the problem, a device was proposed in the Japanese Utility Model Laid-open Gazette No. 59-178070. In this device, the rotation of the spool is automatically braked when a set time has passed since the start of the rotation of the spool. However, this type of device has problems in that it is very difficult to set a time that it takes for a fishhook, fishline and so forth to be cast to a predetermined place after the start of the rotation of the spool. The cast distance or the passed time varies from case to case. Such a device is effective if the fishhook, fishline and so forth land on the water after the lapse of the preset time. If, however, the fishhook, fishline and so forth land on the water before the lapse of the preset time or land on nearby water by mistake, rotation of the spool is not braked and backlash results.
SUMMARY OF THE INVENTION
The present invention was made in order to solve the above-mentioned problems.
It is an object of the present invention to provide a device in which the number of the pulses of the output signal from a sensor which detects the rotation of a spool is counted at every output signal from a reference clock circuit; the speed or acceleration of the rotation of the spool is calculated from the number of counted pulses; and the spool is braked when the calculated speed or acceleration has reached a preset value or a negative value. The braking of the spool is ceased when the calculated speed or acceleration has become zero. With the device, backlash can be completely prevented regardless of the distance of casting of fishhook, fishline and so forth. Furthermore, a failure in casting (i.e., a short cast) will not cause a lashback and the distance of the cast can be increased.
The device is provided for a fishing reel in which the rotation of a spool is controlled by causing an eddy current in a nonmagnetic electroconductive member which is rotated in conjunction with the rotation of the spool. The device comprises a sensor which detects the rotation of the spool; a counter circuit in which the number of the pulses of the output signal from the sensor is counted by a pulse counter at every output signal from a reference clock circuit; a calculation circuit which calculates the speed or acceleration of the rotation of the spool; and a control means for causing the eddy current in the nonmagnetic electroconductive member to occur when the calculated rotation or acceleration has reached the value preset by a data setting unit, thus solving the above-mentioned problems.
In a preferred embodiment when the number of the pulses generated in a prescribed time and corresponding to the speed or acceleration of the rotation of the spool has reached a preset value or a negative value, a magnet ring is rotated by a motor to brake the spool. When the number of the pulses in the prescribed time has become zero, the braking is ceased. For these reasons, the spool is only slightly braked during the casting of the fishhook, fishline and so forth. As a result, the distance of the cast is increased. Even if the distance of the actual cast is less than a set value, or the fishhook, fishline and so forth land on the nearby water due to a failure in casting, the spool is braked to prevent backlash.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a longitudinal cross-sectional view of a fishing reel backlash prevention device which is an embodiment of the present invention.
FIG. 2 shows a schematic view of the device in the state of maximum braking.
FIG. 3 shows a block diagram for the device.
FIG. 4 shows a longitudinal sectional view of a modification of the magnet ring rotation means of the device.
FIG. 5 shows a graph indicating the relation between the revolution speed of a spool and time in casting.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention is described in detail with reference to the drawings. FIG. 1 shows the body 1 of a reel having both bearings is assembled as a frame wherein a right and a left side plates 2 and 2' are secured at a prescribed distance from each other by horizontal bars 3 and covers 4 and 4' are secured to the side plates 2 and 2'.
Both the ends of a spool shaft 5 are supported by bearings, on one side the bearing 7 on the support portion 6 of the cover 4 and on the other by bearing 7' in the cover 4' so that a spool 8 is rotatably supported between the side plates 2 and 2'. A pinion 10 is fitted on the right-hand portion (as to the drawing) of the spool shaft 5 so that the pinion can be slid in the axial direction and can be rotated by a handle 9 through drive gears (not shown). The spool shaft 5 is connected to or disconnected from the handle 9 by sliding the pinion 10 on the spool shaft 5 in the axial direction.
A nonmagnetic electroconductive member 11 shaped as a horizontal cup is secured to the left-hand portion of the spool shaft 5. The peripheral portion lla of the nonmagnetic electroconductive member 11 protrudes into the cover 4 through the opening 2a in the side plate 2. Magnet rings 12 and 13 are disposed together with annular yokes 15 and 16 inside and outside the peripheral portion 11a of the member 11 and are located in an annular recess 14 provided in the cover 4.
The inner magnet ring 13 can be rotated together with an attachment 17 provided on the annular yoke 15. The attachment 17 has a projection 17a extending outwards and inserted into the hole 18 of the cover 4 so that the projection can be moved within a prescribed range.
The outside surface of the cover 4 has a circular recess 19 communicating with the hole 18. A disk-shaped adjusting cam 20 is rotatably supported in the recess 19. One side of the adjusting cam 20 has a straight cam groove 20a as shown in FIG. 2. The projection 17a of the attachment 17 is slidably fitted in the cam groove 20a. The cam groove 20a extends in a radial direction from the center of the adjusting cam groove 20a when the cam 20 is rotated.
A motor 22 is secured to the interior side of a cover 21 fitted in the outer portion of the recess 19. The central portion of the adjusting cam 20 is secured to the shaft 22a of the motor 22 so that the cam 20 is rotated by the motor.
In each of the magnet rings 12 and 13, north poles and south poles are alternately located at regular intervals in the circumferential direction, as shown in FIG. 2. A control means 29 for causing an eddy current in the nonmagnetic electroconductive member 11 is comprised of the magnet rings 12 and 13 and the annular yokes 15 and 16.
A nonmagnetic electroconductive member 11 is made of a nonmagnetic substance such as copper or aluminum.
The magnet ring 13 may be rotated by the motor 22 through a gear transmission means shown in FIG. 4, instead through the adjusting cam 20. In this case, it is preferred that a gear 17a be machined on the peripheral portion of the attachment 17, a gear 22b is provided on the motor shaft 22a, with both the gears 17a and 22b being engaged with one another.
A magnet 23 is secured on one side of the spool 8. A magnetic sensor 24, which detects the rotation of the spool 8, is secured on the side plate 2' so as to face the area on which the magnet 23 is revolved. The magnetic sensor 24 is connected to a pulse counter 26 of a counter circuit 25 shown by the block diagram of FIG. 3. The pulse counter 26 is connected to a latch circuit 27 and a reference clock circuit 28.
Shown at 30 in FIG. 1 is a central processing unit. Shown at 31, 32, 33, 34 and 35 in FIG. 3 are a calculation circuit, a motor control circuit, a data setting unit, an indicator and a magnet position confirmation circuit, respectively.
The rotation of the spool 8 is detected by the magnetic sensor 24. The number of the pulses of the output signal from the sensor 24 is counted by the pulse counter 26 at every output signal from the reference clock circuit 28. The central processing unit 30 calculates the speed or acceleration of the rotation of the spool 8 from the counted number of pulses. When the calculated speed or acceleration has reached a preset value, the central processing unit 30 sends a control signal to the motor 22 to turn the adjusting cam 20 (or the gear 22b by the rotation of the motor) to rotate the inner magnet ring 13 mounted on the attachment 17 sufficient to change the relation of the magnetic poles of the magnet ring 13 to those of the outer magnet ring 12 to control a braking force acting on the spool 8.
The counter circuit 25 receives the output signal from the magnetic sensor 24, and sends the number of counted pulses to the calculation circuit 31. At that time, the number of the pulses between the adjacent output signals from the reference clock circuit 28, which generates the output signal in a prescribed time, is counted. The counted number of the pulses in the prescribed time is sent to the calculation circuit 31 through the latch circuit 27.
The calculation circuit 31 calculates the speed or acceleration of the rotation of the spool 8 from the number of counted pulses in each time interval. When the calculated speed or acceleration has reached the value preset by the data setting unit 33, the reversible motor 22 is put in operation by the motor control circuit 32 to turn the inner magnet ring 13 to a position shown in FIG. 2, to increase the eddy current to brake the spool 8.
When the pulse counter 26 detects no pulse as a result of the stoppage of the outgoing fishline and the rotation of the spool 8, the motor 22 is reversed by the motor control circuit 32 in response to an output signal from the magnet position confirmation circuit 35 which may be a limit switch, a rotary encoder or the like. Consequently, the magnet ring 13 is reversed to such a position relative to the magnet ring 12 as to decrease the eddy current.
An example of operation is now described with reference to FIG. 5 which shows a graph indicating the relation between the revolution speed of the spool 8 and the time in casting the fishline, etc. At a point A where the acceleration of the rotation of the spool 8 reaches a maximum, an increase in the rotational frequency of the spool in a prescribed time such as 0.01 sec., becomes a preset value such as zero. A decrease in the rotational frequency of the spool in such a preset time becomes a preset negative value. For example, when the rotational frequency reaches 1,000 corresponding to a maximum speed and a preset value of zero, or a frequency of 950 after reaching a maximum of 1,000 in the prescribed time of 0.01 sec. corresponding to a preset negative value indicating deceleration, the magnet ring 13 is turned in such a direction (to the position shown in FIG. 2) by the motor 22 to increase the eddy current to brake the rotation of the spool 8 to prevent backlash. At another point 8 where the outgoing of the fishline and the rotation of the spool 8 stop, in other words, when the pulse counter 26 detects no pulses, the magnet ring 13 is reversed to such a position by the motor 22 as to place the north poles of the magnet ring 13 in the face of those of the other magnet ring 12 and place the south poles of the magnet ring 13 in the face of those of the other magnet ring 12 to decrease the eddy current.
The present invention has been disclosed in terms of preferred embodiments. The invention is not limited thereto and is defined by the appended claims and their equivalents. | A fishing reel that includes an eddy current brake mechanism that applies a braking force to the spool of the reel when the speed or acceleration of the spool, as detected electrically, reaches a predetermined value. The reel further includes electrical means for detecting, calculating and comparing rotation of the spool to a predetermined value whereupon a magnetic brake slows the spool to prevent backlash. | 0 |
BACKGROUND OF THE INVENTION
The present invention pertains to vertical cavity surface emitting lasers (VCSELs), and particularly to VCSELs having current confinement. More particularly, the invention pertains to VCSELs having refined current confinement caused by an implant or diffusion not having unwanted damage in the VCSEL structure.
Several patents address the issue of current confinement. U.S. Pat. No. 5,115,442 reveals a structure having a semiconductor quarterwave stack in both mirrors. The entire semiconductor epitaxial structure is deposited first, followed by a deep proton implant to confine the current. This is a commonly used structure. Its drawbacks include the fact that the top mirror is several microns thick, and therefore the implant must be so deep that one is limited in how small the current path can be made. Since the depth is so large, and there is significant straggle of implanted ions, the diameter of the current confined region cannot be made as small as one would like. This makes it more difficult to produce a single mode device and more difficult to keep the current required to reach the threshold for lasing small. In addition, damage is produced in proximity to the active region by the implant, which could eventually limit the lifetime of the device. The limit on size restricts performance. Furthermore, there are reliability concerns due to the proximity of the implanted region next to the gain region.
A second related U.S. Pat. No. 5,256,596 also provides for current confinement using ion implantation, but has a mesa etched before the implanting, so the implant depth is smaller. In that structure, a buried implant is used to provide current confinement. However, the entire epitaxial structure is deposited first, and a mesa must be etched before ion implant, in order to place the implant at the right depth, since the range of dopant atoms is quite small compared to protons. In fact, one can wonder whether the structure shown in FIG. 3 of that patent is even feasible, since it would require the implant of p- type atoms several microns below the surface. The disadvantages of this approach are that it results in a non-planar surface, and requires implantation through or close to the active region, thereby resulting in potential reliability problems.
U.S. Pat. No. 5,475,701, by Mary Hibbs-Brenner and issued Dec. 12, 1995, is hereby incorporated in this specification by reference.
SUMMARY OF THE INVENTION
This invention consists of a vertical cavity surface emitting laser in which the current is confined to the center of the device by the use of an implant or diffusion in mirror layers close to the active layers of either mirror; that is, the implant or diffusion may be placed at the top of the bottom mirror or at the bottom of the top mirror.
The approach outlined here involves a two step metalorganic chemical vapor deposition (MOCVD) growth. The first mirror is grown, and then implanted or diffused to provide current confinement. Then the remainder of the laser structure, i.e., the remainder of the first mirror, the gain region, and the second mirror, is deposited. The structure remains planar, thus facilitating the fabrication of high density arrays. The implant or diffusion is shallow (a few tenths of a micron), so the dimensions can be accurately controlled. The implant or diffusion is clearly below the active region, and ions do not need to be implanted or diffused through the active region. This approach provides a structure for improved reliability.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1a is a diagram of a VCSEL having a current confining implant or diffusion below the active region.
FIG. 1b shows a current confining implant or diffusion above the active region in the VCSEL.
FIG. 2a is a diagram of another VCSEL, having a current confining implant or diffusion below the active region, that can be integrated with other electronic circuits.
FIG. 2b shows the VCSEL of FIG. 2a but with the current confining implant or diffusion above the active region.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1a illustrates configuration 10 of the structure. In this version, alternating epitaxial layers 14 and 16 for laser 10 are deposited on a substrate 12 which is doped n- type. On the bottom side of substrate 12 is formed a broad area contact 15 (i.e., n- ohmic). A bottom mirror 17, consisting of 26 periods of alternating layers of AlAs 16 and Al x Ga.sub.(1-x) As (x=0.15 is preferred, but x may have any value greater than 0.05) 14, all doped n- type, are grown to form a highly reflecting mirror 17. The total number of mirror periods may be greater or less than 26, depending on other parameters. At the top of mirror 17, a p- type or electrically insulating dopant 20 is implanted or diffused in top layers 16 and 14 in order to block current flow on the perimeter of mirror 17, and confine the current to dimension 40. This p- or insulating dopant may be located between 0 and 10 periods (20 layers) below the first confining layers, but preferably is 2 periods below the first confining layer. It is preferable for the depth of implant 20 to be several tenths of a micron but may range between 0.1 and 2 microns. Dimension 40 may be between 0.1 and 60 microns, but is typically several microns, i.e., 2 to 5 microns. Several more mirror periods (0 to 10) may be formed on top of the implanted or diffused surface followed by the mid-portion of structure 10, which consists of two Al x Ga.sub.(1-x) As (x=0.6) confining layers 24. x may be 0.25 or greater. These layers 24 are most likely to be lightly doped, n-type on the layer nearest the n-doped mirror, and p-type on the layer nearest the p-type mirror, although there is a possibility that these could be left undoped. Layers 24 sandwich a region 22 having three GaAs quantum wells 28, separated from one another and confining layers 24 by four Al x Ga.sub.(1-x) As (x=0.25) barrier layers 26. The number of GaAs quantum wells may be from one to five. Alternatively, one could potentially have an active region 22 without quantum wells, e.g., a region having an emitting layer of about 0.2 micron thick. On top of confining layer 24 on active region 22, a p- type mirror 30 is grown, consisting of 18 periods of alternating layers of p- AlAs 31 and p- Al x Ga.sub.(1-x) As 32 (x=0.15 preferably, but may have any value greater than 0.05). The number of periods may be greater or less than 18, depending on other parameters. A GaAs contact layer 34 is formed on top of mirror 30. A proton isolation implant 38 is placed at the perimeter of contact layer 34, mirror 30, active region 22 and confining layers 24, to separate one device 10 from a like neighboring device on a chip. If a single laser chip 10 were to be made, then it is possible that one could eliminate this proton implant 38, if the implant or diffusion made on top of the n-mirror were to extend all the way to the edge of the chip. Laser 10 connections are formed by depositing at least one p- type ohmic contact 36 on the top surface of contact layer 34, and a broad area n- type ohmic contact 15 on the back side of wafer substrate 12. The resulting device 10 emits laser light in the range of 760 to 870 nanometers (nm).
FIG. 1b shows the same VCSEL structure as FIG. 1a, except that dopant 20 is implanted or diffused as an n- type or electrically insulating dopant in layers 31 and 32 of mirror 30, preferably several layers above confining layer 24, to function in blocking current flow from the perimeter of active region 22 and lower mirror 17, and to confine the current flow within dimension 40. Dopant 20 has similar dimensions as implant or diffusion 20 of FIG. 1a.
FIG. 2a illustrates configuration 50 of the structure wherein both contacts of the p-n junction can be made from a top surface thereby permitting integration with electronic circuits or other devices on a semi-insulating substrate. In this version, epitaxial layers 14 and 16 for laser 50 are deposited on a semi-insulating substrate 12. A bottom mirror 17 has 26 periods (i.e., 52 layers) of alternating layers of AlAs 16 and Al x Ga.sub.(1-x) As (x=0.16) 14, of which all can be doped n- type, be entirely undoped, or be undoped except for the last few periods. Layers 16 and 14 are grown to form a highly reflecting mirror 17. A contact layer 54 of n- doped Al x Ga.sub.(1-x) As (x=0.10 but could range from 0.0 to 0.20) is formed on the top layer 16 of mirror 17. In contact layer 54, a p- type or electrically insulating dopant 20 is implanted or diffused in order to block current flow on the perimeter of mirror 17 and confine current flow to dimension 40. Dopant 20 has similar dimensions as implant 20 of FIG. 1a. Unlike the description for FIG. 1a, in this case, the p-type or electrically insulating dopant region cannot extend all the way to the edge of the chip, because it would then prevent us from making this n-ohmic contact 52. The p-type or electrically insulating implant or diffused area 20 looks like a ring. Dimension 40 is typically between two and five microns. The top and mid-portions of structure 50 form a mesa on contact layer 54, after etching. The mid-portion consists of two undoped Al x Ga.sub.(1-x) As (x=0.6 but may have a value of 0.25 or greater) confining layers 24 which sandwich a region 22 having three undoped GaAs quantum wells 28, separated from one another and confining layers 24 by Al x Ga.sub.(1-x) As (x=0.25 as preferred value) barrier layers 26. On top of confining layer 24 on active region 22, a p- type mirror 30 is grown, consisting of 18 periods of alternating layers of p- AlAs 31 and p-Al x Ga.sub.(1-x) As 32 (x=0.15 but x may be at a value of 0.05 or greater). A p+ GaAs contact layer 34 is formed on top of mirror 30. Layers 34, 31, 32, 26, 28 and 24 are etched on their perimeters down to the contact layer to form a mesa on layer 54. Proton isolation implant 38 may be inserted at the perimeter of contact layer 34, mirror 30, active region 22, and confining layers 24 of the mesa to isolate current from the edge of the mesa. Device 50 could still be fabricated without this proton implant, though it may be more reliable with it. The proton isolation implant may extend into a portion of contact layer 54 at a depth which is less than the thickness of layer 54. The distance between the inside edges of proton implant is between 10 and 100 microns. Laser 50 connections for the p-n junction are formed by depositing at least one p- type ohmic contact 36 on the top surface of contact layer 34, and at least one n-type ohmic contact 52 on an external surface of contact layer 54 outside the perimeter of the mesa incorporating active region 22 and mirror 30, and also outside the perimeter of the p-type or electrically insulating implant or diffusion.
FIG. 2b shows the same VCSEL structure with similar dimensions and materials as FIG. 1a, except that the dopant 20 is implanted or diffused as an n- type or electrically insulating dopant in layers 31 and 32 of mirror 30, preferably several layers (0 to 10 periods, or 0 to 20 layers) above confining layer 24, to function in blocking current flow from the perimeter of active region 22 and lower mirror 17, and confining the current flow within dimension 40.
Device 10, 50 can be fabricated by epitaxially depositing an n- type mirror in an OMVPE (Organo-Metallic Vapor Phase Epitaxy) or MBE (Molecular Beam Epitaxy) reactor. The layers of device 10, 50 are removed from the reactor forming the layers, and photoresist is spun onto wafer 10, 50 and patterned in such a way as to protect the layers at an area for a center 40 of device 10, 50. The p-n-, or electrically insulating type dopant is implanted or diffused in a ring outside the protected area having diameter 40. Device 10, 50 is placed back in the epitaxial growth reactor, and the remaining layers of the structure are deposited. After growth of the material, the proton isolation implant 38, and n- and p- ohmic contact 15 and 36 depositions, respectively, are made using normal semiconductor processing techniques. When device 10, 50 is operated by applying a forward bias to the p-i-n junction formed by the top p- doped mirror 30, undoped, or lightly doped active region 22, and bottom n- doped mirror 17, the current is forced to flow only through unimplanted center 40 of device 10, 50.
In the present invention, which has advantages over the above-noted U.S. Pat. No. 5,115,442, the depth of the p- n-, or electrically insulating type implant or diffusion need only be a few tenths of a micron but may range from 0.1 to 2 microns. Therefore, the diameter 40 of the unimplanted or non-diffused region can be kept small to several microns, but may range from 0.1 to 60 microns, with the realization of needing only a very low current to reach lasing threshold, in the cases when this dimension is kept to just a few microns. In addition, the damage due to implant 20 is kept away from the active region 22 of laser 10 and 50, and thus increases device reliability.
This invention provides advantages over the structure disclosed in the above-noted U.S. Pat. No. 5,256,590. Since the epitaxial growth is carried out in two steps, with confining implant or diffusion 20 performed after the first growth, one need only implant or diffuse a few tenths of a micron. In the case of an implant, this limits the energies required, again allowing tighter control of dimensions, and eliminating the need for a mesa etch before the implant. That mesa etch exposes the very reactive AlAs layers 31 in top mirror 30, which would affect reliability. The lower implant 20 energies limit implant damage and magnitude of the implant straggle. In addition, by keeping implant 20 several periods above or below the active region 22, it keeps the reliability limiting implant away from the active layers of the laser.
Other configurations of the device would include the growth of a p- type mirror 17 first, with an n- type or electrically insulating implant or diffusion 20, followed by the active region 22 and an n- type mirror 30. In addition, InGaAs quantum wells 28 can be used for emission in the range of 870-1000 nm. In that case, light can be emitted from either the top or bottom surface of laser 10 or 50. Other materials can be used, such as the AlGaInP material system which results in a laser 10 or 50 emitting in the range 630-700 nm, or the InGaAsP material system for a device 10 or 50 emitting near 1.3 microns. Even in the case of the lasers emitting at 760-870 nm, the various compositions mentioned in the descriptions above can be varied, i.e., "x" compositions in the mirror might vary from 0.05 to 0.3, or the confining layer "x" compositions might vary from 0.4 to 0.8 at the mirrors and from 0.1 to 0.5 between the quantum wells. | A vertical cavity surface emitting laser having a planar structure, having an implantation or diffusion at the top of the mirror closest to the substrate or at the bottom of the mirror farthest from the substrate, to provide current confinement with the gain region, and having an active region and another mirror formed subsequent to the implantation or diffusion. This structure has an implantation or diffusion that does not damage or detrimentally affect the gain region, and does provide dimensions of current confinement that are accurately ascertained. Alternatively, the implantation or diffusion for current confinement may be placed within the top mirror, and several layers above the active region, still with minimal damage to the gain region and having a well-ascertained current confinement dimension. | 7 |
This application is a continuation of application Ser. No. 07/994,981 filed Dec. 22, 1992, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a rope for operating (hereinafter referred to as a rope) particularly, this invention relates to a rope wherein a corrosion. More resistance is improved without lowering its durability for bending and a rope wherein the corrosion resistance is remarkably improved, each of which is preferably used for many technical fields such as a window regulator for an automobile.
A rope is generally produced by stranding a plurality of wire or by stranding a plurality of the rope (in this case the rope is called a strand). Such rope is sometimes corroded by, for example, water containing salt.
In order to prevent the rope from being corroded, the ropes mentioned hereinafter are proposed.
(a) A steel wire plated with zinc is drawn to obtain a wire for a rope. A plurality of the wires are stranded with each other and plated with tin to obtain a wire rope (Japanese Examined Utility Model Publication No. 25500/1979).
(b) A steel wire plated with nickel or nickel alloy is plated with zinc or zinc alloy and is plated with tin or tin alloy on the zinc or the zinc alloy layer. Thus, what is obtained is a steel wire which is drawn and plurality of the steel wires are twisted to obtain a rope (Japanese Examined Utility Model Publication No. 10332/1990).
(c) Steel wires plated with zinc-aluminum alloy are drawn and stranded with other to obtain an inner core for a control cable (Japanese Unexamined Patent Publication No. 212616/1990).
The above-mentioned ropes and the inner cable for a control cable have an anti-corrosion property which has been improved as compared with a normal rope plated with zinc. However, with respect to the wire rope described in (a), the wire must be plated before a step for drawing a wire rod and after the step for stranding the wire, and a step for stranding the wire should be required. For that reason, a number of producing steps becomes rather numerous so that the cost for producing the wire rope is high.
With respect to the rope described in (b), three kinds of plating steps are required for producing the rope. Accordingly, producing steps increase remarkably.
With respect to the inner cable for the control of the wires is plated cable described in (c), each of the wires is plated with zinc-aluminum alloy. Accordingly, the cost for producing the inner cable is high.
On the other hand, for the purpose of improving the durability on bending fatigue of the rope, generally a diameter of the wire is made small in order to decrease the bending stress. Thereof, a tension strength is lowered due to the reduced diameter of a wire. In order to decrease the tension stress, the number of the wire is increased.
As the rope wherein means for improving the durability on bending fatigue is employed, the rope wherein a plurality of side strands are arranged around a core strand having a diameter larger than that of the side strand in such a state that the side strands are closed together is known as disclosed in Japanese Unexamined Utility Model Publication No. 64796/1987.
Further, the conventional rope has been closed in such manner that a tightening percentage is approximately in the range of 0 to 2% in order to prevent the wire from damaging when the strand is twisted. Researching the tightening percentage of available ropes for operating, the result was found that each tightening percentage of the ropes was in the range of 0 to 2%. In other words each tightening percentage was rather small.
Besides, the tightening percentage used in the specification for instance, with respect to the rope having 19+8×7 construction shown in FIG. 7 is obtained as follows: ##EQU1## where the calculated diameter is a sum of outer diameter of each wire and the measured diameter is a value which is obtained by measuring the diameter of a circumscribed circle of the rope.
Furthermore, it has been said that durability on fatigue property is improved when preforming is performed to the side strand so that a preforming percentage which is obtained by dividing the measured diameter into a wave diameter when the rope is loosed can be approximately in a range of 95 to 100% (page 185 of "a hand book of a wire rope" (Oct. 15, 1967) edited by the committee for editing a handbook of a wire rope published by Hakua Shobo).
As mentioned above, the rode having a stranded construction of, such as, the conventional rope wherein a plurality of strands are stranded is generally closed so that the tightening percentage is in a range of 0 to 2% and the preforming percentage is in a range of 95 to 100%.
Besides, the tightening percentage can be obtained by following former (1) with respect to the rope having 19+8×7 construction as shown in FIG. 7. ##EQU2## a: outer diameter of the core wire 43 of the core strand, b 1 : outer diameter of the first side wire 44 of the core strand,
b 2 : outer diameter of the second side wire 45 of the core strand,
c: outer diameter of the core wire 47 of side strand,
d: outer diameter of the side wire 48 of side strand,
D: measured outer diameter of rope 41.
Further, with respect to the wire having W(19)+8×7 construction wherein the core strand is stranded so as to have a Warrington type parallel lay strand as shown in FIG. 8, the tightening percentage is obtained by following formula (2) ##EQU3## where a: outer diameter of the core wire 53 of the core strand,
b 1 : outer diameter of the first side wire 54 of core strand,
b 2 : outer diameter of the second side wire 56 of core strand,
c: outer diameter of the core wire 58 of the side strand,
d: outer diameter of the side wire 59 of the side strands, and
D: measured outer diameter of the rope 51.
On the other hand, the tightening percentage of a rope having 7×7 construction as shown in FIG. 9 can be obtained by following formula. ##EQU4## where a: outer diameter of the core wire 73 of the core strand,
b: outer diameter of the side wired 64 of the core strand,
c: outer diameter of the core wire 66 of the side strand,
d: outer diameter of the side wire 67 of the side strand, and
D: measured outer diameter of the rope 61.
Next, the preforming percentage φ is obtained by following formula (4). ##EQU5## where D: measured outer diameter of a rope as shown in FIG. 16 (A), and
T: wave diameter when the wire is loosed as shown is FIG. 16 (B).
However, in the conventional rope, the tightening percentage is small and the preforming percentage large; that is, in this rope each strand is not stranded so tightly and the rope which is not closed so tightly is subject to deformation in the radial direction of the rope when the rope is used in such a portion that the rope is bent while the rope is slid, for instance in a guide which cannot rotate. Accordingly, there is such a problem that the durability on bending fatigue is low, since the wire is subjected to secondary bending i.e. the wire is subjected to local bending due to an external pressure whereby the wire is pressed against the layer of the wires located innerly.
The object of the present invention is to provide a rope having the same corrosion resistance as that of the conventional wire rope wherein wire employs a steel wire by virtue of using a steel superior corrosion resistant wire for the the specific wire, the corrosion resistance of which is superior, and a rope wherein the endurance property for bending is superior and a cost for producing the wire is lowered. Further, another object of the present invention is to provide a rope wherein the endurance property for bending fatigue when the wire is subjected to bonding in sliding movement is remarkably improved, by virtue of specifying the the tightening percentage and the preforming percentage.
SUMMARY OF THE INVENTION
A first aspect of the present invention is a rope for operating comprising: a plurality of wires made of a steel wire being twisted together; at least the wires which are arranged in such a manner as to be disposed on an outer surface of the rope being made of a steel wire wherein a corrosion resistance is superior; at least the wire which is located in a center of the rode not being made of the wire wherein the corrosion resistance is superior.
For instance, when the rope for operating is a spiral rode composed of a single layer or a plurality of layers and each layer is composed of a plurality of wires and the wires are twisted each other, an outermost layer is composed of the wires made of a steel wire wherein the corrosion resistance is superior, or when the rode for operating is a stranded wire wherein a plurality of strands composed of a plurality of wires and the wires are stranded and the strands are closed each other, side strands are composed of the steel wire wherein a corrosion resistance is superior.
Besides, as the steel wire wherein the corrosion resistance is superior, such a wire that the wires arranged in the outermost layer are plated with zinc-aluminum alloy and another wires may be plated with zinc.
As the rope for operating having the stranded construction, the rope having 7×7 construction wherein a tightening percentage is in the range of 2.5 to 8%, or the rope having 19+8×7 construction or (parallel lay strand)+8×7 construction wherein the tightening percentage is in the range of 4 to 11% and the preforming percentage is in the range of 65 to 90% as mentioned hereinafter.
A second aspect of the present invention is a rope for operating composed of a plurality of strands, each of which are composed of a plurality of stranded wires. The rope is characterized in that the tightening percentage is in the range of 4 to 11% and the preforming percentage is in the range of 65 to 90%.
In the first aspect of the rope of the present invention, steel wires wherein a corrosion resistance is superior are arranged in the outermost layer of the rope. As the above-mentioned wire, the wire which in disposed on the surface thereof is provided with a layer of the steel wire plated with zinc-aluminum alloy. With respect to the layer the zinc-aluminum alloy, the corrosion resistance is far better than that of the conventional layer composed of the steel wire plated with zinc. For This reason, the wire of the present invention can be sufficiently used for a long interval.
However, the cost for plating the wire with the alloy having the corrosion resistance which is superior, such as zinc-aluminum alloy, is high, comparing with the conventional zinc plating. Accordingly, if all wires composing of a rope are plated with the alloy having the corrosion resistance which is superior, the rope is very expensive. If in all the wires of the rope, such a steel wire wherein the corrosion resistance is superior while an endurance property for bending is inferior is employed, the rope is not preferable to the use which is easily subjected to bending.
When the outermost layer is composed of the steel wires plated with the alloy having superior corrosion resistance as the rope of the present invention, the same corrosion resistance property as that of the rope wherein all the wires are plated with the alloy having superior corrosion resistance can be obtained. The cost for producing the rope of the present invention is far smaller than that of the conventional rope. Further, the steel wires wherein the corrosion resistance is superior while the endurance property for bending is inferior are employed only in the outermost layer of the wire wherein the corrosion resistance is inferior while the endurance property for bending is superior is employed in the other layers. Thereby, the rope wherein the corrosion resistance and the endurance property for bending are superior can be produced.
The above-mentioned aluminum is a component which contributes to the superior corrosion resistance in a metal plating layer. If desired, a bit of silicon, magnesium, sodium, Mischmetal or the like may be added.
When weight percentage of the aluminum in the metal plating layer exceeds 10% by weight, the corrosion resistance is lowered. On the contrary, even in the case that the weight percentage is less than is 1%, the corrosion resistance is reduced.
For this reason, the weight percentage of the aluminum is preferably in the range of 1 to 10% by weight, and more preferably in the range of 4 to 5% by weight.
Composition of the metal plating layer is substantially the same as that of plating bath to be used. Accordingly, the composition of the metal plating layer can be adjusted by adjusting the composition of the plating bath.
A deposit weight of the metal plate is preferably more than 15 g/m 2 in order to obtain a rope maintains the corrosion resistance in the state wherein the rope is completed.
When the rope is obtained by stranding the wires which are obtained by drawing the plated wire, the deposit weight on the surface of the wire rod should be more than 100 g/m 2 in order to maintain the above-mentioned deposit weight of 15 g/m 2 in the state wherein the rope is completed. Further, the deposit weight is preferably less than 400 g/m 2 in order that the plated thick wire (or wire rod) can be suitably drawn.
In the present invention, a way wherein, the wire of the rope is plated with zinc-aluminum alloy is not limited to the specific way. However, for instance, there is a way wherein the steel wire is dipped (or immersed) in the plating bath which is mixed with melted aluminum, and the steel wire is drawn. Besides, the above-mentioned plating bath is used when the steel wire is normally plated with zinc by means of hot dipping.
In the above manner, when a content of aluminum in the plating bath is 5% by weight, eutectic point is obtained and homogeneous eutectic structure can be obtained.
The wires plated with zinc-aluminum alloy are in the specific location stranded each other as mentioned hereinafter so that the rope can be produced. Thus produced rope has superior corrosion resistance.
Accordingly, the rope can be used for a long interval.
Besides, as an embodiment of the steel wire having superior corrosion resistance, the steel plated with zinc-aluminum alloy is explained as mentioned hereinbefore. However, the steel wire is not limited to the steel wire plated with zinc-aluminum alloy. For instance, the steel plated with zinc-nickel alloy or stainless steel wire and the like can be employed.
In the second aspect of the rope of the present invention, the rope is more firmly closed than the conventional rope since the tightening percentage of the rope in accordance with the present invention is large. Accordingly, deformation in the radial direction can be prevented from generating so that secondary bending in the wire is not easily generated. Further, since the preforming percentage is small, the side strands of the rope which are closed is subjected to the force directed toward a center of the rope. Accordingly, the deformation in the radial direction can be prevented from generating and the secondary bending of the wire is not easy to be generated.
Accordingly, the rope of the present invention, durability on bending in sliding movement is improved.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an embodiment of a rope of a first aspect in accordance with the present invention;
FIG. 2 is a cross-sectional view of another embodiment of the rope of the first aspect in accordance with the present invention;
FIG. 3 is a cross-sectional view of yet another embodiment of the rope of the first aspect in accordance with the present invention;
FIG. 4 is a cross-sectional view of yet another embodiment of the rope of the first aspect in accordance with the present invention;
FIG. 5 is a cross-sectional view of yet another embodiment of the rope of the first aspect in accordance with the present invention;
FIG. 6 is a cross-sectional view of yet another embodiment of the rope of the first aspect in accordance with the present invention;
FIG. 7 is an explanatory drawing illustrating a tightening percentage of the rope and a sectional view of an embodiment of the rope of the second aspect in accordance with the present invention;
FIG. 8 is an explanatory drawing illustrating the tightening percentage of the rope and a sectional view of another embodiment of the rope of the second aspect in accordance with the present invention;
FIG. 9 is an explanatory drawing illustrating the tightening percentage of the rope and a sectional view of yet another embodiment, of the rope of the second aspect in accordance with the present invention;
FIG. 10 is an explanatory drawing of an apparatus for measuring a durability on bending fatigue of the top in which rollers are used;
FIGS. 11(A) and 11(B) are explanatory drawings of the roller
FIG. 12 is an explanatory drawings of the roller used in the apparatus of FIG. 10;
FIG. 13 is an explanatory drawing of an apparatus for measuring a durability on bending fatigue of the rope by using fixed guides when the rope is subjected to bending in a state of sliding motion;
FIGS. 14(A) and 14(B) are explanatory drawing of the fixed and guides which are used in the apparatus of FIG. 13;
FIG. 15 is an explanatory drawing of the fixed guides which are used in the apparatus of FIG. 14; and
FIGS. 16(A) and 16(B) are explanatory drawings illustrating a preforming percentage of the rope.
DETAILED DESCRIPTION
In the present invention, a rope having for instance a shape in section shown in FIGS. 1 to 9. The present invention is not limited to the above shapes.
In FIG. 1 to 6, wires shown in double circle are steel wires having superior corrosion resistance.
A rope 1 in FIG. 1 is an example of a spiral rope having a single layer or several layers, and each of which is composed of a plurality of the wires. The rope 1 is obtained by twisting the wires each other. The spiral rope is formed by twisting six wires 3 defining a first layer arranged around a core wire 2, and twisting twelve wires 4 defining a second layer arranged around the first layer. The superior corrosion resistance steel wires are used for the wires 4 of the second layer.
A rope 5 shown in FIG. 2 is the same that of FIG. 1 except that the superior corrosion resistant steel wires are used for not only wires 7 of the second layer but also the wires 6 of the first layer.
A rope shown in FIG. 3 has so-called a 7×7 construction. That is, a core strand 9 is defined by stranding six side wires 11 arranged around a core wire 10, a side strand 12 is defined by stranding six side wires 14 arranged around a core wire 13, and a stranded rope is obtained by closing the six side strands 12 arranged around the core strand 9. Besides, the superior corrosion resistant steel wires are used for the side wire 14 of the side strand 12.
A rope 15 shown in FIG. 4 is the same as that of FIG. 3 except that the superior corrosion resistant steel wire is used for the core wire 17 of the side strands 16.
A rope shown in FIG. 5 has a so-called 19+8×7 construction. That is, a core strand 20 is defined by stranding six first side wires 22 arranged around a single core wire 21 and stranding twelve second side wires arranged around the six side wires, and a side strand 24 is defined by stranding six side wires 26 arranged around a single core wire 25. The rope 19 having a stranded construction is obtained by closing eight pieces of the side strands 24 arranged around the core strand 20. Besides, the arranged around the resistance steel wire is used for the core wire 25 and the side wires 26 of the side strands 24.
The rope shown in FIG. 6 has the 19+8×7 construction. However, wires are stranded in the core strand 28, such that the core strand 28 has a parallel lay construction. In other word, the core strand 28 is stranded in such a way that each wire of the core strand is linearly contacted with the other. The parallel lay strand is a type of stranding wires having different outside diameter in the strand. In accordance with the parallel lay strand, each layer of the rope 27 has the same pitch for stranding and the same direction of stranding. When the wires are stranded in the above way, each wire of the second layer (the outer layer) is engaged into a groove defined by the adjoining wires of the first layer (inner layer), one wire being in substantially linear contact with the other wire without crossing each other. As a result, the strand is firmly stranded and the deformation in the radial direction does not happen easily. An internal abrasion in the strand due to a friction between the wires is low and a fatigue due to a secondary bending of wires is not generated. Then, the rode shown in FIG. 6 has superior properties.
The rode 27 shown in FIG. 6 has (parallel lay strand)+8×7 construction. As the parallel lay strand, a core strand 28 having a Warrington type strand construction is used. In other words, the rode 27 has a W(19)+8×7 construction. With respect to the warrington strand, a difference between the maximum diameter and the minimum diameter in the wires of the core strand is the smallest in the strands having parallel lay strand construction composed of 19 pieces of the wires. For that reason. the rode 27 is suitable for the strand having small diameter.
More particularly, 6 pieces of first side wires 30 defining a first layer are arranged around a core wire 29 and a diameter of the first side wire 30 is somewhat smaller than that of the core wire 29. Each of 6 pieces of third side wires 31 having the same diameter as that of the core wire is arranged in the groove defined by the adjoining first side wires 30 and each of six pieces of second side wires 32 is arranged around the first layer in such a way as to be along with the first side wire 30. A diameter of the second side wire 32 is still smaller than that of the first side wire. Further, the above-mentioned side wires are stranded at the same time in such a way that each layer has the same Ditch and in the same direction. Thus, the core strand 28 is formed. Besides, diameter of each wire of the core strand is not limitted to the diameter mentioned hereinbefore. In short, diameter of each wire of the core strand is suitably selected so that each wire can be linearly contacted each other when each wire is stranded in the same pitch and in the same direction.
Further, 8 pieces of side strands 33 are obtained by stranding 6 pieces of side wires 35 around a core wire 34. The superior corrosion resistant steel wire is used for the core wire 34 and the side wire 35 of the side strands 33.
Next the rope of the present invention is explained more particularly on the basis of the concrete example. Besides, in the following example 1 and comparative examples 1 to 3, the above-mentioned rope having strand construction of 7×7 construction is used.
EXAMPLE 1
A wire rod having an outer diameter of 1.05 mm as a wire for a core strand was obtained by immersing a steel wire (material: JIS G 3506, SWRH 62A) into a plating bath composed of zinc being in the condition wherein temperature is in the range of 430° to 480° C. The deposit weight in the specific area was 150 g/m 2 .
Further, as the wire for the side strand the. wire rod was obtained by the same way as that of the above-mentioned wire for the core strand except that the plating both composed of 4% by weight of aluminum and 96% by weight of zinc was used.
Next, the wire rods were drawn so that the core wire 10 for the core strand having an outer diameter of 0.185 mm, the side wire 11 for the core strand having an outer diameter of 0.185 mm, the core wire 17 for the side strand having an outer diameter of 0.185 mm, and the side wire 18 for the side strand having an outer diameter of 0.175 mm were produced. Besides, the deposit weight was 30 g/m 2 after the wire rod were drawn. Then, the strands were closed in such a manner as shown in FIG. 4 wherein the rope has a 7×7 construction, and the rope of example 1 having outer diameter of 1.5 mm was produced.
Comparative Example 1
The wire rods were produced in the same way as example 1 except that zinc-aluminum plating bath used in the example 1 was used for the wires for the core strand and the side strands. Further, the wire rods were drawn and stranded each other so that the rope having the 7×7 construction as a comparative example 1.
Comparative Example 2
The wire rods were produced by the same way as example 1 except that the conventional zinc plating bath was used for the wires for the core strand and the side strands. Further, the wire rods were drawn and stranded each other so that the rope having the 7×7 construction as a comparative example 2.
Besides, the plating weight was 30 g/m 2 after the wire rods were drawn.
Comparative Example 3
The wire rope disclosed in Japanese Examinee Utility Model Publication No. 25500/1979 wherein outer diameter in 1.5 mm and the wire rope has the 7×7 construction was bought as comparative example 3. The wire rope has zinc plating layer and tin layer.
The weight of the plating composed of the zinc plating layer and the tin plating layer was 30 g/m 2 (total weight of both layers). In the produced ropes of example 1 and comparative examples 1 to 3, the time to generate rust was confirmed by "salt spray test" (JIS Z 2371).
The result was shown in Table 1.
TABLE 1__________________________________________________________________________ Example 1 Com. Ex. 1 Com. Ex. 2 Com Ex. 3__________________________________________________________________________Core strandsurface treatment xinc plating zinc-aluminum zinc plating zinc plating alloy platingplating weight (g/m.sup.2) 30 30 30 15Side strandsurface treatment zinc-aluminum zinc-aluminum zinc plating zinc plating/ alloy plating alloy plating tin platingplating weight (g/m.sup.2) 30 30 30 30 (total)Time when red rust 150 hours 150 hours 40 hours 100 hoursoccurs*__________________________________________________________________________ *In accordance with "salt spray test (JIS Z 2371)
As shown in Table 1, the rope of example 1 wherein each wire of the core strand is plated with zinc and each wire of the side strand is plated with zinc-aluminum alloy has improved the corrosion resistance remarkably as compare with the rope of comparative example 2 wherein all the wires are plated with zinc or the rope of comparative example 3 having zinc plating layer and tin plating layer.
On the other hand, comparing with the rope of comparative example 1, the result was that the rope of example 1 has the same corrosion resistance as that of comparative example 1.
As mentioned hereinbefore, superior corrosion resistant steel wire is used for only the wires defining the outermost layer. Then, the cost for producing the rope is low as compared to the rope wherein the superior corrosion resistant steel wire is used for all the wires. Further, the rope can have the same corrosion resistance as that of the rope wherein the superior corrosion resistant steel wires is used for all the wires.
With respect to such a rope having a stranded construction, when the rope has for instance the 7×7 construction, the rope is firmly closed as compare with the conventional rope having 7×7 construction (tightening percentage is in the range of 0 to 2%) if the rope having 7×7 construction is closed with tightening percentage being in the range of 2.5 to 8%. A portion of the rope wherein the rope is bent with sliding motion, such as a fixed guide is not subjected to secondary bending, and endurance property is not reduced.
Especially, with respect to the rope having the 19+8×7 construction or (parallel lay strand)+8×7 construction, the rope has advantages as mentioned hereinbefore as compare with the conventional rope having the 19+8×7 construction (the tightening percentage is in the range of 0 to 2% and the preforming percentage is in the range of 95 to 100%) when the tightening percentage of the rope having the 19+8×7 construction or (parallel lay strand)+8×7 construction is in the range of 4 to 11% and the percentage is in the range 65 to 90% as mentioned hereinafter.
Next, a second aspect of the rope of the present invention wherein the rope has the stranded construction and the rope is closed with a specific tightening percentage and a specific preforming percentage is explained with reference to FIGS. 7 to 9. However, present invention is not limited to the ropes having such shapes shown in FIGS. 7 to 9. Further, the rope is not limited to either the rope using a superior corrosion resistant steel wire or the rope without using a superior corrosion resistant rope.
A rope shown in FIG. 7 has a so-called 19+8×7 construction which is the same as that of the rope shown in FIG. 5. That is, a core strand 42 is defined by stranding six first side wires 44 defining a first layer arranged around a single core wire 43 and stranding twelve second side wires 45 defining a second layer arranged around the first layer, and a side strand 46 is defined by stranding six side wires 48 arranged around a single core wire 47. The rope 41 having a stranded construction is obtained by dosing eight pieces of the side strands 46 arranged around the core strand 42.
Further, the tightening percentage of the rope 41 is in the range of 4 to 11% and the preforming percentage of the rope 41 is in the range of 65 to 90%.
The reason why the tightening percentage is in the range of 4 to 11% is that there is a problem in that it is difficult to close the rope when the tightening percentage is more than 11%, a breakage tends to happen or surface of the wire is sometimes damaged due to excessive closing when the rope is produced, while if the tightening percentage is less than 4%, the endurance property is insufficient when the rode is subjected to bending with sliding motion as clear from the example mentioned hereinafter.
On the other hand, the reason why the preforming percentage is in the range of 65 to 90% is that if the preforming percentage is more than 90%, a closing force in the direction of a center of the rope is not sufficiently applied to the side strand when the rope is used for the portion wherein the rope is bended with sliding such as a fixed guide so that the secondary bending of a wire tends to happen in the wire. Accordingly, the endurance property is lowered as clearly explained in the example and the comparative example mentioned hereinafter.
On the contrary, with respect to the rope wherein the preforming percentage is not more than 65%, the side strand becomes loose when the rope is cut. For that reason, the rope cannot be used.
Next, a rope 51 shown in FIG. 8 is another example of the rope of the present invention which has the same Warrington type strand as that of the rope 27 (referring to FIG. 6) of the above-mentioned example.
That is, 6 pieces of first side wires 54 defining a first layer are arranged around a core wire 53 and a diameter of the first side wire 54 is somewhat smaller than that of the core wire 53. Each of 6 pieces of the third side wires 55 having the same diameter as that of the core wire 53 is arranged in the groove defined by the adjoining first side wires 54 and each of six pieces of second side wires 56 is arranged around the first layer in such a way as to be along with the first side wire 54. A diameter of the second side wire 56 is still smaller than that of the first side wire 54. Further, the above-mentioned side wires 54, 55, 56 are stranded at the same time in such a way as to be in the same pitch and in the same direction around the core wire 53. Thus, the core strand 52 is formed. Besides, diameter of each wire is not limited to the diameter mentioned hereinbefore. In short, diameter of each wire is suitably selected so that each wire can be linearly contacted each other when each wire is stranded in the same pitch and in the same direction.
Further, 8 pieces of side strands 57 are obtained by stranding 6 pieces of side wires 59 around a core wire 58.
Besides, in the rope 51, the tightening percentage is in the range of 4 to 11% and the preforming percentage is in the range of 65 to 90%.
Further, yet another example of the rope of the present invention is shown in FIG. 9. In a rope 61, the tightening percentage is in the range of 4 to 11% and the preforming percentage is in the range of 65 to 90%. The rope 61 has the same 7×7 construction as that of the rope 8, 15 shown in FIGS. 3 and 4.
That is, a core strand 62 is defined by stranding six side wires 64 arranged around a core wire 63, a side strand 65 is defined by stranding six side wires 67 arranged around a core wire 66, and a stranded rope is obtained by closing the six side strands 65 arranged around the core strand 62.
Next, the rope of the present invention is explained more particularly on the basis of examples.
EXAMPLE 2
(referring to FIG. 7)
The wire rod having an outer diameter of 0.93 mm was obtained by plating the steel wire (material: JIS G 3506 SWRH 2A) with zinc.
Next, the wire rod was drawn so that the core wire 43 of the core strand having an outer diameter of 0.170 mm, the first side wire 44 of the core strand having an outer diameter of 0.150 mm, the second side wire 45 of the core strand having an outer diameter of 0.150 mm, the core wire 47 of the side strand having an outer diameter of 0.150 mm, and the side wire 48 of the side strand having an outer diameter of 0.140 mm were produced.
The wires were stranded in the direction shown in Table 2, then the rope having the 19+8×7 construction was obtained. Besides, the measured outer diameter D of the wire was 1.550 mm as shown in example 2.
The calculated outer diameter of the rope was 1.630 min. Accordingly, the tightening percentage of the rope was 4.91%, and the wave diameter of the side strand was measured after loosing the rope so that the diameter was 1.25 mm, then the preforming percentage was 80.6%.
Besides, the rope having the above-mentioned tightening percentage and preforming percentage can not be obtained without adjusting a pressure, tension, and a degree of preforming which are applied to the rope in the producing step.
EXAMPLE 3
The rope of the example 3 was obtained by the same way as that of the example 2 except for the measured outer diameter and the tightening percentage of the rope, and the wave diameter and the preforming percentage of the strand as shown in Table 2.
EXAMPLE 4
The rope of the example 4 was obtained by the same way as that of the example 2 except for the measured outer diameter and the tightening percentage of the rope, and the wave diameter and the preforming percentage of the strand as shown in Table 2.
EXAMPLE 5
The rope of the example 4 was obtained by the same way as that of the example 2 except for the measured outer diameter and the tightening percentage of the rope, and the wave diameter and the preforming percentage of the strand as shown in Table 2.
EXAMPLE 6
The rope of the example 6 was obtained by the same way as that of the example 2 except that as the wire rod of the wire of the side strand, the wire having an outer diameter of 0.93 mm wherein the steel wire (material: JIS G 3506 SWRH 62A) was plated with zinc-aluminum alloy.
Besides, the zinc-aluminum plating was performed by hot dipping into the zinc plating bath containing 4% by weight of aluminum.
EXAMPLE 7
(referring to FIG. 8)
The wire rod having an outer diameter of 0.93 mm was obtained by plating the steel wire (material: JIS G 3506 SWRH 62A) with zinc.
Next, the wire rod was drawn so that the core wire 53 of the core strand having an outer diameter of 0.170 mm, the first side wire 54 of the core strand having outer diameter of 0.160 mm, the third side wire 55 of the core strand having an outer diameter of 0.170 mm, and the second side wire 56 of the core strand having an outer diameter of 0.130 mm, each of which is the wire defining the core strand 52, were produced.
The wire rod having an outer diameter of 0.93 mm was obtained by plating the steel wire (material: JIS G 3506 SWRH 62A) with zinc-aluminum alloy. Further, the wire rod was drawn so that the core wire 58 of the side strand having an outer diameter of 0.150 mm, the side wire 59 of the side strand having an outer diameter of 0.140 mm, each of which is the wire defining the side strand 57, were produced.
The above-mentioned wires were stranded in the direction as shown in Table 2 and the core strand 52 was formed to be a Warrington type strand, then the core strand 52 and the side strands 57 were dosed so that the rope 51 of the example 7 having W(19)+8×7 construction and having the measured diameter D of 1,500 mm was obtained.
Comparative Example 4
The rope of comparative example 4 was obtained by the same way as that of the example 2 except for the measured outer diameter and the tightening percentage of the rope, and the wave diameter and the preforming percentage of the side strand as shown in Table 2.
Comparative Example 5
The rope of the comparative example 5 was obtained by the same way as that of the example 2 except for the wave diameter and the preforming percentage of the side strand as shown in Table 2.
Comparative Example 6
The rope of the comparative example 6 was obtained by the same way as that of the example 6 except for the wave diameter and the preforming percentage of the side strand as shown in Table 2.
Besides, the tightening percentage (%) of each rope of the examples 2 to 6 and the comparative examples 4 to 6 were obtained by the formula (1), and the percentage (%) of the rope of the example 7 was obtained by the formula (2).
Further, the preforming percentage (%) of the examples 2 to 7 and the comparative examples 4 to 6 were obtained by the formula (3).
TABLE 2__________________________________________________________________________ Com. Com. Com. Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 Ex. 4 Ex. 5 Ex. 6__________________________________________________________________________Core strandouter diameter (a) of 0.170 0.170 0.170 0.170 0.170 0.170 0.170 0.170 0.170the core wire (mm)outer diameter (b.sub.1) 0.150 0.150 0.150 0.150 0.150 0.160 0.150 0.150 0.150of the first sidewire (mm)stranding direction .sup. Z*.sup.1 Z Z Z Z Z Z Z Zouter diameter (b.sub.2) 0.150 0.150 0.150 0.150 0.150 0.130 0.150 0.150 0.150of the second sidewire (mm)outer diameter (b.sub.3) -- -- -- -- -- 0.170 -- -- --of the third sidewire (mm)stranding direction Z Z Z Z Z Z Z Z Zplating zinc zinc zinc zinc zinc zinc zinc zinc zincSide strandouter diameter (c) of 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150 0.150the core wire (mm)outer diameter (d) of 0.140 0.140 0.140 0.140 0.140 0.140 0.140 0.140 0.140stranding direction .sup. S*.sup.2 S S S S S S S Splating zinc zinc zinc zinc zinc- zinc- zinc zinc zinc- aluminum aluminim aluminumRopeCalculated outer 1.630 1.630 1.630 1.630 1.630 1.620 1.630 1.630 1.630diameter (mm)2 + 2b.sub.1 + 2b.sub.2 + 2c + 4cmeasured outer 1.550 1.485 1.500 1.530 1.550 1.500 1.600 1.550 1.550diameter (mm)wave diameter of 1.25 1.26 1.08 1.10 1.25 1.10 1.30 1.48 1.48the side strand (mm)Closing direction Z Z Z Z Z Z Z Z Ztightening 4.91 8.90 7.98 6.13 4.91 7.41 1.84 4.91 4.91percentage (%)performing 80.6 84.8 72.0 71.9 80.6 73.3 81.3 95.5 95.5percentage (%)__________________________________________________________________________ *.sup.1 Z means a right hand lay *.sup.2 S means a left hand lay
Next, the bending fatigue test by using rollers and the bending fatigue rest by using a fixed guide were performed to the examples 2 to 7 and comparative examples 4 to 6 which were obtained as mentioned hereinbefore.
The bending fatigue tests, in which the test method uses a pair of rollers, are conducted in the manner as hereinafter described.
As shown in FIG. 10, the rope 41, 51 (hereinafter numeral 41 is represented for the rope) in which overall length was 1000 mm was provided with a weight 71 of 10 kg at one end. Then, the rope 41 was arranged so as to be turned by 90 degree by a roller 72b, then turned by 180 degree by another roller 72a. Further, the other end of the rope 41 was connected with a piston rod of an air cylinder 73.
When the air cylinder 73 reciprocates in the direction of arrow E and arrow F, the roller 72a rotates in the direction of arrow G and arrow H and the roller 72b rotates in the direction of arrow J and arrow K. Besides, the air cylinder 73 moves in the direction of arrow E firstly, then the weight 71 is lifted upwardly and abuts against a stopper 74 thereby, the air cylinder generates a stall force of 35 kgf for 0.5 sec. Thereafter the air cylinder moves in the direction F. Besides, the stroke of the rope was 100 mm and period was 20 strokes/min. Further, a sufficient amount of an olefinic grease is applied to the roller 72a, 72b in the portion wherein the rope 41 is contacted with.
FIG. 11 represents an elevation (FIG. 11(A)) and a side elevation (FIG. 11(B)) of the roller 72a, 72b. A grooved-track diameter L of the roller 72a, 72b is 30 mm and material thereof is nylon 6.
FIG. 12 is a partially enlarged sectional representation.
An inner radius R1 of the grooved track is 1.0 mm, and a angle θ formed with internal side surface of the groove each other is 30 degree. The rope 41 for the test was reciprocated for 20,000 cycles.
(test method using a fixed guide)
As shown in FIG. 13, the rope 41 in which overall length was 1000 mm was provided with a weight 75 of 10 kg at one end. Then, the rope 41 was arranged so as to be turned by 90 degree by a fixed guide 76b, then turned by 180 degree by another fixed guide 76a. Further, the other end of the rope 41 was connected with a piston rod of an air cylinder 77.
When the air cylinder 77 reciprocates in the direction of arrow M and arrow N, the rope 41 is slided on the fixed guide in the direction of arrow P and arrow Q. Besides, the air cylinder 77 moves in the direction of arrow M firstly, then the weight 75 is lifted upwardly and hits a stopper 78. Thereby, the air cylinder generates a stall force of 35 kgf for 0.5 sec. Thereafter the air cylinder 77 moves in the direction N. Besides, the stroking length of the rope was 100 mm and the reversal speed was 20 cycles per minute. Further, a sufficient amount of a defining grease was applied to in the fixed guide 76a, 76b the portion wherein the rope 41 is contacted with.
FIG. 14 represents an elevation (FIG. 14 (A) ) and a side elevation (FIG. 14 (B)) of the fixed guide 76a, 76b. A core diameter S of the fixed guide 76a, 76b is 30 mm and material thereof is nylon 6.
FIG. 15 is a partially enlarged sectional representation. An inner radius R2 of the grooved track is 1.0 mm, and a gash angle γ is 30 degree. The rope 41 for the test was reciprocated for 20000 cycles. Further, the test to confirm the breakage of the wire, was continued until the rope 41 was broke, then the number of the cycles at the break was recorded.
The results of the bending fatigue test in examples 2 to 7 and comparative examples 4 to 6 are shown in Table 3.
TABLE 3______________________________________bending fatigue test bending fatigue test by aby a pare of rollers fixed guide number number number ofnumber of number of cycles whenof broken of broken the rope wascycles wires cycles wires broken______________________________________Ex. 2 20000 0 20000 0 72000Ex. 3 20000 0 20000 0 69000Ex. 4 20000 0 20000 0 132000Ex. 5 20000 0 20000 0 127000Ex. 6 20000 0 20000 0 70000Ex. 7 20000 0 20000 0 186000Com. 20000 0 20000 63 25000Ex. 4Com. 20000 0 20000 18 31000Ex. 5Com. 20000 0 20000 17 31000Ex. 6______________________________________
According to the test results shown in Table 3, breakage was not found in the examples 2 to 7 and the comparative examples 4 to 6 on the bending fatigue test by a pair rollers at 20000 cycles. However, on the test by a fixed guide, 63 pieces of the wires were broken at 20000 cycles in the comparative example 4. In the comparative example 5, 18 pieces of the wires were broken and in the comparative example 6, 17 pieces of the wire were broken at 20000 cycles. On the contrary, any breakage of a wire was not found in the examples 2 to 7 after the bending fatigue test was repeated 20000 cycles.
Further, the bending fatigue test was repeated until the rope was broken so that the rope was broken at 25000 cycles in the comparative example 4 and the rope was broken at 31000 cycles in the comparative examples 5 and 6. On the contrary, it was found that the durability of the examples 2, 3, and 6 were more than two times as much as that of the comparative examples 4 to 6, the durability of the examples 4 and 5 were more than 4 times as much as that of the comparative examples 4 to 6, and the durability of the example 7 was more than 6 times as much as that of the comparative examples 4 to 6.
In the bending fatigue test using a pair of rollers, in other words, under the condition where the wire is subjected to only bending, there is not significant difference in the examples 2 to 7 and the comparative examples 4 to 6. However, there is a remarkable difference in the durability when the rope is bent while the rope is slid on the guide.
Accordingly, the rope wherein the rope is closed such that the tightening percentage is in the range of 4 to 11% and the preforming precentage is in terms of range of 65 to 90% is superior in the durability.
On the other hand, comparing the example 2 with the example 6, even if the wire of the side strand is plated with zinc-aluminum alloy instead of zinc, the durability was improved (i.e. there is no difference in the durability between the wires of the side strand applied to the normal zinc plating and superior corrosion resistant plating).
Besides, the examples 2 to 7 having 19+8×7 construction or W(19)+8×7 construction has the same characteristic. However, it is natural that the rope having, for instance, 7×7 construction using large-diameter-wire or 7×19 construction has the same effect.
The rope of the present invention, wherein the steel wire having superior corrosion resistance is used for the outermost wires can be endurable to corrosion for a long time even under the circumstance wherein salt water is added to the wire for instance.
Furthermore, the superior corrosion resistant steel wire should be used only for the outermost wire. For that reason, the cost for producing the wire is lower than that of the wire wherein the superior corrosion resistant steel is used for all the wires.
Further, even in the case that the superior corrosion resistant steel wires having an usual durability on bending are arranged in the outer layer of the rope, the rope having superior durability for bending superior and corrosion resistance can be obtained when the steel wires having superior durability for bending are arranged in the inner layer of the rope.
In the rope of the present invention wherein the tightening percentage is in the range of 4 to 11% and the preforming percentage is in the range of 65 to 90%, the fatigue durability on bending is not lowered even if the rope is used in the portion, such as a guide wherein the rope is bent with sliding thereon. Therefore, for instance, the rope is preferably used for the control cable for the window regulator of the automobile.
Though several embodiments of the present invention described above, it is to be understood that the present invention is not limited to the above-mentioned embodiments, and various changes and modifications may be made in the invention without departing from the spirit and scope thereof. | A rope comprising a plurality of wires (2, 3, 4) made of a steel wire being twisted together; at least the wires which are arranged in such a manner as to be disposed on an outer surface of the rope (1) being made of a plated steel wire wherein a corrosion resistance is superior; at least said wires which are located in a center of the rope not being made of the wire wherein the corrosion resistance is superior. | 3 |
BACKGROUND OF THE INVENTION
The invention concerns a tank filling nipple of the type connectable with a tank filling pipe with a closure flap arranged inside of the mounting nipple for movement between a closed position at which it engages a sealing seat and an open position at which it is lifted from the sealing seat and with a duct branching from the mounting nipple behind the sealing seat in the filling direction, in which duct an overfill valve operable by the adjustable closure flap is arranged, which overfill valve is closed upon opening of the closure flap, and also including an automatically opening overpressure valve.
In the construction of modern automobiles it is becoming more and more common to apply a filling nipple to the end of the tank filling pipe, which nipple unifies several different functions. Such tank filling nipples generally contain a self-closing closure, which for example may be formed as a closure flap movable in the interior of the tank filling nipple and biased in the direction toward a sealing seat, and which closure flap is movable by the dispensing nozzle to its open position.
A tank filling nipple of the type mentioned in the preamble of claim 1 is already known from DE 37 2-1 049 A1. This nipple is provided with a duct branching from the mounting nipple from behind the sealing seat in the filling direction, and in which duct is arranged an overfill valve operable by the movable closure flap. This overfill valve is open when the closure flap is closed so that in the case of warming the expanding fuel can overflow through this duct into a compensating container. This overfill valve is coupled with the closure flap so that it is closed when the closure flap is opened to avoid an overflow of the fuel into the compensating container. This solution is relatively expensive since in addition to the main tank a separate compensating container must be provided which moreover in a non-described way must be connectable with the main tank in order that the overflown fuel eventually can flow back into the main tank.
Moreover, the known tank filling nipple is provided with an underpressure valve which automatically opens upon an overpressure in the tank so that a pressure compensation can take place. This overpressure valve is arranged on the closure flap with these parts being of complicated construction, heavy and bulky, so that difficulties can arise in the application of the closure flap to the interior of the tank filling nipple, and also the support as well as the return spring for the closure flap must suit its construction weight and size. Also there exists the danger that the overpressure valve which connects with the upper side of the closure flap may be damaged by the insertion of the dispensing nozzle, which damage generally makes necessary a replacement of the entire tank filling nipple.
A further disadvantage of the known construction occurs in the following way: the overfill valve operated by the closure flap is necessarily arranged by the involved construction directly below the sealing seat of the closure flap so that the overflow level also is positioned directly below the closure flap which no longer meets the intended safety requirements. It is much more desired that the highest possible fill level in the normal position of the vehicle be positioned a given amount below the sealing seat.
To assure a trouble-free flow of the fuel from the tank during normal motor operation the tank must also be provided with a ventilating valve which moreover at a given predetermined inclined position of the vehicle, or upon a turning over of the same, must automatically close to, for example in the case of an accident, prevent dangerous discharge of the fuel. Such ventilating valves are generally provided by the tank manufacturer since previously no possibility appeared to apply these in the region of the closure flap similarly to the overpressure valve. Therefore, in the manufacture of vehicles it has generally been necessary to have two separate assembly processes for the ventilating valve on one hand and for the tank filling nipple on the other hand which with the large numbers and short assembly times of modern motor vehicles can amount to considerable assembly costs.
The object of the present invention is to provide a tank filling nipple of the type mentioned in the preamble of claim 1 which with regard to simple construction and reliable function fulfills all desired operating and safety requirements and which in comparison to the functioning of known devices can include additional functions so that some assembly processes in the construction of tanks can be spared.
SUMMARY OF THE INVENTION
This object is solved in that the branching off duct is connected with a dead space formed in the upper region of the fuel tank, the overpressure valve is associated with a second duct connected with the mounting nipple behind the sealing seat, and a ventilating valve is arranged in a third duct connected with the mounting nipple behind the sealing seat which ventilating valve is open in the normal position of the vehicle and which automatically closes at a given inclined position of the vehicle.
The first branching off duct is not connected with a compensating container but with a dead space formed in the upper region of the fuel tank. Since the overfill valve is closed during tanking there is formed, when the condition of fill reaches the lower edge of this dead space, an air or gas bubble. When the dispensing nozzle is withdrawn from the tank filling nipple and the closure flap closes the overfill valve automatically opens so that the gas captured in the dead space escapes and fuel can flow in the return direction whereby the fill condition in the tank filling pipe sinks to the pre-given amount below the sealing seat.
The overpressure valve is not arranged on the closure flap, but is associated with a second duct connected with the mounting nipple behind the sealing seat. Thereby on one hand the construction of the closure flap is considerably simplified, whereby especially the danger is avoided that the overpressure valve will be damaged by the dispensing nozzle upon the opening of the closure flap, and on the other hand the overpressure valve can be better designed for its purposes independently of the size of the closure flap, so that a further improvement in the functional reliability and precision is achieved.
Further, in a third duct connected with the mounting nipple behind the sealing seat is arranged a ventilating valve which in the normal position of the vehicle is open and which in a certain inclined position, or upon overturn, of the vehicle automatically closes. Therefore, since the normal ventilating function is also associated with the tank filling nipple the assembly of a separate ventilating valve is saved so that essentially all of the functions required by the fuel tank can be installed in a single mounting process, namely by the mounting onto the tank of the filling nipple of this invention.
The ventilating valve is designed for the normal operation of the motor, while the overpressure valve is provided for the case in which by certain circumstances an overpressure is formed in the tank which could lead to a bursting of the tank. Also to provide for the case in which a dangerous underpressure forms in the tank, in accordance with one embodiment of the invention an underpressure valve is arranged in a second duct which automatically opens upon the appearance of an underpressure in the fuel tank.
In accordance with a further embodiment of the invention it is provided that the second duct and the third duct branch from a common connecting manifold connecting with the mounting nipple behind the sealing seat. This measure makes it possible on one hand to achieve a compact construction and on the other hand allows a pre-assembly of the overpressure valve, the underpressure valve and the ventilating valve into a single unitary construction group which thereupon can be assembled with the tank filling nipple in a single work procedure.
Further advantages and features of the invention will be apparent from the claims, the drawings, and the description of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings several embodiments of the invention are illustrated which are hereinafter described in more detail. The drawings are:
FIG. 1 - A longitudinal section through a tank filling nipple with an internal closure flap, an overfill valve and further valves;
FIG. 2 - A partial section taken along the section line II--II of the tank filling nipple illustrated in FIG. 1;
FIG. 3 - A longitudinal sectional view through a tank filling nipple comprising another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The tank filling nipple 2 illustrated in FIG. 1 is attached to the end of a tank filling pipe 6 by means of a snap catch 4. Another type of fastening, for example one accomplished by means of welding, is possible, but has not been illustrated.
The tank filling nipple 2 consists essentially of a mounting nipple 8 into which different functional elements, described hereinafter in more detail, are integrated.
Inset in the mounting nipple 8 in the area of its outer mouth is a collar 10 which on one hand serves to guide the dispensing nozzle 12 and which on the other hand serves as a sealing seat for a closure flap 14 also arranged in the mounting nipple 8. As can be seen from FIG. 1 the collar 10 is so formed that the dispensing nozzle 12, when in an inserted condition can undertake a pivotal movement about a given angle to permit the insertion of the nozzle as well as a subsequent hooking of a holding protuberance on the dispensing nozzle behind an edge shoulder 18 formed at the mouth of the mounting nipple 8.
The closure flap 14 is pivotal about a pivot axis 20, positioned transversely to the longitudinal axis of the mounting nipple 8, between a closed position illustrated by heavy lines and an open position illustrated by light lines. In its closed position the closure flap 14 lies sealingly on the lower mouth edge of the collar 10. It is held in position on this lower mouth edge of the collar 10 by a tension spring 22 hooked on one side to an arm 24 formed on the closure flap 14 and hooked on the other side to a fastening hook 26 arranged in the mounting nipple 8. The tension spring 22, the lever length of the arm 24, and the like, are so designed that the closure flap 14 on one hand sealingly engages the sealing seat and on the other hand can be moved from its closed position to its open position by the dispensing nozzle 12.
A duct 31 formed by a tubular part 30 branches from the mounting nipple 8 behind the sealing seat 28 in the filling direction and has arranged in it a disc valve 32. The disc valve 32 is worked on by a compression spring 36 which biases the valve in the direction toward the valve seat 34. The tubular part 30, the disc valve 32 and the valve seat 34 form an overfill valve 38.
As can be seen from FIG. 1, the disc valve 32 has a valve stem 40 extending to the interior of the mounting nipple 8, which stem cooperates with the arm 24 associated with the closure flap 14. In the closed position of the closure flap 14, as shown by solid lines in FIG. 1, the valve stem 40 is laterally displaced so that the valve disc 32 is lifted from the valve seat 34 to open the valve. In the open position of the closure flap, as shown by light lines, the arm 24 is out of engagement with the valve stem 40 so that the valve seats on the valve seat 34 thereby closing the overfill valve 38.
The tubular part 30 forming the duct diverging from the mounting nipple 8 is, as not illustrated in more detail, connected by a conductor with the upper region of the dead space of the fuel tank, in which dead space during the filling of the fuel tank an air or gas bubble is formed, which bubble is captured in the dead space so long as the overfill valve 38 is closed during tanking. After the tanking process the dispensing nozzle is withdrawn from the mounting nipple 8, whereupon the closure flap 14 is closed under the influence of the spring 22 and the overfill valve 28 is opened by the arm 24, so that the gas bubble captured in the dead space can escape now and so that fuel can flow back; whereby the fuel sinks in the mounting nipple 8 or in the filling pipe 6 until reaching a full level which clearly lies below the sealing seat 28.
As can be seen from FIG. 1, further valve arrangements 42 and 44, which are described in more detail in connection with FIG. 2, are associated with the mounting nipple 8. These two valve arrangements 42 and 44 control ducts which likewise are connected, through a junction mouth 46, with the interior of the mounting nipple 8 behind the sealing seat 28 in the filling direction.
FIG. 2 shows the tank filling nipple 2 of FIG. 1 in a view taken in the direction of the arrow 48, with the area of the valve arrangements 42,44 being shown in a section taken on section line II--II. A connecting manifold 50 opens into the mounting nipple 8 through the mouth 46 and has a free end extending away from the mounting nipple 8 and closed by a plug. A duct 52 branches from the connecting manifold 50 and has arranged in it an overpressure valve 54 as well as an underpressure valve 56. The overpressure valve 54 and the underpressure valve 56 are combined into a single device. The overpressure valve 54 is formed essentially as a disc valve 58 which is held in position on a valve seat 62 by a spring 60. The spring 60 is so designed that the disc valve 58 is lifted upon a predetermined overpressure appearing in the tank to permit a pressure compensation. The underpressure valve 56 is likewise formed as a disc valve 64 which is held in position on a valve seat 68 by a spring 66, the valve seat 68 being formed by the edge of a concentric opening 70 formed in the first disc valve 58. The spring 66 is so designed that upon a fixed pre-given underpressure appearing in the tank the disc valve 64 is lifted and permits a pressure compensation to atmosphere.
A further duct 72 branches from the connecting manifold 50 and has arranged in it a ventilating valve indicated generally at 74. This valve includes a valve body 76 which cooperates with a concentric valve seat 78. In the normal case, that is in the normal position of the vehicle, the valve body 76 is removed from the valve seat 78 so that the tank is constantly ventilated through the connecting manifold 50. The valve body 76 is connected with a cage in which is freely movably received an operating mass 82 formed as a ball. The cage bottom has support ramps 84 extending upwardly and outwardly on which the ball 82 rests. Upon the vehicle reaching a given inclined position the ball 82 rolls along the support ramps and engages the upper side of the cage 80, whereupon the valve body 76 lies on the valve seat 78 and the valve becomes closed. Thus, upon the vehicle reaching a given inclined position or upon the vehicle turning over a discharge of fuel through the ventilating valve 74 is avoided. The ventilating valve 74 is connected by a non-illustrated conductor with an activated charcoal filter which captures the environmentally detrimental portions of the gas.
FIG. 3 shows an arrangement which in principle corresponds to the apparatus illustrated in FIGS. 1 and 2. The following description therefore is directed only to the several essential differences relative to the previously described embodiment.
The closure flap 114 is formed somewhat disc-like. It is pivotally supported in the interior of the mounting nipple 108 for movement about a pivot axis 120 positioned perpendicularly to the axis of the mounting nipple 108. A spring 122 arranged coaxially to the pivot axis 120 presses the closure flap 114 to its closed position, in which it engages a sealing seat 128. An extension arm 124 extending from the closure flap 114 is, in the way described in FIG. 1, cooperable with the valve stem 140 of the overfill valve 138, which overfill valve frees a fluid conductor or pipe 139 leading to a dead space of the tank in the case of a closed closure flap 114 and which overfill valve upon opening of the closure flap 114 shuts off the conductor as already described. A valve arrangement 144 forming a combined overpressure and underpressure valve as well as a ventilating arrangement 142, illustrated as a ventilating valve, are arranged in ducts 152 and 172 branching from a connecting manifold 150. The connecting manifold 150 is combined with the valve arrangements 142 and 144 into a pre-assembled unit which is placed into a carrier 109 formed of one piece with the mounting nipple 108. | A nipple is attachable to the outer end of the fill pipe of a motor fuel tank and contains a closure flap and a number of other valves performing various functions. The nipple therefore can have unified in it mechanisms performing most or all of the functions required in association with the tank and can be made as a pre-assembled unit quickly and easily attached to a fuel tank in the manufacture of a vehicle to minimize the number of required assembly procedures. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a highly concentrated mineralised natural complex and the method for its production, with respect to the integration of mineral oligoelements in pharmaceutical, cosmetic and herbal field, for human and animal usage, and for the care of the flora in general.
2. Description of Related Art
Currently, elements obtained by the purification of inorganic material, or, for example, through operations of synthesis, hemi-synthesis, chelation, complexation are being used as integrators of minerals oligoelements.
The so obtained inorganic formulations present considerable problems of absorption and side effects. The ingested substances are thereby absorbed in a very little amount, consequently inducing the user to ingest considerable quantities, so that the absorbed ones can quantitatively satisfy the individual need.
Another disadvantage of the products obtained with the known technique is the one due to the undesired side effects, for example, after the ingestion of substances used for integrating iron gastric disturbances may occur.
On the other hand, it is known that some organic substances, such as some vegetable and/or animal products, contain oligominerals that are effective for man's health and simultaneously do not have negative side effects. However, those elements useful for man's health are contained in the above mentioned organic substances in very small percentages, hence they have poor therapeutic qualities.
SUMMARY OF THE INVENTION
The aim of the present invention is on the one hand to produce mineralised natural complexes of one or more mineral elements at a high concentration, which together predispose the human organism to their high absorption without producing negative side effects, on the other hand, the aim is to determine a process through which the mentioned complexes are realised.
The process, related to this invention, which allows to reach such results, consists in resorting to natural substances, like vegetable and/or animal products, then, usually, in the carrying out of their mixing in definite proportions, therefore in their treatment until the inorganic part is separated from the organic one, and finally, in the transformation of the produced minerals blend into an easily administrated product, like capsules and tablets. For the consumer their intake is the equivalent to the intake of a quantity of minerals comparable in a qualitative and quantitative way to the ones that would be taken, in favourable cases, with the ingestion of an initial high quantity of vegetable or animal material. Moreover, the elaboration of organic natural products, among those containing an oligomineral mixture as close as possible to the wanted optimum, allows to obtain a mineral formulation that has a high biological affinity for man, with a greater bio-availability and compared with those that are nowadays on the market less harmful side effects. These formulation which for the complexity of the elements contained even in traces, cannot absolutely be chemically reconstructed. The invention through which such results have been reached, is realised on the one hand with natural mineralised complexes with a high concentration of one or more main elements of vegetable and/or animal origin and a plurality of other elements equally useful to the human organism, and on the other hand with a process for their production realised through the mixing, in definite proportions, of the vegetal or animal products to be mineralised, and also with their mineralization through the elimination of the organic portion.
Such process is, therefore, characterised by the treatment of natural organic products in order to obtain a mineralised complex containing all the mineral substances originally contained in the raw material treated first in form of oxides and other salts. Such mineralised complexes will be titrated in each element by considering those that are contained in a larger quantity, for example calcium, iron, zinc, potassium, copper, magnesium and manganese, and the aforesaid mineralised complexes will be finally checked to ascertain the absence of elements recognised as toxic, such as lead, cadmium and mercury.
The mineralised natural complexes so produced permit to reach advantageous results, as described here below, unlike the use of single mineral elements obtained with methods known nowadays.
In particular, they allow the organism to be integrated not only with the single primary elements, prevailing in the mineralised complex, but also with an innumerable series of other useful minerals that the mineralised complex contains in a composition which is formulated in nature. For instance, instead of assuming only "Gluconate Iron" as with the existing technique, the mineralised complex is taken as obtained from a mixture of vegetal products such as Capsella bursa pastoris, of which the upper part is used, Cynara of which the leaves are used, Salvia offinalis, of which the leaves are used. Such complex allows to intake iron in form of oxide and salts together with many other oligoelements, such as calcium, zinc, magnesium, potassium, sodium, copper and manganese, besides other ones in tiny traces, which aid the assimilation of iron without creating harmful side effects.
The elaboration of natural organic products allows, that is to say, to produce a mineralised complex from which the human organism perfectly absorbs most of the various oligomineral elements contained in the same complex. The natural formula, possessing precise qualitative and quantitative relations of the single elements--probably due to biological affinity--determines a much greater absorption than the one obtained by ingesting the single elements presently used. Both the ratios between the single elements and the association between the single substances can be the cause of the considerable absorption of these last ones by the organism. In fact, many of the substances present in minimum doses, even if untraceable, act as catalysts, therefore helping the absorption of the primary element needed for the desired integration.
Another advantage is due to the minor side effects resulting from the nature of the formulation more compatible with man.
BRIEF DESCRIPTION OF THE DRAWING
More characteristics of the invention will be evident from the following detailed description with reference to the process illustrated on the block diagram, provided only as example, in the enclosed drawing, which shows in schematic form a flow diagram of the apparatus elements associated with performing the invention, and the steps of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the process exemplified in the drawing figure:
1 indicates the tank containing the mixture of vegetable and/or animal natural products, each one in a clean and fragmented state, containing one or more primary mineral elements in addition to those in smaller quantities, combined with organic substances to be eliminated;
2 indicates the heated cell, normally at a temperature included between 200° and 900° C., in which the mixture coming from container 1 is mineralised, therefore the organic portion is normally separated in vapours and fumes.
The mineralised complex in container 3 is a mineral complex characterised by a qualitative and quantitative composition of the chosen primary mineral elements, each one combined with a plurality of mineral elements already present, sometimes in minimum measures, on the vegetal and/or animal products from which they are originally produced and contained. The product coming out from group 3 is in one case conveyed directly to chamber 6, and in the other case conveyed to mixer 4 in which it is mixed with other active principles coming from container 5 in order to originate in chamber 6 the mixture that is to be transformed into capsules or tablets, then to be packed and after distributed on the market.
In the general formulation the production process of a mineral complex first foresees the quantitative determination of the metals that one wishes to integrate, hence a selection of the vegetal and/or animal raw materials that present a particularly high content of the above-mentioned metals. After having accomplished the choice of the organic raw materials to be used, the process through which the wanted mineral complex is obtained, can be described in a detailed way as follows:
The chosen raw materials are analysed to make sure that the element is to be integrated is constant in them.
The selected raw materials are dried, then individually cut and sieved until obtaining a uniform granulometry that is adapted for being mineralised.
The previously processed raw materials as described above, are eventually mixed between them in the right proportion in order to obtain in the final complex the content of principal elements as wanted in the ratio. The aforesaid mixture is distributed on trays of stainless steel until reaching a layer of 5 cm. for each tray. The trays are stacked in a muffle one on top of the others, with some space between them for combustion fumes to escape.
The normally methane operating muffle is programmed in such a way to reach within it a temperature of approximately 200-400° C. for 1-3 hours, then it is raised to a temperature of about 500-900° C. for 3-5 more hours, or anyway until the complete removal of the organic portion from the mixture of drugs introduced. The first period of time, at a temperature of 200-400° C., is essential in order to obtain a perfect light coloured mineralised product, without any carbonised organic products.
The mineralised product obtained from the muffle is subjected to a quantitative analysis for being titrated, at least in its main elements, and to a control in order to verify the absence of elements recognised as toxic. It can be conveyed in the packaging division, or first mixed with additional chosen active principles, and hence sent to the packaging.
However, the invention is illustrated here as follows with reference to two applications for the production of different highly concentrated mineralised natural complexes.
EXAMPLE 1
A Mineral Complex Particularly Rich in Iron
Drugs used:
Capsella bursa pastoris, of which the upper part is used;
Cynara scolymus, of which the leaves are used;
Salvia officinalis, of which the leaves are used
The proportion for the mixing has been chosen according to the content of iron in the single drugs above-indicated, in particular:
Capsella bursa pastoris: 20%
Cynara scolymus: 70%
Salvia officinalis: 10%
The selected vegetal drugs have been cut until reaching a uniform granulometry that is adequate to be mineralised. The optimal granulomethy is the following:
Capsella bursa pastoris: 1.5-2.0 mm.
Cynara scolymus: 1.5-2.0 mm.
Salvia officinalis: 1.5-2.0 mm.
The aforesaid fragmented mixture has been distributed on the stainless steel trays until reaching a layer of about 5 cm. of drug for each tray. The trays are stacked one on top of the other, with some space between them for the combustion fumes to escape. The methane operating muffle is programmed to reach within it a temperature of approximately 300° C. for a time of 2 hours at first, then it is raised and kept at a temperature of approximately 700° C. for 4 more hours. The first step at 300° C. is essential in order to obtain a perfect white coloured final product completely inorganic. The mineralised product is encapsulated in gelatine capsules with a final weight of about 500 mg. In this process the obtained mineralised complex contains all the mineral substances originally contained in the raw materials in form of oxides and other salts. The composition of the mineralised complex is the following:
______________________________________Element Concentration in the complex in mg/g______________________________________Iron 7.73 Calcium 109.8 Zinc 0.19 Magnesium 21.75 Potassium 85.0 Sodium 9.3 Copper 0.03 Manganese 0.49______________________________________
Due to the high concentration of iron and the relatively high specific weight of the mineralised complex, only four capsules a day are sufficient to obtain a good daily integration of such element (the daily recommended ration of iron is 14 mg. according to the Italian Law). As a matter of fact, the solubility, and therefore the bio-availability with a pH: 1, is extremely high: in fact 2 g. of product are 93.05% soluble in one litre of hydrochloric acid with a pH: 1 at 37° C. (liquid simulating gastric juice).
EXAMPLE 2
A Mineral Complex Particularly Rich in Calcium
Drugs used:
Paretaria officinalis, of which the upper part is used;
Urtica dioica, of which the leaves are used;
Eucalyptus globulus, of which the leaves are used;
Ginkgo biloba, of which the leaves are used.
The proportions for the mixing have been chosen according to the calcium content in the single above-mentioned drugs, in particular:
Paretaria officinalis: 10%
Uttica dioica: 50%
Eucalyptus globulus: 30%
Ginkgo biloba: 10%
The selected vegetable drugs have been cut until reaching a uniform granulometiy, adequate for being mineralised. The optimal granulometry for each drug is the following:
Paretaria officinalis: 1.5-2.0 mm.
Urtica dioica: 1.5-2.0 mm.
Eucalyptus globulus: 1.5-2.0 mm.
Ginkgo biloba: 1.5-2.0 mm.
After having mixed the drugs, separately chopped up by following the above-mentioned granulometry, the mixture is distributed on steel trays until reaching a layer of 5 cm. of drug for each tray. The trays are stacked one on top of each other, with some space between them for the combustion fumes to escape.
The muffle, normally heated with methane, is programmed in such a way to reach within it a temperature of approximately 300° C. for 2 hours, then it is raised and kept at a temperature of about 700° C. for 4 more hours. The first step at 300° C. is essential in order to obtain a perfect white coloured final product and completely inorganic. The mineralised product is encapsulated in gelatine capsules with a final weight of about 500 mg. In this process the obtained mineralised complex contains all the mineral substances originally contained in the raw materials in form of oxides and other salts. The composition of the obtained mineralised complex is the following:
______________________________________Element Concentration in the complex in mg/g.______________________________________Iron 1.9 Calcium 299.5 Zinc 0.46 Magnesium 33.74 Potassium 94.6 Sodium 8.5 Copper 2.5 Manganese 4.08______________________________________
Due to the high concentration of calcium and the relatively high specific weight of the mineralised complex, only five capsules per day are sufficient to obtain a good daily integration of calcium (in Italy the recommended daily ration of calcium is of 800 mg.). In fact, the solubility, and so the bio-availability with a pH: 1, is extremely high: 2 g. of product are 77.15% soluble in a little of hydrochloric acid with a pH: 1 at 37° C. (liquid simulating gastric juice). The process is repeated for any other individually chosen vegetal and/or animal product, or in combination with other organic products characterised by a high content of metal or metals, through which the integration of mineral oligoelements in humans, animals or plants is intended to be operated. | The invention concerns a highly concentrated mineralised natural complex, characterised by at least one main mineral element quantified with nutritional and/or dietetic integrator properties and by other mineral elements obtained in the complex from the mineralization of vegetal and/or animal products. Moreover, it concerns the method for its production consisting in using vegetal and/or animal organic substances, having a high content of oligominerals, in carrying out their fragmentation, their mixing and the mineralization until the inorganic part is completely separated from the organic part, and then in transforming the aforesaid inorganic part in forms of easy commercialization. | 0 |
[0001] This application claims the benefit of U.S. Provisional Application No. 61/343,551, filed May 1, 2010.
BACKGROUND OF THE INVENTION
[0002] Many different kinds of food articles or food products, such as food slabs, food bellies, or food loaves are produced in a wide variety of shapes and sizes. There are meat loaves made from various meats, including ham, pork, beef, lamb, turkey, and fish. The meat in the food loaf may be in large pieces or may be thoroughly comminuted. These meat loaves come in different shapes (round, square, rectangular, oval, etc.) and in different lengths up to six feet (183 cm) or even longer. The cross-sectional sizes of the loaves are quite different; the maximum transverse dimension may be as small as 1.5 inches (4 cm) or as large as ten inches (25.4 cm). Loaves of cheese or other foods come in the same great ranges as to composition, shape, length, and transverse size.
[0003] Typically the food loaves are sliced, the slices are grouped in accordance with a particular weight requirement, and the groups of slices are packaged and sold at retail. The number of slices in a group may vary, depending on the size and consistency of the food article and the desire of the producer, the wholesaler, or the retailer. For some products, neatly aligned stacked slice groups are preferred. For others, the slices are shingled or folded so that a purchaser can see a part of every slice through a transparent package.
[0004] Food articles can be sliced on high speed slicing machines such as disclosed in Published Patent Document WO 2010/011237 A1 or U.S. Pat. No. 5,628,237 or 5,974,925; or as commercially available as the Power Max 4000™ and FX180® slicers available from Formax, Inc. of Mokena, Ill., USA.
[0005] The FX180® machine can be configured as an automatically loaded, continuous feed machine, or an automatically loaded, back-clamp or gripper type machine.
[0006] For an automatically loaded, continuous feed machine, side-by-side upper and lower conveyor pairs drive food articles into the cutting plane. A gate is located in front of the conveyors. The initial food articles are loaded with leading ends abutting the gate. The gate is lowered and the food articles proceed into the conveyors. When the initial food articles are sliced to the extent that the trailing ends of the food articles clear the gate, the gate is raised and new food articles are loaded in the feed paths, held back by the gate. Shortly thereafter the gate is lowered and new food articles slide down to where lead ends of the new food articles abut trailing ends of the initial food articles being sliced. The new food articles are driven into the cutting plane trailing the initial food articles. Food articles are sequentially and continuously loaded in this manner, lead end-to-trailing end, in abutting contact with the preceding food articles.
[0007] U.S. Pat. No. 5,628,237 and European patent EP 0 713 753 describe a back-clamp or gripper type slicing machine. According to this type of slicing machine, food articles are loaded onto a lift tray and the lift tray is raised to a ready-to-sweep position. Loaf grippers are retracted after the previous food articles are sliced. During retraction of the loaf grippers, loaf-to-slicing blade gate doors are closed and ends of the previous food articles are dropped through a loaf end door. After the grippers have reached the retracted position or “home position” remote from the slicing blade, a loaf sweep mechanism is activated, moving the food articles laterally together into the slicing position. A spacing mechanism moves down and spaces the food articles apart. The grippers then advance after it has been determined that the loaf sweep mechanism has moved the food articles to the slicing position. The grippers have onboard sensing mechanisms that are triggered by contact with the food articles. After sensing and gripping the food articles, the food articles are retracted slightly, and the loaf-to-slicing blade gate doors are opened and the food articles are advanced to the slicing plane of the slicing blade. The loaf sweep mechanism retracts and the loaf lift tray lowers, ready for the next reload cycle. According to this design, in practice, the reload cycle is accomplished in about eight seconds. In a high volume slicing operation, reload cycle time can be a significant limitation to optimum production efficiency.
[0008] The machine disclosed in WO 2010/011237 A1 provides an automated, food article tray loading method and apparatus wherein food articles can be loaded into the lift tray into designated and separated lanes which automatically assume a preload condition, and after the food articles are loaded, food article separation is maintained on the lift tray. A food article transfer receives the food articles on the lift tray in their separated positions and transfers the food articles into the slicing feed paths while maintaining the separated positions. A food article end disposal system utilizes a transport that laterally moves end portions outside of the feed path and ejects the end portions as the transport is moved back into the feed path to receive the subsequent end portions. The machine utilizes food article grippers that are fixed onto conveyor belts which support and drive the food articles in the feed paths.
[0009] The present inventors have recognized that it would be desirable to slice plural food articles with independent feeding and weighing capabilities, with hygienic and operational enhancements.
SUMMARY OF THE INVENTION
[0010] The invention provides a mechanism and method for slicing multiple food articles with independency of feed rate and the ability to weigh each product group from each food article respectively to achieve optimal weight control and yield of each food article.
[0011] The present invention provides a high speed slicing apparatus and a weighing and classifying conveyor combination that provides plural advantages in machine cost, productivity, food hygiene, and operation.
[0012] The invention provides a lift tray that is located in line with the food article feed paths and is lowered to receive food articles and raised into the feed paths. There is no need for lateral shifting of food articles into the feed paths. Food article grippers are driven along the feed paths by an overhead conveyor. A laser food article end detection system is employed in each feed path to detect the terminal end of the food article to control the positioning of the gripper for that path.
[0013] The invention provides the use of an automatic debris or scrap removal conveyor that also provides for end portion removal.
[0014] The invention provides an automated cleanup position wherein the elevated food article feed mechanism can be collapsed to a more convenience plane or maintenance position, and the blade cover is automatically pivoted to a cleanup position. The combination provides for enhanced portion control and yield. A food article feed mechanism ensures accurate feeding by the use of servo driven and controlled feed belts and grippers. The slicing mechanism includes three independent drives for slicing multiple food articles simultaneously.
[0015] An improved food article stop gate is provided that also serves as a door for the removal of food article end portions.
[0016] A horizontally radiating laser intrusion detector is used to shut down systems when an unwanted intrusion by an operator is detected.
[0017] An automated, food article tray loading method and apparatus is provided wherein food articles can be loaded into the lift tray into designated and separated lanes which automatically assume a preload condition, and after the food articles are loaded, food article separation is maintained on the lift tray.
[0018] Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a near side elevational view of a slicing machine and a weighing and classifying conveyor combination of the present invention;
[0020] FIG. 1A is an enlarged fragmentary view taken from FIG. 1 ;
[0021] FIG. 1B is a perspective view of the slicing machine of FIG. 1 in a clean-up configuration;
[0022] FIG. 2 is a plan view of the combination of FIG. 1 with some panels and parts removed or made transparent illustrating some underlying components;
[0023] FIG. 2A is a bottom perspective view of a portion of FIG. 2 ;
[0024] FIG. 3 is a sectional view taken generally along line 3 - 3 of FIG. 2 with some panels and parts removed or made transparent and underlying components revealed;
[0025] FIG. 4 is a schematic, sectional view taken generally along line 4 - 4 of FIG. 6 with some panels and parts removed or made transparent and underlying components revealed;
[0026] FIG. 5 is a schematic, sectional view taken generally along line 5 - 5 of FIG. 6 with some panels and parts removed or made transparent and underlying components revealed;
[0027] FIG. 6 is a sectional view taken generally along line 6 - 6 of FIG. 3 with some panels and parts removed or made transparent and underlying components revealed;
[0028] FIG. 7 is a fragmentary elevational view taken generally along line 7 - 7 of FIG. 2 with some panels and parts removed or made transparent and underlying components revealed;
[0029] FIG. 7A is a fragmentary perspective view of a portion of FIG. 7 ;
[0030] FIG. 7B is an enlarged fragmentary view of apportion of FIG. 7A ;
[0031] FIG. 7C is an enlarged rear perspective view of a portion of FIG. 7 ;
[0032] FIG. 7D is a top perspective view of a portion of FIG. 7 ;
[0033] FIG. 7E is an enlarged fragmentary view of a portion of FIG. 7 ;
[0034] FIG. 7F is an enlarged fragmentary view of an alternate embodiment of a lower conveyor.
[0035] FIG. 8 is a fragmentary rear perspective view of the apparatus of FIG. 1 ;
[0036] FIG. 9 is a far side perspective view of the apparatus of FIG. 1 with a lift tray in a lowered position;
[0037] FIG. 10 is a top perspective rear view of the lift tray of FIG. 9 with a tray platform removed;
[0038] FIG. 11 is an enlarged, fragmentary near side perspective view of a portion of the slicing machine of FIG. 1 ;
[0039] FIG. 12 is an enlarged, fragmentary far side perspective view with a door removed to show underlying components;
[0040] FIG. 13A is a schematic diagram of the loaf feed apparatus in a first stage of operation;
[0041] FIG. 13B is a schematic diagram of the loaf feed apparatus in a second stage of operation;
[0042] FIG. 13C is a schematic diagram of the loaf feed apparatus in a third stage of operation; and
[0043] FIG. 13D is a schematic diagram of the loaf feed apparatus taken generally along line 13 D- 13 D of FIG. 13C .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0045] Published Patent Application No. WO 2010/011237 and U.S. Pat. No. 5,628,237 are herein incorporated by reference.
Overall Description
[0046] FIGS. 1-3 illustrate a high speed slicing apparatus 100 and a weighing and classifying conveyor or output conveyor 102 according to a preferred embodiment of the invention. The slicing apparatus 100 includes a base section 104 , a collapsible frame 105 , an automatic food article loading apparatus 108 that receives food articles 110 to-be-sliced, a food article feed apparatus 120 , a food article end and scrap removal conveyor 122 ( FIGS. 13C and 13D ), a laser safety guard system 123 , a slicing head apparatus 124 , and a slice receiving conveyor 130 . The slicing head apparatus includes a slicing blade 125 that defines a slicing plane and a orifice plate or slicing block 126 that guides food articles into the slicing plane, the blade cutting closely to the orifice plate. The slicing apparatus also includes a computer display touch screen 131 that is pivotally mounted on and supported by a support 132 .
Base Section
[0047] The base section 104 includes a compartment 136 having side walls 138 a, 138 b, a bottom wall 140 , and an inclined top wall 142 . The apparatus 100 is supported on four adjustable feet 144 . The compartment 136 has a tapered side profile from back to front wherein the top wall 142 slants down from back to front. The slanted orientation of the top wall 142 ensures water drainage off the top of the compartment 136 . The compartment is supported on adjustable feet 144 .
[0048] The compartment 136 includes a near side door 152 , a far side door 156 ( FIG. 9 ), and a rear door 162 that permit access into the compartment or to modules normally held within the compartment 136 . The compartment 136 typically affords an enclosure for a computer, motor control equipment, a low voltage supply, and a high voltage supply and other mechanisms as described below. The compartment may also include a pneumatic supply or a hydraulic supply, or both (not shown).
Collapsible Frame and Elevated Housings
[0049] The base section 104 supports the collapsible frame 105 as shown in FIGS. 1 , 1 B and 9 . The collapsible frame 105 includes a foldable support mechanism 174 that supports a food article feed mechanism frame 190 .
[0050] The foldable support mechanism 174 includes a servomotor 175 that drives a gear reducer 176 having a drive shaft 178 that extends out of far side of the compartment 136 ( FIG. 9 ). The drive shaft 178 is rotationally fixed to parallel levers 180 a, 180 b which swing out with a turning of the drive shaft 178 . The levers 180 a, 180 b are pivotally connected to a column 182 via a rotary connection 184 . The column 182 is pivotally connected at a pivot connection 192 to the frame 190 which supports the food article feed apparatus 120 .
[0051] For cleaning and maintenance purposes, the collapsible frame 105 is collapsed down by actuating the servomotor 175 and gear reducer 176 to rotate the levers 180 a, 180 b, which draws down the column 182 as shown in FIG. 1B . The frame 190 , and all equipment supported thereby, is lowered for more convenient maintenance and cleaning as illustrated in FIG. 1B . In some cases this eliminates the need for ladders or platforms when servicing the slicing apparatus 100 .
[0052] The slicing head 124 is covered by a guard 119 that is attached to the frame 190 such that when the frame is pivoted down as shown in FIG. 1B , the guard 119 is pivoted away from a slicing head base 117 to expose the slicing blade 125 and internals for cleaning and maintenance.
[0053] Additionally, the elevation of the food article feed apparatus can be adjusted by using the servomotor to selectively pivot the columns 180 a, 180 b and lower the rear of the frame 190 . At a front, the frame 190 is supported on a cross shaft 193 that is eccentrically fixed at each end to a round cam 194 ( FIG. 1A ). The cam is journalled in a round opening 195 in side supports 197 a, 197 b and the cam is fixed for non rotation to the respective side support by fasteners 199 . The far side is shown in FIG. 1A , with the understanding that the near side is mirror image identical across the longitudinal vertical center plane of the machine. As shown in FIG. 1A , because the dimension “a” is smaller than the dimension “b”, the shaft ends can be temporarily loosened by removing the fasteners and the shaft and cams can be rotated 180 degrees about a centerline of the shaft, and the cams can be re-fastened to be fixed to the side supports. The elevation will be different between the two 180 degree adjustable positions. Thus, the machine will accommodate two different height settings for different types of food articles.
Food Article Feed Apparatus
[0054] An upper conveyor assembly 530 of the food article feed apparatus 120 is shown in FIG. 2 . The conveyor assembly 530 includes three independently driven endless conveyor belts 802 , 804 , 806 . Each belt 802 , 804 , 806 is identically driven so only the drive for the belt 802 will be described.
[0055] The belt 802 is wrapped around a toothed front drive roller or pulley 812 and a back idler roller or pulley 816 . The belt 802 preferably has teeth that engage teeth of the two rollers 812 , 816 . Each drive roller 812 includes a toothed outer diameter 812 a and a toothed, recessed diameter 812 b.
[0056] An endless drive belt 820 wraps around the recessed diameter 812 b. The drive belt 820 also wraps around a drive roller 824 that is fixed to a drive shaft 828 . The drive shaft 828 extends transversely to the belt 802 and is journaled for rotation within a bearing 830 mounted to a near side frame member 836 .
[0057] The drive shaft 828 penetrates a far side frame member 838 and extends to a bearing 843 , coupled to a gear reducer 842 mounted to a support frame 854 . The gear reducer 842 is coupled to a servomotor 850 that is mounted to the support frame 854 .
[0058] The servomotor 850 drives the drive shaft 828 which turns the roller 824 which circulates the belt 820 which rotates the roller 812 which circulates the belt 802 .
[0059] Three servomotors 850 are mounted to the support frame 854 and all are located within an upper compartment 855 that is supported by the frame 190 .
[0060] The idler rollers 816 are provided with a pair of mirror image identical adjustable cam belt tension adjustment mechanisms 882 a, 882 b. As shown in FIG. 7A , each mechanism 882 a, 882 b includes a fork 885 that is braced from the respective side frame member 836 , 838 by an adjustable cam 883 . The fork 885 is guided by upper and lower pins 886 a, 886 b so as to slide rearward and forward and has an end 891 that captures an axle 889 that rotationally supports the idle rollers 816 . For adjustment, the cam fastener 883 a is loosened so as to be rotatable on the respective side frame member 836 , 838 , rotated to achieve the desired belt tension, and then the cam fastener is tightened to hold the cam fixed.
[0061] FIG. 7B illustrates a gripper 894 used in cooperation with the belt 802 . The gripper 894 is mounted to a bottom run of the belt 802 and is translated along the food article path by the belt 802 . The gripper 894 is clamped to a belt joint and guide assembly 896 by a fixture 901 that engages the assembly 896 and is fixed thereto by a clamping set screw 897 . The assembly 896 comprises a pair of upper members 899 and a lower member 900 . The upper members 899 can include teeth 899 a that mesh engage the teeth of the belt 802 once the members 899 , 900 are fastened together to splice the free ends 802 e, 802 f of the belt 802 ( FIG. 7D ). For clamping, fasteners 902 , 904 ( FIG. 7D ) are provided which are inserted from above the members 899 through plain holes in the members 899 and tightly threaded into threaded holes in the member 900 .
[0062] The block 900 includes guides 906 , 907 that contain slide bearings 906 a, 907 a composed of friction reducing material. The slide bearings 906 a, 907 a partly surround longitudinal rails 912 , 913 that are in parallel with, and straddle the belt 802 . The rails 912 , 913 support the gripper along its working path from a retracted position to a fully forward position nearto the slicing plane.
[0063] For each gripper there are two rails 912 , 913 to support and guide that gripper. Thus, there are two rails that straddle the belt 804 and two rails that straddle the belt 806 .
[0064] The gripper 894 is connected to the fixture 901 by a front plate 920 having a predominant lateral face and a rear plate 922 having a predominant longitudinal face. Each gripper 894 is provided with two air lines 930 , 932 for two way pneumatic gripper open-and-close operability.
[0065] The air lines 930 , 932 are guided through lower rings 940 and upper rings 942 to an air tube storage area 950 above the food article feed apparatus 120 ( FIG. 7D ). The air tube lines are routed around weighted rollers or slides 951 that are guided by longitudinal slots 952 and extend to a source of pressurized air. Thus, the movement of the rollers or slides along the slots under force of gravity, will take up slack in the air tubes when the grippers 894 are moving toward, and when in, the retracted position.
[0066] The gripper 894 travels from the retracted home position shown in FIG. 7A to the advanced, forward position approaching the slicing plane.
[0067] The grippers 894 are as described in Published Patent Application No. WO 2010/011237, herein incorporated by reference.
Lower Conveyor
[0068] As illustrated in FIGS. 3 , 6 , 7 , and 7 E at a front end of the food article feed apparatus 120 , are three lower feed conveyors 992 , 994 , 998 , having endless belts 1002 , 1004 , 1008 , respectively. The endless belts 1002 , 1004 1008 are independently driven and are directly opposed to pressure plates 1003 , 1005 , 1007 respectively.
[0069] FIG. 6 shows the conveyor 992 has a drive roller 1010 having a central hub 1012 with a center bore 1014 . The drive roller 1010 has tubular stub axles 1016 , 1018 extending from opposite ends of the central hub 1012 . The tubular stub axles 1016 , 1018 are journaled for rotation by bearings 1020 , 1022 that are fastened to carrier blocks 1023 a.
[0070] The conveyor 994 includes a drive roller 1038 having a central hub 1042 with a bore 1044 . The drive roller 1038 has tubular stub axles 1046 and 1048 extending from opposite ends of the central hub 1042 . The tubular stub axles 1046 , 1040 are journaled by bearings 1050 , 1052 respectively that are attached to carrier blocks 1023 b.
[0071] A motor housing 1054 , including a baseplate 1054 b and a cover 1054 a, is mounted to an end of an upper conveyor support bar 1056 . The base plate 1054 b of each side of the machine is fastened to a linear actuator, such as a pneumatic cylinder 1055 a and 1055 b respectively. The cylinders 1055 a, 1055 b are connected together by the support bar 1056 . Each cylinder slides on a fixed vertical rod 1057 a, 1057 b respectively. Thus, controlled air to the cylinders 1055 a, 1055 b can be used to uniformly raise or lower the near side housing 1054 and the far side housing 1054 uniformly.
[0072] A spindle 1060 extends through the motor housing 1054 , through a sleeve 1064 , through a coupling 1065 , through the tubular stub axle 1016 , through the central bore 1014 , through the tubular stub axle 1018 , through the tubular stub axle 1046 , and partly into the bore 1044 . The spindle 1060 has a hexagonal cross-section base region 1070 , a round cross-section intermediate region 1072 , and a hexagonal cross-section distal region 1074 . The hexagonal cross-section base region 1070 is locked for rotation with a surrounding sleeve 1071 to rotate therewith.
[0073] The intermediate region 1072 is sized to pass through the sleeve 1064 , through the tubular stub axle 1016 , through the central bore 1014 , and through the tubular stub axle 1018 to be freely rotatable therein. The distal region 1074 is configured to closely fit into a hexagonal shaped central channel 1078 of the tubular stub axle 1046 to be rotationally fixed with the tubular stub axle 1046 and the drive roller 1038 .
[0074] The sleeve 1064 includes a hexagonal perimeter end 1064 a that engages a hexagonal opening 1065 a of the coupling 1065 . The coupling 1065 includes an opposite hexagonal opening 1065 a that engages a hexagonal perimeter end 1016 a of the tubular stub axle 1016 . The coupling 1065 couples the sleeve 1064 and the stub axle 1016 for mutual rotation such that the sleeve 1064 and the drive roller 1010 are locked for rotation together, i.e., turning of the sleeve 1064 turns the drive roller 1010 .
[0075] Within the motor housing 1054 are two servomotors 1090 , 1092 mounted to the housing by fasteners. As shown in FIGS. 4 and 6 , the servomotor 1090 has a vertically oriented output shaft 1096 that rotates about a vertical axis connected to a worm gear 1098 that is enmesh with and drives a drive gear 1100 that rotates about a horizontal axis. The drive gear 1100 drives the sleeve 1071 that drives the region 1070 of the spindle to rotate the spindle 1060 . Rotation of the spindle 1060 rotates the drive roller 1038 via the hexagonal cross-section distal end region 1074 .
[0076] Adjacent to the servomotor 1090 is the servomotor 1092 . The servomotor 1092 is configured substantially identically with the servomotor 1090 except the worm gear 1098 , as shown in schematic form in FIG. 5 , of the servomotor 1092 drives a drive gear 1100 that drives the sleeve 1064 to rotate. The sleeve 1064 rotates independently of the round cross-section region 1072 of the spindle 1060 , and drives a stub axle 1016 to rotate, which rotates the drive roller 1010 .
[0077] The sleeves 1071 and 1064 are journaled for rotation by bearings. The drive gears 1100 , 1100 are fastened to the respective sleeve 1071 , 1064 using fasteners 1116 .
[0078] Each conveyor belt 1002 , 1004 , 1008 is wrapped around the respective drive roller and a front idle rollers 1134 , 1135 , 1136 that is supported by respective side frames 1131 , 1132 .
[0079] Also, as shown in FIGS. 7 , 7 E, and 13 A- 13 C, the underside of the support bar 1056 carries pneumatic cylinders 1130 . Each pneumatic cylinder 1130 is supplied with a preselected air pressure to extend a piston rod 1013 , 1015 , 1017 to press down on pressers 1003 , 1005 , 1007 to lightly press down on a top of the product below, clamping the food article between the pressers 1003 , 1005 , 1007 and the belts 1002 , 1004 , 1008 . Piston rods 1013 a, 1015 a, 1017 a in their extended position and pressers, in their depressed position 1003 a, 1005 b, 1007 a are illustrated in FIG. 7E . The conveyor belts 1002 , 1004 , 1008 drive the food articles through corresponding orifices in the slicing block and into the slicing plane.
[0080] FIG. 7F illustrates an alternate embodiment of the lower conveyor. The same reference signs indicate similar parts as described above. In the embodiment illustrated in FIG. 7F , the lower conveyor 992 a, 994 a, 998 a is pivotable about an axis A parallel to the central axis of a drive roller 1010 a. Each conveyor belt 1002 , 1004 , 1008 is wrapped around the respective drive roller and a front idle rollers 1134 , 1135 , 1136 that is supported by respective side frames 1131 , 1132 . Side frames 1131 , 1132 may be connected to a transverse bottom surface or bar 1133 which provides at least a region of contact for at least one piston rod 1137 disposed below the top surface of the conveyors. A support bar 1058 below the lower conveyors carries one or more pneumatic cylinders 1139 , such as three pneumatic cylinders, supplied with a pre-selected air pressure, each of which extends a piston rod to pivot the lower conveyor about the pivot axis. Extension of the piston rods tilts the lower conveying surface towards presser plates 1003 , 1005 , 1007 to provide pressure in grasping the food product between the presser plates and the lower conveyor 992 a, 994 a, 998 a. The tilt or pivot of the lower conveyor can be adjustable over a variable angular distance, such as 7 degrees. The lower conveyor 992 b, 994 b, 998 b is illustrated in is lowered position.
[0081] The drive roller 1010 a can be driven by a hexagonal shaft 1011 connected to a motor (not shown in FIG. 7F ). Hexagonal shaft 1011 comprises a circular channel 1014 which allows the hexagonal shaft, and accordingly the drive roller 1010 a, to pivot about the axis A of the circular channel 1014 . A combination of multiple concentric hexagonal shafts with a circular channel for coupling about a circular shaft can be used to drive adjacent lower conveyors.
[0082] Side frames 1131 , 1132 comprises an opening 1021 in the shape of an arc, which accommodates the cross-sectional dimensions of a support or alignment bar 1019 , which can extend across the span of lower conveyors and intersect the side frames of each lower conveyor. The angular angle of the arc corresponds to the degree of angular movement of the lower conveyor.
Feed Paths
[0083] The illustrated apparatus provides three feed paths, although any number of paths are encompassed by the invention. The near side feed path is defined by the gripper 394 driven by the belt 802 which feeds the near side food article into the space between the conveyor belt 998 and presser 107 . The middle feed path is defined by the gripper 394 driven by the belt 804 which feeds the middle food article into the space between the conveyor 994 and the presser 105 . the far side fed path is defined by the gripper 394 driven by the belt 806 which feeds the far side food article into the space between the conveyor 992 and the presser 103 .
Food Article Loading Apparatus
[0084] As illustrated in FIG. 1 , the automatic food article loading apparatus 108 includes a lift tray assembly 220 , and a lift tray positioning apparatus 228 . The lift tray assembly 220 receives food articles to-be-sliced. The tray positioning apparatus 228 pivots the tray assembly 220 to be parallel with, and below the food article feed apparatus 120 in a staging position.
Lift Tray Positioning Apparatus
[0085] FIGS. 8-10 illustrate the food article lift tray assembly 220 includes a frame 290 that supports movable food article support tray 302 . The tray 302 is removed in FIG. 10 . The frame 290 includes an end plate 291 . Food article are loaded onto the tray 302 until they abut the end plate 291 . The tray 302 includes four spaced-apart guard rails 303 that define three lanes corresponding to three feed paths for the slicing machine.
[0086] As illustrated in FIGS. 1 and 10 , the frame 290 is connected by a rear connection 330 and a front connection 332 to a lever 336 . The lever 336 is pivotally mounted onto the shaft 193 .
[0087] The mechanism 228 includes a pneumatic or hydraulic, extendable cylinder 350 that has a rod 352 pivotally connected to the lever 336 or the frame 290 at a connection 353 , and a cylinder body 354 pivotally connected to the floor 140 at a connection 356 . Extension or retraction of the rod 352 pivots the lever 336 and frame 290 about the connection 342 .
Lift Tray Assembly
[0088] As shown in FIG. 10 , an inner frame 375 supports the tray 302 within the frame 290 . The inner frame 375 is movable vertically with respect to the frame 290 . The inner frame 375 is liftable by pneumatic cylinders 380 to an elevated position above the staging position below the feed paths to lift the food articles to be in the food paths and to be gripped by the grippers The cylinders 380 have rods connected to cross members of the frame 375 and cylinder bodies fastened to cross members of the frame 290 . In the elevated position, the tray top surface 302 a is just above the top of the end plate 291 so the food articles can be moved longitudinally off the tray 302 .
Food Article Gate
[0089] As illustrated in FIG. 13A-13D a food article gate 2020 is operable to be used as a gate, to be used as a floor for supporting the food article, and to be used as a trap door to drop a food article remainder end through the trap door against a baffle 2022 and onto a scrap conveyor 122 . The scrap conveyor 122 is also located below the cutting plane to dispose of shaving scrap caused by the blade on the food article during idle dwell periods.
[0090] The scrap conveyor 122 can be continuously circulated by use of a drum motor on one of the rollers. The conveyor delivers scrap to a discharge chute 2030 ( FIGS. 13D and 9 ) where the scrap can be collected in a bucket or other means.
[0091] The gate 2020 can be operated to be positioned according to FIG. 13A-13C by a linear actuator such as a servomotor actuator or a pneumatic cylinder, as shown in FIGS. 11 and 12 . A servomotor actuator 2036 is pivotally connected to the cabinet 855 at a pivot point 2038 and has an actuator rod 2040 pivotally connected to a lever 2042 which is fixedly connected to an axle rod 2044 . The axle rod 2044 sealing penetrates through the cabinet wall as shown in FIG. 11 . The axle rod 2044 is fixed to the gate 2020 . the axle rod 2044 is journalled at an opposite end to a bracket 2048 . By extension or retraction of the rod 2044 the gate 2020 can be selectively pivoted. By machine control.
Laser Detectors
[0092] A separate food article end detector is used for each of the three illustrated food paths. Preferably, the detectors are laser distance sensors 2002 , 2004 , 2006 . Once the food articles are pivoted by the apparatus 228 to the staging position below the feed paths, the sensors 2002 , 2004 , 2006 sense the ends of each food article in the three lanes on the tray 302 , and communicate that information to the machine control. The machine control uses this information to control the servomotors 850 to control the positioning of the grippers to the ends of each food article and also controls the actuation of each gripper. By knowing the exact end of the food article the grippers know when to be activated to seize the food article.
Slicing Head Section
[0093] The slicing head section is as described in WO 2010/011237, herein incorporated by reference.
[0094] The slicing block with orifices is also as described in WO 2010/011237, herein incorporated by reference.
[0095] The jump conveyor can also be configured as described in U.S. Ser. No. 11/449,574 filed Jun. 8, 2006 or WO 2010/011237, herein incorporated by reference.
Laser Safety Guard System
[0096] The laser safety guard system 123 is illustrated in FIGS. 1 and 8 . The system comprises a central sensor 123 that projects a horizontal fan beam approximately 360 degrees or as much of an angle as needed. If an obstruction is sensed, such as an operator's arm, one or more machine operations are halted by the machine control. The machine operations, such as the lift tray positioning apparatus, may be halted by machine controls when an obstruction in the fan beam is sensed. Other operations such as the slicing movement of the slicing blade, or the food article feeding apparatus, may also be halted with the laser safety guard system.
[0097] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. | A high speed food article slicing machine with a slicing station, a moveable frame supporting a food article feed mechanism frame, a food article gate, and a safety guard system for detecting an intrusion into the machine. Food articles are loaded onto a lift tray and raised to a staging position where food articles are in contact with a food article gate. The lift tray is located inline with the food article feed paths such that lateral shifting of food articles into the feed paths is not needed. Food article grippers, individually driven along feed paths by an overhead conveyor, move food articles over the food article gate towards the slicing station. The food article gate functions to assist in removal of food article end portions. The slicing machines utilizes a horizontally radiating laser intrusion detector to shut down systems when an unwanted intrusion is sensed. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in or relating to propellers, now more generally referred to as "impellers", of the type designed for producing a turbulent motion within a gaseous, liquid or other medium, or a medium having a more or less pronounced consistency, in order to effect in such medium the stirring of a mixture, an aeration, a mixing or dispersive action. However, this enumeration should not be construed as limiting the scope of the present invention.
As a rule, the problem to be solved in the technical field concerned is to produce in a closed or open vessel or the like a stirring or turbulent action distributed throughout the vessel in which the impeller is mounted and the medium is to be processed, with the minimum power consumption.
The various research efforts performed up to now with a view to solve this problem have been directed principally to the study of the vessel shapes and also of the impeller blade profiles, with correlative attempts to reduce through the use of suitable techniques the sometimes high cost of the vessel and blades.
Prior researches made by the Applicant proved that substantial power savings could be made when preparing a mixture by using an impeller having the best possible "pumping" (or "blowing") characteristics.
Pumping, which is the fluid flow output passing through the impeller determines the creation, in the medium receiving the impeller, of movements causing both the transport of particles constituting the medium and a distortion of the particles. This distortion, due to differential speeds, is due to the turbulent energy (W T ) created by the impeller, and the transport proper is due to the displacement energy (W D ) also created by the impeller.
The level of turbulent energy required for producing a predetermined effect is actually subordinate to this desired effect. Thus, for instance, it is easy to mix two miscible liquids, but on the other hand it is difficult to create particles of gradually decreasing magnitude in one phase dispersed in another phase.
Generally, the permissible energy savings are achieved by not exceeding the strict minimum amount of turbulent energy W T which is necessary for obtaining the desired result.
Having thus ascertained the importance of the flow output per unit of power consumption of the impeller, the Applicant directed his search more particularly towards the fluid flow patterns in the mixer vessel. This study eventually proved that a number of advantageous properties could be obtained by improving the knowledge of these flow patterns. As a rule, these improved properties led to a substantial reduction in the power consumption required for obtaining a given local effect through a better distribution of the active areas in the mixing volume, in general.
Observing the phenomena produced in a mixing vessel due to the operation of a conventional propeller proves that, in contrast to what occurs in a indefinite medium (the term "indefinite medium" denotes a liquid area not influenced by solid walls, for example in the case of a ship propeller churning sea water, in opposition to a closed vessel in which the dimensions of the vessel are small in relation to the dimensions of the impeller so that certain reflexion effects occur due to the presence of the walls) wherein the propeller jet is cylindrical, a characteristic outflaring of the jet a is produced, this jet thus assuming the shape of a more or less open cone having an apex angle α (see FIG. 1 of the attached drawings). This outflaring effect is subordinate to the proximity of the lateral walls and also to the viscosity of the fluid filling the vessel c. The more or less outflared configuration of the jet under given geometrical properties of the vessel and fluid viscosities may constitute an advantage, but in most instances it constitutes an inconvenience, inasmuch as the jet energy is considerably diluted therein and the local effects at points remote from the impeller may drop below a critical limit. Thus, the apex angle α of the cone formed by the blowing impeller may attain 120° in water if ratio d/D of the impeller diameter to the vessel diameter is 0.7 and the jet bursts out either in the bottom of the said vessel or against its vertical side wall, according to the distance from the impeller to the bottom.
Moreover, the slower the dissipation of the jet energy, the greater the distance attained by the fluid to which energy is impressed by the impeller, the dissipation being due not only to the peripheral friction forces increasing with the external surface and therefore with the outflaring, but also to the internal turbulent effects. These effects depend on the continuity of the impeller profile characteristics.
SUMMARY OF THE INVENTION
In actual practice, it is therefore very important to have the possibility, in a vessel of a given configuration of creating from the onset a conical or cylindrical jet shape of predetermined geometry and turbulence, and this constitutes the essential object of the invention.
This object is achieved according to this invention by so shaping the impeller blades that the axial effect of these blades is completed by a centrifugal or centripetal effect obtained by preserving an optimum pumping efficiency, i.e. by limiting to a minimum value the energy dissipated in the form of turbulence.
Moreover, the use of auxiliary profiles according to this invention enhances the axial or centrifugal or centripetal effect and creates in addition localized turbulences of predetermined amplitude.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will be apparent from the following detailed description, taken with the accompanying drawings, wherein:
FIG. 1 is a schematic view of an impeller within a vessel;
FIGS. 1a, 1b and 1c are schematic views of portions of impeller blades illustrating the forces involved during rotation thereof;
FIG. 1d is a perspective view of an impeller according to the invention;
FIGS. 2 and 3 are perspective views of the formation of impeller blades by rolling and pressing, respectively;
FIGS. 2a and 3a are end views of the arrangements of FIGS. 2 and 3, respectively;
FIGS. 4 through 6 are perspective schematic views illustrating various impeller blade configurations;
FIGS. 7 and 8 are perspective views of compound configurations of impeller blades;
FIGS. 9 and 10 are a perspective view and an end view, respectively, of an impeller blade having one type of an auxiliary flap; and
FIGS. 11 through 13 are schematic views of further auxiliary flap configurations.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on the to be discussed presently theoretical principles, the understanding of which will be facilitated by the following definitions.
Lift coefficient -- (See FIG. 1a)
When a propeller or impeller is rotating in a viscous fluid, a section of a blade of the impeller, having an area (S), located at the radius (R) reacts on the fluid with a force having two components, i.e. the lift force (L) which is perpendicular to the direction of the velocity (W) of the section relative to the fluid flow, and the drag force (D) parallel to (W). In hydrodynamics it is well known that (L) and (D) can be written as:
L=1/2d.sub.m C.sub.L S W.sup.2
D=1/2d.sub.m C.sub.D S W.sup.2
wherein:
d m is the fluid density;
C l is the lift coefficient;
C d is the drag coefficient; and
W 2 =V 2 +(ωR) 2 , with
V=axial velocity through the propeller, and
ω=angular velocity of the propeller.
In FIG. 1b is indicated the angle of incidence (I) between the velocity (W) and the axis (p) for which L is equal to zero. The values of (I) and (C L ) are correlated for this profile as:
I=10 C.sub.L
up to now, and particularly for marine type propellers, when designing the propeller the coefficient C L was chosen approximately constant. Such propellers give a very weak radial movement in an infinite volume.
It has been found that if I is chosen to increase continuously from the rotational axis to the tip, a centrifugal component of velocity appears, and the angle (α) of the blowing cone increases.
Conversely, when I is chosen to decrease from the rotational axis up to the tip, a centripetal component appears, and angle (α) decreases for given conditions.
This angle α is determined by the construction of the impeller blade, and the construction may be as follows.
The sheet metal member or plate from which the blade element e is to be made is formed to have a substantially trapezoidal contour. The major base e 1 of this blank is used as the blade portion located near the shaft or axis. Therefore, this portion operates at a relatively low speed but has a strong incidence in the fluid and a relatively great cross-sectional area. For opposite reasons, the minor base e 2 of the trapezium is adapted to constitute the external portion of the blade. The ratio of the major base to the minor base is selected according to the area preferred for the maximum flow intensity.
The plate thus cut is shaped either by rolling as illustrated in FIGS. 2 and 2a, or in a press, as illustrated in FIGS. 3 and 3a of the drawings, in order to impart a cylindrical or tapered configuration thereto, or a compound shape by combining cylindrical, conical and/or flat portions.
The variation in the lift coefficient C L is obtained by varying both the angle of incidence of the fluid (medium) on the average chord of the profile, and the relative sag i.e. the ratio CD/AB as indicated in FIG. 1c.
The most advantageous positions for mixing operations are as a rule and according to this invention those wherein the section AB of FIG. 1c is either circular or elliptical with a relative sag i.e. ratio CD/AB, between 2% and 12%, and blade incidence angles i.e. angle (I), between 3° and 10°, whereby C L values of from 0.7 to 1.6 for a-10-degree incidence and a 12% relative are obtained.
According to this invention and to a typical embodiment thereof, in which the blades are obtained by cylindrical circular rolling between the rollers d of FIG. 2, in a first case illustrated in FIG. 4 the minor base e 2 is engaged first into the nip formed by rollers d or similarly between the V-sectioned bending tools 4, 4a of a bending press of FIG. 3.
Thus, the angle β formed between the roller generatrix and the center line M 1 M 2 of blade e is directed as shown by the arrow in FIG. 4, and will be referred to as a positive angle.
Therefore, the incidence of the blade section chord decreases as the distance from the rotational axis f increases, and the lift coefficient C L increases accordingly. Therefore, this blade has a centripetal corrective component with respect to the fluid jet, which tends to reduce the blowing cone angle of the impeller, the term "blowing" having the same meaning as "pumping" but being employed more particularly when the impeller pumps the fluid downwardly.
Conversely, when as in the case illustrated in FIG. 6 the major base of the trapezium is engaged first, β will be "negative", and the blade chord incidence will increase from the axis of rotation of the impeller to the outer periphery thereof, so that the C L and the blade correction will be centrifugal, thus resulting in an increase or opening of the blowing cone angle.
By way of example, when the ratio d/D of the impeller diameter to the vessel diameter approximates 0.5 with a 1-centipoise viscosity and a given value (approximating 20°) of the positive angle β, movable blades producing a purely axial flow are obtained, the blowing volume having in this case a cylindrical pattern.
When, as illustrated in FIG. 5, β is zero, the conical flow is characteristic and the angle α of FIG. 1 has a value close to 45° under the same conditions.
Another exemplary embodiment is illustrated in FIGS. 7 and 8. In this case the blade has been given a compound cylindrical -plano-conical shape. In FIGS. 7 and 8, the area 1 is cylindrical as in the preceding example.
The area 2 is flat, either tangent to the preceding cylindrical area 1 (FIG. 7) or bent along this tangent (FIG. 8). The next area 3 is cylindrical in FIG. 7 and corresponds to a definitely centrifugal helix. Area 3 is tapered in FIG. 8 which is clearly centripetal.
In this case the corrective effect is due to the fact that the sag and the incidence, and therefore also the C L thereof, increase from the axis to the outer periphery of the blade in the case illustrated in FIG. 7, and decrease in the case of FIG. 8.
Auxiliary flaps may also be added to the improved impellers of this invention without departing from the basic principles of the invention. These auxiliary flaps consist of profiles designed and calculated with a view to obtain a well-defined and desired result. They are constructed like the main blades from plate blanks and are roller-shaped or pressed. If desired, they can be disposed to constitute either extensions or projections on the lower and/or upper surfaces of the main blades.
These auxiliary flaps may serve the purpose of either simply enhancing an axial or centrifugal or centripetal effect, or developing an eddy area of predetermined intensity and location.
FIGS. 9 to 13 of the attached drawings illustrate diagrammatically by way of example, not of limitation, several embodiments of these auxiliary flaps.
In FIG. 9 the flaps are similar to the ailerons currently added to aircraft wings for modifying the lift thereof.
In the case of FIGS. 9 and 10, the flap i is secured for instance to the lower surface of the blade e and its axis intersects that of the blade e so as to produce a centripetal action. Flap i could as well constitute an extension of blade e.
In FIG. 11, the desired effect is centrifugal. The flap j is secured to the outer tip of the blade, it has a vertical cylindrical circular configuration, it projects from both the lower and upper surfaces of the blade, and its total height corresponds to the chord of the main blade, at 0.7 of its radius. The desired result may be inverted, for example by using a concave flap instead of a convex flap, as seen by an observer standing at the impeller axis. Finally, FIG. 12 illustrates a particularly simple embodiment in which the main blade e consists of a possibly flat member to which flat or curved elements k disposed or bent in one direction are secured in one section, the next section comprising similar elements k 1 but disposed in the opposite direction.
If the total lift of the elements bent in one direction is equal to the lift of the elements bent in the opposite direction, and if the lengths of each section are relatively moderate, the whole of the complmentary energy absorbed by these elements is converted into turbulence. Of course, the bent elements may be located either along the trailing edge as shown or along the leading edge, or possibly along both edges simultaneously.
A specific arrangement illustrated in FIG. 13 comprises the use of only two sets of elements m, m 1 bent in opposite directions. If the total lift thus obtained is zero, then equal flows, i.e. a central flow and a peripheral flow, are obtained.
This specific arrangement is particularly advantageous when non-newtonian fluids are to be mixed together, for, in contrast to all other impellers, the assembly illustrated in FIG. 13 and described hereinabove occupies the entire cross-sectional area of the mixing vessel, whereby the peripheral dead area possibly resulting from the existence of a mixed fluid shearing threshold is eliminated.
Of course, this invention should not be construed as being strictly limited by the specific embodiments described, illustrated and suggested herein, since various modifications and variations may be made thereto without departing from the basic principles of the invention as set forth in the appended claims. | An impeller for producing a stirring action within a fluid medium contained in a vessel includes blades, each blade being shaped to produce a variation in the lift coefficient of the impeller from the rotational axis thereof to the blade tip, in order to provide a centrifugal or centripetal component, as case may be, of the outflaring or reduction imparted to the impeller blowing cone. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a gun lock, namely to a device which can be engaged with a gun so that the gun is rendered incapable of being fired until the device is disengaged.
At present, there are wall-mounted brackets, racks and the like by means of which a gun such as a rifle or shotgun can be immobilised. But if a gun is released so as to be portable, there is no convenient way of rendering it inoperable by unauthorised persons.
Various gun locks have been proposed. GB No. 2,143,623 and U.S. Pat. No. 4,512,099 disclose devices that are insertable into gun barrels and lockable by radial expansion. These have various disadvantages. For example, they do not prevent the accidental firing of a gun. U.S. Pat. Nos. 3,392,471, 4,084,341 and GB No. 1,290,330 disclose devices having two plates connectable by shanks. In use the plates are located on respective sides of a trigger guard and clamped firmly together by the shank which passes through the guard. Such constructions are not convenient to use, and suit only a limited range of guns. U.S. Pat. Nos. 4,654,992, 4,723,370 and GB No. 2,044,417 disclose locks having pairs of jaws that are relatively movable. Thus U.S. Pat. No. 4,723,370 discloses a device having a ratchet arm that is slidable through a slot in a body when a detent is released with a key. The arm and the body have hook formations pointing away from each other. For use, the arm is slid to bring the hooks close together, and they are inserted into a trigger guard so that one engages the guard and the other engages the trigger. They are then manually urged as far apart as possible, and locked by removal of the key. This operation is rather tricky. The fact that both body and arm have to be insertable between a trigger and a guard imposes severe manufacturing constraints. A particular device is likely to fit only a limited range of guns.
SUMMARY OF THE INVENTION
The present invention provides a lock for a gun comprising:
a body having a rear face;
first and second elongate jaw means mounted to said body and extending rearwardly of said rear face, said first and second jaw means having oppositely directed hook formations;
pivot means pivotally mounting said first jaw means to said body so that it is pivotable towards and away from said second jaw means;
cam means displaceably mounted to said body adjacent said first jaw means, said cam means having a cam surface and said first jaw means having follower means for cooperating with said cam surface, said cam surface being shaped so that displacement of the cam means in one sense urges said first jaw means to pivot away from said second jaw means; and
security actuator means for actuating displacement of said cam means.
Thus the lock can be used to hold components apart, particularly relatively movable portions of a gun, e.g. a trigger and a trigger guard, or the finger grip portion of the action of a pump action shotgun and a fixed part of the stock. Of course, such a lock can also be used for other purposes.
The cam means may be rotary. The security actuation means may be operable by insertion and rotation of a key, or by rotating combination tumblers.
A key lock may comprise a member rotatable by means of a key, said cam means being rotatable by engagement with said member. Preferably this engagement is via a lost motion coupling. Thus a key may be insertable and removable only in a specific orientation, and a key that has been inserted and turned to rotate the cam to a desired extent can be returned to that orientation for removal without displacing the cam.
In another aspect, the invention provides, in combination, a gun and a said lock.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a gun lock embodying the invention, partly cut away;
FIG. 2 is a plan view; and
FIG. 3 is a side elevation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The illustrated lock 10 has a body providing a hollow casing 12 having approximately D-shaped front and rear flat walls 14,16 and a peripheral wall 18. A fixed jaw 20 projects from the rear wall 16, adjacent a slot 22 through which a movable jaw 24 projects. The movable jaw 24 comprises a projecting arm portion 26, and a lever portion 28 which extends at an angle to the projecting portion within the casing 12. The lever portion 28 is generally triangular in shape, one vertex being fast with the projecting portion 26, and one vertex being pivotally mounted (30) to brackets 32 that project inwardly from the rear wall 16. The slot 22 allows the movable jaw 24 to pivot, so that the projecting portion 26 is movable towards and away from the fixed jaw 20. Both have, at their outer ends, oppositely directed hook portions 34.
A cam 36 with a spiral cam surface 38 is rotatably mounted on the inner face of the rear wall 16 so that its cam surface 38 confronts the movable jaw 24, adjacent the vertex 29 of the lever portion which is fast with the projecting portion. The movable jaw 24 is urged against the cam surface 38 by means of a spring 40 extending between the lever portion 28 and a peg 42 projecting from the rear wall 16. Rotation of the cam 36 causes displacement of the movable jaw 24 away from the fixed jaw 20. The cam 36 bears a pair of inwardly projecting pins 44, diametrically opposite one another.
A lock assembly 46 is mounted to the front wall 14. It includes a key plate 48 fast with the front wall, and a rear actuating member 50 which is rotatable by means of a key 52 when this is inserted into the lock and turned. The actuating member 50 is coaxial with the cam 36. It has a radial projection 52 for abutting the pins 44 of the cam. The arrangement of the projection 52 and the pins 44 constitutes a lost motion coupling. Thus when the key 52 is inserted in the lock and turned, the cam 36 is not moved until the actuating member 50 has moved so that its projection 52 engages a pin 44. Thereafter, continued rotation of the member 50 rotates the cam. If it is being rotated clockwise (as viewed in FIG. 1), then the movable jaw 24 is moved progressively away from the fixed jaw 20. At any time the rotation can be stopped. The key can be turned back to the vertical position without moving the cam, and the key can then be withdrawn.
For use, the movable jaw 26 will initially be close to the fixed jaw 20. The jaws are then engaged with members that are to be held relatively immobile, e.g. between a trigger and a trigger guard. The key is then inserted and turned to move the movable jaw 26 until the engagement with the trigger and guard is such that it can be moved no farther. The key is then turned back to the vertical position and removed.
The body of the lock 10 can be formed of metal. For the jaws, a preferred material is hardened nitrile rubber. This is very tough. Its non-slip surface facilitates engagement. If someone endeavours to smash off the lock using a hammer, it is far more likely that the trigger of the gun will be broken than that the lock will break.
While the invention has been described above with reference to the preferred embodiment, it will be understood by those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the invention; and it is intended to cover all such changes and modifications by the appended claims. | A gun lock has two relatively movable and lockable hooked jaws for restraining movement of components of a gun that must be relatively moved for its operation (e.g. trigger and guard, or grip and stock of a pump action shotgun). The jaws project rearwardly from a body housing a cam rotatable via a key to displace one jaw away from the other. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates primarily to sign displays in stores, or the like and particularly with respect to quick-connect-disconnect attachments for securing displays of this type to a ceiling.
2. Description of the Prior Art
Heretofore, it has been a general practice, particularly with respect to store displays, to mount placards, or signs such as advertising displays, by supporting then directly on the store shelves, or counter tops and when advertising banners were to be supported from the walls or ceiling of the store, fastenings of various types were secured directly to the walls, or ceiling and the banners were connected to such fastenings. However, the fastenings usually were of a semi-permanent nature and consequently when they were installed damage to the store structure resulted which had to be patched or restored to avoid unsightlyness.
SUMMARY OF THE INVENTION
This invention provides a ceiling hung suspension fixture for advertising signs, or the like, including so called swag lamps and hanging plants, or any element intended to be suspended from a ceiling. The invention includes a twist-lock element for attachment to an existing ceiling beam such as the flanged rails used in supporting a dropped ceiling which may be translucent and conceals plumbing fixtures, light fixtures, ducts and other elements encountered in buildings when such elements are normally maintained out of sight. The flanged rails for supporting the ceiling panels of such a dropped ceiling are usually of an inverted T-section so that oppositely extending horizontal flanges are disposed beneath adjacent ceiling panels in supporting relationship with the panels merely lying on the flanges and prevented from shifting by the upstanding web of the T-section.
The twist-lock element is adapted to engage and be supported from the T-section flanges and for this purpose the twist-lock device includes a flat seating surface on its upper face with spaced apart upward projections each having a laterally directed fin. These fins are adapted to engage over the T-section flanges when the element is twisted thus to attach the twist-lock element to the ceiling T-section. The twist-lock element includes a downwardly extending bottom flange forming an anchor point for attaching supports for signs, or placards, or such articles as may be suspended from a ceiling. When furnished as a ceiling support for store devices a suitable cord may be secured to the depending flange and wound thereabout as a convient means of attaching a sign or the like to a store ceiling.
OBJECTS OF THIS INVENTION
The primary purpose of this invention is to provide a ceiling hanging device that may be readily attached to a ceiling member and just as readily detached without damaging the ceiling in anyway.
The principal object of the invention is the provision of a hang-up device that may be secured to a ceiling element by a twist-lock action to provide a very simple attachment that is easily installed and removed.
An important object of the invention is to provide a hang-up device having a flat upper seating surface with a pair of spaced apart upward projections each having a laterally directed fin for engagement over respectively opposite flanges of a ceiling member and a downwardly extending flange on the hang-up device providing an anchor element.
Another object of the invention is the provision of a suspended type ceiling hang-up device in combination with a ceiling member having oppositely extending flanges to which the hang-up device may be secured by a slight twisting action.
A further object of the invention is to provide a ceiling hang-up device including an upwardly directed flat seating surface having a pair of spaced apart upward projections each of which has a laterally directed fin and a downwardly extending bottom flange on the underside of the hang-up device having an anchor element for a cord adapted to be wound around the bottom flange and secured in a slot provided in the flange.
DESCRIPTION OF THE DRAWINGS
The foregoing and other and more specific objects of the invention are attained by the structure and arrangement illustrated in the accompanying drawings wherein
FIG. 1 is a top plan view of a ceiling hang-up device showing the pair of upward projections and respective laterally directed fins;
FIG. 2 is an exploded side view of the hang-up device disposed immediately beneath the ceiling in position to be raised against the underside of the ceiling panels at opposite sides of the supporting flanges;
FIG. 3 is an end elevational view of the hang-up device clearly showing the upward projection and laterally extending fin with the downwardly extending flange;
FIG. 4 is a sectional view through the hang-up device at the upward projection showing one of the laterally directed fins;
FIG. 5 is a top plan view of a ceiling adaptor for securement to a ceiling and having oppositely directed flanges for embracement by the opposite fins of a hang-up device;
FIG. 6 is a side elevational view of the adaptor of FIG. 5;
FIG. 7 is an exploded side elevational view of a form of the adaptor wherein two plates are secured together to form the adaptor;
FIG. 8 is a perspective view of another adaptor which is secured to the ceiling by self-adhering means;
FIG. 9 is a top plan view of a preferred form of hang-up device of narrower form but having the upward projections in spaced relation and laterally directed fins;
FIG. 10 is a side elevational view of the hang-up device of FIG. 9 showing the downwardly extending flange and the upward projections with laterally extending fins;
FIG. 11 is an elevational view of a mounting device for use with the hang-up fixture; and
FIG. 12 is a top plan view of the upper mounting end of the device of FIG. 11;
DESCRIPTION OF FIRST EMBODIMENT
In the drawings as shown in FIGS. 1-4, a hang-up fixture 1 is illustrated as having an upwardly disposed flat surface 2 which is circular and which comprises a seating surface adapted to engage a ceiling member such as an inverted T-section strip 15. The surface 2 of the hang-up fixture engages the underside of the horizontally extending flanges 15.1 of the T-section while the ceiling panels 16 are supported on the upper surfaces of the flanges at opposite sides of the T-section vertical web 15.2. The ceiling panels 16 merely rest on the flanges 15.1 so that they can readily be raised slightly to install the hang-up fixtures as will hereinafter appear.
The hang-up fixture 1 includes a pair of spaced apart upward projections 3 which are spaced sufficiently to receive the flanges 15.1 of the T-section between the projections so that the flat surface 2 bears against the underside of the flanges. The upward projections 3 each have a laterally extending fin 4 which it will be noted parallels the adjacent side edge of the flange 15.1 as best shown in FIG. 4 and when the hang-up fixture 1 is disposed in the relative position shown in FIG. 1 the upward projections 3 and fins 4 are disposed at the respective sides of the flanges 15.1 so that in applying the hang-up fixture to the T-section it may be said that the upward projections and fins straddle the horizontal flanges.
With the hang-up fixture in this relative position it is necessary merely to twist the fixture slightly whereupon the fins 4 will engage over the top surfaces of the respectively adjoining flanges 15.1 so that the fixture will thereby be effectively locked to the T-section with the respective flanges 15.1 engaged in the slot 10 formed by the fins. The fins 4 thus engage under the ceiling panels 16 lifting them slightly as the fins pass over the upper surface of the flanges 15.1 but since the ceiling panels are relatively light weight this involves no difficulty. The ceiling panels are of plastic material and usually translucent to provide for light transmission from lighting elements above the ceiling but concealing the lights from view beneath the ceiling.
The hang-up fixture 1 is provided with a downwardly extending flange 5 on its underside and this flange incorporates an eyelet, or opening 8, as best illustrated in FIG. 2. The opening 8 provides a convenient anchor point for securement of a cord, or the like, or possibly a hook of some kind to which advertising cards, or banners are attached. A cord for instance might be tied quite readily through the opening 8. The dependent flange affords a convenient place to grasp the hang-up fixture when applying the device to the T-section 15 and the flat sides 7 also enables the fixture to be held securely for placement relative to the flanges 15.1 and provides an effective means of twisting the fixture into locked relationship with the flanges.
DESCRIPTION OF PREFERRED EMBODIMENT
The hang-up fixture 41 illustrated in FIGS. 9 and 10 represents the preferable form of the invention reduced to its simplest structure and which makes for the most effective installation and ready attachment of articles to be hung therefrom. In this embodiment the hang-up fixture has a flat upper seating surface 42 but this area of the fixture is of narrower construction than the fixture of FIG. 1 so that the device takes a somewhat elongated shape that actually makes for better handling as well as a more attractive appearance. The length of the device is substantially similar to the diameter of the FIG. 1 form of the hang-up device.
The fixture 41 incorporates a pair of upward projections 43 that are spaced apart by a dimension such that the flanges 15.1 of the inverted T-section may be received therebetween with the upper flat surface 42 of the fixture bearing against the bottom surface of the flanges. Each upward projection 43 is provided with a laterally extending fin 44 that will overlie the adjacent flange 15.1 when the hang-up fixture is installed on the T-section. With the T-section bottom flanges disposed between the projections 43 it is necessary merely to twist the fixture 41 slightly to engage the fins 44 over the horizontal flanges and beneath the ceiling panels 16 to securely lock the hang-up fixture on the T-section. The flanges of the T-section fit into slots 50 formed between the fins and the surface 42 just as in the FIG. 1 form of the invention.
A downwardly extending flange 45 having the flat side surfaces 47, depends from the underside of the hang-up device as best illustrated in FIG. 10. This depending flange in this form of the invention performs several functions. It provides the most convenient place to grasp the hang-up fixture to apply the device to the T-section flanges 15.1, the flat sides 47 enabling the fixture to be held securely for proper placement relative to the horizontal flanges and affords the most effective means for twisting the fixture into locked position relative to the flanges.
The depending flange 45 also is equipped for receiving a suitable length of cord to be wound thereabout when not in use. Such a cord may be secured to an anchor member 51 that is formed integrally with the flange 45 more or less centrally thereof but adjacent to the bottom of the flange. A cord might be tied to this anchor point and wound about the flange and the free end of the cord caught in one or the other of the bottom slots 52 formed in the bottom edge of the flange thus to secure the cord against coming loose. Projection 53 on the face of the flange 45 prevent the cord wound about the flange from slipping downwardly and possibly come off the flange.
INSTALLATION EQUIPMENT
FIGS. 11 and 12 illustrate an installing device that might be utilized with either form of the hang-up fixture as represented by the device shown in FIG. 2 or that illustrated in FIG. 10. This device comprises essentially an extension pole 55 having a forked head 54 secured thereto at its upper end. The pole 55 may be hollow and the head 54 secured thereto by means of a bottom projection on the head which is entered into and secured in the top end of the hollow pole. The head 54 is adapted to receive either the flange 5 of the first form of the invention, or the flange 45 of the preferred form and to this end the forked head is provided with an upwardly facing slot 57 in which the flange 5, or the flange 45, is inserted when it is desired to install one or the other of the hang-up fixtures on the T-section flange 15.1. In this manner a person standing on the floor may install as many of the hang-up fixtures as may be required without the necessity of using a ladder to stand on in order to reach the ceiling.
CEILING FIXTURES
Where a store or other area may not be equipped with a drop ceiling of the type utilizing the inverted T-section strips 15 for supporting ceiling panels 16 mounted thereon it is possible to provide fixtures for attachment to a ceiling to which the hang-up fixtures can be secured in exactly the way they are mounted on the T-section strips. In FIGS. 5,6 and 7 a fixture is shown that is adapted to be secured to a ceiling by a single screw which may be countersunk as indicated by the counter-bored hole 28 as indicated in FIG. 6. The ceiling device 20 of these Figures is disclosed as being comprised of two flat plates, or strips 21 and 22 which are secured together face to face by cement, or the like.
The strips are of similar thickness and length and have end portions that are arcuate as at 25 between the parallel longitudinal side edges 24. The arcs thus indicated are of substantially the same radius as that of the circular fixture 1, illustrated in FIG. 1, whereby the hang-up devices will mate with the ceiling fixture and function just as in the attachment to the T-section strip 15. The strip 22 disposed at the bottom of the assembly is of full extent both longitudinally and across the full width thereof but the top strip 21 has two diagonally opposite corners cut away as at 21.2. These cut away portions are cut on an arc and extend approximately the longitudinal center line of this strip where the longitudinal edge 21.3 extends to the respectively adjacent arcuate end of the fixture. The end portions 23 of the top strip 21 extend fully to the opposite ends of the assembled strips even through this area is disposed only to one side of the center line 21.3 at the areas opposite to the diagonal corner recesses provided for receiving the fins 4 or 44.
The fixture 20 of course could be of integral molded construction if preferred whereby the recesses afforded by the cut-away areas 21.2 would provide pockets into which the fins 4 or 44 would be received. The laminated strips 21 and 22 however afford an economical way of achieving the same result. The bottom strip 22 at the diagonally opposite corners will be spaced from the ceiling by the thickness of the top strips 21 so that when the hang-up fixture is placed astraddle of the fixture 20 and twisted, the fins 4 or 44 will enter the spaces between the strip 22 and the ceiling at the diagonal corners and be secured just as described in reference to the T-section installation.
Another form of ceiling fixture for the attachment of the hang-up fixtures is illustrated in FIG. 8. In this form a ceiling element 30 of generally H-shape in section lying on its side, having lower and upper oppositely extending flanges 31 and 32 spaced apart and connected by a vertical web 33. On the top surface of the upper flange 32 a self-adhesive 33.1 is applied and this is covered by a releasable protective sheet 34. Thus when this fixture is to be applied to a ceiling the protective sheet 34 is removed and the exposed adhesive 33.1 is pressed against the ceiling in the desired location to stick the H-section fixture to the ceiling. In this manner the lower flange 31 is disposed to receive the hang-up devices 4 or 44 exactly as described in connection with the installation on the bottom flange of the T-section strip 15. The hang-up device will be positioned astraddle of the flange 31 and then twisted slightly to lock and secure the device on this bottom flange.
From the above description it is apparent that the word "ceiling" as herein used is intended to include not only the overhead inside lining of a room, but also, the under side of shelving or of a support on the underside of a cabinet from which it may be desired to suspend an object by means of a hang-up device, which device may be secured in place by using an adapter of FIGS. 5 or 8 if there is no ceiling member such as the strip 15. | The invention relates to a hang-up fixture for ceiling mounting adapted to have a twist-lock releasable connection with a ceiling element to provide a support for a hanging article such as a display sign, or banner in a store, or a hanging plant, or lamp, or the like. | 5 |
This is a continuation of application Ser. No. 741,068, filed 6/4/85.
BACKGROUND OF THE INVENTION
Trauma to the brain or spinal cord caused by physical forces acting on the skull or spinal column, by ischemic stroke, arrested breathing, cardiac arrest, Reye's syndrome, cerebral thrombosis, cerebral embolism, cerebral hemorrhage, encephalomyelitis, hydrocephalus, post-operative brain injury, cerebral infections and various concussions results in edema and swelling of the affected tissues. This is followed by ischemia, hypoxia, necrosis, temporary or permanent brain and/or spinal cord injury and may result in death. The tissue mainly affected are classified as grey matter, more specifically astroglial cells. The specific therapy currently used for the treatment of the medical problems described include various kinds of diuretics (particularly osmotic diuretics), steroids (such as, 6-α-methylprednisolone succinate) and barbiturates. The usefulness of these agents is questionable and they are associated with a variety of untoward complications and side effects. Thus, the compounds of this invention comprise a novel and specific treatment of medical problems where no specific therapy is available.
A recent publication entitled "Agents for the Treatment of Brain Injury" 1. (Aryloxy)alkanoic Acids, Cragoe et al, J. Med. Chem., (1982) 25, 567-79, reports on recent experimental testing of agents for treatment of brain injury and reviews the current status of treatment of brain injury.
Some compounds having structures related to the compounds of the present invention have been reported to be diuretic and saluretic agents in U.S. Pat. No. 4,249,021 of Cragoe et al. and as useful in the treatment of calcium oxalate kidney stone formation in U.S. Pat. No. 4,342,776 of Cragoe, et al. Additionally, Williams, H. W. R. et al., J. Org. Chem., 44, 4060 (1979), a pertinent reference, reported a method of synthesis of related compounds. There is, however, no suggestion in the patents or publication that any of the compounds disclosed therein would be of use in the treatment of brain injury.
The compounds of the invention have the added advantage of being devoid of the pharmacodynamic, toxic or various side effects characteristic of the diuretics, steroids and barbiturates.
DESCRIPTION OF THE INVENTION
The compounds of the instant invention are best characterized by reference to the following structural Formula (I): ##STR1## wherein R is aryl such as phenyl, halo substituted aryl such as p-fluorophenyl or p-chlorophenyl or cycloalkyl containing from 3 to 6 nuclear carbon atoms such as cyclopropyl, cyclobutyl, cyclopentyl and the like. R 1 is hydrogen or lower alkyl, branched or unbranched, containing from 1 to 5 carbon atoms such as methyl, ethyl, n-propyl, isopropyl and the like. R 2 is hydrogen, lower alkyl or lower alkyl-amino-lower-alkyl such as 2-(dimethylamino)ethyl. X and Y are halo or lower alkyl, and n is 2 to 6.
When the R and R 1 substituents are different, the 2-position carbon atom of the indane ring is asymmetric and these compounds of the invention are racemic. However, these compounds or their precursors can be resolved so that the pure enantiomers can be prepared, thus the invention includes the pure enantiomers. This is an important point since some of the racemates consist of one enantiomer which is much more active than the other one. Furthermore, the less active enantiomer generally possesses the same intrinsic toxicity as the more active enantiomer. In addition, it can be demonstrated that the less active enantiomer depresses the inhibitory action of the active enantiomer at the tissue level. Thus, for three reasons it is advantageous to use the pure, more active enantiomer rather than the racemate.
Since the products of the invention are acidic, the invention also includes the obvious pharmaceutically acceptable salts, such as the sodium, potassium, ammonium, trimethylammonium, piperazinium, 1-methylpiperazinium, guanidinium, bis-(2-hydroxyethyl)ammonium, N-methylglucosammonium and the like salts.
It is also to be noted that the compounds of Formula I, as well as their salts, often form solvates with the solvents in which they are prepared or from which they are recrystallized. These solvates may be used per se or they may be desolvated by heating (e.g. at 70° C.) in vacuo.
Although the invention primarily involves novel (2,3-dihydro-1-oxo-1H-inden-5-yl)alkanoic acids, and their salts, it also includes their derivatives, such as esters, amides, oximes, hydrazones and the like. Additionally, this invention includes pharmaceutical compositions in unit dosage form containing a pharmaceutical carrier and an effective amount of a compound of Formula I, its (-) or (+) enantiomer, or the pharmaceutically acceptable salts thereof, for treating brain injury. The method of treating a person with brain injury by administrating said compounds or said pharmaceutical compositions is also a part of this invention.
PREFERRED EMBODIMENT OF THE INVENTION
The preferred embodiments of the instant invention are realized in structural Formula II wherein: ##STR2## R 3 is aryl, such as phenyl, halo substituted aryl, such as p-fluorophenyl or p-chlorophenyl, or cycloalkyl containing from 3 to 6 nuclear carbon atoms such as cyclopropyl, cyclobutyl, cyclopentyl and the like; R 4 is lower alkyl containing from 1 to 5 carbon atoms; n is 2 to 6.
Also included are the enantiomers of each racemate.
Preferred compounds are 5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid, its (+) and (-) enantiomers, and their salts.
Other preferred compounds are 3-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)propionic acid, its (+) and (-) enantiomers, and their salts.
Other preferred compounds are 3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)propionic and, its (+) and (-) enantiomers, and their salts.
Especially preferred are the pure enantiomers since, in most instances, one enantiomer is more active biologically than its antipode.
Included within the scope of this invention are the pharmaceutically acceptable salts of (2,3-dihydro-1-oxo-1H-inden-5-yl)alkanoic acids since a major medical use of these compounds is solutions of their soluble salts which can be administered parenterally.
Thus, the acid addition salts can be prepared by the reaction of the substituted (2,3-dihydro-1-oxo-1H-inden-5-yl)alkanoic acids of this invention with an appropriate amine, ammonium hydroxide, guanidine, alkali metal hydroxide, alkali metal carbonate, alkali metal bicarbonate, quaternary ammonium hydroxide and the like. The salts selected are derived from among the non-toxic, pharmaceutically acceptable bases.
The synthesis of the (2,3-dihydro-1-oxo-1H-inden-5-yl)alkanoic acids of Formula I are generally carried out by the following route illustrated by preparation of 5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid.
The starting material, 2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one, dissolved in dimethylformamide was treated with potassium carbonate and trifluoromethanesulfonyl chloride to form (2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)trifluoromethanesulfonate (Step 1). This material was subjected to triflate displacement by reaction with diethyl malonate to form diethyl-5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)malonate (Step 2). The malonate of Step 2 was then alkylated with ethyl 4-bromobutyrate to form diethyl 2-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-2-(ethoxycarbonyl)-1,6-hexanedioate (Step 3). Upon hydrolysis the hexanedioic acid is formed (Step 4) which undergoes monodecarboxylation by treatment with copper in quinoline to form a compound of the present invention such as 5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid (Step 5). The starting materials used in these examples is obtained as shown in the Journal of Medicinal Chemistry, 20, 1400 (1977); and 21, 437 (1978). This synthetic route is illustrated below: ##STR3##
Those compounds possessing an asymmetric carbon atom at the 2-position of the indane ring consist of a racemate composed of two enantiomers. The resolution of the two enantiomers may by accomplished by forming a salt of the racemic mixture with an optically active base such as (+) or (-)amphetamine, (-)cinchonidine, dehydroabiethylamine, (+) or (-)-α-methylbenzylamine, (+) or (-)(1-naphthyl)ethylamine. (+)cinchonine, brucine, or strychnine and the like in a suitable solvent such as methanol, ethanol, 2-propanol, benzene, acetonitrile, nitromethane, acetone and the like. There is formed in the solution, two diastereomeric salts, one of which is usually less soluble in the solvent than the other. Repetitive recrystallization of the crystalline salt generally affords a pure diastereomeric salt from which is obtained the desired pure enantiomer. The optically pure enantiomer of the compound of Formula I is obtained by acidification of the salt with a mineral acid, isolation by filtration and recrystallization of the optically pure antipode.
The other optically pure antipode may generally be obtained by using a different base to form the diastereomeric salt. It is of advantage to isolate the partially resolved acid from the filtrates of the purification of the first diastereomeric salt and to further purify this substance through the use of another optically active base. It is especially advantageous to use an optically active base for the isolation of the second enantiomer which is the antipode of the base used for the isolation of the first enantiomer. For example, if (+)-α-methylbenzylamine was used first, then (-)-α-methylbenzylamine is used for the isolation of the second (remaining) enantiomer.
The acid addition salts are prepared by reacting the acids of Formula I with an appropriate base, for example, alkali metal or alkaline earth bicarbonate, carbonate or alkoxide, an amine, ammonia, an organic quaternary ammonium hydroxide, guanidine and the like.
The reaction is generally conducted in water when alkali metal hydroxides are used, but when alkoxides and the organic bases are used, the reaction may be conducted in an organic solvent, such as ether, ethanol, dimethylformamide and the like.
The preferred salts are the pharmaceutically acceptable salts such as sodium, potassium, ammonium and the like.
Inasmuch as there are a variety of symptoms and severity associated with grey matter edema, particularly when it is caused by head trauma, stroke, cerebral hemorrhage or embolism, post-operative brain surgery trauma, spinal cord injury, cerebral infections and various brain concussions, the precise treatment is left to the practioner. Generally, candidates for treatment will be indicated by the results of the patient's initial general neurological status, findings on specific clinical brain stem functions and findings on computerized axial tomography (CAT) scan of the brain. The sum of the neurological evaluation is presented in the Glascow Coma Score or similar scoring system. Such a scoring system is often valuable in selecting the patients who are candidates for therapy of this kind.
The compounds of this invention can be administered by a variety of established methods, including intravenously, intramuscularly, subcutaneously, or orally. The parenteral route, particularly the intravenous route of administration, is preferred, especially for the very ill and comatose patient. Another advantage of the intravenous route of administration is the speed with which therapeutic brain levels of the drug are achieved. It is of paramount importance in brain injury of the type described to initiate therapy as rapidly as possible and to maintain it through the critical time periods. For this purpose, the intravenous administration of drugs of the type of Formula I in the form of their salts is superior.
A recommended dose range for treatment is expected to be from 0.05 mg/kg to 50 mg/kg of body weight as a single dose, preferably from 0.5 mg/kg to 20 mg/kg. An alternative to the single dose schedule is to administer a primary loading dose followed by a sustaining dose of half to equal the primary dose, every 4 to 24 hours. When this multiple dose schedule is used the dosage range may be higher than that of the single dose method. Another alternative is to administer an ascending dose sequence of an initial dose followed by a sustaining dose of 11/2 to 2 times the initial dose every 4 to 24 hours. For example, 3 intravenous doses of 8, 12 and 16 mg/kg of body weight can be given at 6 hour intervals. If necessary, 4 additional doses of 16 mg/kg of body weight can be given at 12 hour intervals. Another effective dose regimen consists of a continuous intravenous infusion of from 0.05 mg/kg/hr. to 3.0 mg/kg/hr. Of course, other dosing schedules and amount are possible.
One aspect of this invention is the treatment of persons with grey matter edema by concomitant administration of a compound of Formula I or its pharmaceutically acceptable salts, and an antiinflammatory steroid. These steroids are of some, albeit limited, use in control of white matter edema associated with ischemic stroke and head injury. Steroid therapy is given according to established practice as a supplement to the compound of Formula I as taught elsewhere herein. Similarly, a barbiturate may be administered as a supplement to treatment with a compound of Formula I.
The compounds of Formula I are utilized by formulating them in a composition such as tablet, capsule or elixir for oral administration. Sterile solutions or suspensions can be used for parenteral administration. A compound or mixture of compounds of Formula I, or its physiologically acceptable salt, is compounded by a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, flavor, etc. in a dosage form as called for by accepted pharmaceutical practice.
Illustrative of the adjuvants which may be incorporated in tablets, capsules and the like are the following: a binder such as gum tragacanth, acacia, corn starch or gelatin; an excipient such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; a sweetening agent such as sucrose, lactose, or saccharin; a flavoring agent such as peppermint, oil of wintergreen or cherry. When the dosage unit from is a capsule, it may contain in addition to materials of the above type a liquid carrier such as a fatty oil. Various other materials may be present as coatings or to otherwise enhance the pharmaceutical elegance of the preparation. For instance, tablets may be coated with shellac, sugar or the like. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propyl parabens as preservatives, a dye and a flavoring such as cherry or orange flavor.
Sterile compositions for injection or infusion can be formulated according to conventional pharmaceutical practice by dissolving the active sustance in a conventional vehicle such as water, saline or dextrose solution by forming a soluble salt in water using an appropriate base, such as a pharmaceutically acceptable alkali metal hydroxide, alkali metal bicarbonate, ammonia, amine or guanidine. Alternatively, a suspension of the active substance in a naturally occurring vegetable oil like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or a synthetic fatty vehicle like ethyl oleate or the like may be formulated for injection or infusion. Buffer, preservatives, antioxidants and the like can be incorporated as required.
The basic premise for the development of agents for the treatment of brain injury of the types described is based on the studies in experimental head injury by R. S. Bourke et. al. (R. S. Bourke, M. A. Daze and H. K. Kimelberg, Monograph of the International Glial Cell symposium, Leige, Bel. Aug. 29-31, 1977 and references cited therein) and experimental stroke by J. H. Garcia et. al. (J. H. Garcia, H. Kalimo, Y. Kamijyo and B. F. Trump, Virchows Archiv. [Zellopath.], 25, 191 (1977).
These and other studies have shown that the primary site of traumatic brain injury is in the grey matter where the process follows a pattern of insult, edema, ischemia, hypoxia, neuronal death and necrosis followed, in many instances, by irreversible coma or death. The discovery of a drug that specifically prevents the edema would obviate the sequalae.
Experimental head injury has been shown to produce a pathophysiological response primarily involving swelling of astroglia as a secondary, inhibitable process. At the molecular level, the sequence appears to be: trauma, elevation of extracellular K + and/or release of neurotransmitters, edema, hypoxia and necrosis. Astroglial swelling results directly from a K + -dependent, cation-coupled, chloride transport from the extracellular into the intracellular compartment with a concommitant movement of an osmotic equivalent of water. Thus, an agent that specifically blocks chloride transport in the astroglia is expected to block the edema caused by trauma and other insults to the brain. It is also important that such chloride transport inhibitors be free or relatively free of side effects, particularly those characteristics of many chloride transport inhibitors, such as diuretic properties. Compounds of the type illustrated by Formula I exhibit the desired effects on brain edema and are relative free of renal effects.
That this approach is valid has been demonstrated by the correlation of the in vitro astroglial edema inhibiting effects of chloride transport inhibitors with their ability to reduce the mortality of animals receiving experimental in vivo head injury. As a final proof, one compound (ethacrynic acid) which exhibited activity both in vitro and in vivo assays was effective in reducing mortality in clinical cases of head injury. These studies are described in the Journal of Medicinal Chemistry, Volume 25, page 567 (1982), which is hereby incorporated by reference.
Three major biological assays can be used to demonstrate biological activity of the compounds. The (1) in vitro cat cerebrocortical tissue slice assay, (2) the in vitro primary rat astrocyte culture assay and (3) the in vivo cat head injury assay. The first assay, the in vitro cat cerebrocortical tissue slice assay has been described by Marshall, L. F.; Shapiro, H. M.; Smith, R. W. In "Seminars in Neurological Surgery: Neural Trauma"; Popp, A. J.; Bourke, R. S.; Nelson, L. R.; Kimelberg, H, K,. Eds.; Raven Press: New York, 1979; p. 347, by Bourke, R. S.; Kimelberg, H, K.; Daze, M. A. in Brain Res. 1978, 154, 196, and by Bourke, R. S.; Kimelberg, H. K,; Nelson, L. R. in Brain Res. 1976, 105, 309. This methos constitutes a rapid and accurate method of determining the intrinsic chloride inhibitory properties of the compounds of the invention in the target tissue.
The second assay method involves the in vitro primary rat astrocyte assay. The method has been described by Kimelberg, H. K.; Biddlecome, S.; Bourke, R. S. in Brain Res. 1979, 173, 111, by Kimelberg, H. K.; Bowman, C.; Biddlecome, S.; Bourke, R. S., in Brain Res. 1979, 177, 533, and by Kimelberg, H. K.; Hirata, H. in Soc. Neurosci. Abstr. 1981, 7, 698. This method is used to confirm the chloride transport inhibiting properties of the compounds in the pure target cells, the astrocytes.
The third assay method, the in vivo cat head injury assay has been described by Nelson, L. R.; Bourke, R. S.; Popp, A. J.; Cragoe, E. J. Jr.; Signorelli, A.; Foster, V. V.; Creel, in Marshall, L. F.; Shapiro, H. M.; Smith, R. W. In "Seminars in Neurological Surgery: Neural Trauma"; Popp, A. J.; Bourke, R. S.; Nelson, L. R.; Kimelberg, H. K., Eds.; Raven Press: New York, 1979; p. 297.
This assay consists of a highly relevant brain injury in cats which is achieved by the delivery of rapid repetitive acceleration-deceleration impulses to the animal's head followed by exposure of the animals to a period of hypoxia. The experimental conditions of the assay can be adjusted so that the mortality of the control animals falls in the range of about 25 to 75%. Then, the effect of the administration of compounds of this invention in reducing the mortality over that of the control animals in concurrent experiments can be demonstrated.
Using the in vitro cat cerebrocortical tissue slice assay, described in Example 1, compounds of the present invention exhibited marked activity. This test provided the principal in vitro evaluation and consisted of a determination of concentration vs. response curve. The addition of HCO 3 - to isotonic, K + -rich saline-glucose incubation media is known to specifically stimulate the transport of Cl - coupled with Na + and an osmotic equivalent of water in incubating slices of mammalian cerebral cortex. Experiments have demonstrated that the tissue locus of swelling is an expanded astroglial compartment. Thus, the addition of HCO 3 - to incubation media stimulated statistically significant and comparable increases in cerebrocortical tissue swelling and ion levels. After addition of drug to the incubation media, detailed drug concentration-response curves were then obtained. The data were expressed as percent HCO 3 - -stimulated swelling vs. drug concentration, from which the concentration of drug providing 50% inhibition of HCO 3 - -stimulated swelling (I 50 in molarity) was interpolated. The results which illustrate the instant invention are expressed in Table I, below:
TABLE I______________________________________ Enantiomer I.sub.50, M______________________________________5-(2-methyl-6,7-dichloro- ± (racemate) 2 × 10.sup.-82-cyclopentyl-2,3-dihydro-1-oxo-1H--inden-5-yl)-pentanoic acid______________________________________
Thus, in the in vitro assay compounds of Formula I inhibit chloride transport by 50% at concentrations as low as 10 -8 molar.
The following examples are included to illustrate the in vitro cerebrocortical tissue slice assay, the preparation of representative compounds of Formula I and representative dosage forms of these compounds. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.
EXAMPLE 1
In Vitro Cerebrocortical Tissue Slice Assay
Adult cats of 2-3 kg body weight were employed in tissue slice studies. Prior to sacrifice, the animals were anesthetized with ketamine hydrochloride (Ketaset), 10 mg/kg im. Eight (three control, five experimental) pial surface cerebrocortical tissue slices (0.5-mm thick; approximately 150 mg initial fresh weight) were cut successively with a calibrated Stadie-Riggs fresh tissue microtome without moistening and weighed successively on a torsion balance. During the slice preparation all operations except weighing were confined to a humid chamber. Each slice was rapidly placed in an individual Warburg flask containing 2 ml of incubation medium at room temperature. The basic composition of the incubation media, in millimoles per liter, was as follows: glucose, 10; CaCl 2 , 1.3; MgSO 4 , 1.2; KH 2 SO 4 , 1.2; Hepes (N-2-hydroxyethylpiperazine-N'-2-ethanesulfonic acid, titrated with NaOH to pH 7.4), 20. Except when adding HCO 3 - , the osmolarity of the media was maintained isosmotic (approximately 285 mOsm/L) by reciprocal changes of Na + or K + to achieve a concentration of K + of 27 mM. The basic medium was bubbled for 30 minutes with 100% O 2 before use. When added, NaHCO 3 or triethylammonium bicarbonate (TEAB) was initially present in the sidearm of each flask at an initial concentration of 50 mM in 0.5 ml of complete medium. Nonbicarbonate control slices were incubated at 37° C. in 2.5 ml of basic medium for 60 minutes. Bicarbonate control slices were similarly incubated for an initial 20 minutes at 37° C. in 2.0 ml of basic medium to which was added from the sidearm an additional 0.5 ml of incubation medium containing 50 mM HCO 3 - , which, after mixing, resulted in a HCO 3 - concentration of 10 mM and a total volume of 2.5 ml. The incubation continued for an additional 40 minutes. The various compounds tested were dissolved by forming the sodium salts by treatment with a molar equivalent of NaHCO 3 and diluting to the appropriate concentrations. Just prior to incubation, all flasks containing HCO 3 - were gassed for 5 minutes with 2.5% CO 2 /97.5% O 2 instead of 100% O 2 .
Following the 60-minute incubation period, tissue slices were separated from incubation medium by filtration, reweighed, and homogenized in 1N HClO 4 (10% w/v) for electrolyte analysis. The tissue content of ion is expressed in micromoles per gram initial preswelling fresh weight. Control slice swelling is expressed as microliters per gram initial preswelling fresh weight. The effectiveness of an inhibitor at a given concentration was measured by the amount of HCO 3 - -stimulated swelling that occurred in its presence, computed as a percent of the maximum possible. Tissue and media Na + and K + were determined by emission flame photometry with Li + internal standard; Cl - was determined by amperometric titration. Tissue viability during incubation was monitored by manometry.
EXAMPLE 2
Preparation of 5-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid
Step A: (2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)trifluoromethanesulfonate
Racemic 2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one (34.1 g, 0.1M) was stirred in dimethylformamide (100 ml) with K 2 CO 3 (41.5 g, 0.3M) at 25° for 20 minutes. The mixture was cooled to 15°, and trifluoromethanesulfonyl chloride (19.4 g, 0.115M) was added at 15°-20° over 20 minutes. The mixture was then stirred at 25° for 30 minutes and poured into a liter of ice and water. The oil was extracted with diethyl ether (4×125 ml) and the combined organic extracts were thoroughly washed with water, dried over (MgSO 4 ) and concentrated under vacuum to obtain the product as a viscous amber oil weighing 47.3 g. This product was used in the next step without further purification.
Step B: Diethyl 5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)malonate
Diethyl malonate (43.2 g, 0.27M) dissolved in dimethylformamide (40 ml) was added with stirring under nitrogen to a suspension of 56% sodium hydride in mineral oil (11.6 g, 0.27M) in dimethylformamide (150 ml) at 8°-15°. The mixture was stirred at 25° for 1/2 hour after the addition of malonate, cooled to 5° and the (2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)trifluoromethanesulfonate (47.3 g, 0.1M) in toluene (40 ml) was added at 5°-7° over 1 hour. After stirring at 25° for 20 hours the mixture was poured into ice water (1400 ml) and extracted with diethyl ether. The ethereal extracts were washed successively with water, diluted Na 2 CO 3 , very dilute HCl, dried over MgSO 4 and concentrated under vacuum. 59 g out of the 68 g of residual oil was chromatographed twice on silica with methylene chloride elution. The material (32 g) thus obtained was dissolved in ether washed with dilute Na 2 CO 3 , water, dried over MgSO 4 and concentrated to yield the diethyl 5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)malonate as a viscous yellow oil weighing 31 g. This product was used directly in the next step.
Step C: Diethyl 2-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-2-(ethoxycarbonyl)1,6-hexanedioate
The diethyl malonate (9.67 g, 0.02M) dissolved in diemethylformamide (10 ml) and toluene (15 ml) was added with stirring at 25° over 1/2 hour under nitrogen to 56% sodium hydride in mineral oil (0.943 g, 0.022M) suspended in dimethylformamide (25 ml). The mixture was stirred 20 minutes after completion of the addition and then a few milligrams of KI followed by ethyl 4-bromobutyrate (4.49 g, 0.023M) in toluene (10 ml) were added. After stirring 30 hours at 88° the mixture was cooled, poured into ice water and extracted with diethyl ether. The ethereal extracts were washed with water, dried over MgSO 4 and concentrated under vacuum. The residue was chromatographed on silica (450 g) by first eluting with methylene chloride then 5% isopropanol/methylene chloride to obtain the product as a viscous oil (6.6 g) which was used directly in the next step.
Step D: 5-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid
The diethyl 2-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihyro-1-oxo-1H-inden-5-yl)-2-(ethoxycarbonyl)-1,6-hexanedioate (6.5 g) was refluxed with sodium hydroxide (5 g) dissolved in methanol (100 ml) and water (20 ml) for 3 hours. The mixture was cooled, diluted with water, acidified with hydrochloric acid and extracted with diethyl ether. The organic extracts were washed with water, dried over MgSO 4 and concentrated to obtain 2-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)-1,6-hexanedioic acid (4.3 g). The dioic acid was heated at 130°-135° C. for 25 minutes with copper powder (1.52 g) in quinoline (35 ml). The mixture was cooled, poured into water and extracted with diethyl ether after acidification with hydrochloric acid. The organic extracts were washed with water, dried over MgSO 4 and concentrated under vacuum. The residue was chromatographed twice on silica eluting with a mixture of toluene, dioxane and acetic acid in the ratio of 900:80:10 to obtain 2.9 g of the product as viscous oil.
Elemental analysis for: C 23 H 30 Cl 2 O 3 . Calc'd: C, 64.94%; H, 7.11%; Found: C, 64.63%; H, 7.18%
EXAMPLE 3
3-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid (+)-enantiomer
By following substantially the procedure described in Example 2, Steps A through D, but substituting for the racemic 2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one an equal quantity of (+)-2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one (J. Med. Chem., 25, 579 (1982)) there is obtained (+)-3-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid.
EXAMPLE 4
3-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid (-)-enantiomer
By following substantially the procedure described in Example 2, Steps A through D, but substituting for the racemic 2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one an equal quantity of (-)-2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one (J. Med. Chem., 25, 579 (1982)) there is obtained (-)-3-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid.
EXAMPLE 5
3-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)propionic acid
By following substantially the procedure described in Example 2, Steps A-D, but substituting for the ethyl 4-bromobutyrate in Step C, an equimolar amount of ethyl bromoacetate there is obtained 3-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)propionic acid.
Elemental analysis for C 21 H 26 Cl 2 O 3 : Calc'd: C, 63.47; H, 6.60; Found: C, 63.38; H, 6.83.
EXAMPLE 6
3-(6,7-Dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)propionic acid
By following substantially the procedure described in Example 5, but substituting for the 2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-5-hydroxy-1H-inden-1-one described in Step A an equimolar amount of 6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-5-hydroxy-1H-inden-1-one there is obtained 3-(6,7-dichloro-2-cyclopentyl-2,3-dihydro-2-methyl-1-oxo-1H-inden-5-yl)propionic acid which is solvated with 1/8 mole of methylene chloride from the extraction process.
Elemental analysis for C 18 H 20 Cl 2 O 3 .1/8CH 2 Cl 2 : Calc'd: C, 59.50; H, 5.55; Found: C, 59.46; H, 5.68.
EXAMPLE 7
Parenteral Solution of the (+)-enantiomer of 5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid
(+)-5-(2-Butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid (500 mg) is dissolved by stirring and warming with 0.25N sodium bicarbonate solution (5.4 ml). The solution is diluted to 10 ml and sterilized by filtration. All the water that is used in the preparation is pyrogen-free. The concentration of the active agent in the final solution is 5%.
Similar parenteral solution can be prepared by replacing the active ingredient of the above example by any of the other compounds of this invention.
EXAMPLE 8
Dry-Filled Capsules Containing 100 mg of Active Ingredient Per Capsule
______________________________________ Per Capsule______________________________________(+)-enantiomer of 5-(2-Butyl- 100 mg6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H--inden-5-yl)pentanoic acidLactose 99 mgMagnesium Stearate 1 mgCapsule (Size No. 1) 200 mg______________________________________
The (+)-enantiomer of 5-(2-butyl-6,7-dichloro-2-cyclopentyl-2,3-dihydro-1-oxo-1H-inden-5-yl)pentanoic acid is reduced to a No. 60 powder and then the lactose and magnesium stearate are passed through a No. 60 bolting cloth onto the powder and the combined ingredients admixed for 10 minutes and then filled into a No. 1 dry gelatin capsule.
Similar capsules can be prepared by replacing the active ingredient of the above example by any of the other compounds of this invention. | The invention relates to novel substituted (2,3-dihydro-1-oxo-1H-inden-5-yl)alkanoic acids, their derivatives and their salts. The compounds are useful for the treatment and prevention of injury to the brain and of edema due to head trauma, stroke (particularly ischemic), arrested breathing, cardiac arrest, Reye's syndrome, cerebral thrombosis, cerebral embolism, cerebral hemorrhage, cerebral tumors, encephalomyelitis, spinal cord injury, hydrocephalus, post-operative brain injury trauma, edema due to cerebral infections and various brain concussions. | 2 |
BACKGROUND OF THE INVENTION
This invention concerns improvements in or relating to fabrics, in particular fabrics having physical characteristics suitable for arresting ballistic articles. Such articles typically include fragments of compressor fan blades from aircraft engines such as turbofans. However, the term ‘ballistic article’ is also intended to embrace eg; bullets and shells, or fragments thereof.
It has for some years been common practice for manufacturers of aircraft engines having rotating parts to provide within the engine a barrier capable of arresting ballistic articles arising from mechanical failure within the engine. The object of this practice is to minimise the damage to the remainder of the engine that may be caused by such articles.
In the early days of aviation, such barriers were provided by rigid, metal components. However, these are of limited utility because of the tendency of metal barriers to transmit impulses directly to other parts of the engine, thereby causing potentially catastrophic damage.
The development of aramid fibres led to replacement of the rigid barriers by barriers comprised essentially of woven fabrics made of aramid yarns. Typically, the woven fabrics are produced in widths of up to 1000 mm that are wrapped several times about an annular frame defining eg the periphery of the compressor stage of a turbofan engine. The thus-wound fabric is effectively exposed, on the inner face of the barrier, to the exterior of the compressor stage, so that high velocity articles resulting from mechanical failure within the compressor stage tend to be thrown outwardly into the fabric wrap. The fabric absorbs the resulting impulse.
This method of arresting ballistic articles is successful because aramid fibres possess almost no elasticity yet are flexible and have extremely good tensile strength characteristics. Typically, the elongation to failure of an aramid fibre is less than 3%, yet the fibre can withstand huge tensile loads before such failure occurs. Thus, a woven fabric consisting of aramid fibres is most unlikely to rupture when it experiences the impulse from a ballistic article in an aircraft engine; yet the energy of such an impulse is successfully absorbed by the woven fabric structure without any significant part of the energy being transferred to the remainder of the engine components.
In this way, woven aramid fibre barriers have prevented many instances of catastrophic aircraft engine failure.
The high strength/low elasticity characteristics of aramid fibres also make them highly suitable as ballistic barriers in eg; flak jackets and bullet-proof vests.
In view of their characteristics, fabrics woven from aramid fibres are known as ‘rigid fabrics’. There are other fibres (including high-density polypropylene and polyethylene) that are also potentially suitable in such applications. The weaving of such alternative fibres also results in so-called rigid fabrics. The term “rigid fabric” also embraces fabrics made from mixes of fibres, not all of which need necessarily possess low elasticity/high strength characteristics.
Tests have revealed that in typical instances of aircraft engine component failure, known rigid fabric barriers exhibit extensions significantly greater than the approximately 3% figure mentioned above. The precise performance characteristics depend in part on the engine in which the fabric is installed.
There is a constant effort to improve the efficiency of aircraft engines, by reducing their specific fuel consumption characteristics. One way of achieving this is to increase the compressor fan area, thereby permitting a higher charge compression ratio to be used. However, for reasons of weight saving and because it is often not possible simply to increase the overall dimensions of an engine, such increases in fan area are usually accomplished at the expense of reducing the size of other components constituting the generally annular shape of the compressor chamber. Thus there is a need for a rigid fabric that offers comparable performance to previous rigid fabrics, whilst occupying a reduced volume and/or possessing reduced mass.
It is known from U.S. Pat. No. 4,699,567 to produce a ballistic barrier for an aircraft turbofan engine in the form of a fabric wrap comprising a plurality of squares of woven, rigid fabric. The squares are secured together in a series, by means of low strength stitching threads, for example cotton, to create an elongate fabric that is wrapped around the compressor stage of the turbofan engine during its construction.
The size of the squares is chosen so that when a length of the fabric is wrapped several times around the compressor stage, the joints between squares in the layers of fabric are out of phase with one another so that there are no radial lines of weakness in the fabric wrap.
The wrap is applied under low or zero tension. When a ballistic article such as a blade tip strikes the wrap, the joints between adjacent squares in the vicinity of the impact fail in a progressive and controlled manner, thereby absorbing the energy of the ballistic article. Thus the fabric of U.S. Pat. No. 4,699,567 damps the initially high frequency oscillation of the ballistic article in a short period.
However, the fabric wrap of U.S. Pat. No. 4,699,567 is complex and time consuming the manufacture, partly because of the need to produce numerous discrete squares of rigid fabric; and partly because of the need subsequently to stitch the squares together using a blanket stitch in yarn or low strength thread such as cotton. Such stitching has to be carried out as a separate step from the weaving of the squares.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a fabric for arresting ballistic articles comprising first and second woven layers secured together, the first layer including a plurality of substantially inextensible, first working fibres extending generally parallel to one another and the second layer including a plurality of substantially inextensible, second working fibres extending generally parallel to one another and generally perpendicular to the first working fibres.
This arrangement advantageously provides working fibres in mutually orthogonal directions in a single fabric that can be continuously woven in virtually any length. Thus the fabric of the invention overcomes the disadvantages of the fabric of U.S. Pat. No. 4,699,567.
In a second aspect, the invention resides in a fabric comprising first and second, substantially parallel, woven layers secured together by a plurality of binder threads, whereby the deflection characteristic of the fabric is controllable in dependence on the positioning and/or density of the said binder threads.
The density and positioning of the binder threads determines firstly the length of each floater yarn (ie. an exposed, working yarn); and secondly the degree of bonding between the parallel woven layers constituting the fabric.
As In contrast to the fabric of U.S. Pat. No. 4,699,567, the fabric of the invention is believed to function by transferring the energy of an impacting ballistic article about an annulus defined by the wrap of the fabric about the compressor stage. Thus it is believed that the energy of the impacting, ballistic article decays as its energy is absorbed in the length of the fabric wrap. This technique is believed to result in lesser damage to the fabric wrap in the event of a ballistic impact than occurs in the case of the stitched squares of U.S. Pat. No. 4,699,567.
Preferably the working fibres of the first layer are weft fibres, and the working fibres of the second layer are warp fibres. The fabric of the invention may include one or more of the following:
a single weft sateen;
a double weft sateen;
a warp sateen;
a double warp sateen.
In particularly preferred embodiments, one layer of the fabric is a weft sateen (particularly a double weft sateen) and the other layer is warp sateen (particularly a single or double warp sateen). This construction conveniently permits the continuous weaving of the fabric.
Preferably the layers are secured together by means of a binder yarn. In preferred embodiments the binder yarn is substantially inextensible. If the binder yarn is of the same material as the remainder of the fabric, it can be introduced substantially simultaneously with the weaving of the fabric.
Preferably the first and second layers of the fabric are substantially integral with one another at opposed edges of the fabric. This feature confers strength on the fabric.
Preferably the working fibres are aramid fibres. It is also preferable that the binder yarn is an aramid fibre, and preferably the same aramid fibre as the working fibres.
In particularly preferred embodiments, all components of the fabric are of the same aramid fibre, depending on the type of loom used for manufacture of the fabric.
According to a third aspect of the invention there is provided a method of manufacturing a fabric comprising the steps of:
weaving first and second layers; and
securing the said layers together generally parallel to one another, wherein the first layer includes substantially inextensible working fibres extending parallel to one another in a first direction; and the second layer includes substantially inextensible working fibres extending generally parallel to one another in a second direction.
This method advantageously may be used to produce a fabric according to the invention.
Conveniently the first and second layers are woven substantially simultaneously.
Preferably the first layer is a weft sateen (in particular a double weft sateen); and the second layer is a warp sateen (in particular a single or double warp sateen as desired).
Conveniently the first and second layers are substantially continuous along opposed edges of the fabric. This permits the continuous weaving of the fabric according to the method of the invention.
Conveniently the working fibres of the fabric are or include aramid fibres.
The method optionally includes weaving of one or more substantially inextendable binder threads securing the first and second layers together. The or each binder thread preferably is or includes an aramid yarn.
The advantages of the foregoing features in the method of the invention are comparable to the equivalent advantages concerning the fabric defined hereinabove.
According to a fourth aspect of the invention, there is provided a ballistic barrier including a fabric as defined hereinabove or manufactured according to the method defined hereinabove.
The invention is also considered to reside in a turbofan engine including a ballistic barrier as defined herein.
According to a sixth aspect of the invention, there is provided a turbofan engine including a fabric as defined herein or manufactured according to the method defined herein encircling the compression stage of the engine at generally negligible tension, the fabric defining a ballistic barrier for the turbofan of the engine.
According to an seventh aspect of the invention, there is provided use of aramid working fibres in the manufacture of a multi layer, woven, rigid fabric.
According to the eighth aspect of the invention, there is provided the use of aramid binder threads in the manufacture of a multi layer, woven, rigid fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a partly dismantled fabric according to the invention; and
FIG. 2 is a schematic representation of the FIG. 1 fabric in its assembled condition.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawing figures, there is shown in FIG. 1 a sample of fabric according to the invention, showing the principles of its construction.
In FIG. 1 the fabric 10 comprises first 11 and second 12 layers of fabric each woven from a substantially inextensible yarn such as Kevlar brand fibre manufactured by Du Pont Engineered Fibres, PO Box 50, CH 1218, Le Grand-Saconnex, Geneva, Switzerland.
First layer 11 is a double weft sateen the working (weft) fibres 1 lb of which are shown in exemplary fashion on the top face of layer 11
Since layer 11 is a double weft construction, its inner face (shown folded back in FIG. 1) also possesses working weft fibres of substantially inextendable character.
Second layer 12 is a single warp sateen, the working warp fibres 12 a of which extend substantially perpendicular to the weft floaters of upper layer 11 .
A binder yarn (not visible in FIG. 1) in the form of a warp thread interconnecting layers 11 and 12 secures the two layers together. In practice the binder warp threads are distributed along the weft direction of the fabric, whereby the layers are secured together at a great number of substantially evenly distributed points.
As is well known in the art, a sateen is a weave in which the pattern of floaters (that give the outer face of the sateen its appearance) is substantially randomised or at least pseudorandomised, in order to provide a variable distribution of floaters.
The density and positioning of the binder yarns also influences the degree of exposure of the floaters, and hence their lengths. It will thus be appreciated that the deflection characteristic of the fabric of FIG. 1 may be controlled, by virtue of the spacing of the binder yarns in the warp direction and the concentration of their interloopings with the layers 11 , 12 in the weft direction.
Referring now to FIG. 2, the fabric of FIG. 1 is shown using a graph paper notation conventional in the textile industry.
The weft fibres 11 a of the top face of layer 11 , the weft fibres 11 b of the inner face of top layer 11 , the warp fibres 11 c of top face 11 , the warp fibres 12 a of the layer 12 and the weft fibres 12 b of the layer 12 are all visible in FIG. 2 . Also shown is the presence of binder warp 13 .
Although the invention has been described in relation to upper layer 11 being formed as a double weft sateen and lower layer 12 as a warp sateen, other combinations are possible. For example, upper layer 11 may be a single weft sateen, or a double or single warp sateen; and layer 12 may be a double warp sateen, or a double or single weft sateen. The important requirement is to provide in each of the layers 11 , 12 floaters (the lengths of which are adjustable by means of the positioning and density of the binder threads 13 ) that act as working fibres in the fabric and extend in mutually orthogonal directions when the fabric is assembled by means of the binder threads 13 .
The preferred method of manufacturing the fabric includes continuously weaving layers 11 and 12 , and substantially simultaneously applying binder yarn 13 in such a way as to secure the layers 11 , 12 together as aforesaid.
The preferred weaving method involves tubular weaving of the layers 11 , 12 so that opposed edges of the layers 11 , 12 in eg. the warp direction are secured together.
The result is a rigid fabric of lower elongation (eg. a maximum elongation in the range 5 to 8%) than prior art fabrics. Since the fabric possesses working fibres extending in orthogonal directions in the respective layers 11 , 12 , its ability to arrest ballistic articles is extremely good.
An aircraft turbofan engine having a length of the fabric according to the invention wrapped around its compressor stage at zero tension or substantially zero tension is believed to exhibit extremely good blade tip arrestation characteristics. It is believed that the fabric so secured has a tendency to distribute the energy from the impact of a ballistic article about the annulus of the wrap. The annulus oscillates for a short period following the impact, during which time all energy of the impact is dissipated and the blade tip is arrested without penetrating or substantially tearing the rigid fabric of the invention. | The invention relates to a fabric ( 10 ) for arresting ballistic articles, the fabric ( 10 ) comprising first ( 11 ) and second ( 12 ) woven layers secured together. The working fibers of the first ( 11 ) and second ( 12 ) layers are of substantially inextensible yarns such as aramid fibers. The working fibers of the first layer ( 11 ) are perpendicular to the working fibers of the second layer ( 12 ). | 8 |
BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates to DC-to-DC converters, DC-to-AC, AC-to-AC inverters and AC-to-DC converters. The major characteristic of this power conversion technique is that all the magnetic elements are implemented on the same multilayers structure, and th e power transfer is made highly efficient and by minimizing the common mode noise.
2. Description of the Prior Art
There is a continuing industry demand for increasing power density, which means more power transferred in a given volume. A method for increasing the power transfer through the converter is to increase the switching frequency in order to minimize the size of magnetic and the capacitors. Using prior art topologies such as forward or flyback, which employ "hard" switching techniques, makes high frequency operation less efficient. The switching losses associated with switching elements, which turn on when there is a voltage across them, are proportional with the switching frequency. An increase in switching frequency, leads to an increase in switching losses and an increase in level of electromagnetic interference (EMI).
In order to overcome limitations in switching speeds, the prior art has devised a new family of resonant and quasi-resonant converters. In the case of quasi-resonant converters, the prior art technique consists of shaping the current or voltage to become half sinusoidal and to perform the switching when the current or voltage reaches zero. The reactive elements which contribute to shaping the current or voltage are part of the basic circuit and are considered undesirable in classic topologies. An example of one such circuit can be found in Vinciarelli, "Forward Converter Switching at Zero Current", U.S. Pat. No. 4,415,959. The technique utilized by Vinciarelli consists of adding a resonant capacitor across the fly wheeling diode to create a resonant circuit in combination with the leakage inductance of the transformer. During the ON time of the main switch, a current charges the resonant capacitor. When the current reaches zero, the main switch turns OFF in the primary of the transformer. The output inductor discharges the resonant capacitor, transferring the energy to the load. This topology eliminates part of switching losses which allows the converter to run at a high frequency. However, this topology exhibits several drawbacks which limit its utilization to power under 200 W.
Another family of quasi-resonant converters which switch at zero voltage is described by F. C. Lee in High Frequency Power Conversion International Proceedings (April 1987), Intertec Communications, Ventura, Calif. These prior art circuits operate similarly to those described above with the exception that the main switch turns ON and OFF at zero voltage. This has the advantage of eliminating the losses caused by the discharged of the capacitance of the switch at turn ON and also decreases the driving current utilized in the MOSFET switch due to the elimination of the Miller effect. However, the voltage across the main switch and the frequency modulation which is required for controlling the output power makes this topology unattractive.
New topologies structures which are refereed to as "Soft transitions Technologies" were developed, in order to eliminate the limitations associated with Quasi-resonant and resonant converters, but still maintaining the advantage of soft commutations for the switching elements. Such technologies are described by Mr. Jitaru in "Fixed Frequency Single Ended Forward Converter Switching at Zero Voltage" U.S. Pat. No. 5,126,931 and in "Square Wave Converter having an Improved Zero Voltage Switching Operation: U.S. Pat. No. 5,231,563. Using these topologies the converter operates at constant frequency, modulating the power by varying the duty cycle, the current and voltages on the switching elements are square-wave to decrease the current and voltages stress, the transitions are done at zero voltage conditions, and the power is transferred to the output, both during the ON time and OFF time.
These latest topologies have proven superior in respect of efficiency over the previous resonant and Quasi-resonant topologies. However, the parasitic elements of the circuit such as leakage inductance and stray inductance, will negatively affect the efficiency due the circulating energy contained in these parasitic elements. Due to the inter winding capacitance of the transformer the common mode noise will be injected into the secondary. In planar, low profile magnetic required for low profile packaging the inter-winding capacitance is larger, and as result the common mode noise injection via these parasitic capacitance is larger.
BRIEF SUMMARY OF THE INVENTION
The invention offers a construction technique of the main transformer which also extends to all the magnetic elements, wherein the parasitic elements of the circuit are minimized. In the same time the common mode current injected to the secondary via the inter winding capacitance is reduced and even eliminated. The construction technique claimed in this inventions offers a simple and low cost method in further suppressing the differential and common mode noise at the converter level. This novel construction technique offers an avenue in increasing the power density of the converter and allows full compliance with the safety agencies.
The planar multilayers magnetic is characterized by the use of flat copper spirals located on separate dielectric layers. Each layer can contain one turn or multiple spiral turns. The interconnection between the layers can be done by vias or an interconnecting heater. The insulator material can be laminated epoxy filled board, such as FR4 or different dialectic materials. The planar multilayers structure has been described by Mr. Alex Estrov in " Power Transformer Design for 1 Mhz Resonant Converter" at High Frequency Power Conversion in 1986. However, by decreasing the height of the planar magnetic the footprint will increase in order to maintain the same winding resistance. This will sacrifice the power density of the converter. In this invention the transformer winding is buried between minimum two layers of dielectric and the space in top of the winding can be populated with surface mounted components for a better volumetric efficiency. The invention claims several winding structures in a planar transformer, designed to minimize the common mode noise. The inventions further claims a full integrated multilayers structure in which all the magnetic elements are located on the same multilayers structure. The winding arrangements in the input and output inductor are also structured to minimize the common mode noise. It further utilizes the inter layers capacitance to create a low impedance for the common mode and differential mode noise, and to short it back to the source. To compensate for the common mode noise injected by the primary switching elements into the common baseplate to the secondary, the invention claims a noise cancellation technique by injected into the secondary a common mode current of the same amplitude but in opposite phase, through the common baseplate or through the multilayers structure. The invention claims a packaging configurations in which some the components of the converter are surface mounted, located on the same multilayers structure and for higher power applications cuts in the multilayers structure are performed to allow for the body of the power components. The heat-sink of the power components is connected to external heat-sinks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section view of the buried multilayers magnetic for a better volumetric efficiency.
FIG. 2 is a top view if the assembled power converter using full integrated multilayers magnetic.
FIG. 3A is an inner layer in the full integrated multilayers magnetic which contains a section of the input filter winding and a section of the transformer's primary winding.
FIG. 3B is an inner layer in the full integrated multilayers magnetic which contains a section of the input filter winding, a section of the transformer's secondary winding and a section of the output inductor winding.
FIG. 4 depicts the injection of the common mode current through the primary to secondary winding capacitance, due to the voltage gradient across the primary winding of the transformer.
FIG. 5 presents the effect of a shield between primary and secondary winding in order to decrease the common mode current via the primary to secondary winding capacitance.
FIG. 6 presents the use of a differential mode and common mode input choke together with two "Y" capacitors in order to reduce the common mode current flowing towards the input source.
FIG. 7 presents a typical "sandwich" layer distribution in the transformer for a reduced leakage inductance and a reduced ac copper losses.
FIG. 8 depicts a layer distribution aimed to decrease the common mode current injection to the secondary, by locating the secondary layers in between "quiet" primary layers. Quiet primary windings are those which exhibit a lower amplitude voltage swing in report to the primary ground.
FIG. 9 presents a further common mode current reduction by using a shield between the secondary and two "quiet" primary layers.
FIG. 10 presents a method for the cancellation of the common mode current into the secondary by locating the secondary layers between the "quiet" layer connected to the input DC voltage source and a "Noise cancellation winding" which creates a negative imagine of the common mode current injected by first layer.
FIG. 11 depicts a configuration in which the secondary windings are located between two symmetrical auxiliary windings, which are wound in a such way to cancel the common mode current injected to the secondary via the primary to secondary winding capacitance.
FIG. 12 presents a configuration in which the switching element is connected in the middle of the primary winding, creating a perfect symmetry in which the common mode current injected into the secondary winding via the primary to secondary capacitance is canceled.
FIG. 13 depicts a winding arrangement in a magnetic element designed to reduce the inter-winding capacitance and for a better utilization of the copper. The width of each turn becomes larger as one moves from the inside turn to the outermost turn. In this way the winding resistance for the shorter turn can equal to the winding resistance for the longer turn. There is a shift between the layers to minimize the capacitance in between two adjacent layers.
FIG. 14 presents a method of compliance with IEC950 in which three layers of core material are used, for example FR4, between the primary winding and secondary winding.
FIG. 15 presents a second method of compliance with IEC950 wherein the core material in between primary and secondary winding has to be thicker than 0.4 mm.
FIG. 16 depicts a method of compliance with safety agencies in which the magnetic core is reported to the primary and the transformer does not have to be buried. The secondary winding has to comply with the creapage distances in accordance with coating environment, based on the RMS voltages measured in the transformer.
FIG. 17 presents a configuration in which multiple multilayers transformers on the same multilayers structure are utilized for higher power applications or for a reduced number of layers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The multilayers planar magnetic, in which the windings are continuous flat copper spirals located on separate dielectric substrates, have been used before for signal and data processing. In power conversion filed the multilayers magnetic started to be used since 1986. However, there are several limitations with multilayers magnetic which prevented this technology from a large utilization. Decreasing the height of the magnetic, by utilizing flat winding leads to an increased footprint. As a result a large portion of the board on which the multilayers planar magnetic is mounted, cannot be used for another purpose, having a negative impact on the volumetric efficiency. Another limitation associated with planar multilayers magnetic is the increased inter winding capacitance, which leads to higher switching losses on the switching elements and a larger common mode current injected to secondary via the capacitance between primary and secondary winding. The parasitic elements such as the leakage inductance can be decreased in planar multilayers technology, but there is still the negative effect of parasitic elements associated with the interconnection pins. The interconnection pins will add to the cost of the magnetic and also will contribute an increase in losses.
This invention offers a solution to the limitations associated with the prior art planar multilayers magnetic. Turn now to FIG. 1 wherein a methodology of the invention is illustrated. The planar windings of the magnetic 8 are incorporated in an multilayers PCB structure 16. The top and bottom layer of the multilayers board 16 are utilized for interconnection and for pads of the surface mounted components 20, or for shielding purposes or different other interconnections. By burying the magnetic winding inside of multilayers construction the footprint of the magnetic is reduced to the footprint of the core. This will allow a better utilization of the board, increasing also the power density. By burying the magnetic inside of a epoxy filled multilayers structure such as multilayers PCB, the creapage distances requirement in between the windings and the edge of the board or cuts will be decreased. This is due to the fact that the spacing between primary and secondary inside of multilayers PCB has to comply with the coating environment. These spacing are several times smaller than those in the air. Another advantage of this construction technique is the fact that the interconnection between the magnetic elements, for example between the transformer and output choke are done though the same multilayers PCB, eliminating the need for interconnection pins. The power components can be located in top of the multilayers PCB, interconnecting with the magnetic winding through vias, or can be located on an external heatsink, using cuts in the PCB tailored to the body of power components as is depicted in FIG. 2. In FIG. 2 is presented a full integrated multilayers PCB structure which incorporates all the magnetic elements such as the input filter 10, the main transformer 12, and the output choke 14. The body of the power components is accommodated by using cuts in the multilayers PCB structure. The connection of the power components to the windings is done by through holes in which the terminals of the components can be soldered to. For lower power levels the power components are located in top of the PCB and through vias or large parallel pads a low thermal impedance is created to the bottom of the multilayers PCB to which an external heatsink can be attached. The additional heatsink may not be required if there is an air flow in top of the converter.
The magnetic core 18, will have its legs penetrating through the multilayers PCB. The core will create a closed magnetic path with or without an air gap, function of the electrical topology which utilized.
In FIG. 3A is presented the structure of a inner layer which contains a section of the input choke winding 22 and a section of the primary winding 24 of the transformer. The cores of the input choke 10, main transformer 12 and output choke 14, are penetrating through the multilayers PCB. The vias 26, are designed to interconnect the winding from different layers. Some of the vias are designed to interconnect the magnetic windings to the components located on top and bottom of the multilayers PCB.
In FIG. 3B is presented the structure of a inner layer which contains a section of the input choke winding 22, a section of the secondary winding of the transformer 28 and a section of the winding of the output choke 30. The connection from the transformer to output choke is done directly without supplementary interconnections. This will minimize the stray inductance associated with the interconnection pins.
One of the novelty claimed by this invention is the integration of all the magnetic elements on the same multilayers structure and for a better utilization of the space, the magnetic windings are buried inside, allowing the top and bottom layer to be utilized for locating surface mounted components. This leads to a very efficient utilization of the volume due to a three dimensional utilization. This form of integration leads to a minimization of the interconnection impedance and as result leads to a higher efficiency in power processing.
The multilayers PCB magnetic offers a good avenue in addressing the creapages and clearances requirements demanded by the safety agencies. By burring the transformer inside of PCB as is depicted in FIG. 14, the spacing between primary and secondary is determined in accordance with the RMS voltages in transformer applied to a coating environment. These spacing are several times smaller than those in the air. However, between primary and secondary windings two or three layers of core material 92, 94, 96 is demanded, each two able to withstand the dielectric test. Another method requires the core material between the primary and secondary 98, to be at least 0.4 mm. The magnetic core can be reported to the primary or to the secondary. In FIG. 16 is presented a case in which the core is reported to the primary. The secondary winding 104 are buried inside and the distance from the secondary winding 104 to the edge of the core slot has to comply with the creapage requirements for the RMS voltage measured in the transformer. Using this method the primary winding 102 and the interconnecting vias do not have to be buried in the multilayers PCB.
The AC voltage gradient across each turn of the winding is equal, but reported to the input ground the amplitude of the voltage swing increases from the turn connected to the input DC source to the maximum level to the turn connected to the switching element. As is depicted in FIG. 4 the voltage swing 32 across the primary winding, injects a current in the secondary winding 38 via the primary to secondary winding capacitance 34, 36. This current is further flowing through the decoupling capacitor 40, through the earth ground 44, returning through the connections of the input source 46. Again, common-mode noise is not differential with respect to the output. It does, however, flow in both input and output leads of the power supply and is a noise parameter that is measured by the FCC and VDE.
One method in suppressing some of the common mode noise is by utilizing a shield 54, or two located in between primary and secondary winding and connected to the input DC source or the input ground. This method is depicted in FIG. 5. The capacitance between the shield 54 and the primary winding creates a low impedance path for the common mode current created by the AC voltage across the primary winding 32. However the stray impedance of the shield itself will create a voltage gradient across it which will inject a common mode current via the capacitance 56 between the shield and the secondary winding 38. This common mode current 42, is reduced in comparison to the structure without the shield. However, the parasitic inductance of the connection to the input DC source 46, is critical for shielding effectiveness. One of the major drawback associated with the use of the shield is the fact that an increased parasitic capacitance will be created across the primary winding and across the secondary winding. This will increase the switching losses on the switching elements. This parasitic capacitance 52 will be in parallel with the inter winding capacitance of the primary and the parasitic capacitance of the switch itself. The switching losses will become more significant at higher operation frequency and for high input voltage applications such as Off-line converters.
In FIG. 7 is presented a winding arrangement in a converter in which the secondary windings 80 are sandwiched between the primary windings. For simplicity, I consider that the primary winding of the transformer is contained in four layers and the secondary winding in one layer. The winding of layer 1 connected to the input voltage source 72, exhibit a lower voltage swing reported to the input ground comparative to the winding 78 of layer 4 connected to the switching element 70. In this particular case the voltage swing reported to the primary ground is four times larger for layer 4, 78 than for the layer 1, 72. It is logical to locate the secondary 80 in the vicinity of the "quiet" primary such as 72. However the secondary has to be located symmetrically in between primary windings for two reasons. One reason is to minimize the magnetic field intensity in between winding for lower AC copper loss, and the second reason is to lower the leakage inductance between primary and secondary. In order to decrease the common mode current injection into the secondary via the capacitance between primary winding to secondary winding, and maintaining in the same time the sandwiched structure, the configuration of FIG. 8 is suggested. In FIG. 8 the secondary winding is located between two "quiet" layers. The voltage swing across layer 1 is much smaller than the voltage swing across layer 3. This structure does not eliminated the common mode injection to the secondary but it will reduce it. The advantage of this configuration is the fact that it does not require any additional layer. In FIG. 9 is presented a configuration in which two layers in top and bottom of the secondary are used as a shield. The location of the shield in vicinity of two "quiet" layers, layer 1, 72 and layer 2, 74 will not increase significantly the parasitic capacitance across the primary winding. However two layers of the multilayers structure will be allocated to the shield.
A configuration which can reduce the common mode noise injection to the secondary to zero is depicted in FIG. 10. In this configuration a noise cancellation winding 82, is added. The polarity of the voltage swing across this winding is in opposite to the polarity of the voltage swing across the winding in layer 1. As result the common mode current injected into the secondary winding will be canceled. This method will require only one additional layer and if a perfect geometrical symmetry can be accomplished, the common mode current injected in the secondary can be totally canceled. The single drawback of this method is the fact that one layer will be allocated just for the noise cancellation.
In FIG. 11 is presented a configuration in which two layers are added, one in top and one in the bottom of the secondary winding. This windings have a common symmetrical connection which is connected to the input ground. The connection can be also to the input DC voltage source. The voltage swing across the winding 1, 84 and auxiliary winding 2, 86 will inject a common mode current into the secondary, but of the opposite polarity of each other. As a result the total common mode current injected to the secondary will be zero. These auxiliary windings can be utilized to provide power in the primary section such as the necessary bias power, or can provide the power for a primary reported output.
Another path for the common mode current is through the capacitance between the switching elements in the primary and in the secondary, and the baseplate. This applies for higher power applications in which a common heatsink baseplate is used for the power components in primary and secondary. Due to a large voltage swing of the power switch tab, this source of common mode noise can be dominant. This invention claims a method for cancellation of the common mode current produced by the switching elements. This is done by creating a supplementary capacitor between secondary and the termination of the noise cancellation winding not connected to the input DC source or input ground. The noise cancellation windings are described in FIG. 10 and FIG. 11. By properly tailoring this additional capacitance a current will be injected into the secondary, of the same amplitude but in opposite phase to the current injected by the switching elements to the secondary via the capacitance between the switches and the baseplate. The additional capacitance between the noise cancellation winding and secondary can be implemented in the metal basepalte or in the multilayers structure.
Another method which does not require supplementary layers for output common mode noise cancellation is presented in FIG. 12. In this case the primary winding is symmetrically cut in a half and the power switch is connecting to these sections. The voltage swing on the layers which surrounds the secondary, layer 2, 74 and layer 3, 76, will have the same amplitude but will be of opposite polarity. As a result the common mode noise injected into the secondary will be zero.
The structures presented above will reduce the common mode noise injection to the secondary via the inter winding capacitance of the transformer. However, if the common mode noise will be generated by different circuitry or if a further reduction of common mode is required, a supplementary common mode filter may be required. Such a structure is described in FIG. 6. By utilizing a EE or EI core gapped in the center leg, the input choke can exhibit a common mode and a differential mode impedance. By using the outer legs of the E core, two inductive elements can be implemented in the PCB. The coupling in between these inductors will determine the CM impedance, and it can be tailored by the gaping configuration of the core. For example, if there is not a gap in the core, the coupling coefficient is K=0.071. If there is 1 mill gap in all the legs, K=0.276. If only the center leg is gapped to 2 mil, K=0.724. The common mode and differential mode inductance can be tailored by properly gapping the core, and making sure that under all loading conditions the core does not saturate. Utilizing full integrated multilayers PCB, the cost of the input EMI filter is reduced to the cost of the magnetic core. The capacitors 62, and 64 are used to create a low impedance for the common mode current which will work against the high impedance exhibited by the input filter. The capacitors 62 and 64 can be created in the structure of the multilayers PCB, which will lead to a cost reduction of the converter and to a better utilization of the multilayers structure. These capacitors can be constructed to comply with the safety agencies by using the recommendations suggested for the transformer compliance with safety agencies, previously discussed.
In FIG. 13 is presented a method for reduction of the parasitic capacitance across the magnetic winding. This is accomplished by shifting the adjacent layers. For a better utilization of the copper, the turn width will vary in a such way to ensure an equal resistance per each turn. The turn width is made larger as one moves from the inside turn to the outermost turn.
For higher power applications or in applications which require large currents multiple planar multilayers transformer can be utilized on the same multilayers structure as is depicted in FIG. 17. The number of layers in primary 112, 114, 116 and in the secondary 118, 120, 122 of these transformers 106, 120, 122, can be reduced to one, which will allow the use of two layer multilayers structure. Another advantage of this configuration is the fact that the leakage inductance in each transformer can be very low, which will make this configuration ideal for high current and low output voltage.
Many alternations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, the invention must be understood as being set forth above only for the purpose of example and not by way of limitation. The invention is defined by the following claims wherein means may be substituted therein for obtaining substantially the same result even when not obtained by performing substantially the same function in substantially the same way. | A multilayers structure in which all the magnetic elements have the windings edged in the inner layers and the magnetic core which surrounds the winding has the legs penetrating through the multilayers structure. The interconnection between the magnetic elements and the rest of electronic components are done through the layers of the multilayers board, horizontally and vertically through vias. For higher power components special cuts are performed in the multilayers board to accommodate the body of the components which may be connected to an external heatsink. The winding arrangement in the transformer is done in a such way to minimize and even eliminate the common mode noise injected through the capacitance between primary and secondary winding. The input filter is constructed to exhibit a differential and a common mode impedance. Supplementary capacitors are incorporated in the multilayers structure to offer a low impedance to the noise to short it to the source, or for injecting currents of opposite polarity to cancel the common mode current transferred through the transformer's inter winding capacitance and through the parasitic capacitance of the switching elements to the secondary. The insulation between winding can be in accordance with the safety agency requirements, allowing much shorter creapage distances inside of the multilayers PCB structure than in the air due to the compliance with coating environment. | 7 |
BACKGROUND FIELD OF INVENTION
[0001] This invention relates to the field of highway safety devices, this is an improved safety triangle, more practical, safe and easy to use hazard alert unit for the every day motorist traveling the highways.
BACKGROUND DESCRIPTION OF PRIOR ART
[0002] Among the types of warning devices regularly in use are standard highway safety triangles with a lower base and upper sections, usually collapsible, triangular shaped devices that are commonly referred to as safety triangle or hazard warning marker. It is a legal requirement that most commercial vehicles carry these devices on board to be used in a potentially hazardous situation in regards to highway safety.
[0003] Some methods and designs used to optimize the standard hazard warning triangle is shown in foreign Pat. GB2192017 to Ryland C. Henry (1987), U.S. Pat. No. 5,349,346 to Wu (1994), foreign Pat. GB2312457 to Lin Wei, and Quan Song (1997), U.S. Pat. No. 6,389,720 to Hsieh (2002), U.S. Pat. No. 6,535,117 to Haerer (2003), and U.S. Pat. No. 6,543,165 to Youseph et al (2003), all these devices are unique in its own way however most have shortfalls such as not being able to fold for storage when not in use or non-reflective ability and overtly bulky, while some are a bit complex with delicate external components that may cause the device to be less practical for most applications.
[0004] In the foreign Pat.GB2192017 to Ryland C. Henry (1987), the prior art uses bulbs. Bulbs have short lifespan and generate heat when illuminated thus create condensation in cold weather, said prior art has limited mobility a result of using a power cord attached to the vehicle; further more if the battery in the vehicle is dead there would be no electricity to power the device.
[0005] With U.S. Pat. No. 5,349,346 to Wu (1994) the prior art has many LED's. LED's can be very bright and when there is too many LED's in a sing the intended image that is being projected becomes distorted; also the lights in this prior art does not blink. Wu's triangle has many external parts to contend with during deployment with limited mobility according to the length of the power cord; also it is non-folding therefore pose a problem in storing it.
[0006] In U.S. Pat. No. 6,389,720 to Hsieh (2002), this prior art has flashing light but it does not reflect light. The device is complicated with delicate external parts and is very bulky; this will make storage and usage difficult for the average user.
[0007] In U.S. Pat. No. 6,535,117 to Haerer (2003), this prior art is not one complete device it has two separate pieces, the triangle, and an illuminating device that is placed within the center portion of the triangle therefore not projecting an illuminated triangular figure, traditionally the triangle has always been a symbol of caution and this prior art does not project a illuminated triangular figure nor the triangle in the prior art appears as if it would be stable if deployed in windy condition.
[0008] In U.S. Pat. No. 6,543,165 to Youseph, et al (2003) this prior art is a light only, non-reflective device similar to that of Hsieh U.S. Pat. No. 6,389,720 they do not reflect light, the light reflecting ability of a safety triangle could act as a back up if the light emitting ability of the device fails said prior art U.S. Pat. No. 6,543,165 does not have a protective edge around it's translucent halves to protect against chips or cracks that might allow moisture to enter causing circuit failure; cracks that could occur while handling, especially with it's overt bulk which could be a problem for the motorists who values storage space.
[0009] In U.S. Pat. No. 3,934,541 to May, et al (1976), this prior art has no illumination ability, it was design for use in a time when the average speed limits was 55 mph, on major highways. On today's interstate highways the traffic speed ranges from 65 to 75 mph much faster than the days of the prior art.
Objects and Advantages
[0010] When trucks with a gross weight of 80,000 lbs traveling at 65 to 70 mph, 200 ft. isn't adequate safe stopping distance for such a vehicle on dry road surface, or even traveling 55 mph on an unlit but familiar highway at night shortly after it rained, with headlights from vehicles traveling in opposite direction affecting ones vision, it isn't safe to for any stalled vehicle on the side of such a highway. This invention will provide a multiple alert over a safe distance to allow motorist adequate time to safely respond to any hazard up-ahead.
[0011] Therefore accordingly the objects and advantages of this invention is proper to provide an improved light emitting reflective hazard alert unit with GPS that is:
[0012] (a) Compactable for storage due to mounting the LEDs on a PC board that is fitted to the chassis wherein achieving a sturdy slender structure, and not a bulky construction.
[0013] (b) Fully mobile using own power source and not depending on the vehicle for electricity to operate incases the vehicle have dead battery/batteries.
[0014] (c) Not distorted in image projection by oscillating less light emitting diodes (LED).
[0015] (d) Easy to assemble and deployed with no detachable external parts to contend with.
[0016] (e) Has protection all around the outer edges of the chassis (frame) to protect lenses.
[0017] (f) Constructed to reduce and deflect wind pressure, preventing said invention from being blown about, if deployed in high wind; with a cylindrical base, concave/convex lenses to facilitate wind deflection, and wind-slots/apertures to allow the passage of air through the flat sections of structure in accordance with said invention. These improvements enhance stability in high winds.
[0018] (g) Capable of reflecting light as a backup if the power source need replacing.
[0019] However this invention aim to provide a improved light emitting reflective hazard alert unit in the traditional triangular configuration that is visible over a safe distance allowing motorist adequate time to respond to a potential hazard.
[0020] (h) Technically advanced by incorporating GPS transmitter that is activated whenever device is turn on, therefore approaching motor vehicles will be alerted of the stalled vehicle on roadway, or shoulder from a safe distance, upon approach there will be visual conformation of this hazard, (a good device for bad driving conditions).
[0021] Said invention is simple to operate, easy to configured, totally moisture resistant with all internal circuitry said invention is totally mobile, with a wide range of visibility due to oscillating light emitting diodes that is visible on both sides of the device.
[0022] This present invention is collapsible for compact storage, and lightweight.
[0023] The light emitting ability of said invention has the working duration of at least twenty-four consecutive hours under normal circumstances.
[0024] Further objects and advantages will become apparent from a study of the following description and accompanying drawings.
SUMMARY
[0025] In accordance with this invention; an improved light emitting reflective hazard alert unit that have the ability to configure a triangular shape when deployed, said invention emits light on interval via means for controlling light, the lights are visible through concave/convex translucent reflective lenses as a beacon across great distance.
[0026] This invention transmits a signal using GPS transmitter to forewarn approaching traffic of potential hazard up-ahead before its in visual range; said invention is practical for use in almost any traffic situation where public safety is a concern.
[0027] This said invention is a compact collapsible unit for convenient storage; said invention is a composition of two upper-blades of equal dimension that is hinge-joined to both ends of a base-blade, both upper-blades and base-blade is coupled to a base at a central axial point that allow for a ninety degree horizontal rotation of triangular upper portion and base in preparation for deployment.
DRAWING
[0000] Drawing Figures
[0028] In these drawings, closely related figures have the same numbers but different alphabetical suffixes.
[0029] FIG. 1 is a isometric perspective view of a triangle in its' erected form in accordance with this invention.
[0030] FIG. 1 -A is a magnified view of a lower corner of said triangle
[0031] FIG. 2 is a front view of a triangle in compact collapsed position.
[0032] FIG. 3 is a partially exploded perspective view of a cylindrical base.
[0033] FIG. 4 is a front view of a cap, (one of two identical caps).
[0034] FIG. 5 is a cutaway view of said cap.
[0035] FIG. 6 is a exploded inverted view of one of two identical ends of base, cap, and O-ring.
[0036] FIG. 7 is a partly cutaway front view of a base-blade fully detached.
[0037] FIG. 7 -A is a magnified view of a base-blade outer corner.
[0038] FIG. 8 is a cutaway end view of a base-blade.
[0039] FIG. 9 is a front view of said invention with one upper-blade erected, and other upper-blade partially erected.
[0040] FIG. 10 is a fragmentary enlarged front view of both upper-blades in unlocked position.
[0041] FIG. 11 is a fragmentary enlarged front view of both upper-blades in locked position.
[0042] FIG. 12 is a cutaway front view of a upper-blade.
[0043] FIG. 13 is an enlarged fragmentary isometric view of a upper-blade in accordance with this invention showing locking mechanism and a release-boss.
[0044] FIG. 14 is a cutaway end view showing alternative configuration of lenses.
[0045] FIG. 15 is a fragmentary enlarged cutaway view of center section of a base, and a base-blade.
[0046] FIG. 16 is an exploded cutaway end view of a upper-blade showing chassis with convex/concave lenses.
[0047] FIG. 17 is a fragmentary vertical front view of a upper-blade without lens, showing chassis with LEDs affixed to PC-board, and PC-board fitted in chassis via PC-retainer-clip.
[0048] FIG. 18 is a perspective fragmentary view of an alternative configuration of a base.
[0049] FIG. 18 -A is a perspective fragmentary view of base in accordance with said invention.
[0050] FIG. 19 is a preliminary layout of a integral circuitry in accordance with this invention.
Improved Light Emitting Reflective Hazard Alert Unit Numerals Reference
[0000]
20 , 20 A Caps
22 , 22 A Stabilizer-recess
24 Flange-mount
26 , 26 A, 26 B Orifice
28 On/Off-switch
30 Base
32 , 32 A Adhesive-friction-pad
34 Coil-spring
35 Rivet
36 Cap-electrode
37 Rivet-conductor
38 Base-electrode
39 Power-source-retainer
40 , 40 -A O-A O-ring
42 , 42 -A O-ring-groove
44 Cap-locking-stud
46 Cap-locking-slot
47 Flange-O-ring
48 Flange-mount-hole
49 Flange-O-ring-groove
50 Flange-shank
52 Flange
54 , 54 A Stabilizer
56 Base-blade
58 Rotation-stop
60 Flange-mount-rotation-stop
64 Flat-nut
65 Flat-washer
62 , 62 A Gudgeon
68 , 68 A Rivet/pin
70 , 70 A Upper-blade
72 , 72 A Release-boss
74 , 74 A, 74 B, 74 C Retainer-clip
76 , 76 A Stud
78 , 78 A Snap-lock
80 , 80 A, 80 B Concave/convex-translucent-reflective-lens
81 , 81 A, 81 B Flat-lens
82 Protective-edge
84 PC-Retainer-clip
86 Rib
88 Light-emitting-diode (LED)
90 , 90 A Printed-Circuit (PC) board
90 , 92 A, 92 B Chassis
94 , 94 A wiring-groove
96 , 96 A, 96 B Wind-slot
98 Line for showing how the concave/convex lenses would be fitted to the chassis
100 Rotation line of upper-blades from collapsed to erect position and vice versa
DETAILED DESCRIPTION
[0000] Description— FIGS. 1-13 , 15 - 17 , and 18 -A- 19 are Preferred Embodiment
[0098] A preferred embodiment of an improved light emitting reflective hazard alert unit respectively constructed in accordance with the present invention, FIG. 1 is a isometric view of a hazard triangle that is composed of four main parts. a base 30 a base-blade 56 a upper-blade 70 , and other upper-blade 70 -A. FIG. 1A is a perspective magnified view of one of two hinge-joints of a triangle where the upper-blade 70 -A is coupled to the base-blade 56 using a gudgeon 66 and a rivet 68 on one end of upper-blade 70 -A, and base-blade 56 forming a hinge joint.
[0099] FIG. 2 is a isometric view of said triangle in a completely compact collapsed position also showing is a magnified view of a flat-nut 64 that is used in coupling a base-blade-flange 52 (as in FIG. 8 ) and base 30 by placing a flange-O-ring 47 in a flange-O-ring-groove 49 then putting a flange-shank 50 through a flange-mount-hole 48 that is located in a flange-mount 24 , (as in FIG. 3 ) then placing a flat-washer 65 (as seen in FIG. 15 ) onto flange-shank 50 after it passes through the flange-mount 24 , at this point the flat-nut 64 is screwed onto the flange-shank 50 thereby coupling base-blade 56 to the flange-mount 24 , next step is fitting a PC-board 90 -A (LED driver and GPS unit) to underside of the flange-mount 24 using proper fastening means, at this point connect electrical circuitry in said base 30 , fit the flange-mount 24 to the base 30 using proper fastening means and sealant, thereby assembling base 30 and base-blade 56 , as in FIG. 15 .
[0100] FIG. 3 is a exploded perspective view of a cylindrical base 30 showing a flange-mount 24 with a on/off-switch 28 , and a flange-mount-rotation-stop 60 , and two adhesive-friction-pads 32 , 32 -A also showing is one of two stabilizer-recess 22 , ( 22 -A not visible) to accommodate stabilizers 54 , 54 -A as in FIG. 2 , also showing are caps 20 , 20 -A in assembly with the base 30 .
[0101] FIG. 4 is a front view of one of two identical caps 20 , ( 20 -A not showing) that is used on both ends of the base 30 to secure power source (batteries/power-pack) within the base 30 , also showing is a coil-spring 34 that serve as locking aid in conjunction with one of two identical cap-locking-studs 44 , (as in FIG. 6 ) and a cap-locking-slots 46 , (as in FIG. 6 ) as a bayonet style locking mechanism, while coil-spring 34 maintaining firm contact with power source. Connected to the coil-spring 34 is a cap-electrode 36 that makes contact with a rivet-conductor 37 when cap 20 , 20 -A is fitted to the base 30 .
[0102] FIG. 5 is a perspective cutaway view of said cap 20 showing a coil-spring 34 , a adhesive-friction-pad 32 , a cap-electrode 36 , and a cap-locking-slot 46 .
[0103] FIG. 6 is a perspective exploded inverted view of one of two identical ends of a cylindrical base 30 showing a cap-locking-stud 44 , and a cap-locking-slot 46 used for coupling cap 20 and base 30 . a O-ring-groove 42 , ( 42 -A not showing) is for installing O-ring 40 , ( 40 -A not showing) that is use to seal both ends of the base 30 to ensuring a watertight integrity within the base where electrical components are installed in accordance with said invention.
[0104] FIG. 7 is a isometric front view of a base-blade 56 detached from said invention showing a plurality of wind-slots 96 that allow wind to pass through inner flat surface of all blades thereby reducing wind pressure against said invention when erected for deployment, also showing gudgeon 66 , 66 -A at both ends of the base-blade 56 , both upper-blades 70 , 70 -A are coupled on opposite ends of said base-blade 56 by putting rivet 68 , 68 -A through all gudgeon 66 , 66 -A to form hinge joints as in FIG. 1A , a retaining-clip 74 , ( 74 -A not visible) is used to secure upper-blade 70 , 70 -A to base-blade 56 when said invention is collapsed and compact for storage as in FIGS. 2 and 14 . a orifice 26 , 26 -A, ( 26 -B not showing) allow wiring to connect all electrical circuit throughout said invention. a wiring-groove 94 , and 94 -A as in FIG. 7 -A, and 17 is part of a passageway that allows wire coming up from base-blade 56 to coil around inside both hinge-joints then connecting PC-board 90 in base-blade 56 to PC-boards 90 in both upper-blades 70 , 70 -A (wherein wiring is unexposed) as in FIG. 9 . a rotation-stop 58 is located at bottom edge of a flange 52 , it is used during deployment process to stop the base 30 and the base-blade 56 at end of rotation as in FIG. 1 . a stabilizer 54 , 54 -A. along with base 30 keep said invention in an upright position during deployment as in FIG. 1 .
[0105] FIG. 8 is a fragmentary end view of a base-blade 56 showing configuration of a stabilizer 54 , a lens 80 , and a chassis 92 , along with a orifice 26 that allow wiring to pass through a flange 52 to upper circuits, a flange-o-ring 47 seats in a flange-o-ring-groove 49 to seal against moisture after flange 52 and flange-mount 24 are coupled as in FIG. 14 .
[0106] FIG. 9 is a front view of said invention showing a upper-blade 70 -A fully erected and other upper-blade 70 partially erected. to the inside flat section of triangle in accordance with said invention are wind-slots 96 , 96 -B, also showing are retainer-clips 74 , 74 -B ( 74 -A, and 74 -C not visible) as in FIGS. 7 and 13 . to the unattached end of both upper-blades 70 , 70 -A are snap-lock 78 , 78 -A and stud 76 ( 76 -A not visible) means of interlocking both upper-blades 70 , 70 -A as illustrated in FIGS. 1 and 11 . on the said end of upper-blades 70 , 70 -A are release-boss 72 , 72 -A that aid in the unlocking of the upper-blades 70 , 70 -A as in FIGS. 11 and 13 , line 100 shows the path of travel for both upper blades when setting up for deployment.
[0107] FIG. 10 is a fragmentary view of both upper-blades 70 , 70 -A showing locking mechanism a snap-lock 78 , 78 -A on locking end of upper-blade 70 , 70 -A. as in FIG. 13 is the configuration of a stud 76 , ( 76 -A not visible) that works with snap-locks 78 , 78 -A as a locking mechanism.
[0108] FIG. 11 is a fragmentary view of upper-blade 70 , 70 -A in the locked position.
[0109] FIG. 12 is a cutaway front view of one of two identical upper-blades 70 , 70 -A detached, showing a PC-board 90 with LEDs 88 in attachment and multiple PC-board-clip 84 , the PC-board with LEDs are encased with concave/convex translucent reflective lenses 80 -B of upper-blade 70 -A, a protective-edge 82 and 82 -A of chassis 92 , 92 -A, and 92 -B protect the outer corners of concave/convex translucent reflective lenses 80 , 80 -A, and 80 -B as in FIG. 16 .
[0110] FIG. 13 is as illustrated above.
[0111] FIG. 14 is a cutaway side view of alternative lens configuration, (except for the lenses, the remainder of FIG. 14 is consistent with present invention)
[0112] FIG. 15 is a fragmentary cutaway view of said invention showing a base-blade 56 assembled to a base 30 ; a flat-washer 65 and a flat-nut 64 , showing is a printed circuit board/PC-board 90 -A (LED driver and GPS means) and showing is a on/off-switch 28 , LEDs 88 , PC-board-clip 84 , and a flange-mount-rotation-stop 60 , and flange-rotation-stop 58 . assembling lower portion of said invention by inserting power-source-retainer 39 , and fasten it with rivet 35 on inside of base the power-source-retainer 39 is used for hold batteries/power-pack at a position, (keeping batteries from going into center of base where light controlling means are installed) while holding batteries in place, power-source-retainer 39 also act as positive (+) contact for power source therefore has a wire connecting both power-source-retainer 39 to a PC-board in center of base 30 , both power-source-retainer 39 being installed in both ends of base 30 not only act as retainer, and positive (+) contact it aids locking method by providing a block (using batteries/power-pack) for coil-spring 34 to push against when both caps 20 , and 20 -A are fitted to base 30 , using power-source-retainer 39 and batteries/power pack as a block for coil-spring 34 therefore creating enough spring pressure for locking mechanism while maintaining firm contact with negative (−) end of batteries/power-pack, as in FIGS. 4 and 5 coil-spring 34 and cap-electrode 36 are connected in cap 20 , when caps 20 and 20 -A are affixed to base 30 cap-electrode 36 make contact with a rivet-conductor 37 that is used to install a base-electrode 38 in a base 30 , both base-electrode 38 have insulated wiring connected to a on/off-switch 28 (switch is watertight) where on/off-switch 28 is connected to a PC-board 90 -A which is mounted to underside of a flange-mount 24 as in FIG. 15 , with all electrical connections completed within lower portion of said invention and a flange-mount 24 is assembled with a base-blade 56 , assemble a flange-mount 24 to a base 30 using proper fastening and sealant means to secure and maintain watertight integrity in accordance with present invention.
[0113] FIG. 16 is an exploded end view of a upper-blade 70 , (or 70 -A) with convex/concave lenses 80 -B detached and exposing LED 88 and PC-board 90 , line 98 shows path of assembly for lenses to chassis wherein all blades are similarly constructed in accordance with this invention.
[0114] FIG. 17 is a vertical fragmentary view of a upper-blade 70 -A without lens, showing a chassis 92 -B, a PC-board 90 with LEDs 88 affixed thereto, (whereas both upper-blades 70 , 70 -A are identically constructed with a PC-board 90 and an array of LED 88 mounted to PC-board), showing is a gudgeon 66 through which rivet/pin are placed to form hinge joint with a base-blade 56 , (as in FIGS. 1 -A and 9 ) showing is a retainer-clip 74 -B that mates with a retainer-clip 74 -A on base-blade 56 whenever said device is in storage, (as with retainer-clip 74 and 74 -C in FIG. 14 ), also showing a upper-blade 70 -A having a rib 86 (to reinforce the part of upper-blades that is not overlapping). The base-blade 56 as in FIG. 7 , and 8 is similarly constructed as both upper-blades 70 , 70 -A with multiple LEDs 88 , affixed to a PC-board 90 , duly mounted to the chassis 92 using PC-retainer-clips 84 , insulated wires passed through orifice 26 located in flange 52 (as in FIG. 8 ) connecting to a PC-board 90 in base-blade 56 using fastening means; using fastening means to connect insulated wires at both ends of PC-board 90 located in base-blade 56 , place wiring through orifices 26 -A and 26 -B, coil insulated wire around in wiring-groove 94 , and 94 -A to allow flexibility of the wiring within the hinge-joint of upper-blade 70 , 70 -A, and base-blade 56 , put wire through orifices 26 -A, 26 -B of upper-blades 70 and 70 -A, and connect the wire to PC-boards in both upper-blade 70 and 70 -A using fastening means, after connecting insulated wiring to PC-board, orifice 26 , 26 -A, and 26 -B are then sealed with sealant means to ensure watertight integrity within said invention, affix all concave/convex translucent reflective lenses to chassis using a proper sealant to further ensure a totally moisture free environment within said device. Subsequent to construction of upper-blade 70 , 70 -A and base-blade 56 , added sealant is applied within crevice of all protective-edges 82 , 82 -A, and concave/convex-translucent-reflective-lenses 80 - 80 -B of all blades, as in FIG. 16 .
ALTERNATIVE EMBODIMENTS
[0115] With regards to flat-lenses 81 , 81 A, and 81 B as in FIG. 14 wherein the lenses has a flat outer surface unlike the illustrations in FIG. 16 , wherein the lenses of FIG. 16 having a concave/convex shape.
[0116] FIG. 18 is a rectangular base 31 that could otherwise be used with this invention.
[0000] Operation:
[0117] In the operation of this invention one would use the Improved Light Emitting Reflective Hazard Alert Unit in the purpose intended, such as: a proper beacon for potential hazard; likewise an alternative use on winding dark one lane country roads as a reference for hidden driveways. Or in the event of poor driving conditions the GPS transmitter aid in early warning providing that approaching vehicles are equipped with GPS.
[0118] Four simple steps to complete in achieving a hazard alert unit in accordance with this invention:
[0119] Step 1; remove invention from storage box
[0120] Step 2, to achieve intended triangular configuration of this invention t for deployment (after removing from box) raise both upper-blades 70 and 70 -A as in FIG. 9 , following lines 100 - 100 simultaneously creating a scissors like motion from collapsed to erect position, at end of upward travel both upper-blades 70 and 70 -A must be shifted to opposite sides of each other where studs 76 , 76 -A ( 76 -A not visible) and snap-lock 78 , 78 -A as in FIGS. 10, 13 . bringing upper-blades together overlapping and interlocking as in FIG. 11 using snap-lock 78 , 78 -A and studs 76 , 76 -A ( 76 -A not visible) as in FIGS. 9 , 10 , 11 , and 13 .
[0121] Step 3, after configuration of the triangular portion of said invention then rotate triangle clockwise, until stopped by the rotation-stop 58 , and 60 while base 56 remain stationary.
[0122] Step 4, the final step in the procedure is to deploy said invention at prescribed distance away from potential hazard, setting down unit on roadway/ground with stabilizers 54 , 54 -A and adhesive-friction-pad 32 , 32 -A thus keeping said invention from sliding around in high wind, by pressing on/off switch 28 located in the on flange-mount 24 deployment is complete. This device will operate for over 30 hours continuously. the use of LEDs which produce almost no heat, the chances of hot/cold condensation is to a minimal therefore the invention can be operated in cold temperatures as a beacon.
[0123] To disassemble and store said invention:
[0124] Step 1, turn device off.
[0125] Step 2, squeeze firmly on release-boss 72 , and 72 -A unlocking both upper-blade 70 , and 70 -A.
[0126] Step 3, fold upper-blades 70 , and 70 -A downwards following line 100 (as in FIG. 9 ) to base-blade 56 where all retainer-clips 74 , 74 -A, 74 -B, and 74 -C are interlocked (as in FIG. 14 )
[0127] Step 4, rotate triangular portion of device anticlockwise, locking the stabilizers 54 , 54 -A in stabilizer-recesses 22 , 22 -A as in FIGS. 1, 2 , and 3 .
[0128] Step 5, return said invention to storage
[0000] Conclusion, Ramifications, and Scope
[0129] Respectively, the reader will see that the GPS, light emitting, and reflective ability of this invention is readily practical for use on today's highways, furthermore the device will be constructed from some recycled material and is affordable, said invention has additional advantages in that:
[0130] (a) It permit use in vehicles where weight and space is a factor, by not being overtly bulky or heavier than those of it's same class and are in use today.
[0131] (b) It permits total mobility with no strings attached due to having integral circuitry, and power source.
[0132] (c) It reflect light continuously while illuminating on interval using a specified amount of light emitting diodes that project a clearly visible triangular image across great distance with the oscillation illumination of bank-A, and bank-B.
[0133] (d) It allows wind to flow through and around it due to a unique shape and design whereby using concave/convex lenses, and a cylindrical base the wind passes easily around said invention wherein the use of wind-slots in the flat inner portions of frame allowing wind to pass through thus reducing wind pressure against said invention keeping it from being blown about in high wind.
[0134] (e) It is totally moisture proof/resistant as a result of proper means for sealing and fastening, fusing the concave/convex lenses to chassis then adding sealant to crevice between concave/convex lenses and outer protective-edge of frame along with O-rings around the openings of base and moisture proof on/off switch.
[0135] (f) It use a GPS transmitter that is activated when device is turned on, to alert vehicles equipped with onboard navigation systems (via satellite) of a stalled motor vehicle up ahead during poor driving conditions, such as dense fog or near blinding cloud burst.
[0136] The above description has lots of specificity; they should not be construed as a limit for the scope of the present invention but rather providing illustrations of the presently preferred embodiments of this invention. For example, the device can have other shapes such as a recangulr-elongated base. A base made partly from rubber, or other non-slip materials, and lenses that are flat on the broader surface area. | An improved light emitting reflective hazard alert unit that is of a triangular configuration when erected, that emits light as a beacon and reflect in light beams aimed in general direction of device. Said invention provides GPS early warning via satellite, and practical for use in any condition. A foldable device conveniently stored in a protective case. Said invention is composed of two upper-blades ( 70 ), ( 70 -A) of equal dimension that is hinge-joined to a base-blade ( 56 ) nearing both ends of the base-blade ( 56 ) using gudgeon ( 66 ), ( 66 -A) and pin-rivet ( 68 ), ( 68 -A) and overlapping interlocking at unhinge end of upper-blades ( 70 ), ( 70 -A) thereby configuring a triangle as in FIG. 1 . This invention possess means for illumination affixed to the center section of chassis ( 92 ), ( 92 -A), ( 92 -B) and are respectively encased by all concave/convex translucent reflective lenses ( 80 ), ( 80 -A), ( 80 -B). The protective-edges ( 82 ), ( 82 -A) of the chassis ( 92 ), ( 92 -A), ( 92 -B) protect the outer corners of concave/convex translucent reflective lenses ( 80 ), ( 80 -A), ( 80 -B from being damaged during handling thereby preventing moisture to enter and causing said invention, the autonomous power supply, on/off switch ( 28 ), means for illumination control and GPS are housed in base ( 30 ) to become the ballast for said invention. It's the intention of this present invention to promote safety on all roadways during adverse driving conditions, by communicating hazard, and or potential hazards allowing approaching motorist adequate response time. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The disclosure relates to introducing a pattern onto the surface of elastomeric fabric supported gloves made from conventional sulphur vulcanised formulations in the wet gel state using an engraved moulding plate, and a flat former using compression moulding technique. The pattern so produced is permanent, uniform throughout the whole of the patterned area, and may be of any design—single pattern or multi pattern. The pattern so formed also provides the glove with enhanced grip as a consequence of the uniformity of the pattern.
(2) Description of Related Art
Conventional methodology for making patterns on supported gloves rely on the following techniques: screen printing elastomer-pattern is provided from pattern on screen; use of a solvent/solvent mixture to provide a pattern to the dipped glove during the production process; laminating with the aid of an adhesive pre-embossed piece of elastomer film onto a supported glove; laminating a liner onto a glove which has been previously dipped onto a former containing a patterned surface using an adhesive; and/or laminating a glove onto a liner dressed onto a former using an adhesive
WO 2000/019847 describes a method of producing grip-enhanced gloves by way of a mould that has convex patterns on it so that when a glove is manufactured using a dipped process, the glove contains concave indentations that give a gripping effect. Practically, these gripping areas are considerably large, work well on flat surfaces only and apply only to an un-supported glove.
WO 2006/053140 describes a method of producing grip-enhanced gloves by using negatively and positively pattered moulds. In this method, gripping elements could be made very small, but due to the fact that two plates—negative and positive—are used this method cannot be used to transfer patterns to supported (using liners made of textile, aramides, etc) gloves.
U.S. Pat. No. 5,098,755 describes a means of embossing uniform patterns onto films of thermoplastic elastomers. It also refers to applications on condoms and certain other items such as surgical gloves made from thermoplastic elastomers. Thermoplastic elastomers are a special type of material composed at a molecular sub micron level of hard and soft domains. They are different from conventional elastomers. The strength of the thermoplastic material is present by virtue of the hard and soft domains. Therefore Thermoplastic materials can easily be reshaped heated (embossed) and cooled, and the embossing effect will prevail until it is heated above the softening point of the hard blocks.
U.S. Pat. No. 4,283,244 refers to making fabric lined elastomeric articles, wherein the pattern is on the outside. This process involves a methodology wherein a composite liner is dressed onto an uncured latex glove prior to oven cure and stripping the composite liner from the glove. After stripping, the glove is turned inside out and the pattern is on the outer surface.
Normally in supported glove manufacturing involving latex systems based on natural rubber latex, nitrile latex, neoprene latex, and SBR latex, embossing the pattern onto a glove during the wet gel state of the glove manufacturing operation has not been performed. Patterns are introduced to enhance grip, and in conventional technology the pattern is made by using the methodology identified in (b) above, in which the pattern is introduced to the glove by dipping into a solvent or solvent mixture prior to vulcanisation whilst still in the wet gel state. The pattern so formed is often wavy and non-uniform (i.e. the intensity of pattern varies along patterned area).
Therefore there exists a need to emboss different types of patterns and have a uniform pattern distribution in supported glove manufacturing after dipping and prior to vulcanisation. The present application provides a solution for this need.
BRIEF SUMMARY OF THE INVENTION
In the present disclosure, a pattern is introduced to the elastomeric component of the supported glove whilst in the wet gel state prior to vulcanisation. The pattern formed by the present methodology is uniform throughout the whole of the patterned area. Furthermore, the pattern can be of any design and variations being limited to what can be embossed on to the metal plate employed to impart the pattern on to the elastomer. Employment of such a methodology provides an easy method that transfers patterns consistently onto an elastomeric supported glove surface to render the glove more aesthetically pleasing and/or incorporate other desirable patterns such as company logos or brand names and/or give the glove a higher degree of flexibility and/or give the glove a better gripping ability, also to facilitate better wet grip.
The present process applies to conventional latex elastomers, which require chemicals to be added to the elastomer during the manufacturing process (e.g. vulcanising ingredients mixed into latex) in which the strength is achieved by a vulcanising process and application of heat in an oven. The product so formed is a thermoset. In our process the embossing is performed prior to vulcanisation in the wet gel state stage of the operation. Furthermore, once vulcanised the embossed effect is permanent. The latex we are working with is a conventional rubber (natural rubber, nitrile rubber, neoprene rubber), which requires vulcanising ingredients to impart strength to the elastomer.
The present disclosure provides a supported elastomeric glove with an enhanced gripping surface and a method of transfer of patterns onto a glove outer surface using a preformed moulding plate/mould other than the glove fabricating mould itself without the use of a solvent process in the wet gel state prior to vulcanisation of the elastomer. It applies to gloves made by a dipping process using latex as the elastomer.
Furthermore the pattern transfer process may also be applied to rubbers dissolved in solvents prior to the vulcanisation operation. The pattern may take any shape and any such pattern can be transferred onto the glove using the compression moulding method. The pattern shall be used to enhance the aesthetic appearance of the glove or the functionality of the glove in terms of better grip and/or higher flexibility. The pattern may or may not be uniform throughout the surface. The pattern can either cover the outer surface completely or only part/parts of it. The pattern can also have company logos, brand names or other shapes incorporated into it giving variation in the pattern within a glove. The glove may be made of any natural or synthetic elastomer or a blend thereof. The fabric liner may be made of any knitting yarn or made by cutting and sewing.
The process disclosed in the present application eliminates the need to have negative and positive plates as mentioned in the prior art. This process makes it much easier to have wide variety of patterns because only one plate needs to be cut where a matching negative plate is not required. This process does not alter the dimensions of the glove; compression moulding process removes entrapped water, which is also advantageous when energy required for curing is considered. The methods described in prior art cannot be used to make a pattern on a supported glove.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a plan view of a glove generally shown prior to pattern being transferred using the present process of the application.
FIG. 2 shows a flat former used in compression moulding.
FIG. 3 shows the process of moulding a pattern onto the latex dipped supported glove using compression moulding.
FIG. 4 is a plan view of a glove manufactured using the present process of the application.
FIG. 4 a shows an enlarged view of a square impression on the plan view of the glove.
FIG. 5 shows an engraved plate used in compression moulding.
FIG. 6 shows a non-exhaustive list of example patterns that may be a transferred to an elastomeric glove by the process described in the present application.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a fabric supported elastomeric glove ( 10 ) is generally shown. The present disclosure relates to a method of transferring patterns (see FIG. 6 ) onto a fabric supported elastomeric glove surface ( 12 ) rendering the glove ( 10 ) aesthetically pleasing and having enhanced gripping properties compared to a supported glove made with a natural or synthetic fibre based liner (not shown) coated with Natural Rubber or Synthetic elastomer or a blend thereof, consisting of a permanent pattern impression (see FIG. 6 ) made by a non chemical process on the palm ( 13 ) and fingers ( 15 ) to improve grip and other properties related to the usage of the glove ( 10 ). A drying process of the glove ( 10 ) is interrupted at a stage where the gel strength of the glove film (not shown) is such that it could withstand compression force without cracking up, or disintegrating. The glove ( 10 ) is then removed from a dipping former (not shown) and dressed on to a flat former ( 14 ), as shown in FIGS. 2 and 3 .
The surface ( 12 ) of the glove ( 10 ) is then subjected to compression force by a hydraulic machine ( 16 ), shown generally in FIG. 3 , to leave a desired imprint (See FIG. 6 ) on the elastomeric surface ( 12 ), which will become a special grip pattern, such as one selected from FIG. 6 .
The special grip pattern on the elastomer can have any design but a series of square depressions ( 18 ), as shown in FIG. 4 a , which will come into contact with a handled object (not shown), is recommended for better grip.
The introduction of the grip pattern by pressing and moulding the elastomer glove ( 10 ) using a preformed engraved moulding plate ( 20 ) makes it possible for the formation of a series of depressions ( 18 ), which are very uniform in arrangement and dimensions on the elastomer glove ( 10 ).
There is provided according to one embodiment of the present disclosure a glove ( 10 ) with a polycotton fabric lining (not shown) and a natural rubber partial coating (not shown) with a preformed moulded pattern (See FIG. 6 ).
A latex based compound for an elastomer film is made using accelerators, activators, sulphur which are mixed using high speed stirrers, ball mills, etc. A textile liner is made by special purpose glove knitting machine of gauge 10 (or 13, 15, 18 or using Whole Garment Technology™ (WG)) with poly cotton 65:35 yarn. This liner can be replaced with a cut and sewn liner if it is desired. The gloves may be made of any blends of material or any knitted/woven material derived from cotton, nylon, polyester, polyester cotton, wool, para-aramid synthetic fiber, thermoplastic polyethylene, leather, or other engineering yarns. Commonly the latex includes natural rubber latex, nitrile latex/dispersions, neoprene latex, either by themselves or in combination with each other as blends. Other less common latex types based on other elastomers where chemicals are added to vulcanise the elastomer (e.g. Styrene butadiene rubber, silicone rubber, cis poly isoprene, butyl rubber, gunk rubber, etc.) may also be used to make the gloves.
The liners are dressed on to a mould. The mould referred to here consists of five fingers, palm and section of arm, where the hand is shaped to suit the dipping operation, and is made of Aluminum, Ceramic, or with heat resistant polymer resin. Then the dressed liner is dipped in elastomer to obtain a precise coating of elastomer using special purpose dipping machine or a robotic arm.
The elastomer coated liner is then dried and dipped in a special solvent free compound to increase the gel strength of the elastomer coating for the next process to take place.
A pre designed pattern (See FIG. 6 ) is engraved on to a engraved plate ( 20 ) for formation of a grip pattern (See FIG. 6 ). A engraved plate ( 20 ) is cut using a programmable robot (not shown) programmed on three axis to cut a precise pattern (see FIG. 6 ), having specific length, breadth and depth as shown in FIG. 5 . The robot is used to get a precise finish. A engraved plate can be cut also using other conventional tools and techniques, or by a chemical engraving process.
The pattern is cut on the engraved plate ( 20 ) which has sufficient thickness ( 28 ) for cutting and strength to prevent deformation during heating and compression. If a logo (not shown) is intended for the glove ( 10 ) then in fabrication of the engraved plate, the logo is embedded at the base of the engraved plate. The location of the logo is carefully selected so that the logo appears at the base of the palm ( 13 ) or elsewhere; which does not hinder the function of the elastomer surface ( 12 ) in gripping an object. Alternatively chemical engraving of the metal plate ( 20 ) is also possible. The engraved plate ( 20 ) is fixed to preferably a hydraulically operated pressing machine ( 16 ) designed to deliver a specific predetermined force/pressure. The engraved plate could be heated by suitable means ( 30 ) to achieve a temperature of around 50-100° C. before pressing is done.
The partially dried supported glove ( 10 ) is removed whilst still in a wet gel state and dressed on to a special moulding plate called a flat former ( 14 ). The flat former ( 14 ) is made of a metal plate with sufficient thickness, has five fingers, palm, and section of arm, and called a flat former due to its shape. The glove ( 10 ) is dressed onto it carefully. The dressed glove ( 10 ) is then placed on the lower platen ( 34 ) of the hydraulic press machine ( 16 ) and compressed under the engraved plate ( 20 ) to make an impression on the elastomer surface ( 12 ). The pressure is controlled so that the elastomer ( 12 ) is not damaged. In engraving the pattern (see FIG. 6 ) onto the engraved plate ( 20 ), care has to be taken to not to have edges too sharp which will cut in to the elastomer surface ( 12 ) of the glove ( 10 ) and ruin its performance. This is achieved in designing phase of pattern. The glove ( 10 ) with the moulded pattern (see FIG. 6 ) is then removed from the flat former ( 14 ), washed, dressed onto another former (not shown) and cured completely in a curing oven having temperature controls and moisture management technology.
In another embodiment, instead of working with latex, the flat former ( 14 ) pre-dressed with a liner is dipped into a solution (not shown) of an elastomer+vulcanising ingredients. After full or partial drying of the solvent, the supported glove ( 10 ) is embossed with a pattern as described above prior to curing whilst still in the wet gel state or fully uncured state prior to full vulcanisation in an oven. In such an instance prior to making the solution of the elastomer, the vulcanising agents and other formulation ingredients are either mixed into the solid elastomer in a mill (2-roll mill, Bambury, Busco-Kneader, or other type of mill used for milling ingredients into solid rubber), a technique well known to those working in the field of solid rubber mixing or they are added to a solution of the elastomer in the solvent as solutions/dispersions in suitable miscible solvents.
While the present description relates to the manufacture of the said glove ( 10 ) it will be understood that the present disclosure can easily be applied to the manufacture of any other type of fully elastomeric glove or glove with a fabric liner and a partial or full elastomeric coating by those of ordinary skill in the art of glove manufacture. | A semi cured supported elastomeric glove with enhanced gripping surfaces achieved by the method of transferring of patterns by compression molding, including a plurality of concave indentations of any pattern and molded into the gripping surfaces of the semi cured glove. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
The subject matter of this application is related to that of applicant's co-pending application Ser. No. 07/382,813 filed July 19, 1989.
BACKGROUND OF THE INVENTION
The present invention relates to novel 2-,4-or 5-substituted thiazole compounds, pharmaceutical compositions containing the compounds and to the use of the compounds for the treatment of central cholinergic disfunction.
The novel compounds described herein are useful as cholinergic agents. A chronic deficiency in central cholinergic function has been implicated in a variety of neurologic and psychiatric disorders, including Senile Dementia of the Alzheimer's type (SDAT), tardive dyskinesia, Pick's disease and Huntington's chorea. Post mortem neurochemical investigations of patients with SDAT have demonstrated a reduction in presynaptic markers for acetylcholine-utilizing neurons in the hippocampus and the cerebral cortex. [P. Davies and A. J. R. Maloney, Lancet, 1976-II, 1403, (1976); E. K. Perry, R. H. Perry , G. Blessed, B. E. Tomlinson, J. Neurol. Sci., 34, 247, (1976)]. The basis for this cholinergic abnormality is unclear, but evidence suggests that the cholinergic neurons in the neucleus basalis of Meynert may selectively degenerate in SDAT [J. T. Coyle, D. J. Price, M. R. DeLong, Science, 219, 1184, (1983)]. If this degeneration plays a role in behavior symptoms of the disease, then a possible treatment strategy would be to compensate for the loss of cholinergic output to the cortex and hippocampus.
In an aged monkey animal model, designed to mimic the symptoms of SDAT, the direct muscarinic agonists arecoline [R. T. Bartus, R. L. Dean, B. Beer, Neurobiology of Aging, 1, 145, (1980)]and oxotremorine [R. T. Bartus, R. L. Dean, B. Beer, Psyohopharmacology Bulletin, 19, 168, (1983)]produced significant improvement in performance. These results in aged monkeys were corroborated in SDAT patients with arecoline which produced a more-consistent improvement when compared to the anticholinesterase inhibitor physostigmine [J. E. Christie, A. Shering, J. Ferguson, A. M. Glen, British Journal of Psychiatry, 138, 46, (1981)].
These animal behavioral and clinical results have instigated significant efforts in a search for a muscarinic agonist which will selectively compensate for the loss of cholinergic input in the hippocampus and cereberal cortex. However, the search must be refined to seek agonists Which will not effect significantly the remaining body cholinergic functions. The recent disclosure (T. I. Bonner, N. J. Buckley, A. C. Young, M. R. Brann, Science, 237,527, (1987)] that muscarinic receptors are not all the same but exist as a heterogenous population of receptors substantiates the possibility for the discovery of a selective muscarinic agonist.
N-methyl-N-(1-methyl-4-pyrrolidino-2-butynyl) acetamide(BM-5) having the structure set forth below, has been reported to be a presynaptic cholinergic antagonist (which should disinhibit the release of endogenous acetylcholine) and a postsynaptic partial cholinergic agonist (which should mimic the effects of acetylcholine). See Resul. B. and co-workers, Eur. J. Med. Chem., 1982, 17. 317. ##STR2##
Chemically, BM-5 is a fairly flexible molecule that can assume a number of different conformations. The present invention describes the synthesis of a series of novel (3-amino-1-propynyl)thiazoles which are derivatives of BM-5 in which one degree of freedom (bond a) has been restricted.
SUMMARY OF THE INVENTION
This invention is concerned with new compounds described by the following Formula I: ##STR3## where R is selected from hydrogen or lower alkyl, NR'" is selected from NR" and NR'; NR" is (C 1 -C 6 )trialkylamino; NR' is amino, (C 1 -C 6 )alkylamino, (C 1 -C 6 ) dialkylamino, pyrrolidino or piperidino; and pharmaceutically acceptable acid addition salts thereof. The compounds have cholinergic activity and accordingly, the invention includes methods for treating diseases of the central nervous system in mammals employing these new compounds; with pharmaceutical preparations containing these compounds; and with processes for the production of these compounds.
DESCRIPTION OF THE INVENTION
The novel compounds of the present invention may be prepared in accordance with the following Scheme I, wherein --NR' is selected from amino, (C 1 -C 6 )alkylamino, (C 1 -C 6 )dialkylamino, pyrrolidino or piperidino; NR" is trialkylamino; and R iv X is a (C 1 -C 6 )alkyl halide. ##STR4##
The synthesis of the 2-, 4- or 5-substituted thiazoles is accomplished by palladium (o) catalyzed coupling reactions between the appropriate propargylamine and a 2-, 4- or 5-bromothiazole in the presence of a base such as a tertiary amine and a cuprous halide at the reflux temperature for several hours, giving the desired product. Reaction of the amine product NR' with a (C 1 -C 6 )alkyl halide gives the quaternary ammonium salt where NR" is (C 1 -C 6 )trialkylamino.
Whereas the 4- and 5-(3-amino-1-propynyl)-thiazoles formed hydrochloride salts in the expected manner, the treatment of 2-(3-amino-1-propynyl) thiazoles with methanolic hydrogen halide (X═Cl, Br,I) gives the hydrohalide addition products across the triple bond as shown in Scheme II. ##STR5##
The compounds of this invention were tested for cholinergic activity according to the following procedures.
[ 3 H] Quinuclinyl Benzilate Binding Assay
This assay is utilized in conjunction with the 3 H-Cismethyldioxolane binding assay to evaluate antagonist and high affinity agonist binding properties of CNS cholinergic agents. The procedure is adapted from Watson, M., Yamamura, H. I., and Roeske, W. R., J. Pharmacol. Exp. Ther. 237: 411-418 (1986) and Watson, M., Roeske, W. R., and Yamamura, H. I., J. Pharmacol. Exp. Ther. 237: 419-427 (1986).
Tissue Preparation:
Rats are sacrificed by decapitation and the brain removed and placed on ice. The cerebral cortex is dissected on a cold stage, weighed and homogenized (Polytron, setting 5.5 with PT-10 saw-tooth generator for 15 seconds) in 50 volumes (wet wt/vol) of ice-cold 10 mM (8.1 mM Na 2 HPO 4 , 1.9 mM KH 2 PO 4 ) sodium-potassium phosphate buffer (NaKPB), pH 7.4. The homogenate is placed in an ice bath for 30 seconds and homogenized again as above. This procedure is repeated once again for a total of three times. The resulting homogenate is then diluted 1:3000 (original wet wt/vol) With ice-cold NaKPB for use in the assay. The final protein content per 2.0 ml of incubation mixture is 0.1 mg.
Dilution of Compounds:
A stock solution of Atropine is prepared at 0.2 mM to define non-specific binding (1 μM final conc). Test compounds are prepared at 40 mM (final conc 1 mM) in buffer (if water soluble) or in absolute ethanol - 1 N HCl (1:1, v/v) and serially diluted to the desired concentrations. In general, dose-response profiles are examined between 1 mM and 1 pM final concentrations.
Preparation of 3 H-QNB:
3 H-QNB (NEN, NET-656; specific activity=30.0 Ci/mmol) is diluted to 5 nM, with NaPB (final concentration =0.25 nM activity -18,000 cpm at a counting efficiency of 55%).
3 H-QNB Binding Assay:
A typical protocol is outlined below:
______________________________________ Test Com-Tube Buffer Atropine pound .sup.3 H-QNB TissueNo. ID* μL μL μL μL ml______________________________________1-2 Total 50 -- -- 100 1.853-4 NS 40 10 -- " "5-6 4e-11 -- -- 50 " "7-8 4e-10 -- -- " " "9-10 4e-09 -- -- " " "11-12 4e-08 -- -- " " "13-14 4e-07 -- -- " " "15-16 4e-06 -- -- " " "17-18 4e-05 -- -- " " "19-20 4e-04 -- -- " " "21-22 4e-03 -- -- " " "23-24 4e-02 -- -- " " "______________________________________ *Stock concentration [M] of compound to be tested.
Components are added in the following order: test compound, pound, radioligand, buffer or tissue to give a final volume of 2.0 ml. After adding the tissue homogenate, the tubes are thoroughly mixed and incubated at 25° C. for 120 minutes. At the end of 120 minutes, the samples are filtered through GF/B glass fiber filters (Whatman) using a 24 sample cell harvester (Brandel) under a vacuum of 15 mm Hg. The tubes are washed with 5×3 ml ice-cold NaKPB. The filters are then placed in scintillation vials with 10 ml of scintillation cocktail (Beckman HP or HP/B), allowed to stand overnight, shaken and then counted. Specific binding is calculated as Total--NS (non-specific). The percent is inhibition of specific binding is then calculated and the IC50 values computed using either the LlGAND or LUNDON software packages for competition binding. The results of this test on representative compounds of this invention appear in Table I.
[ 3 H]-Cis-methyldioxolane Binding Assay (High Affinity)
This assay is utilized in conjunction with 3 H-QNB binding to evaluate high affinity agonist binding and and tagonist properties of CNS cholinergic agents. The procedure is adapted from Vickroy, T. W., Roeske, W. R, and Yamamura, H. I., J. Pharmacol. Exp. Ther. 229: 747-755 (i984). This is a rapid filtration assay that is set up to label only the high affinity agonist conformation of the muscarinic cholinergic receptor.
Tissue Preparation:
Rats are sacrificed by decapitation and the brain removed and placed on ice. The cerebral cortex is dissected on a cold stage, weighed and homogenized (Polytron, setting 5.5 with Pt-10 saw-tooth generator for 15 seconds in 50 volumes (wet wt/vol) of ice-cold 10 mM (8.1 mM Na 2 HPO 4 , 1.9 mM KH 2 PO 4 ) sodium-potassium phosphate buffer (NaKPB), pH 7.4. The homogenate is placed in an ice bath for 30 seconds and homogenized again as above. This procedure is repeated once again for a total of three times. The resulting homogenate is then diluted 1:300 (original wet wt/vol) with ice-cold NaKPB for use in the assay. The final protein content per 2.0 ml of incubation mixture is 0.75 mg.
Dilution of Compounds:
A stock solution of Atropine is prepared at 0.2 mM to define non-specific binding 1 μM final conc). Test compounds are prepared at 40 mM (final conc 1 mM) in buffer (if water soluble) or in absolute ethanol-1 N HCl (1:1, v/v) and serially diluted to the desired concentrations. In general, dose-response profiles are examined between 1 mM and 1 pM final concentrations.
Preparation of 3 H-CD:
3 H-CD (NEN, NET-647; specific activity=55.5 Ci/mmol) is diluted to 20 nM with NaPB (final conc=1.0 nM, activity -75,000 cpm at a counting efficiency of 55%).
Technical Notes:
3 H-CD adheres readily to both glass and plastic surfaces. To eliminate this problem (and the chance for introducing artifacts into the results), stock vials, pipette tips and all glass tubes are routinely treated with Prosil-28, a siliconizing agent, and oven dried prior to use in an assay. Additionally, the GF/B glass fiber filters are pre-soaked in an aqueous polyetbylenimine (PEI) solution (0.1%, pH 7.0) prior to use.
All points in the inhibition curve (including total and non-specific binding)are always measured on single PEI treated filter strips to minimize filter-to-filter variability. (see Bruns, R. F., et al. Anal. Biochem. 132: 74-81 (1983) for the use of PEI treated filters in filtration receptor assays).
The 3 H-CD is prepared fresh in buffer just prior to use in the assay to avoid possible decomposition. It should be kept on an ice bath after dilution in buffer.
3 H-CD Binding Assay:
A typical protocol is outlined below:
______________________________________ Test Com-Tube Buffer Atropine pound .sup.3 H-CD TissueNo. ID* μL μL μL μL ml______________________________________1-2 Total 50 -- -- 100 1.853-4 NS 40 10 -- " "5-6 4e-11 -- -- 50 " "7-8 4e-10 -- -- " " "9-10 4e-09 -- -- " " "11-12 4e-08 -- -- " " "13-14 4e-07 -- -- " " "15-16 4e-06 -- -- " " "17-18 4e-05 -- -- " " "19-20 4e-04 -- -- " " "21-22 4e-03 -- -- " " "23-24 4e-02 -- -- " " "______________________________________ *Stock concentration [M] of compound to be tested.
Components are added in the following order: compound, radioligand, buffer or tissue to give a final volume of 2.0 ml. After adding the tissue homogenate, the tubes are thoroughly mixed and incubated at 25° C. for 120 minutes. At the end of 120 minutes, the samples are filtered through PEI pretreated GF/B glass fiber filters (Whatman) using a 24 sample cell harvester (Brandel) under a vacuum of 15 mm Hg. The tubes are washed with 5×3 ml ice-cold NaKPB. The filters are then placed in scintillation vials with 10 ml of scintillation cocktail (Beckman HP or HP/B), allowed to stand overnight, shaken and then counted. Specific binding is calculated is Total--NS (non-specific). The percent inhibition of specific binding is then calculated and the IC50 values computed using either the LIGAND or LUNDON software packages for competition binding. The results of this test on representative compounds of this invention appear in Table I.
TABLE I______________________________________ .sup.3 H-QNB .sup.3 H-CDCompound IC.sub.50 μM IC.sub.50 nM______________________________________2-[3-(1-Pyrrolidinyl)-1-propynyl]thiazole 44 14261-[3-(2-Thiazolyl)-2-propynyl]piperidine 182 10180 --N, --N-Dimethyl-3-(2-thiazolyl)-2-propyn-1- 1311 9978amine --N, --N, --N-Trimethyl-3-(2-thiazolyl)-2-propyn- 123 6731-aminium, iodide2-[2-Chloro-3-(1-pyrrolidinyl)-1- 186 2230propenyl]thiazole1-[2-Chloro-3-(2-thazolyl)-2- 117 6594propenyl]piperidine2-Chloro- --N, --N-dimethyl-3-(2-thiazolyl)- 222 10692-propen-1-amine2-[2-Bromo-3-(1-pyrrolidinyl)-1- 90propenyl]thiazole4-[3-(1-Pyrrolidinyl)-1-propynyl]thiazole 71 39541-[3-(4-Thiazolyl)-2-propynyl]piperidine 124 281401-[3-(4-Thiazolyl)-2-propynyl]piperidine, 114 14010hydrochloride --N, --N-Dimethyl-3-(4-thiazolyl)-2-propyn- 504 129201-amine --N, --N-Dimethyl-3-(4-thiazoyl)-2-propyn- 381 190301-amine --N, --N, --N-Trimethyl-3-(4-thiazolyl)-2- 119 1459propyn-1-aminium, iodide5-[3-(1-Pyrrolidinyl)-1-propynyl]thiazole 73 2451-[3-(5-Thiazolyl)-2-propenyl]piperidine 164 12640 --N, --N-Dimethyl-3-(5-thiazolyl)-2-propyn- 765 33751-amine --N, --N, --N-Trimethyl-3-(5-thiazolyl)-2- 131 273propyn-1-amine, iodide5-[3-(1-Pyrrolidinyl)-1-propynyl] 115 4699thiazole1-[3-(5-Thiazolyl)-2-propynyl] 119 658piperidine, monohydrochloride -- N, --N-Dimethyl-3-(5-thiazolyl)-2- 482propyn-1-amine, monohydrochloride______________________________________
Those compounds which have 3 H- CD IC 50 values of <1000 nM and/or 3 H-QNB IC 50 values of <1000 μM are considered active.
The effective dosage of active ingredient employed may vary with the particular compound employed, the mode of administration, and the severity of the condition being treated. In general, however, satisfactory results are obtained when the compounds of the invention are administered at a daily dosage of from about 0.02 mg to about 100 mg/kg of patient body weight, preferably given in divided doses two to four times a day, or in sustained release form. For most patients, the total daily dosage is from about 1 mg to about 5,000 mg, preferably from about 1 mg to 20 mg.
The pharmaceutical preparations of the present invention may contain, for example, from about 0.5% up to about 90% of the active ingredient in combination with the carrier, more usually between 5% and 60% by weight. This dosage regimen may be adjusted to provide the optimal therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
Dosage forms suitable for internal use comprise from about 0.25 to 5.0 mg of the active compound in intimate admixture with a solid or liquid pharmaceutically acceptable carrier. A decided practical advantage is that these active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes if necessary. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose, and kaolin, while liquid carriers include sterile Water, polyethylene glycols, non-ionic surfactants, and edible oils such as corn, peanut, and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, and antioxidants, e.g., vitamin E, ascorbic acid, BHT and BHA.
The preferred pharmaceutical compositions from the standpoint of ease of preparation and administration are solid compositions, particularly tablets and hard-filled or liquid-filled capsules. Oral administration of the compounds is preferred.
These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exits. It must be stable under the conditions or manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water ethanol, polyol (e.g., glycerol, propylene glycol, and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oils.
As used herein, "pharmaceutically acceptable carriers" includes any and all solvents, dispersion media, coatings, antibacterial and antifungal agents, isotonic and absorption delaying agents and the like. The use of such media and agents for pharmaceutically active substances is well known in the art. Except insofar as any conventional media or agent is incompatible with the active ingredient, its use in therapeutic compositions is contemplated.
The following examples describe in detail the chemical synthesis of representative compounds of the present invention. The procedures are illustrations, and the invention should not be construed as being limited by chemical reactions and conditions they express. No attempt has been made to optimize the yields obtained in these reactions, and it would be obvious to one skilled in the art that variations in reaction times, temperatures, solvents, and/or reagents could increase the yields.
The following Reference Examples describe the preparation of the intermediates used to make some of the final products in this invention.
Reference Example 1
2,4-Dibromothiazole
Following the procedure of P. Reynaud, et al., Bul. Soc. Chim. France, 1735-8, 1962; a mixture of 6.3 g of 2,4-thiazolidine-dione and 50 g of phosphorus oxybromide is stirred at 110°-115° C. for 3 hours. The reaction is poured into 250 g of ice treated portionwise with 80 ml of 10 N sodium hydroxide and 250 ml of methylene chloride. The solution is filtered through diatomaceous earth, the layers are separated and the aqueous layer is re-extracted with methylene chloride. Sodium chloride is added to the aqueous phase and re-extracted with diethyl ether. The organic layers are combined, dried over sodium sulfate, filtered and concentrated in vacuo to give 10.7 g of product. The dibromide is purified by cbromatography to give 7.6 g of the product as white crystals, m.p. 70°-72° C.
Reference Example 2
4-Bromothiazole
Following the procedure of M. Robba and R. C. Moreau, Annales pharm. franc. 22, #3, 201-210 (1965); 10 g of 2,4-dibromothiazole and 5 g of powdered zinc in 40 ml of glacial acetic acid is stirred at 60°-65° C. for 45 minutes. The mixture is cooled in an ice bath, as 40 ml of 10 N sodium hydroxide is added in portions. Stirring is continued for 30 minutes. Ten milliliters of 10 N sodium hydroxide is added and the reaction is extracted with diethyl ether followed by methylene chloride. The combined organic layers are dried over sodium sulfate, filtered and concentrated in vacuo to give 5.4 g of the product as a yellow oil. The 1 H PMR spectrum indicates the presence of thiazole (10%) as an impurity. Chromatography is used to remove any additional impurities after the final coupling reactions.
Reference Example 3
5-Bromothiezole
The procedure of H. C. Beyerman, et al., Rev. Trav. Chim. 73,325 (1954) is used for the preparation of this intermediate. To a stirred mixture of 27.2 g of 2-amino-5-bromothiazole in 212 ml of 86% phosphoric acid is added at room temperature 43 ml of concentrated nitric acid. The mixture is cooled to -10° C. and a solution of 15.9 g of sodium nitrite in 52 ml of water is added slowly over 45 minutes, while maintaining the temperature between -5° to -10° C. The reaction is stirred at the low temperature for an additional 30 minutes. Eighty milliliters of 50% hypophosphorous acid is added over 75 minutes, maintaining the temperature between -5° C. and -10° C., followed by stirring for 2 hours at -5° C. The reaction mixture is stirred at room temperature for 16 hours and carefully added to a cooled solution of 161.5 g of sodium hydroxide in water. Ice is added to keep the reaction temperature under control. The reaction is extracted with methylene chloride, passed through a pad of diatomaceous earth and concentrated in vacuo to give 13.4 g of a dark brown oil. The crude 5-bromothiazole is purified by Kugelrohr distillation to give 10.2 g of colorless oil, b.p. 70°-80° C. (20 mm Hg).
Reference Example 4
1-(2Propynyl)piperidine, hydrochloride
Following the procedure of J. J. Biel and F. DiPierro, JACS, 80, 4609 (1958), 87.6 g of propargyl bromide (80% by wt. in toluene) is added over 40 minutes with stirring to an ice cooled solution of 102.2 g of piperidine in 600 ml of dry diethyl ether. The reaction mixture is stirred under mild reflux of 6 hours followed by stirring at room temperature for 16 hours. The precipitate is filtered, washed 3 times with ether and the combined filtrates are concentrated in vacuo at 50° under water aspirator pressure. The 1-(2-propynyl)-piperidine is purified by distillation is give 52.5 g of pure product, b.p. 55°-60° C. (5 mm Hg). The hydrochloride salt of the product is prepared by the addition of an excess ethanolic hydrogen chloride to a solution of the amine in ether. The hydrochloride salt of the product is recrystallized from acetonitrile to give the product as a crystalline solid, m.p. 180°-182° C.
The following Examples pertain to the preparation of final products encompassed by the present invention.
Example 1
N,N-Dimethyl-3-(2-thiazolyl)-2-propyn-1-amine
A mixture of 5.02 g of 2-bromothiazole, 20 ml of triethylamine, and 4.3 ml of 1-dimethylamino-2-propyne is stirred under argon for 5 minutes. Seven hundred and fifty milligrams of bis(triphenylphosphine) palladium (II) chloride and 0.450 mg of copper (I) iodide is added and the stirred reaction is heated at 80°-85° C. for 3 hours. The reaction mixture is cooled, partitioned between diethyl ether and 65 ml of 10% sodium carbonate, and the layers are separated. The organic layer is filtered through diatomaceous earth, washed with aqueous sodium chloride and dried over magnesium sulfate. The crude product is purified by chromatography using silica gel as absorbant followed by filtration of the product band through a pad of magnesium silicate to give 0.35 g of the desired product as an oil, MH + 167. Purity is determined by 1 H PMR spectroscopy and by thin layer chromatography.
Table II sets forth compounds which may be prepared by the procedure of Example 1 using appropriately substituted starting materials.
TABLE II______________________________________ mp °C. or massExample spectrum# Product m/e (MH.sup.+)______________________________________2 --N, --N-Dimethyl-3-(4-thiazolyl) oil(MH+)=1672-propyn-1-amine3 --N, --N-Dimethyl-3-(4-thiazolyl)-2- mp 145-147° C. propyn-1-amine, hydrochloride4 --N, --N-Dimethyl-3-(5-thiazolyl) oil(MH+)=1672-propyn-1-amine5 --N, --N-Dimethyl-3-(5-thiazolyl)-2- mp 145-147° C. propyn-1-amine, hydrochloride6 2-[3-(1-Pyrrolidinyl)-1- oil(MH+)=193 propynyl]thiazole7 4-[3-(1-Pyrrolidinyl)-1- oil(MH+)=193 propynyl]thiazole8 4-[3-(1-Pyrrolidinyl)-1-pro- mp 190-192° C. pynyl]thiazole, hydrochloride9 5-[3-(1-Pyrrolidinyl)-1- oil(MH+)=193 propynyl]thiazole10 5-[3-(1-Pyrrolidinyl)-1-pro- mp 206-208° C. pynyl]thiazole, hydrochloride11 1-[3-(2-Thiazolyl)-2-pro- oil(MH+)=193 pynyl]piperidine12 1-[3-(4-Thiazolyl)-2-pro- oil(MH+)=207 pynyl]piperidine13 1-[3-(4-Thiazolyl)-2-propynyl] mp 219-221° C. piperidine, hydrochloride14 1-[3-(5-Thiazolyl)-2-pro- oil(MH+)=207 pynyl]piperidine15 1-[3-(5-Thiazolyl)-2-propynyl] mp 210-212° C. piperidine, hydrochloride______________________________________
Example 16
N,N,N-Trimethyl-3-(2-thiazolyl)-2-propyn-1-aminium iodide
A mixture of 0.7 g of N,N-dimethyl-3-(2-thiazolo)-2-propyn-1-amine prepared by the procedure of Example I and 2 ml of methyl iodide in 5 ml of diethyl ether is stirred at room temperature for 2 hours. The precipitate is collected by filtration to give 1.2 g of the crude product. Recrystallization of the product from acetonitrile gives colorless crystal, mp 217°-219° C.
Table III sets forth compounds which may be prepared by the procedure of Example 16 using appropriately substituted starting materials.
TABLE III______________________________________ mp °C. or massExample spectrum# Product m/e (MH+)______________________________________17 --N, --N, --M-Trimethyl-3-(4-thiazolyl)- mp 220-222° C. 2-propyn-1-aminium iodide18 --N, --N, --N-Trimethyl-3-(5-thiazolyl)- mp 195-197° C. 2-propyn-1-aminium iodide______________________________________ ##STR6## Whereas the 4- and 5-(3-amino-1-propynyl)thiazoles formed hydrohalides in a normal manner, the addition of methanolic hydrogen chloride or methanolic hydrogen bromide to the 2-(3-amino-1-propynyl)thiazoles yielded the 2-halo-2-propen-1-amines listed below in Table IV. The position of the halogen is determined by .sup.1 HPMR spectral analysis.
TABLE IV______________________________________ mp °C. or massExample spectrum# Product m/e (MH+)______________________________________19 2-Chloro- --N, --N-dimethyl-3-(2- oil(MH+) = 203 thiazolyl)-2-propen-1-amine,(E)20 1-[2-Bromo-3-(2-thiazolyl)-2- oil(MH+) = 288 propenyl]piperidine,(E)21 2-[2-Chloro-3-(1-pyrrolidinyl)- oil(MH+) = 229 1-propenyl]thiazole,(E)22 1-[2-Chloro-3-(2-thiazolyl)-2- oil(MH+) = 243 propenyl]piperidine,(E)23 2-[2-Bromo-3-(1-pyrrolidinyl)- waxy solid 1-propenyl]thiazole,(E) MH+ = 274______________________________________ | Pharmaceutical compounds and compositions which may be represented by the following structural formulae: ##STR1## where R is hydrogen or lower alkyl and NR'" is amino, (C 1 -C 6 ) alkylamino, dialkylamino, or trialkylamino, pyrrolidino or piperidino. The compounds are useful in treating central cholinergic disfunction in mammals. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The subject matter described here generally relates to wind turbines, and, more particularly, to differential vibration sensing and control of wind turbines.
[0003] 2. Related Art
[0004] A wind turbine is a machine for converting the kinetic energy in wind into mechanical energy. If the mechanical energy is used directly by the machinery, such as to pump water or to grind wheat, then the wind turbine may be referred to as a windmill. Similarly, if the mechanical energy is converted to electricity, then the machine may also be referred to as a wind generator or wind power plant.
[0005] Vibrations in various components of a wind turbine may considerably reduce the life of those components and/or lead to early fatigue failures. These vibrations are typically measured with respect to a stationary reference point using accelerometers arranged at critical locations on the components of interest. However, such conventional approaches to vibration sensing do not adequately protect the wind turbine and can lead to unnecessary system shutdown “trips.”
BRIEF DESCRIPTION OF THE INVENTION
[0006] These and other drawbacks associated with such conventional approaches are addressed here in by providing, in various embodiments, a wind turbine including a first vibration sensor for producing a first vibration signal; a second vibration sensor, displaced from the first vibration sensor, for producing a second vibration signal; and a processor for comparing the first vibration signal to the second vibration signal and controlling the wind turbine in response to the comparison. Also provided is a method of operating a wind turbine including sensing vibration at a first location on the wind turbine; sensing vibration at a second location on the wind turbine; comparing the sensed vibration at the first location to the sensed vibration at the second location; and controlling the wind turbine in response to an outcome of the comparing step.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Various aspects of this technology will now be described with reference to the following figures (“FIGS.”) which are not necessarily drawn to scale, but use the same reference numerals to designate corresponding parts throughout each of the several views.
[0008] FIG. 1 is a schematic side view of a wind generator.
[0009] FIG. 2 is a cut-away orthographic view of the nacelle and huh of the wind generator shown in FIG. 1 .
[0010] FIG. 3 is an orthographic view of a frame for the nacelle shown in FIG. 2 .
[0011] FIG. 4 is a schematic control diagram.
DETAILED DESCRIPTION OF THE INVENTION
[0012] FIG. 1 illustrates one example of a wind turbine 2 . This particular configuration for a wind generator type turbine includes a tower 4 supporting a nacelle 6 enclosing a drive train 8 . The blades 10 are arranged on a hub to form a “rotor” at one end of the drive train 8 outside of the nacelle 6 . The rotating blades 10 drive a gearbox 12 connected to an electrical generator 14 at the other end of the drive train 8 along with a control system 16 that may receive input from an anemometer 18 . A first or tower vibration sensor 20 is arranged on the tower 4 , such as near the top of the tower, or at any other location on the tower. Other vibration sensors may also be arranged at other locations on the tower 4 and/or at other locations on the wind turbine 2 .
[0013] FIG. 2 is a cut-away orthographic view of the nacelle 6 and hub 110 of the wind turbine 2 shown in FIG. 1 . The drive train 8 of the wind turbine 4 (shown in FIG. 1 ) includes a main rotor shaft 116 connected to hub 110 and the gear box 12 . The control system 16 (in FIG. 1 ) includes one or more processors, such as microcontrollers 111 within the panel 112 , which provide signals to control the variable pitch blade drive 114 and/or other components of the wind turbine 2 . A high speed shaft (not shown in FIG. 2 ) is used to drive a first generator 120 via coupling 122 . Various components in the nacelle 6 are be supported by a frame 132 .
[0014] FIG. 3 is an orthographic view of the frame 132 from the nacelle 6 shown in FIG. 2 . As illustrated in FIG. 3 , the frame 132 typically includes a main frame, or “bedplate,” 203 , and generator support frame, or “rear frame,” 205 that is typically cantilevered from the bedplate. A second or frame vibration sensor 22 is secured to the frame 132 , such as near the end of the rear frame 205 , for measuring lateral and vertical vibrations. Alternatively, or in addition, other vibration sensors may be secured to other locations on the rear frame 205 , to the bedplate 203 , and/or at other locations on the wind turbine 2 .
[0015] Each of the vibration sensors 20 and/or 22 includes a motion sensor for measuring acceleration, velocity, and/or displacement in one or more dimensions. For example, the vibration sensors 20 and/or 22 may be tri-axial or biaxial, measuring lateral and longitudinal vibrations in the time domain. Other process variables besides vibration, such as displacement, velocity, temperature, and/or pressure, may also be similarly sensed at various turbine locations in a similar manner. The vibration sensors 20 and 22 are arranged to communicate with the control system 16 . For example, the vibrations sensors 20 and 22 may be arranged to communicate with a local or remote processor such as the microcontroller 111 via wired and/or wireless means.
[0016] As illustrated in the schematic control diagram for microcontroller 111 shown in FIG. 4 , some or all of the vertical and/or lateral outputs from the frame vibration sensor 20 are compared to some or all of the corresponding outputs from the tower vibration sensor 22 . This may be accomplished by a comparator, such as the illustrated adder 24 , or other device, in order to provide a “differential vibration” signal. In the particular example illustrated here, the lateral acceleration signal from the tower vibration sensor 20 is subtracted from the lateral acceleration signal provided by the rear frame vibration sensor 22 . Alternatively, or in addition, the vertical acceleration signal from the tower vibration sensor 20 may subtracted from the vertical acceleration signal provided by the rear frame vibration sensor 22 . Signals on other axes may be compared in a similar manner.
[0017] In this manner, the output signal from the adder 24 is referenced against vibrations sensed in the tower 4 rather than at a stationary reference such as ground. In other words, the cumulative effect of tower vibrations are removed from the output of the adder 24 , so that the signal corresponds more closely to just the vibrations caused by equipment near the rear frame 205 . Relative movement between the tower 4 and frame 205 are therefore more accurately accounted for. Other vibration sensors may also be used so that the output from the second sensor 22 , and/or other sensors, is referenced against vibrations sensed at any other location in the wind turbine 4 .
[0018] A filter 26 may be optionally applied to the signal from the adder 24 in order to exclude frequencies and/or times which are not of interest. However, the filter 26 may also be applied to the signals from other locations, including to the output from the vibration sensors 20 and 22 . Other types of signal processing beside filtering may also be used, such as amplification and/or noise reduction. The “filtered differential vibration signal” from the filter 26 is them sent to an optional adjuster 28 for further processing. For example, the adjuster 28 may be used to calculate a root mean square “RMS” and/or other statistical measure for evaluating whether the “adjusted and filtered differential vibration signal” is within normal operating parameters. The adder 24 , filter 26 , and/or adjuster 28 may be implemented as part of the microcontroller 111 (in FIG. 2 ) or other processor that is arranged local to or remote from for the wind turbine 2 .
[0019] The differential, filtered differential, and/or adjusted filtered differential signals can then be made at decision point 30 to take further action based upon whether the signal is above a threshold. For example, the adjusted signal may be used to initiate an automatic or manual shutdown “trip” of the wind turbine 2 during periods of excessive vibration when the RMS value rises above a predetermined set point. Such trips may be implemented, for example, by causing variable pitch blade drives 114 to rotate the blades 10 to a feathered position. Other process variables may also be taken into consideration before making a initiating a turbine shut down, or other process change, at decision point 30 .
[0020] In one example where lateral vibration signals from the tower 4 and rear frame 205 were compared in the manner described above, peak vibration amplitudes were reduced 34% and RMS values were reduced 33%. For vertical vibrations, peak vibration amplitudes were reduced 14% and RMS values were reduced 15%. It is therefore expected that, by more accurately measuring the vibration levels at the rear frame 205 , unnecessary turbine shutdowns for excessive vibration may be avoided using the various techniques described above.
[0021] It should be emphasized that the embodiments described above, and particularly any “preferred” embodiments, are merely examples of various implementations that have been set forth here to provide a clear understanding of various aspects of this technology. One of ordinary skill will be able to alter many of these embodiments without substantially departing from scope of protection defined solely by the proper construction of the following claims. | A wind turbine includes a first vibration sensor for producing a first vibration signal; a second vibration sensor, displaced from the first vibration sensor, for producing a second vibration signal; and a processor for comparing the first vibration signal to the second vibration signal and controlling the wind turbine in response to the comparison. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Application Nos. 10-2005-0057821 and 10-2005-0058011 both filed on Jun. 30, 2005, which are hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to laundry machines, and more particularly, to a control unit assembly for controlling a laundry machine.
[0004] 2. Discussion of the Related Art
[0005] In general, the laundry machine is a general term for a washing machine for washing and spinning, a dryer for drying, a dryer and washing machine for washing and drying. In the washing machines, there are a drum type washing machine and a pulsator type washing machine.
[0006] Of the washing machines, the drum type washing machine removes dirt from laundry by friction taken place between washing water and the laundry as the laundry is dropped by a weight of the laundry lifted as a drum coupled to a motor with a shaft rotates in regular/reverse directions by rotation force of the motor, after introduction of the laundry into the drum type washing machine, and supply of the washing water to the drum through a detergent box together with detergent in the detergent box.
[0007] Owing to less entangling of the laundry, and an excellent washing capability compared to the pulsator type washing machine, recently the drum type washing machines spread, rapidly.
[0008] A related art drum type washing machine will be described with reference to FIG. 1 .
[0009] The drum type washing machine is provided with a substantially hexahedral body 1 , having a laundry opening in a front for introduction and taking out the laundry, with a door 2 on one side of the front having the laundry opening for selective opening/closing of the laundry opening.
[0010] At an upper portion of the front of the body 1 , there is a control unit 3 for operation of the drum type washing machine.
[0011] The control unit 3 is provided with a plurality of buttons and a rotary knob for user's application of washing functions, and a display window for displaying a progress of operation of the drum type washing machine.
[0012] The control unit 3 assembly will be described in more detail with reference to FIG. 2 .
[0013] The control unit is provided with a control panel 31 which forms an exterior of the control unit 3 , a printed circuit board (PCB) 32 having various electric devices mounted thereon, and a coating guide 33 for mounting the PCB 32 .
[0014] The control panel 31 is provided with fastening portions for coupling the coating guide 33 thereto. The fastening portions are fastening bosses 31 a projected outwardly from a rear surface of the control panel 31 , respectively.
[0015] Moreover, on the front of the control panel 31 , there are a plurality of pass through holes 31 b, buttons 31 c, and transparent windows 31 d, for user's easy operation and notice of operation progress.
[0016] Referring to FIGS. 2 and 3 , in order to make the exterior of the drum type washing machine elegant, the exterior of the control panel 31 is curved.
[0017] Mounted on the PCB 32 , there are electric devices for controlling operation of the drum type washing machine, input devices 32 a, such as the knob or switches, and so on for transmission of control signals of the drum type washing machine to the control unit (not shown), and display devices 32 b, such as LED lamp, for displaying a progress of operation.
[0018] The coating guide 33 receives the PCB 32 , and has fastening portions 331 at an upper portion and a lower portion in correspondence to the fastening bosses 31 a on the control panel 31 for coupling the coating guide 33 to the control panel 31 .
[0019] Each of the fastening portions 331 has a fastening hole 331 a. At the time of coupling the coating guide 33 to the control panel 31 , the fastening bosses 31 a and the fastening holes 331 a are brought into contact respectively, and screws are driven thereto from a rear surface of the fastening portions 331 .
[0020] However, the related art control unit assembly has the following problems.
[0021] First, as can be known from FIG. 3 , the coupling of the coating guide 33 having the PCB mounted thereon to an inside of the control panel 31 with the curved exterior surface causes to form a large gap T between the input devices 32 a and the display devices 32 b on the PCB and the control buttons and so on on the control panel 31 , to cause problems of defective contact between the input device 32 a and the buttons 31 c, and poor brightness of the display device 32 b at the transparent window 31 d due to the large gap between the display device 32 b and the transparent window 31 d.
[0022] Second, referring to FIG. 4 , there have been poor alignments happened between the coating guide 33 having the PCB mounted thereon and the control panel 31 in processes of coupling the coating guide 33 to the control panel 31 , i.e., the input device 32 a and the display device 32 b on the PCB 32 are aligned with the buttons and the transparent window on the control panel 31 , inaccurately.
[0023] That is, in the process for coupling the coating guide 33 to the control panel 31 , there can be misalignment between the fastening hole 331 a in the fastening portion 331 and the screw hole in the fastening boss 31 a. In this case, it is liable that the worker forcibly fastens a screw through the screw hole in the fastening boss 31 a and the fastening hole 331 a in the fastening portion 331 , failing exact contact of the button on the control panel 31 with the input device 32 a on the PCB 32 and exact match between the LED lamp 32 b of the PCB 32 and the transparent window 31 d in the control panel 31 .
[0024] The mismatch between the LED lamps 32 b with the transparent window 31 d, causing the LED lamps to illuminate wrong transparent windows, is liable to make the user misunderstand operation of the drum type washing machine.
SUMMARY OF THE INVENTION
[0025] Accordingly, the present invention is directed to a laundry machine that substantially obviates one or more problems due to limitations and disadvantages of the related art.
[0026] An object of the present invention is to provide a laundry machine having a control unit assembly of an improved structure which can improve an assembly work of the control unit assembly, and enables exact match between relevant components in the assembly.
[0027] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may. be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0028] To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a laundry machine includes a drum, a cabinet which forms an exterior of the laundry machine and protects the drum, a control panel having various operational buttons for operation of the drum, and coupling portions, a plurality of coating guides having fastening portions corresponding to the coupling portions for mounting to a rear surface of the control panel, a plurality of printed circuit boards (PCB) respectively mounted on the coating guides each having an electric circuit mounted thereon, joining portions for joining the coating guides together so as to place the coating guides closer to an inside of the control panel, and holders for preventing the coupling portions and the fastening portions from moving with respect to each other at the time the coupling portions are brought closer to the fastening portions, respectively.
[0029] Preferably, the fastening portion includes walls on an upper portion of the coating guide having fastening hole, and the holder includes at least one rib projected from the wall around the fastening hole.
[0030] Preferably, the holders are formed opposite to each other with respect to the fastening hole.
[0031] Preferably, the coupling portion includes a fastening boss, and the holder has an end sloped for easy placing in of the fastening boss.
[0032] Preferably, the holders opposite to each other with respect to the fastening hole is distanced enough to allow sliding of the fastening boss.
[0033] Preferably, the fastening portion is walls on an upper portion of the coating guide, and the holder is a cylinder projected from the wall around the fastening hole.
[0034] Preferably, the cylinder has an inside diameter with a size enough to allow sliding of the fastening boss.
[0035] Preferably, the fastening portion is walls on an upper portion of the coating guide, and the holder is an arc projected from the wall around the fastening hole.
[0036] The holder may be formed on an upper side and a lower side or a left side and a right side of the fastening hole.
[0037] Preferably, the joining portion is formed on a side of each of the coating guides.
[0038] Preferably, the coating guides joined together form an outside appearance having a curvature at which the PCBs and the operation buttons can be placed closer.
[0039] Preferably, the joining portion includes a hook on one of the coating guide, and a joining surface on the other coating guide having a hook hole for holding the hook.
[0040] Preferably, at least one hook and hook hole are formed, respectively.
[0041] Preferably, a plurality of hooks are formed, and the plurality of hooks have holding directions to be held at the hook holes different from one another.
[0042] Preferably, the joining portion further includes position guide means for guiding the hook to the hook hole for easy fastening of the hook to the hook hole.
[0043] Preferably, the position guide means includes a guide projection from one of the coating guides, and a guide projection receiver at the other coating guide for receiving the guide projection.
[0044] Preferably, the projection is adjacent to the hook.
[0045] Preferably, at least one of the guide projections and the guide projection receivers are formed, respectively.
[0046] In another aspect of the present invention, a control unit assembly includes a control panel having various operation buttons and coupling portions, a plurality of coating guides coupled to a rear surface of the control panel having fastening portions corresponding to the coupling portions, a plurality of printed circuit boards respectively mounted on the coating guides, each having an electric circuit mounted thereon, joining portions for joining the coating guides together so as to place the coating guides closer to an inside of the control panel, and holders for preventing the coupling portions and fastening portions from moving with respect to each other when the fastening portions are aligned with the coupling portions.
[0047] The drum type washing machine of the present invention has the following advantages.
[0048] The placing of the PCB mounted on the coating guide closer to the inside of the control panel, enabling accurate alignment of the buttons and the transparent windows on the control panel with the input devices on the PCB, permits to enhance perfection of the product.
[0049] The placing of the PCB mounted on the coating guide closer to the inside of the control panel, enabling accurate alignment of the buttons and the transparent windows on the control panel with the input devices on the PCB, permits smooth operation of the buttons, and to provide an accurate operation progress to the user.
[0050] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings;
[0052] FIG. 1 illustrates a perspective view of a related art drum type washing machine;
[0053] FIG. 2 illustrates an exploded perspective view of a control unit of a related art drum type washing machine;
[0054] FIG. 3 illustrates a plan view of a control unit of a related art drum type washing machine, schematically;
[0055] FIG. 4 illustrates a transverse section of a control unit of a related art drum type washing machine;
[0056] FIG. 5 illustrates an exploded perspective view of a control unit of a drum type washing machine in accordance with a preferred embodiment of the present invention;
[0057] FIG. 6 illustrates a plan view of a control unit of a drum type washing machine in accordance with a preferred embodiment of the present invention, schematically;
[0058] FIG. 7 illustrates an enlarged view of “A” part in FIG. 5 ;
[0059] FIG. 8 illustrates a transverse section of a control unit of a drum type washing machine in accordance with a preferred embodiment of the present invention; and
[0060] FIG. 9 illustrates an exploded perspective view of a control unit of a drum type washing machine in accordance with another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0061] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0062] A control unit assembly 3 of a drum type washing machine will be described with reference to FIG. 5 .
[0063] Referring to FIG. 5 , the control unit 3 assembly includes a printed circuit board (PCB) 32 having various electric devices mounted thereon for operation of the drum type washing machine, a control panel 31 which forms an exterior of the control unit, and a coating guide 33 having the PCB 32 mounted thereon and fastening portions 331 for coupling the coating guide 33 to the control panel 31 .
[0064] The PCB 32 has the electric devices mounted thereon for controlling the drum type washing machine.
[0065] The PCB 32 has input devices 32 a, such as switches and knobs, for user's direct control of the electric devices, as well as display devices 32 b, such as LED lamps for displaying a progress of washing of the drum type washing machine.
[0066] In the meantime, after mounting the PCB 32 on the coating guide 33 , coating liquid is applied thereto as an water proof treatment.
[0067] This is because the drum type washing machine 1 has frequent contact with water due to the introduction/taking out of the wet laundry. That is, the coating prevents the electric devices on the PCB 32 from being happened to contact with water.
[0068] On the other hand, the control panel 31 forms an exterior of the control unit and protects the electric devices mounted on the PCB 32 .
[0069] In addition to this, the control panel 31 has button portions 31 c connected to the input devices 32 a on the PCB 32 for user's control of the drum type washing machine from an outside thereof, and transparent windows 31 d for transmission of a light from the display devices 32 b on the PCB 32 .
[0070] It is preferable that the button portions 31 c are push buttons for user's easy operation.
[0071] It is preferable that the control panel 31 has fastening portions for coupling the coating guide 33 to the control panel 31 , preferably formed of a plurality of fastening bosses 31 a.
[0072] The coating guide 33 includes a body 321 of rectangular plates each having a cavity for receiving the PCB 32 , and a plurality of fastening portions 331 at an upper portion and a lower portion of the body 321 .
[0073] It is preferable that the body 321 has individual bodies in correspondence to a number of the PCBs 32 . For reference, though the embodiment shows two bodies 321 and two PCBs 32 , number of the bodies 321 and the PCBs 32 are not limited to two. In the following description of the embodiment, the individual bodies 321 a and 321 b will be called as a first body 321 a and a second body 321 b.
[0074] In the meantime, it is preferable that each of the bodies 321 a and 321 b has supporting members 35 formed on an inside for supporting the PCB 32 , more preferably with holding members 34 for preventing the PCB 32 supported thus from falling off to an outside of the body 321 a, or 321 b.
[0075] The fastening portions 331 at the upper portion and the lower portion of the body 321 are formed matched to the fastening bosses 31 a on the inside of the control panel 31 .
[0076] In this instance, the fastening portion 331 has at least one face directed upward vertically, and a fastening hole 331 a in a fastening surface 331 b opposite to the fastening boss 31 a.
[0077] Also, the fastening portion 331 has opposite walls 331 c, and a holder 331 d on an inside of each of the opposite walls and on an upper surface of the body 321 in contact to the inside of the walls 331 c perpendicular thereto.
[0078] It is preferable that the holder 331 d is a rib projected outwardly from a fastening surface 331 b, more preferably three in total around the fastening hole 331 a. This is for making movement of the fastening boss 31 a the smallest by supporting the fastening boss 31 a from three directions at the time the fastening boss 31 a of the control panel 31 is in contact with the fastening hole 331 a.
[0079] It is preferable that the ribs 331 d have distances centered on the fastening hole 331 a which permits the fastening boss 31 a slide.
[0080] It is preferable that the body 321 has a plurality of wire fastening ribs 36 formed on upper and lower sides of the fastening portion 331 for fastening wires lead from the PCB 32 .
[0081] The body 321 has joining portions 40 for joining the individual bodies 321 a and 321 b together. The joining portions 40 are on sides of the bodies 321 a and 321 b respectively, for joining the bodies 321 a and 321 b, together.
[0082] In this instance, referring to FIG. 6 , it is preferable that a plan view of an outside appearance of the first body 321 a and the second body 321 b joined together with the joining portions 40 is not in straight line, but knuckled at a predetermined angle.
[0083] It is preferable that the curvature the two bodies 321 a and 321 b form is the same with the curvature of the exterior of the control panel 31 . This is for placing the input devices 32 a on the PCB 32 mounted on the coating guide 321 closer to the button portions 31 c, the transparent windows 31 d and so on of the control panel 31 .
[0084] That is, this is for enhancing accuracy of alignment of the button portions 31 c with the input devices 32 a by placing the input devices 32 a closer to the button portions 31 c of the control panel 31 at the time the coating guide 32 is coupled to the control panel 31 .
[0085] The joining portion 40 will be described in more detail with reference to FIG. 7 .
[0086] The joining portion 40 includes hooks 41 on a side of the second body 321 b of the plurality of individual bodies 321 a and 321 b, and a joining surface 42 having hook holes 42 a on a side of the first body 321 a which is to be coupled to the second body 321 b for holding the hooks 41 on the second body 321 b.
[0087] Though the embodiment shows the hooks 41 on the second body 321 b and the joining surface 42 on the first body 321 a, it does not matters even if positions of the hooks 41 and the joining surface 42 are interchanged.
[0088] It is preferable that numbers of the hooks 41 and the joining surfaces 42 are at least one, respectively. It is preferable that at least one hook hole 42 a is formed in the joining surface 42 , for enabling hooking of a plurality of hooks 41 to the joining surface 42 .
[0089] The embodiment shows three hooks 41 on the side of the second body 321 b. The joining surface 42 has spaces for receiving the hooks 41 respectively, and sockets each with a hook hole 42 a in a circumference for holding the hooks 41 .
[0090] It is preferable that the hooks 41 have holding directions different from adjacent one, more preferably, as shown in FIG. 7 , opposite to adjacent one.
[0091] The socket shape of the joining surface 42 also has a plurality of hook holes 42 a equal to a number of the hooks 41 , and the hook holes 42 a are formed in opposite directions of the joining surfaces 42 in order to match to the hooks 41 formed in opposite directions. According to this, a plurality of the joining surface 42 are formed.
[0092] Shapes of the hook 41 and the joining surface 42 are not limited to the embodiment.
[0093] Thus, as the hooks 41 are held at the hook holes 42 a, the first body 321 a and the second body 321 b are coupled, and because the hooks 41 are held at the hook holes 42 a in opposite directions, even if the coating guide 33 is pressed in one direction, the hooks 41 do not fall off the hook holes 42 a, to couple the first body 321 a and the second body 321 b, more firmly.
[0094] Moreover, the joining portion 40 may further include guide means for guiding joining positions of the hooks 41 and the socket shape of joining surface 42 .
[0095] Referring to FIG. 7 , it is preferable that the position guiding means holds the first body 321 a and the second body 321 b so that the first body 321 a and the second body 321 b do not move in addition to a function for guiding joining positions of the hooks 41 and the joining surfaces 42 .
[0096] The position guiding means includes a guide piece 43 projected from a side of the first body 321 a, and a guide piece receiver 44 on a side of the second body 321 b for receiving the guide piece 43 .
[0097] It is preferable that at least one guide piece 43 is formed adjacent to each of the hooks 41 .
[0098] It is preferable that the guide piece receiver 44 is formed within a space of the socket shaped joining surface 42 of the first body 321 a.
[0099] It is preferable that the guide piece 43 is formed to fit in the guide piece receiver 44 , for preventing the first body 321 a and the second body 321 b coupled together from moving.
[0100] A process for coupling the coating guide having bodies joined together to the control panel will be described.
[0101] The PCB 32 is mounted on the coating guide 33 . Then, the coating guide 33 is fastened to the control panel 31 with screws.
[0102] In this instance, the fastening bosses 31 a on the inside of the control panel 31 are brought into contact with the plurality of fastening portions 331 on the coating guide 33 , respectively.
[0103] In this instance, the fastening boss 31 a is guided by the holders 331 d on the fastening portion 331 until the fastening boss 31 a is in contact with the fastening surface 331 b having the fastening hole 331 a, such that the screw hole in the fastening boss 31 a is aligned with the fastening hole 331 a in the fastening portion 331 .
[0104] In this instance, lateral movement of the fastening boss 31 a is held by the holders 331 d so that the fastening boss 31 a is aligned with the fastening surface 441 b exactly without any lateral movement.
[0105] By this, referring to FIG. 8 , the coating guide 33 can be easily fastened to the control panel 31 having the fastening boss 31 a aligned with the fastening surface 441 b, exactly.
[0106] In the meantime, the wires lead from the PCB 32 are fastened to the wire fastening ribs 36 on the upper portion and the lower portion of the body 321 , to arrange the wires neatly, and to prevent the wires from coming between the body 321 and the control panel 31 to cause inaccurate assembly.
[0107] A coating guide in a drum type washing machine in accordance with another preferred embodiment of the present invention will be described with reference to FIG. 9 attached herein.
[0108] The coating guide in a drum type washing machine in accordance with another preferred embodiment of the present invention is identical to the coating guide in a drum type washing machine in accordance with a preferred embodiment of the present invention, except the holder.
[0109] The holder 50 has a section of an arc around the fastening hole 331 a of the fastening portion 331 projected from the fastening surface 331 b, formed on upper and lower sides or right and left sides of the fastening hole 331 a.
[0110] Though not shown, the holder 50 may have, not only a shape of the arc, but also a shape of a cylinder having the same arc.
[0111] If the holder 50 has the shape of a cylinder, it is preferable that an inside diameter of the cylinder has a size to allow the fastening boss slides in/out therethrough.
[0112] A process for assembling the control panel 31 to the coating guide 33 will be described.
[0113] Once an outside circumferential surface of the fastening boss 31 a of the control panel 31 is placed on an inside circumferential surface of the arc or cylinder shaped holder 50 , the fastening hole 331 a of the fastening portion 331 having the holder 50 formed thereon is aligned with the screw hole in the fastening boss 31 a.
[0114] In this instance, since the fastening portion, placed in the fastening boss 31 a, does not move, the control panel 31 can be fastened to the coating guide 33 with screws, easily.
[0115] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | The present invention relates to laundry machines, and more particularly, to a control unit assembly in a laundry machine which enables easy assembly and accurate alignment of an input device of a printed circuit board with a button portion of a control panel. The control unit assembly includes a control panel having various operation buttons and coupling portions, a plurality of coating guides coupled to a rear surface of the control panel having fastening portions corresponding to the coupling portions, a plurality of printed circuit boards respectively mounted on the coating guides, each having an electric circuit mounted thereon, joining portions for joining the coating guides together so as to place the coating guides closer to an inside of the control panel, and holders for preventing the coupling portions and fastening portions from moving with respect to each other when the fastening portions are aligned with the coupling portions, thereby improving assembly work, preventing malfunction of the laundry machine, and permitting easy detection of an operation progress. | 3 |
This application is a continuation of application Ser. No. 07/715,987 filed Jun. 17, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of this invention is medical extraction devices, particularly such devices which are used to endoscopically remove foreign bodies from a patient.
2. Description of the Prior Art
In the medical field of gastroenterology, extraction devices are commonly used to endoscopically incise and/or grasp and remove foreign bodies from a patient. For example, a wire basket stone extractor might be used to extract gallstones from the bile duct of a patient. In such an operation, the stone extractor would be advanced through an endoscope, with its wire basket retracted within a retaining cannula. Once advanced, the wire basket would then be extended out of the retaining cannula, with the basket wires opening up into their pre-formed basket configuration. The basket is then manipulated to grasp and remove the gallstones from the patient.
The wire material used in prior art wire basket stone extractors and the like has most commonly been either monofilament or stranded stainless steel wire, and has generally been found to be satisfactory for the purpose intended. The stainless steel wire retains its pre-formed orientation, and returns to its basket configuration when extended from its retaining cannula, even after repeated use. After extended periods of non-use or after long-term repeated use, however, these wire baskets slowly tend to lose their pre-formed orientation, and eventually need to be replaced. The medical art in this area would benefit from an improved extraction device which holds its designed orientation longer and more precisely, and which therefore has to be replaced less frequently.
SUMMARY OF THE INVENTION
The present invention makes available to the medical practitioner endoscopic extraction devices which retain their operative usefulness for longer periods of time, and therefore need to be replaced less frequently. This extended instrument life is accomplished through the use of a composite wire construction, which includes, according to one embodiment, an inner monofilament wire of nitinol material surrounded by six stranded stainless steel wires. In a second disclosed embodiment, the inner nitinol wire is surrounded by five stranded stainless steel wires. After constructing, for example, a wire basket in the normal manner using this material, heat is applied to the formed basket in its pre-formed shape to set the memory characteristics of the inner nitinol core. The result is a durable wire basket which is easy to construct and which maintains its operative usefulness, even after continuous repeated use over long periods of time, or after extended periods of non-use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is schematical view of a 1×7 stranding configuration used in the present invention, wherein a central wire of nitinol material is surrounded by six stranded stainless steel wires. FIG. 1b shows a cross-sectioned view of the composite construction illustrated in FIG. 1a.
FIG. 2a is schematical view of a 1×6 stranding configuration used in the present invention, wherein a central wire of nitinol material is surrounded by five stranded stainless steel wires. FIG. 1b shows a cross-sectioned view of the composite construction illustrated in FIG. 1a.
FIG. 3 is a partial fragmentary and partially cross-sectioned illustration of a wire basket stone extractor according to the present invention, with wire basket 77 retained within retaining cannula 79.
FIG. 4 is a illustration of the wire basket stone extractor of FIG. 3, with wire basket 77 extended out from retaining cannula 79 and into its preformed basket configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the 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 nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principlesof the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring now to the drawings, FIG. 1a is schematical view of an extractionwire 10 formed in a 1×7 configuration, wherein a central wire 11 of nitinol material is surrounded by stranding 12 of six stranded stainless steel wires 12a-f. The spacing between wiring, as shown by the FIG. 1a, isfor illustration purposes to show the relative orientation of the wiring, and does not occur in extraction wire 10, as actually constructed. The stranded construction of extraction wire 10 has a right hand lay 0.053". Inner wire 11 has a diameter of 0.005" and surrounding wires 12a-f each have a diameter of 0.004". The overall diameter of extraction wire 10 is 0.013". FIG. 1b shows a cross-sectioned view of the composite constructionof extraction wire 10.
FIG. 2a is schematical view of a second extraction wire 20 formed in a 1×6 configuration, wherein a central wire 21 of nitinol material is surrounded by a stranding 22 of five stainless steel wires 22a-e. As with FIG. 1a, the spacing between wiring shown by the FIG. 2a is for illustration purposes to show the relative orientation of the wiring, and does not occur in the actually constructed extraction wire 20. The construction of extraction wire 20 has a right hand lay of 0.082". Inner wire 21 has a diameter of 0.005" and surrounding wires 22a-e each have a diameter of 0.055". The overall diameter of extraction wire 20 is 0.017". FIG. 1b shows a cross-sectioned view of the composite construction of extraction wire 20.
FIGS. 3 and 4, in combination, show the operation of a wire basket stone extractor made according to the present invention. FIG. 3 is a partial fragmentary and partially cross-sectioned illustration of a wire basket stone extractor 70, which includes wire basket assembly 71 and retaining cannula 79. Wire basket assembly 71 includes push rod 72, pushrod/cable solder joint 73, cable 74, proximal basket hub solder joint 75, distal basket hub solder joint 76, and extraction wires 77a-d. Extraction wires 77a-d are made of the composite construction shown for wire 10 in FIGS. 1a-b, and each include a central wire 11 of nitinol surrounded by a stranding 12 of six stainless steel wires 12a-b, as shown and described inrelation to wire 10 in FIG. 3, wire basket assembly 71 is shown in its retracted position in relation to retaining cannula 79, with wire basket 77 being held within, and being retained in a collapsed condition by, retaining cannula 79. FIG. 4 illustrates the wire basket stone extractor 70 of FIG. 3, with wire basket 77 extending out from retaining cannula 79 and into its preformed basket configuration for its intended operative purpose. This is accomplished by pushing push rod 72, which movement projects wire basket 77 distally out of retaining cannula 79, allowing wire basket 77 to assume its preformed shape.
The method of construction of wire basket stone extractor 70 will now be discussed with reference to the elements of wire basket stone extractor 70shown in FIGS. 3 and 4 and the extraction wire construction shown in FIGS. 1a-b. Extraction wires 77a-d are constructed of approximately equal lengthout of a composite construction which includes an inner monofilament wire 11 of shape memory material (nitinol) surrounded by a stranding 12 of a six stainless steel wires 12a-f. Extraction wires are joined by soldering stainless steel strands 12 together at one end at push rod/cable solder joint 73 and attached to push rod 72 at joint 73. At the distal end, extraction wires 77a-d are also joined by soldering at stainless steel strands 12 together at distal basket hub soldering joint 76. Extraction wires 77a-d are then also joined at a set position a set distance from thedistal end of extraction wires 77a-d by soldering stainless steel strands 12 together at proximal basket hub solder joint 75.
Wire basket 77 may then be formed by separating extraction wires 77a-d fromeach other in the area between proximal basket hub soldering joint 75 and distal basket hub soldering joint 76, and bending extraction wires 77a-d into a desired configuration for use, as shown in FIG. 4. The remaining portion of extraction wires 77a-d between joints 74 and 75 are stranded together to form cable 74. After wire basket 77 has been formed, heat is applied to wire basket 77 to set the shape memory characteristics of innermonofilament wires 11. After cooling, wire basket assembly 71 may then be placed in retaining cannula 79 to complete the assembly of extractor 70.
The shape memory material used in extraction wires 10 and 20 is a nickel titanium alloy known as nitinol, which is composed of about 55% Ni and 44%Ti, with trace elements of Cu (150 ppm), Fe (110 ppm), and Mn (21 ppm). As a shape memory material, nitinol central wires 11 and 21 have the characteristic of superelasticity whereby they exhibit a superelastic tendency to retain the shape in which they are formed when heat is appliedto a suitable presorting temperature. This characteristic serves to reinforce the orientation toward the configuration into which extraction wires constructed in this manner are bent to form a wire basket or other extracting configuration, such as a snare. The use of the composite construction with a nitinol inner core and surrounding stainless steel strands, as described herein, allows for ease of construction in that the surrounding stainless steel strands 12 and 22 can easily be soldered to each other at joints 73, 75, and 76, whereas nitinol material is not nearly so readily joinable. In addition to the improvements in efficiency of construction and enhanced durability and reliability of operation, the use of the described composite construction also provides a savings in cost of material over the use of a single superelastic material for the forming of extraction wires.
It is to be noted that, while two specific examples of extraction wire construction have been disclosed herein, other configurations are suitablewhich fall within the scope of this invention. Also, while stainless steel is particuarly suited for strands 12 and 22, other materials which are readily joinable relative to shape memory material may satisfactorily serve in an alternative construction. And it is to be further noted that while an example as been provided in which the present invention has been incorporated into a four wire basket, there are many other extraction configurations for wire baskets, stent retrievers, snares etc. in which the present invention is useful. Therefore, while the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | Disclosed herein is an endoscopic extraction device which retains its operative usefulness for longer periods of time, and therefore need to be replaced less frequently. This extended instrument life is accomplished through the use of a composite wire construction, which includes, an inner monofilament wire of nitinol material surrounded by six stranded stainless steel wires. A wire construction in which a nitinol wire is surrounded by five stranded stainless steel wires is also disclosed. After constructing a wire basket in the normal manner using this material, heat is applied to the formed basket in its pre-formed shape to set the memory characteristics of the inner nitinol core. | 3 |
FIELD OF THE INVENTION
[0001] This invention relates to improvements in noise reduction in FM reception.
INTRODUCTION
[0002] A characteristic of FM reception is the so-called ‘threshold effect’, whereby impulsive noise appears in the FM demodulator output when the input signal to noise ratio (SNR) to the FM demodulator is low. In systems using analogue FM modulation to transmit an audio signal, the noise impulses are heard as ‘clicks’ in the demodulated audio signal. The process that leads to the impulsive noise has been studied extensively in [1] S. O. Rice, “Statistical properties of a sine wave plus random noise”, Bell Sys. Tech. J., vol. 27, pp. 109-157, January 1948, and [2] M. J. Malone, “On the threshold effect in FM data systems”, IEEE Transactions on Communication Theory, Vol. COM-14, No. 5, pp. 625-631, October 1966. The process is briefly described below.
[0003] An FM-modulated signal can be represented as:
[0000] c ( t )=sin(2 π*Fc*t+∫m ( t ) dt ),
[0004] where ‘t’ represents time, Fc is the carrier frequency and m(t) is the modulating signal. The FM signal available at a receiver often contains additive noise and can be represented at baseband (for Fc=0) by the mathematical expression
[0000] y ( t )= e j∫m(t)dt +n ( t )
[0005] Note that m(t) is the instantaneous frequency deviation relative to Fc. In stereo FM broadcasts, m(t) is called ‘stereo multiplex’ and is a frequency multiplex of ‘left+right’ (L+R) and ‘left−right’ (L−R) audio signals, a ‘pilot’ tone of 19 kHz, and optionally other data or audio signals.
[0006] When the SNR of the received signal y(t) is below a certain value, the receiver component which estimates the carrier angle of the received signal loses accuracy. This results in fast steps of 2π appearing in the carrier angle estimated by the receiver. For example, in the absence of modulation (m(t)=0), a step of 2π in the estimated carrier angle occurs when noise causes the vector representing y(t) in the ‘complex plane’ to circle around the origin.
[0007] The rapid steps of 2π in the phase of the estimated carrier angle create impulses in the instantaneous carrier frequency estimated by the receiver. The estimated instantaneous frequency is equal to the differential of the estimated angle with respect to time and so a rapid change in phase results in a high value in the estimated output signal. These impulses are relatively short and are heard as clicks in the audio signal recovered from the stereo multiplex. With decreasing SNR, these clicks become more and more frequent per unit of time, until eventually they can no longer be heard individually, sounding like white noise to a listener.
[0008] From the equation describing y(t) above, an estimate of the modulating signal m(t) can be obtained by first estimating the angle of y(t) and then differentiating this estimated angle. This is a simple and viable method of FM demodulation. By comparison with this simple FM demodulation method, FM demodulation methods that reduce the number of noise impulses present in the demodulated signal per unit of time are known as ‘threshold extension’ methods.
[0009] Threshold extension by removing clicks post-demodulation has been previously researched. [3] M. J. Malone, “FM threshold extension without feedback”, Proc. IEEE, pp. 200-201, February 1968, and [4] I. Bar-David, S. Shamai, “On the Rice model of noise in FM receivers”, IEEE Transactions on Information Theory, vol. 34, no. 6, November 1988, show techniques for removing clicks by estimating the position of a click and applying a 2π correction to the demodulated signal at the estimated position.
[0010] What is required is an improved method of removing the clicks which takes advantage of modern signal processing technologies and accounts for the characteristics of FM stereo broadcast signals to achieve better performance.
SUMMARY OF THE INVENTION
[0011] According to a first aspect of the present invention there is provided apparatus for reducing FM click noise on a demodulated FM signal, the apparatus comprising, filter means configured to produce a click detection signal according to the demodulated FM signal, click detection means configured to receive the click detection signal and produce a click occurrence signal, and click correction means configured to correct FM clicks on the demodulated FM signal according to the click occurrence signal.
[0012] According to a second aspect of the present invention there is provided a method of reducing interference in received FM signals, the method comprising: estimating a carrier angle of a received FM signal and demodulating the signal according to the estimated carrier angle, determining that a fast step of 2π has occurred in the estimated carrier angle which results in an instance of click interference, correcting the click interference instance in the demodulated FM signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be described by way of example with respect to specific embodiments thereof, and reference will be made to the drawings, in which:
[0014] FIG. 1 illustrates a click correction system according to the present invention.
[0015] FIG. 2 illustrates a detection filter impulse response according to a typical embodiment of the present invention.
[0016] FIG. 3 illustrates the frequency response of a detection filter according to a typical embodiment of the present invention.
[0017] FIG. 4 illustrates the click detection signal before cancellation and its frequency spectrum, when the FM modulation consists of a stereo multiplex signal including a mono (L=R) 1 kHz audio tone with 75 kHz frequency deviation and a pilot tone with 6.75 kHz frequency deviation.
[0018] FIG. 5 illustrates the click detection signal after one pass of the click cancellation algorithm and its frequency spectrum, for the same FM modulating signal as the one corresponding to FIG. 4 .
[0019] FIG. 6 illustrates a short section in time of the click detection signal prior to click cancellation and after one, two or three passes (iterations) of the click cancellation algorithm.
[0020] FIG. 7 illustrates audio output signal to noise ratio (SNR) vs. Intermediate Frequency SNR, when varying the number of applications of the click cancellation algorithm, and when the click cancellation algorithm includes rejecting the pilot tone or not.
[0021] FIG. 8 illustrates an enlarged view of the graph shown in FIG. 7 .
DETAILED DESCRIPTION
[0022] The present invention provides an improved method for reducing the number of clicks in a demodulated signal by detecting each instance of this type of interference, and applying a correction to the output signal which removes each click.
[0023] In the system illustrated in FIG. 1 , the FM signal is received by antenna 5 and amplified by FM signal amplifier 10 . Amplified signal 15 is then down-converted by down-converter module 11 to produce an intermediate frequency (IF) signal 16 . Signal 16 is sent to carrier angle estimator 20 . Carrier angle estimator 20 produces an uncorrected output signal 25 which is then split and fed into both click corrector 50 and differentiator 60 . Differentiator 60 differentiates the estimated carrier angle and provides differentiated signal 65 to detection filter 30 . Detection filter 30 filters out any unwanted frequencies from signal 65 to produce the click detection signal 35 which is suitable to allow click detector 40 to determine the location of clicks in the signal 25 . The click location signal 45 is then applied to click corrector 50 , which uses signal 45 to apply click corrections to signal 25 . The output of click corrector 50 is the corrected estimated carrier angle signal 55 . Signal 55 is passed to differentiator 70 whose output signal is the estimated FM modulating signal.
[0024] In an embodiment of the present invention, the procedure for removing clicks consists of the following steps:
1. Filtering the differential of the demodulated angle, to produce a ‘click detection’ signal. 2. Estimating where clicks occur in the demodulated angle. 3. Cancelling each click by adding a correction at the estimated location of the click.
[0028] Each of these steps will now be described in detail.
Filtering
[0029] In an embodiment of the invention, a filter 30 is used to filter the differential of the demodulated angle to produce a click detection signal 35 which allows easier identification of click positions. Unlike the filters described in the prior art, the filter of this embodiment is specially designed for reception of FM stereo broadcast signals.
[0030] To produce a ‘click detection’ signal, the filter is designed according to the following criteria
[0031] a. The filter should reject the wanted signal and preserve or amplify the clicks. Ideally, the click detection signal should be clear of most of the received signal except for the clicks caused by the noise present in the IF signal.
[0032] b. The filter should not cause excessive dispersion of the clicks. i.e. when a click is applied to the input of the detection filter, the filter should not be such that the resulting output signal has components of large amplitude (relative to its largest amplitude) occurring over a long period of time. A reduced dispersion of the filtered clicks allows a good estimation of the click positions and reduces the likelihood that the estimated position of the click is far from its true position. This also means that the amplitude of the filter output signal peak (for a click input) is larger for equal energy, resulting in a more reliable detection of clicks on the basis of the filter output signal amplitude
[0033] c. The filter should attenuate high frequencies, to reduce ‘non-click’ noise. High frequencies which do not form the clicks are effectively excluded from the click detection signal this way.
[0034] A typical detection filter impulse response according to one embodiment of the invention is illustrated in FIG. 2 . FIG. 3 illustrates its frequency response. The detection filter is designed to have a high attenuation around the ‘mono’ and ‘stereo’ sub-carrier frequencies, respectively 0 and 38 kHz in a typical FM broadcast receiver. The filter is designed to preserve other frequencies, in particular relatively low frequencies located between the mono and stereo sub-carriers.
[0035] In one embodiment of the present invention, the pilot tone is removed from the click detection signal prior to the step of estimating click positions. The phase and amplitude of the pilot tone are stable and so they are easy to estimate in order to remove the pilot tone from the click detection signal by subtraction. If it is not rejected in this way, the pilot tone interferes with the threshold-based detection of the clicks. For example, if the pilot tone happens to add destructively to a detection filter output corresponding to a click, in conjunction with noise it can reduce the detection filter output below the threshold and so it can cause the detection of that click to fail. Therefore, rejecting the 19 kHz pilot tone from the click detection signal improves the reliability of click detection.
Estimation/Detection
[0036] In one embodiment of the invention, a click is detected by click detector 40 when the click detection signal 35 meets either of the following conditions at that time:
[0037] 1. Its absolute value exceeds a first threshold and is largest within a first time neighbourhood surrounding it; or
[0038] 2. Its absolute value exceeds a second, higher threshold, and is largest within a second, smaller time neighbourhood surrounding it.
[0039] The first type of test is suitable for the detection of isolated clicks, whereas the second type of test resolves some occurrences of multiple adjacent clicks. Therefore, the advantage provided by using the two types of threshold tests is that both isolated clicks and clusters of clicks can be effectively detected from the filtered signal.
[0040] The click cancellation performs well when the audio component within the FM modulating signal is of a frequency below 5 kHz, regardless of the signal frequency deviation, for R=L, R=0 and R=−L signals. Audio modulation that is high frequency (above 7 kHz) and also has large frequency deviation may not be sufficiently rejected by the detection filter to allow reliable click detection, resulting in ‘false’ detection of clicks.
[0041] Click detection may be unreliable in the presence of high-frequency wanted modulation with large frequency deviation. Therefore, in a preferred embodiment, to prevent degradation of the demodulated signal caused by false click detection, the click detection is disabled when the click detection signal medium-term average power exceeds a threshold. However, on average the signal power in real FM broadcasts is concentrated in low frequencies, and therefore most of the time the click detection is not disabled in this way.
Cancelling
[0042] Cancellation of the clicks is performed by click corrector 50 on demodulated signal 25 according to the click location signal 45 . In one embodiment, the click cancellation is performed by adding a correction of magnitude 2π and opposite polarity to the detected click.
[0043] An advantage of cancelling the clicks from the demodulated FM signal in this way, compared with alternative methods of threshold extension such as a phase locked loop FM demodulator (PLL FM demodulator) or an FM feedback (FMFB) demodulator, is that high frequency information in the modulating signal, such as the stereo sub-carrier and RDS sub-carrier, is preserved. In comparison, the bandwidth of PLL or FMFB demodulators has to be reduced to improve their sensitivity, for example to select only the ‘mono’ or ‘left+right’ audio component of the stereo multiplex signal, which occupies frequencies below 15 kHz.
[0044] FIG. 4 illustrates the click detection signal and its frequency spectrum before click cancellation and FIG. 5 illustrates the click detection signal and its frequency spectrum after one iteration of the click cancellation algorithm, when the FM modulation consists of a stereo multiplex signal including a mono (L=R) 1 kHz audio tone with 75 kHz frequency deviation and a pilot tone with 615 kHz frequency deviation. Clicks are visible as large amplitude impulses present in the click detection signal. FIGS. 4 and 5 demonstrate (a) the effectiveness of the cancellation (there are much fewer clicks left after one iteration of the click cancellation algorithm); (b) removing the clicks reduces the noise especially in low frequencies, suggesting that that is where a lot of the power of clicks is located.
Iterative Application
[0045] In one embodiment of the invention, iterative application of the click removal process provides improved click removal success and as a result it improves the quality of the demodulated signal.
[0046] FIG. 6 illustrates a short section in time of the click detection signal prior to click cancellation and after one, two or three passes (iterations) of the click cancellation algorithm. FIG. 6 shows that (a) isolated clicks can be resolved in one pass of the click cancellation algorithm, while (b) iterative application of the click cancellation algorithm can resolve multiple clicks that are very close together in time.
[0047] FIG. 7 presents the results of Monte-Carlo simulation of the audio output signal to noise ratio (SNR) vs. Intermediate Frequency SNR (IF SNR}, when varying the number of applications of the click cancellation algorithm, and with or without rejecting the 19 kHz pilot tone prior to click cancellation. The simulation assumes a mono (L=R) 1 kHz audio tone modulation with 22.5 kHz audio frequency deviation and including a pilot tone with a 6.75 kHz frequency deviation. The click cancellation improves sensitivity (for 26 dB output SNR) by more than 3 dB. Using two iterations provides a gain of about 0.5 dB compared to using a single iteration. Rejecting the 19 kHz pilot tone from the click detection signal prior to click cancellation provides a further SNR gain of around 0.3 dB.
[0048] FIG. 8 is a ‘zoomed-in’ version of FIG. 7 , showing that to achieve 26 dB audio output SNR, with 2 click cancellation iterations and pilot tone rejection, the receiver requires a 2.5 dB IF SNR in 256 kHz bandwidth. For example, this means that with a receiver noise figure of 2 dB, the receiver sensitivity is equal to −119.75+2+2.5=−115.25 dBm (the power of thermal noise fed into a matched receiver at room temperature is −119.75 dBm).
[0049] The applicant hereby discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the present specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the present invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention. | Apparatus for reducing FM click noise on a demodulated FM signal, the apparatus comprising, filter means configured to produce a click detection signal according to the demodulated FM signal, click detection means configured to receive the click detection signal and produce a click occurrence signal, and click correction means configured to correct FM clicks on the de-modulated FM signal according to the click occurrence signal. | 7 |
OBJECT OF THE INVENTION
[0001] The invention described herein is a lighting device whose lighting source is made up of light emitting diodes (known as LED by its English acronym). This lighting device may be connected to any socket into which a conventional light bulb may be connected and also offers a variation that consists of being able to connect it to photovoltaic cell-powered batteries, even directly to the photovoltaic cells or to any direct current voltage source. The lighting device contains an LED network distributed in arrangements which may be linear, matrix, circular, or any other type of standard or non-standard arrangements. These LEDs are connected individually or in groups according to the amount of LEDs placed in the device and the need for lighting required by the user.
[0002] The main objective of this invention is to reduce the consumption of electric power necessary for lighting and to produce efficient lighting. This is accomplished because the LED array only lights one or a group of LEDs at a time. This is performed through the technique called “scanning” by our research group through which the LEDs light up and turn off consecutively, either one by one, or group by group. A group is made up by two or more LEDs. This turning on and turning off is carried out at a frequency that is imperceptible to the human eye, which creates the perception that the LED array is constantly on. Consequently, the LEDs of the lighting device appear to always be on but the energy consumed is proportional to the number of LEDs which are on resulting in an energy consumption which is 80% less than a conventional light bulb.
BACKGROUND
[0003] This invention refers to a technology to generate lighting with low energy consumption. More specifically, the invention which is disclosed herein is a lighting device made up of a network of LEDs.
[0004] It is generally known that the current resources for electric power generation in the world are very limited, and therefore, it is vital to consume as little energy as possible, for financial reasons as well as to preserve the environment.
[0005] And with the purpose of finding a solution, primarily for the problem of lighting, different types of lighting devices have been developed, among which we may mention conventional devices, such as for example, the incandescent light bulb described in the publication: WO/2006/070190, which is low in cost, but very inefficient and fragile.
[0006] After attempting to reduce high energy consumption other devices have been developed such as that described in the publication: WO/2006/006097 which describes a compact fluorescent lamp, that with a principal similar to its antecedents uses inert gas which, in the presence of electricity, lights up; in general this lighting device is more efficient than the incandescent light bulb because it does make energy saving possible, however, the fluorescent bulb or tube requires ballasts and lighters which makes them more complicated and expensive, together with the fact that they are generally voluminous and fragile.
[0007] Another variety is the energy saving light which is known as the high-intensity discharge (HID—by its English acronym) lamp, such as the one described in U.S. Pat. No. 4,431,942; these lamps achieve higher efficiency than the fluorescent lamps, although they have the disadvantage of a high level of ultraviolet light emissions, which requires special filters. They also have the disadvantage of requiring ballasts and lighting aids similar to the fluorescent lamps described in U.S. Pat. No. 5,339,005. Another disadvantage of the HID lamp is that they require power factor correction as mentioned in U.S. Pat. No. 7,078,870. HID lamps are also susceptible to an elevation in their noise level due to acoustical resonance, which requires special measures such as those described in U.S. Pat. No. 7,078,870. The use of HID lamps has spread to automotive lights, as well as in places where large area lighting requires high intensity illumination.
[0008] One more variety focused on saving electric power, are light emitting diodes (LED); LEDs represent an advance in the technology, because they consume up to 80% less energy that incandescent lamps because they do not generate heat thanks to their size, but; in the case of white light, the level of efficiency of fluorescent lamps has not yet been reached. Even though competitive levels of efficiency were envisaged in their development. One characteristic of an LED lighting device, is that as light emitting diodes they may be used as part of the electronics required to rectify the current, reducing in this way the total cost. As shown in the application of patent MXNL05000079, in which LEDs are used to rectify the alternating current of an electrical network socket. This concept is also used in this patent for said purpose, however this invention differs from patent MXNL05000079 in that in said patent the LED array turn on and off all the 120 Hz frequencies (60 Hz×2 due to the fact that the diode bridge changes the frequency). In this invention, there is a digital logic stage, which enables the ability to exert special control on portions of the total of LEDs, which results in greater energy savings.
[0009] In this invention, the LEDs serve a double purpose, the first of these as lighting devices and additionally, to rectify the alternating current, thus impacting a reduction in cost. Below we will make a review of patents related to LED lighting devices, such as U.S. Pat. No. 6,016,038 which claims an apparatus to generate light, made up by one or more LEDs, a terminal for connection to a source, and a processor that generates signals through which the intensity or the color of the LEDs may be changed; another example is U.S. Pat. No. 6,149,283 that consists of a lamp made up by a line of blue, red, green LEDs, and that are arranged in such a way that the resulting light is white in color and that may be connected like a conventional light bulb, however its objective is limited to lighting without taking into consideration any reduction in cost. On the other hand, U.S. Pat. No. 6,227,679 claims an LED light bulb designed for general lighting and various other types of lighting, for example, decorative lamps and traffic lights among other applications; this light bulb includes a conical base with two circular openings, the first being of a greater diameter than the second; a flat disk inserted in the first opening, where the circuitry and the LEDs are found, and circuitry designed to provide current to the LEDs. This patent focuses on lighting but not in a special configuration as that which we are presenting and which is the reason for this invention. U.S. Pat. No. 6,268,801 claims a method to adjust a traffic signal by substituting the conventional light bulb used with a module that contains light emitting diodes, a power source connected to the LEDs and cables that connect the power source to a screw in light bulb, however they do not use LEDs for rectification nor do they show an LED array, as in this application, which are laid out in the form of a network.
[0010] After mentioning some patents that describe LED lighting systems, we will focus on patents that show the current state of the art related to energy saving techniques base on LEDs and that can be compared to the invention which is the motive for this application. U.S. Pat. No. 5,850,126 presents a screw in light bulb in a conventional form, made up of LEDs. The LEDs turn on and off at a set frequency and they manage currents higher than those they support. Said concept turns all the LEDs on and off and they remain turned off for a greater time than they are turned on, since the pulses that turn them on are smaller than those that keep them turned off By comparing this light bulb with the device presented in this application, we may describe an advantage in that the LEDs are controlled in such a way that we control the number of LEDs that are turned off or on, in such a way that illumination is maintained with the lower number of LEDs turned on and that this is imperceptible by the human eye, generating thus a lower consumption of energy.
[0011] U.S. Pat. No. 6,160,354 controls LEDs which are interconnected as a network, whose configuration and purpose are not lighting.
[0012] In addition to these patents, there is a concept known as PWM, (Pulse Width Modulation—by its English acronym) for managing LEDs, however, the use of said concept is for intensity effects and do not offer much in the way of energy savings given their focus. All these patents and applications give us a panorama of the current state of the art. However, in the patent documents mentioned, the focus is on using LEDs as an alternative source of lighting but the efforts do not focus on looking for efficient manners to use LEDs to save electricity. This invention is based on a design that makes it possible to use LEDs in an efficient manner, without significant losses in illumination, with which an even more substantial savings is obtained which may be more than 80% of the total consumption of the LEDs.
DETAILED DESCRIPTION OF THE INVENTION
Brief Description of the Figures
[0013] FIG. 1 : Illustration Exterior of the lighting device to which this invention refers.
[0014] FIG. 2 . Block Diagram of the lighting device in its Alternating Current (AC) variation.
[0015] FIG. 3 . Block Diagram of the lighting device in its Direct Current (DC) variation.
[0016] FIG. 4 : Schematic Diagram of the LED array.
[0017] FIG. 5 : Schematic Diagram of the LED controller.
[0018] FIG. 6 : Full Schematic Diagram of the Zener device without diodes.
[0019] FIG. 7 : Full Schematic Diagram of the Zener device with diodes.
FIGURES OF THE EXISTING ELEMENTS IN THE STATE OF THE ART
[0020] FIG. 8 : Simple full wave bridge rectifier
[0021] FIG. 9 : Schematic of a simple rectification.
[0022] FIG. 10 : Schematic of a bridge rectification in parallel.
[0023] FIG. 11 : DC-DC Converter.
DESCRIPTION OF THE INVENTION
[0024] The invention described herein is a lighting device whose light source is made up of light emitting diodes (known as LED by its English acronym). This device may be connected to any conventional light bulb socket as well as being able to be connected to batteries powered by photovoltaic cells, or any direct current voltage source. The device may be in the form of any conventional light bulb, but its principal technological advantage with respect to other known or conventional light bulbs is that electronic scanning is used to turn them on for the purpose of obtaining low energy consumption.
[0025] FIG. 1 , shows the general diagram of the lighting device where it can be seen that it is made with a conventional screw-in light bulb ( 1 ), making it possible to connect it to a conventional socket. In the base ( 2 ) the controller is found with the necessary electronics to manage sequential lighting (scanning) of the LEDs as well as to provide the necessary voltage for its operation and within the cube ( 3 ) the printed circuits (PCBs) are found with the LED array. This invention has the versatility of a lighting device that is able to operate on Alternating Current (AC) as well as Direct Current (DC), i.e., it is possible to connect it to a residential, commercial, and/or industrial electric network or to a direct current source, such as a commercial type battery.
[0026] FIG. 2 shows a block diagram of the elements of the lighting device when it is connected to a residential electrical network, operating on the AC variation. Said device has a rectification stage for alternating current (AC) ( 4 ) the function of which is to rectify the current converting the alternating current into direct current and transforming the voltage to a constant value of DC-DC ( 5 ), obtaining thusly DCV and VAC voltage where the DCV voltage functions as the power source for the LED array ( 6 ) and the VAC voltage powers the controller ( 7 ), the function of which is to designate the lighting sequence of the LEDs.
[0027] However, if the lighting device is powered by a DC source, the AC rectifying stage ( 4 ) is not used, giving as a result the device shown in the block diagram of the lighting device in its DC variation that is shown in FIG. 3 in which only the DC-DC converter ( 8 ) is required to produce VDC and VAC voltages where these voltages power the LED array ( 9 ) and the controller ( 10 ), respectively. The advantage of using this configuration with a DC source is that it is possible to power this device with alternate power sources such as solar, wind, among others.
[0028] One of the novelties of this invention is shown in FIG. 4 where an example of the preferred LED array may be seen forming a configuration similar to a network that contains columns and rows of LEDs.
[0029] In FIG. 4 , the LED network may be seen that is made up of rows listed from Y 1 to Yn ( 11 ) and by columns listed from X 1 to Xm ( 12 ). It is important to mention that each column (X 1 to Xm) has its own transistor ( 13 ) (in the case that BJT, NPN is used) which has an RB resistance ( 14 ) in its base, a GND is connected at its emitter or reference and in its collector an Rc resistance ( 15 ) is found. Additionally, each row (Y 1 to Yn) also has its own transistor ( 16 ) (in the case that BJT or bipolar junction transistor, PNP, is used) which has an RB resistance ( 14 ) in its base, a VDD is connected at its emitter and from its collector a number of LEDs are connected which is equal to the number of columns that may range from “1” to “m”. In FIG. 4 , the interconnection of the LEDs may be seen, where the columns, Xi are interlinked with the rows, Yi, the Rc resistance ( 15 ) sets the current that passes through the LED. It is important to point out that the model, family and characteristics of the transistors are neither definitive nor specific to the operation of the circuit.
[0030] To facilitate the explanation of the controller circuit (scanner) an example shall be shown setting “n” as well as “m” in 4 , i.e., it will be explained as an array of 4 LEDs by 4 LEDs giving a total of 16 LEDs.
[0031] For addressing and selection of the LEDs the corresponding coordinate is activated, through the controller ( 7 ) and ( 10 ) which is described in detail in FIG. 5 . In the specific case of 16 LEDs, these are selected through a calculation generated by a 4 bit binary counter. Addressing the 16 LEDs is achieved with these 4 bits because the LEDs are located as “rows” and “columns”.
[0032] For example, when Y 4 and X 4 are activated at the same time only the LED in the upper right corner will be turned on. If Y 4 and X 3 were the positions activated, only the preceding LED would be turned on. If only one column transistor is activated as well as another one from a row, only one LED will light at a time.
[0033] Said transistors in this example are activated with the controller from FIG. 5 . Its function is to select only one row and one column at a time and after a certain time select another row-column pair until the entire “n by m” has been completed, 4 by 4 for example, and after it restarts its count. In the case of the example with 4 bit rows and columns, this controller is preferably implemented through a binary counter ( 17 ) connected to two decoders ( 18 and 19 ) as shown in FIG. 5 , the specific components for the 16 bit example is specified later.
[0034] The decoder ( 19 ) used to select the columns (X 1 to Xm); its outlets should be negated with an inverter to implement the proper control over the NPN transistor in the interconnection between the LED network and the controller. In addition, there is another decoder ( 18 ) for the rows, which is directly connected to the base of the PNP transistor, i.e., there so not require being inverted.
[0035] In this particular case, the scanning sequence first lights up LED by LED of the first row (Y 1 ), and when it finishes, it does the same in the second row (Y 2 ) and thus successively until it reaches the last row Yn (Y 4 for the example) with the last column Xm (X 4 for the example) and it starts again. However, the scanning sequence may adapt itself to different requirements being able to perform lighting in any order desired or even may be carried out in random order.
[0036] A binary counter provides counts that go up in multiples of 2, for example, 4, 6, 16, 32, and successively duplicating itself. For this circuit, a counter is used that may generate a count that is equal to or greater than the number of LEDs. The circuit design is expandable to a higher number of rows and columns (n by m), here only a small one is shown having 16 bits arranged 4 by 4 to facilitate the explanation, but the invention here proposed may use higher numbers of rows and columns, where the number of rows and columns are not necessarily equal.
[0037] The scan may be enlarged, with only one counter, in different forms, one of which is the following: the number of columns is determined in a multiple of 2, and the number of rows should also be thus. Afterwards, the number of bits that generate said counts are determined and linked, assigning a decoder to each count that has the lines necessary per column and if applicable, per row.
[0038] Generally speaking, a count of X bits divided into Y and Z bits is had, where Y+Z=X (Y:Z=X). A decoder is used for Y to 2 Y lines that is controlled by the bits called Y. Another decoder is used for Z to 2 Z lines that is controlled by the bits called Z. The circuit would control a total of 2 X LEDs that would light only one at a time. The count generated by the single decimal counter in the circuit would be the Z count.
[0039] Returning to FIG. 5 , a schematic diagram of the 16 LED controllers is shown. The following components are shown in said diagram:
A 74393 binary counter ( 17 ) powered by a square signal generator with a frequency dependent upon the number of LEDs (60 Hz×# of LEDs or greater), in the example that is described herein would be 960 Hz (60 Hz×16). To said binary counter a pair of decoders is connected where the first of them is 74138, ( 18 ) and controls the rows, takes the most significant number of bits, and the second, the 74138 decoder ( 19 ) controls the columns, and takes the least significant number of bits. The second decoder's ( 19 ) outlet must be inverted to control the NPN transistors as mentioned above.
[0041] The control system requires two voltages, VAC and VDC; said voltages may be obtained from the AC network as well as from a DC source after being converted and regulated.
[0042] As illustrated in FIG. 6 , the value of VAC 2 ( 0 ) and VDC ( 21 ) may vary. By definition VAC is 5V and VDC will be set in accordance with the model, number, configuration, and type of LEDs and the voltage and/or current requirements. Said value may be equal to 5V for ease. If VAC is greater than or equal to VDC the schematic shown in FIG. 6 is used. Otherwise, see FIG. 7 which is the complete schematic diagram with Zener diodes ( 22 ); which is used if the VDC is greater than the VAC (5V), and that consists in that a Zener diode must be added to each row to protect the circuit.
[0043] As shown in FIG. 7 . The value of said Zener diode ( 22 ) must be the same as the VDC minus the VAC rounded up to the nearest Zener commercial value and must be placed in such a way that it generates a fall in voltage in the direction of the base of the outlet transistor of the row decoder as shown in said Figure.
[0044] In summary, the scanning handles the selected lighting (scanning by rows and columns), alternate and consecutive of the individual LEDs or groups of LEDs that represent a fraction of the total LEDs in the lighting device.
[0045] Another of the important characteristics of this device is that the rectification phase is also made up by LEDs, which may be connected in the form of a full wave bridge rectifier FIG. ( 8 ), and in this way fulfills a double function of lighting and rectifying, achieving as a result low energy consumption since an extra rectifying phase (AC-AC) is not required to power the LED array and it also achieves greater illumination, the rectifier also may have variations using more LEDs in the bridge as can be seen in FIG. 9 , or several bridges in parallel as shown in FIG. 10 , which would allow for greater rectification and also take advantage of the use of the rectifying LEDs as a light and power source.
[0046] For the circuit rectification stage shown in FIG. 8 a typical rectifier is shown with a full wave diode bridge rectifier. Its purpose is to rectify the voltage of a light bulb socket (110 or 220 Volts AC to 60 or 50 Hz). This rectification is carried out using the four LEDs identified in the Figure as D 1 , D 2 , D 3 and; D 4 ; obtaining a pulsating voltage which is always positive. A capacitor ( 23 ) for converting the pulses into a constant voltage value is used, causing the rectifying circuit outlet to be DC voltage with no ripple, which passes to the DC-DC conversion stage.
[0047] This variation substitutes the diodes with light emitting diodes. In this invention, the above fulfills two functions: rectification of the sinoidal wave input (110 or 220 Volts CA) and at the same time the production of light, and for this reason it is able to use fewer LEDs during the scanning stage, and thus obtain greater energy savings. The frequency of oscillation is approximately constant, since it only depends on the frequency of the power outlet (50 or 60 Hertz).
[0048] The principal objective of the DC-DC conversion stage is to reduce the DC voltage that delivers the rectifier to a VDC voltage that is useful for the LED network, and which is determined according to the operational parameters of these. The basic circuit of this stage, shown in FIG. 11 , consists of a DC-DC converter, known as a “chopper” reducer. This circuit is basically made up of a transistor ( 24 ), a diode ( 25 ), and an inducer ( 26 ), the objective of which is to maintain a relatively constant current to the circuit outlet. The transistor ( 24 ) makes it possible, through a trigger circuit, to decide what percentage of the input voltage (V input) is transmitted to the output, which makes it possible to vary the average output voltage as desired. Given that the output voltage is a pulsating square voltage, a capacitor ( 27 ) is used to make a constant V output. For technical reasons it is necessary to place several of these circuits in cascade.
[0049] At the output of these two stages, the voltage obtained is that required for proper operation of the LED array. The values of the components and the number of circuits that must be placed in cascade for the DC-DC conversion stage is determined by the parameters of VDC voltage and the current required for the LED array. When the VDC voltage is not equal to that required for VAC (for example 5 volts), a circuit with a built-in commercial voltage regulator may be used. | This invention describes a lighting device with low energy consumption, which is made up of light emitting diodes known by the English acronym of LEDs, that use the technique known as “scanning”; with the purpose of reducing the consumption of energy required for lighting. Said scanning is performed by an efficient circuit that determines the sequence and time required for the activation of each LED or group of LEDs. The invention does not limit itself to only using LEDs, other types of elements for control may be used that may be sequenced without altering its operation or useful life. In this case, the speed that may support the LEDs is taken advantage of and that is higher than can be seen by the human eye, where each LED or group of LEDs are turned on and off at a frequency that is imperceptible by the human eye.
Solutions are also presented to reduce the voltage by electronic means and rectification of the current using the LEDs themselves that intervene in the lighting. | 5 |
BACKGROUND
A modern application specific integrated circuit (ASIC) must meet very stringent design and performance specifications. One of the factors that influence the design and performance of an ASIC is inductance. Typically, it is desirable to minimize the inductance in the power supply network as well as in the signal distribution network. Minimizing inductance improves signal isolation and reduces cross talk between signal paths. A modern ASIC is typically assembled into a package, which is then mounted to a structure, such as a printed circuit board, using one of a number of known mounting techniques. The ASIC package frequently includes a laminate structure that includes a laminate core and one or more material layers on opposing sides of the core that include conductive traces and that are used to distribute power, to route signals and to provide ground connections for both power and signal connections. The laminate structure is typically located between the ASIC chip and the PCB to distribute power and signals between the ASIC and the PCB. Due to the many power and signal connections in a modern ASIC, inductance between power supply and ground connections, and inductance between signal and ground connections and between signal lines can easily become so large that it negatively affects the performance of the ASIC.
Therefore, it would be desirable to have a way of minimizing power supply inductance and signal inductance in an ASIC.
SUMMARY
In an embodiment, a laminate interconnect structure includes a core material and at least one additional layer adjacent the core material, a first electrically conductive via formed in the core material, and a second electrically conductive via formed in the core material, coaxial with the first electrically conductive via and separated from the first electrically conductive via by a non-conductive material.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is a schematic diagram illustrating a portion of an application specific integrated circuit (ASIC) assembly including a laminate structure having one or more coaxial via structures.
FIG. 2 is a schematic diagram illustrating a portion of the assembly of FIG. 1 .
FIG. 3 is a schematic view illustrating a cross-section the coaxial via of FIG. 2 .
FIGS. 4A through 4D are a series of schematic drawings showing an example of a process or method that can be used to form a coaxial via in a laminate structure.
FIG. 5 is a schematic diagram illustrating an alternative embodiment of a coaxial via structure.
FIG. 6 is a plan view illustrating the coaxial via shown in FIG. 4 .
FIG. 7 is a plan view illustrating the coaxial via shown in FIG. 5 .
DETAILED DESCRIPTION
A laminate interconnect having a coaxial via structure can be used in any application specific integrated circuit (ASIC) in which it is desirable to reduce loop inductance between power and ground connections, reduce loop inductance between signal and ground connections, and reduce inductive coupling between signal connections. Minimizing inductance and inductive coupling improves signal isolation and reduces cross talk between signal paths. The laminate interconnect having a coaxial via structure can be implemented in circuits having single-ended signals, or in circuits having differential signals. The laminate interconnect having a coaxial via structure will be described below as being implemented in an ASIC package. However, the laminate interconnect having a coaxial via structure can be implemented in any laminate structure such as a printed circuit (PC) board interconnect.
FIG. 1 is a schematic diagram illustrating a portion of an application specific integrated circuit (ASIC) assembly 100 including a laminate structure having one or more coaxial via structures. The assembly 100 comprises a printed circuit (PC) board 102 over which a circuit package 105 is located and attached to the PC board 102 using solder balls 122 . An example of a circuit package 105 can be a DRAM package or another circuit package. Further, the circuit package 105 can be a flip-chip package, or another circuit package as known to those skilled in the art. The PC board 102 can be any single-layer or multi-layer structure used to mount a circuit package, such as the circuit package 105 as known in the art. The solder balls 122 are an example of an attachment structure that can be used to electrically and mechanically attach the circuit package 105 to the PC board 102 , and are known to those skilled in the art.
The circuit package 105 comprises a circuit element, also referred to as a “chip” 106 located and attached to a laminate structure 104 using solder bumps 124 . The chip 106 generally comprises the active circuit elements of the ASIC circuitry. The solder bumps 124 are an example of an attachment structure that can be used to electrically and mechanically attach the chip 106 to the laminate structure 104 , and are known to those skilled in the art. A lid 112 is attached to the circuit package 105 using an adhesive 108 as known to those skilled in the art.
The laminate structure 104 generally comprises a laminate core and one or more layers formed on one or both sides of the laminate core. The laminate core and the layers formed thereon will be shown in greater detail below. The laminate structure 104 generally comprises a power distribution network and signal distribution connections, sometimes referred to as circuit traces, which transfer power and signal connections between the PC board 102 and the chip 106 . Generally, the form factor and the array of solder bumps 124 of the chip 106 dictate that connection to the PC board 102 and the array of solder balls 122 occur through an adaptive connection. The laminate structure 104 serves this adaptive connection function of coupling the chip 106 to the PC board 102 , and distributing the connections between the chip 106 and the PC board 102 . The laminate structure 104 generally comprises one or more power layers, ground plane layers, and wiring interconnects. The laminate structure 104 may also include one or more passages, referred to as “vias” that provide electrical connectivity between and among the various layers of the laminate structure 104 . In an embodiment, the laminate structure 104 may include a coaxial via structure, an example one of which is illustrated using reference numeral 150 . The coaxial via structure 150 will be described in greater detail below.
In the embodiment shown, the chip 106 is located over the laminate structure 104 and a periphery of the chip 106 is generally contained within the periphery of the laminate structure 104 . Further, the laminate structure 104 is located over the PC board 102 , and a periphery of the laminate structure 104 is generally contained within a periphery of the PC board 102 .
FIG. 2 is a schematic diagram illustrating a portion 200 of the assembly of FIG. 1 . The portion 200 generally comprises portions of the circuit package 105 , chip 106 and laminate structure 104 .
The laminate structure 104 generally comprises a laminate core 202 and layers 204 and 206 . For example purposes only, the laminate core 202 can be fabricated from a glass fiber material, or another suitable material known to those skilled in the art. For example purposes only, the layers 204 comprise individual layers 208 and 212 , and the layers 206 comprise individual layers 214 and 216 . The layers 204 and 206 are illustrated as each comprising two layers, sometimes referred to as “build-up” layers, but those skilled in the art will recognize that layers 204 and 206 may comprise more or fewer layers, and may each comprise a different number of layers. The layers 204 and 206 generally include a combination of non-conductive high density build-up material and material used to construct electrical interconnects including, but not limited to, copper, or other conductive material circuit traces, or other conductive material circuit pads, and other conductive elements and structures.
The laminate structure 104 also comprises an embodiment of a coaxial via structure 150 . In the embodiment shown, the coaxial via structure 150 comprises a central via 220 and a peripheral via 225 , which in this embodiment, can be constructed as a through hole electrically conductive plated via or an electrically conductive filled via. In the example shown in FIG. 2 , the peripheral via 225 is constructed as a through hole electrically conductive plated via, whereby the peripheral via 225 comprises a vertical portion 227 and layer portions 228 and 229 , each of which is formed by plating, or another process by which electrically conductive material is applied or formed. The coaxial via structure 150 also comprises non-conductive fill material 226 , which can be, for example purposes only, a non-conductive resin or another structurally stable non-conductive dielectric material.
In the embodiment shown in FIG. 2 , the coaxial via structure 150 electrically connects the solder bump 231 to the central via 220 , through the conductive elements 232 and 234 , and electrically connects the solder bump 236 to the peripheral via 225 , through the conductive elements 237 and 238 . On the opposing side of the laminate structure 104 , the coaxial via structure 150 electrically connects the solder ball 251 to the central via 220 , through conductive elements 252 , 254 and 255 , and electrically connects the solder ball 256 to the peripheral via 225 , through the conductive elements 257 and 258 . The conductive elements 232 , 234 , 237 and 238 are formed in the laminate layers 206 , as known in the art. Similarly, the conductive elements 252 , 254 , 255 , 257 and 258 are formed in the laminate layers 204 , as known in the art. In this manner, a coaxial via structure 150 provides two electrical paths of connectivity between the chip 106 and the PC board 102 (not shown in FIG. 2 ), while minimizing inductance and while minimizing the amount of area consumed on the laminate structure 104 . This arrangement improves signal isolation and minimizes the likelihood of cross talk for signals carried through the coaxial via 150 .
FIG. 3 is a schematic view illustrating a cross-section of an example coaxial via 300 , which is similar to the coaxial via 150 of FIG. 2 . The elements in FIG. 3 and in the subsequent figures to follow are numbered using the convention XX, where “XX” refers to a similar element in FIG. 2 .
A coaxial via 300 is formed in a laminate core 302 . The coaxial via 300 comprises a peripheral via 325 and a central via 320 . The peripheral via 325 is formed from a conductive material and comprises a vertical portion 327 and layer portions 328 and 329 . In an embodiment, the peripheral via 325 is formed by drilling, etching, boring, or otherwise forming a hole in the laminate core 302 and then plating or otherwise covering the exposed surface of the laminate core 302 with a conductive material to form the vertical portion 327 and the layer portions 328 and 329 . Subsequently, conductive elements 351 are formed as generally indicated, but are generally not part of the peripheral via 325 .
A non-conductive fill material 326 , such as a glass fiber resin or other suitable non-conductive material fills the space within the interior portion of the peripheral via 325 . The fill material 326 is then drilled, etched, bored, or otherwise processed to form an opening within which to form the central via 320 . The central via 320 can be a plated or filled via, depending upon application. The conductive elements 354 and 334 are formed subsequently as described above in the laminate layers 204 and 206 (not shown in FIG. 3 ), as described with respect to FIG. 2 .
FIGS. 4A through 4D are a series of schematic drawings showing an example of a process or method that can be used to form a coaxial via in a laminate structure. FIG. 4A shows a schematic diagram 400 including a laminate core 402 having an opening 407 formed therein. The opening 407 can be formed by drilling, boring, etching, eroding, or another known process for creating an opening in a laminate core. In an embodiment, the opening 407 has an initial diameter “a.” The diameter “a” as sometimes referred to as the “drill diameter.” The peripheral via 425 is formed by plating, or otherwise applying a conductive material to the portions of the laminate core 402 exposed when forming the opening 407 . The conductive material forms the vertical portion 427 and the layer portions 428 and 429 of the peripheral via 425 . A circuit pad 405 is also formed by portions of the vertical portion 427 and the layer portion 428 . The dimension “d” refers to a diameter of the circuit pad to 405 . A circuit pad 411 can be similarly formed on the opposing side of the laminate core 402 and may have a dimension that is the same or different than the dimension “d.” In the embodiment shown in FIG. 4A , the thickness of the vertical portion 427 is illustrated using dimension “b” and the width of the opening after plating is shown by dimension “c.” The thickness of the layer portions 428 and 429 can be the same or different than the dimension “b.”
FIG. 4B is a schematic diagram 415 illustrating the peripheral via 425 after being filled with a non-conductive material 426 . In an embodiment, the non-conductive material 426 can be a glass resin or other structurally sound material. The dimension “e” refers to the diameter of the resin film material 426 .
FIG. 4C is a schematic diagram 430 illustrating the formation of an opening 409 through the fill material 426 . The diameter of the opening 409 corresponds to dimension “f” and allows for the formation of the central via therein. The dimension “g” refers to the thickness of the resin material 426 on either side of the opening 409 .
FIG. 4D is a schematic diagram 435 showing a central via 420 formed within the opening 409 . The central via 420 can be a solid filled conductive structure, or can be a cylindrical plated hole, so long as the central via 420 is formed using a conductive material. Conductive elements 451 are formed as described above on the pads 405 and 411 of the peripheral via 425 while conductive elements 434 and 454 are formed on opposing ends of the central via 420 .
FIG. 5 is a schematic diagram 500 illustrating an alternative embodiment of a coaxial via structure. The coaxial via structure shown in FIG. 3 is generally suitable for power and ground connections and for circuit paths having what is referred to as a “single-ended” signal conductor and a single ground path (or power path). The coaxial via structure shown in FIG. 5 is suitable for circumstances in which there may be multiple signal paths and a single ground path, or in applications referred to as a “differential-signal.” For example, the coaxial via structure shown in FIG. 5 is suitable for a differential signal path where two signals of opposing polarity and a ground plane (or power plane) are carried.
FIG. 5 illustrates a laminate core 502 within which a peripheral via 525 is formed as described above. The peripheral via 525 is one of three vias shown in FIG. 5 . A fill material 526 is used to create a non-conductive solid structure within the peripheral via 525 . In the embodiment shown in FIG. 5 , two central vias 520 and 523 are formed in and electrically isolated from each other and from the peripheral via 525 by the fill material 526 as described above.
Conductive elements 551 are formed in contact with the peripheral via 525 , conductive elements 552 are formed in contact with the central via 520 , and conductive elements 553 are formed in contact to the central via 523 , as described above. The embodiment shown in FIG. 5 can be used for differential signals in which the opposing polarity signals are carried by the central vias 520 and 523 and a ground connection is carried by the peripheral via 525 .
FIG. 6 is a plan view 600 illustrating the coaxial via shown in FIG. 4 . The central via 420 is located in the approximate center of the fill material 426 . The peripheral via 425 surrounds the fill material 426 and the central via 420 . The pad 405 is shown as comprising portions of the peripheral via 425 and layer portion 428 , but typically, the material that forms the pad 405 and the peripheral via 425 is a single continuous material. The laminate core 402 is shown for reference.
FIG. 7 is a plan view 700 illustrating the coaxial via shown in FIG. 5 . The central via 520 and central via 523 are located approximately as shown within and electrically isolated from each other and from the peripheral via 525 by the fill material 526 . The peripheral via 525 surrounds the fill material 526 and the central vias 520 and 523 . A pad 505 is shown as comprising portions of the peripheral via 525 and layer portion 528 , but typically, the material that forms the pad 505 and the peripheral via 525 is a single continuous material. The laminate core 502 is shown for reference.
This disclosure describes the invention in detail using illustrative embodiments. However, it is to be understood that the invention defined by the appended claims is not limited to the precise embodiments described. | A laminate interconnect structure includes a core material and at least one additional layer adjacent the core material, a first electrically conductive via formed in the core material, and a second electrically conductive via formed in the core material, coaxial with the first electrically conductive via and separated from the first electrically conductive via by a non-conductive material. | 7 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application 61/666,800, filed Jun. 30, 2012.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to enhancement systems for floating recreational boards such as paddleboards and surfboards. More specifically, the invention relates to a device which attaches to a recreational board and improves flotation, can be used to hold beverages and other items, and protects the edges of a recreational board.
2. Description of the Prior Art
Stand-up paddleboards (“SUPs”) are gaining in popularity for a variety of reasons including recreation, exercise, ease in learning, and short-distance transportation. However, traditional SUPs have certain limitations. For one, not everyone is coordinated enough to maintain their balance on a SUP, especially where the water is turbulent from waves, water movement, wakes, and so forth. As a result, a paddler may fall off their board. Another limitation is that a conventional SUP doesn't provide a compartment or other place to secure personal belongings such as keys, wallets, and beverage containers. As a result, the paddler must keep these items on their person, which can be uncomfortable. If the paddler falls off the board, which can happen frequently, items will be submerged in water, and possibly lost. Thus, it would be advantageous to provide a device that increased the overall stability of a SUP, and provided storage.
While SUPs have conventionally been used for actual stand up paddleboarding, some use SUP's as a congregation point for people enjoying aquatic activities, for example a floating bar of sorts. In this manner one or more people drape their arms over the top surface of the SUP to provide flotation. However, the buoyancy of the SUP is decreased as people weigh down the SUP. In addition, just as people paddleboarding lack a compartment where they can store their belongings, people congregating around a SUP lack a secure place for their belongings. Thus, it would be advantageous to provide a device that increased the overall buoyancy of a SUP, and provided storage.
SUPs are designed to be strong, yet light. However, as they are intended for use in water, they are prone to dings, abrasions, and other damage. The likelihood of this damage is increased because SUPs are large and somewhat cumbersome. Thus, it would be advantageous to protect the perimeter of the SUP to increase longevity of use.
As can be seen, there is a need for a flotation device that increases the overall stability and buoyancy of a recreational board, while providing storage for beverages and other personal items. It is also desirable that a flotation device would afford protection to the recreational board. Further, it is also desirable for the flotation device to be lightweight, inexpensive and easy to manufacture. It is also desirable that the flotation device can be easily attached and removed.
SUMMARY OF THE INVENTION
A flotation system includes an elongated substrate that is sized and shaped to releaseably wrap around the perimeter of a recreational board. The elongated substrate is constructed of a buoyant material such as foam, and defines a plurality of apertures that can be used to store items such as beverages and personal belongings. The elongated substrate is releaseably attached to the board by a variety of fastening means including a sheath having webbing and buckles, or ropes or elastomeric ropes that essentially tie the substrate to the board.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a top perspective view of an embodiment of the invention;
FIG. 2 depicts a bottom view of an embodiment of the invention;
FIG. 3 depicts a side perspective view of an elongated substrate of the invention;
FIG. 4 depicts a top perspective view of an alternative embodiment of the invention;
FIG. 5 depicts a side perspective view of an alternative embodiment of the invention;
FIG. 6 depicts a bottom perspective view of an alternative embodiment of the invention;
FIG. 7 depicts a top view of an alternative embodiment of the invention;
FIG. 8 depicts a bottom view of an alternative embodiment of the invention;
FIG. 9 depicts a cross-sectional view of an alternative embodiment of an elongated substrate;
FIG. 10 depicts a cross-sectional view of an alternative embodiment of an elongated substrate;
FIG. 11 depicts a cross sectional view of an alternative embodiment of FIG. 9 taken along FIG. 7 ; and
FIG. 12 depicts a cross sectional view of an alternative embodiment of FIG. 10 taken along FIG. 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
The following numbers apply to structures among the various FIGS:
10 —Flotation system; 11 —Elongated substrate; 12 —Top portion; 13 —Cup holder; 14 —Longitudinal channel; 15 —Side portion; 16 —Bottom portion; 17 —Cupholder insert; 18 —Slot; 20 —Recreational board; 22 —Planar top 23 —Planar bottom 24 —Perimeter 30 —Fastening member; 31 —Sheath; 32 —Channel; 33 —Channel sleeve; 34 —Belts; and 35 —Buckles.
Referring to FIG. 1 , flotation system 10 includes conventional recreational board 20 outfitted with elongated substrates 11 along perimeter 24 of board 20 , and fastening member 30 holding elongated substrates in position. As used herein, “recreational board” can refer to a variety of floating vessels including SUPs, surfboards, and the like, and it should be understood that the invention is not limited in any way to SUPs. In the embodiment of FIGS. 1 and 2 , fastening member 30 includes sheath 31 , which is preferably constructed of a resilient textile, with belts 34 and buckles 35 that connect on planar bottom 23 of board. While webbing belts and snap together buckles are preferred, other fastening means are also within the scope of this invention. In this manner elongated substrates 11 are held taut to the perimeter of recreational board 20 .
FIG. 3 depicts a perspective side view of preferred elongated substrate 11 . It generally includes top portion 12 , side portion 15 , and bottom portion 16 , with those three sides defining longitudinal channel 14 . Longitudinal channel 14 releaseably receives perimeter 24 of recreational board 20 . The width of the top portion W T , is preferably greater than the width of the bottom portion W B . Top portion 12 preferably defines a plurality of cup holder apertures 13 , and optionally includes a plurality of removable cup holder inserts 17 . While the embodiment of FIG. 3 depicts a shape having angular vertices and substantially planar sides, it should be understood that a variety of sizes and shapes could be employed, so long as they releaseably engaged with the board's perimeter. FIGS. 9 and 10 set forth examples of alternative shapes for elongated substrate 11 .
It is preferred that top portion 12 has a thickness of 5 cm to 7 cm, side portion 15 has a thickness of 4 cm to 5 cm, and bottom portion 16 has a thickness of 4 cm to 6 cm. It is preferred that top portion 12 has a width of 17.5 cm to 19 cm, side portion 15 has a width of 10 cm to 15 cm, and bottom portion 16 has a width of 15 cm to 18 cm.
Elongated substrate 11 can be connected to recreational board 20 in a variety of ways. By way of example, FIGS. 4 and 5 depict embodiments whereby fastening member 30 is a tying or cinching means, such as rope or elastomeric rope. As shown in FIG. 6 , fastening member may be in crisscross orientation on underside of board 20 , with channels 32 defined by elongated substrate 11 slideably receiving fastening member 30 . Alternatively, as suggested in FIGS. 7 and 8 , fastening member 30 may run longitudinally along length of elongated substrate 11 , and be tied off on planar top 22 of the board ( FIG. 7 ) and planar bottom 23 of the board ( FIG. 8 ). In this embodiment it is preferred that channels 32 , as shown in FIGS. 9 and 10 , run longitudinally along the length of the substrate. Although not shown in the figures, channel sleeve 33 , such as an elongated tube, may line channels 32 so as to provide additional strength.
It is desirable that elongated substrate 11 covers at least 50% of the perimeter of the board, with coverage preferably being a mirror image relative to the longitudinal midline of the board so as to enhance stability. It is preferred that the elongated substrate is engaged with between 80% and 100% of the perimeter. It is also desirable that the elongated substrate floats in water, having an approximate density between 0.0114 gm/cm 3 and 0.032 gm/cm 3 . One example of a suitable material is closed cell foam “Polyplank” manufactured by Pregis Corp. of Deerfield, Ill.
Cup holders 13 preferably extend through the entire height of top portion 12 , and are preferably each a cylindrical aperture defined by elongated substrate 11 , and having a diameter between 7.5 cm and 10 cm. Cup holder inserts 17 are preferably constructed of plastic, such as the rigid members used in some drink coozies.
In use, one would enhance a recreational board by positioning an elongated substrate around at least 50% of a recreational board, and securing the elongated substrate to the board with a fastening member. The fastening member may be a tying means such as a rope threaded through channels of the elongated substrate. Alternatively, the fastening member may be a sleeve that substantially covers the top and perimeter of the board, and has a fastening means such as buckles and straps for securing on the underside of the recreational board. The enhanced recreational board is then ready for use in the normal manner, except it floats better, is more stable, and securely holds beverages and other items.
It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. By way of example, it is possible to use the device with a variety of recreational boards, including lumber such as sheets of plywood and board planks, in order to create a floating bar. It should also be understood that ranges of values set forth inherently include those values, as well as all increments between. | A flotation system for a recreational board such as a stand up paddleboard includes an elongated substrate that is sized and shaped to releaseably wrap around the perimeter of a recreational board. The elongated substrate is constructed of a buoyant material such as foam, and defines a plurality of apertures that can be used to store items such as beverages and personal belongings. The elongated substrate is releaseably attached to the board by a variety of fastening means, and serves to increase stability and buoyancy of the board, and to protect the board. | 1 |
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to an injector and method for discretely delivering gaseous chemicals to an area above a surface where the gases mix, react and form a layer on the surface. More particularly, it relates to an injector and method for uniformly depositing films or layers to a surface of a wafer or substrate in conjunction with an atmospheric pressure chemical vapor deposition apparatus.
BACKGROUND OF THE INVENTION
An apparatus for producing films or layers on substrates or wafers by conveyorized atmospheric pressure chemical vapor deposition (APCVD) is described in U.S. Pat. No. 4,834,020 and owned by assignee. This patent is expressly incorporated herein by reference.
In general, the APCVD apparatus includes a conveyor belt which transports a wafer or substrate through one or more coating chambers. Each coating chamber includes an injector for creating and maintaining a chemical vapor atmosphere at the wafer or substrate surface such that a reaction occurs between the chemical vapors or between the chemical vapors and the wafer or substrate. The reaction byproducts form a layer on the wafer or substrate to produce a layer or film.
An important element in creating and maintaining the chemical vapor atmosphere at the wafer surface is the injector. The injector receives a number of gases and discretely conveys them to the area above the surface of the wafer or substrate where they mix, react and then form a layer on the wafer or substrate.
The gases must be uniformly mixed over the surface of the wafer or substrate in order to provide a proper chemical reaction. When the gases are not uniformly delivered, they do not mix properly. Thus, the chemical reaction that transpires is one with undesirable chemical concentrations. Consequently, defective films or coatings are deposited on the wafers or substrates. Therefore, to insure a proper film or coating, the gases must be introduced substantially uniformly.
To achieve an advance in the art of depositing a film or coating on a wafer or substrate it is important to refine the apparatus and method of delivering gaseous chemicals to a wafer or substrate. This largely involves refining the means for achieving a uniform, or laminar, flow of reaction chemicals. The prior art has met with limited success in achieving such a uniform flow of reaction chemicals.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of this invention to provide a method and apparatus for delivering gaseous chemicals to a surface.
It is a more particular object of this invention to provide a method and apparatus for use within an atmospheric chemical vapor deposition apparatus, for delivering gaseous chemicals to the surface of a wafer or substrate in order to deposit a film or layer on the surface.
Another object of this invention is to provide a method and apparatus for improving the uniformity in which individual gaseous chemicals are delivered.
A related object of this invention is to provide a method and apparatus for improving the quality of films or layers deposited on wafers or substrates.
These and other objects are achieved by an injector with a number of stacked plates with each plate including a number of linear hole arrays. The stacked plates produce a number of cascaded hole arrays. A chute surrounded by a cooling plate is positioned beneath the last hole array. The chute includes a central passage and the regions between the cooling plate and the chute form ducts. The top plate receives a number of gases and discretely conveys them to the top of the individual cascaded hole arrays. The gaseous chemicals are then forced through the cascaded hole arrays which induces the gases to flow in an increasingly uniform manner. The gases are then individually fed to the chute passage and ducts which convey them to a region above the surface where the gases are mixed, react, and form a layer on the surface of an underlying substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent on reading the following detailed description and upon reference to the drawings, in which:
FIG. 1 is a schematic cross-sectional view of an atmospheric chemical vapor deposition apparatus in accordance with the prior art.
FIG. 2 is a side view of a prior art chemical vapor injector.
FIG. 3 is a cross-sectional view of another prior art chemical vapor injector.
FIG. 4 is a cross-sectional view of the injector of this invention.
FIG. 5 is a plan view of the top surface of the top plate of the injector shown in FIG. 4.
FIG. 6 is a plan view of the bottom surface of the top plate of the injector shown in FIG. 4.
FIG. 7 is a plan view of the top surface of the middle plate of the injector shown in FIG. 4.
FIG. 8 is a cross-sectional view of the middle plate of the injector shown in FIG. 4.
FIG. 9 is a plan view of the top surface of the bottom plate of the injector shown in FIG. 4.
FIG. 10 is a plan view of the bottom surface of the bottom plate of the injector shown in FIG. 4.
FIG. 11 is an enlarged partial side view of the chute of the injector.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, wherein like components are designated by like reference numerals in the various figures, attention is initially directed to FIG. 1. The figure represents a schematic cross-sectional view of an atmospheric pressure chemical vapor deposition apparatus 20. The apparatus 20 includes a muffle 22 and a conveyor belt 24. The conveyor belt 24 delivers a substrate or wafer 26 into the muffle 22 which includes a coating chamber 28.
The wafer or substrate 26 moves along the conveyor belt 24 into the muffle 22 toward and through the coating chamber 28. In the coating chamber 28, the chemical delivery system 34 produces a chemical vapor atmosphere. The chemical delivery system 34 includes a number of delivery lines 35 which individually convey gaseous chemicals (gases or vapors) to the injector assembly 31. The vapor atmosphere produced by the chemical delivery system 34 is cleared by the exhaust system 30 which includes a number of exhaust lines 32.
As the wafer or substrate 26 passes through the chemical vapor atmosphere within the coating chamber 28, a reaction between the individual vapors occurs, or a reaction between the individual vapors and the wafer or substrate 26 occurs. In either case, a film or layer is deposited on the wafer or substrate 26 as a result of the reaction. In order to realize a uniform film or layer on the wafer or substrate, the injector 31 must generate a uniform flow for the different gases and then mix those gases in a uniform manner.
A prior art approach to realizing these objectives is depicted in FIG. 2. An injector 31A includes several conduits 38 which discretely convey gaseous chemicals. Each conduit leads to a chamber 40 where the gases diffuse, but remain separated. The gases are force to the bottom of each of the chambers 40 where they are free to interact with one another and the wafer or substrate 26, resulting in a film or layer on the wafer or substrate 26. As can be appreciated from the figure, the conduits 38 feeding the expansive chambers 40 with gases provide inadequate flow control to insure a uniform chemical reaction when the gases eventually meet above the wafer or substrate 26.
This prior art problem was alleviated by the prior art approach depicted in FIG. 3. The figure depicts a chemical delivery system 34 including delivery lines 35 and an injector 31B. The injector includes primary distribution plenums 50 which lead to openings 54. In turn, the openings 54 lead to secondary plenums 58 which then lead to ports 62. The gases interact after they leave ports 62. This approach lends itself to enhanced uniform flow control of gases. On the other hand, flow control can be improved.
The injector of the present invention is depicted in FIG. 4. The chemical delivery lines 35 of the chemical delivery system 34 lead to the injector 36. In the present embodiment, the injector 36 includes stacked plates, a top (first) plate 66, middle (second) plate 68, and a bottom (third) plate 70. Positioned beneath the bottom plate 70 is a chute 96. A cooling plate 72 surrounds the chute 96. The region between the chute 96 and the cooling plate 72 defines ducts 102. Preferably, the injector is constructed of aluminum.
It is noted that the width of the chute 96 is depicted in FIG. 4 as being above only a small portion of the wafer 26. On the other hand, a view along the length of the injector would depict that the chute 96 in that dimension extends across the entire wafer 26.
The details of the various plates which comprise the injector will now be described. Turning to FIG. 5, depicted therein is the top surface of the top plate 66. Arrow 77 indicates the width of the plate, while arrow 79 indicates its length. In this embodiment, the top plate 66 includes three input passages 76. A chemical delivery line 35 is attached to each passage 76, as can be appreciated by referring to FIG. 4. The plate also includes several fastener receiving holes 86, which are used to connect the stacked plates to one another.
The dimensions may vary, but in this embodiment the first plate 66 is approximately 15 inches in length and approximately 2 inches in width. The plate is approximately 0.72 inches deep. The conduits 76 are approximately 0.272 inches in diameter. The fastening holes 82 are approximately 0.218 inches in diameter.
The passages 76 of the top plate 66 individually lead to plenums 78 where the gases spread lengthwise, as can be appreciated with reference to FIG. 4. The plenums 78 feed individual linear hole arrays 80. The nature of the linear hole arrays may be appreciated with reference to FIG. 6. The figure depicts the bottom surface of the top plate 66 which, in this embodiment, includes three linear hole arrays 80, running along the length of the plate, and each communicating with a plenum 78. In this embodiment, each hole 85 of the linear hole array 80 is approximately 0.052 inches in diameter. Each of the three linear hole arrays 80 includes 11 holes 85.
Thus, in the present embodiment, three delivery lines 35 convey three gaseous chemicals to the first plate 66. Each chemical is individually conveyed through the plate by a passage 76, a plenum 78, and an linear hole array 80. The linear hole arrays 80 of the first plate convey the gases to the second plate 68.
FIG. 7 depicts the top surface of the second plate 68 which is aligned with and attached to the bottom of the first plate 66. More particularly, the three linear hole arrays 80 at the bottom of the first plate 66 are positioned over and aligned with slot 90, which is aligned directly beneath a hole array 80 from the first plate 66. The slot 90 leads to a trough 92. At the bottom of each trough is another linear hole array 81.
Note that in this embodiment, each linear hole array 81 of the second plate 68 includes 34 holes 85A, a larger number of holes than in the top plate hole array. Each hole 85A is approximately 0.028 inches in diameter. Each slot 90 is approximately 0.125 inches long and 0.010 inches deep. Each trough 92 is approximately 0.125 inches in diameter and 0.2 inches deep.
The precise nature of this configuration is more fully appreciated with reference to FIG. 8. The figure depicts the cross-sectional width oriented view of the middle plate 68. The nature of the slot 90 and its relation to the trough 92 are more fully appreciated with reference to the figure.
Returning to FIG. 7, a few additional elements of the invention are depicted. Groove 94 surrounds the three inlet linear hole arrays 88 and is adopted to receive a sealing ring. The figure also depicts several fastening holes 86, used to attach the plates to one another.
Referring to FIG. 9, the top surface of the bottom plate 70 is depicted. The three linear hole arrays 81 at the bottom of the second plate 68 are positioned over the three slots 91. As before, each slot 91 leads to a trough 93, which in turn leads to a linear hole array 83, positioned at the base of the trough 93.
The three linear hole arrays 83 of the third plate 70 lead to chute 96, as depicted in FIGS. 4 and 11. The connection between these linear hole arrays 83 and the chute 96 is more fully appreciated with reference to FIG. 10. The figure depicts the bottom surface of the bottom plate 70 which includes two linear hole arrays 83 and a central passage 98. Each linear hole array 83 includes 133 holes 85B, each hole 85B is approximately 0.020 inches in diameter.
Returning to FIG. 11, depicted therein is a cross-sectional view of the chute 96, chute walls 97 defining the central passage 98, and two linear hole arrays 83A (in communication with the linear hole arrays 83 of the third plate 70). The chute 96 is surrounded by cooling plate 72, the region therebetween forming slots 100 and ducts 102. Chute walls 97 continue to partition the individual gases. The gases are finally free to interact at the base of the chute 96, which is approximately 1/4 inch above the surface of the wafer substrate 26. The chute 96 is about 0.725 inches from top to bottom.
In sum, in the particular embodiment disclosed, the three delivery lines 35, of the chemical delivery system 34, are attached to three passages 76 of the top plate 66. The delivery lines 35 may, for instance, convey tungsten hexa-fluoride in one line and nitrogen and hydrogen in the other two to realize a blanket tungsten coating.
Whatever gases are involved, each of them discretely proceeds through a plenum 78, and a first plate linear hole array 80. Each gas then proceeds through the second plate 68 which includes a second plate slot 90, a second plate trough 92, a second plate linear hole array 81 which includes more holes than the first plate linear hole array 80. Each gas then proceeds through the third plate 70 which includes a third plate slot 91, a third plate trough 93, and a third plate linear hole array 83 which includes more holes than the second plate linear hole array 81. At the bottom of this third plate is the chute 96. The gases' input into one of the delivery lines 35 is conveyed through the passage 98, while the gases fed into the other two delivery lines 35 are conveyed through the ducts 102. At the bottom of the chute 96, the three gases are free to react with one another.
Consequently, in this particular embodiment of the invention, the three gases may be viewed as discretely flowing through cascaded hole arrays. The cascaded hole arrays include three distribution stages (each distribution stage being a plate). More particularly, each cascaded hole array includes the sequence of elements set forth in the previous paragraph. Particularly noteworthy is the fact that each cascaded hole array includes a number of linear hole arrays and as the gases cascade down the cascaded hole arrays they encounter a linear hole array with more holes. This feature leads to a laminar-like chemical flow. This laminar-like flow is enhanced by the series of slots, troughs, and other features disclosed in this particular embodiment.
Through this cascading action, the individual gases achieve a laminar-like flow heretofore unknown in the art. This resultant flow lends itself to improved interaction between the gases when they finally interact. Moreover, this improved chemical flow leads to more uniform and precise layer or film on the wafer or substrate.
Thus, it is apparent that there has been provided an injector and method for delivering gaseous chemicals to a surface that fully satisfies the objects, aims, and advantages set forth above.
While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and scope of the appended claims. | What is disclosed is an injector of the type commonly used in atmospheric pressure chemical vapor deposition equipment. The injector includes a number of plates with a number of linear hole arrays. The plates are layered in order to produce a number of cascaded holes arrays. The layered plates define a hole matrix. A chute is positioned beneath the hole matrix. On both sides of the chute is a cooling plate. The chute includes a passage, the regions between the cooling plate and the chute form ducts. The top of the hole matrix receives a number of gases and discretely conveys them to the top of the individual cascaded hole arrays. The gaseous chemicals are then forced through the cascaded hole arrays which induces the gases to flow in an increasingly uniform manner. The gases are then individually fed to the passage and ducts which convey them to a region above the surface where the gases are exposed to one another, react and form a layer on the surface. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ozonizer for generating ozone from the oxygen contained in air, and more particularly, to an ozonizer well adapted for use in 24-hour working baths, circulating water purifiers such as a Jacuzzi, ozonized water generators, water purifiers and the like. Furthermore, the present invention relates to a water purifier equipped with an ozonizer for use with 24-hour working baths, Jacuzzis, ponds, water tanks and pools, and to a method of cleaning the ozonizer.
2. Description of the Related Art
Ozone has conventionally been used in industrial as well as household applications for purifying and deodorizing water and the like. A relatively small-sized apparatus for generating ozone for household use employs a creeping discharge element including a filamentary discharge electrode and a surface induction electrode disposed opposite each other and a dielectric layer interposed therebetween. A voltage is applied between the electrodes to thereby excite discharge on the filamentary discharge electrode. This type of creeping discharge element is disclosed, for example, in U.S. Pat. No. 4,652,318.
More particularly, such ozonizers include a creeping discharge element, a power circuit and a resin case for housing the creeping discharge element and power circuit. The creeping discharge element is typically composed of a dielectric layer formed from ceramic, a filamentary discharge electrode disposed on one surface of the dielectric layer, and a surface induction layer disposed on the other surface of the dielectric layer opposite the filamentary discharge electrode. The power circuit applies a voltage between the filamentary discharge electrode and surface induction electrode so as to excite a discharge from the filamentary discharge electrode.
In Japanese Patent Application Laid-Open (kokai) No. 8-171979, the present applicant proposed an ozonizer employing a creeping discharge element for use in the circulating water purifier of a 24-hour working bath. This ozonizer is described below with reference to FIGS. 8A-8D. FIG. 8B shows a plan view of the ozonizer 310. FIG. 8A shows a plan view of a cover 330 that attaches to the ozonizer. FIG. 8C shows the ozonizer of FIG. 8B as viewed in the direction of arrow C of FIG. 8B. FIG. 8D shows a sectional view along line 8D--8D of FIG. 8B.
As shown in FIG. 8D, a creeping discharge element, i.e. an ozonizing element, is formed as part of a high-voltage generating board 350 including a high-voltage-generating circuit element 352. Specifically, the high-voltage generating board 350 is formed from a dielectric having a surface induction electrode 366 embedded in a portion thereof and a filamentary discharge electrode 368 disposed on the top surface thereof. The high-voltage generating board 350 is disposed within a housing 320 such that the filamentary discharge electrode 368 mounted on the high-voltage generating board 350 faces an opening 320a formed in the housing 320. The cover shown in FIG. 8A is attached to the housing 320 so as to close the opening 320a, to thereby prevent ozone leakage from the housing 320.
Large-sized creeping discharge type ozonizers for industrial use employ pure oxygen or dry air as a starting material, whereas small-sized ozonizers for household use employing the above-described creeping discharge element use untreated air as a starting material. Accordingly, small-sized ozonizers are disadvantageous in that when the creeping discharge element is used continuously, the material of the creeping discharge element reacts with nitrogen or the like in air to form an ammonium salt on the element surface. The ammonium salt hinders creeping discharge with a resulting failure in the proper generation of ozone. Thus, for such small-sized creeping discharge type ozonizers, it is important to check whether ozone continues to be generated. Hitherto, this checking was difficult to conduct.
More particularly, because untreated air has a humidity higher than that of artificially-produced dry air, large amounts of nitrogen oxides are produced when ozone is generated by discharge.
The nitrogen oxides chemically react with ammonia present in the air to produce ammonium nitrate. The thus-produced ammonium nitrate covers the filamentary discharge electrode.
Accordingly, the density of the electric field generated by the filamentary discharge electrode is reduced. Also, ammonium nitrate covering the filamentary discharge electrode absorbs water present in the air and becomes electrically conductive, thus increasing the apparent area of the filamentary discharge electrode. As a result, the capacitance of the dielectric increases.
That is, in a conventional ozonizer, because ammonium nitrate covers the filamentary discharge electrode, the density of the electric field generated by the filamentary discharge electrode is reduced. The capacitance of the dielectric increases, resulting in reduced ozone generation.
Conventionally, therefore, the ozonizer is disassembled, and adhering ammonium nitrate is wiped off from the filamentary discharge electrode using water or a solvent. That is, a conventional ozonizer must be maintained through manual labor.
After cleaning, the creeping discharge element resumes discharging to thereby generate ozone. However, a high electric potential of several kilovolts is applied to the creeping discharge element even though the current flowing through the element is very small. Therefore, it is dangerous for an ordinary household user to clean the element. That is, even though designed for household use, conventional ozonizers are difficult to maintain.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an ozonizer which is easy to maintain and a water purifier equipped with the ozonizer.
Yet another object of the present invention is to provide an ozonizer, a water purifier and a method of cleaning the ozonizer which allows for easy removal of at least ammonium nitrate among those substances adhering to a discharge element without the need for manual cleaning and which dispenses with the need for touching the discharge element.
The above objects have been achieved according to a first aspect of the present invention by providing an ozonizer which comprises an ozonizing discharge element, an electric circuit for applying a voltage to said ozonizing discharge element so as to produce an ozone-generating discharge; a housing having an opening formed therein for receiving said ozonizing discharge element, a cover which seals the ozonizing discharge element in said housing, and means for turning off the voltage applied to said ozonizing discharge element when the cover is removed.
In the ozonizer according to the above first aspect of the present invention, it is safe to clean the ozonizing discharge element because the voltage applied to the ozonizing discharge element is turned off when the cover is removed.
In the ozonizer, preferably at least part of the cover or housing is transparent so as to enable visual detection of the discharge state of the ozonizing discharge element. Instead of visual inspection, for example, a light sensor which detects a discharge light of the ozonizing discharge element through the transparent cover or housing may be placed outside the transparent cover or housing to confirm the discharge state of the ozonizing discharge element. Thus, the ozonizer is easy to maintain.
According to a second aspect, the present invention provides an ozonizer which comprises an ozonizing discharging element, an electric circuit for applying a voltage to said ozonizing discharge element so as to produce an ozone-generating discharge, a housing having an opening formed therein for receiving said ozonizing discharge element, and a cover which seals the ozonizing discharge element in said housing, wherein at least part of said cover or housing is transparent so as to enable visual detection of the discharge state of the ozonizing discharge element.
In the ozonizer according to the above second aspect of the present invention, the discharge state of the ozonizing discharge element can be visually observed or easily detected with a sensor.
Also, in the above-described ozonizers, an ozone discharge pipe is preferably provided on said housing separate from said cover.
Namely, because a piping portion is provided on the housing side, the piping portion, to which an ozone pipe is connected, remains stationary when the cover is removed. Accordingly, protection is provided against accidentally disconnecting the ozone pipe from the piping portion, to thereby prevent a gas leak which might otherwise result and assure safe operation.
In the above-described ozonizers, each of the housing and the cover preferably comprises engagement means for fixedly engaging one another. More preferably, one of the engagement means comprises a hook portion and the other comprises an engagement portion for engaging the hook portion.
In this case, because the housing and the cover are fixed together via the engagement means, the cover is easily detached from or attached to the housing by disengaging or engaging the engagement means.
According to a third aspect, the present invention provides a water purifier equipped with an ozonizer which comprises an ozonizing discharge element, an electric circuit for applying a voltage to said ozonizing discharge element so as to produce an ozone-generating discharge; a housing having an opening formed therein for receiving the ozonizing discharge element, and a cover which seals said ozonizing discharge element in said housing, wherein at least part of the cover or housing is transparent so as to enable visual detection of the discharge state of the ozonizing discharge element.
In the water purifier according to the above third aspect of the present invention, the discharge state of the ozonizing discharge element can be visually observed with ease because at least a part of the cover or housing is transparent. Thus, the water purifier is easy to maintain.
The water purifier preferably includes a window through which the transparent portion of the cover of the ozonizer can be visually observed from the outside. Thus, it is easy to visually observe the discharge state of the ozonizing discharge element.
According to a fourth aspect, the present invention provides a water purifier equipped with an ozonizer which comprises an ozonizing discharge element, a power unit for energizing and applying a voltage to said ozonizing discharge element so as to produce an ozone-generating discharge, a housing having an opening formed therein for receiving said ozonizing discharge element, a cover which seals said ozonizing discharge element in said housing, and means for turning off the voltage applied to the ozonizing discharge element when the cover is removed.
In the water purifier according to the above fourth aspect of the present invention, it is safe to clean the ozonizing discharge element because the voltage applied to the ozonizing discharge element is turned off when the cover is removed.
Furthermore, in the above first through fourth aspects of the present invention, the cover preferably hermetically seals the ozonizing discharge element in the housing.
According to a fifth aspect, the present invention provides an improved ozonizer having a discharge element for generating ozone by electric discharge. The ozonizer includes a heat generating element for generating heat upon input of current so as to heat the discharge element. The ozonizer also includes a heat generating circuit for supplying current to the heat generating element so as to heat the heat generating element and thereby heat the discharge element to a predetermined temperature. This induces scattering of at least ammonium nitrate molecules among those substances adhering to the discharge element.
In the ozonizer according to the above fifth aspect of the present invention, the discharge element preferably includes a dielectric formed from ceramic, a discharge electrode disposed on one surface of the dielectric, and an induction electrode disposed in the dielectric opposed to and separate from the discharge electrode. The heat generating element is preferably disposed on the other surface of the dielectric opposed to the induction electrode.
Because ammonium nitrate adhering to the discharge element can be evaporated by operating the heat generating circuit, the user does not have to touch or handle the discharge element to clean the same. In contrast, in a conventional cleaning practice, the user wipes off adhering ammonium nitrate from a discharge element using water or a solvent.
In the ozonizer according to the above fifth aspect of the present invention, the discharge element is heated preferably to a set temperature within a range of from 200° C. to 500° C., more preferably, within a range of from 250° C. to 350° C. A broad temperature range of from 200° C. to 500° C. is employed because ammonium nitrate adhering to the discharge element can be evaporated at a temperature within this range. Ammonium nitrate adhering to the discharge element begins to evaporate at a temperature slightly above 200° C. However, in order to reduce the evaporation time, the discharge element is preferably heated to a temperature of at least 250° C. Also, if the discharge element is heated to an excessively high temperature, the resin case which houses the discharge element may become deformed. Therefore, a temperature range of from 250° C. to 350° C. is more preferred.
In the ozonizer according to the above fifth aspect of the present invention, a heat generating time control means is preferably provided in order to control the period of time during which the heat generating element generates heat.
In this manner, the heating time for heating the discharge element can be controlled. That is, the discharge element can be maintained at the set temperature under control of the heat generating time control means.
The heat generating time control means preferably comprises a thermistor having a positive characteristic connected in series with the heat generating element.
Because the thermistor having a positive characteristic increases in resistance with an increase in temperature, the thermistor connected to the heat generating element shuts off current flow to the heat generating element after a predetermined time has elapsed, to thereby prevent overheating of the discharge element.
Also, the use of the thermistor reduces the cost of the ozonizer as compared with the case where a complicated timer circuit is employed.
The ozonizer according to the above fifth aspect of the present invention preferably comprises a discharge element housed in a resin case. The induction electrode is connected to a high-voltage supply, and the discharge electrode is connected to ground. A portion of the discharge electrode is covered with a protective film against wear caused by discharge, and the uncovered portion of the discharge electrode is exposed from one surface of the dielectric.
In this structure, the induction electrode is connected to a high-voltage supply, and the discharge electrode is connected to ground. Therefore, even when water enters the case and wets the discharge electrode, the electric potential between the electrodes is rendered identical to that of the water. Accordingly, one would not suffer electric shock by touching the ozonizer.
Furthermore, the discharge electrode excluding a certain portion thereof is covered with a protective film against wear caused by discharge, and the uncovered portion is exposed from one surface of the dielectric. Accordingly, even if the dielectric breaks with the resulting exposure of a high-voltage portion (for example, a portion of the induction electrode or heat generating element), current flows into the exposed portion of the discharge electrode such that electric shock is prevented.
The discharge element is preferably housed in a case with a heat resistant rubber gasket interposed therebetween. This prevents heat generated by the discharge element from being transmitted to the resin case which might otherwise cause the resin case to deteriorate or deform.
In the ozonizer according to the above fifth aspect of the present invention, a timer is preferably provided in order to control the period of time during which electrical power is supplied to the discharge element and the heat generating circuit.
According to a sixth aspect, the present invention provides a water purifier which includes the above described ozonizer, a filter for filtering water, and ozone discharging means for discharging ozone generated by the ozonizer into water filtered through the filter.
When a water purifier equipped with an ozonizer is disassembled and maintained, water entering into the ozonizer may cause electric shock. By contrast, in the case of a water purifier equipped with the ozonizer according to the present invention, the ozonizer can be maintained merely by operating the heat generating circuit with no need of disassembly. Thus, maintaining the ozonizer does not involve the risk of electric shock.
According to a seventh aspect, the present invention provides a method of cleaning an ozonizer having a discharge element for generating ozone by electric discharge. In this method, the discharge element is heated to a predetermined temperature using a heat generating element and a heat generating circuit for supplying current to the heat generating element so as to heat the heat generating element, to thereby evaporate at least ammonium nitrate among those substances adhering to the discharge element.
Because the cleaning method of the present invention allows a user to evaporate ammonium nitrate adhering to the discharge element by operating the heat generating circuit, the invention dispenses with the need for handling the discharge element in order to clean the same. In contrast, in a conventional cleaning practice, the user wipes off adhering ammonium nitrate from a discharge element using water or a solvent.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be understood by reference to the following detailed description of the preferred embodiments when considered with the accompanying drawings, in which:
FIG. 1 is a schematic view showing the structure of a circulating water purifier according to a first embodiment of the present invention;
FIG. 2A is a perspective front-side view of an ozonizing element used in an ozonizer according to the first embodiment;
FIG. 2B is a perspective back-side view of the ozonizing element of FIG. 2A;
FIG. 2C is a side view of another type of ozonizing element according to another embodiment of the present invention;
FIG. 3A is a front view of the ozonizer according to the first embodiment;
FIG. 3B is a side view of the ozonizer of FIG. 3A;
FIG. 3C is a view showing the ozonizer of FIG. 3A with its cover separated therefrom;
FIG. 3D is a sectional view along line 3D--3D of FIG. 3A;
FIG. 3E is a bottom view of the ozonizer of FIG. 3A;
FIGS. 3F and 3G show the ozonizer of FIG. 3A mounted on the circulating water purifier of FIG. 1;
FIGS. 4A and 4B are circuit diagrams of the high-voltage generating board of the ozonizer according to the first embodiment;
FIG. 4C is a circuit diagram of the high-voltage generating board of an ozonizer according to a second embodiment of the present invention;
FIG. 5A is a front view of the ozonizer according to the second to embodiment;
FIG. 5B is a side view of the ozonizer of FIG. 5A;
FIG. 5C is a view showing the ozonizer of FIG. 5A with its cover separated therefrom;
FIG. 5D is a sectional view along line 5D--5D of FIG. 5A;
FIG. 5E is a bottom view of the ozonizer of FIG. 5A;
FIG. 6 is a front view of an ozonizer according to a modification of the second embodiment;
FIG. 7A is a perspective view of an ozonizer according to a third embodiment of the present invention;
FIG. 7B is a side view of the cover of the ozonizer of FIG. 7A;
FIG. 7C is a side view of the housing of the ozonizer of FIG. 7A;
FIG. 7D is a sectional view along line 7D--7D of FIG. 7A;
FIG. 7E is a sectional view of an ozonizer according to a modification of the third embodiment;
FIG. 8A is a plan view of a cover for mounting on a conventional ozonizer;
FIG. 8B is a plan view of a conventional ozonizer;
FIG. 8C is a view of the ozonizer of FIG. 8B in the direction of arrow C of FIG. 8B;
FIG. 8D is a sectional view along line 8D--8D of FIG. 8B.
FIG. 9 is an exploded view of an ozonizer according to an embodiment of the present invention;
FIG. 10A is an exploded view of a discharge element employed in the ozonizer of FIG. 9;
FIG. 10B is a perspective bottom view of the discharge element of FIG. 10A; and
FIG. 11 is a circuit diagram of an electric circuit used in the ozonizer of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in greater detail below with reference to the drawings.
FIG. 1 shows the structure of a circulating water purifier 80 for use in a 24-hour working-type Jacuzzi (whirlpool bath) according to a first embodiment of the present invention.
Hot water in a bathtub 98 is drawn in through a water intake unit 82, and debris such as hair is filtered from the hot water by a filter 84 disposed within the water intake unit 82. Bucket 86 purifies the filtered hot water drawn in through the water intake unit 82. The bucket 86 contains activated carbon 86B and porous natural stone 86A containing silicon dioxide (SiO 2 ) as a main component, and a temperature sensor 88 is disposed at the bottom of the bucket 86. Microorganisms adhering to the natural stone 86A and activated carbon 86B act as a biofilter to decompose impurities contained in the hot water. The temperature of the hot water leaving the bucket 86 is monitored by the temperature sensor 88, and the hot water is heated to an appropriate bathing temperature of 42° C. to 44° C. by a heater 90 equipped with a ceramic heater (not shown). Hot water heated by the heater 90 is pumped by a circulation pump 92 and discharged into the bathtub 98 from a jet nozzle 96 via a water flow sensor 94. The water flow sensor 94 monitors water flow from the circulation pump 92 and turns off the circulation pump 92 when needed to protect its built-in motor. This occurs, for example, when the filter 84 is clogged and hot water in the bathtub 98 is not being pumped to the circulation pump 92.
The circulating water purifier 80 contains an ozonizer 10 for generating ozone from oxygen contained in air. A first solenoid valve 16A is mounted on a first air intake pipe 12a used for drawing air into the ozonizer 10. A pipe 18a open to the atmosphere at the tip end thereof is connected to the first solenoid valve 16A. A second air intake pipe 12b is connected to a discharge pipe 14 used for discharging ozone generated in the ozonizer 10 into the jet nozzle 96. A second solenoid valve 16B is mounted at the tip end of the second air intake pipe 12b. A pipe 18b open to the atmosphere at the tip end thereof is connected to the second solenoid valve 16B.
Under control of a controller (not shown), the ozonizer 10 is operated intermittently (for example, a 10-minute operation followed by a 50-minute pause). While the ozonizer 10 is operating, the first solenoid valve 16A is opened, and the second solenoid valve 16B is closed, so that air is taken into the ozonizer 10 through the first solenoid valve 16A to thereby generate ozone. The ozone thus generated is drawn into the jet nozzle 96 via the discharge pipe 14 and discharged into the hot water contained in the bathtub 98 in the form of bubbles. Thus, the ozone is introduced into the hot water. On the other hand, while operation of the ozonizer 10 is suspended, the first solenoid valve 16A is closed, and the second solenoid valve 16B is opened. As a result, air is taken in through the second solenoid valve 16B and drawn into the discharge pipe 14 via the second air intake pipe 12b. Then, air is discharged from the jet nozzle 96 into hot water contained in the bathtub 98 in the form of bubbles.
Next, an ozonizing element accommodated in the ozonizer 10 is described below with reference to FIGS. 2A-2C.
As shown in FIG. 2A, a creeping discharge type ozonizing element 60 includes a first dielectric layer 62 and a second dielectric layer 64, both formed from ceramic. A surface induction electrode 66 is interposed between the first dielectric layer 62 and the second dielectric layer 64. A filamentary discharge electrode 68 is disposed on the upper surface of the first dielectric layer 62. The surface of the filamentary discharge electrode 68 is covered with a glaze layer or ceramic layer (not shown) to prevent wear due to discharge. FIG. 2B shows the ozonizing element 60 of FIG. 2A viewed from underneath (back side). A terminal 66a connected to the surface induction electrode 66 and a terminal 68a connected to the filamentary discharge electrode 68 are exposed on the surface of the second induction layer 64. Also, heaters H are mounted on the surface of the second dielectric layer 64 to prevent dew condensation on the ozonizing element 60 which is described below. Power from a high-voltage generating board, which is also described below, is supplied to the electrodes 66 and 68 via the terminals 66a and 68a.
FIG. 2C shows another type of ozonizing element 160 according to another embodiment of the present invention. In the creeping discharge type ozonization element 160, a filamentary discharge electrode 168 is disposed on the upper surface of a dielectric layer 164, and electrodes 167a and 167b for connection to a power supply are disposed on the lower surface of the dielectric layer 164.
Next, the structure of the ozonizer 10 shown in FIG. 1 is described below with reference to FIGS. 3A-3G. FIG. 3A shows a front view of the ozonizer 10; FIG. 3B shows a side view of the ozonizer 10; and FIG. 3C shows the ozonizer 10 with a cover 30 separated therefrom. FIG. 3D shows a sectional view along line 3D--3D of FIG. 3A; FIG. 3E shows a bottom view of the ozonizer 10; FIGS. 3F and 3G show the ozonizer 10 mounted on the circulating water purifier 80.
As shown in FIG. 3C, the ozonizer 10 includes the ozonizing element 60, a box-like housing 20 which accommodates a high-voltage generating board 50, described below, for driving the ozonizing element 60, and a cover 30 for hermetically closing a first opening 20a formed in the housing 20. In the present embodiment, the housing 20 comprises a rectangular box-shape, but may assume various kinds of shapes such as a cylindrical shape.
The housing 20 is integrally formed from a material resistant to ozone-induced oxidation such as vinyl chloride, stainless steel, Teflon, or the like. A flange portion 20b having a second opening 20c formed therein is provided inside the housing 20. The ozonizing element 60 is mounted on the flange portion 20b via a packing 24 formed from an ozone-resistant fluorine-containing rubber. The packing 24 prevents ozone generated by the ozonizer 10 from leaking into the high-voltage generating board 50 side through the second opening 20c. A through-hole 20d is provided in a side wall of the housing 20. A screwdriver can be inserted through the through-hole 20d to adjust a variable resistor, described below, provided on the high-voltage generating board 50. On the bottom portion of the housing 20 are formed a socket flange 20f for accommodating sockets 22a and 22b and six screw flanges 20e through which corresponding screws 28 (see FIG. 3B) are inserted in order to fix the cover 30 on the housing 20. As shown in FIG. 3D, the sockets 22a and 22b are connected to the high-voltage generating board 50 via lead wires 56a and 56b.
The cover 30 is formed from a transparent vinyl chloride which is resistant to ozone. Here, the term "transparent" means a degree of transparency such that a user can determine whether or not there is a discharge at the inner ozonizing element 60, and thus includes semitransparent materials. Therefore, in order to achieve the above objects of the present invention, the cover 30 is preferably located so as to face the filamentary electrode 68 side of the creeping discharge element (creeping discharge type ozonization element) 60, namely, the side of the creeping discharge element 60 where corona discharge occurs. As shown in FIG. 3C, an upright wall 30a is formed on the cover 30. The upright wall 30a is inserted into the first opening 20a of the housing 20 and abuts the flange portion 20b via the packing 24 to thereby prevent ozone from leaking out of the apparatus.
An air intake pipe 30b for taking in air and an ozone discharge pipe 30c for discharging ozone are provided on the cover 30. The first air intake pipe 12a shown in FIG. 1 is connected to the air intake pipe 30b, whereas a discharge pipe 14 shown in FIG. 1 is connected to the ozone discharge pipe 30c. On the periphery of the cover 30, six screw flanges 30d are provided into which the corresponding screws 28 are driven in order to fix the cover 30 on the housing 20 (see FIG. 3B), and a terminal flange 30e is provided which supports terminals 32a and 32b for inserting into the sockets 22a and 22b, respectively. In the terminal flange 30e, external lead wires 54a and 54b are connected to the terminals 32a and 32b, respectively.
Also, as shown in FIGS. 3B and 3C, a pair of mounting brackets 30f extend longitudinally outward from both ends of the cover 30. As shown in FIG. 3F, the ozonizer 10 is fixedly mounted on the housing 81 of the circulating water purifier 80 by means of screws 34 which are inserted through the through-holes 30g formed in the mounting brackets 30f.
As shown in FIG. 3E, the ozonizing element 60 can be visually observed because the cover 30 is transparent. As shown in FIG. 3F, the ozonizer 10 is mounted on a window 81a formed in the housing 81 of the circulating water purifier 80. Accordingly, the discharge state of the ozonizer 10 can be monitored from outside the circulating water purifier 80. In FIG. 3F, the window 81a is formed in the housing 31 in the form of an opening. However, as shown in FIG. 3G, a glass plate 83 may be fit into the window 81a.
As described above, the ozonizer 10 allows a user to monitor the discharge state of the ozonizing element 60 from outside the circulating water purifier 80. When the discharge is properly carried out, a purple corona discharge light shines around the filamentary discharge electrode 68 of the ozonizing element 60 shown in FIG. 3E. The corona discharge light indicates that ozone is being generated.
In contrast, when the discharge is disabled due to accumulation of an ammonium salt on the ozonizing element 60 over long-term use, the above-described discharge light is not observed. In that case, the screws 28 (see FIG. 3F) are removed to thereby separate the cover 30 from the housing 20 as shown in FIG. 3C. Then, the ozonizing element 60 equipped in the housing 20 is cleaned using water or a solvent, to thereby remove the accumulated ammonium salt. This restores the ozonizing element 60 which can once again generate ozone. When the cover 30 is separated from the housing 20, the terminals 32a and 32b are disconnected from the sockets 22a and 22b, respectively, whereby the power supply is shut off. Thus, voltage applied to the ozonizing element 60 is reliably turned off. In yet another embodiment, a push-button switch (on when depressed) connected in series with the power supply may be employed. In this embodiment, the push-button switch is mounted such that the cover 30 depresses and engages the switch when fixed to the housing 20. When the cover 30 is removed, the circuit is broken such that the voltage applied to the ozonizing element 60 is reliably turned off. This enables a user to safely carry out the above-described cleaning work.
The circuit of the high-voltage generating board 50 is described below with reference to FIGS. 4A-4C. As shown in FIG. 4A, the high-voltage generating board 50 has an IC1 which receives an external electric potential of 12 V sequentially via the lead wires 54a and 54b, the terminals 32a and 32b, the sockets 22a and 22b, and the lead wires 56a and 56b (see FIG. 3D) and which provides a regulated voltage supply. The heater H for heating the ozonizing element 60 is connected to the IC1. Being located on the back surface side of the ozonizing element 60, the heater H continues heating the ozonizing element 60 to a temperature of approximately 40° C. even when power to the ozonizing element 60 is shut off, to thereby prevent dew condensation on the ozonizing element 60. In FIG. 4B, the oscillation of transistor TR1 can be stopped by applying a voltage from a terminal 69. This discontinues ozone generation while power is continuously supplied to the heater H.
As shown in FIG. 4B, the high-voltage generating board 50 includes a transformer T, the transistor TR1, a transistor TR2, an IC2 and a variable resistor RV. The transistor TR1 together with the transformer T oscillate to generate a high electric potential of 5 kV at 40 kHz. The thus-generated high electric potential of 5 kV is applied to the ozonizing element 60. The transistor TR2 is adapted to cause the transistor TR1 to start or stop oscillating. The IC2 is used to adjust the amount of ozone that is generated by the ozonizing element 60 by altering its duty ratio. In order to adjust the value of the variable resistor RV to thereby set the duty ratio of the IC2, a user may insert a screwdriver through the through-hole 20d formed in the housing 20 as shown in FIG. 3A. The high-voltage generating board 50 can include a power source such as a battery.
Next, an ozonizer 110 according to a second embodiment of the present invention is described below with reference to FIGS. 5A-5E. As in the case of the first embodiment, the ozonizer 110 is also intended for a circulating water purifier for use in a 24-hour working bath. A circulating water purifier employing the ozonizer 110 is similar to that of the first embodiment described above. Thus, a description thereof is not repeated. Members of the ozonizer 110 similar to those of the ozonizer 10 are denoted by common reference numerals, and the description thereof is not repeated.
FIG. 5A shows a front view of the ozonizer 110; FIG. 5B shows a side view of the ozonizer 110; and FIG. 5C shows the ozonizer 110 with a cover 130 separated therefrom. FIG. 5D shows a sectional view along line 5D--5D of FIG. 5A, and FIG. 5E is a bottom view of the ozonizer 110.
As shown in FIG. 5C, the ozonizer 110 includes the ozonizing element 60 which has been described above with reference to FIGS. 2A-2C, a box-like housing 120 which accommodates a high-voltage generating board 150 (FIG. 5D), and a cover 130 for hermetically closing a first opening 120a of the housing 120.
The housing 120 is integrally formed from vinyl chloride. A flange portion 120b having a second opening 120c formed therein (see FIG. 5A) is provided inside the housing 120. The ozonizing element 60 is mounted on the flange portion 120b via a packing 124 formed from ozone-resistant fluorine-containing rubber. On the bottom portion of the housing 120 are provided a socket flange 120f for accommodating sockets 122a and 122b and six screw flanges 120e through which corresponding screws 28 are inserted in order to fix the cover 130 on the housing 120. A through-hole 120d is provided in a side wall of the housing 120 to allow for adjusting the variable resistor of the high-voltage generating board 150. As shown in FIG. 5D, the socket 122a is connected to a lead wire 154b, and the socket 122b is connected to the high-voltage generating board 150 via a lead wire 156b. Furthermore, an external lead wire 154a is directly connected to the high-voltage generating board 150.
In contrast to the ozonizer 10 of the first embodiment which has been described above with reference to FIGS. 3A-3G, in the ozonizer 110 of the second embodiment, an air intake pipe 120h and an ozone discharge pipe 120g are provided on the housing 120. The air intake pipe 12a shown in FIG. 1 is connected to the air intake pipe 120h, and the discharge pipe 14 shown in FIG. 1 is connected to the ozone discharge pipe 120g. Furthermore, a pair of mounting brackets 120j extend longitudinally outward from both ends of the top portion of the housing 120. After the ozonizer 110 is turned upside down from the state shown in FIG. 5A, the ozonizer 110 is fixedly mounted on the housing 81 of the circulating water purifier 80 by means of screws (not shown) which are inserted through through-holes 120k formed in the mounting brackets 120j.
The cover 130 is formed from a transparent vinyl chloride which is resistant to ozone. As shown in FIG. 5C, an upright wall 130a is formed on the cover 130. The upright wall 130a is inserted into the first opening 120a of the housing 120 and abuts the flange portion 120b via the packing 124 to thereby prevent ozone from leaking out of the apparatus as shown in FIG. 5A. Through-holes 130f are formed in the upright wall 130a so as to communicate with the air intake pipe 120h and the ozone discharge pipe 120g provided on the housing 120. A flange 130g extends outward from the cover 130 and abuts the bottom surface 120n of the housing 120 as shown in FIG. 5A. A packing 126 interposed between the flange 130g and the bottom surface 120n maintains a hermetic seal. That is, in the second embodiment, an ozone leak is prevented by using the packings 124 and 126.
On the periphery of the cover 130 are provided six screw flanges 130d through which the corresponding screws 28 (see FIG. 5A) are inserted in order to fix the cover 130 on the housing 120, and a terminal flange 130e which supports a U-shaped jumper 132 for inserting into the sockets 122a and 122b. Via the jumper 132, the external lead wire 154b and the lead wire 156b connected to the high-voltage generating board 150 are connected as described above with reference to FIG. 5D.
The circuit of the high-voltage generating board 50 in the second embodiment is described below with reference to FIGS. 4A-4C.
As shown in FIG. 4C, the high-voltage generating board 50 has the voltage regulating IC1 which receives an external electric potential of 12 V sequentially via the lead wire 154b, the jumper 132 and the lead wire 156b, and via the lead wire 154a. The circuit diagram of the high-voltage generating section of the high-voltage generating board 150 shown in FIG. 4B is similar to that of the first embodiment, and thus a description thereof is not repeated.
As shown in FIG. 5E, the ozonizing element 60 can be visually observed because the cover 130 is transparent. When ozone is not properly generated due to accumulation of ammonium salt on the ozonizing element 60, the cover 130 is removed and the ozonizing element 60 is cleaned. When the cover 130 is removed, the jumper 132 is disconnected from the sockets 122a and 122b as shown in FIG. 5D. As a result, the lead wire 154b is disconnected from the lead wire 156b such the electric potential is no longer applied to the ozonizing element 60. Accordingly, it is then safe to clean the ozonizing element 60.
Also, in the ozonizer 110, an air intake pipe 120h and an ozone discharge pipe 120g are provided on the housing 120. Accordingly, when the cover 130 is removed, the ozone discharge pipe 120g to which the discharge pipe 14 (see FIG. 1) is connected remains stationary. This prevents the discharge pipe 14 from accidentally being disconnected from the ozone discharge pipe 120g with a resultant ozone leak. Thus, safety is assured.
Next, an ozonizer according to a modification of the second embodiment is described below with reference to FIG. 6.
In this modification, a check valve is unitarily provided in an ozone discharge pipe 120v. A slit 120r is formed in the interior of the cylindrical portion 120s of the ozone discharge pipe 120v, and a valve disk 128 moves along the slit 120r. When ozone flows back toward the ozonizer 110, the valve disk 128 abuts the inner wall 120q (a right-hand inner wall in FIG. 6) of the cylindrical portion 120s, to thereby prevent ozone from entering the ozonizer 110. This modification of the second embodiment does not involve installation of an external check valve, thereby avoiding an ozone leak which could otherwise occur at the connection between the check valve and a pipe used for connecting the check valve to the ozonizer 110.
Next, an ozonizer according to a third embodiment of the present invention is described below with reference to FIGS. 7A-7E.
An ozonizer 210 according to the third embodiment has a structure substantially similar to that of the second embodiment as described above with reference to FIGS. 5A-5E. In the second embodiment, the cover 130 is fixed onto the housing 120 with screws, whereas in the third embodiment, a cover 230 is removably attached to a housing 220 by means of hook-like engagement portions.
FIG. 7A shows a perspective view of the ozonizer 210 according to the third embodiment. FIG. 7B shows a side view of the cover 230. FIG. 7C shows a side view of the housing 220. FIG. 7D shows a sectional view along the line 7D--7D of FIG. 7A. As shown in FIG. 7B, the cover 230 has engagement portions 230b serving as the engagement means of the present invention. The engagement portion 230b includes a flexible support piece 230c extending sideward from the cover 230, a hook 230e formed at the tip end of the support piece 230c, and a projection 230d formed substantially at the center of the support piece 230c and projecting upward. Engagement hole portions 220b serving as the engagement means of the present invention are formed in the housing 220 so as to engage the engagement portions 230b of the cover 230. The engagement hole portion 220b includes a stepped engagement portion 220c for engaging the hook 230e and a through-hole 220d for receiving the projection 230d.
In the ozonizer 210, the cover 230 is press-fitted into the housing 220, whereby the hooks 230e of the engagement portions 230b of the cover 230 engage the stepped engagement portions 220c of the engagement hole portions 220b of the housing 220. Thus, the cover 230 is fixed on the housing 220. When the cover 230 is to be removed from the housing 220, the projections 230d of the engagement portions 230b are pressed down to thereby disengage the hooks 230e from the stepped engagement portions 220c of the engagement hole portions 220b. In FIG. 7B, 230a is a peripheral projecting portion for holding a packing inside and providing an air-tight seal.
In the third embodiment, the ozonizing element can be readily cleaned because the cover 230 is removably attached to the housing 220 without using screws. In FIGS. 7A-7E , a jumper used for shutting off power to the high-voltage generating board is omitted for convenience of illustration.
FIG. 7E shows an ozonizer 210 according to a modification of the third embodiment. In this modification, the housing 220 has an engagement portion 220e, and the cover 230 has an engagement hole 230f formed therein.
In the above-described first, second, and third embodiments, the entire cover 30, 130, or 230 is transparent. However, only a portion of the cover 30, 130 or 230 or housing need be transparent so long as the ozonizing element 60 is visible. The transparent part of the cover or housing is preferably made of an inorganic transparent material such as glass as opposed to a transparent plastic (organic) material. This is because the transparent plastic loses its transparency faster than glass over an extended period of use.
In the above-described embodiments, a low electric potential supplied to the high-voltage generating board is disconnected when the cover is removed. Alternatively, a high electric potential applied to the ozonizing element 60 is disconnected when the cover is removed. Also, in the above-described embodiments, the high-voltage generating board is accommodated within the housing. Alternatively, the ozonizing element 60 alone may be accommodated within the housing, and a high electric potential may be applied to the ozonizing element 60 from a high-voltage generating board disposed outside the housing.
Next, the main structure of the ozonizer 10 in accordance with the fifth through seventh aspects of the present invention is described below with reference to FIG. 9.
The ozonizer 10 includes a box-shaped resin case 11, which houses a circuit board 12 on which an electric circuit shown in FIG. 11 is formed. A board 13 is mounted on the top portion of the case 11. The board 13 has four sockets 14, 15, 16, and 17, which are electrically connected to the electric circuit formed on the circuit board 12. A frame-shaped packing 18 formed from a heat resistant rubber is disposed on the peripheral edge of the top of the case 11. An ozone generating element 21 is fitted into the space surrounded by the packing 18. Four connection pins 21a, 21b, 21c, and 21d project from the back surface of the ozone generating element 21 and are inserted into the sockets 14 through 17, respectively.
A frame-shaped packing 40 formed from a heat resistant rubber is disposed on the peripheral edge of the upper surface of the ozone generating element 21 fitted into the packing 18. A cover 41 is placed on the upper surface of the case 11 with the packing 40 interposed therebetween.
That is, the ozone generating element 21 is not in direct contact with the case 11. This prevents heat generated from the ozone generating element 21 from being transmitted to the case 11 which might otherwise deteriorate or deform the case 11.
An opening 42 is formed in the lower surface of the cover 41. The air intake valve 43 for drawing in the air and the discharge pipe 44 for discharging ozone are provided on opposing end surfaces of the cover 41, respectively. The air intake pipe 43 and the discharge pipe 44 communicate with the opening 42. A mounting bracket 19 for mounting the ozonizer 10 inside the housing 81 of the water purifier 80 is provided at each end surface of the case 11 at a lower position thereof. A screw hole 19a is provided through the mounting bracket 19.
In this embodiment, a fluorine-containing rubber is used as the heat resistant rubber.
Next, the structure of the ozone generating element 21 is described below with reference to FIGS. 10A and 10B.
As shown in FIG. 10A, the ozone generating element 21 includes a discharge element 22, which in turn includes a sheet-like first dielectric layer 25 and second dielectric layer 26, and a third dielectric layer 27 in the form of a laminate. A filamentary discharge electrode 25a is provided on the surface of the first dielectric layer 25. Most of the surface of the filamentary discharge electrode 25a is covered with a protective film 25b to protect against wear caused by the discharge. A portion of the filamentary discharge electrode 25a that is not covered with the protective film 25b is exposed to the atmosphere and forms an exposed portion 25d.
Even if the ozone generating element 21 breaks with a resulting exposure of a surface of the induction electrode 26a or heater electrode 27a, current flows into the exposed portion 25d. Thus, a user is protected from electric shock.
The surface induction electrode 26a is provided on the front surface of the second dielectric layer 26 such that its position corresponds to that of the filamentary discharge electrode 25a. The heater electrode 27a serving as the heat generating element of the present invention is provided on the front surface of the third dielectric layer 27 such that its position corresponds to that of the filamentary discharge electrode 25a.
In this embodiment, the heater electrode 27a is preferably located within 5 mm from the filamentary discharge electrode 25a for better heating efficiency.
One end of the filamentary discharge electrode 25a is electrically connected to a terminal 25c formed on the back surface of the third dielectric layer 27. The terminal 25c is electrically connected to the ground side of the electric circuit via the connection pin 21a (see FIG. 9). One end of the surface induction electrode 26a is electrically connected to a terminal 26c. The terminal 26c is electrically connected to the high-voltage side of the electric circuit via the connection pin 21c. Both ends of the heater electrode 27a are connected to terminals 27c. The terminals 27c are electrically connected to a heat generating circuit formed in the electric circuit via the connection pins 21b and 21d.
In this embodiment, the filamentary discharge electrode 25a and the surface induction electrode 26a are preferably formed from tungsten, and the protective film 25b is preferably formed from glaze or a ceramic. A material for the heater electrode 27a is selected such that the temperature of the discharge element 22 reaches 200° C. to 500° C. approximately 10 seconds after power is applied to the discharge element 22 in the case of using a 110V AC power source.
This is because ammonium nitrate adhering to the discharge element 22 can be evaporated at a temperature of 200° C. to 500° C.
The discharge element 22 preferably reaches a temperature of from 250° C. to 350° C.
That is, ammonium nitrate adhering to the discharge element 22 begins to vaporize at a temperature slightly above 200° C. However, in order to reduce evaporation time, the discharge element 22 is preferably heated to a temperature of at least 250° C. Also, if the discharge element 22 is heated to an excessively high temperature, the case 11 may deteriorate or deform.
Thus, in view of the above, the heater electrode 27a having a resistance of 50Ω at room temperature and a power consumption of 50 W is preferably formed from a mixed material of tungsten and ceramic so that the temperature of the discharge element 22 reaches 250° C. to 350° C. in 10 seconds.
Next, the electric circuit formed on the circuit board 12 is described with reference to FIG. 11.
A heat generating circuit 53 and a power circuit 65 are provided on the circuit board 12. The heat generating circuit 53 supplies current to the heater electrode 27a so as to generate heat from the heater electrode 27a. The power circuit 65 supplies power to the ozone generating element 21 and the heat generating circuit 53.
The heat generating circuit 53 includes a thermistor 51 having a positive characteristic and a diode 52. The thermistor 51 is connected in series with the heater electrode 27a and functions as the heat generating time control means of the present invention. The diode 52 is connected in series between the thermistor 51 and the heater electrode 27a. The power circuit 64 includes a half-wave diode bridge 61, a transistor 62, and a transformer 63. The diode bridge 61 rectifies alternating current supplied from an AC power source 71. The thus half-wave rectified current causes the transistor 62 to perform a switching operation. Switching of the transistor 62 causes the transformer 63 to apply a voltage between the filamentary discharge electrode 25a and the surface induction electrode 26a.
Also, the filamentary discharge electrode 25a of the ozone generating element 21 is connected to a ground wire 64.
Accordingly, even when water enters the case 11 and wets the filamentary discharge electrode 25a, there is no potential difference between the filamentary discharge electrode 25a and the water. Thus, a user does not suffer from electric shock.
Next, the operation of the water purifier 80 and ozonizer 10 is described below.
In this embodiment, the voltage applied between both electrodes is 5 kV at 40 kHz. The resistance of the thermistor 51 is 15Ω at room temperature. The maximum voltage of the AC power source 71 is approximately 140 V.
When the timer 70 turns ON at a predetermined time, power from the AC power source 71 is supplied to a pump-driving circuit 72. As a result, the circulation pump 92 is driven to thereby pump hot water from the bathtub 98 through the water intake 82. Hot water is then filtered by the bucket 86 and heated by the heater 90. The thus-heated hot water is discharged from the jet nozzle 96. The first solenoid valve 16A is opened, and the second solenoid valve 16B is closed, such that air is drawn into the ozonizer 10 through the air intake pipe 12a.
When the timer 70 is turned ON, alternating current is supplied from the AC power source 71 to the circuit board 12. The thus-supplied alternating current undergoes half-wave rectification by the diode bridge 61. An electrolytic capacitor C1 is charged with the thus half-wave rectified current. When the electrolytic capacitor C1 is charged, base current flows to the base of the transistor 62 via a resistor R1; consequently, the transistor 62 turns ON. As a result, current flows to the secondary of the transformer 63, and an electric potential is established between the filamentary discharge electrode 25a and surface induction electrode 26a of the ozone generating element 21 sufficient to generate a discharge. The discharge converts oxygen contained in the air, which has been drawn into the opening 42 through the air intake pipe 12a (see FIG. 1), into ozone. The ozone thus generated is transferred through the discharge pipe 14 and discharged from the jet nozzle 96 into hot water contained in the bathtub 98 in the form of bubbles.
The above-described alternating current supplied from the AC power source 71 to the circuit board 12 also flows through the thermistor 51 and then to the diode 52. The diode 52 performs half-wave rectification on the alternating current to thereby produce a DC voltage of approximately 70 V. Thus, direct current flows through the heater electrode 27a to thereby heat the heater electrode 27a. The magnitude of current I flowing to the heater electrode 27a is approximately 1A (I=70 V/(15Ω+50Ω)≅1A). Accordingly, the power consumption P of the heater electrode 27a is approximately 50 W (P=1 2 ×50).
Subsequently, as current flows continuously, the temperature of the discharge element 22 reaches 250° C. to 350° C. in approximately 10 seconds. This elevated temperature induces scattering of ammonium nitrate molecules adhering to the filamentary discharge electrode 25a. Meanwhile, the resistance of the thermistor 51 increases to 2.5 kΩ due to temperature rise, such that current stops flowing through the thermistor 51. Consequently, the heater electrode 27a stops generating heat.
In this embodiment, the timer 70 goes ON at 50-minute intervals and goes OFF 10 minutes after it goes ON. The ozone generating element 21 discharges continuously to generate ozone until the timer 70 goes OFF.
As described above, according to this embodiment, the ozone generating element 21 is heated by the heater electrode 27a to thereby induce scattering of ammonium nitrate molecules adhering to the filamentary discharge electrode 25a. This, in turn, removes the adhering ammonium nitrate.
Accordingly, this aspect of the present invention dispenses with the need for conventional manual maintenance which involved disassembling an ozonizer and wiping the discharge element using water or a solvent.
Furthermore, because measures for preventing electric shock are employed, maintenance can be readily performed.
Particularly, when an ozonizer used in a water purifier is maintained, there is a high possibility of electric shock due to the entry of water. However, the ozonizer of the present invention provides an electric shock-free environment.
The ozonizer of the present invention can be used in various ozonized water-producing apparatuses without particular limitation. Namely, the water purifier of the present invention is applicable to water purification systems for ponds, water tanks, pools and the like.
It should further be apparent to those skilled in the art that various changes in form and detail of the invention as shown and described above may be made. It is intended that such changes be included within the spirit and scope of the claims appended hereto. | An ozonizer and water purifier equipped with the ozonizer comprising an ozonizing discharge element; an electric circuit for applying a voltage to the ozonizing discharge element so as to produce an ozone-generating discharge; a housing having an opening formed therein for receiving the ozonizing discharge element; a cover which seals the ozonizing discharge element in the housing; and a device for turning off the voltage applied to the ozonizing discharge element when the cover is removed. In another embodiment, at least a part of the cover or housing is transparent so as to enable detection of the discharge state of the ozonizing discharge element. Also included is an ozonizer and a water purifier comprising the ozonizer which includes a discharge element for generating ozone by discharge, wherein ammonium nitrate and other substances adhere to the discharge element upon discharge; and a heat generating element for heating the discharge element to a predetermined temperature which induces scattering of at least ammonium nitrate molecules among those substances adhering to the discharge element. Also included is a method of cleaning an ozonizer having a discharge element for generating ozone by discharge wherein ammonium nitrate and other substances adhere to the discharge element upon discharge, which includes heating the discharge element to a predetermined temperature so as to evaporate at least ammonium nitrate among those substances adhering to the discharge element. | 2 |
FIELD OF APPLICATION OF THE INVENTION
[0001] This invention relates to a method for obtaining cationic O/W emulsions to be used for skin care, which present good viscosity and stability together with high water resistance, associated with excellent “skin feeling” characteristics and a low total polymer content. In particular, the method claimed involves the addition of a cationic polymer with formula I to an O/W emulsions free of polymers added specifically to increase the water resistance.
BACKGROUND
[0002] The water resistance and sensory properties of an O/W emulsion are characteristics very commonly required in skin care products. For example, water resistance is of crucial importance in sunscreen products, children's skin care products, insect-repellent compositions and make-up products.
[0003] Sensory properties are also important for any product designed to be applied to the skin, and particularly important for products which, for reasons of composition, tend to be somewhat sticky. Stickiness may be due to the presence of a high content of UV filters and/or film-forming polymers added specifically to increase the water resistance of the final composition.
[0004] Nowadays, the cosmetics industry is constantly searching for ingredients that perform more than one function in a composition.
[0005] This kind of result can be obtained by adding an effective quantity of homo- or copolymers as described below, as a single ingredient, according to the invention. The addition of said single ingredient produces different characteristics which, to date, have required the combined action of more than one ingredient: viscosity and stability, water resistance and excellent “skin feeling”.
DESCRIPTION OF THE INVENTION
[0006] Surprisingly, it has been found that the addition of 0.1% to 10% by weight of homo- or copolymers as described below gives the O/W emulsions that contain them a high degree of water resistance together with excellent sensory properties, good viscosity and stability.
[0007] The water resistance of the cosmetic emulsions used for skin care is commonly obtained by adding a polymer or monomer additive that forms a protective water-repellent film on the treated skin. Examples include patent U.S. Pat. No. 6,274,124, which claims increased water resistance of cosmetic formulations due to the addition of an appropriate quantity of 1,2-pentanediol, and many patents relating to the use of polymeric film formers, such as U.S. Pat. No. 7,060,257, U.S. Pat. No. 5,725,844 and U.S. Pat. No. 5,093,107, wherein classic emulsions, viscosified with anionic polymers, are made resistant or highly resistant to water by the addition of 1-3% of vinylpyrrolidone copolymers, such as the copolymer PVP/Eicosene.
[0008] In all cases, the emulsions obtained are water resistant but characterised by a high content of polymers, which are not generally biodegradable, and/or a high degree of stickiness, especially in the case of cosmetic emulsions containing large amounts of organic sunscreens.
[0009] The subject of the invention is consequently a method of giving O/W emulsions high water resistance together with excellent sensory properties, good viscosity and stability, by incorporating in the emulsion 0.1 to 10% by weight, preferably 0.1 to 5%, and more preferably 0.1 to 3% of a homopolymer obtainable by polymerising a monomer A or B or a copolymer obtainable by copolymerising monomers A and B, where A represents:
[0010] a) a dialkylaminoalkyl acrylate of formula I
[0000]
[0011] where R and R1, which may be the same or different, represent a straight-chain or branched alkyl group C1-4
[0012] and x is an integer between 2 and 10 or a salt thereof with hydrochloric, nitric, sulphuric or phosphoric acid, or an organic acid;
[0013] or:
[0014] b) its quaternary ammonium salt of formula II
[0000]
[0015] wherein R and R1 are as defined above and R2 is a straight-chain or branched alkyl group C1-4, y takes values from 1 to 3 and X is Cl − , NO 3 − , SO 4 2− , PO 4 3− , CH 3 —OSO 3 − or C 2 H 5 —O—SO3 −
[0016] B represents:
[0017] a) a dialkylaminoalkyl methacrylate of formula III
[0000]
[0018] wherein R and R1 are as defined above, and x is an integer between 2 and 10 or a salt of compound III with hydrochloric, nitric, sulphuric or phosphoric acid, or an organic acid;
[0019] or:
[0020] b) its quaternary ammonium salt of formula IV
[0000]
[0021] wherein R, R1, R2 and y are as defined above, and X may be Cl − , NO 3 − , SO 4 2− , PO 4 3− , CH 3 —OSO 3 − , C 2 H 5 —O—SO3.
[0022] The polymer according to the invention may also contain a crosslinking agent, such as a compound containing two or more unsaturations. The choice will preferably fall on methylenebisacrylamide, diallyldialkylammonium chloride, polyalkenyl polyethers of polyalcohols, or allyl acrylates. The preferred crosslinking agent is methylenebisacrylamide.
[0023] A preferred polymer according to the invention is a polymer obtained from a monomer B which is preferably a dialkylaminoalkyl methacrylate or a quaternary ammonium derivative thereof.
[0024] The method according to the invention is used to prepare o/w emulsions, wherein both the water phase and the oil phase can contain well-known ingredients. Said emulsions can have a very variable viscosity, ranging from a few hundred to a few thousand centipoise, measured with a Brookfield viscosimeter at 20 rpm.
[0025] The pH of the compositions can range from very low values, as in the case of emulsions containing alpha-hydroxyacids (pH 2-3.5), to fairly low values, as in the case of tanning emulsions containing dihydroxyacetone (pH 3-4.5), or only slightly acid, as in the case of sunscreen emulsions or simple skin care emulsions (pH 5-7).
[0026] The fatty phase of the emulsion may contain the following ingredients:
[0027] i) hydrocarbons such as paraffin, mineral oils and analogues;
[0028] ii) oils, butters and natural waxes such as avocado oil, sunflower seed oil, almond oil, apricot seed oil, karite butter, evening primrose oil, blackcurrant oil, borage oil, jojoba oil, safflower oil, wheatgerm oil, macadamia oil, rice husk oil, sesame seed oil, castor oil, coconut oil, unsaponifiable fractions of olive, avocado and soya, cocoa butter, beeswax, candelilla wax, carnauba wax and analogues;
[0029] iii) silicone oils such as dimethicones, cyclomethicones, dimethiconols, alkyldimethicones, and analogues;
[0030] iv) saturated or unsaturated, straight-chain or branched esters of aliphatic acids, or of aromatic or alkylaromatic acids, having 1 to 25 carbon atoms, with mono- or polyhydroxylated, saturated or unsaturated, straight-chain or branched aliphatic alcohols, having 1 to 25 carbon atoms, such as octyldodecyl-neopentanoate, pentaerythritol-dioleate, trimethylolpropane trioleate, triisostearyl citrate, diacetin, triacetin, 2-ethylhexyl-acetate, neopentylglycol-oleate, triethylene glycol diacetate, isopropyl myristate, isopropyl palmitate, bis-diglyceryl-caprylate/caprate/isostearate/stearate/hydroxystearate, bis-diglyceryl adipate, dioctyl maleate, di-(2-ethylhexyl)-malate, (C12-1)alkyl benzoates, cetyl stearyl octanoate, cetylstearyl isononanoate, 2-ethylhexyl-palmitate, 2-ethylhexyl-stearate, C8-10 triglyceride, PEG7-glyceryl cocoate, and analogues;
[0031] v) amides such as those mentioned in EP 0 748 623, especially N,N-diethyl-3-methylbenzamide and ethyl 1-[(N-acetyl-N-butyl)amino]-propionate;
[0032] vi) alcohols containing 6 to 35 carbon atoms, such as cetyl alcohol, stearyl alcohol, behenyl alcohol, octyldodecyl alcohol, 3,5,5-trimethylhexyl alcohol, 2-butoxyethanol, 2-phenoxyethanol, 2-ethyl-1,3-hexanediol, and analogues;
[0033] vii) ethers of fatty alcohols containing 8 to 40 carbon atoms, such as di-n-octylether;
[0034] viii) glycol butylethers such as propylene glycol-tert-butylether, diethylene glycol butylether, a (polypropylene glycol)3-53 butylether, and analogues;
[0035] ix) esters of (C 1-6 )alkylethers such as diethylene glycol butylether acetate, propylene glycol methylether acetate, and analogues.
[0036] For the purposes of this invention, the substances from i) to ix), all of which are easily available on the market, can be used individually, or as one of the possible mixtures thereof, such as the wax mixtures known under the trade name CUTINA™ (Henkel).
[0037] The oily ingredient is generally used in quantities of between approx. 0.5 and 99.5% or more of the total weight of the composition.
[0038] A preferred group of oily ingredients are esters of saturated or unsaturated, straight-chain or branched aliphatic acids, or of aromatic or alkylaromatic acids, having 1 to 25 carbon atoms, which said acids can optionally be hydroxylated and/or ethoxylated with mono- or polyhydroxylated saturated or unsaturated aliphatic alcohols having 1 to 25 carbon atoms.
[0039] Another preferred group of oily ingredients are amide derivatives, including N,N-diethyl-3-methylbenzamide and ethyl 1-[(N-acetyl-N-butyl)amino]-propionate.
[0040] A third preferred group of oily ingredients are mixtures of esters of saturated or unsaturated straight-chain or branched aliphatic acids, or of aromatic or alkylaromatic acids, having 1 to 25 carbon atoms, with mono- or polyhydroxylated, saturated or unsaturated, straight-chain or branched aliphatic alcohols having 1 to 25 carbon atoms, and N,N-diethyl-methylbenzamides and/or ethyl 1-(N-acetyl-N-butyl)-propionate.
[0041] A fourth preferred group of oily ingredients consists of silicone oils. The quantity of the oily phase can range between 5 and 40%.
[0042] The preparation of the emulsions claimed includes the addition of one or more conventional emulsifiers, available on the market. They may be cationic or non-ionic emulsifiers. The latter are, for example, ethoxylated compounds of derivatives of natural oils, such as castor oil (7)OE hydrogenate (ARLACEL™ 989, ICI); mono- and diglycerides of ethoxylated and non-ethoxylated fatty acids, such as glyceryl stearate (CUTINA™ GMS, Henkel) and glyceryl(20)OE stearate (CUTINA™ E-24, Henkel); ethoxylated sorbitan esters (TWEEN™, ICI and CRILLET™, Croda) and non-ethoxylated sorbitan esters (SPAN™, ICI and CRILL™, Croda); esters of polyglycerol with fatty acids, such as triglyceryl diisostearate (LAMEFORM™ TGI, Henkel) and triglyceryl distearate (CITHROL™2623, Croda); esters of glucose, methylglucose and saccharose with ethoxylated and non-ethoxylated fatty acids, such as methylglucose dioleate (GLUCATE™ DO, Amerchol) and methylglucose (20)OE sesquistearate (GLUCAMATE™ SS E-20, Amerchol); ethers of glucose and its oligomers, optionally esterified with aliphatic acids C10-30, such as triglyceryl methylglucose distearate (TegoCare™ 450, Goldschmidt), or etherified with aliphatic alcohols C 8-30 , such as cetylstearyl glucoside (MONTANOV™ 68, Seppic); ethoxylated fatty acids (MYRJ™, ICI); ethoxylated fatty alcohols (BRIJ™, ICI); lanolin and its ethoxylated and non-ethoxylated derivatives, such as lanolin (30)OE (AQUALOSE™ L 30, Westbrook); alkylglycol/polyethylene glycol copolymers, such as copolymer PEG-45/dodecylglycol (ELFACOS™ ST 9, Akzo); silicone emulsifiers (Silicone Fluid 3225 C, Dow Corning; ABIL™ WS05, Th. Goldschmidt A G); fluoride emulsifiers (FOMBLIN™ Ausimont). Cationic emulsifiers which can be advantageously used in the compositions are quaternary ammonium salts having one or two fatty alkyl chains with a number of carbon atoms ranging between 12 and 22, preferably between 14 and 22, and a counter-ion selected from chloride, bromide, iodide, acetate, phosphate, nitrate, sulphate, methylsulphate, ethylsulphate, tosylate, lactate, citrate, and glycolate. Quaternary ammonium derivatives with 2 alkyl chains are preferred, due to their low irritant power. Examples of preferred cationic emulsifiers are distearyl dimethyl ammonium chloride, dimyristyl dimethyl ammonium chloride and dipalmityl dimethyl ammonium chloride, present on the market as Genamin™, Clariant and Varisoft™, Degussa.
[0043] The quantity of emulsifiers which can be used ranges between approx. 0.1 and approx. 20% of the total weight of the composition, preferably between 0.1 and 10% and more preferably between 0.1 and 6%. They can be used individually or mixed together.
[0044] The fatty phase of the cosmetic compositions according to the invention can also include, in combination, one or more anti UV-A or anti UV-B sunscreens chosen, for example, from derivatives of benzylidene camphor, derivatives of dibenzoylmethane, esters and salts of alkoxycinnamic acids, benzophenone derivatives, diphenylcyanoacrylates, derivatives of salicylic acid, derivatives of benzimidazole sulphonic acid, derivatives of p-aminobenzoic acid, 2-(2H-benzotriazol-2-yl)-4-methyl-6-{2-methyl-3-[1,3,3,3-tetramethyl-1-[(trimethylsilyl)oxy]-disiloxanyl]-propyl}-phenol (silatriazole), and oxides of metals with an atomic number between 21 and 30.
[0045] Representative examples of the sunscreens belonging to the classes of compounds mentioned above are benzylidene camphor derivatives such as bicyclo[2.2.1]heptan-2-one 1,7,7-trimethyl-3-[(4-methylphenyl)methylene]; 3-(4′-trimethylammonium)benzylidene-bornan-2-one methylsulphate; and 3,3′-(1,4-phenylendimethin)-bis-(7,7-dimethyl-2-oxobicyclo[2,2,1]heptan-1-methanesulphonic) acid, commercially known as EUSOLEX™ 6300, MEXORIL™ SK and MEXORIL™ SX respectively; 4-methoxy-4′-tert-butyldibenzoylmethane, a derivative of dibenzoylmethane commercially known as PARSOL™ 1789; 2-ethylhexyl-4-methoxycinnamate and 4-methoxycinnamic acid diethanolamine salt, alkoxycinnamic acid derivatives commercially known as PARSOL™ MCX and BERNEL™ HYDRO; 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxy-benzophenone and 5-benzoyl-4-hydroxy-2-methoxy-benzene sulphonic acid, benzophenone derivatives commercially known as UVASORB™ 20H, UVASORB™ MET; 2-ethylhexyl 2-cyano-3,3-diphenylacrylate, commercially known as UVINUL™ N-539 or EUSOLEX OCR; 2-ethylhexyl 2-hydroxybenzoate, (+)3,3,5-trimethylcyclohexyl salicylate and salicylic acid triethanolamine salt, salicylic acid derivatives commercially known as ESCALOL™ 587, KEMESTER™ HMS and SUNAROME™ W; ethyl 2-ethylhexyl 4-dimethylamino-benzoate, N,N-bis-(2-hydroxypropyl)-benzoate and 4-aminobenzoic acid PEG 25, p-aminobenzoic acid derivatives commercially known as UVASORB™ DMO, AMERSCREEN™ P and UVINUL™ P25; triazine derivatives sold as UVASORB™ HEB by from 3V Sigma, TINOSORB™ S by CIBA and UVINUL™ T150 by BASF; benzalmalonate derivatives sold as Parsol SLX by Hoffmann-LaRoche.
[0046] Among the oxides of metals having an atomic number between 21 and 30, titanium dioxide (TiO 2 ) and zinc oxide (ZnO) are preferred.
[0047] Said oxides are preferably used in micronised form, with a particle size not exceeding approx. 100 nm for TiO 2 , and between approx. 15 and approx. 300 nm for ZnO. Even more preferably, the particle size of TiO 2 is between approx. 5 and approx. 50 nm. Titanium dioxide may have an anatase, rutyl or amorphous structure. These micronised metal oxides can be used as such or coated with other agents such as Al 2 O 3 or aluminium salts with aliphatic fatty acids C10-18 or silicones.
[0048] These products are readily available on the market. For example, TiO 2 is micronised and sold under the trade name P25 (Degussa), while TiO 2 is coated with aluminium stearate and sold as METRES100T (Taika Corp.), while the version coated with Al 2 O 3 is known as UFTR (Miyoshi). Micronised ZnO is obtainable as Z-COTE™ (sunSMART) or SPECTRAVEIL™ (Tioxide).
[0049] The emulsions claimed can contain 40 to 95% water, preferably 60 to 90%, and even more preferably 70 to 90% by weight.
[0050] The compositions according to the invention comprise 0.1 to 10%, preferably 0.1 to 5%, and more preferably 0.1 to 3% of a polymer or copolymer as defined above.
[0051] The class of cationic polymers of trimethylaminoethyl methacrylate cross-linked with methylenebisacrylamide is preferred. A commercial example of a cross-linked cationic polymer belonging to this class is Synthalen CR (3V Sigma S.p.A.), which corresponds to the name CTFA Polyquaternium-37.
[0052] Dihydroxyacetone (DHA) can be added to the water phase, possibly in the presence of erythrulose, to give a tan with a less yellowish hue than the shade obtained with DHA alone. Said artificial tanning products can be present in quantities of between approx. 0.1 and approx. 20% by weight of the composition, preferably between 2 and 10%, and more preferably between 2 and 7%. In order to be stable, compositions containing DHA must have a pH of less than 4.5, and preferably less than 4.0. At these pH values, it is not easy to achieve good viscosity and stability values using anionic rheology modifiers.
[0053] One or more alphahydroxyacids (AHA), more specifically identified as 2-hydroxycarboxylic acids with the following formula, can be added to the formulations according to the invention:
[0000] (R 1 )(R 2 )C(OH)COOH
[0054] wherein R1 and R2 may be the same or different and are selected from H, F, Cl, Br, alkyl and arylalkyl, wherein alkyl and arylalkyl may have 1 to 29 carbon atoms and may be straight-chain, branched or cyclic, and may contain groups such as OH and COOH. Said organic acids may be present in quantities of between approx. 0.1 and approx. 20% by weight of the composition, preferably 2 to 15% and more preferably 2 to 10%. In order to present good exfoliating activity, compositions containing AHA must have a pH of between 3.5 and 2. At these pH values, it is practically impossible to achieve good viscosity and stability values using anionic rheology modifiers.
[0055] The cosmetic compositions according to the invention can also include other conventional ingredients such as humectants, like glycerin, diglycerin, propylene glycol or 1,3-butylene glycol, in quantities ranging from approx. 0.1 to approx. 30% by weight of the composition; sequestering agents, such as EDTA salts, in quantities not exceeding 1% by weight of the composition; antioxidants, such as tocopherols and esters thereof, hydroxytoluene butylate or butylhydroxyanisol, in quantities not exceeding 2% by weight of the composition; insect-repellent agents such as diethyltoluamide in quantities of between 2 and 20%; moisturising agents in quantities not exceeding 5% by weight of the composition; agents to adjust the pH to the required values, such as sodium or potassium citrate, sodium or potassium hydroxide, or citric acid monohydrate, in quantities not exceeding 1% by weight of the composition; preservatives, such as 2-bromo-2-nitro-propanediol, sodium dehydroacetate, isothiazolone, imidazolidinyl urea, diazolidinylurea, parabens and hydantoin derivatives (GLYDANT™ Lonza), sorbic acid, benzoic acid and their salts, chlorhexidine and its salts, phenoxyethanol, benzyl alcohol, and analogues, in quantities not exceeding 10% by weight of the composition. Perfumes and colorants can also be added.
[0056] The cosmetic compositions according to the invention can also be prepared according to known methods. In particular, as these are O/W emulsions, it is preferable to prepare the two phases separately, dissolving or dispersing the required lipophilic or hydrophilic constituents/ingredients in each of them, and then mixing them. The cationic polymer can be dispersed in the water phase, before the homogenisation stage, or in the emulsion already formed.
[0057] Examples of these compositions are sunscreens, tanning creams, wrinkle creams, exfoliant creams, day creams, moisturising creams, insect-repellent emulsions, lipstick, mascara and analogues.
[0058] They contain the ingredients in the weight ratios stated above, and any other ingredients compatible with them which are conventionally used in the said cosmetic preparations.
[0059] Evaluation of the Water resistance
[0060] 100 mg of emulsion containing an UV filter is applied to a microscope slide with an area of 50 cm 2 and covered with Transpore™ Surgical Tape 1527 manufactured by 3M. After 20 minutes in the dark, the slide is immersed in tap water at 25±1° C., and the water is allowed to recirculate to simulate moderate activity. After 20 minutes' immersion the slide is left to dry in the air, protected from the light. The complete immersion/drying cycle for each slide is repeated up to 4 times in total. For each emulsion, a control slide (blank) is prepared and stored in the dark throughout the duration of the experiment.
[0061] At the end of the immersion/drying cycles the emulsion left on the slides is recovered, washed with cotton, wet with absolute ethanol and then left fully immersed for two hours in the ethanol solution obtained, protected against the light. The final solutions are then analysed for UV filter content by UV/Visible spectroscopy. The water resistance of the emulsions, calculated in terms of retention of the UV filter, is obtained from the ratio between the mean absorbance value of four samples immersed (for each emulsion) and the absorbance of the blank (sample not immersed in water).
[0062] Measurement of Viscosity
[0063] The viscosity of the emulsions prepared was evaluated with a Brookfield viscosimeter using the appropriate impeller, according to the value to be measured, on samples left to stand overnight, after preparation, and thermostated at 25° C. The measurement was performed at 20 rpm, and the value expressed in cps.
EXAMPLES
[0064] Some representative examples of cosmetic compositions containing the associations according to the invention are given below, together with the water resistance values measured in vitro. The quantities of the individual ingredients are expressed as percentages of the total weight of the composition. The individual ingredients are indicated by their CTFA name.
Examples 1-6
[0065]
[0000]
Sunscreen emulsions
Example 1
Example 2
Example 3
Example 4
Example 5
Example 6
Distearyldimonium Chloride
3
Glyceryl Monostearate
0.5
0.5
0.5
0.5
0.5
1
Steareth-100
0.4
0.4
0.4
0.4
0.4
Dimethicone
1
1
1
1
1
Cetyl Alcohol
3
3
3
3
3
1
C 12-15 Alkyl Benzoate
2
2
2
2
2
4
Ethylhexyl Palmitate
4
Isononyl Isononanoate
Propylene Glycol Dicaprylate/Dicaprate
2
Butyrospermum Parkii
BHT
0.1
0.1
0.1
0.1
0.1
0.1
PVP/Eicosene Copolymer
1
Ethylhexyl Methoxycinnamate
3
3
Diethylhexyl Butamido Triazone
3
3
3
3
H 2 O
Balance
Balance
Balance
Balance
Balance
Balance
Polyquaternlum-37 (SYNTHALEN CR)
0.3
0.3
0.3
Carbomer 940
0.2
0.2
0.2
Glycerin
3
3
3
3
3
3
Allantoin
0.2
0.2
0.2
0.2
0.2
0.2
Lactic Acid (40%)
to pH 5.5-6.0
to pH 5.5-6.0
AMP
to pH 5.5-6.0
to pH 5.5-6.0
to pH 5.5-6.0
to pH
5.5-6.0
Phenoxyethanol & Parabens
1
1
1
1
1
1
Brookfield viscosity, 20 rpm, 25° C. (cps)
24500
9200
20500
12000
30000
26000
UV filter recovery after 40 sec. immersion
53
96
50
97
96
97
(%)
UV filter recovery after 80 sec. immersion
33
94
32
90
89
94
(%)
[0066] Examples 1 and 3 both represent a classic anionic emulsion viscosified with an anionic polymer. Their water resistance does not comply with COLIPA guidelines. To obtain water resistance in line with the COLIPA guidelines it is necessary to add 1% of PVP/eicosene copolymer, thus modifying the biodegradability of the product (1.2% of polymer as against 0.3% of the emulsions with Synthalen CR) and, above all, the “skin feeling” of the final cream, which is sticky both at the spreading stage and after application. All three examples with Synthalen CR (2, 4 and 6) demonstrated excellent water resistance, together with excellent sensory properties during spreading and after application.
Examples 7-12
[0067]
[0000]
Example
Example
Example
Tanning emulsions with sunscreen
Example 7
Example 8
Example 9
10
11
12
Polyglyceryl-10 Pentastearate & Behenyl
2.5
Alcohol & Stearamidopropyl Dimethylamine
Lactate
Distearyldimonium Chloride
3
3
Glyceryl Monostearate
1
1
Cetearyl Alcohol & Ceteareth-20
3
3
Paraffinum Liquidum
6
6
Ethylhexyl Sterate
2
2
Ethylhexyl Palmitate
4
4
Ethylhexyl Cocoate
5
Cetearyl Alcohol
2
1
2
1
Neopentyl Glycol Dicaprylate/Dicaprate
5
Dimethicone
1
Ceteareth-20
0.5
C 12-15 Alkyl Benzoate
5
5
4
5
4
Glyceryl Stearate
1
Propylene Glycol Dicaprylate/Dicaprate
5
4
4
Diethylhexyl Butamido Triazone
3
3
3
3
Ethylhexyl Triazone
3
3
Stearyl dimethicone
2
H2O
Balance
Balance
Balance
Balance
Balance
Balance
Polyquaternium-37 (Synthalen CR)
0.2
0.3
0.2
0.3
0.2
0.3
Butylene Glycol
3
Dihydroxyacetone
3
3
3
3
3
3
Glycerin
5
5
5
5
5
Allantoin
0.2
0.2
0.2
0.2
0.2
0.2
Lactic Acid
to pH 3.5
to pH 3.5
to pH 3.5
to pH 3.5
to pH 3.5
to pH 3.5
Sodium Sulfite
0.2
0.2
0.2
0.2
0.2
0.2
Cyclopentasiloxane
5
Phenoxyethanol & Parabens
1
1
1
1
1
1
Brookfield viscosity, 20 rpm, 25° C. (cps)
9400
8000
25000
11000
23000
10500
UV Filter recovery after 40 sec. immersion
97
96
94
95
93
95
(%)
UV Filter recovery after 80 sec. immersion
90
88
88
86
87
85
(%)
Examples 13-18
[0068]
[0000]
Exfoliant face creams with
Example
Example
Example
Example
Example
Example
sunscreen
13
14
15
16
17
18
Distearyldimonium Chloride
3
3
3
Glyceryl Monostearate
1
0.5
1
1
0.5
0.5
Steareth-100
0.4
0.4
0.4
Stearyl Alcohol
1.5
1.5
1.5
Cetyl Alcohol
1
1.5
1
1
1.5
1.5
C12-15 Alkyl Benzoate
4
2
4
4
2
2
Ethylhexyl Palmitate
4
4
4
Propylene Glycol Dicaprylate/Dicaprate
2
2
2
Diethylhexyl Butamido Triazone
3
3
3
3
3
Ethylhexyl Triazone
3
Dimethicone
1
1
1
H2O
Balance
Balance
Balance
Balance
Balance
Balance
Polyquaternium-37 (Synthalen CR)
0.5
0.5
0.75
0.75
0.5
0.5
Propylene Glycol
3
3
3
Glycerin
3
3
3
Allantoin
0.2
0.2
0.2
0.2
0.2
0.2
Aqua & Passiflora Quadrangularis & Citrus
0.5
0.5
0.75
0.75
0.75
0.75
Medica Limonum
Glycolic Acid
2
2
5
10
10
10
NaOH
to pH 3.5
to pH 3.5
to pH 3.5
to pH 3.5
to pH 3.5
to pH 3.5
Cyclopentasiloxane
3
3
3
3
3
3
Diazolidinyl Urea
0.2
0.2
0.2
0.2
0.2
0.2
Phenoxyethanol & Parabens
0.4
0.4
0.4
0.4
0.4
0.4
Brookfield Viscosity
9500
10000
12500
11500
12500
11800
UV Filter recovery after 40 sec. immersion
97
95
96
93
91
90
(%)
UV Filter recovery after 80 sec. immersion
88
86
87
84
82
83
(%) | This invention relates to a method for obtaining cationic O/W emulsions designed for skin care, which present high water resistance associated with excellent “skin feeling” characteristics. | 0 |
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/624,346, filed Apr. 15, 2012, which is hereby incorporated by reference herein.
BACKGROUND AND SUMMARY
[0002] As a result of the ever expanding demand for energy, the world's easily accessible oil reserves become swiftly depleted. The oil and gas industry today has a typical recovery of hydrocarbons with value of 30-40% 1,2 which indicates that the majority of the existing oil remains trapped in the pores of the oil bearing porous media. An increase in recovery efficiency (up to 60-80%) 1 will therefore be a key factor for meeting the increasing energy demands. To this end, there is a need for new and more sophisticated mapping and production techniques.
[0003] Injection of water, also referred to as water flooding, 3 is commonly applied to produce so-called secondary oil, resulting in an increase of the total recovery efficiency up to 50%. 4 The recovery results of a water flooding process is largely influenced by the rock and fluid characteristics within the particular reservoir. 5 Due to viscosity and capillary effects, water may however bypass confined oil that remains in the reservoir, leading to a so-called water breakthrough, 6 in which preferred water pathways are developed in the reservoir connecting injection sites directly to the producer well where the recovery of water overtakes that of the secondary oil; water breakthrough can set in long before depletion of a reservoir. 5
[0004] These complex and challenging reservoir conditions require an improved knowledge of the subsurface physical and chemical properties. Reservoir flow characterization is regularly performed using isotope tracers, which are injected with the water flooding process to obtain the flow dynamics in a reservoir. 7 This is further extended with complementary techniques to image additional reservoir parameters, such as analysis on production profiles of reservoir fluids, pressure tests, and time lapse seismic examinations. 4
[0005] The limitation of the commonly applied isotope tracers is that they primarily provide information on flow characteristics, and often do not possess any physical and chemical sensor functionality. 10 In addition, a significant number of reported tracers consist of either toxic compounds or radioactive nuclides. 8,9 This limits their use due to health, safety, environmental, and legislation issues.
[0006] As any additional information of physical and chemical properties within the reservoir and its fluids can add a significant contribution to improve the production process, there is a quest for an improved sensor system. Key characteristics for these sensors' functionalities are the temperature, amount and nature of dissolved ions, pressure, pH, and reservoir chemistry. As a consequence of the complex and hostile reservoir environment often encountered, many classical sensor materials (e.g., organic chromophores) have shown to be not suitable. 10,11
[0007] Recent publications suggested nanomaterials with extended sensor functionality as one next step in reservoir characterization. 12,13 An important class of these nanomaterials are the so-called quantum dots (“QDs”). QDs are semiconductor nanocrystals, 14 which are not only brightly fluorescent, with a size-tunable fluorescent emission color, but have also proven to be a versatile platform for further functionalization. 15 QDs have been used as fluorescent nanomaterials in areas where stability, endurance, and specialized chemical functionalization are crucial. These areas are typically found in biomedical research where robust nano-sensors are demanded, often extended with dedicated surface functionality. 15,16
[0008] Another and relative new type of “nano” particles are the so-called noble metal clusters. Their bright optical behavior, which is size-tunable, is to a certain extent comparable to that of QDs. 17 Their inert inorganic nature together with their relatively high chemical stability and solution process ability makes these noble metal clusters an interesting material to combine with the earlier discussed QDs in a mixed sensor for reservoir imaging. Water-dispersed nano-sensors are compatible with the commonly applied technique of water flooding and therefore an ideal starting point, as its infrastructure is readily available throughout the oil and gas industry for enhanced oil recovery. 3 Extended information about the specific chemical and physical conditions within the reservoir is beneficial to optimize secondary oil production.
[0009] Application of fluorescent nanomaterials as sensors added in a water flooding process for reservoir imaging demands a water-dispersible nanoparticle with a controlled stability. Embodiments of the present invention synthesize brightly luminescent InP/ZnS QDs and silver clusters with different emission colors and various water stabilizing surface coatings. The different emission colors are clearly easy to discriminate from each other, which is beneficial for multiplexing in a dedicated sensor composition. The challenging reservoir conditions (e.g., high salinity, high pH, and temperature) have often been found as the limiting factor on the stability of fluorescent materials for reservoir imaging. The use of inorganic chromophors based on the QDs and metal clusters described herein show improved stability in these challenging conditions. By applying different surface coati the nanomaterials, several sensor applications have been identified with respect t chemical environment, temperature, and presence of solids representative withi reservoir.
[0010] In practical situations, the ratio of the photoluminescent intensity of different pa may be measured at the producer well. Direct interpolation of the emission ratios prov unique fingerprint of the reservoir environment with respect to pH, chemical enviror temperature, and present solids. In addition, as the sensors were developed to function water phase, the typical background luminescence of oils showed not to be affected l sensor functionality.
[0011] QDs and silver clusters are described herein as a class of materials for applicati luminescent probes with dedicated sensor functionalities for reservoir imaging, exhi stability and a significant freedom for surface chemistry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A shows a TEM image of orange InP/ZnS QDs.
[0013] FIG. 1B shows a graph of normalized fluorescence (λ exc =370 nm; thick line absorbance (thin lines) spectra of InP/ZnS quantum dots and Ag clusters in chlorofor aqueous solutions, respectively, at room temperature.
[0014] FIG. 2A shows a graph of relative PL intensity of various nano-sensors upon exp to different reservoir conditions.
[0015] FIG. 2B shows a graph of normalized fluorescence spectra of a mixture of Ag el and green emissive PEG-coated QDs; the top line represents the emission spectrum Ag/QD mixture in brine prior to heating; the bottom line represents the Ag/QD mixt brine after heating to 120° C.
[0016] FIG. 3A shows a graph of the relative PL intensity of lipid micelle coated In QDs and silver nanoclusters in the presence of clay or calcium carbonate.
[0017] FIG. 3B shows a photograph of the behavior of lipid coated QD and nanclusters in the presence of clay.
[0018] FIG. 3C shows a photograph of the behavior of lipid coated QD and nanoclusters in the presence of calcium carbonate.
[0019] FIG. 4A shows photographs of the behavior of (a) silica and (b) lipid coated InP/ZnS QDs and (c) silver nanoclusters in the presence of crude oil.
[0020] FIG. 4B shows a graph of a normalized PL intensity of the silica-coated (top line), lipid-coated (middle line) InP/ZnS QDs and silver nanoclusters (bottom line) dispersed in the water phase in the presence of crude oil, wherein the thin line to the far left represents the emission spectrum of Shell North Sea crude oil.
[0021] FIG. 5 shows a digital image of dispersed rolls of foil of 200 nm thick amorphous ZnS using an optical microscope (50×).
[0022] FIG. 6A shows a digital image of a piece of silicon wafer with a 200 nm protective layer of SiO 2 before exposure to hot alkaline brine.
[0023] FIG. 6B shows a digital image of a piece of silicon wafer with a 200 nm protective layer of SiO 2 after exposure to hot alkaline brine.
[0024] FIG. 6C shows a digital image of an unprotected reference piece of silicon, which is however severely damaged by exposure to hot alkaline brine.
[0025] FIG. 7 shows a graph of absorbance spectra of API brine dispersed silver clusters prior to heating (top line) and after heating to 120° C. (bottom line).
[0026] FIG. 8 shows a graph of size dependence of the band gap energy of InP QDs as a function of the particle size.
[0027] FIG. 9 illustrates a system and method for injecting particles into a reservoir in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
[0028] Referring to FIG. 9 , in embodiments of the present invention, QDs and noble metal clusters are implemented as a nano-sensor with specific functionality customized for reservoir management in a water flooding process. Embodiments of the present invention develop a nano-sensor composition based on InP/ZnS core shell QDs and atomic silver clusters. As these materials lay within the size range of 1-20 nm, there is no size limitation with respect to the pore size of the reservoir formation. 12 Due to the differences in surface chemistry of the nanomaterials, they experience different reactions depending on the specific local conditions. The nano-sensors may be injected into a formation at an injection well, including accompanying a water flooding process. After recovery of the nano-sensors from the production well, they are analyzed and the chemical and optical properties are compared to the initial situation before injection. The differences between both measurements provide a unique fingerprint of the reservoir and allow each of its signals to be attributed to specific chemical and physical parameters. Benefits of these nanoparticles are their proven robustness and chemical stability, 18 combined with the ability for extended surface chemistry to develop a mixed multifunctional sensor composition. To this end, developed were different types of QD and silver cluster based nano-sensors. These nano-sensors have their own specific targeted sensor functionality with respect to the reservoir environment. The relative bright and narrow band photoluminescence typically found for these nanomaterials enables the optical discrimination of the different sensor functionalities. The QD and Ag nano-sensors are completely water dispersible to avoid partition into the oil phase. Partial affinity for oil would increase the retention time tremendously. Water-dispersed luminescent nano-sensors also have a much lower detection limit compared to oil-dispersed QDs because their photoluminescence is not camouflaged by the absorption and background luminescence of crude oil itself.
[0029] Materials and Methods:
[0030] All quantities, times, temperatures, etc. are approximate.
[0031] Reagents: Zinc n-undecylenate, indium chloride, tris(trimethylsilyl)phosphine (TMS) 3 P, hexadecylamine (HDA), stearic acid, sublimed sulfur, n-dodecanethiol, 1-octadecene (ODE), O-[2-(3-mercaptopropionylaminolethyl]-O′-methylpolyethylene glycol 5000, silver nitrate (AgNO 3 ), α-lipoic acid, sodium borohydride (NaBH4), and calcium carbonate were commercially obtained from Sigma Aldrich. PE 18:0/18:0-PEG 2000 was commercially obtained from Lipoid. Natural crude oil (e.g., North Sea) was commercially provided by Shell directly after production without any additional processing. The EXMS75 clay was commercially obtained from Stidchemie, and Rhodamine 101 commercially obtained from Radient Dyes Chemie.
[0032] Synthesis of QDs: InP/ZnS quantum dots were synthesized under a nitrogen flow in accordance to a method published by Xu et al. 19 with modifications as described herein. (TMS) 3 P (60 mg; 0.2 mmol) was dissolved in ODE (1 mL) and swiftly injected into a reaction mixture of stearic acid (57 mg; 0.2 mmol), HDA (65 mg; 0.7 mmol), ODE (6 mL), zinc undecylenate (172 mg; 0.39 mmol) and indium chloride (44 mg, 0.2 mmol) at 280° C. After stirring for 20 minutes at 240° C., the reaction was allowed to cool down to room temperature, followed by the addition of 100 mg zinc undecylenate (0.23 mmol), 108 mg HDA (0.45 mmol), and 6 mL ODE. Elemental sulfur (15 mg; 0.47 mmol) dissolved in ODE (2 mL) was added drop-wise during 20 minutes at 230° C., followed by an annealing step of 60 minutes at 200° C. The core shell InP/ZnS crystals were subsequently isolated by dissolving the reaction mixture in chloroform (10 mL), followed by precipitation through addition of acetone (20 mL). The QDs were isolated by centrifugation and re-dispersed in chloroform.
[0033] Synthesis of Ag nano-clusters: The Ag atomic clusters were synthesized following a method published by Adhikari et al. 20 with modifications described herein. α-□Lipoic acid (19 mg) and 14 mL of demi water were placed into a 50 ml flask. Subsequently, 7 mg of sodium borohydride was added, while stirring, a clear solution was obtained after 30 minutes. A solution of 2.94 mg of AgNO 3 in 700 μL water was added to the reduced dihydrolipoic acid (DHLA) solution while stirring. This was followed by the addition of an excess of sodium borohydride (10 mg dissolved in 2 ml water). Stirring was continued for more than 5 hours. A clear color change was observed from dark brown to a bright orange color after 4-5 hours.
[0034] Surface modification: The silica coating was performed with a procedure similar to the one published by Nann et al. 19 The capping exchange of surface bound ligands (HDA and stearic acid) with, O-[2-(3-mercaptopropionylaminolethyl]-O′-methylpolyethylene glycol 5000 (PEG-SH) or dodecanethiol, was performed following the procedure published by Querner et al. 21 A 2-fold excess amount of thiol ligands was added to a 0.5 ml colloidal dispersion of HDA capped InP/ZnS QDs (10 mg/ml) and stirred at room temperature for >12 hours. Subsequently, the dodecanethiol-capped QDs where isolated by two cycles of precipitation through addition of methanol (0.5 mL) and redispersion in chloroform.
[0035] Lipid coating of QDs: A micellar polyethylene glycol (“PEG”) coating was applied to make the QDs water-soluble. 22 This micellar coating comprised a pegylated phospholipid, PEG-DSPE (1,2-distearoyl-sn-glycero-3-phosphoethanolamine-N-[methoxy-(poly(ethylene glycol))-2000]). The 6 mg InP/ZnS dodecanethiol-capped single washed QDs (3.2 mg InP/ZnS from TGA) were dissolved in 2 mL of chloroform and mixed with 18 mL PEG-DSPE (174 mg) dissolved in chloroform. The chloroform solution was slowly added to 70 mL water (1.5 hours) at 80° C. under vigorous stirring and nitrogen flow. Thermogravimetric analysis (“TGA”) showed that on average 52% (w/w) of the single washed quantum dot content consists of InP/ZnS, whereas 48% of the mass was attributed to organic surfactants.
[0036] Optical Spectroscopy: UV-vis spectra were recorded (e.g., using a Hitachi U-2001 or Perkin Elmer Lambda 3b spectrophotometer). Steady state fluorescence spectra were measured (e.g., with a Perkin Elmer LS55 spectrophotometer).
[0037] Quantum yield: Photoluminescence quantum yields (η F ) were estimated usi rhodamine 101 as a reference (in ethanol+0.01% HCl; η F =100%). 23 All solutions had optical density <0.1 at the excitation wavelength (λ ex =520 nm) to minimize re-absorpti and avoid absorbance saturation. The quantum yield was derived from luminescence spec by correcting for the optical density and the refractive index of the solvents used for sam and reference. 24
[0038] Transmission electron microscopy: TEM images were recorded (e.g., using TECNAI G2 20 (FEI Company) microscope operated at 200 kV). TEM samples w prepared by placing a drop of QDs dispersed in chloroform on a carbon coated copper (e. 400-mesh) TEM grid. The excess liquid was removed with a filtration paper.
[0039] Simulated subterranean reservoir conditions: The influence of simulated reserv conditions on the dispersed nano-sensors was tested using different media and the presence solids. The influence of salt concentrations was tested by dispersing the nano-sensors in 2 (w/w) aqueous solution of CaCI 2 , or 8% (w/w) aqueous solution of NaCl. Subsequently, the influence of pH was tested in multi-component API brine solutions, simulating an act reservoir environment To this end, the nano-sensors were dispersed in buffered API bri (pH 6.5 and pH 9), containing 8% NaCl and 2% CaCl 2 . The effect of elevated subterrane temperatures was tested by heating the dispersed nano-sensors in buffered pH 6.5 API bri (8% NaCl and 2% CaCI 2 ) for 10 minutes at 120° C. The acidic API brines were buffer using a 0.1 M acid, sodium acetate buffer (pH 6.5), and the alkaline brines were buffer using 0.1 M glycine at pH 9.5.
[0040] The behavior of the nano-sensors in the presence of solids was studied using the A brine pH 6.5 dispersed nano-sensors. Followed by the addition of solid Ca 2 CO 3 or EXM7 clay, after vigorously mixing, the solid and the liquid phase were separated by centrifugi The liquid phase was subsequently characterized using UV-vis and fluorescen spectroscopy.
[0041] Testing of influence of crude oil: In a reservoir, crude oil is in close contact with water phase (brine). The influence of the presence of crude oil in the near vicinity of t water-dispersed nano-sensors was tested using a light North Sea crude oil. As-received cru oil was added to the dispersions. Samples were shaken vigorously and left standing for t hours to redistribute in well-separated phases. The PL spectra of the water phase w recorded, and the optical absorbance of the QDs was compared to the initial situation before addition of the oil.
[0042] Results:
[0043] Challenging reservoir conditions can affect the stability of the nano-sensor materials. Therefore, several different bulk materials, which are commonly used for QDs, were tested under commonly encountered reservoir conditions (see Supplementary Information disclosed hereinafter). These experiments showed stability for both ZnS as well as SiO 2 under the predominant reservoir conditions. Therefore ZnS and/or SiO 2 may be selected as a protective outer surface for the QDs. The InP/ZnS QDs were synthesized from indium chloride and tris(trimethylsilyl)phosphine in a mixture of octadecene, stearicacid, zindundecylenate, and hexadecylamine (HDA) in a similar procedure as described by Xu et al. 19 The InP/Zn core had a diameter of respectively 3.1 nm (orange) and 2.4 nm (green), as determined using the exciton energy derived from the emission maximum reference with literature values (see Supplementary Information hereinafter with respect to FIG. 8 ). The InP/Zn cores were passivated by growing a shell of 2 mono layers ZnS using zincundecylnate and sulfur dissolved in octadecene. 19 The final InP/ZnS quantum dots showed fluorescence maximum at 600 nm (orange) and 531 nm (green) and a quantum yield of η F ≈70% (orange) and η F ≈78% (green). FIG. 1A shows the TEM images of the orange InP/ZnS core shell QDs.
[0044] The luminescent Ag clusters with an expected size of 4-5 atoms 20 were synthesized by the reduction of silver nitrate in the presence of α-lipoic acid in a similar method as described by Adhikari et al. 20 The Ag clusters showed a clear deep red emission with a maximum at 654 nm, and a sharp first absorption peak at 495 nm with a typical fluorescence quantum yield of η F =5%.
[0045] Sensor functionality of the nanomaterials was studied under simulated reservoir conditions, using the optical properties of the InP/ZnS QDs and Ag clusters. DH LA-coated Ag clusters and InP/ZnS QDs with PEG-SH, Silica, and PEG lipid surface coatings were tested in commonly encountered reservoir conditions as is described hereinafter. The nano-sensors were subjected to the following variables: temperature, pH, and composition (presence of crude oil or additional solids like clay or calcium carbonate, which are added to the API brine). A “high” salinity brine was formulated in accordance with standards set by the American Petroleum Institute (“API”). As shown in FIGS. 2A-2B , the specific environmental influences on the sensors may cause changes in the photoluminescence (PL) intensity and the optical absorbance spectra. The changes in optical properties are a measure of the stability and the sensor functionality upon exposure to different conditions. In FIGS. 2A-2B , the PL intensity is plotted relative to the intensity in pure water as a function of the different particles under different reservoir conditions. The relative PL intensity shows a small decrease in the presence of high salinity (8% NaC) and calcium ions (2%) for most of the particles, except for the PEG-lipid coated QDs, which showed a small increase in PL intensity. These differences in PL intensity can be the result of the difference in polarity between pure water and water with (high) salt concentrations. A similar decrease in PL intensity is described for organic chromophores as a consequence of the interaction of their excited energy state and with the solvents polarity. 25,26
[0046] The influence of the different pH-levels of the brine dispersions showed significant changes between PL intensities of the diverse particles. The silver clusters with an alpha lipoic acid coating showed an overall decrease in PL intensity of ≈50% for both a high pH 9 and a low pH 6.5. However, an opposite behavior pH dependence was found between the silica-coated QDs and the PEG-SH coated QDs, where an average difference in the relative PL intensity was found of ≈40% at the different pH levels (pH 6.5 and pH 9). Here the silica-coated QDs showed a high relative (94%) PL intensity at pH 9, and PEG-SH coated QDs showed low relative (63%) PL intensity. This was opposite at pH 6.5, where the silica-coated QDs showed a low relative (59%) PL intensity and PEG-SH coated QDs showed high relative (100%) PL intensity. The opposite pH behavior found for these two QDs shows a clear application for a reservoir pH sensor.
[0047] An exposure of these nanoparticles to a high temperature results, for all particles, in a strong decrease in PL intensity >60%. At these elevated temperatures, several effects can take place which can cause a decrease in PL intensity. The complete disappearance of the silver cluster emission upon heating was subsequently evaluated by the absorbance spectra of the Ag clusters (see FIG. 7 in the Supplementary Information hereinafter). This shows that clusters degrade at 120° C. in API brine, as the optical absorbance shows a strong decrease upon heating. Furthermore, the decrease in PL intensity of the QDs (see FIG. 2A ) can possibly be contributed to an increased mobility of surface-bound ligands and oxidation of the QD surface introducing surface trap states, which reduce the overall PL intensity upon heating. The difference in PL stability of the various nano-sensors enables an application for reservoir temperature monitoring. An example is shown in FIG. 2B where a mixture of Ag clusters (red emission) and PEG-SH coated QDs (green emission) may be used for this purpose in API brines. The emission spectrum shows (upper line) the emission spectrum of the mixture of red thiolated Ag (λ max =650 nm) and PEG-SH green emissive (λ max =531 nm) coated QDs at room temperature (“RT”), and the inset photo of FIG. 2B shows that this mixture has a clear and predominantly orange emission. Upon heating up to 120° ° C., the emission spectrum shows the disappearance of the red Ag clusters emission (λ max =650 nm) and leaves the green QD emission (λ max =520 nm) as the dominant emission. The effect remains preserved after cooling the sample down to RT. This is shown in the inset photo of FIG. 2B revealing a clear green QD emission.
[0048] The presence of mineral solids in the reservoir on which the nano-sensors can absorb is an important element for the sensor composition of embodiments of the present invention. Two mineral solids often encountered in reservoirs are clay and limestone. Stability with respect to immobilization of the nano-sensors onto the natural clay (caused by ion exchange) was evaluated using a natural Na-montmorillonite (e.g., EXM757). This clay exhibits a large cationic exchange capacity and therefore closely resembles some natural clays that are commonly encountered in reservoirs. Limestone is a sedimentary rock, which is primarily composed of CaCO 3 crystals. CaCO 3 is the primarily naturally occurring source of divalent calcium ions source in reservoirs. This is of significant consequence as it forms a specific thread with respect to the precipitation of anionic nano-particles dispersions.
[0049] The API brine dispersed silver cluster and the PEG-lipid coated QDs were mixed with either the clay or the limestone to study the potential selective binding of these nano-sensors. FIG. 3C confirms that red emitting silver clusters do not show precipitation nor selective binding in the presence of EXM757 clay in API brine (pH 6.5). However, in a presence of CaCO 3 , silver clusters show complete immobilization on the solid CaCO 3 as result of the negatively charged carboxylic acid groups on their surface. The orange emitting PEG-micelle coated InP/ZnS QDs, on the other hand, show the opposite behavior. The PEG-micelle coated QDs remain well dispersed in API brine in the presence of additional calcium carbonate, but they reveal selective binding towards the EXM757 clay. This opposite behavior in selective binding of the negatively charged silver clusters and the PEG-micelle coated QDs confirms that combinations of such particles can be used as a sensor with respect to the solids in the reservoir environment.
[0050] The large heterogeneity of the conditions within a reservoir makes the design of the sensor composition challenging. The sensors according to embodiments of the present invention are designed for integration with a water flooding process and should therefore stay confined within the water phase of the reservoir. FIGS. 4A-4B show that the nanoparticles retain their bright luminescence in the presence of crude oil and stay confined in the water phase; they do not partition into the oil phase. The nanoparticles were dispersed in API brine in the presence of Northern sea crude oil. Crude oil is a mixture of a wide variety of hydrocarbons, some of which exhibit fluorescence by themselves. 27 The influence of the crude oil on the stability and luminescence of the nanoparticles is shown in FIGS. 4A (a), (b), and (c). The PL spectra of three types of QD sensors (InP/ZnS-lipid coated, InP/ZnS-silica coated, and Ag-clusters) dispersed in water are shown in FIG. 4B . The presence of crude oil in the vicinity of the QDs did not influence their bright luminescence, which can be clearly discriminated from the crude oil luminescence.
Supplementary Information
[0051] Stability tests on commonly materials typically used for QDs:
[0052] Challenging reservoir conditions are likely to affect the stability of nano-sensor materials; therefore, several different bulk materials, which are typically used for QDs, were tested under commonly encountered reservoir conditions (e.g., acidic and alkaline brine conditions at elevated temperatures).
[0053] Materials were tested in bulk form before testing with nanoparticles. An instability of the bulk material is more easily determined and can function as an indication on the expected behavior of the nano-sized form of the materials. The stability of nano-sized materials is in general lower than their macroscopic counterpart.
[0054] Bulk CdSe, CdTe, ZnO, ZnS, Si, and SiO 2 powders were exposed to hot acidic API brine as well as hot alkaline API brine (see Table 1, which shows stability with respect to reservoir conditions of bulk materials that are conventionally used for QDots). Both the acidic and alkaline brine were buffered with acetic acid (pH 5) and glycine (pH 9), respectively. Samples were heated for approximately 1 hour at 150° C. (e.g., autoclave conditions) after which they were filtered. Precipitation experiments with the filtrate were conducted to confirm stability of the material. Only ZnS and SiO 2 met the basic stability requirements. Silicon passes halfway, as it is stable in hot acidic brine but not in the hot alkaline brine.
[0000]
TABLE 1
CdSe
CdTe
ZnO
ZnS
Si
SiO 2
Hot alkaline API brine
X
X
X
Stable
X
Stable
Hot acidic API brine
X
X
X
Stable
Stable
Stable
[0055] Subsequently, it was determined if ZnS and SiO 2 remain stable when scaling down to the nano-regime. An amorphous 200 nm film of ZnS was synthesized using chemical vapor deposition techniques. This inorganic film however dissolves in hot brine. As shown in FIG. 5 , dispersed rolls of foil of 200 nm thick amorphous ZnS are clearly visible using an optical microscopy (50×). However, after exposure to hot brine, they cannot be seen anymore due to degradation.
[0056] Referring to FIGS. 6A-6C , alternatively, a 500 nm layer of SiO 2 was thermally grown on a common silicon wafer. The silica layer was stable and protected a silicon wafer against degradation under influence of hot alkaline brine. Summarizing these experiments, apart from silica, all conventional QD materials that were tested failed. Other materials are required for the sensors that have a much higher chemical stability.
[0057] FIG. 6A shows a piece of silicon wafer with a 200 nm protective layer of SiO 2 before exposure to hot alkaline brine. FIG. 6B shows a piece of silicon wafer with a 200 nm protective layer of SiO 2 after exposure to hot alkaline brine, which looks the same as the piece in FIG. 6A . FIG. 6C shows an unprotected reference piece of silicon that is severely damaged by exposure to hot alkaline brine.
[0058] Since it is expected that the divalent nature of the semiconductors could be the main cause of the observed leaching, alternatively, indiumphosphide QD was considered. InP is a trivalent component and therefore more stable compared to cadmiumselenide and other conventionally used QD materials. In addition, the InP core was overcoated with a ZnS shell, which further increased its chemical stability.
[0059] Some sulphur components have extremely low dissociation constants, which also explains why ZnS is much more stable than ZnO. Silversulphide is another high stability component.
[0060] Degradation of Silver Nanoclusters
[0061] The silver nanoclusters revealed a complete disappearance of their luminescence upon heating in API brine. The absorbance spectrum shown in FIG. 7 showed an almost absence of the characteristic absorbance peaks of these silver clusters, indicating that the silver clusters were almost fully degraded upon heating in API brine at 120° C. FIG. 7 shows the absorbance spectra of API brine dispersed silver clusters prior to heating (upper line) and after heating to 120° C. (lower line). Furthermore, precipitation of “reaction products” was observed explaining the slope in the absorbance spectrum as a result of scattering of the incident light.
[0062] FIG. 8 is a graph showing size dependence of the band gap energy of InP QDs as a function of the particle size derived from literature.
[0063] References, which are all hereby incorporated by reference herein:
1 Smith, R. G.; Mailand, G. C. Trans. I. Chem. E, 1998, 76A, 539-552, 2 Essen, G. M.; Zanvliet, M. J.; Van den Hof, P. M. J.; Bosgra, O. H. IEEE, 2006, 699 3 I. A. Munza, H. Johansen, O. Huseby, E. Rein. O. Scheire, Marine and Petroleum Geology 2010, 27, 838-852 4 Radiotracer applications in industry: a guidebook.—Vienna: International Atomic Energy Agency, 2004, p. 176 5 Buckley S. E.; Leverett. M. C. Trans. AIME 1942, 146, 107-116 6 Elkens, L. F.; Skov A. M. J. Petrol. Technol. 1963, 15, 877-884 7 Dugstad, ø., Aurdal, T., Galdiga, C., Hundere, I., Torgersen, H. J., SPE Paper Number Texas 1999, 56427 8 Gulati, M. S., Lipman, S. C.; Strobel, C. J. Geothermal Resources Councel. Trans. 1978, 2, 237-240 9 McCabe, W. J.; Barry, B. J.; Manning, M. R. Geothermics, 1983, 12, 83-110 10 Zemel, B. Tracers in the Oil Field, Developments in Petroleum Science, 43, Elsevier Science B.V. 1995 11 Home, R. N. J. Perolt. Technol. 1982, 34, 495-503 12 Barron, A. R.; Tour, J. M.; Busnaina, A. A.; Jung, Y. J.; Somu, S.; Kanj, M. J.; Potter, D.; Resasco, D.; Ullo, J. Oilfield Rev. 2010, 22, 38-49 13 Krishnamoorti, R.; Houseten, U. J. Petrol. Technol. 2006, 24 14 Brus, L. J. Phys. Chem. 1986, 90, 2555-2560 15 Gao, X. H., Cui, Y. Y., Levenson, R. M., Chung, L. W. K.; Nie, S. M. Nat. Biotechnol. 2008, 22, 969-976 16 Mulder, W. J. M.; Koole, R.; Brandwijk, R. J.; Storm, G.; Chin. P. T. K.; Strijkers, G. J.; de Mello Donega, C.; Nicolay, K.; Griffioen A. Nano Lett. 2006, 6, 1-6 17 Zheng, J.; Nicovich, P. R.; Dickson, R. M.; Annu. Rev. Phys. Chem. 2007, 58, 409-431 18 Medintz, I. L.; Uyeda, H. T.; Goldman, E. R.; Mattoussi H. Nat. Mater. 2005, 4, 435-446 19 Xu, S., Ziegler, J. & Nann, T. J. Mater. Chem. 2008, 18, 2653-2656. 20 Adhikari, B., Banerjee, A., Chem. Mater. 2010, 22, 4364-4371 21 Querner, C.; Reiss, P.; Bluese, Pron, A. J. Am. Chem. Soc. 2004, 126, 11574-11582 22 Dubertret, B. et al. Science 2002, 298, 1759-1762. 23 Karstens, T.; Kobs, K. J. Phys. Chem. 1980, 84, 1871-1872. 24 Eaton, D. F. J. Photoch. Photobio. B 1988, 2, 523-531. 25 Do, J.; Huh, J.; Kim, E. Langmuir 2009, 25, 9405-9412 26 Nair, R. B.; Cullum, B. M.; Murphy, C. J. Inorg. Chem. 1997, 36, 962-965 27 John, P.; Souter, I. Anal. Chem. 1976, 48, 520-524. | Enhanced oil recovery becomes increasingly important in satisfying the growing demand for fossil fuel. The efficiency of secondary recovery processes like water flooding is however largely influenced by the rock characteristics, fluid characteristics, chemistry and physics. For development of the full potential of secondary oil recovery, it remains a challenge to obtain sufficient knowledge about the reservoir conditions. The present invention provides a novel water-dispersed, nano-sensor composition based on. InP/ZnS quantum dots (“QDs”) and atomic silver clusters, which exhibit a bright visible fluorescence combined with dedicated sensor functionalities. The QD and silver nano-sensors were tested in simulated reservoir conditions to determine their selected functionality to these reservoir conditions. The developed nano-sensors showed improved sensor functionalities towards pH, temperature, and subterranean reservoir rock, such, as clay or limestone. | 6 |
PRIORITY
This application claims priority from German Patent Application No. DE 10 2005 030 600.4, which was filed on Jun. 30, 2005, and is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The invention relates to a method for controlling a displacement element such as a vehicle window, a sunroof, a lift gate, a vehicle door or the like by means of a motor, preferably a DC motor, wherein parameter values, preferably in the form of a characteristic curve, which are stored by means of a learning run are compared with parameter values generated in real-time during operation of the motor and required for controlling same and as a function of which the motor is stopped or its rotational direction is reversed, and an apparatus for carrying out said method, and a method for generating parameter values of a learning run.
BACKGROUND
Automatic displacement elements are used in a wide variety of applications to enable the user to operate windows, doors and other closing devices conveniently and easily. For this purpose a DC motor is generally used which serves to drive the displacement element via an appropriate mechanism. Particularly in the automotive field, automatic window lifts and sunroofs as well as doors and lift gates have become commonplace and are already being fitted as standard in the vast majority of new cars.
However, particularly in the automotive field, the potential hazard of electric window lifts or sunroofs is already well recognized also, as numerous accidents involving them have already been recorded and given extensive media coverage.
If, for example, an object or body part is trapped between vehicle frame and electrically operated window or door, it may be subject to adverse effects or crushing because of the not inconsiderable motive force of the power actuator. Children, dogs or even adults can be injured by accidental actuation of electrical closing devices, such accidents even proving fatal in extreme cases. This is particularly the case with an automatic up/down feature whereby a brief touch of the switch suffices to open or close a window automatically. Tests have found that a closing force of even 100 Nm acting on the human neck can be life-threatening, and for small children the danger limit is as low as 30 Nm.
The experience of recent decades has therefore made it necessary to create devices for limiting the closing force, i.e. providing anti-trap protection, in order to stop the closing movement of motor-driven elements such as windows and doors if necessary and prevent such accidents from occurring. Although an EU directive specifies limiting the force of window lifts to 100 Nm, many automobile manufacturers are voluntarily aiming for a limitation to 10 Nm in order to make sure that any kind of crushing of fingers or other extremities is eliminated.
For this purpose any resistance to the closing movement of the window is registered by an open-loop controller, causing the motor-driven closing movement to be stopped or, in the case of intelligent control, even reversed by reversing the motor direction so that the trapped object or body part is immediately released. The window or door closing movement therefore lasts only until such time as an obstacle gets in the way.
A resistance is mainly detected by means of computer-assisted analysis of the motor current. If an object impedes the movement of the window pane, the motor is slowed down and the motor current increases. In such cases the controller which is measuring the motor current interrupts the supply of current or causes the displacement element, i.e. the window pane, to return in the opposite direction by reversing the polarity at the terminals of the DC motor via a suitable circuit.
Particular requirements are also placed on the software components of closed-loop control units, as the control system must not only detect a real obstacle, but also differentiate it from a defect such as icing-up or sticking of the power window due to dirt. Since in the latter case the resistance occurring must be overcome and the control unit must not be “fooled” by changing operating and environmental conditions, precisely operating and intelligent software solutions are required.
For driving window lifts, sunroofs, lift gates and other movable elements (hereinafter referred to globally as displacement elements), DC motors are normally used, whereby there is mounted on a motor shaft an at least two-pole rotor by means of whose rotation the motor's rotary motion is converted via Hall sensors into a Hall signal which is in turn used for speed calculation. The Hall sensor is a semiconductor device which produces a voltage as the result of current flow and an external magnetic field, said voltage increasing with the intensity of the current flow and the magnetic flux density.
As the Hall sensor changes its voltage level more quickly the faster the motor shaft rotates, the speed of the displacement element during its translational opening or closing movement can be determined, the motor speed being dependent on the voltage present and the necessary force which the motor must exert to produce the desired movement of the displacement element. Due to changing operating conditions such as temperature, gearing and various frictional resistances caused in particular by rubber seals, the force required to move the displacement element varies, which causes the speed of the system to vary while the voltage dropped across the motor remains constant.
As it is desired on the part of the industry to keep the displacement element speed constant throughout the opening and closing movement, the voltage applied to the motor is varied accordingly. In practical terms this means that the voltage must be increased equivalently the more force the motor requires to maintain the desired speed even under changed conditions. For this purpose the system is clocked via pulse width modulation (PWM), the input voltage supplying the motor being switched on and off at a high frequency of normally 20 kHz in short variable cycles. These cycles are termed the switching period T s , the ratio of the on-time t on to the off-time t off during such a switching period T s being variable as required.
If the on-time t on is increased, a larger arithmetic mean of the output voltage and therefore a higher output current is produced. In technical terms this is also known as a “duty cycle”, whereby if the on-time t on and off-time t off are of equal length a duty cycle of 50% is present, which means that the input voltage is also halved. If the on-time t on is only a quarter of the switching period T s , this is termed a duty cycle of 25% with consequently only a quarter of the input voltage being applied to the motor. The duty cycle and therefore the output of the motor is continuously controllable from 0 to 100%.
In known methods according to the prior art, the required displacement force which the motor needs to move the displacement element is calculated via the voltage and speed of the motor and stored in a nonvolatile memory. For this purpose a learning run is executed subject to clocking by means of constant PWM in order to determine the various frictional forces occurring in the system over the movement range of the displacement element. The frictional forces result primarily from the contact of the displacement element with seals and other mechanical transitions.
A learning run is necessary for each individual closing system because, in spite of standardization and mass production, every mechanical system proves to be unique and possesses individual characteristics which means that, due to manufacturing tolerances in the mechanism, it also does not behave in the same way in terms of its movement. Thus prior to initial commissioning of a new system, a one-off learning run is therefore performed and the characteristic data obtained is stored as a frictional or displacement force curve in order to then serve as a reference for all subsequent closing movements of the displacement element during normal operation.
For all the closing movements taking place in the future, the required PWM clocking is determined by means of complicated calculations on the basis of motor voltages and the associated stored reference data concerning the displacement forces which is obtained during the learning run in order to enable the different mechanical forces present at various points in time to be compensated. Comparison of the reference data with the forces currently present during a closing movement of the displacement element finally allows an object or body part to be detected and suitable control pulses to be triggered in order to stop the closing movement or reverse it by reversing the polarity of the direction of the motor. In practical terms, the exceeding of a particular permissible displacement force is therefore computationally registered and the motor drive is controlled accordingly in order to release the trapped object, the duty cycles for controlling the motor with constant speed being calculated on the basis of the characteristic values obtained from the learning run according to the displacement forces and not on the basis of the current speed actually occurring in the system.
As the learning run merely constitutes a simulation of the movement sequence of the displacement element as it occurs under learning run conditions (in the laboratory, workshop, etc.), but cannot allow for any current operating conditions and environmental effects present at the time of any displacement movements occurring subsequent to the learning run under real environmental conditions, it is also realistically impossible to match the speed to new circumstances.
One of the disadvantages of this method is that the reference data obtained during the learning run is also used as reference for all movements of the displacement element taking place in the future and the speed of the system is always reproduced in a rigid manner according to the calculation performed for the learning run. As the system's mechanism is subject to aging and changing environmental and operating conditions such as increased dust and temperature exposure, the speed of the displacement element cannot be kept constant and tends to vary from one path section to another, which also makes it difficult to define a precise closing force limitation, with the result that extremities trapped by the displacement element may in some cases suffer slight injury even with anti-trap protection provided. The irregularity of the displacement movement is likewise accompanied by undesirable audible and visual characteristics.
Moreover, the data recognition algorithm cannot reliably reflect all the operating ranges and physical conditions, such as changes resulting from mechanical aging, and requires complex adjustments for the simulation of same.
SUMMARY
The object of the present invention is therefore to avoid these disadvantages and to create a method and an apparatus for controlling a displacement element whereby quicker and more stable adjustment to suit current physical conditions can be achieved during system actuation. In addition, the method and apparatus according to the invention are designed to ensure a uniform speed of the displacement element throughout its movement, irrespective of the current operating conditions. The measures according to the invention are designed to provide anti-trap protection detection which is characterized by direct and realistic data utilization in order to enable the displacement mechanism to react rapidly and effectively in hazardous situations.
This object can be achieved by a method for controlling a displacement element such as a vehicle window, a sunroof, a lift gate, a vehicle door or the like by means of a motor, preferably a DC motor, the method comprising the step of comparing parameter values, preferably in the form of a characteristic curve, which are stored by means of a learning run with parameter values generated in real-time during operation of the motor and, depending on the result of the comparison, stopping the motor or reversing the motor rotational direction, wherein the speed of the motor is kept constant allowing for the mechanical forces actually occurring on the displacement element at the time of motor actuation and the parameter values generated in real-time are the result of closed-loop speed control causing the speed to remain constant and are used for controlling the motor.
The parameter values generated in real-time can be the ratio of the on-time of the motor to the off-time of the motor. If a defined difference between the stored parameter values and the parameter values generated in real-time is exceeded, the motor can be stopped and its drive motion can be preferably put into reverse. The parameter values stored by means of a learning run can be the ratio of the on-time of the motor to the off-time of the motor. The speed of the system can be maintained constant throughout the learning run.
The object can also be achieved by an apparatus for controlling a displacement element such as a vehicle window, a sunroof, a lift gate, a vehicle door or the like by means of a motor, preferably a DC motor, an open-loop control unit for motor clocking and a characteristic handler as well as a nonvolatile memory in which parameter values, preferably in the form of a characteristic curve, obtained in the course of a learning run are stored, wherein the open-loop control unit is preceded by a closed-loop control unit which causes the motor to operate at constant speed, the characteristic handler continuously comparing the parameter values of the open-loop control unit that are critical for motor control with the parameter values stored in the nonvolatile memory. The closed-loop control unit may comprise a PID controller.
The object can also be achieved by a method for generating parameter values of a learning run for use in the above mentioned method or apparatus, wherein the speed of the motor can be kept constant by means of a closed-loop control unit, preferably a PID controller.
The travel path of the displacement element can be subdivided into a plurality of sections within which an average of the parameter values required for controlling the motor while its speed is maintained constant is calculated, the difference between the current parameter value and the previously stored parameter value being stored in the nonvolatile memory at the end of the section. The totality of all the stored parameter values can be stored as a characteristic in the nonvolatile memory. The parameter values can be the ratio of the on-time of the motor to the off-time of the motor.
Whereas open-loop motor control systems according to the prior art use stored parameter values, namely the above-described displacement force characteristic, in order to control the motor via complicated calculations so that it runs at a constant speed, in the method according to the invention the motor speed is closed-loop controlled using parameter values generated in real-time and which allow for the displacement forces actually required.
The speed of the motor is kept constant taking into account the mechanical forces actually occurring on the displacement element at the time of motor actuation, the parameter values generated in real-time being the result of closed-loop speed control causing the speed to remain constant and being used for controlling the motor.
For this process a closed-loop control unit is used, preferably a PID controller which keeps the rotation speed constant during the learning run and also during operational use. By means of said closed-loop control unit, the output of the motor and therefore the closing speed of the displacement element can now be quickly and reliably adapted to actual higher frictional resistances which in the case of a car window lift occur primarily at the beginning and end of a closing movement as a result of contact between the glass and the window sealing lips, the closed-loop control unit causing an open-loop control unit to generate the parameter values required for controlling the motor. In this way a duty cycle meeting the stated requirements can be provided.
Obviously, instead of the PID controller other closed-loop control systems can likewise be used for the purpose of speed regulation such as proportional and integral controllers together with their modifications and control circuits specifically designed to solve a particular problem, without departing from the inventive idea.
According to the characterizing feature of claim 2 , the parameter values generated in real-time for controlling the motor output are registered in the form of duty cycle values which are stored preferably as a duty cycle characteristic corresponding to the sluggishness or ease of movement of the displacement element as a result of the frictional resistance. As already explained above, the duty cycle is the ratio of the on-time of the motor to the off-time of the motor or, more precisely, the ratio of the on-time t on to the switching period T s , said switching period T s comprising one cycle of off-time t off and on-time t on . By means of appropriate variable clocking of the motor, a constant speed of the displacement element during its actuation can thus be achieved in spite of the different displacement forces required. This speed homogenization also provides auditory benefits, as the closing noise of the displacement element is now more evenly spread. Likewise the sight of a displacement element moving at a uniform speed is more visually acceptable particularly in the case of a car window lift.
As a result of the characterizing features of claim 3 , the motor is stopped and its drive direction preferably reversed if a defined difference between the stored parameter values and the parameter values generated in real-time is exceeded. In this way, an object or body part trapped by the displacement element can be detected in a direct and reliable manner.
By comparing the duty cycle characteristic currently being obtained with the characteristic already correctly stored during the learning run in respect of a constant speed, any obstruction in the path of the displacement element can be detected more quickly and more reliably. As there is now no need to calculate displacement forces required to overcome frictional resistances, the duty cycle set by the PWM controller can be compared directly with the values from the characteristic obtained in the learning run.
According to the characterizing features of claim 4 , the parameter values stored by means of the learning run are likewise the ratio of the on-time of the motor to the off-time of the motor, i.e. they are duty cycle values or a duty cycle characteristic. Directly comparing duty cycle values or characteristics permits direct data analysis using a simpler algorithm than that used in existing known methods according to the prior art. Any desired system speed can be defined, which means that an atypical or arbitrary speed characteristic can also be generated if required for particular applications.
Even during the learning run the speed of the system is controlled in accordance with the characterizing features of claim 5 in order to maintain it constant and thus obtain a realistic characteristic in respect of the displacement element's closing speed which is used as a reference for all subsequent closing movements. For all other closing movements of the displacement element following the learning run the speed is again maintained constant via the closed-loop control unit and the currently obtained duty cycle is compared directly with the stored duty cycle by a characteristic handler.
The characterizing features of claims 6 and 7 apply to an apparatus arrangement for implementing the described method, claim 6 providing that the open-loop control unit clocking the motor is preceded by a closed-loop control unit which causes the motor to be operated at constant speed, there being provided a characteristic handler which continuously compares the open-loop control unit's parameter values critical for motor control with the parameter values stored in a nonvolatile memory. The characteristic handler is disposed in a superordinate manner to all the other open- and closed-loop control units and can directly check the motor output control at any time in order to take the described action to stop the motor or reverse the drive motion.
According to the characterizing features of claim 7 , the closed-loop control unit described comprises a PID controller. By providing a permanently active PID controller, a desired speed of the displacement element can always be adjusted to suit the circumstances even after modification of the mechanism as the result of aging or changed operating conditions and kept constant at all times. In accordance with the comments made in connection with claim 1 , it is self-evident that other closed-loop control systems can likewise be used in place of the PID controller without departing from the inventive concept.
The apparatus according to the invention permits a simpler and direct data computation algorithm and the quality of the anti-trap protection can be set by means of the PID controller via the accuracy of the speed control system. This means that, the more accurately the PID controller is set, the more quickly it is possible to react to speed changes as the result of trapping. Any crushing of limbs can be reliably eliminated by accurate setting of the closed-loop control unit.
The characterizing features of claims 8 to 11 describe a method corresponding to the preceding claims for generating parameter values of a learning run.
In accordance with the characterizing features of claim 8 , the motor speed is kept constant during the characteristic-determining process by means of a closed-loop control unit, preferably a PID controller. In contrast to the prior art where a force profile over the travel path of the displacement element is stored before a duty cycle is calculated therefrom, with the system according to the invention a duty cycle corresponding to the frictional forces occurring is generated as early as the learning cycle with the speed already being kept constant. Consequently, in accordance with the characterizing features of claim 9 , a plurality of duty cycle values corresponding to different sections of the path traversed by the displacement element during its closing movement are calculated, an average of those parameter values required for controlling the motor while its speed is kept constant being calculated. For this purpose, at the end of each section the difference between the current parameter value and the previously stored parameter value is stored in the nonvolatile memory.
In accordance with the characterizing features of claim 10 , the totality of all the stored parameter values, which are likewise duty cycle values in accordance with the characterizing feature of claim 11 , are stored as characteristics in the nonvolatile memory. In practical terms this provides a ready-made predefined duty cycle for controlling the motor with constant speed while allowing for the specific mechanical properties of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in greater detail with reference to an exemplary embodiment in which:
FIG. 1 schematically illustrates a control circuit according to the invention
FIG. 2 shows pulse width modulation (PWM) clocking of the system
FIG. 3 schematically illustrates a duty cycle
DETAILED DESCRIPTION
FIG. 1 shows a control circuit as used in the method according to the invention, comprising a motor 1 , a closed-loop control unit 2 and a characteristic handler 3 . In this system the motor 1 is used to drive a displacement element 4 via an intermediate mechanism (not shown). The displacement elements 4 are openable and closable windows, doors or other closing devices, the use of the system according to the invention in the automotive industry being described in the present application with particular reference to power windows or sunroofs. However, the system according to the invention can also be used just as well, and prove advantageous, in building and gardens, for garage doors or automated closing devices generally.
The illustrated combination shows that the motor 1 is clocked mainly by means of pulse width modulation (PWM) via the open-loop control unit 2 (see FIG. 2 ). Output control by means of PWM allows the displacement force and speed required on the part of the motor to move the displacement element 4 to be randomly controlled. For this purpose the input voltage supplying the motor is switched on and off at high frequency in brief switching periods T s in the known manner. By extending the on-time t on a larger arithmetic mean of the output voltage and therefore a larger output current is achieved. The output of the motor is continuously controllable from 0 to 100% via this ratio known as a “duty cycle”. Purely by way of example, FIG. 2 shows the resulting square-wave signal 8 , the on-time t on here accounting for 50% of the switching periods T s , i.e. a duty cycle of 50%.
According to the invention, a closed-loop control unit 9 is used which keeps the speed in the system constant during a learning run and also during operational use. Although in the example a PID controller is proposed as closed-loop control unit because of its optimum and rapid control characteristics, another kind of controller can likewise also be employed. The PID controller reacts quickly and reliably to effective higher frictional resistances which the displacement element 4 has to overcome especially at the beginning and end of a closing movement as a result of mechanical transitions and adapts the output of the motor in such a way as to ensure a constant closing speed of the displacement element 4 .
The learning run must be carried out prior to initial commissioning of a new system, as each individual mechanical system always possesses a certain range of uncertain parameters and an individual characteristic as a result of manufacturing. The obtained parameter values characterizing the particular mechanical system according to the frictional resistances are stored as a duty cycle characteristic 5 in a nonvolatile memory 10 in order to serve as reference for all future closing movements of the displacement element 4 during operational use.
Such a duty cycle characteristic 5 is shown by way of example in FIG. 3 . Here the entire path over which the displacement element 4 travels when actuated is subdivided into small sections 6 and within each of these sections 6 an average of the above described duty cycle required is computed. Thus for each position of the displacement element 4 in its displacement path an output value is calculated with which the motor 1 must be controlled in order to overcome the particular frictional resistances while maintaining a constant displacement speed and to move the displacement element 4 to the end position provided. At the end of each section 6 , the difference between the current duty cycle value and the previous duty cycle value is stored so that a characteristic 5 is eventually produced from the total number of duty cycle values obtained at the predefined positions.
When the learning run has been completed, it is now the task of the characteristic handler 3 , for all future actuations of the displacement element 4 , to compare these stored duty cycle values with the current duty cycle values occurring on the relevant sections 6 . If a defined permissible deviation from the stored duty cycle characteristic 5 and therefore from the normal case provided by the learning run is exceeded, any obstacle trapped by the displacement element 4 is immediately detected by the characteristic handler 3 . In such cases appropriate action is taken by the characteristic handler 3 to eliminate the trapping hazard. This action can be either to stop the motor 1 or reverse is drive motion, and can also include suitable audible or visual signals.
The reference numeral 7 in FIG. 3 relates to the starting position for the comparison of the current duty cycle with the duty cycle characteristic 5 .
During all the closing movements of the displacement element 4 following the learning run, it is also the task of the PID controller to keep the speed constant. Whereas with known methods according to the prior art the necessary displacement force required by the motor 1 to move the displacement element 4 is calculated via the voltage and speed of the motor 1 and compared with stored displacement forces, in the system according to the invention any such displacement force calculation is no longer necessary, as the PID controller continuously monitors the speed of the motor 1 .
The duty cycle produced by the open-loop control unit 2 , which is created on the basis of the closed-loop control unit 9 , can now be compared directly with the duty cycle characteristic obtained in the learning run.
In this way, even after mechanical alteration as the result of aging or changing operating conditions, a desired characteristic of the displacement element 4 can always be approximated accordingly.
Now the trapping sensitivity can be adjusted using the PID controller via the accuracy of the speed control system.
The reliable speed regulation is accompanied by a more acceptable (because more uniform) closing noise of the displacement element 4 .
LIST OF REFERENCE NUMERALS USED
1 Motor
2 Open-loop control unit
3 Characteristic handler
4 Displacement element
5 Duty cycle characteristic
6 Sections
7 Starting position
8 Square-wave signal
9 Closed-loop control unit
10 Memory | In order to create a method and an apparatus for anti-trap protection detection for displaceable window and door elements by means of which faster and more stable adjustment to current physical conditions can be achieved during system actuation, in the system the motor ( 1 ) is controlled using parameter values generated in real-time using a closed-loop control unit, preferably a PID controller, to keep the speed in the system constant during a learning run and during operational use and to ensure timely trapping detection. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/910,941, filed Apr. 10, 2007, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
The present application is generally related to a header design for an implantable pulse generator for accepting one or more stimulation leads.
BACKGROUND
Neurostimulation systems are devices that generate electrical pulses and deliver the pulses to nerve tissue to treat a variety of disorders. Spinal cord stimulation (SCS) is an example of neurostimulation in which electrical pulses are delivered to nerve tissue in the spine for the purpose of chronic pain control. Other examples include deep brain stimulation, cortical stimulation, cochlear nerve stimulation, peripheral nerve stimulation, vagal nerve stimulation, sacral nerve stimulation, etc. While a precise understanding of the interaction between the applied electrical energy and the nervous tissue is not fully appreciated, it is known that application of an electrical field to spinal nervous tissue can effectively mask certain types of pain transmitted from regions of the body associated with the stimulated nerve tissue. Specifically, applying electrical energy to the spinal cord associated with regions of the body afflicted with chronic pain can induce “paresthesia” (a subjective sensation of numbness or tingling) in the afflicted bodily regions. Thereby, paresthesia can effectively mask the transmission of non-acute pain sensations to the brain.
Neurostimulation systems generally include a pulse generator and one or more leads. The pulse generator is typically implemented using a metallic housing that encloses circuitry for generating the electrical pulses, control circuitry, communication circuitry, a rechargeable battery, etc. The pulse generation circuitry is coupled to one or more stimulation leads through electrical connections provided in a “header” of the pulse generator. Specifically, feedthrough wires typically exit the metallic housing and into a header structure of a moldable material. Within the header structure, the feedthrough wires are electrically coupled to annular electrical connectors. The header structure holds the annular connectors in a fixed arrangement that corresponds to the arrangement of terminals on a stimulation lead. When a stimulation lead is properly inserted within a port of the header, each terminal of the lead contacts one of the annular electrical connectors and, thereby, is electrically coupled to the pulse generating circuitry through the feedthrough wires.
A number of fabrication issues are associated with the selection of the material for the header. If a non-compliant high durometer material is selected for the header, additional complexity is typically provided to the header design to hold the electrical connectors in place. Also, the placement of the electrical connectors in such a header can be unduly difficult. Alternatively, if a compliant material is selected for the header, the header can be easily punctured or otherwise damaged by surgical tools during an implantation procedure.
SUMMARY
In one embodiment, an implantable pulse generator for electrically stimulating a patient comprises: a metallic housing enclosing pulse generating circuitry; a header mechanically coupled to the metallic housing, the header adapted to seal terminals of one or more stimulation leads within the header and to provide electrical connections for the terminals; the header comprising an inner compliant component for holding a plurality of electrical connectors, the plurality of electrical connectors electrically coupled to the pulse generating circuitry through feedthrough wires, wherein the plurality of electrical connectors are held in place in recesses within the compliant inner component, the header further comprising an outer shield component adapted to resist punctures, the outer shield component fitting over at least a portion of the inner compliant component.
The foregoing has outlined rather broadly certain features and/or technical advantages in order that the detailed description that follows may be better understood. Additional features and/or advantages will be described hereinafter which form the subject of the claims. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the appended claims. The novel features, both as to organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an implantable pulse generator that includes a header according to one representative embodiment.
FIGS. 2A and 2B depict known electrical connectors that can be utilized within a header according to representative embodiments.
FIG. 3 depicts a compliant inner component of a header according to one representative embodiment.
FIG. 4 depicts a shield component of a header according to one representative embodiment.
FIG. 5 depicts a structure for holding an antenna in a helical manner according to one representative embodiment.
FIG. 6 depicts a schematic of an equivalent circuit for an antenna according to one representative embodiment.
DETAILED DESCRIPTION
Some representative embodiments are directed to a header design for a neurostimulation system. The header design preferably comprises a compliant silicone component and a shield component of a non-compliant material. The silicone component and the shield component cooperate to provide seals between the lead electrodes and to provide a barrier to protect against damage or punctures from surgical tools used during implantation. The header design also preferably comprises an antenna component that defines a helical antenna path to support RF communications. Also, the antenna component is preferably adapted to facilitate coupling of the antenna with tissue of the patient to achieve a greater communication range for the implantable pulse generator.
FIG. 1 depicts implantable pulse generator 100 according to one representative embodiment. Implantable pulse generator 100 comprises metallic housing 110 that encloses the pulse generating circuitry, control circuitry, communication circuitry, battery, etc. of the device. An example of pulse generating circuitry is described in U.S. Patent Publication No. 20060170486 entitled “PULSE GENERATOR HAVING AN EFFICIENT FRACTIONAL VOLTAGE CONVERTER AND METHOD OF USE,” which is incorporated herein by reference. A microprocessor and associated charge control circuitry for an implantable pulse generator is described in U.S. Patent Publication No. 20060259098, entitled “SYSTEMS AND METHODS FOR USE IN PULSE GENERATION,” which is incorporated herein by reference. Circuitry for recharging a rechargeable battery of an implantable pulse generator using inductive coupling with an external charging device is described in U.S. patent Ser. No. 11/109,114, entitled “IMPLANTABLE DEVICE AND SYSTEM FOR WIRELESS COMMUNICATION,” which is incorporated herein by reference. An example of a commercially available implantable pulse generator that may be adapted to include a header according to some representative embodiments is the EON® implantable pulse generator available from Advanced Neuromodulation Systems, Inc.
As shown in FIG. 1 , header 120 comprises compliant inner component 121 , non-compliant shield component 122 , and antenna component 123 . Compliant inner component 121 is preferably fabricated using an injection molding process and silicone based materials. Compliant inner component 121 is adapted to receive two stimulation leads (not shown) through strain relief elements 132 , although header 120 could be alternatively adapted to couple to any suitable number of stimulation leads. To minimize the profile of implantable pulse generator 100 , compliant inner component 121 is adapted to receive the stimulation leads in a side-by-side manner in one embodiment. Other embodiments may be configured to receive the stimulation leads in an above-below manner or even in an array-like manner for several stimulation leads.
Compliant inner component 121 is adapted to hold a plurality of electrical connectors 131 for each stimulation lead. Specifically, compliant inner component 121 comprises a plurality of recesses defined between respective wall structures 135 in which electrical connectors 131 are disposed. The compliant material characteristic of component 121 holds electrical connectors 131 in place by applying an elastomeric force. Electrical connectors 131 are spaced apart in relation to the spacing of the terminals of the stimulation leads intended to function with implantable pulse generator 100 . Each electrical connector 131 is electrically coupled to pulse generation circuitry within metallic housing 110 through a respective feedthrough wire as is known in the art. Compliant inner component 121 is shown in isolation in FIG. 3 . Apertures 301 within walls 135 are shown in FIG. 3 for the respective stimulation leads.
Typically, electrical connectors 131 are fabricated using an outer conductive annular or ring-like structure. Within the ring-like structure, one or more conductive members are held to engage a respective terminal of the stimulation lead. An example of known connector 200 is shown in FIG. 2A in which a canted spring is held within a conductive ring. Such connectors are commercially available from Bal Seal, Inc. of Foothill Ranch, Calif. Another example of known connector 250 is shown in FIG. 2B in which a conductive disk having arcuate connector tabs is held within a conductive ring as shown in U.S. Patent Publication No. 20050107859, entitled “SYSTEM AND METHOD OF ESTABLISHING AN ELECTRICAL CONNECTION BETWEEN AN IMPLANTED LEAD AND AN ELECTRICAL CONTACT,” which is incorporated herein by reference. It shall be appreciated that other types of electrical connectors could be employed such as “block electrical connectors” which are known in the art. Also, different types of electrical connectors could be employed within the same header in any suitable configuration.
Shield component 122 (shown in isolation in FIG. 4 ) is adapted to fit over a significant portion of and mechanically couple to inner compliant component 121 . Shield component 122 may also be adapted to fit over a portion or all of antenna component 123 . When header 120 is fully assembled and stimulation leads are placed in header 120 through strain relief elements 132 , the various conductive elements are sealed within the components of header 100 . Specifically, when implantable pulse generator 100 is implanted within a patient, the electrical components are sealed and are prevented from contacting bodily fluids. Additionally, shield component 122 is fabricated from a relatively hard material to prevent damage to or puncture of compliant inner component 121 . Specifically, if a sharp object used during the implantation procedure were to contact compliant inner component directly, compliant inner component 121 could be punctured somewhat easily. The puncture could allow entry of body fluids and cause the patient to experience electrical stimulation in the subcutaneous implantation pocket. By utilizing a suitable material for shield component 122 , compliant inner component 121 is protected from sharp surgical tools, needles, staples, and the like. An example of a suitable material for shield component 122 is a relatively high durometer Bionate® polycarbonate urethane.
Header 120 comprises antenna component 123 to facilitate RF communication between the implantable pulse generator 100 and an exterior controller device (not shown). The exterior shell of antenna component 123 is preferably a relative high durometer polymer. In one preferred embodiment, the exterior shell of antenna component 123 is a relatively high durometer Bionate® polycarbonate urethane. Platinum ribbon 133 forms the actual far field antenna and is preferably wrapped around a helical path defined within the interior of antenna component 123 . Preferably, the antenna and communication circuitry enable wireless communications within a range of several meters. In one embodiment, platinum ribbon 133 is wrapped around molded polymer component 501 (shown in FIG. 5 ) which is enclosed within the exterior shell of antenna component 123 . Polymer component 501 may provide any suitable number of revolutions for antenna ribbon 133 .
Referring again to FIG. 1 , platinum ribbon 133 is coupled to communication circuitry within metal housing 110 through feedthrough 134 . The upper segments of platinum ribbon 133 are disposed immediately below slots 136 of exterior shell of antenna component 123 . Slots 136 are formed by reducing the thickness of the polymer material of the exterior shell at the appropriate locations. The reduced thickness of the polymer material at these locations promotes the efficiency of the coupling of the RF signal with tissue of the patient. Such coupling facilitates a greater communication range for the RF signal.
Antenna 123 is preferably fully insulated from contact with human tissue by header 120 so that no corrosion products from the conductor of the antenna enter tissue, and, there is little surface impedance variation caused by fibrosis, scar tissue, etc, after implant. Surface impedance variation on the conductor may cause the distribution of radiating current density to change, possibly in a manner which deleteriously affects the radiation pattern outside the human body. Furthermore, gross surface impedance alterations may alter the amount of total electromagnetic energy radiated from/or into the antenna by causing intended emitted/absorbed energy to be reflected back to the transmitter.
The skewed cross-section shape of antenna 123 is preferably an inverted triangle with finite radius curves replacing triangle vertices. In one embodiment, the lowest, rounded, vertex is designed to be furthest from the straight top segment of each section, so that the enclosed area maximizes the storage of magnetic energy. But it is not so close to the conductive (“ground”) surface of the enclosure that coupling to the enclosure is more than a small fraction of the coupling from the top segment to tissue. In that way, RF displacement current is provided with a lower impedance path from top segments of the antenna, much lower than that between lowest rounded vertices.
In some embodiments, the lowest rounded vertices may have any radius of curvature up to and including half the width of header 120 . Or, as small as the minimum bend radius of conductor 133 according to some embodiments. However, as the radius of vertex curvature decreases, the RF electric field flux density increases in proximity to that vertex. The coupling to the enclosure would increase, and so to compensate those vertices would have to be displaced closer to the top segments of antenna 123 . This would reduce the magnetic energy storage (“inductance”) of each spiral revolution, or “turn” of the antenna. The intent of some embodiments is to optimize the inductance per turn with the (“electrostatic”) coupling between turns so that the overall impedance of the antenna maximizes coupling into human tissue along the top sections of antenna 123 , while also presenting an easily-matched impedance at the antenna feed terminal. The schematic 600 ( FIG. 6 ) shows the approximate lumped element equivalent circuit.
The intent of some embodiments is to enhance emission from the top of the antenna, with a return path through human tissue, such that the current density distribution maximizes radiation outside the human body. The alignment of antenna 123 is preferably adapted such that directions of maximum radiation power density tend to be located symmetrically either side of the antenna mid-plane. The optimum electric field polarization direction is transverse to the antenna mid-plane. There would be a null (minimum) of the transverse polarization radiation intensity in the antenna mid-plane, provided the surrounding medium (human tissue) was isotropic and homogeneous.
Each complete path (“revolution”) of inverted triangle with curved vertices, mentioned above, connects conductively with the adjacent triangular paths at one location, so that the complete antenna consists of multiple inverted triangular spiral elements connected together. The approximate equivalent circuit is shown in FIG. 6 , for the example of a six turn inverted triangular spiral antenna (6T ITSA).
The conductor 133 of antenna 123 preferably consists of a metal strip presenting a large surface area along the top segments of the antenna, so that capacitances (C12-17, above) are maximized for a given thickness of insulation (dielectric), having a certain dielectric constant. For example, a rectangular cross section with a surface resistance per unit area much less than the surface reactances per unit area, presented by C12-17, at the radio frequency of operation.
Although certain representative embodiments and advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate when reading the present application, other processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the described embodiments may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | In one embodiment, an implantable pulse generator for electrically stimulating a patient comprises: a metallic housing enclosing pulse generating circuitry; a header mechanically coupled to the metallic housing, the header adapted to seal terminals of one or more stimulation leads within the header and to provide electrical connections for the terminals; the header comprising an inner compliant component for holding a plurality of electrical connectors, the plurality of electrical connectors electrically coupled to the pulse generating circuitry through feedthrough wires, wherein the plurality of electrical connectors are held in place in recesses within the compliant inner component, the header further comprising an outer shield component adapted to resist punctures, the outer shield component fitting over at least a portion of the inner compliant component. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Korean Patent Application No. 10-2013-0113046, filed on Sep. 24, 2013, and all the benefits accruing therefrom under 35 U.S.C. §119, the contents of which in its entirety are herein incorporated by reference.
BACKGROUND
1. Field
The present disclosure relates to a method for producing a hexagonal boron nitride film by using a borazine oligomer as a precursor and a boron nitride film obtained thereby.
2. Description of the Related Art
Boron nitride (also referred to as BN hereinafter) is a material having a boron atom (atomic number 5) and a nitrogen atom (atomic number 7) bound to each other at a stoichiometric ratio of 1:1. Between the boron atom and the nitrogen atom bound to each other, a strong sp 2 covalent bonding is formed. In addition, weak van der waals force is present between two layers of boron nitride. Due to the difference in interatomic distance and in distance between two layers of boron nitride depending on bonding structures and types, different structures, such as cubic-boron nitride (c-BN), hexagonal-boron nitride (h-BN) and wurtzite-boron nitride (w-BN), are present.
Among those, hexagonal boron nitride (white graphene, h-BN) film is an insulator and is transparent and flexible. Basically, it is stable at high temperature, has thermal properties characterized by high heat conductivity, and shows mechanical properties, including a low elastic modulus and heat expansion coefficient, and high heat resistance and thermal shock resistance. In addition, such a hexagonal boron nitride film has a low dielectric constant and dielectric loss and shows a band gap of about 5.5-6.06 eV, thereby providing characteristics as a dielectric material. Meanwhile, it has a hexagonal structure, which is the same as the structure of graphene, a two-dimensional material having excellent physical properties and shows a lattice mismatch of merely about 1.7%, and thus may form various structures together with graphene. Therefore, by virtue of the excellent thermal properties, mechanical properties, electrical properties and structural characteristics as described above, a hexagonal BN film may be used for various industrial fields, and may be utilized particularly as a next-generation electronic material.
There are several methods for producing a hexagonal boron nitride film. Typical methods include a mechanical method, chemical exfoliation of bulk flake, vapor deposition using sputtering, ion implantation, atomic layer deposition (ALD), or the like. Particularly, chemical vapor deposition (CVD) method is used most frequently.
The mechanical method includes exfoliation of at least two layers of hexagonal boron nitride using Scotch tape. Upon exfoliation, weal van der waals force exists between two layers of boron nitride. Thus, the mechanical method is problematic in that it is limited in size of the exfoliated hexagonal boron nitride and in productivity.
The chemical exfoliation of bulk flake includes exfoliating bulk flake of hexagonal boron nitride by way of sonication in the presence of a solvent, such as dimethyl formamide and dichloroethane. The hexagonal boron nitride exfoliated by the chemical exfoliation has problems of its limited size and thickness control.
The CVD method includes gasifying borazine to allow its flow, decomposing borazine into boron and nitrogen at high temperature and allowing the reaction of boron and nitrogen on the surface of a specific metal catalyst substrate to form a hexagonal boron nitride film. The hexagonal boron nitride film obtained by the CVD method has low defects. However, the CVD method is problematic in that the film thus obtained has a different number of layers due to the difference in growth rate, an expensive gas controller or vacuum system is required, and gases showing a difficulty in handling are used.
REFERENCES OF THE RELATED ART
Patent Document
(Patent Document 1) Korean Laid-Open Patent Publication No. 10-2009-0124330 (1996 Mar. 26)
(Patent Document 2) U.S. Pat. No. 5,502,142 (1996 Mar. 26)
(Patent Document 3) U.S. Pat. No. 6,025,454 (2000 Feb. 15)
(Patent Document 4) U.S. Pat. No. 4,970,095 (1990 Nov. 13)
(Patent Document 5) U.S. Pat. No. 4,971,779 (1990 Nov. 20)
(Patent Document 6) U.S. Pat. No. 5,204,295 (1993 Apr. 20)
(Patent Document 7) U.S. Pat. No. 6,277,348 (2001 Aug. 21)
(Patent Document 8) US Patent Application Laid-Open No. 2011-0256386 (2011 Oct. 20)
Non-Patent Document
(Non-patent Document 1) Journal of Materials Research—L. G. Sneddon (1996) Vol. 11, No. 2, 373-380.
(Non-patent Document 2) Journal of Industry and Engineering Chemistry Dong-pyo Kim (2004) Vol. 10, No. 6, 936-939.
(Non-patent Document 3) Surface and Coatings Technology Berangere Toury (2007) 201, 7822-7828.
SUMMARY
The present disclosure is directed to providing a high-quality highly crystalline hexagonal boron nitride film and a method for producing the same. To solve the above-mentioned problems, a hexagonal boron nitride film is provided by dissolving a borazine oligomer into a solvent to form a boron nitride precursor solution and coating the boron nitride precursor solution onto a metal catalyst, followed by annealing.
In one aspect, there is provided a method for producing a boron nitride film, including:
mixing a borazine oligomer with an organic solvent to form a boron nitride precursor solution;
coating the boron nitride precursor solution onto a substrate; and
carrying out phase transfer of the borazine oligomer in the coated boron nitride precursor solution to produce a hexagonal boron nitride film.
According to an embodiment, the substrate used for the coating may be a metal catalyst substrate. According to another embodiment, the method for producing a boron nitride film may further include, after the coating, depositing a metal catalyst onto the substrate coated with the boron nitride precursor solution.
In another aspect, there is provided a boron nitride film obtained by the above method.
According to the present disclosure, a borazine oligomer ((B 3 N 3 H 4 ) x ) that is obtained by thermal oligomerization of borazine and is controllable in its viscosity is dissolved in a currently used solvent so that it may be used as a precursor. In this manner, the problems, such as control of a gaseous precursor and vapor pressure control, occurring in the CVD (Chemical vapor deposition) method according to the related art are solved, and a high-quality hexagonal boron nitride film is obtained through a simple process at low cost. In addition, the borazine oligomer may be coated onto a metal catalyst substrate or a metal catalyst may be deposited after coating so that a metal catalyst layer is positioned under or on the precursor. Subsequently, heat treatment is carried out to obtain a highly crystalline hexagonal boron nitride (h-BN) film having the same level as graphene formed of carbon, i.e., white graphene, on various structures and materials.
Further, selective coating is allowed so as to carry out coating in a predetermined area and scale-up is also allowed. Therefore, a high-quality hexagonal boron nitride film may be grown directly on electric materials, various substrates and composite materials such as carbon fibers, and thus functional coating may be accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the disclosed exemplary embodiments will be more apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic view showing a solubilized borazine oligomer coated on nickel and a hexagonal boron nitride film prepared on nickel;
FIG. 2 is a schematic view illustrating Method I and Method II according to an embodiment of the present disclosure;
FIG. 3 is a photographic image showing the hexagonal boron nitride film obtained according to an embodiment and transferred on a SiO 2 /Si wafer substrate;
FIG. 4 shows lattice vibration scattering modes of the hexagonal boron nitride film obtained according to an embodiment and transferred onto a SiO 2 /Si wafer substrate, as determined by Raman analysis;
FIG. 5 shows lattice vibration absorption modes of the hexagonal boron nitride film obtained according to an embodiment and transferred onto a SiO 2 /Si wafer substrate, as determined by Fourier transform infrared (FT-IR) analysis;
FIG. 6 a shows the results of qualitative elemental analysis of the hexagonal boron nitride film obtained according to an embodiment and transferred onto a SiO 2 /Si wafer substrate, as determined by X-ray photoelectron spectroscopy (XPS);
FIG. 6 b shows the element of boron (B) 1s of the hexagonal boron nitride film obtained according to an embodiment and transferred onto a SiO 2 /Si wafer substrate, as determined by XPS;
FIG. 6 c shows the element of nitrogen (N) 1s of the hexagonal boron nitride film obtained according to an embodiment and transferred onto a SiO 2 /Si wafer substrate, as determined by XPS;
FIG. 7( a ) - FIG. 7( d ) show the interlayer structure of the hexagonal boron nitride film obtained according to an embodiment, as determined by transmission electron microscope (TEM) analysis;
FIG. 8 shows the hexagonal structure of the hexagonal boron nitride film obtained according to an embodiment, as determined by selected area electron diffraction (SAED); and
FIG. 9 shows the sp 2 bonding of the hexagonal boron nitride film obtained according to an embodiment, as determined by electron energy loss spectroscopy (EELS).
DETAILED DESCRIPTION
Exemplary embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. The present disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth therein. Rather, these exemplary embodiments are provided so that the present disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. In the description, details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the presented embodiments.
In one aspect, there is provided a method for producing a boron nitride film, including:
mixing a borazine oligomer with an organic solvent to form a boron nitride precursor solution;
coating the boron nitride precursor solution onto a substrate; and
carrying out phase transfer of the borazine oligomer in the coated boron nitride precursor solution to produce a hexagonal boron nitride film.
More particularly, according to an embodiment, the substrate used for the coating is a metal catalyst substrate, which is metal foil functioning as a catalyst or thin film having a catalyst metal deposited thereon. According to another embodiment, the method may further include, after coating the precursor solution onto a substrate, depositing a metal catalyst onto the coated precursor solution. In other words, the borazine oligomer in the boron nitride precursor solution is coated on the metal catalyst substrate or a metal catalyst is deposited after the coating so that the metal catalyst layer may be positioned under or on the precursor. In this manner, it is possible to obtain a high-quality highly crystalline hexagonal boron nitride film with ease as a result of phase transfer through activation energy.
According to an embodiment, the borazine oligomer used for the method for producing a boron nitride film is obtained by carrying out thermal oligomerization of borazine. According to another embodiment, the organic solvent used for forming the boron nitride precursor solution may be at least one selected from the group consisting of benzene, chlorobenzene, nitrobenzene, toluene, phenol, hexane and cyclohexane.
In addition, the method for producing a boron nitride film may further include, after forming the boron nitride precursor solution, aging the precursor solution thus formed to adjust the viscosity thereof. According to an embodiment, in order to control the viscosity while the precursor solution is aged, the precursor solution (the borazine oligomer in the boron nitride precursor solution) may be refrigerated at a temperature ranging from −24° C. to −36° C.
According to an embodiment, the substrate may be formed of at least one material selected from the group consisting of silicon, silicon oxide, sapphire, quartz, glass, graphite, indium oxide, polyacrylonitrile (PAN), polyethylene terephthalate (PET), polydimethylsiloxane (PDMS), polyethylene (PE), steel and carbon fibers. According to another embodiment, the metal of the metal catalyst substrate or the metal of the metal catalyst to be deposited on the precursor solution coated on the substrate may be at least one selected from the group consisting of nickel, palladium, platinum, copper, titanium, ruthenium, chrome, iron, aluminum, silver, and alloys thereof. According to still another embodiment, the metal catalyst may be deposited on the precursor solution coated on the substrate by at least one process selected from the group consisting of sputtering, thermal evaporation and electron beam evaporation.
According to an embodiment, the substrate may have a thickness of 100 nm to 40 μm. According to another embodiment, the metal catalyst substrate may be one treated by at least one process selected from the group consisting of annealing, electrochemical polishing and metal surface cleaning. For example, the metal surface cleaning may be performed by cleaning the metal substrate surface with at least one selected from the group consisting of a metal etchant, acetone, ethanol, methanol and isopropanol.
According to an embodiment, the coating operation in the method for producing a boron nitride film may be carried out under the condition of inert gas by at least one coating process selected from the group consisting of spin coating, spray coating, drop coating and dip coating. For example, the inert gas may be at least one selected from the group consisting of argon and nitrogen. According to another embodiment, after the coating, the method may further include baking the coated substrate to remove the organic solvent.
According to an embodiment, the phase transfer from the borazine oligomer to hexagonal boron nitride may be one using at least one type of energy selected from thermal energy, plasma, laser, electron beams, ion beams and UV irradiation. Particularly, the phase transfer may be carried out under the condition of at least one gas selected from argon, nitrogen, hydrogen, ammonia and helium. For example, the phase transfer may be carried out by using thermal energy through heat treatment at 800-1200° C. for 1-2 hours. During the heat treatment, the pressure in the reaction chamber may be controlled within a range of 100 mtorr-760 torr.
According to an embodiment, the method for producing a boron nitride film may further include transferring the obtained hexagonal boron nitride film to a substrate by using a polymeric protective film. Herein, the substrate may be formed of at least one material selected from the group consisting of silicon, silicon oxide, sapphire, quartz, glass, graphite, indium oxide, polyacrylonitrile (PAN), polyethylene terephthalate (PET), polydimethylsiloxane (PDMS), polyethylene (PE), steel and carbon fibers.
According to an embodiment, the method for producing a boron nitride film may further include treating the obtained hexagonal boron nitride film with at least one solution selected from the group consisting of ammonium persulfate, ferric chloride (FeCl 3 ), nitric acid, hydrochloric acid and sulfuric acid etching solutions in order to remove the metal catalyst deposited as an overlayer or the metal catalyst substrate layer as an underlayer.
In another aspect, there are provided a boron nitride film obtained by the method as described above, and an electronic material including the boron nitride film.
Hereinafter, two embodiments of the method for producing a boron nitride film, i.e., a method (Method I) for producing a boron nitride film including coating the borazine oligomer in the boron nitride precursor solution onto a metal catalyst substrate so that the metal catalyst layer may be positioned under the precursor, and a method (Method II) for producing a boron nitride film including depositing a metal catalyst after coating so that the metal catalyst layer may be positioned on the precursor will be described separately in a stepwise manner.
Method I
First, a borazine oligomer (B 3 N 3 H 4 ) x is prepared. The borazine oligomer to be prepared is not particularly limited but should be one that can be mixed with an organic solvent to form a boron nitride precursor solution.
According to an embodiment, the borazine oligomer (B 3 N 3 H 4 )x may be obtained by reacting ammonia borane (NH 3 BH 3 ) with metal nanoparticles and tetraglyme at 80° C. to obtain borazine, which, in turn, is subjected to thermal oligomerization at a temperature of 70° C. for 48-60 hours.
In the above embodiment, the metal nanoparticles used for preparing borazine may serve to reduce the reaction temperature. For example, the metal nanoparticle may be at least one selected from the group consisting of Ni, Pd, Fe, Co, Cu, Au, Ag and Mn.
When preparing the borazine oligomer, it is possible to control the oligomerization degree by adjusting the time required for thermal oligomerization of borazine.
Next, the borazine oligomer thus obtained is mixed with an organic solvent to form a boron nitride precursor solution.
The organic solvent is not particularly limited, as long as it can be mixed with the borazine oligomer to form a boron nitride precursor solution.
According to an exemplary embodiment, the organic solvent may be at least one selected from the group consisting of benzene, chlorobenzene, nitrobenzene, toluene, phenol, hexane and cyclohexane. The organic solvent may be one capable of maintaining the chain structure of borazine oligomer and having adequate viscosity so as to increase the efficiency of the subsequent coating operation.
According to an exemplary embodiment, in order to control or optimize the viscosity of the boron nitride precursor solution (solubilized borazine oligomer), the method may further include aging the boron nitride precursor solution by refrigerating it at a temperature ranging from −24° C. to −36° C.
Then, the aged boron nitride precursor solution is coated onto a metal catalyst substrate.
For example, the metal of the metal catalyst substrate may be at least one selected from the group consisting of nickel, palladium, platinum, copper, titanium, ruthenium, chrome, iron, aluminum and silver, or an alloy thereof.
The catalyst reactivity and dehydrogenation degree vary with the particular type of the metal catalyst substrate, which affects the time and temperature required for carrying out heat treatment for the purpose of phase transfer.
Although there is no particular limitation in the thickness of the metal catalyst substrate, the metal catalyst substrate may have a thickness of 100 nm to 40 μm. The thickness of the metal catalyst substrate may affect etching during the subsequent transferring operation, and may be a factor that causes a difference in surface state after heat treatment.
According to an embodiment, the metal catalyst substrate may be one treated by at least one process selected from the group consisting of annealing, electrochemical polishing and metal surface cleaning, before it is coated with the boron nitride precursor solution.
According to another embodiment, the metal surface cleaning may be performed by cleaning the metal substrate surface with at least one selected from the group consisting of a metal etchant, acetone, ethanol, methanol and isopropanol.
When the precursor solution is coated onto the metal catalyst substrate, the coating operation may be carried out under the condition of inert gas by at least one coating process selected from the group consisting of spin coating, spray coating, drop coating and dip coating. In the coating operation, the inert gas may be at least one selected from the group consisting of argon and nitrogen, or a mixed gas thereof.
According to still another embodiment, after the precursor solution is coated onto the metal catalyst substrate, the method may further include baking the coated metal catalyst substrate to remove the organic solvent. The baking operation is not particularly limited but may be carried out by heat treatment within a temperature range of 150-200° C. for 5-30 minutes. By virtue of such baking operation, it is possible to remove the organic solvent, to minimize the risk of reaction of the boron nitride film precursor upon its exposure to air, and to reduce the loss of precursor mass during the subsequent phase transfer.
After the completion of the coating operation, the borazine oligomer coated on the metal catalyst substrate is allowed to undergo phase transfer to obtain a hexagonal boron nitride film.
The phase transfer is not particularly limited, as long as it allows conversion from the solubilized and dried borazine oligomer into a hexagonal boron nitride film. For example, the phase transfer may be one using at least one type of energy selected from thermal energy, plasma, laser, electron beams, ion beams and UV energy.
As an activation energy source for the phase transfer, it is possible to apply various energy sources to the borazine oligomer coating film in addition to thermal energy.
According to an exemplary embodiment, for the heat treatment through a thermal process, the phase transfer may be carried out by heat treatment at 800-1200° C. for 1-2 hours. During the heat treatment under the above conditions, the borazine oligomer having low crystallinity may undergo phase transfer into a highly crystalline hexagonal boron nitride film. In addition, during the heat treatment, the pressure in the reaction chamber may be controlled within a range of 100 mtorr-760 torr.
The phase transfer from the borazine oligomer to hexagonal boron nitride may be carried out under gaseous atmosphere. For example, the gas atmosphere for the phase transfer may be at least one gas selected from argon, nitrogen, hydrogen, ammonia and helium, or a mixed gas thereof. The gaseous atmosphere may affect the phase transfer reaction rate. When using hydrogen or nitrogen alone, it is possible to accelerate the phase transfer reaction. However, in this case, reverse-reaction may occur undesirably. Therefore, it is important to control the atmosphere as desired.
According to an embodiment, the method may further include treating the hexagonal boron nitride film obtained through the phase transfer with at least one solution selected from the group consisting of ammonium persulfate, ferric chloride (FeCl 3 ), nitric acid, hydrochloric acid and sulfuric acid etching solutions in order to remove the metal substrate layer as an underlayer of the hexagonal boron nitride film.
According to an embodiment, the method may further include transferring the hexagonal boron nitride film obtained through the phase transfer to a substrate by using a polymeric protective film. Herein, the polymer serving as a protective film may be poly(methyl methacrylate), polydimethylsiloxane, or the like. The use of such a polymeric protective film allows selective etching of the metal catalyst substrate alone. Thus, it is possible to transfer the hexagonal boron nitride film to a predetermined substrate.
The substrate for use in the transferring operation is not particularly limited, but particular examples thereof include substrates made of at least one material selected from the group consisting of silicon, silicon oxide, sapphire, quartz, glass, graphite, indium oxide, polyacrylonitrile (PAN), polyethylene terephthalate (PET), polydimethylsiloxane (PDMS), polyethylene (PE), steel and carbon fibers.
The hexagonal boron nitride film obtained by the method including the operations as describe above has high quality, and is produced more efficiently at lower cost as compared to the CVD process according to the related art so as to allow mass production.
In addition, the hexagonal boron nitride film thus obtained may be applied to various materials, such as dielectric materials of transistor devices or memory devices. Further, it may be applied to printing processes, electronic materials, composite materials, or the like.
Then, Method II will be explained in a stepwise manner.
Method II
In the same manner as described in Method I, a borazine oligomer is prepared, the borazine oligomer thus prepared is mixed with an organic solvent to form a boron nitride precursor solution, and the precursor solution thus formed is aged to control the viscosity thereof.
After the aging, the aged boron nitride precursor solution is coated onto a substrate. The precursor solution may be coated onto a predetermined substrate. The substrate is not particularly limited, but particular examples thereof include substrates made of at least one material selected from the group consisting of silicon, silicon oxide, sapphire, quartz, glass, graphite, indium oxide, polyacrylonitrile (PAN), polyethylene terephthalate (PET), polydimethylsiloxane (PDMS), polyethylene (PE), steel and carbon fibers. In addition, the substrate is not particularly limited, as long as it is one requiring protective or functional coating.
When the precursor solution is coated onto the substrate, the coating operation may be carried out under the condition of inert gas by at least one coating process selected from the group consisting of spin coating, spray coating, drop coating and dip coating. In the coating operation, the inert gas may be at least one selected from the group consisting of argon and nitrogen, or a mixed gas thereof.
After the precursor solution is coated onto the substrate, the method may further include baking the coated substrate to remove the organic solvent. The baking operation is not particularly limited but may be carried out by heat treatment within a temperature range of 150-200° C. for 5-30 minutes. By virtue of such baking operation, it is possible to remove the organic solvent, to minimize the risk of reaction of the boron nitride film precursor upon its exposure to air, and to reduce the loss of precursor mass during the subsequent phase transfer.
After the completion of the coating operation, a metal catalyst is deposited on the borazine oligomer coated on the substrate, and the borazine oligomer is allowed to undergo phase transfer to obtain a hexagonal boron nitride film.
For example, the metal of the metal catalyst may be at least one selected from the group consisting of nickel, palladium, platinum, copper, titanium, ruthenium, chrome, iron, aluminum and silver, or an alloy thereof.
When the metal catalyst is deposited on the substrate, the deposition process is not particularly limited but may be carried out by at least one selected from the group consisting of sputtering, thermal evaporation and electron beam evaporation.
After the completion of the deposition of the metal catalyst, phase transfer is carried out. The phase transfer is not particularly limited, as long as it allows conversion from the solubilized and dried borazine oligomer into a hexagonal boron nitride film. For example, the phase transfer may be one using at least one type of energy selected from thermal energy, plasma, laser, electron beams, ion beams and UV energy.
As an activation energy source for the phase transfer, it is possible to apply various energy sources to the borazine oligomer coating film in addition to thermal energy.
According to an exemplary embodiment, for the heat treatment through a thermal process, the phase transfer may be carried out by heat treatment at 800-1200° C. for 1-2 hours. During the heat treatment under the above conditions, the borazine oligomer having low crystallinity may undergo phase transfer into a highly crystalline hexagonal boron nitride film. In addition, during the heat treatment, the pressure in the reaction chamber may be controlled within a range of 100 mtorr-760 torr.
The phase transfer from the borazine oligomer to hexagonal boron nitride may be carried out under gaseous atmosphere. For example, the gas atmosphere for the phase transfer may be at least one gas selected from argon, nitrogen, hydrogen, ammonia and helium, or a mixed gas thereof. The gaseous atmosphere may affect the phase transfer reaction rate. When using hydrogen or nitrogen alone, it is possible to accelerate the phase transfer reaction. However, in this case, reverse-reaction may occur undesirably. Therefore, it is important to control the atmosphere as desired.
According to an embodiment, the method may further include treating the hexagonal boron nitride film obtained through the phase transfer with at least one solution selected from the group consisting of ammonium persulfate, ferric chloride (FeCl 3 ), nitric acid, hydrochloric acid and sulfuric acid etching solutions in order to remove the metal catalyst deposited as an overlayer of the hexagonal boron nitride film.
The hexagonal boron nitride film obtained by the method including the operations as describe above has high quality, and is produced more efficiently at lower cost as compared to the CVD process according to the related art so as to allow mass production.
In addition, the hexagonal boron nitride film thus obtained may be applied to various materials, such as dielectric materials of transistor devices or memory devices. Further, it may be applied to printing processes, electronic materials, composite materials, or the like.
EXAMPLES
The examples and experiments will now be described. The following examples and experiments are for illustrative purposes only and not intended to limit the scope of the present disclosure.
Example 1
A solubilized borazine oligomer (boron nitride precursor solution) is used to prepare a hexagonal boron nitride film. For this, a borazine oligomer ((B 3 H 3 H 4 ) x ) is prepared through the thermal oligomerization of borazine.
Next, the borazine oligomer is mixed with chlorobenzene to obtain a boron nitride precursor solution optimized for coating.
As a metal catalyst substrate, nickel foil is provided. The nickel foil is treated by electrochemical polishing under the condition of 2 volt for 20 minutes. Then, metal surface treatment is carried out through a 5-minute cleaning process including introduction into acetone and ethanol, followed by sonication.
The solubilized borazine oligomer is coated onto the metal catalyst substrate through spin-coating under the condition of 9000 rpm. Then, baking is carried out at 150° C. for 20 minutes.
Then, the borazine oligomer coated on the metal catalyst substrate is subjected to heat treatment by increasing the temperature to 1000° C. and carrying out heat treatment under argon (Ar) atmosphere at a pressure of 600 mtorr for 1 hour, followed by cooling for 2 hours.
Example 2
A solubilized borazine oligomer (boron nitride precursor solution) is used to prepare a hexagonal boron nitride film. For this, a borazine oligomer ((B 3 H 3 H 4 ) x ) is prepared through the thermal oligomerization of borazine.
Next, the borazine oligomer is mixed with chlorobenzene to obtain a boron nitride precursor solution optimized for coating.
The solubilized borazine oligomer is coated onto a silicon substrate through spin-coating under the condition of 9000 rpm. Then, baking is carried out at 150° C. for 20 minutes.
Then, a nickel metal catalyst is deposited on the borazine oligomer coated on the silicon substrate trough electron beam evaporation.
Then, the borazine oligomer coated on the metal catalyst substrate is subjected to heat treatment by increasing the temperature to 1000° C. and carrying out heat treatment under argon (Ar) atmosphere at a pressure of 600 mtorr for 1 hour, followed by cooling for 2 hours.
Example 1 and Example 2 are illustrated schematically in FIG. 2 .
Test Example 1
In order to transfer the hexagonal boron nitride film obtained from Example 1 to a SiO 2 /Si substrate, poly(methyl methacrylate) is spin-coated on the hexagonal boron nitride film as a polymeric protective film. FeCl 3 is used as an etchant solution, to remove the nickel catalyst substrate. After etching, rinsing is carried out several times with tertiary distilled water to transfer the hexagonal boron nitride film to the SiO 2 /Si substrate. Then, the hexagonal boron nitride film is immersed into acetone to remove poly(methyl methacrylate), and then rinsed several times with tertiary distilled water, followed by drying in an oven at 50° C.
The photographic image of the hexagonal boron nitride film prepared on the SiO 2 /Si substrate in the manner as described above is shown in FIG. 3 .
Test Example 2
The hexagonal boron nitride film obtained from Example 1 is subjected to Raman spectroscopy, and the scattering modes of lattice vibration of the hexagonal boron nitride film are shown in FIG. 4 . As the position of the lattice vibration mode of boron and nitrogen in the hexagonal boron nitride film, 1364 cm −1 is checked.
Test Example 3
The hexagonal boron nitride film obtained from Example 1 is subjected to Fourier transform infrared (FT-IR) analysis, and the absorption modes of lattice vibration of the hexagonal boron nitride film are shown in FIG. 5 . As the position of the in-plane stretching vibration mode of boron and nitrogen in the hexagonal boron nitride film, 1368 cm −1 is checked. In addition, as the position of the out-of plane bending vibration mode of boron and nitrogen, 818 cm −1 is checked.
Test Example 4
The hexagonal boron nitride film obtained from Example 1 is subjected to X-ray photoelectron spectroscopy (XPS), and the results of qualitative elemental analysis of the hexagonal boron nitride film are shown in FIG. 6 . It can be seen from the results of elemental analysis that oxygen and silicon are derived from the substrate.
As can be seen from FIGS. 6 b and 6 c , the elemental binding energy of B 1s and that of N 1s are 190.75 eV and 398.2 eV, respectively.
Test Example 5
The hexagonal boron nitride film obtained from Example 1 is subjected to electron energy loss spectroscopy (EELS) and sp 2 bonding is shown in FIG. 9 .
While the exemplary embodiments have been shown and described, it will be understood by those skilled in the art that various changes in form and details may be made thereto without departing from the spirit and scope of the present disclosure as defined by the appended claims. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular exemplary embodiments disclosed as the best mode contemplated for carrying out the present disclosure, but that the present disclosure will include all embodiments falling within the scope of the appended claims. | Provided is a method for producing a high-quality boron nitride film grown by using a borazine oligomer as a precursor through a metal catalyst effect. The method solves the problems, such as control of a gaseous precursor and vapor pressure control, occurring in CVD (Chemical vapor deposition) according to the related art, and a high-quality hexagonal boron nitride film is obtained through a simple process at low cost. In addition, the hexagonal boron nitride film may be coated onto various structures and materials. Further, selective coating is allowed so as to carry out coating in a predetermined area and scale-up is also allowed. Therefore, the method may be useful for coating applications of composite materials and various materials. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Serial No. 60/373,568, filed Apr. 18, 2002, and German Application No. 103 12 464.0, filed Mar. 20, 2003, the disclosures of each of which are hereby incorporated herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates generally to industrial rolls, and more particularly to covers for industrial rolls.
BACKGROUND OF THE INVENTION
[0003] Cylindrical rolls are utilized in a number of industrial applications, especially those relating to papermaking. Such rolls are typically employed in demanding environments in which they can be exposed to high dynamic loads and temperatures and aggressive or corrosive chemical agents. As an example, in a typical paper mill, rolls are used not only for transporting a fibrous web sheet between processing stations, but also, in the case of press section and calender rolls, for processing the web sheet itself into paper.
[0004] Typically rolls used in papermaking are constructed with the location within the papermaking machine in mind, as rolls residing in different positions within the papermaking machines are required to perform different functions. Because papermaking rolls can have many different performance demands, and because replacing an entire metallic roll can be quite expensive, many papermaking rolls include a polymeric cover that surrounds the circumferential surface of a typically metallic core. By varying the material employed in the cover, the cover designer can provide the roll with different performance characteristics as the papermaking application demands. Also, repairing, regrinding or replacing a cover over a metallic roll can be considerably less expensive than the replacement of an entire metallic roll. Exemplary polymeric materials for covers include natural rubber, synthetic rubbers such as neoprene, styrene-butadiene (SBR), nitrile rubber, chlorosulfonated polyethylene (“CSPE”—also known under the trade name HYPALON® from DuPont), EDPM (the name given to an ethylene-propylene terpolymer formed of ethylene-propylene diene monomer), polyurethane, thermoset composites, and thermoplastic composites.
[0005] In many instances, the roll cover will include at least two distinct layers: a base layer that overlies the core and provides a bond thereto; and a topstock layer that overlies and bonds to the base layer and serves the outer surface of the roll (some rolls will also include an intermediate “tie-in” layer sandwiched by the base and top stock layers). The layers for these materials are typically selected to provide the cover with a prescribed set of physical properties for operation. These can include the requisite strength, elastic modulus, and resistance to elevated temperature, water and harsh chemicals to withstand the papermaking environment. In addition, covers are typically designed to have a predetermined surface hardness that is appropriate for the process they are to perform, and they typically require that the paper sheet “release” from the cover without damage to the paper sheet. Also, in order to be economical, the cover should be abrasion- and wear-resistant.
[0006] Some rolls are present as “nip” rolls, wherein two or more rolls are positioned such that they form a “nip” through which a web can pass. Such rolls are often found, for example, in the press section of a papermaking machine. The rolls press against the web at a prescribed pressure in order to advance processing. However, in some instances the rolls can apply pressure unevenly on the web. Uneven pressure application can result from many circumstances, including (a) the cover of one or more rolls being slightly “out of round”, (b) one roll being mounted so that its axis is not parallel to that of its mating roll, or (c) increased localized wear on one of the roll covers. Irrespective of the cause of the uneven pressure, its presence can negatively impact processing of the web, and can in extreme instances harm the cover or even cause it to fracture.
[0007] Further, the temperature of a roll can influence processing. Uneven or undesirable temperature distributions can be created in a roll by some of the same mechanisms described above for uneven pressure application.
[0008] Some systems for attempting to detect the pressure or temperature within a roll are available. One system includes a flexible strip on which are mounted multiple pressure sensors that can be placed between the rolls and provide pressure and/or temperature readings (see, e.g., U.S. Pat. No. 5,953,230 to Moore). Another system employs sensors that are embedded in the roll cover itself and provide signals to an external processor (see, e.g., U.S. Pat. No. 5,699,729 to Moschel et al.). However, each of these systems include electric or electronic communications equipment and data that may require processing, maintenance and the like and that may malfunction or interfere with operations. As such, it would be desirable to provide an alternative system for detecting pressure and/or temperature levels and distribution in rolls.
SUMMARY OF THE INVENTION
[0009] The present invention can provide rolls and polymeric roll covers therefore that are able indicate levels of pressure and/or temperature present in the cover without the need for additional or external devices. Such a roll includes a substantially cylindrical core and a cover overlying the core. The cover includes at least one layer (typically the top stock layer) that comprises a mixture of a polymeric material and at least one of a piezochromic material and a thermochromic material. In this configuration, the pressure and/or temperature experienced by the roll cover at any location thereon can be determined visually, without the need for external equipment.
BRIEF DESCRIPTION OF THE FIGURES
[0010] [0010]FIG. 1 is a cutaway perspective view of an industrial roll and roll cover of the present invention.
[0011] [0011]FIG. 2 is a section view taken through lines 2 -- 2 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention will now be described more fully hereinafter, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements throughout, and thicknesses and dimensions of some components or features may be exaggerated for clarity. It will be understood that when an element or layer is referred to as being “connected” or “coupled” to or “overlying” another element or layer, it can be directly connected or coupled to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to or “directly overlying” another element or layer, there are no intervening elements or layers present.
[0013] Referring now to the drawings, a papermaking roll, designated broadly at 10 , is illustrated in FIGS. 1 and 2. The roll 10 includes in overlying relationship a core 12 (typically metallic), an adhesive layer 14 , and a cover 16 . Each of these components is discussed in greater detail hereinbelow.
[0014] The core 12 is a substantially cylindrical, hollow structure typically formed of steel, some other metal, or even a composite material. The core 12 is typically between about 1.5 and 400 inches in length and 1 and 70 inches in diameter, with lengths between about 100 and 400 inches and diameters of between about 20 and 70 inches being preferred. At these preferred length and diameter ranges, the core 12 typically has walls between about 1 and 5 inches in thickness. Components such as journals and bearings (not shown) are typically included on the core 12 to facilitate its mounting and rotation in a papermaking machine. The surface of the core 12 may be treated by blasting, sanding, sandblasting, or the like to prepare the surface for bonding to the adhesive layer 14 .
[0015] Referring again to FIGS. 1 and 2, the adhesive layer 14 comprises an adhesive (typically an epoxy adhesive) that can attach the core 12 to the cover 16 . Of course, the adhesive comprising the adhesive layer 14 should be chosen to be compatible with the materials of the core 12 and the base layer 18 of the cover 16 (i.e., it should provide a high-integrity bond between these structures without unduly harming either material); preferably, the bond has a tensile bond strength of between about 1,200 and 5,000 psi. The adhesive may have additives, such as curing agents, that facilitate curing and physical properties. Exemplary adhesives include Chemlok 220X and Chemlok 205, which are epoxy adhesives available from Lord Corporation, Raleigh, N.C.
[0016] The adhesive layer 14 can be applied to the core 12 in any manner known to be suitable to those skilled in this art for applying a thin layer of material. Exemplary application techniques include spraying, brushing, immersion, scraping, and the like. It is preferred that, if a solvent-based adhesive is used, the adhesive layer 14 be applied such that the solvent can evaporate prior to the application of the cover 16 in order to reduce the occurrence of trapped solvent that can cause “blows” during the curing process. Those skilled in this art will appreciate that the adhesive layer 14 may comprise multiple coats of adhesive, which may comprise different adhesives; for example, two different epoxy adhesives with slightly different properties may be employed. It should also be noted that, in some embodiments, the adhesive layer may be omitted entirely, such that the cover 16 is bonded directly to the core 12 .
[0017] Still referring to FIGS. 1 and 2, the cover 16 comprises, in overlying relationship, a base layer 18 and a top stock layer 22 . In the illustrated embodiment, the base layer 18 is adhered to the adhesive layer 14 . The base layer 18 comprises a polymeric compound (preferably an elastomeric compound) that typically includes fillers and other additives. Exemplary elastomeric compounds include polyurethane, natural rubber and synthetic rubbers such as SBR, EPDM, CSPE, nitrile rubber, neoprene, isoprene, silicone, and fluoroelastomers, and blends and co-polymers thereof, including blends with polyvinylchloride (PVC). An exemplary polymeric material that may be suitable for use in the base layer is epoxy. Additional monomers and monomer coagents, such as trimethyl propane trimethacrylate and 1, 3 butylene glycol dimethacrylate, may also be added to the base layer 18 to enhance polymerization.
[0018] Fillers are typically added to the base layer 18 to modify the physical properties of the compound and/or to reduce its cost. Exemplary filler materials include inorganic oxides such as aluminum oxide (Al 2 O 3 ), silicon dioxide (SiO 2 ), magnesium oxide (MgO), calcium oxide (CaO), zinc oxide (ZnO) and titanium dioxide (TiO 2 ), carbon black (also known as furnace black), silicates such as clays, talc, wollastonite (CaSiO 3 ), magnesium silicate (MgSiO 3 ), anhydrous aluminum silicate, and feldspar (KAlSi 3 O 8 ), sulfates such as barium sulfate and calcium sulfate, metallic powders such as aluminum, iron, copper, stainless steel, or nickel, carbonates such as calcium carbonate (CaCo 3 ) and magnesium carbonate (MgCo 3 ), mica, silica (natural, fumed, hydrated, anhydrous or precipitated), and nitrides and carbides, such as silicon carbide (SiC) and aluminum nitride (AlN). These fillers may be present in virtually any form, such as powder, pellet, fiber or sphere.
[0019] Also, the base layer 18 may optionally include other additives, such as polymerization initiators, activators and accelerators, curing or vulcanizing agents, plasticizers, heat stabilizers, antioxidants and antiozonants, coupling agents, pigments, and the like, that can facilitate processing and enhance physical properties. These components are generally compounded into the polymer prior to the time of application of the base layer 18 to the adhesive layer 14 or directly to the core 12 . Those skilled in this art will appreciate that the identity and amounts of these agents and their use in a base layer are generally known and need not be described in detail herein.
[0020] The base layer 18 can be applied by any manner known to those skilled in this art to be suitable for the application of polymers to an underlying surface. Preferably, the base layer 18 is applied through an extrusion process in which strips of the base layer 18 are extruded through an extrusion die, then, while still warm, are overlaid over the adhesive layer 14 as it is still somewhat tacky. The base layer strips are preferably between about 0.030 and 0.125 inches in thickness and are applied in an overlapping manner, with the result that total thickness of the base layer 18 is typically between about 0.0625 and 0.25 inches. Those skilled in this art will appreciate that, in some embodiments, the base layer 18 may be omitted such that the topstock layer 22 is adhered directly to the adhesive layer 14 or, in the absence of an adhesive layer, to the core 12 .
[0021] In the illustrated embodiment, the topstock layer 22 overlies and, unless one or more tie-in layers are included as described below, is adhered to the base layer 18 . The topstock layer 22 comprises a polymeric compound that typically includes fillers and other additives. Exemplary elastomeric compounds for the topstock layer 22 include polyurethane, natural rubber and synthetic rubbers such as SBR, EPDM, CSPE, nitrile rubber, neoprene, isoprene, silicone, and fluoroelastomers, and blends and co-polymers thereof, including blends with polyvinylchloride (PVC). Other exemplary polymeric compounds include epoxies.
[0022] As noted above, the topstock layer 22 includes thermochromic or piezochromic compositions within the polymeric formulation. As used herein, a “thermochromic composition” is a substance that changes color when subjected to different levels of temperature or heat, either reversibly or irreversibly. Exemplary thermochromic compositions include those that comprise an electron-donating component, an acidic material and an organic medium or solvent (see, e.g., U.S. Pat. Nos. 4,666,949 to Shimizu et al., 5,688,592 to Shibahashi et al.), those including an electron-donative color former, an electron-accepting developer and a color change temperature controlling agent (see, e.g., U.S. Pat. No. 4,681,791 to Shibahashi et al.), and liquid crystals such as chiral nematic cholesteric, biphenyl and related liquid crystals (see, e.g., U.S. Pat. Nos. 5,194,183 to Münch et al. and 5,690,857 to Osterried et al.).
[0023] As used herein, a “piezochromic composition” is a substance that changes color when subjected to different levels of pressure, either reversibly or irreversibly. Exemplary piezochromic compositions include: 9-(p-nitrophenylphenylmethylene)xanthene, diflavine, dehydrodianthrone, hexaphenylbiimidazolyl, tetraphenylvinyl dimer, phthalocyanine-cobalt complex and hydroxycarboxylic acid derivatives, spiropyranthiopyrans and spirobenzopyranoxadiazoline derivatives, both of which are commonly referred to briefly as spiropyrans (see U.S. Pat. No. 5,320,784 to Miyashita), samarium sulfides (such as samarium monosulfide and disamarium trisulfide) (see U.S. Pat. No. 6,132,568 to Jin et al.), and three-dimensionally periodic materials (such as those disclosed in U.S. Pat. No. 6,261,469 to Zakhidov et al.). Piezochromic materials are preferably included in an amount of between about 0.001 and 10 parts (more preferably between about 0.01 and 5 parts) by weight to 100 parts polymer of the topstock layer 22 , and preferably provide an identifiable color change at a pressure of between about 1,450 and 15,000 psi (more preferably between about 2,000 and 10,000 psi). Thermochromic materials are preferably included in an amount of between about 0.001 and 10 parts (more preferably between about 0.01 and 5 parts) by weight to 100 parts polymer of the topstock layer 22 , and preferably provide an identifiable color change at a temperature of between about 40 and 180 degrees C. (more preferably between about 70 and 160 degrees C.). A topstock layer 22 may include both piezochromic and thermochromic materials, but these should be selected so that their color change characteristics are compatible with one another. Exemplary compositions are described in German Application No. 103 12 464.0, filed Mar. 20, 2003, the disclosures of which is hereby incorporated herein in its entirety.
[0024] Preferably, the piezochromic and/or thermochromic materials are microencapsulated prior to inclusion in the topstock layer 22 . It is also preferred that these materials be generally homogenously distributed on the surface of the topstock layer 22 , if not throughout the topstock layer 22 , in order to provide a more accurate indication of the pressure and/or temperature being experienced by the cover 16 .
[0025] The topstock layer 22 typically also includes fillers that are added to modify and enhance the physical and processing properties and/or to reduce the cost of the topstock layer 22 . Exemplary fillers include silicone dioxide, carbon black, clay, and titanium dioxide (TiO 2 ) as well as others set forth hereinabove in connection with the base layer 18 . Typically, fillers are included in an amount of between about 3 and 70 percent by weight of the topstock layer 22 . The fillers can take virtually any form, including powder, pellet, bead, fiber, sphere, or the like.
[0026] The topstock layer 22 also typically includes other additives, such as polymerization initiators, activators and accelerators, curing or vulcanizing agents, plasticizers, heat stabilizers, antioxidants, coupling agents, pigments, and the like, that can facilitate processing and enhance physical properties. Those skilled in this art will understand the types and concentrations of additives that are appropriate for inclusion in the topstock layer 22 , so these need not be discussed in detail herein.
[0027] The top stock layer 22 can be applied over the base layer 18 by any technique known to those skilled in this art to be suitable for the application of elastomeric materials over a cylindrical surface. Preferably, the components of the topstock layer 22 are mixed separately, then blended in a mill. The blended material is transferred from the mill to an extruder, which extrudes feed strips of top stock material onto the base layer 18 . Preferably, the top stock layer 22 is applied such that it is between about 1 and 2.5 inches in thickness (at higher thickness, multiple passes of material may be required). It is also preferred that the thickness of the top stock layer 22 be between about 50 and 75 percent of the total cover thickness (i.e., the total thickness of the combined base and top stock layers 18 , 22 ). Alternatively, either or both of the base and top stock layers 18 , 22 can be applied through the overlaying of calendered sheets of material.
[0028] The elastomeric compounds of the base layer 18 and the top stock 22 may be selected such that the base layer 18 has a higher hardness value than the top stock layer 22 . As an example, the base layer 18 may have a hardness of between about 5 and 15 P&J, and the top stock layer 22 may have a hardness of between about 170 and 230 P&J. The graduated modulus concept can reduce the bond line shear stresses that can occur due to mismatches of the elastic properties (such as elastic modulus and Poisson's ratio) of the various layers in the cover constructions. This reduction in interface shear stress can be important in maintaining cover integrity.
[0029] Those skilled in this art will also appreciate that the roll 10 may be constructed with a tie-in layer sandwiched between the base layer 18 and the top stock layer 22 , such that the tie-in layer would directly underlie the top stock layer 22 . The typical properties of a tie-in layer are well-known to those skilled in this art and need not be described in detail herein.
[0030] After the top stock 22 has been applied, the roll 10 is then cured, typically in an autoclave, for a suitable curing period (generally between about 16 and 30 hours). After curing, it is preferred that any crust that has developed is skimmed from the surface of the top stock layer 22 , and that the top stock layer 22 is ground for dimensional correctness.
[0031] Roll covers formed of the compositions described above can be employed in nip rolls or other roll positions within papermaking machines or other devices. In position, and during operation of the machine, the roll cover, due to the presence of a thermochromic and/or piezochromic composition therein, can provide information about the temperature and/or pressure experienced by the roll cover. As such, undesirable circumstances, such as uneven application of pressure, misalignment or miscrowning of nip rolls, improper roll profile, overloading of the roll beyond a preselected limit, the presence of “hot spots” in the cover, localized wear, or the like, can be discerned visually during operation. Also, photographs can be taken of the cover and compared to other photographs taken later in time to determine whether processing conditions have changed. Any of these techniques may be preferable to the use of external devices, particularly in locations of a machine that are difficult to access.
[0032] It should also be noted that, in some embodiments, the cover may include a tie-in or other intermediate layer that comprises a thermochromic or piezochromic material, and the top stock layer is transparent to permit the visual examination of the intermediate layer.
[0033] The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein. | An industrial roll includes: a substantially cylindrical core and a cover overlying the adhesive layer. The cover typically comprises a polymeric top stock layer which comprises a mixture of a polymeric material and at least one of a piezochromic material and a thermochromic material. In this configuration, the pressure and/or temperature experienced by the roll cover at any location thereon can be determined visually, without the need for external equipment. | 3 |
TECHNICAL FIELD
[0001] This description relates to fault protection, and more particularly to traveling wave based relay protection.
BACKGROUND
[0002] Power transmission lines can carry alternating current (AC). When a fault occurs on a line, it is useful to rapidly determine the existence and location of the fault, so that protective measures can be taken before components connected to the line are damaged. The location of the fault also may be used in fixing the cause of the fault.
SUMMARY
[0003] In one general aspect, an apparatus includes at least one Rogowski coil and a processor. The at least one Rogowski coil is positioned within an electrical power distribution network to detect a first traveling wave current caused by a fault on an electrical power transmission line of the network, generate a first signal indicative of detection of the first traveling wave, detect a second traveling wave current caused by the fault on the transmission line, and generate a second signal indicative of detection of the second traveling wave. The processor is adapted to receive the first signal and the second signal and to determine, based on the first signal and the second signal, where on the transmission line the fault occurred.
[0004] Implementations may include one or more of the following features. For example, the apparatus can include a single Rogowski coil that generates the first and second signals, or a first Rogowski coil that generates the first signal and a second Rogowski coil that generates the second signal. The processor can be further operable to receive a timing synchronization signal. When a bus electrically connected to the transmission line, the second traveling wave current can be caused by the fault on the electrical power transmission line and can be reflected by the bus.
[0005] In another general aspect, an electrical protection apparatus includes a first Rogowski coil, a second Rogowski coil, and a protection device. The first Rogowski coil is positioned to detect a first traveling wave current on a first transmission line of a power distribution network and to generate a first signal indicative of a polarity of the first traveling wave caused by a fault within the network. The second Rogowski coil is positioned to detect a second traveling wave current on a second transmission line of the network and to generate a second signal indicative of a polarity of the second traveling wave caused by the fault within the network. The protection device is adapted to receive the first signal and the second signal and is operable to determine, based on the first signal and the second signal, where in the network the fault occurred.
[0006] Implementations may include one or more of the following features. For example, the protection device can include a relay and a processor. The apparatus can further include a circuit breaker operable to open in response to a signal from the protection device, where the signal is generated by the protection device upon the determination by the protection device of where the fault in the network occurred. The apparatus can further include a first circuit breaker positioned on the first transmission line and a second circuit breaker positioned on the first transmission line, where the protection device is further operable to cause the first circuit breaker, the second circuit breaker, or both circuit breakers to open in response to a determination by the protection device of where the fault in the network occurred. The apparatus can further include a busbar, to which the first transmission line and the second transmission line are electrically connected.
[0007] In another general aspect, determining the location of a fault on an electrical power transmission line includes receiving a first signal from a Rogowski coil positioned to detect a first traveling wave current caused by the fault, where the first signal is indicative of a time at which the first traveling wave is detected, receiving a second signal from a Rogowski coil positioned to detect a second traveling wave current caused by the fault, where the second signal is indicative of a time at which the second traveling wave is detected, and determining, based on the first signal and the second signal, where on the transmission line the fault occurred.
[0008] Implementations may include one or more of the following features. For example, the first signal and the second signal can be received from the same Rogowski coil, or the first signal can be received from a first Rogowski coil and the second signal can be received from a second Rogowski coil. A timing synchronization signal may be received, and, based on the timing synchronization signal, the first signal, and the second signal, a determination may be made as to where on the line the fault occurred.
[0009] The transmission line can include a bus electrically connected to the transmission line. At least one of the Rogowski coils can be adapted for detecting a traveling wave current caused by a fault on the electrical power transmission line that is reflected by the bus and can be adapted for generating a third timing signal indicative of a time at which the reflected traveling wave is detected.
[0010] In another general aspect, protecting a power apparatus from a fault in a power distribution network includes receiving a first signal from a first Rogowski coil positioned to 10 detect a first traveling wave current on a first transmission line of the network, where the first signal is indicative of a polarity of the first traveling wave; and receiving a second signal from a second Rogowski coil positioned to detect a second traveling wave current on a second transmission line of the network, where the second signal is indicative of a polarity of the second traveling wave. The location of the fault in the network is determined based on the first signal and the second signal, and a current flow on a transmission line of the network is halted based on the determination of the fault location. The transmission line upon which the current flow is halted can be the first or second transmission line, or can be a transmission line in the network other than the first transmission line or the second transmission line. A first tracking pulse having a predetermined amplitude and width may be generated in response to a first detected traveling wave current that exceeds a predetermined threshold value, and a second tracking pulse having a predetermined amplitude and width can be generated in response to a second detected traveling wave current that exceeds a predetermined threshold value. Based on the first tracking pulse and the second tracking pulse, a determination may be made as to where the fault in the network occurred.
[0011] The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a diagram of the temporal relations between the generation of traveling waves on a transmission line at a fault location and reflections of the traveling waves at points of impedance changes on the line.
[0013] FIG. 2 is a graph of instantaneous current on a transmission line shortly before and shortly after a fault in the line occurs.
[0014] FIG. 3 is a schematic view of a transmission line and two Rogowski coils used to measure current changes on the line.
[0015] FIGS. 4 and 5 are graphs of the instantaneous current and the instantaneous change in current on a transmission line on opposite sides of a fault in the line shortly before and shortly after the fault occurs.
[0016] FIG. 6 is a schematic diagram of a power network protection system.
[0017] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0018] A fault in a power system causes traveling waves (TWs) that propagate through the system away from the fault location at velocities close to the speed of light. The TWs reflect at points where the impedance of the system changes. TWs can totally reflect, or can partially reflect and partially refract, with the refracted portion continuing to travel in the same direction. TWs have a fast rising front and a slower decaying tail, and have magnitudes that decrease with time. When TWs are generated, then both traveling wave voltages (TWVs) and traveling wave currents (TWCs) exist. TWCs can be used for fast relay protection and accurate determination of fault locations in power systems.
[0019] The surge impedance Z S of a transmission line is given by
Z s =√{square root over (L/C)} (1)
where L is the line inductance in Henries per unit length, and C is the line capacitance in Farads per unit length. Faults in power lines cause traveling waves that propagate along the line away from the fault. The velocity of a traveling wave, C TW , is given by
C TW =1 /√{square root over (LC)} (2)
and is approximately equal to the speed of light for most transmission lines. The traveling wave emitted from a fault has a traveling wave voltage (TWV or V TW ) and a traveling wave current (TWC or i TW ). At the instant of the fault, the TWV and the TWC are related by
V TW =Z s ×i TW , (3)
where V TW is the instantaneous voltage on the line, and i TW is the instantaneous current in the line.
[0020] After a traveling wave is emitted from the fault location, the wave propagates along the line until the wave reaches a point on the line where the impedance changes (e.g., a transformer or a bus). Because of the impedance change, the wave is reflected back along the line or is partially reflected and partially transmitted. The time at which individual reflections and transmissions occur on the line can be used to determine the location of the fault on the line.
[0021] For example, as shown in FIG. 1 , a transmission line 102 is connected to a first bus 104 , to a second bus 106 , and to two sources 108 and 110 . When a fault occurs at a location 112 on the line, traveling waves propagate away from the fault location 112 on the line 102 towards the buses 104 and 106 at a speed given by equation (2). When a traveling wave reaches a point of changing impedance on the line 102 (e.g., a bus 104 or 106 ), the wave is either reflected or partially reflected and partially transmitted. The amplitude, v r , of the reflected wave is
v r = Z b - Z s Z b + Z s v i , ( 4 )
where v i is the amplitude of the incident traveling wave, Z b is the impedance of the bus 104 or 106 , and Z S , as noted above, is the surge impedance. The amplitude, v t , of the transmitted wave is
v t = 2 Z b Z b + Z s v i . ( 5 )
When the impedance of the bus 104 or 106 is much smaller than the surge impedance (Z b <<Z s ), the reflected wave amplitude may be approximated as being equal to the incident wave amplitude (|v r |=|v i |), and the transmitted wave amplitude may be approximated as being zero (v t =0).
[0022] Because the ionized fault resistance at fault location 112 is usually much less than the surge impedance Zs, the traveling wave that reflects off bus 104 is totally reflected at fault location 112 and travels back to bus 104 , with a reversal of the polarity of the pulse. If the fault resistance has a higher value that is comparable to the value of the surge resistance, the TWC will not totally reflect at the fault location 112 , and, instead, will also be partially transmitted through the fault location 112 toward the bus 106 with a reduced magnitude as given in equation (5). The energy of the first incoming traveling wave to arrive at bus 104 is significantly larger than the energy of the wave that arrives at bus 104 after being reflected from bus 106 and transmitted through fault location 112 . This enables reliable differentiation between the reflected and transmitted waves. Similarly, the TWC that reflects off bus 106 will be partially reflected and partially transmitted by the ionized fault resistance at fault location 112 .
[0023] The arrival times of the TWCs at buses 104 and 106 are shown in the lower portion of FIG. 1 , where distance is measured on the horizontal axis and time is measured on the vertical axis. For example, the TWC emitted from fault location 112 at time t=t o in the direction of bus 104 (i.e., the first direct wave) travels at speed C TW =1/√{square root over (LC)} over a distance A and arrives at bus 104 at time t A1 =t o +Δt A . The speed, distance, and time are related by Δt A =A√{square root over (LC)}. The first TWC that is reflected from bus 106 and transmitted through fault location 112 arrives at bus 104 at time t A2 , which is defined as:
t A2 =t o Δt A +2 Δt B =t o +( A +2 B )√{square root over (LC)},
where B is the distance from the fault location 112 to bus 106 . The first TWC that is reflected from bus 104 and from fault location 112 arrives at bus 104 at time t A3 , which is defined as:
t A3 =t o +3 Δt A =t o +3 A√{square root over (LC)}.
[0024] The second TWC that is reflected from bus 106 and transmitted through fault location 112 arrives at bus 104 at time t A4 , which is defined as:
t A4 =t o +Δt A +4 Δt B =t o +( A +4 B ) √{square root over (LC)}.
[0025] The initial TWC emitted from fault location 112 arrives at bus 106 at time t B1 , which is defined as:
t B1 =t o +Δt B +2Δ t B =t o +B√{square root over (LC)}.
[0026] The first TWC that is reflected from bus 106 and from fault location 112 arrives at bus 106 at time t B2 , which is defined as:
t B2 =t o +3 Δt B =t o +3 B√{square root over (LC)}.
[0027] The first TWC that is reflected from bus 104 and transmitted through fault location 112 arrives at bus 106 at time t B3 , which is defined as:
t B3 =t o +2 Δt A +Δt 3 =t o +(2 A+B ) √{square root over (LC)}.
[0028] The second TWC that is reflected from bus 106 and from fault location 112 arrives at bus 106 at time t B4 , which is defined as:
t B4 =t o +5 Δt B =t o +5 B√{square root over (LC)}.
[0029] FIG. 2 shows current waveforms recorded at buses 104 and 106 due to a fault at location 112 on an 80-mile long transmission line 102 (as shown in FIG. 1 ). The arrival of TWCs at bus 104 (referred to as “Bus A” in FIG. 2 ) and bus 106 (referred to as “Bus B” in FIG. 2 ) is also evident in the current waveforms shown in FIG. 2 . The fault simulated in FIG. 2 is a single-phase-to-ground fault in the A-phase of the AC transmission line that occurs at t o =0.5 ms at a distance of 50 miles from bus 104 near the voltage peak (at 500 μs, 79°) of an AC cycle. For simplicity, FIG. 2 shows only the currents measured on the A-phase line and omits representation of the currents on the B-phase line and the C-phase line.
[0030] The lower trace of FIG. 2 shows the current at bus 106 . The first incoming TWC pulse reaches bus 106 at t B1 =660 μs and produces an approximately 218 A positive step change in the line current. The first TWC pulse to be reflected by bus 106 and by fault location 112 reaches bus 106 at t B2 =980 μs. The first TWC pulse that is reflected from bus 104 and transmitted through fault location 112 arrives at bus 106 at t B3 =1199 μs and produces an approximately 75 A negative step change in the line current.
[0031] The third TWC pulse reflected from the fault location 112 reaches bus 106 at t B4 =1300 μs and produces an approximately 43 A positive step change in the line current.
[0032] The upper trace of FIG. 2 shows the current at bus 104 . The first incoming TWC pulse reaches bus 104 at t A1 =767 μs, and produces an approximately 206 A positive step change in the line current. The first TWC pulse to be reflected by bus 106 and transmitted through fault location 112 reaches bus 106 at t A2 =1090 μs and produces an approximately 88 A negative step change in line current. The second TWC pulse to arrive at bus 104 after being reflected from bus 104 and reflected by the fault location 112 produces an approximately 77 A positive step change in line current and reaches bus 104 at t A3 =1300 μs. The second TWC pulse to be reflected by bus 106 and transmitted through fault location 112 reaches bus 106 at t A4 =1413 μs and produces an approximately 23 A negative step change in line current.
[0033] The fault location 112 on the line 102 can be determined by measuring the time difference between the time at which the initial pulse is received at bus 104 and the time at which the second pulse, which is reflected from the bus 104 and then from the fault, is received at bus 104 . The distance, D, from the bus 104 to the fault location 112 is given by:
D = c TW × ( t A3 - t A1 ) 2 . ( 6 )
[0034] In the similar way, the fault location 112 on the line 102 can be determined by measuring the time difference between the time at which the initial pulse is received at bus 106 and the time at which the second pulse, which is reflected from the bus 106 and then from the fault, is received at bus 106 . The distance, D, from the bus 106 to the fault location 112 is given by:
D = c TW × ( t B2 - t B1 ) 2 . ( 7 )
[0035] The fault location can also be determined using synchronized measurements of the arrival times of pulses that reach buses 104 and 106 at the two ends of the transmission line 102 . The times can be synchronized by a GPS reference time signal available at each bus. Using arrival times of pulses at the two ends of the line 102 , the distance, D, from the bus 104 to the fault location 112 is given by
D = l - c TW × ( t A1 - t B1 ) 2 , ( 8 )
where l is the line length.
[0036] To reliably detect and time tag the arrival of a traveling wave, the TWC pulse must be filtered out from the current component corresponding to the fundamental power frequency (e.g., 60 Hz). The arrival of a TWC at a location on the line 102 (e.g., at bus 104 or 106 ) can be detected by a coil positioned on the transmission line 102 just before the bus 104 or 106 . The coil can be, for example, a Rogowski coil. Generally speaking, a Rogowski coil includes a conductive element that is wound around a non-magnetic core. The conductive element may be, for example, a metal wire or a metal deposit. The non-magnetic core may be made of any material that has a magnetic permeability that is substantially equal to the permeability of free space, such as, for example, an air core or a printed circuit board (PCB) on which the conductive element is traced.
[0037] The output voltage of a Rogowski coil is proportional to the rate of change of measured current (di/dt) enclosed by the coil. Thus, Rogowski coils are particularly sensitive to high-frequency components, and are able to amplify high-frequency signal components without using special filters. This unique feature of Rogowski coils makes them particularly suitable for measuring rapid current changes and for detecting TWCs.
[0038] As shown in FIG. 3 , a transmission line 302 is connected to power sources 304 and 306 and to buses 308 and 310 . Rogowski coils 320 and 322 are located on the transmission line 302 in close proximity to the buses 308 and 310 , respectively. The coils 320 and 322 can be constructed according to various techniques. Examples of such techniques are discussed in, for example, U.S. Pat. No. 6,313,623, titled “High Precision Rogowski Coil,” and U.S. Pat. No. 6,680,608, titled “Measuring Current Through An Electrical Conductor,” both of which are incorporated by reference. For example, the coils 320 and 322 can include two or more arms that form a main loop (or loops) of the coils 320 and 322 when coupled together. Various winding techniques for winding the conductive element may be used in constructing the coils 320 and 322 , and the coils 320 and 322 can include multiple coils that are associated with one another in various ways. These and other construction details related to the coils 320 and 322 may be selected so as to ensure high levels of sensitivity and accuracy in determining the current changes on the transmission line 302 .
[0039] The output signal from the Rogowski coils 320 and 322 , which can be located at a high voltage potential near the transmission line 302 , can be passed to electrical-to-optical converters 324 and 326 , respectively, and then transmitted by optical fibers 328 and 330 to optical-to-electrical converters 332 and 334 , respectively, which can be located close to electrical ground. Once the Rogowski coil signals have been re-converted to electrical signals, they can be further processed by processors 336 and 338 . Processors 336 and 338 can communicate with each other through a data transmission line 340 to compare the signals that they receive and generate.
[0040] Although the communications line 340 may communicate information between the processors 333 and 338 , there may nonetheless be some amount of delay in transmitting the various signals. When comparing current signals from the coils 308 and 310 , relative timing information for the current signals may be required in order to account for this delay (as well as other delays that may occur) so as to make a meaningful comparison of the current signals.
[0041] Such timing information can be obtained from various sources. For example, an external synchronizing network 342 (e.g., a network that provides a GPS clock) may be set up to provide timing information. Processors 336 and 338 can receive timing information from the synchronizing network, so that the arrival times of TWCs at Rogowski coils 320 and 322 can be compared to an absolute reference standard. As another example, the processors 336 and 338 may time stamp their respective current measurements before transmission of the measurements.
[0042] FIG. 4 shows an instantaneous current measurement 400 at a bus 308 at one end of an 80-mile long transmission line 302 along with the change in current 405 measured by the Rogowski coil 320 located close to the bus 308 . FIG. 5 shows the instantaneous current measurement 500 at a bus 310 at the other end of the transmission line 302 and the change in current measured by the Rogowski coil 322 located close to the bus 310 . When a fault occurs at a time t=500 μs, high-frequency transients are superimposed on the 60 Hz fundamental frequency in the current traces. The Rogowski coils 320 and 322 detect the changes in current and register signals that are proportional to the temporal derivative of the current. When the output signal of a Rogowski coil 320 or 322 exceeds a threshold value, processor 336 or 338 , respectively, generates a standard amplitude and width tracking pulse that can be used by timing logic within the processor 336 or 338 to determine the location of the fault on the transmission line according to equations (6) (7), or (8).
[0043] To achieve reliable fault detection, an instantaneous current level detector (ICLD), which can be implemented in hardware or software, provides a supervisory function by monitoring the instantaneous value of the current. Whenever a TWC having an amplitude within predetermined threshold values is detected by a processor 336 or 338 , the processor generates a standard amplitude and width tracking pulse. A relay that is operated in response to the detection of a TWC will not issue a trip command until the ICLD asserts and latches.
[0044] As discussed above, Rogowski coils may be used as the current sensing coils of FIGS. 3-5 . Rogowski coils are very sensitive to even low-level current changes, and, thus, are capable of, for example, detecting and initiating clearing of sustained arcing fault currents. Such fault currents generally are at a small fraction of the maximum available fault current, and are not much higher than the load currents themselves.
[0045] The ability to detect small current changes means that fault detection levels may be set relatively low, thereby reducing stress on (or damage to) equipment and speeding fault response times without sacrificing reliability. Moreover, a risk of fire propagation is reduced, and faster response times (including a faster restoration of service) may be provided.
[0046] Rogowski coils do not saturate, and, therefore, are capable of handling large currents and avoiding false tripping of circuit breakers in response to faults outside the protected zone. The ability of a particular Rogowski coil to avoid saturation may allow a-single Rogowski coil to provide current measurements over a wide measurement range, such as, for example, from several amps to several hundred thousand amps. As a result, such coils may be used to measure currents having a large DC component. Also, Rogowski coils may operate over a wide frequency range, such as, for example, from approximately 0.1 Hz to over 1 MHz. Rogowski coils also may be designed to provide a bandpass frequency response of up to approximately 200 MHz or more. Additionally, Rogowski coils are generally immune to external magnetic fields, and, therefore, may avoid any effects of such fields on current measurements. Moreover, Rogowski coils are relatively inexpensive and typically do not require substantial space or wiring. Finally, a Rogowski coil is easily installed by, for example, simply placing the relevant conductor through the coil (or by placing the coil around the conductor).
[0047] Because Rogowski coils are sensitive to changes in current, they can be used to detect a fault in less than one full 60 Hz cycle (i.e., 16.67 ms). As is evident from the example described above, because TWCs produced by a fault 112 propagate on the transmission line 102 at close to the speed of light, and Rogowski coils can detect a TWC with sub-millisecond accuracy, a Rogowski coil can detect a TWC indicating a fault in far less time than the time period of a 60 Hz cycle (i.e., 16.67 ms). Thus, one or more Rogowski coils can quickly identify a fault in a power transmission system and respond to the fault to protect the system (as explained in further detail below).
[0048] A differential busbar protection system using Rogowski coils is illustrated with reference to FIG. 6 . As shown, an electrical power system includes a busbar 602 electrically connected to a first power system 604 (e.g., a source or a load) by a first transmission line 614 and to a second power system 606 (e.g., a source or a load) by a second transmission line 616 and a third transmission line 618 . Thus, current can flow into the busbar 602 on line 614 and out of busbar 602 on lines 616 and 618 . During normal operation, the sum of currents flowing into the busbar 602 is equal to the sum of currents flowing out of the busbar 602 .
[0049] Rogowski coils 624 , 626 , and 628 are located close to busbar 602 and sense current and current changes in lines 614 , 616 , and 618 , respectively. A relay 630 electrically connected to the Rogowski coils 624 , 626 , and 628 and to circuit breakers 644 , 646 , and 648 located on respective lines 614 , 616 , and 618 serves to provide integrated protection against short circuits and other system malfunctions and/or failures, as described in more detail below. As such, the relay 630 may be programmed or otherwise associated with a predetermined algorithm for automatically implementing the integrated protection scheme. For example, the relay 630 can include an ICLD to monitor the instantaneous level of the current and to generate a standard amplitude and width tracking pulse whenever a TWC having an amplitude within predetermined threshold values is detected by Rogowski coils 624 , 626 , and 628 . The tracking pulses can be used to make logical decisions for protecting the network (as explained in more detail below). Although only one relay 630 is shown, two or more relays in communication with each other can be used in the system. For example, a separate relay can be associated with an individual Rogowski coil 624 , 626 , or 628 .
[0050] With regard to the protection system 600 , the relay 630 is capable of providing multiple types of protection against electrical or mechanical malfunctions and failures, and of integrating these types of protection into a cohesive protection scheme. Moreover, the relay 630 is capable of interacting with other relays and/or other coils in order to provide further options for constructing an integrated electrical protection system.
[0051] One type of protection afforded by the relay 630 is differential protection. In a differential protection scheme, the relay 630 operates to compare the currents on lines 614 , 616 , and 618 to check if the currents have some predetermined relationship to one another. As one example, when a fault occurs at busbar 602 or otherwise between coils 624 , 626 , and 628 , a transient current pulse is created on each of the lines 614 , 616 , and 618 . Because the fault occurs within the zone between coils 624 , 626 , and 628 , the transient pulses on each of the lines has the same polarity. In such a case, the relay 630 can determine that the fault is located within the zone and can trip each circuit breaker 644 , 646 , and 648 to protect the busbar 602 from overload due to power supplied from power system 604 or 606 .
[0052] As another example, when a fault occurs outside the busbar 602 , such as, for example, on transmission line 616 , the polarity of the transient pulse moving toward the busbar 602 (e.g., on line 616 ) will be opposite to the polarity of the transient pulse moving away from the busbar 602 (e.g., on lines 614 and 618 ). In such a case, the relay 630 can determine that the fault is located on line 616 because the polarity of the pulse detected by Rogowski coil 626 is different from the polarity of the pulses detected by coils 624 and 628 . Thus, relay 630 can trip circuit breaker 646 to protect the busbar 602 from the fault on line 616 but can allow power to continue to flow to/from power system 604 to busbar 602 on line 614 and to/from power system 606 on line 618 . Similarly, when a fault occurs on line 618 , relay 630 can determine that the polarity of the pulse measured by coil 628 is different from the polarity measured by coils 624 and 626 and, in response, can trip circuit breaker 648 while leaving breakers 644 and 646 closed.
[0053] As a further example, when a fault occurs upstream of coil 624 , the polarity of the pulse measured by coil 624 is different from the polarity measured by coils 626 and 628 . Based on this information, relay 630 can determine the location of the fault but need not trip any of the circuit breakers.
[0054] The relay 630 may be, for example, a microprocessor-controlled, multi-function relay, such as a three-phase relay having multiple voltage and/or current inputs. As discussed above, the relay 630 may be in communication with circuit breakers 644 , 646 , and 648 , companion relays (not shown), control equipment (not shown), and other circuit elements. For example, the relay 630 may be connected to a network switch/hub that supports having the relay 630 communicate with other relays in implementing an electrical protection system.
[0055] Using these and related techniques, electrical equipment may be protected from damage due to fault currents. Moreover, by placing the coils 624 , 626 , and 628 around selected pieces of circuitry/equipment, and thereby establishing the protection zones, a location as well as an existence of a fault current may be accurately detected. Additionally, a number of current sensors (coils) and relays may be minimized (relative to other electrical protection systems) so as to increase an ease of installation.
[0056] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. Accordingly, other implementations are within the scope of the following claims. | An apparatus includes at least one Rogowski coil and a processor. The at least one Rogowski coil is positioned within an electrical power distribution network to detect a first traveling wave current caused by a fault on an electrical power transmission line of the network, generate a first signal indicative of detection of the first traveling wave, detect a second traveling wave current caused by the fault on the transmission line, and generate a second signal indicative of detection of the second traveling wave. The processor is adapted to receive the first signal and the second signal and to determine, based on the first signal and the second signal, where on the transmission line the fault occurred. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a Continuation of application Ser. No. 09/969,072, filed Oct. 2, 2001, by Fredlund et al., which is a Continuation of application Ser. No. 09/487,065, filed Jan. 19, 2000, by John R. Fredlund et al., now issued as U.S. Pat. No. 6,353,487, which is a continuation application of Ser. No. 08/510,733, filed Aug. 3, 1995, by Fredlund et al., now issued as U.S. Pat. No. 6,154,295 which is a continuation-in-part of application Ser. No. 08/201,735 filed Feb. 25, 1994, now abandoned.
TECHNICAL FIELD
[0002] The present invention is directed to the field of photo processing and, more particularly, to the selection of photographic images for printing.
BACKGROUND OF THE INVENTION
[0003] A number of systems have been proposed for electronic processing of prints. These include Kodak's Creat-a-Print, where the operator goes to a photo store or mini lab location, inserts his negatives, and zooms and crops or enlarges the image prior to printing. Other systems, like Kodak's Image Magic, provide for a combination of a stored image with that of a “live” image of the customer, for prints which have been cropped and composed at a theme park. In addition, Photo CD™ provides a method for putting selected images at full 35 mm film resolution on a Photo CD™ disc.
[0004] Often, however, a consumer faces a problem in that he has received a number of prints from a photo dealer or in the mail from a photo finisher and he wishes to send additional copies of these prints to other friends or relatives, or receive additional copies for himself.
[0005] In traditional photo processing environments, there has always been the difficulty of determining which photographic negative contains the image of choice. The customer often has difficulty determining which photographic negative contains the image of choice. Also, the customer often has difficulty interpreting the negative as it would appear when printed. The customer must identify the images of interest on the negative by identifying each negative to the prints he wants. He must then return the negative to the mini lab, photo store, or photo processor, either in person or by mail, and then must specify the size and number of each print. He must then wait for the new prints to be made and then obtain these prints from the drug store, mini lab, or photo finisher.
[0006] There are a number of problems with this approach. For instance, the sensitive film negative must be handled multiple times by the customer, adding a potential for scratching, fingerprinting, and otherwise damaging the film. Also, the sleeve must be written on to convey the ordering information. This works well if the customer does not insert the negatives into the sleeve before writing on it. Otherwise, there is a potential for damaging the film by writing on the sleeve while the film is within. There is also a potential for improper recording of data. Furthermore, the small negative image is not easily identifiable by the customer, particularly when there are several similar images. Another problem is that the images on the film do not always line up well with the preflashed numbers on the edge of the film. The customer is often confused as to whether an image is “number 9”, number “9A”, or number “10”. This confusion can result in selection of the wrong images for reprint.
[0007] Recently, in an attempt to facilitate the process of ordering photographic reprints, customers have been supplied with an index print containing a number of miniature images along with an associated index number corresponding to the frame number on the film. Customers return the negatives bearing the images corresponding to the desired reprints to the photofinisher and indicate the desired frame number from the index print for reprints. Although this approach represents an improvement over prior techniques, it still has the drawback of having the customers handle the negatives, which can become soiled, damaged or lost while in the possession of the customer. When a customer does order reprints, the negatives may be stored haphazardly and apart from the original prints, making the negatives difficult to retrieve at a later date. Finally, this somewhat arduous process of obtaining additional prints provides little impetus for reprints. The inconvenience of ordering is a barrier to ordering reprints.
[0008] It is seen then that it would be desirable to have an improved system and method for facilitating ordering and re-ordering of prints from negatives or slides.
SUMMARY OF THE INVENTION
[0009] In accordance with one aspect of the present invention there is provided a method for remotely ordering image products or services with respect to digitally stored images, comprising the steps of:
[0010] obtaining a digital file of at least one image;
[0011] storing the digital file in a memory device and associating an order number that identifies the digital file;
[0012] facilitaing viewing of the images prior to ordering image products with respect to the at least one image; and
[0013] facilitating remote electronically ordering an image product or service with respect to the at least one image over a communication network using the order number.
[0014] In another aspect of the present invention there is provided a method for remotely ordering image products or services with respect to digitally stored images, comprising the steps of:
[0015] obtaining a digital file of at least one image;
[0016] storing the digital file in a memory device and associating an order number that identifies the digital file;
[0017] facilitating electronically ordering an image product or service with respect to the at least one image over a communication network using the order number by a customer;
[0018] providing the image product or server; and
[0019] providing the image product to the party designated.
[0020] Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a schematic diagram of the system for remotely selecting photographic prints according to the method of the present invention;
[0022] [0022]FIG. 2 shows an index print employed in the method of the present invention;
[0023] [0023]FIG. 3 is a flow chart illustrating the ordering of photographic prints according to the present invention;
[0024] [0024]FIG. 4 shows an alternative embodiment of the present invention;
[0025] [0025]FIG. 5 is a flow chart showing the digital image compression steps used in one embodiment of the present invention; and
[0026] [0026]FIG. 6 is a flow chart showing the image decompression steps performed on the compressed digital image.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring to FIG. 1, in one embodiment of the present invention, a customer exposes a roll of film in a cartridge 10 in her camera 12 and sends the film to a photo processing lab 14 to be developed. As is well known, a retail outlet such as a photo store, drugstore, or supermarket may be an intermediary in sending the film to the photoprocessing lab. At the photoprocessing lab 14 , the film is developed in a processor 16 to produce processed film 18 . The processed film 18 is printed in a photographic printer 20 to produce a set of prints 22 . The processed film 18 is also scanned in a scanner 24 to produce a digital image file of the images on the film.
[0028] A computer 26 controls the scanner 24 , processes the digital image file, and stores the digital image file along with a customer order number and a unique customer identification number in a mass storage device 28 such as a magnetic tape drive or an optical disc. An index printer 30 is connected to the computer 26 and employs the digital image file stored on storage device 28 to produce an index print. The index printer 30 may comprise for example a separate color thermal printer, or a color CRT printer for exposing photographic film. As shown in FIG. 2, the index print 32 includes the customer order number 34 that identifies the digital image file from which the index print was made, and a series of images 36 , each having an associated index number 37 .
[0029] The developed film 18 , and prints 22 are returned to the customer along with the index print 32 . Instructions 38 may be included with the customer order, informing the customer of the printing and related photographic services available, and the prices for the services. The instructions 38 may be printed out using a coupon printer 39 connected to computer 26 . The customer is instructed that a digital record of their negatives was made and that by calling, for example, a 1-800 number, they can either have the digital file of their negatives deleted or extended for a certain period of time, such as a month. The customer can then have a specified period of time to respond by ordering a service. If the customer does not order any service in that period of time, their file is automatically deleted. During the time period, there are several services that they can order, and special price advantages may be offered. If any service is ordered, maintenance of the digital negatives file may be extended.
[0030] The customer calls on her touch tone telephone 40 and connects with an operator or computer voice ordering system 42 . As shown in FIG. 3, the voice ordering system instructs the customer to enter the order number ( 44 ), and then requests a frame number to be entered ( 46 ). Next, the customer is directed to enter a code for the desired service ( 48 ) to be performed with respect to the image corresponding to the desired frame number. The customer is queried as to whether additional services are required ( 50 ). If the answer is yes, the previous steps are repeated; if no, the address and credit card number of the customer is verified ( 52 ), and the order process is ended.
[0031] During the ordering process, the customer may be prompted to record a voice message that is recorded and provided with a print related service, such as a voice chip associated with the print, or a magnetic or other type of recording on the print or associated with the print. The voice message may also be transcribed and printed on a label or on the back of the print.
[0032] Returning to FIG. 1, computer 26 is connected to a print server 54 that controls a number of digital printers 56 , and 58 . The digital printers may include, for example, digital printers for exposing conventional silver halide color photographic paper to make high quality enlargements, thermal dye transfer printers and ink jet printers for making poster size enlargements. A Photo CD™ writer 60 is also connected to the computer 26 for recording the customer selected images on a Photo CD™ A bill printer 62 is connected to the computer 26 for printing the customer bill.
[0033] After completion, the customer order, generally designated 64 , including any photographic prints 66 , Photo CD™'s 68 and the customer bill 70 is sent to the customers delivery address 72 , either by mail or parcel service.
[0034] Services which may be ordered include requesting a Photo CD™ from the digital image file whose images appear on the index print. Digital enlargements may be made from selected digital image files whose images appear on the index print. Digital prints, enlargements, and other image bearing items made from selected digital image files may be sent directly to the customer or to any person designated by the customer. Digital greeting cards or business cards may be made from selected digital negatives. Other products and services such as images inserted in pre-prepared templates, printed album pages, collages, recorded voice messages, etc. can be offered. Additionally, for a nominal fee, the customer can extend the length of time their digital negatives are stored.
[0035] Alternatively, the photofinisher may not make any prints originally and can keep the film 18 for use in optical printing later when the customer places his or her order (or a set of prints could be made and sent to the customer while the negatives are retained by the photofinisher). If the customer chooses to maintain the digital file or make a print order, the customer then has that specified period of time to respond by ordering a service. If the customer does not order anything within that time period, their file is automatically deleted. The negatives could be destroyed or returned. During the time period, there are several services that can be ordered, and special prices may apply. Ordering a service may also extend the maintenance of their digital negative files. Services may be ordered using a touch tone telephone and the unique ID number, without requiring additional personnel to take the orders. As images are discarded by the customer, the storage devices can be reused.
[0036] Because the digital printers and digital storage are capital intensive items, it may be preferable to separate the digital printing part of the operation from the photo processing lab and place it in a digital image center that serves several photo processing labs. FIG. 4 illustrates this approach. After the films are scanned at the photo processing lab 14 , and the index prints made, the digital image files are stored on magnetic tape cassettes 76 in digital cassette recorder 77 . Several orders, such as one day's production may be placed on one cassette. The cassettes 76 are shipped to a digital image center 78 , where they are placed in a multiple cassette drive 80 for future access.
[0037] Alternatively, the digital image files on the cassettes may be transferred to another storage medium such as optical disc at the digital image center 78 . Also, rather than physically shipping a tape cassette 76 , the digital image file may be transmitted to the digital image center over a high speed data link such as a fiber optic cable.
[0038] As shown in FIG. 5, to minimize storage size, the digital image files may be compressed prior to storage. The digital images from scanner 24 are passed as 3-plane, 2K×3K pixel, digitized color images. The digital images are processed ( 100 ) to convert the negative film scans from cyan, magenta, and yellow color space to Kodak's YCC color space (a luminance Y, and color difference signal CC color space). Slide film scans are converted from red, green, blue color space to Kodak's YCC color space. The bit-depth of each pixel in a color plane is reduced from 12-bits to 8-bits using a non-linear luminance mapping which more evenly distributes quantization errors based on human perception rather than image intensity.
[0039] The high resolution version of the YCC image is now down sampled ( 102 ) in each chrominance channel by a factor of 2:1 in each of the x-direction and y-directions in the image. This can generally be done with very little loss of data due to the reduced information content in these channels.
[0040] The image is further reduced in storage requirement by performing JPEG image compression ( 106 ) on both the low and high resolution images. The compression ratio achieved will depend on the image content and the desired image quality (i.e. the level of acceptable compression induced artifacts in the decompressed image). The compression technique and quantization matrix are selected to enable compression ratios on the order of 5:1 to 15:1 to be achieved.
[0041] Alternately, a lower spatial resolution scanner 24 may be used to scan the film image in combination with a compression module which uses smaller compression ratios (e.g. 1.5:1 to 3:1) to achieve a similar compressed storage image file size. The lower scanning data rate advantage of this method is offset by more limited ability to enlarge the resulting stored image without introducing visible image artifacts. The resulting compressed digital image files are stored ( 108 ).
[0042] To decompress the digital image file, the operations performed by the computer 26 in the photo processing lab 14 , or computer 80 in the digital image center 78 will now be described with reference to FIG. 6. To utilize the stored compressed image, JPEG decompression is applied ( 112 ) to reverse the effects of the JPEG compression step ( 106 ). The chrominance channels are then up sampled ( 114 ) to reverse the down sampling ( 102 ) previously performed on these channels.
[0043] Color transformation is performed ( 116 ) as necessary to translate the encoded Kodak YCC image color space image into the control signal space necessary to drive the intended printing device.
[0044] The image is then resized ( 118 ) based on the desired final image size and the image printer's writing resolution (i.e. pixels per inch). The previous two steps are sometimes reversed to eliminate unnecessary pixel computations (e.g. color transformation may be performed after resizing when the resulting image is to be significantly reduced in size to avoid color correcting pixels which would never be printed as a result of a subsequent resizing step).
[0045] Image sharpening is generally performed ( 120 ) as one of the last steps in the processing chain to compensate for the image printer's natural modulation transfer function (MTF). Alternately, this sharpening step is sometimes performed prior to resizing to save processing time if significant enlargement is requested and the resulting loss of image quality will not be objectionable.
[0046] Next, if a device which is not able to reproduce “continuous-tone” color (i.e. 8-bits per pixel per color plane) is used to make this final print, a halftoning step ( 124 ) is employed to render the image to the reduced number of bits capable of being printed per pixel per color by the final image printing device (e.g. an inkjet print might be reduced to 1-bit per pixel per color to accommodate this device's bitonal printing capability).
[0047] As will be obvious to those skilled in the art, various modifications of the present invention are possible without departing from the scope of the invention. For example, the customer is able to order goods and services via a telephone, by looking at the index print and making selections on the touch tone pad.
INDUSTRIAL APPLICABILITY AND ADVANTAGES
[0048] The present invention is useful in the field of photo processing in that it reduces the inconvenience of ordering prints and reprints from photographic negatives. The present invention has the advantage of streamlining the previously inconvenient means of selecting and ordering photographic prints and reprints. The present invention has the further advantage of decreasing the multiple handling of sensitive film negatives by the customer. The present invention offers the potential for eliminating unwanted prints by allowing the customer to peruse the images before ordering an initial printing of the negative. The present invention also has the advantage of eliminating improper recording of data. Finally, the present invention has the advantage of making negative images more easily identifiable by the customer, particularly when there are several similar images.
[0049] It is to be understood that various modifications and changes may be made without departing from the present invention, the present invention being defined by the following claims.
Parts List
[0050] [0050] 10 film cartridge
[0051] [0051] 12 camera
[0052] [0052] 14 photo processing lab
[0053] [0053] 16 film processor
[0054] [0054] 18 processed film
[0055] [0055] 20 photographic printer
[0056] [0056] 22 photographic prints
[0057] [0057] 24 film scanner
[0058] [0058] 26 computer
[0059] [0059] 28 storage device
[0060] [0060] 30 index printer
[0061] [0061] 32 index print
[0062] [0062] 34 customer order number
[0063] [0063] 36 index images
[0064] [0064] 37 index number
[0065] [0065] 38 instructions
[0066] [0066] 40 telephone
[0067] [0067] 42 voice ordering system
[0068] [0068] 44 enter order number step
[0069] [0069] 46 enter frame number step
[0070] [0070] 48 enter code for desired service step
[0071] [0071] 50 identify additional services step
[0072] [0072] 52 verify customer credit information step
[0073] [0073] 54 print server
[0074] [0074] 56 digital printer
[0075] [0075] 58 digital printer
[0076] [0076] 60 Photo CD™ writer
[0077] [0077] 62 bill printer
[0078] [0078] 64 customer order
[0079] [0079] 66 photographic prints
[0080] [0080] 68 Photo CD™
[0081] [0081] 70 customer bill
[0082] [0082] 72 customer delivery address
[0083] [0083] 76 magnetic tape cassette
[0084] [0084] 77 cassette recorder
[0085] [0085] 78 digital image center
[0086] [0086] 80 multiple cassette drive
[0087] [0087] 100 image processing step
[0088] [0088] 102 down sample step
[0089] [0089] 106 JPEG compress step
[0090] [0090] 108 store digital image step
[0091] [0091] 112 JPEG decompress step
[0092] [0092] 114 chrominance up sample step
[0093] [0093] 116 color transformation step
[0094] [0094] 118 resize image step
[0095] [0095] 120 sharpen image step
[0096] [0096] 124 halftone image step | A method for remotely selecting and ordering photographic prints, includes the steps of: sending a photographic film bearing a plurality of latent images to a photofinisher; developing the photographic film to produce visible images and scanning the visible images to create a digital image file at the photo finisher; producing an index print having a plurality of images from the photographic film along with an index number associated with each image and an order number; sending the index print to a customer; selecting images for which prints are desired from the index print; ordering photographic prints via telephone from the customer's home to the photofinisher, specifying the order number and the index numbers associated with the images for which prints are desired; and making photographic prints of the selected images at the photofinisher and sending the photographic prints to the customer. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to camshaft arrangements having cams supported for limited angular motion. German Offenlegungsschrift No. 41 22 251 discloses a camshaft arrangement in which cams supported for limited angular motion are provided with stops formed as claws projecting from a tube extending parallel to the camshaft and held stationary with respect to the cam. Another configuration of cam stops, in which they are beneath the cam rather than extending laterally with respect to the cam, is disclosed in German Patent No. 32 34 640. In that arrangement, the stop is a strip mounted in the camshaft and projecting into an angular recess extending over a selected angle in an inner surface of the cam adjacent to the camshaft so as to define the limits of angular motion of the cam with respect to the camshaft. In one form, the recess is a closed hydraulic system, while in another form a passage having a check valve connects the recess with a passage in the camshaft to provide hydraulic damping fluid to the recess.
The above-mentioned prior art movable cam arrangements provide the advantageous possibility of optimizing an engine valve stroke curve as a function of the rotational speed of the engine during operation. In principle, this is accomplished because the cam is held in fixed position with respect to the camshaft only during certain angular intervals of each camshaft revolution when it rotates at the same speed as the camshaft while, in the other angular intervals, the angular velocity of the cam is greater or less than the rotational speed of the camshaft. Assuming a constant camshaft speed during a revolution, therefore, these arrangements provide angular intervals of uniform and nonuniform rotational motion of the cam.
To the extent that the prior art discloses the use of damping fluid, a longitudinal passage in the camshaft is provided for this purpose, which must, accordingly, be connected to a source of damping fluid. Generally, the lubricating oil supply for the engine is used as the damping fluid and is supplied to the longitudinal passage in the camshaft at a central location in the engine. When the camshaft is comparatively long, however, the flow resistance of the passage may cause pressure losses which adversely affect the damping action in the cam recess. The adverse effect of this pressure loss is especially noticeable when the engine generates a comparatively low oil pressure in its lubricating system as, for example, when it is idling.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a camshaft arrangement having cams mounted for limited angular motion which overcomes the disadvantages of the prior art.
Another object of the invention is to provide such a camshaft arrangement in which damping fluid is supplied at the required pressure to the cam recesses for all of the cams mounted on the camshaft.
These and other objects of the invention are attained by providing a camshaft arrangement having a cam which is angularly movable thereon and a stationary bearing sleeve surrounding the camshaft having a fluid passage therein communicating with the camshaft passage through which hydraulic damping fluid is supplied to a recess in which a cam motion-limiting stop member is movable.
One important advantage of the camshaft arrangement according to the invention is that it requires practically no additional space since the damping fluid passages are provided in camshaft bearings which are required in any event.
In one embodiment, a check valve prevents damping fluid from draining out of the camshaft passage when the engine is idling. Moreover, the bearing passage may act as a valve if it is arranged to be connected to the camshaft passage by way of a connecting passage only when the cam is at predetermined angles with respect to the camshaft.
In another embodiment, the camshaft bearing may be very narrow in the regions between the cams, or it may be omitted entirely in those regions to save space.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will be apparent from a reading of the following description in conjunction with the accompanying drawings, in which:
FIG. 1 is a cross-sectional view illustrating a representative embodiment of a camshaft arrangement according to the invention; and
FIG 2 is a cross-sectional view illustrating another representative embodiment of a camshaft arrangement according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the typical embodiment of the invention shown in FIG. 1, a cam 1 is mounted for limited angular motion on a camshaft 2. The cam 1 is located behind the plane of the drawing which is selected so that a neck 3, which is adjacent to and fixed with respect to the cam, is shown in section in the drawing. The angle of motion of the cam 1 and, hence, also of the neck 3 with respect to the camshaft 2, is determined by the angular length of a recess 4 formed in the inner surface of the neck 3 which receives a roller-shaped driver 5. The driver 5 extends perpendicular to the plane of the drawing and is rotatably received in a correspondingly-shaped recess 6 in the camshaft 2. The driver 5 and the recess 4 preferably extend beneath the cam 1.
When the camshaft 2 rotates in the clockwise direction, as indicated by the arrow in the drawing, the force exerted on a portion 7 of the cam contour at the left as seen in FIG. 1 by the closing spring for the valve which is driven by the cam, produces a driving contact between the driver 5 and a stop surface 8 at the left end of the recess 4 which is fixed with respect to the cam so that the cam 1 rotates at the same angular velocity as the camshaft 2. When the cam has rotated far enough so that the valve-closing spring force acts on the right portion 9 of the cam contour as seen in FIG. 1, and the cam has a relatively low rotational speed, the force of the valve-closing spring produces an angular acceleration of the cam 1 relative to the camshaft 2 moving the cam in the direction of the arrow until a stop surface 10 at the right end of the recess 4 as seen in FIG. 1 engages the cam driver 5. Accordingly, the angular length of the recess 4 in the circumferential direction defines the limits of angular motion of the cam 1 with respect to the camshaft 2. The recess 4 thus forms an interchamber between the camshaft stop formed by the driver 5 and the cam stop 8 at one end of the recess.
To damp the relative motion between the cam and the camshaft, damping fluid is supplied to the recess 4 through a transverse passage 11 from a longitudinal passage 12 in the camshaft 2 when the cam 1 is in the position shown in FIG. 1 so that the flow of damping fluid into the recess 4 is possible.
As described above, the pressure in the longitudinal camshaft passage 12 may not be sufficient to ensure a required pressure build-up in the interchamber 4, at least when the engine is idling. To overcome this problem, a sleeve 13, which is part of a stationary camshaft bearing, is formed with a passage 14 which extends over a preassigned angular interval and is open toward the neck 3. The passage 14 communicates with a source damping of fluid and also communicates at all positions of the cam 1 with respect to the neck 3 by way of a communicating passage 15 therein with a transverse passage 16 in the camshaft. The transverse passage 16 has a check valve 17 permitting flow of the damping fluid from the passages 14 and 15 into the longitudinal camshaft passage 12, but not in the opposite direction. Emptying of the longitudinal passage 12, for example when the engine is idling, is thereby prevented.
In the embodiment illustrated in FIG. 1, the check valve 17 consists of a housing 18 which is pressed into the transverse passage 16 and forms a seat 19 for a valve ball 20 so that, when the pressure in the passage 14 is higher than the pressure in the longitudinal camshaft passage 12, the ball is pressed to the right as seen in FIG. 1 against the force of a valve spring 21, permitting fluid to flow through a bypass duct 22 in the check valve 17.
Referring now to the alternative embodiment shown in FIG. 2, an angularly movable cam 30 also positioned behind the plane of the drawing has a neck 31 and is mounted on a camshaft 32 formed with a longitudinal passage 33 and transverse passages 34 and 35, and the neck 31 is surrounded by a sleeve 36 having an angular passage 37. The neck 31 has a recess 38 which receives a roller-shaped driver 39, which is rotatably supported in a recess 40 in the camshaft 32.
In this embodiment, a check valve such as the check valve 17 in the embodiment of FIG. 1 is dispensed with and, instead, a communicating passage 41 formed in the neck 31 establishes flow communication between the transverse camshaft passage 34 and the angular passage 37 in the sleeve 36 only in certain relative angular positions of the cam 30 and the camshaft 32. Hence it may be said that the neck 31 by itself forms a check valve, by preventing communication between the longitudinal passage 33 in the camshaft 32 and the angular passage 37, for example when the engine is idling. In the operating conditions in which the communicating passage 41 provides a flow connection between the passage 237 and the transverse camshaft passage 34, communication between the recess 38 and the longitudinal camshaft passage 33 through the transverse passage 35 is prevented.
The invention provides, by a simple constructing, a dependable supply of damping fluid for a camshaft arrangement having an angularly movable cam.
Although the invention has been described herein with reference to specific embodiments, many modifications and variations therein will readily occur to those skilled in the art. Accordingly, all such variations and modifications are included within the intended scope of the invention. | A camshaft arrangement includes a cam mounted for angular motion on a camshaft with the angular motion being limited by cooperating stops in the camshaft and in a neck portion of the cam defining an interchamber filled with damping fluid. Damping fluid is supplied to the interchamber by a passage in a camshaft bearing sleeve which is in communication with a longitudinal passage in the camshaft through a valve designed to prevent the longitudinal passage from draining. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to chair construction. More particularly, the invention concerns a novel chair construction having connector means for releasably interconnecting together a plurality of adjacent chairs in either a generally straight line array or in a curved array.
2. Discussion of the Prior Art
It is frequently necessary in schools, churches, hotels, auditoriums, convention centers and similar public and private meeting places to provide seating arrangements which usually comprise a plurality of parallel rows of auditorium type chairs. Preferably the chairs, which typically comprise interconnected seats and backs that are supported by pairs of spaced apart front and rear legs are releasably connected together by some type of connector means, often affixed to the chair legs.
Exemplary of one type of chair coupling construction is that described in U.S. Pat. No. 3,009,738 issued to Piker. The Piker coupling means comprises primary and secondary interlocking half parts of identical configuration which are affixed to the upper portions of the front and rear chair legs. Another type of prior art ganging attachment is disclosed in U.S. Pat. No. 3,614,157 issued to Hendrickson. This ganging attachment comprises identical fittings that are attached in mutually inverted positions at vertically spaced points on the legs of folding chairs. Each of the fittings is generally channel shaped with its flanges welded to the leg and its web provided with a headed stud at one end and a slot at the other. Relative vertical movement between the chairs will engage the slotted ends of the respective fittings of one chair with the projecting studs of the adjacent chair thus interlocking the chairs against lateral separation. A somewhat similar arrangement is described in U.S. Pat. No. 3,227,487 issued to Blanchard, Jr. et al. The Blanchard et al coupling means comprises pin and plate connectors for folding chairs which are constructed so as to resist torsional stresses, while at the same time permitting the chairs by leg movement to be readily disassembled.
While the prior art chair coupling constructions generally perform in a satisfactory manner, some are rather difficult to operate and often tend to become jammed making chair separation difficult. Additionally, certain of the prior art coupling means are unduly complex making them difficult and costly to manufacture and install. Further, most of the prior art chair coupling constructions are of limited versatility and permit ganging of the chair only in a straight line configuration.
As will be better appreciated from the discussion which follows, the novel coupling means of the present invention are of a simple easy to use construction and uniquely permit the chairs to be ganged together either in a straight line or curved arrays.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel chair construction which includes connector means for rigidly anchoring chairs in assembled relation either in a linear fashion or in a curved array depending upon the positioning of the rear connector of a pair of front and rear connectors which comprise the connector means of the invention.
Another object of the invention is to provide a chair construction of the aforementioned character in which the connector means is easily fabricated and can be readily affixed to the legs of the chair in a manner to enable the chairs by leg movement to be readily assembled and disassembled into the desired array.
Another object of the invention is to provide a chair construction in which the connector means thereof are unobtrusive and do not interfere with the normal use of the chair.
Another object of the invention is to provide a chair construction of the character described in the preceding paragraphs which is of a simple and extremely attractive design and one which permits easy stacking of the individual chairs when they are not in use.
As will be better understood from the discussion which follows, the present invention improves upon the prior art chair construction by providing an elegantly simple, easy-to-use and highly versatile chair construction which embodies novel connector mechanisms that permit a plurality of individual chairs to be releasably interconnected together either in straight or curved rows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally perspective view of one form of chair construction of the invention.
FIG. 2 is a generally perspective illustrative view showing two chairs of the invention releasably interconnected together by the novel connector means of the invention.
FIG. 3 is a top plan view of a straight line array of interconnected chairs of the invention partly broken away to show the connector means in a first orientation.
FIG. 4 is a top plan view of a curved array of interconnected chairs of the invention partly broken away to show the connector means in a second orientation.
FIG. 5 is a greatly enlarged view of the area designated in FIG. 3 by the numeral 5.
FIG. 6 is a greatly enlarged view of the area designated in FIG. 4 by the numeral 6.
FIG. 7 is an enlarged, cross-sectional view taken along lines 7--7 of FIG. 6.
FIG. 8 is an enlarged, cross-sectional view taken along lines 8--8 of FIG. 6.
FIG. 9 is a cross-sectional view similar to FIG. 8, but showing the rear connector in a position to form a straight array.
FIG. 10 is an enlarged, generally perspective, exploded view of the front connector assembly of one form of the invention.
FIG. 11 is an enlarged, generally perspective, exploded view of the rear connector assembly on one form of the invention showing the connector in a first orientation to form a straight line array.
FIG. 12 is a view similar to FIG. 11, but showing the rear connector assembly in a second orientation to form a curved array of chairs.
FIG. 13 is a generally perspective view of a group of chairs of the present invention in a stacked configuration.
DESCRIPTION OF THE INVENTION
Referring to the drawings and particularly to FIGS. 1 through 6, one form of chair construction of the present invention is there shown and generally designated by the numeral 14. As best seen in FIG. 1, the chair construction here comprises a seat portion 16 and a back rest portion 18 which is interconnected with seat portion 16. Seat portion 16 is supported by transversely spaced apart, generally U-shaped first and second leg frames 20 and 22 respectively. Leg frame 20 comprises a downwardly extending rear leg 20a and a downwardly extending front leg 20b. Similarly, leg frame 22 comprises a downwardly extending rear leg 22a and a downwardly extending front leg 22b. Back rest 18 is supported by a curved frame 24, the lower portions of which are connected to frames 20 and 22 by any suitable means such as spot welding.
Affixed to leg frame 20 is the novel connector means of the invention for releasably interconnecting first and second chairs 28 and 30 in an assembled relationship (FIG. 2). The connector means here comprises a front leg connector assembly 32 and a rear leg connector assembly 34. Turning particularly to FIGS. 7 and 10, the front leg connection assembly 32 can be seen to comprise a front leg connector 37 and a front leg connector support 39. Connector 37 includes a body portion 37a having a base 37b, which as shown in FIG. 10, includes a pair of spaced-apart grooves 37c. Body portion 37a is uniquely provided with a generally centered leg receiving channel 37d which, in a manner presently to be described is adapted to receive the front leg of an adjacently disposed chair.
As best seen in FIGS. 8 and 11, rear leg connector assembly 34 comprises a rear leg connector 41 and a rear leg connector support 43. Connector 41 includes a body portion 41a having a base 41b which, as shown in FIGS. 11 and 12, is provided with a pair of grooves 41c. Body portion 41a is uniquely provided with an offset or off centered leg receiving channel 41d which, in a manner presently to be described, is adapted to receive the rear leg of an adjacently disposed chair.
Each of the front and rear leg connector supports 39 and 43 comprises a base portion and an end wall portion. More particularly, support 39 includes a pair of spaced-apart base defining, rod-like members 46 which have first and second ends 46a and 46b respectively. Connected to ends 46b is a generally U-shaped end wall defining member 48. Similarly, support 43 includes a pair of spaced-apart base defining rod-like members 50 which have first and second ends 50a and 50b respectively. Connected to ends 50b is a generally U-shaped end wall defining member 52.
As best seen by referring to FIGS. 1 and 7, ends 46a of front leg connector support 39 are affixed as by welding or other suitable means to a front leg 20b of the chair construction of the invention. Similarly, ends 50a of rear leg connector support 43 are affixed as by welding or other suitable means to a rear leg 20a of the chair construction (see also FIGS. 8 and 9).
With supports 39 and 43 affixed to the legs of the chair, connectors 37 and 41 can be readily connected thereto. More particularly, connector 37 is connected to support 39 by inserting rod-like members 46 into grooves 37c in the manner indicated in FIG. 10. Connector 41 is affixed to support 43 in a similar manner. However, it is to be noted that connector 41 can be connected to support 43 in either the first position shown in FIGS. 9 and 11 wherein channel 41d is proximate leg 20a or in the second position shown in FIGS. 8 and 12 wherein channel 41d is spaced apart from leg 20a. Described another way, as shown in FIGS. 9 and 11, when connector 41 is in a first position, a first end wall 41e of connector 41 is in engagement with rear leg 20a. On the other hand, when connector 41 is in the second position shown in FIGS. 8 and 12, a second, operably disposed end wall 41f of the connector 41 is in engagement with rear leg 20a.
The novel construction of connector 41 as described in the preceding paragraph permits the connector means of the invention to be used to interconnect a plurality of chairs, such as those shown in FIG. 3, in a generally straight line array, or, alternatively, in a curved array of the character shown in FIG. 4. As best seen in FIG. 5, when connector 41 is in the first position there shown with end wall 41e in engagement with rear chair leg 20a, channel 41d is located proximate leg 20a and when the rear leg 22a of an adjacent chair is positioned within the channel, a generally straight line array will be formed. Conversely, as shown in FIG. 6, when connector 41 is in the second position, end wall 41f is located proximate rear chair leg 20 and channel 41d is spaced therefrom. With this arrangement when the rear leg 22a of an adjacent chair is positioned within channel 41d a gracefully curved array of the character shown in FIG. 4 will be formed.
With the groups of chairs interconnected together in either the manner shown in FIG. 3 or in FIG. 6, it is a simple matter to disassemble the chairs by simply lifting the chair at the left end of the array relative to the next adjacent chair. Once the chair is lifted a sufficient distance so that the front and rear legs thereof clear the channels 37d and 41d (see also FIGS. 5 and 6), the chairs can be expediciously separated. To interconnect the chairs into the selected array, the reverse procedure is, of course, accomplished.
After the chairs have been separated in the manner described in the preceding paragraphs, they can readily be stacked into the vertical array shown in FIG. 13. For this purpose, the front legs of each of the chairs is provided with a pair of semi-cylindrically shaped spaced elements 55. These spacer elements, which are affixed to the lower rear portion of the front legs 20b and 22b engage the upper front portions of the legs of the adjacent chair when the chairs are stacked in the manner shown in FIG. 13. In similar fashion, each of the rear legs 20a and 20b is provided with similarly configured spacer elements 57. When the chairs are stacked, elements 57, which are affixed to the lower inside surfaces of legs 20a and 20b, engage the upper rear surfaces of the rear legs of adjacent chair. With this novel construction, the chairs can be stacked in a stable configuration for transport and storage.
Spaced elements 55 and 57 as well as connectors 37 and 41 are preferably molded from a thermoplastic rubber or like material. The chair legs and back supporting frames, on the other hand, are preferably formed from a tubular steel or aluminum material although other suitable high strength materials could be used.
Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims. | A chair construction which includes connector mechanisms for rigidly anchoring chairs in assembled relation either in a linear fashion or in a curved array depending upon the positioning of the rear connector of a pair of front and rear connectors. The connector mechanisms are easily fabricated and can be readily affixed to the legs of the chair in a manner to enable the chairs by leg movement to be readily assembled and disassembled into the desired array. The connector mechanisms are specially designed and located so as to be unobtrusive and so as not to interfere with the normal use of the chair. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a coupling adapted to be connected to an end portion of a tube made of plastic composite material to be used as a structural member in a structure or the like.
2. Description of the Prior Art
A conventional coupling means for coupling an end portion of a tube made of plastic composite material to be used as a structural member to another member includes a mechanical coupling means or a fastener such as a rivet, bolt and nut. However, in such a mechanical coupling means, when a stress such as a tensile stress is generated between the plastic tube and the other member connected thereto, a stress concentration is generated at a wall surface of the plastic tube at a position around a through fole in which the rivet or the bolt is inserted through the plastic tube, causing breakage of the plastic tube or a reduction in strength as the structural member. There exists another coupling means employing adhesive for bonding the plastic tube to the other member. However, this kind of coupling means has a problem of low and ununiformity of the adhesive strength.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a coupling designed to be connected to an end portion of a tube made of plastic composite material (which will be hereinafter referred to as a plastic tube) to be used as a structural member, which coupling has a large strength without the necessity of adhesive as a bonding means.
It is another object of the present invention to provide a coupling designed to be connected to the end portion of the plastic tube having acute cutouts, which coupling has a tapering portion for holding the end portion of the plastic tube.
It is a further object of the present invention to provide a coupling having a tapering portion which may firmly hold the end portion of the plastic tube by utilizing a wedge effect of the tapering portion.
It is a still further object of the present invention to provide a coupling employing a fiber reinforced plastic for a part of the coupling.
According to the present invention, there is provided a coupling for a plastic tube comprising the plastic tube having an end portion formed with a plurality of acute cutouts, a fitting having a small-diameter front end portion formed with a tapped hole for receiving a connecting rod and a bell-shaped tapering rear portion, and a bell-shaped sleeve having an inner wall surface of a shape corresponding to a tapering shape of the fitting, wherein the end portion of the plastic tube is held between the fitting inserted into the plastic tube and the bell-shaped sleeve mounted on the fitting through the end portion of the plastic tube.
In assembling the coupling of the present invention, the fitting is first inserted into the end portion of the plastic tube which end portion is formed with the acute cutouts. Then, the bell-shaped sleeve is mounted on the outer periphery of the end portion of the plastic tube. Then, a locking means such as a nut is tightened to the front end portion of the fitting to thereby draw the fitting toward the sleeve. As a result, the end portion of the plastic tube is taperingly deformed and held between the tapering portion of the fitting and the tapering portion of the bell-shaped sleeve, thus assembling these three members as a unit. Then, the connecting rod is connected to the coupling by threadedly engaging the former with the tapped hole of the fitting, thus reliably connecting the plastic tube with the other member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of the end portion of the plastic tube;
FIG. 2 is a left side view of FIG. 1;
FIG. 3 is an elevational view of the end portion of the plastic tube under the taperingly deformed condition;
FIG. 4 is an elevational view, partly in section, of the fitting;
FIG. 5 is an elevational view, partly in section, of the bell-shaped sleeve;
FIG. 6 is an elevational view, partly in section, of a preferred embodiment of the coupling connected to the connecting rod; and
FIG. 7 is an elevational view, partly in section, of another preferred embodiment of the coupling connected to the connecting rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There will now be described a preferred embodiment of the present invention. FIG. 1 is an elevational view of an end portion 2 of a tubular member 1 made of plastic composite material, and FIG. 2 is an end view of the tubular member 1. The end portion 2 of the tubular member 1 is formed with a plurality of acute cutouts 3 extending in a longitudinal direction of the tubular member 1. The acute cutouts 3 are arranged at equal intervals over the circumference of the end portion 2 to form a plurality of lips 2a. The number of lips 2a formed to the end portion 2 may depend upon the size of the tubular member 1. As shown in FIG. 3, when a force is applied to the end portion 2 from the outer circumference toward the center thereof , the lips 2a are inwardly deformed in such a manner that each acute cutout 3 defined between the adjacent lips 2a is narrowed to form a tapering configuration of the end portion 2.
FIG. 4 is an elevational view, partly in section, of a fitting 4. The fitting 4 is made of aluminum alloy or the like, and has a bell-shaped configuration such that an outer diameter of a maximum-diameter rear end portion 5 of the fitting 4 is substantially equal to an inner diameter of the tubular member 1, and that a tapering portion 5a is formed between the rear end portion 5 and a minimum-diameter front end portion 6. The front end portion 6 is formed with internal threads 7 to be threadedly engaged with a bolt portion 2 of a connecting rod 15 which will be hereinafter described. Further, the fitting 4 is formed at its front portion with external threads 8 to be threadedly engaged with a lock nut 14 which will be hereinafter described.
FIG. 5 is an elevational view, partly in section, of a bell-shaped sleeve 9 designed to be fitted with the outer periphery of the fitting 4 through the end portion 2 of the tubular member 1. The bell-shaped sleeve 9 is made of aluminum alloy or the like, and has a bell-shaped configuration such that an inner diameter of a maximum-diameter rear end portion 10 of the sleeve 9 is substantially equal to an outer diameter of the tubular member 1, and that a tapering portion 10a is formed between the rear end portion 10 and a minimum-diameter front end portion 11. The tapering portion 10a of the sleeve 9 has a tapering angle equal to that of the tapering portion 5a of the fitting 4. The front end portion 11 of the sleeve 9 is formed with an opening 12 for inserting the front end portion 6 of the fitting 4 therethrough.
FIG. 6 shows an assembled condition of the tubular member 1, the fitting 4 and the sleeve 9 wherein the tubular member 1 is connected through a connecting rod 15 having a bearing 13 to another member (not shown).
First, the rear end portion 5 of the fitting 4 is inserted into the end portion 2 with the acute cutouts 3. Then, the bell-shaped sleeve 9 is fitted with the outer periphery of the end portion 2 of the tubular member 1 in such a manner that the opening 12 of the sleeve 9 is positioned near the external threads 8 of the fitting 4. Then, the nut 14 is threadedly engaged with the external threads 8 of the fitting 4, and is tightened to strongly hold the end portion 2 of the tubular member 1 between the tapering portion 5a of the fitting 4 and the tapering portion 10a of the sleeve 9 by a wedge effect.
Then, the connecting rod 15 having a connecting bearing 13 is threadedly engaged with the internal threads 7 formed in the end portion 6 of the fitting 4, and is fixed by an adjusting nut 16.
In this manner, a gap between the fitting 4 and the sleeve 9 is reduced by tightening the nut 14, and the end portion 2 of the tubular member 1 held between the fitting 4 and the bell-shaped sleeve 9 is gradually tapered in accordance with the tapering shapes of the fitting 4 and the sleeve 9, thus assembling the fitting 4, the end portion 2 of the tubular member 1 and the bell-shaped sleeve 9 as a coupling unit.
The connecting rod 15 to be connected to another member is connected to the coupling by threadedly engaging a bolt portion 20 of the rod 15 with the internal threads 7 of the front end portion 6 of the fitting 4. The connecting bearing 13 of the connecting rod 15 is formed with a through-hole to be engaged with another shaft member, for example.
In threadedly engaging the bolt portion 20 of the connecting rod 15 with the internal threads 7 of the front end portion 6 of the fitting 4, the adjusting nut 16 together with a washer 17 is engaged with the bolt portion 20, so as to adjust an engaging position of the connecting rod 15.
In this embodiment, the end portion of the plastic tubular member is coupled to the metal coupling by a large frictional force generated at the plural lips 2aof the end portion 2, thus receiving a load at a wide area of the end portion 2. Accordingly, when a tensile force is applied to the tubular member 1, there is hardly generated a stress at the end portion 2. Further, a stress distribution may be made uniform to thereby avoid a stress concentration at the coupling and improve a strength of the coupling.
Further, as the connecting rod is axially adjustably connected to the front end portion of the coupling, a connecting position of the end portion 2 of the tubular member 1 to be connected to another member may be easily adjusted.
Referring next to FIG. 7 which shows another preferred embodiment of the present invention, a fiber reinforced sleeve 18 is substituted for the bell-shaped sleeve 9 of the previous embodiment. The other parts are substantially the same as those of the previous embodiment, and are designated by the same reference numbers.
In the same manner as the previous embodiment, the rear end portion 5 of the fitting 4 is inserted into the end portion 2 having the plural acute cutouts 3 of the tubular member 1. Then, a roving of carbon fiber impregnated with epoxy resin is wound around the outer periphery of the end portion 2 of the tubular member 1 substantially perpendicularly thereto to thereby inwardly deform the lips 2a of the end portion 2 along the tapering shape of the fitting 4. Then, the epoxy resin is cured to form a bell-shaped fiber reinforced plastic sleeve 18. Then, the nut 14 toghether with a washer 19 is threadedly engaged with the external threads 8 formed at the front end portion 6 of the fitting 4, thereby strongly holding the end portion 2 tapered between the fitting 4 and teh bell-shaped fiber reinforced sleeve 18.
Further, similarly to the previous embodiment, the connecting rod 15 having the connecting bearing 13 is threadedly engaged with the internal threads 7 formed in the front end portion 6 of the fitting 4, and is fixed by the adjusting nut 16. The gap between the fitting 4 and the sleeve 18 is reduced by tightening the nut 14, and the end portion 2 of the tubular member 1 held between the fitting 4 and the fiber reinforced sleeve 18 is gradually tapered in accordance with the tapering shapes of the fitting 4 and the sleeve 18. Thus, the end portion 2 of the tubular member 1 is firmly held between the fitting 4 and the fiber reinforced sleeve 18 as shown in FIG. 7.
Further, also similarly to the previous embodiment, the length of the engaged portion of the connecting rod 15 with the internal threads 7 of the fitting 4 is suitably adjusted by the adjusting nut 16.
In the second preferred embodiment, as the sleeve 18 is formed by curing the epoxy resin impregnated in the carbon fiber, the sleeve 18 is lightened in weight. When the fitting 4 is firmly coupled to the sleeve 18, the sleeve 18 tends to be expanded outwardly to generate a tensile force against the carbon fiber of the sleeve 18. However, the carbon fiber has a large resistance against the tensile force. Accordingly, the strength of the coupling may be increased.
As described above, the coupling for the plastic tube according to the present invention may effect reliable connection without the necessity of adhesive. Furthermore, as the coupling has a large connection area for connecting with the tube, power transmission may be smoothly carried out, and no stress concentration is generated. As the tightening force to be applied to the end portion of the tube is increased in proportion to a tensile force to be applied, and the frictional force is increased, the power transmission may be reliably effected. Further, upon application of a compressive force to the coupling, the frictional engagement between the sleeve and the end portion of the tube is increased to thereby ensure the power transmission.
In using the bell-shaped sleeve of the first embodiment shown in FIGS. 5 and 6, the assembling operation of the coupling may be simplified to thereby reduce the cost. On the other hand, in using the fiber reinforced sleeve of the second embodiment shown in FIG. 7, the coupling may be made light in weight and strong. | A coupling comprising a tube made of plastic composite material to be used as a structural member and having an end portion formed with a plurality of acute cutouts, a fitting having a small-diameter front end portion and a bell-shaped tapering rear portion, and a bell-shaped sleeve having an inner wall surface of a shape corresponding to that of the tapering portion of the fitting. The end portion of the plastic tube is held between the fitting inserted into the end portion and the sleeve mounted on the outer periphery of the taper fitting, and a nut threadedly engaged with external threads of the fitting is tightened to assemble the fitting, the plastic tube and the sleeve as a unit. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to raisable and lowerable, self-standing, sound reflective shell tower modules and systems of the type used on stage to enhance the performance of orchestras, bands, choruses, dramatic groups and the like. Typically such towers are comprised of a plurality of panel modules which are placed in side by side abutting relation to provide a shell structure in conjunction with overhead sound reflective ceilings, or without them.
The following listed patents, which are incorporated herein by reference, disclose various structures which are known to us:
U.S. Pat. No. 2,671,242 Lewis
U.S. Pat. No. 3,007,539 Brewer et al
U.S. Pat. No. 3,180,446 Wenger
U.S. Pat. No. 3,232,370 Jaffe
U.S. Pat. No. 3,435,909 Wenger et al
U.S. Pat. No. 3,630,309 Wenger et al
U.S. Pat. No. 3,975,850 Giaume
U.S. Pat. No. 3,908,787 Wenger et al
U.S. Pat. No. 4,108,455 James
U.S. Pat. No. 4,278,145 Eade et al
U.S. Pat. No. 5,069,011 Jenne
U.S. Pat. No. 5,168,129 D'Antonio
One of the difficulties with prior art structures, which have been of a relatively complex nature, has been the time and effort required to set up these older style shells. The present invention is conceptualized to remove the weight of the raisable panel as a deterrent to persons of slight build and strength raising it into operative position, while, at the same time, providing rigid, multifaceted panels which blend and mix sounds to enhance the music for both the performers and audience.
SUMMARY OF THE INVENTION
The present invention contemplates a shell structure comprising shell modules consisting of a lower panel mounted on a base which can be rolled to and from an assembly position, and at least one raisable panel which is mounted for vertical telescoping movement from a demounted position, in which the module will readily pass through standard doorways, to a raised position extending sufficiently above the lower panel to provide the height required for the module to function as one tower of an operative acoustic shell which mixes and diffuses the sound. Preferably, a handle crossbar, connected to counterweights which substantially exactly balance the weight of the raisable panel, is depressable with very little effort to elevate the raisable panel and is infinitely adjustable to positions in which it will be automatically retained in position.
One of the prime objects of the present invention is to provide an improved shell tower panel structure of the character described which can be readily assembled in modules consisting of lower panels and raisable and lowerable upper panels to form an optimal acoustical shell which reinforces and blends the sound projected toward the audience, while also enhancing the ability of the musicians to hear themselves and adjust their performance accordingly.
A further object of the invention is to provide a sound mixing and distributing acoustic shell formed of free standing tower modules which, because of the telescoping height adjustment which is possible, will pass through standard doorways and may be set up in rooms having low ceilings at any height within the range of telescopic movement of the upper panel.
Still another object of the invention is to provide a simply constructed non-complex tower module of the character described which can provide the sound mixing effect which is desirable.
Still another object of the invention is to provide a shell tower module system which, while utilizing sound reflective materials in its construction, is relatively strong and durable.
Still another object of the invention is to provide a shell tower system of the type described wherein the telescoped individual modules can be very conveniently compactly stored in nested position.
Other objects and advantages of the invention will become apparent with reference to the accompanying drawings and the accompanying descriptive matter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective front elevational view of a music shell system formed of four modules constructed according to the present invention which are disposed in edge abutting relation, the casters on the various modules, except for the end casters, being only fragmentarily illustrated in the interest of convenience;
FIG. 2 is a schematic perspective elevational view showing a module in a storage position in which the upper and lower panels are generally in horizontal alignment;
FIG. 3 is a similar view showing the modules in a position in which the upper panel has been partially raised;
FIG. 4 is a view showing the module in a configuration in which the upper panel is fully elevated;
FIG. 5 is a schematic, front elevational view of one of the tower modules with the raisable panel in lowered position;
FIG. 6 is a schematic end elevational view thereof;
FIG. 7 is a schematic top plan view thereof;
FIG. 8 is a partly sectional, schematic, end elevational view illustrating various operating parts of the shell tower and showing the upper panel in a partly raised position;
FIG. 9 is an exploded, schematic, perspective elevational view illustrating various operating parts in considerable detail; and
FIG. 10 is an enlarged exploded, schematic, perspective elevational view of certain operating parts which are shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings and in the first instance particularly to FIG. 1, it will be noted that an orchestral shell system, generally designated S, is shown as made up of tower modules 1, 2 3, and 4 which are constructed according to the present invention, the modules being disposed in edge to edge abutting relation as shown to form a shell which, in plan, is shallowly concave as it faces an audience. As FIGS. 7 and 8 particularly illustrate, each of the identical modules 1, 2, 3 and 4 includes a generally U-shaped base generally designated B, supported for rolling transport movement at front and rear by, preferably, twin caster wheel assemblies 10. On each side rail 11 of the base B, a split collar 12 is anchored to the rail 11, as with bolts 13, to support a tubular post 14. A lower panel, which may generally be designated 15 and functions as a rear panel when the module is in a knocked down, storage condition, is fixed to the posts 14 as shown and counterweighted by the base B. As FIG. 7 particularly indicates, the fixed panel 15 is of shallowly V-shaped configuration and may be described as of shallowly concave configuration.
Also supported by each sleeve 12 on the base B, rearward of each post 14, is a fixed tubular mast 16, which is open at its upper end as at 16a, as shown in FIG. 8, to receive a telescoping support and guide tube assembly, generally designated 17. Each telescoping assembly 17 is connected by a bridging bracket 18 to a raisable upper panel, generally designated 19, which may also be referenced as the front panel. As the top plan view FIG. 7 particularly indicates, each panel 19 has protrudent sound reflecting and mixing projections 19a of generally inversely triangular configuration forming a shallowly convex configuration of downwardly divergent character above the flat lower portion 19b of the panel 19. The panels 15 and 19 are formed of sound reflective acoustic material. This may include suitable polystyrene foam core panels, with ABS plastic skins, received by aluminum channel edge members 20 along all edges.
The front panel 19 may be manually raised by a cable and pulley system, generally designated CS, which includes a pair of cables 22, each passing over a set of pulleys 23 and securing to the lower end of the front panel 19 as at 21. At their opposite ends, the cables 22 secure to counterweights, generally designated 25 (see FIG. 8), which have forwardly extending projections 25a with openings 25b to pass the cables which have threaded ends 25c secured by nuts 25d. The counterweights 25 comprise a counterweight system and are connected by a handle, generally designated H, which may have handle grips 26 secured thereon.
Brackets 27, for supporting the pulleys 23, as shown more particularly in FIG. 10, secure to the upper end of the panel 15, the brackets 27 having openings 27a permitting them to be secured by suitable screws 28a extending into openings 28 provided in the panel 15. The brackets 27 further have upstanding plates 27b, with openings 27c. Bushings 30 are provided for the rotatable pulleys, the pulleys being protected by a pulley cover plate 31 with openings 31a aligning with the openings 27c. The bracket assembly further includes bolt fasteners 32 which pass through the openings 31a, bushings 30, and openings 27c, and nuts 32a for retaining them. As FIG. 10 further discloses, the pulley support brackets 27 include rearwardly extending plate portions 33, with openings 34 through which the upper ends of mast 16 extend to maintain the plumb of the masts and panel 15.
It will be noted that each of the counterweights 25 is recessed as at 35 (FIG. 10) to receive the cables 22, and is further generally cylindrically vertically slotted as at 36 to receive the masts 16 and guide thereon in up and down movement. To facilitate aligned sliding movement, the counterweights 36 are provided with slots 38a for receiving linear weight glide bushings 38 which mount in slots 38a provided in the masts 16. Two or three such slots 38a and glides 38 may be provided.
The telescopic guide assembly 17 includes, for each mast 16, an inner tube, generally designated 39, fixed to the bracket 18, a mid-tube, generally designated 40, and a plunger assembly, generally designated 41 which telescopically connects each mid-tube 40 with an inner tube 39. The mid-tubes 40 are slidably received within the tubular masts 16, the inner tubes 39 are slidably received within the mid-tubes 40, and the plungers 41 are received within the inner tubes 39 and extend down through them into the mid-tubes 40. The masts 16 function as a guide system for the raisable panel 19.
Mounted on the lower end of each plunger 41 is a washer 41a retained by a pin 41b. Above it a mid-tube washer assembly 42 is fixed to the interior wall of the mid-tube 40 and may comprise a steel washer 42a with rubber pads 42b at top and bottom. An inner tube washer 43 is similarly fixed within each inner tube 39 and may comprise a steel washer 43a with a top rubber pad 43b.
When the tubes 39 are drawn upwardly by upward movement of the brackets 18, the tubular members 39 move upwardly within tubes 40 to the extent permitted. Thereafter the washers 43 engage the heads 41a of plungers 41 and, with plungers 41 engaging washers 42, pull the mid-tube members 40 upwardly to the extent permitted.
Some of the detail which is involved in the telescopic assembly, although not necessary to an understanding of its operation, is disclosed in the exploded view FIG. 9. In the lower end of masts 16, cushioning pads 45 are shown, as FIG. 8 best discloses, to absorb any shock and minimize noise created when the mid-tube assembly 40 comes into contact with it. It will be observed, further, that the inner tubes 39 are provided with openings 46 to receive glide buttons 47 which protrude slightly therefrom to facilitate sliding movement of the inner tubes 39. These glide bushings or buttons 47 may be spaced relatively to the tubes 39 by washers 48. Similar glide bushings 49 spaced by washers 50 can be received in openings 51 provided in the mid-tubes 40 for the same purpose.
THE OPERATION
In operation, and referring in the first instance to FIGS. 2-4, it will be seen that the handlebar H is in its raised position when the panels 15 and 19 are substantially in horizontal alignment in the storage position illustrated in FIG. 2. As shown in FIG. 3, to fully raise the upper panel 19, the erector need only push the handle H downwardly through the FIG. 3 position, and then through to the FIG. 4 position. In so doing, the forces of gravity aid the music shell erector. Because the weights 25 counterbalance the weight of the panel 19, it is a relatively easy maneuver to raise the upper panel 19 to the extent desired. The telescopic assembly 17 of course is telescopically extended by the raising movement of the brackets 18 fixed to panel 19 to provide the desired guiding support. To lower the upper panel 19, it is only necessary to pull upwardly on the handle 24 which, because it is counterbalanced by the weight of the upper panel 19, will render lowering of the panel 19 a comparatively easy task.
To set up the shell system disclosed in FIG. 1, the respective modules 1, 2, 3, and 4 are, of course, rolled to the abutting relation in which they are shown in FIG. 1, after which it is a relatively easy task as indicated to raise their upper panels 19 to the extent desired. In low ceiling rooms they will, of course, not be completely raised. It is again to be emphasized that the counterbalance system which has been disclosed retains the upper panel 19 automatically in any position to which it is elevated.
It is to be understood that the embodiments described are exemplary of various forms of the invention only and that the invention is defined in the appended claims which contemplate various modifications within the spirit and scope of the invention. | An acoustic shell tower module of sound enhancing character assemblable with other such towers to form an orchestral shell, has a first sound enhancing panel mounted on a generally horizontally rearwardly extending counterweighting base. A second sound enhancing panel is mounted for vertical telescoping movement from a storage position, generally horizontally aligned with the first panel, upwardly to a raised position in which it extends above the first panel to form a sound reflecting and enhancing upper extension thereof, and a system is provided for easily raising and lowering the second panel and retaining it in raised position. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
The present application claims benefit under 35 USC 119(e) of U.S. provisional Application No. 60/863,536, filed on Oct. 30, 2006, entitled “Targeted Advertisement In The Digital Television Environment,” the content of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
Television advertisements have traditionally used viewership statistics such as those provided by Nielsen ratings to select which advertisements to show during a given program. This method for reaching potential markets is far less precise than Internet advertisement, which uses available knowledge of the web surfer's preferences (i.e., search terms) and past viewing history to place advertisements in a targeted manner so that the most relevant advertisements are seen by the people most likely to be interested in the products and services being advertised.
With the advent of digital television (DTV) standards such as DVB-H, Media-FLO™, T-DMB, and ISDB-T 1/3 segment, a wide range of mobile handset users and non-mobile digital television viewers become potential targets of advertisement.
BRIEF SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, a method for targeted advertisement includes, in part, storing a profile tag associated with each user in a device maintained by that user. Each profile tag includes the demographic information of its associated user. A multitude of target tags each associated with an advertisement is also transmitted to the users. The target tags include the demographic information of the targeted users. The advertisements and their corresponding target tags are transmitted and cached in the devices maintained by the users. The number of matches between the target tags and the user profiles are supplied to their respective advertisers. The advertisers use the matching number to modify the prices they are willing to offer for the right to advertise during the commercial break. The target tags include information that is used to select one of the cached advertisement for playing in a commercial space or commercial break.
In one embodiment, the advertisements are transmitted using a logical channel different than a logical channel used to broadcast regular programming. The logical channel used to transmit advertisement has a data rate lower than the data rate of the logical channel used to transmit regular programming. The regular programming interrupted during the commercial break is resumed in a time-shifted manner following the termination of the first commercial break. In another embodiment, the advertisement may be displayed on a portion of the screen simultaneously with the regular programming.
In one embodiment, the played advertisement is stored in a cache and is periodically refreshed. The number of interactions between the user and the advertisement stored in the cache is tracked and supplied to the advertiser. In one embodiment, each profile tag further includes preference information supplied by its user in an optional survey. The preference information may be periodically updated in accordance with the user's behavior. In one embodiment, the number of matches for each advertisement is further defined by geographical locations of the users.
In one embodiment, after playing the advertisement, a web browser is loaded to enable the user to access a web site to make an inquiry about the advertised product/service. In another embodiment, a phone number is automatically dialed to enable the user to make an inquiry about the advertised product/service.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a high-level block diagram of an exemplary system adapted to deliver targeted advertisement in a digital television/video format, in accordance with one embodiment of the present invention.
FIG. 2A shows a number of exemplary logical channels and time slots used for broadcasting regular programs as well as advertisements, in accordance with one embodiment of the present invention.
FIG. 2B shows an exemplary time sequence according with which regular programs and advertisements are broadcast.
FIG. 3 is a flowchart of steps used to cache an advertisement, in accordance with one embodiment of the present invention.
FIG. 4 is a flowchart of steps used to cache an advertisement, in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with one embodiment of the present invention, targeted advertisements are delivered to mobile handset, such as cell phone users (subscribers), as well as to non-mobile digital television viewers in a manner that maximizes its effectiveness and potential benefits to the advertisers and the service providers. In one embodiment, the present invention enables the broadcast advertiser to deliver commercial information (advertisement) to targeted audiences in a timely manner that uses the broadcast bandwidth efficiently. The advertisement is stored and viewer feedback is provided, thus allowing the advertiser to consider the amount paid to the service provider for the advertisement and further to monitor the effectiveness of the advertisement. In one embodiment, the consideration of the amount paid by the advertiser is established through a bidding process carried out in real-time and based on feedbacks from the handsets. Accordingly, the present invention maximizes the value of the broadcast medium to both the advertisers and the broadcast service providers by enabling them, in part, to efficiently price and deliver the advertisements in a timely manner, as described further below. The following description applies equally to handheld mobile digital devices as well as to any other digital device capable of receiving and displaying digital video and audio data.
FIG. 1 is a high-level block diagram of an exemplary system 100 adapted to deliver targeted advertisement in a digital television/video format, in accordance with one embodiment of the present invention. In this exemplary embodiment, advertisers 102 and service providers 104 negotiate to deliver advertisements to mobile handset or digital television receiver 150 . To achieve this and as described further below, in one embodiment, advertisers 102 compete for a commercial time slot and enter into a bidding process facilitated by auction server 106 . The advertiser with a winning bid secures the right to have its commercial played to the targeted users. In another embodiment, the advertiser who has paid a lock-in rate is accorded the time slot for its commercial. The lock-in rate could be fixed or float to match or exceed the highest bid.
In accordance with one aspect of the present invention, the demographic information of the users as well as any preference information the user (hereinafter alternatively referred to herein as subscriber) provides, for example, in an optional a priori survey, is used to determine what advertisements to cache and/or play during a given commercial break. When the mobile handset device includes a location identifier, the user's location which is subject to dynamic changes, may also be used in this determination. Such demographic, geographic and preference information is referred to herein as tag data or tag profile, and is stored on the handset in a coded form when the handset is activated. The preference information may be updated over time with additional surveys or by passively monitoring the habits and behaviors of its respective subscriber.
The advertiser or broadcaster attaches target tags to the advertisement; the tags contain characteristics of the target audience. As described further below, in one embodiment, an advertisement is played to a user when there is a match between the user's tag profile and the target tag included in the advertisement. Matching can be assessed by a variety of flexible algorithms such as detecting whether the least mean squared error between the advertisement tag and the subscriber's tag falls within a certain range. These algorithms can be set by the advertiser and run on the mobile handset device to identify which subscribers are most receptive to viewing the advertisement. Such an advertisement is referred to hereinbelow as a matched advertisement. A matched advertisement thus substantially increases the value of that advertisements to the advertiser by ensuring that it is viewed by an audience most likely to interact positively to it, and to make further inquiry and/or purchase the advertised product or service. At the same time, the broadcaster can sell the same time slot for an advertisement to several different advertisers targeting a viewing audience with a mix of tag profiles, thereby increasing the advertisement revenue. The target tag contains pricing information representing the amount the broadcaster has offered to pay for the advertisement. A previously cached advertisement can have its target tag replaced or modified to reflect price adjustments made by the advertiser. The pricing information is used to select one of the cached advertisements for playing during the designated commercial break.
As is well known, in a television broadcast, advertisements are typically inserted during so-called commercial breaks which can last for some set period of time, such as 15 seconds or 30 seconds. Other breaks may also occur during broadcasts. For example, in some standards such as the DVB-H standard, there may be a delay (latency) between the time when the user selects a logical channel and the time when the selected channel content is displayed on the screen. In accordance with one embodiment of the present invention, the service provider inserts a matched advertisement during such a latency. The latency may occur upon initial selection of the logical channel or when switching between the channels occur. In some embodiments, additional latency is introduced to provide the time required to insert the advertisement. In other embodiments, advertisements are displayed on a small portion of the viewable area of the screen dedicated to advertising.
In some embodiments, the advertisement matching, i.e., the comparison between the tag profile and the target tag, is performed on the handset. In yet other embodiments, the advertisement matching is performed using a server and a database remote to the handset. Such a remote matching may be carried out at the base station or anywhere on a network or the Internet that is coupled to the base station. For example, the advertisement matching may be done in a cable distribution head end where the video programming is distributed from.
The broadcast network 104 transmits data containing the advertisements on one logical channel using advertisement server 112 while at the same time sending a live broadcast on another logical channel using content server 110 . The advertisement may thus be transmitted at a low data rate, thereby conserving broadcast bandwidth and also achieving greater reliability of data transmission, e.g. by using a higher coding rate for the advertisement data stream. The advertisement, presented to the user during commercial breaks, may be displayed in a separate area of the screen, or as a background image on the handset. It is understood that the advertisement may include audio, video, pictures, slideshows, etc. It is also understood that the advertisement may be intended for a particular program, a category of programs or any program the subscriber watches.
In one embodiment, handset 150 includes an advertisement cache 152 and a subscriber cache 154 . The advertisement cache 152 is configured to store advertisement information (e.g. video, sound), that are automatically stored on the handset and displayed to the subscriber at the selected advertisement spot (commercial break). The subscriber cache 154 is content or advertisement which the subscriber selects for storage on the handset in order to view at a later time in a time-shifted manner. The size of each of the handset caches is programmable based upon the capabilities of the handset and other items stored therein. Such information may be stored remotely, i.e., outside the user's digital device to enable sending advertisements that are likely to fit in the cache. Any type of storage medium, e.g., static random access memory (SRAM), dynamic random access memory (DRAM), hard disk, flash memory, etc, may be used for caches. The stored advertisements, the interaction between the subscriber and the stored advertisement, the number of viewings of the advertisement, its dwell time, etc. may be tracked and reported to the advertiser.
A number of different algorithms or quantitative metrics may be used to determine the similarity and/or disparity between the user's tag profile and the target tag to determine if there is a match between the two and to decide whether to cache the advertisement or not. Such algorithms determine a matching score or a measure of similarity used to cache only the most relevant advertisements and discard those that are not. The amount of advertisement stored in the cache is used to determine how many advertisements to keep at any given time.
An advertisement may have a number of versions each customized for a different demographic, handset location and cache size. For example, an older phone may get a slideshow instead of an animation or video. Also, a database containing geographical information may be used to preferentially display advertisements on handsets within a certain proximity to defined business locations offering the advertised product or service.
FIG. 2A shows a number of exemplary logical channels and time slots used for broadcasting content (regular programming) as well as advertisements, in accordance with one embodiment of the present invention. Logical channels 1 , 2 and 3 are used for broadcasting during time slot 200 , and logical channels 4 , 5 and 6 are used for broadcasting during time slot 202 . FIG. 2B shows the time sequence according with which content and advertisements are broadcast. During period T 1 content is broadcast using logical channel 1 . During period T 2 when the commercial break occurs, the program is interrupted and the matched advertisement inserted earlier in the device is displayed to the user. During period T 3 the broadcasting of program resumes on a time shifted basis.
Advertisers can also pay higher rates to ensure their ads are preferentially cached when competing for the same commercial breaks. Assume, for example, that two or more advertisements intended for broadcast during a particular commercial break are matched to a group of users. To secure the right to advertisement during a commercial break, the advertisers enter into a bidding contest and bid up their offers until the advertiser whose offer is accepted secured the right to broadcast its advertisement during that break. In one embodiment, the bidding adjustment is carried out in real time—to increase the likelihood that the advertisement is cached—based on the feedback that the advertiser receives, as described further below.
Referring to FIG. 1 , standards such as DVB-H and Media FLO, include provisions for a reverse channel 116 , which enable the user to send data back to the broadcaster through the handset's mobile phone data link, e.g., GSM, EDGE, WCDMA or other physical layers). In accordance with one embodiment of the present invention, the reverse channel 116 is used, in part, to provide real-time feedback to the advertiser regarding the number of subscriber tag profiles that have matched an advertisement's target tag for any given commercial break, and/or provide feedback regarding the location of the subscriber handsets/terminals. As described above, an advertiser may, in response to the feedback, change the advertisement, offer to pay a higher rate or a better financial package for the right to broadcast the commercial during the target commercial break so as to increase the rate at which the advertisement is cached. The bidding may continue until the commercial break occurs. As also described above, in some embodiments, the advertiser who has paid a lock-in rate is accorded the time slot for its commercial. The lock-in rate may be fixed or float to match or exceed the highest bid. Advertisers may be charged based on the frequency that their bids win matches as well as the particular times during which the advertisement is scheduled to be broadcast. For example, the cost for advertisement varies depending on the time of the day or the programs during which the advertisement(s) is scheduled to be played.
FIG. 3 is a flowchart 300 of steps used to cache an advertisement, in accordance with one embodiment of the present invention. The advertisement is received 302 via a broadcast channel. Next, a matching operation 304 , using any one of a number of algorithms or a quantitative metrics, is performed to determine whether a match exists between the subscriber's profile tag and the target tag of the advertisement. If an acceptable match is not detected 308 , the advertisement is discarded and thus is not cached. If an acceptable match is detected 304 , and the advertiser has an offer that is accepted or the advertiser has a lock-in rate 306 , the advertisement is cached 314 and a corresponding notification is sent to the service provider via a reverse channel. If an acceptable match is detected 304 but the advertiser's offer is not accepted by the service provider, the advertisement is discarded 310 and a corresponding notification is sent to the service provider via the reverse channel.
Assuming an agreement is reached between the advertiser and the service provider, after the advertisement is played 316 , if the user chooses not to interact 324 with the played advertisement, the user is provided with an option to save the advertisement 324 . The advertisement is either discarded 322 or is saved 324 in the subscriber cache, depending on the user's selected option. The user may select to act upon the viewed commercial 318 . If the user so selects, in one embodiment, a web browser is loaded to enable the user to make additional inquiries about, or to attempt to purchase, the advertised product/service from the advertiser or related companies. The web access may be carried out to keep a count of the activity and the tag profile of the user making the web access. To maintain the subscriber's privacy, the identity of the subscriber is disassociated from his/her profile. In another embodiment, in response to the user's selection 318 , a phone number is dialed to enable the user to make additional inquiries about, or to attempt to purchase, the advertised product/service.
FIG. 4 is a flowchart 400 of steps used to bid for an advertisement to be viewed during a commercial break, in accordance with another embodiment of the present invention. The advertiser offers to pay 402 a basic fee to have its advertisement viewed. The service provider receives the offer price and transmits 404 the advertisement. Thereafter, the number of users whose tag profiles match the target tag of that advertisement is determined and fed back 406 to the advertiser. The advertiser is thus enabled to adjust the offer price based on the number of matches until the advertisement is played 408 . The advertiser pays a final rate 410 based on the number of advertisements that are cached and viewed.
In some embodiments, the advertisements are inserted at a frequency determined entirely by the subscription rate that the viewer is paying. This allows the viewer to trade off subscription cost for the convenience of advertisement-free viewing. To achieve this, in one embodiment, the service provider can broadcast a given program over a channel continuously without inserting any commercial breaks. The handset, based on a subscriber's level of payments, is adapted to select the frequency with which commercial breaks occur and insert a matching advertisement by retrieving it from the viewer's advertisement cache. While the advertisement is being displayed, the regular programming is stored in a buffer which is thereafter retrieved and played in a time-shifted manner and after the advertisement is played.
Such embodiment may be used in demographic segments that are relatively more price sensitive and are willing to endure more frequent commercial breaks in order to reduce their monthly subscription rates. The advertisement frequency is determined using the information stored in the handset related to subscription rates. The subscriber may choose to watch certain programs and channels without advertising by paying an additional amount over a subscription that would normally have the advertisement.
Some embodiments of the present invention may credit the user for watching certain advertisement and to reduce the occurrence of future advertisements as a consequence. For example, a played long infomercial may allow one or more future programs to have no or a relatively reduced number of advertisements. A positive reaction by the subscriber to a viewed advertisement that leads to a call to advertiser or to a loading of an advertiser's web page may also accumulate credits. Accordingly, in such embodiments, enhanced exposure to advertisements provides credits toward viewing future commercial-free programs.
The above embodiments of the present invention are illustrative and not limiting. Various alternatives and equivalents are possible. The invention is not limited by the type of digital device, mobile, etc. used for targeted advertisement. The invention is not limited by the rate used to transfer the data. Other additions, subtractions or modifications are obvious in view of the present disclosure and are intended to fall within the scope of the appended claims. | A method for targeted advertisement includes storing a profile tag associated with each user in a device maintained by that user. Each profile tag includes the demographic information of its associated user. A multitude of target tags are also transmitted to the users. Each target tag is associated with an advertiser and includes the demographic information of the users. The advertisements and their corresponding target tags are transmitted and cached in the devices maintained by the users. The number of matches between the target tags and the user profiles are supplied to their respective advertisers. The advertisers use the matching number to modify the prices they are willing to offer for the commercial break. The target tags include information that is used to select one of the cached advertisement for playing during the commercial break. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/743,457, filed Mar. 10, 2006, and is related to PCT Application No. PCT/US2004/026952, filed Aug. 20, 2004, published as WO2005/018402, which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to cleaning bare floor surfaces. In one aspect, the invention relates to a bare floor cleaner that performs dry pickup. In another aspect, the invention relates to a bare floor cleaner that selectively performs dry vacuuming and wet mopping by convenient movement of a manipulating handle. In yet another aspect, the invention relates to a bare floor cleaner having a diverter for selectively blocking a dry nozzle opening, wherein the diverter is actuated by movement of a handle assembly. In yet another aspect, the invention relates to a bare floor cleaner wherein cleaning solution is prevented from being deposited on the surface to be cleaned when in a dry vacuuming mode and a dry vacuuming motor is shut off when cleaning solution is deposited on the surface to be cleaned.
[0004] 2. Description of the Related Art
[0005] The common procedure of cleaning a bare floor surface, such as tile, linoleum, and hardwood floors, involves several steps. First, dry or loose dust, dirt, and debris are removed, and then liquid cleaning solution is applied to the surface either directly or by means of an agitator. Motion of the agitator with respect to the bare surface acts to loosen the remaining dirt. The agitator can be a stationary brush or cloth that is moved by the user, or a motor-driven brush that is moved with respect to a base support by a motor. If the agitator is absorbent, it will remove the dirt and collect a portion of the soiled cleaning solution from the floor.
[0006] Cleaning a bare floor commonly requires multiple cleaning tools. For example, the first step of removing dry debris most often employs a conventional broom and dustpan. A user sweeps dry debris into a pile and then transfers the pile to the dustpan for disposal. However, the broom and dustpan are not ideal for removing dry particles because it is difficult to transfer the entire debris pile into the dustpan. Additionally, the user typically bends over to hold the dustpan in place while collecting the debris pile. Such motion can be inconvenient, difficult, and even painful for some users. Dust cloths can also be used, but large dirt particles do not sufficiently adhere thereto. Another option is vacuuming the dry debris, but most homes are equipped with vacuum cleaners that are designed for use on carpets and can damage bare surfaces.
[0007] Tools for applying and/or agitating cleaning solution have similar deficiencies. The most common cleaning implement for these steps is the traditional sponge or rag mop. Mops are capable of loosening dirt from the floor and have excellent absorbency; however, when the mop requires more cleaning solution, it is placed in a bucket to soak up warm cleaning solution and returned to the floor. Each time more cleaning solution is required, the mop is usually placed in the same bucket, and after several repetitions the cleaning solution becomes dirty and cold. As a result, dirty cleaning solution is used to remove dirt from the bare surface. Furthermore, movement of the mop requires physical exertion, and the mop head wears with use and must be replaced periodically. Textured cloths can be used as an agitator, but they also require physical exertion and regular replacement. Additionally, cloths are not as absorbent as mops and, therefore, can leave more soiled cleaning solution on the floor.
[0008] Some household cleaning devices have been developed to eliminate the need for multiple cleaning implements for cleaning a bare floor and alleviate some of the problems described above that are associated with the individual tools. Such cleaning devices are usually adapted for vacuuming or sweeping dry dirt and dust prior to application of cleaning solution, applying and agitating the cleaning solution, and, subsequently, vacuuming the soiled cleaning solution, thereby leaving only a small amount of cleaning solution on the bare surface. Common agitators are rotating brushes, rotating mop cloths, and stationary or vibrating sponge mops. A good portion of the multifunctional cleaning devices utilize an accessory that is attached to the cleaning device to convert between dry and wet cleaning modes. Others are capable of performing all functions without accessories, but have complex designs and features that can be difficult and confusing to operate.
[0009] An example of a dry suctioning and wet mopping floor cleaner is disclosed in U.S. Patent Application Publication No. 2004/0139572 to Kisela, incorporated herein by reference in its entirety, which discloses a dry suctioning and wet mopping device wherein a solution distributor is affixed to a dry suction nozzle that is rotatable relative to a foot assembly of the device so that the dry suction nozzle can be placed in contact with or away from the surface to be cleaned at the user's discretion.
[0010] Examples of multifunctional bare floor cleaners are disclosed in U.S. Pat. Nos. 2,622,254 and 6,101,668 and in U.S. Patent Application Publication Nos. 2003/0051301, 2003/0051306, 2003/0051308, 2003/0051309, and 2003/00513010, which are incorporated herein by reference in their entirety. The '254 patent discloses an apparatus for cleaning bare and carpeted floors and comprises several independently adjustable cleaning implements, such as a squeegee attached to a suction pipe, a scrubbing roll, and a sweeping roll. The apparatus can accomplish wet pickup through the suction pipe, wet scrubbing by means of the scrubbing roll, and dry pickup with a dust collecting nozzle disposed adjacent the sweeping roll.
[0011] The publications listed in the above paragraph are a family of patent applications that disclose a bare floor cleaner having independently adjustable nozzle and brush assemblies. The nozzle assembly comprises a single nozzle opening that is surrounded by an overmolded squeegee and through which both wet and dry debris can enter. The cleaner operates in a wet pickup mode with the nozzle assembly in contact with the surface to be cleaned. The nozzle assembly is raised to a position above the surface to be cleaned for operation in a dry pickup mode.
[0012] The '668 patent is an example of a cleaner that can accomplish all the steps required to clean a bare floor with the assistance of an attachment. The cleaner has a cleaning head equipped with a nozzle having squeegees on the front and rear sides thereof and a vertically adjustable scrubbing pad through which cleaning solution can be dispensed. When a cover is attached to the bottom of the cleaning head, the entire cleaning head, including the squeegees, nozzle, and scrubbing pad, are raised from the floor to permit dry pickup.
SUMMARY OF THE INVENTION
[0013] According to the invention, a wet/dry bare floor cleaner comprises a base, a handle pivotally connected to the base for movement between a dry mode position and a wet mode position, a recovery system for collecting dirt when the handle is in the dry mode position, a fluid delivery system comprising a source of cleaning fluid and a fluid distributor in fluid communication with the source of cleaning fluid for dispensing cleaning fluid onto a surface to be cleaned and an interlock coupled to the fluid delivery system that prevents cleaning fluid from being dispensed to a surface to be cleaned when the handle is in the dry mode position.
[0014] The interlock can comprise a mechanical interlock. The mechanical interlock can comprise a movable element that moves under gravity to a first position when the handle is in the dry mode position and to a second position when the handle is in the wet mode position. The handle can be at an acute angle with respect to the vertical in a first direction in the dry mode position and the handle in at an acute angle with respect to the vertical in a second direction in the wet mode position.
[0015] The recovery system can include a disabling mechanism for disabling the recovery system when the fluid distributor is dispensing cleaning fluid onto the surface to be cleaned. The recovery system can comprise a motor/fan assembly mounted to one of the handle and the base, and the motor/fan assembly is deactivated when fluid is being dispensed. The recovery system can include a diverter valve movable between an open position when the handle is in the dry mode position and a closed position when the handle is in a wet mode position. The fluid delivery system can include a trigger operably connected to a switch that controls the supply of electrical energy to the motor/fan assembly. The trigger can be positioned on one side of a hand grip for convenient operation by a finger of a user in the wet mode position and for inconvenient operation in the dry mode position. The hand grip can be an elongated shaft that is gripped by the user by wrapping one hand around the shaft in both the dry mode and wet mode positions.
[0016] The wet/dry bare floor cleaner can further comprise a suction nozzle on one side of the base. The fluid distributor can be positioned on another side of the base. The wet/dry bare floor cleaner can further comprise a cleaning pad mounted to the underside of the base. The fluid distributor can include a spray nozzle for projecting cleaning fluid onto the surface to be cleaned laterally of the base. The wet/dry bare floor cleaner can further comprise a heating element to raise the temperature of the cleaning fluid to be dispensed to the surface to the cleaned.
[0017] Further according to the invention, a wet/dry bare floor cleaner comprises a base, a handle pivotally connected to the base for movement between a dry mode position and a wet mode position, a recovery system for collecting dirt when the handle is in the dry mode position and a fluid delivery system comprising a source of cleaning fluid and a fluid distributor in fluid communication with the source of cleaning fluid for dispensing cleaning fluid onto a surface to be cleaned. The recovery system includes a disabling mechanism for disabling the recovery system when the fluid distributor is dispensing cleaning fluid onto the surface to be cleaned.
[0018] The handle can be at an acute angle with respect to the vertical in a first direction in the dry mode position and the handle in at an acute angle with respect to the vertical in a second direction in the wet mode position. The recovery system can comprise a motor/fan assembly mounted to one of the handle and the base, and a deactivator mechanism coupled to the motor/fan assembly to deactivate the motor/fan assembly when fluid is being dispensed. The deactivator mechanism can include a trigger operably connected to a switch that controls the supply of electrical energy to the motor/fan assembly. The recovery system can include a diverter valve movable between an open position when the handle is in the dry mode position and a closed position when the handle is in a wet mode position.
[0019] Still further according to the invention, a wet/dry bare floor cleaner comprises a base having a plurality of support glides to reduce the surface area contact between the base and the surface to be cleaned, a handle pivotally connected to the base, a recovery system for collecting dirt when the handle is in the dry mode position, a fluid delivery system comprising a source of cleaning fluid and a fluid distributor in fluid communication with the source of cleaning fluid for dispensing cleaning fluid onto a surface to be cleaned and a cleaning pad mounted the base, between the support glides and the surface to be cleaned. The support glides can include a plurality of bristles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the drawings:
[0021] FIG. 1 is a perspective view of a bare floor cleaner according to the invention, comprising a foot assembly and a handle assembly.
[0022] FIG. 2 is an exploded perspective view of the bare floor cleaner handle assembly shown in FIG. 1 .
[0023] FIG. 3 is a partial front view of a lower portion of the handle assembly of the bare floor cleaner shown in FIG. 1 with a front enclosure removed for clarity.
[0024] FIG. 4 is a side view of the lower portion of the handle assembly shown in FIG. 3 .
[0025] FIG. 5 is an exploded view of a switch assembly of the base floor cleaner.
[0026] FIG. 6 is a schematic diagram of a solution delivery system of the bare floor cleaner shown in FIG. 1 .
[0027] FIG. 7 is an exploded view of the foot assembly of the bare floor cleaner shown in FIG. 1 .
[0028] FIG. 8 is a perspective view of a fluid distributor shown in FIG. 7 .
[0029] FIG. 9A is a sectional view of a support glide shown in FIG. 7 .
[0030] FIG. 9B is a sectional view of an optional pad for the foot assembly.
[0031] FIG. 10 is a partial view of the handle assembly of the bare floor cleaner of FIG. 1 , illustrated in a dry suction mode configuration.
[0032] FIG. 11 is a sectional view of the foot assembly of the bare floor cleaner of FIG. 1 , illustrated in the dry suction mode configuration.
[0033] FIG. 12 is a partial view of the handle assembly of the bare floor cleaner of FIG. 1 , illustrated in a wet mop mode configuration.
[0034] FIG. 13 is a sectional view of the foot assembly of the bare floor cleaner of FIG. 1 , illustrated in the wet mop mode configuration.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] Referring to the drawings and to FIGS. 1 and 2 in particular, a bare floor cleaner 10 according to the invention comprises a handle assembly 12 pivotally mounted to a base or foot assembly 14 . The handle assembly 12 can pivot from an upright or vertical position, where the handle assembly 12 is substantially vertical relative to a surface to be cleaned, to either a first or second lowered position, whereby the handle assembly 12 is respectively moved in an forward or rearward direction relative to the foot assembly 14 and is angled relative to the surface to be cleaned.
[0036] The handle assembly 12 comprises an upper handle assembly 16 and a lower handle assembly 18 . The upper handle assembly 16 comprises a hollow handle tube 20 having a grip assembly 22 fixedly attached to a first end of the handle tube 20 and the lower handle assembly 18 fixedly attached to a second end of the handle tube 20 via screws or other suitable commonly known fasteners. The grip assembly 22 is essentially an elongated handle shaft that is gripped by the user by wrapping one hand around the shaft; however, it is within the scope of the invention to utilize other grips commonly found on other machines, such as closed-loop grips having circular or triangular shapes. The grip assembly 22 comprises a right handle half 21 that mates with a left handle half 23 and provides a user interface to manipulate the bare floor cleaner 10 . Additionally, the mating handle halves 21 , 23 form a cavity 26 therebetween. Referring to FIG. 2 , wherein the right handle half 21 of the grip assembly 22 is removed for illustrative purposes, a trigger 24 is partially mounted within the cavity 26 , with a portion of the trigger 24 projecting outwardly from the grip assembly 22 where it is accessible to the user. The remainder of the trigger 24 resides in the cavity 26 formed by the handle halves 21 , 23 and communicates with a push rod 25 that is positioned within the hollow interior of the handle tube 20 . The trigger 24 is pivotally mounted to the handle halves 21 , 23 so that the trigger 24 can rotate relative to the grip assembly 22 in a conventional manner.
[0037] The lower handle 18 comprises a generally elongated rear enclosure 28 that provides structural support for components of the bare floor cleaner 10 contained therein. A front enclosure 29 mates with the rear enclosure 28 to form a central cavity 36 therebetween. A first recess 32 is formed above the rear enclosure 28 and a second recess 34 is formed below the front enclosure 29 . A lower end of the lower handle assembly 18 comprises a generally rectangular conduit 31 that defines a working air inlet to the handle assembly 12 and is in fluid communication with the foot assembly 14 .
[0038] A dirt bin assembly 50 is removably mounted in the second cavity 34 . The dirt bin assembly is preferably constructed, at least partially, of a translucent material. A suitable dirt bin assembly is more fully described in PCT Application No. PCT/US2004/026952, which is incorporated herein by reference in its entirety. The dirt bin assembly 50 is in fluid communication with the conduit 31 when it is mounted in the second cavity 34 such that working air from the foot assembly 14 is drawn through the dirt bin assembly 50 by a motor/fan assembly 33 . Dry debris entrained in the working air will be separated and collected by the dirt bin assembly 50 .
[0039] The motor/fan assembly 33 is mounted in the cavity 36 , and is vertically located between the first recess 32 and the second recess 34 . The motor/fan assembly 33 creates airflow in a conventional manner, which moves debris from the surface being cleaned into the cleaner 10 . The motor/fan assembly 33 is powered by a commonly known rechargeable battery pack 37 that is also located within the cavity 36 . The battery pack 37 is selectively connected to the motor/fan assembly 33 through an electrical on/off switch 38 operable through a switch aperture 39 in the front enclosure 29 via a switch button 41 . Alternatively, the motor/fan assembly 33 can be mounted to the foot assembly 14 in a commonly known fashion.
[0040] Referring to FIGS. 3 and 4 , the lower handle assembly 18 further comprises a transfer rod 52 that is slidably secured therein via a pair of cutouts 54 surrounding corresponding screw bosses that partially secure the rear enclosure 28 to the front enclosure 29 . A solution valve assembly 56 is fixedly mounted in spaced relation to a valve assembly engagement surface 58 on one end of the transfer rod 52 . A trigger stop pivot 60 , located adjacent to the cutouts 54 , extends from a side surface of the transfer rod 52 and pivotally mounts a trigger stop 62 on a pin 63 extending therefrom. A mechanical stop 64 is located on the trigger stop pivot 60 to limit rotational movement of the trigger stop 62 . A stop rib 66 is integrally formed on the rear enclosure 28 in close proximity to one end of the trigger stop 62 . A resilient spring arm 72 protrudes from a side surface of the transfer rod 52 , and the free end of the spring arm 72 engages with a corresponding spring support 74 integrally formed in the rear enclosure 28 . The spring support 74 can further be a screw boss used to secure the rear enclosure 28 to the front enclosure 29 . The trigger stop 62 further comprises a bearing surface 68 that rotates about the pin 63 as well as a stop rib engagement surface 70 that makes selective contact with the rib stop 66 depending upon the orientation of the handle assembly 12 relative to foot assembly 14 as will be discussed in more detailed herein.
[0041] Referring to FIGS. 4 and 5 , a rigid switch interface arm 76 extends orthogonally from a front face of the transfer rod 52 and selectively engages an upper surface of the switch button 41 . The switch button 41 further comprises a pair of switch button bosses 80 to which the on/off switch 38 is attached by a pair of screws 81 . Specifically, the on/off switch 38 comprises a commonly known switch body 85 containing a slideable switch actuator 84 that can be moved by the user to open or close the electrical circuit. The switch body 85 is fixedly attached to the bosses 80 of the switch button 41 for movement therewith. This configuration holds the switch actuator 84 stationary while the switch body 85 is moved. The switch button 41 therefore controls the position of the switch actuator 84 since the switch button 41 is directly coupled to the switch body 85 . The switch interface arm 76 is dimensioned so that a portion overlaps the upper switch button boss 80 . A switch bridge 82 is rigidly attached to an inside surface of the front enclosure 29 via a pair of screws 83 A received in screw bosses 83 B. The switch bridge 82 further comprises a generally central aperture 96 that receives the switch actuator 84 .
[0042] Referring to FIGS. 2 and 6 , a solution tank assembly 40 is removably mounted to the lower handle 18 such that it partially rests on the rear enclosure 28 and is partially received by the first recess 32 . The solution tank assembly 40 comprises a tank to hold a predetermined amount of cleaning solution which comprises a liquid, such as water, cleaning detergent, or a mixture thereof. As shown schematically in FIG. 6 , when the solution tank assembly 40 is mounted to the lower handle 18 , it is in fluid communication with a commonly known receiver 43 . A first solution conduit 42 fluidly communicates between the receiver 43 and a solution valve assembly 56 . A second solution conduit 35 fluidly communicates between an outlet of the solution valve assembly 56 and a solution tee 44 located in the foot assembly 14 as will be described in more detail below. Each of a pair of distribution conduits 67 fluidly communicates between the solution tee 44 and a corresponding pair of solution distributors 112 . Optionally, a heating element 90 can be provided between the solution valve assembly 56 and the fluid distributors 112 to heat the cleaning solution prior to distribution onto the surface to be cleaned as is more fully disclosed in U.S. Pat. No. 6,131,237 which is incorporated herein by reference in its entirety. The heating element 90 can be powered through the battery pack 37 in a commonly known manner. A suitable solution tank assembly and fluid distribution system is more fully described in the above referenced '952 PCT application.
[0043] Referring to FIG. 7 , the foot assembly 14 comprises a top enclosure 86 mounted to a base platform 88 to define therebetween a cavity that houses several components of the foot assembly 14 . The base platform 88 provides structural support for several of the foot assembly components, including a handle pivot 98 , the solution distributors 112 , solution conduits 67 , solution tee 44 , a plurality of support glides 46 , a plurality of lower pad attachment devices 47 , and a pair of upper pad attachment devices 48 . The base platform 88 also forms an integral dry suction nozzle 92 near one edge thereof.
[0044] The handle pivot 98 pivotally mounts the handle assembly 12 to the foot assembly 14 and comprises a barrel 100 with a longitudinal inlet aperture 102 formed in a sidewall thereof to create a working air path from the dry suction nozzle 92 to the dirt bin assembly 50 through a conduit 104 that is integrally formed with the barrel 100 . The conduit 104 is in fluid communication with conduit 31 and can be at least partially received within conduit 31 . A suitable handle pivot is more fully described in the above referenced '952 PCT application.
[0045] A working air passage 106 is substantially integrally formed between the dry suction nozzle 92 and the handle pivot 98 . However, to simplify the manufacturing process, the base platform 88 can also accept individual pieces such as a working air cap 110 to complete the working air passage 106 . One advantage of incorporating removable parts into the working air path is that access can be gained to the air path for cleaning out occasional clogs.
[0046] Referring to FIG. 8 , the solution distributors 112 each comprise a hollow body 114 mated to an outlet manifold 1 16 . The hollow body 114 further comprises a conduit barb 118 to fluidly communicate with the aforementioned solution conduits 67 . The outlet manifold 116 further comprises a plurality of orifices 122 to deliver solution to the surface to be cleaned. The orifices 122 can be angled relative to each other so that fluid distribution can be spread in any desired pattern, such as a fan-shaped pattern. A solution conduit 67 is attached to the conduit barb 118 on one end. The other end of the solution conduit 67 is attached to a conduit barb on the solution tee 44 , placing the solution distributors 112 and the solution tee 44 in fluid communication. The solution distributors 112 are securely positioned in corresponding recesses 113 in the base platform 88 by a mounting feature 120 that extends from the hollow body 14 , and are oriented on a side of the foot assembly 14 opposite the dry suction nozzle 92 .
[0047] Referring to FIG. 9A , the support glides 46 are secured to the base platform 88 and comprise a retaining portion 124 , a retaining wall 126 , and a support surface 128 . The support surface 128 can comprise a plurality of support bristles. The retaining portion 124 is secured to the base platform 88 by pushing the retaining portion 124 through a corresponding aperture in the base platform 88 so that the retaining wall 126 deforms as it passes through the aperture and snaps into place. The support surface 128 protrudes beneath the base platform 88 so that the weight of the bare floor cleaner 10 is supported solely through the support glides 46 . This minimizes the surface area contact between the bare floor cleaner 10 and the surface to be cleaned, resulting in lower frictional forces and easing the push force required to be supplied by the user as the foot assembly 14 is moved across the surface to be cleaned.
[0048] Referring to FIG. 7 , the lower pad attachment devices 47 are located on a bottom surface to the base platform 88 and the upper pad attachment devices 48 are located on a top surface of the base enclosure 86 . The attachment devices 47 , 48 are preferably made of the hook portion of a commonly known hook and loop fastener material, such as Velcro®, and are secured to the base platform 88 and base enclosure 86 with adhesive. A mop cloth 130 is wrapped over the support glides 46 ( FIG. 9 ) and secured to the foot assembly 14 via the pad attachment devices 47 , 48 .
[0049] Referring to FIG. 9B , optional non-skid pads 132 can be secured to the base platform 88 in place of or in addition to the support glides 46 to achieve a different result. The pads 132 comprise a retaining portion 134 and a support portion 136 . The retaining portion 134 has a retaining wall 138 and is secured to the base platform 88 by pushing the retaining portion 134 through a corresponding aperture in the base platform 88 so that the retaining wall 138 deforms as it passes through the aperture and snaps into place. The support portion 136 protrudes beneath the base platform 88 so that the weight of the bare floor cleaner 10 is supported solely through the non-skid pads 132 . The non-skid pads 132 are typically made of a rubber or elastomeric material that has a high coefficient of friction and provide a high friction surface area contact between the bare floor cleaner 10 and the surface to be cleaned, increasing the push force required to be supplied by the user as the foot assembly 14 is moved across the surface to be cleaned. The non-skid pads 132 discourage use of the bare floor cleaner 10 when no mop cloth 130 is present, thus minimizing the possibility of the bare foot assembly 14 causing damage to the surface to be cleaned.
[0050] The bare floor cleaner 10 can be selectively operated in a dry suction mode, in which dry dirt and debris from the surface to be cleaned is collected in the dirt bin assembly 50 via the dry suction nozzle 92 , or a wet mopping mode, in which solution is distributed onto the surface to be cleaned from the solution distributors 112 and scrubbed using the mop cloth 130 . Referring to FIGS. 10 and 11 , the dry suction mode is described wherein the handle assembly 12 is in a first lowered position, in which the handle assembly 12 is generally oriented over the solution distributors 112 such that the dry nozzle assembly 92 is positioned ahead of the handle assembly 12 relative to the solution distributors 1 12 . In this position, the trigger 24 is oriented on an upper portion of the grip assembly 22 and out of convenient reach of the user. The inlet aperture 102 of the handle pivot 98 is aligned with an aperture 109 in a pivot cradle 108 formed in the base platform 88 . As a result, a working air path extends from the dry nozzle assembly 92 , through space 115 between the base platform 88 and the working air cap 100 , through the conduit 104 that projects from the pivot barrel 100 , and through conduit 31 to an inlet of the dirt bin assembly 50 . A suitable air path is more fully described in the above referenced '952 PCT application The motor/fan assembly 33 can be activated and de-activated by the user via the switch button 41 . The switch button 41 position, and hence whether the motor/fan assembly 33 is activated or deactivated, can be changed by the user regardless of the handle orientation.
[0051] No solution is intended to be distributed during dry suction mode. As previously mentioned, the trigger 24 is out of convenient reach of the user to minimize activation. Furthermore, with the handle assembly 12 in the first lowered position, the trigger stop 62 rotates about the pin 63 under force of gravity and comes to rest on the inside wall of the rear enclosure 28 in close proximity to the trigger stop rib 66 . Therefore, even if the trigger 24 is inadvertently engaged by the user, the trigger stop 62 prevents the transfer rod 52 from moving.
[0052] Referring now to FIGS. 12 and 13 , a wet mop mode is described wherein the handle assembly 12 is in a second lowered position, in which the handle assembly is generally oriented over the dry nozzle assembly 92 such that the solution distributors 112 are positioned ahead of the dry nozzle assembly 92 relative to the handle assembly 12 . When the handle assembly 12 is in the second lowered position, the barrel 100 blocks the aperture 109 and no air is drawn into the dirt bin assembly 50 .
[0053] When the handle assembly 12 is in second lowered position, the trigger 24 is on an underside of the grip assembly 22 and within convenient reach of the user. Referring to FIG. 12 and the schematic in FIG. 6 , cleaning solution can be selectively dispensed from the solution tank assembly 40 via depression of the trigger 24 , which engages the push rod 25 . As the push rod 25 moves, an engagement surface 77 on one end of the push rod 25 contacts a push rod engagement surface 78 on the transfer rod 52 . Since the handle assembly 12 is inclined, the trigger stop 62 falls, under the force of gravity, away from the stop rib 66 and comes to rest on the mechanical stop 64 on the transfer rod 52 . With the trigger stop 62 in this position, the transfer rod 52 can move in response to the force from the push rod 25 , whereby the solution valve assembly engagement surface 58 contacts a transfer rod engagement surface 71 on the solution valve assembly 56 , thus opening the solution valve assembly 56 . Subsequently, cleaning solution flows by gravitational feed from the solution tank assembly 40 sequentially through the receiver 43 , through the fluid conduit 42 , through the now open solution valve assembly 56 , through the second solution conduit 35 , through the solution tee 44 , through the distribution conduits 68 , and finally to the fluid distributors 112 , where cleaning solution is dispensed in the desired pattern onto the surface to be cleaned.
[0054] Referring to FIGS. 5 , 12 , and 13 , movement of the transfer rod 52 further causes the spring arm 72 to deflect against the spring support 74 , creating an opposing force to the trigger 24 and tending to return the transfer rod 52 to an at rest position. Additionally, as the transfer rod 52 moves, the switch interface arm 76 contacts the upper switch button boss 80 forcing the switch button 41 and switch body 85 down. As the switch body 85 moves down, the switch actuator 84 is held stationary by the switch bridge 82 , thus moving the on/off switch from an “on” position to an “off” position. Therefore, with the cleaner 10 in the wet mop mode, cleaning solution can be applied to the surface to be cleaned and the motor/fan assembly 33 is automatically turned off. It is desirable to turn off the motor/fan assembly 33 during the wet mode because the dirt bin assembly 50 of the cleaner 10 is not designed to perform wet extraction and the battery life of the cleaner 10 can be extended.
[0055] When the trigger 24 is released, the spring arm 72 biases the transfer rod 52 back to the normal position, a spring 94 on the solution valve assembly 56 closes the solution valve assembly 56 and the flow of cleaning solution from the solution tank assembly 40 is stopped. The user can then move the foot assembly 14 over the dispensed cleaning solution and use the mop cloth 130 to agitate debris on the surface and absorb excess cleaning solution. The motor/fan assembly 33 remains deactivated and will remain so until the user manually actuates the switch button 41 . Since the weight of the bare floor cleaner 10 is fully supported by the support glides 46 , surface contact between the bare floor cleaner 10 and the surface to be cleaned is minimized and friction is reduced, resulting in a low push force required to manipulate the bare floor cleaner 10 . Since the support glides 46 are always indirectly in contact with the surface to be cleaned through the mop cloth 130 , lower push forces are encountered in both the wet mop and dry suction modes.
[0056] While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and combination are possible with the scope of the foregoing disclosure without departing from the spirit of the invention, which is defined in the appended claims. | A bare floor cleaner has a foot with a dry suction nozzle and a handle assembly pivotally connected to the foot assembly. A diverter mounted in the working air conduit between the foot assembly and the handle assembly is movable by movement of the handle assembly between a dry suction position and a wet mop position for selectively at least partially blocking working air flow from the dry suction nozzle to a collection assembly. A fluid delivery system includes a user operated trigger for actuating the fluid delivery system to distribute fluid in the wet mop position and deactivating a motor/fan assembly. A trigger lock prevents cleaning solution from being distributed when the handle is in dry mode position. The fluid delivery system includes a heating element to raise the temperature of the cleaning solution before it is distributed to the surface to be cleaned. Support glides on the foot reduce the surface area contact between the foot pad and the surface to be cleaned. | 0 |
The present invention relates to a locking sleeve connector for an electrical conductor cable. Specifically, the present invention relates to an insulated locking sleeve connector that is disposed about mating male and female conductor plugs to fixedly retain the conductor plugs in mating relationship and to isolate the conductor plugs from the environment.
Electrical conductor cables are used in many industrial applications including the supply of single phase and three phase electric power. Conductor cables that may be removably interconnected often have the advantage of convenience over permanently connected conductor cables, particularly in experimental circuit configurations and in applications where the conductor cables provide power to a location on a temporary basis. One such application is the entertainment film making industry which requires the temporary application of electric power to onsight filming locations. Typically, electric power is produced by one or more mobile generator units and the power is then distributed by a network of conducting cables throughout the filming location to the filming equipment and temporary structural facilities. In the past, removably interconnected conductor cables have been used in the film making industry, and these cables have been connected by a standard male and female connector plug fixedly retained by frictional forces. The standard cable connector used throughout the film making industry is a single pole separable connector plug NEC CODE 520-53(K) made from brass and having no insulation. These connector plugs however have the disadvantage that they are easily disconnected and are exposed to the environment thereby creating a serious risk of electrical shock and loss of power. It has been suggested to apply adhesive tape over the conductor plug in order to avoid disconnection of the male and female ends of the conductor plug and to provide electrical insulation. Tape however has the disadvantage that it is often haphazardly applied, is difficult to remove and may not provide an adequate moisture barrier. It has also been suggested to apply a phenolic plastic sleeve about the conductor plug, but these phenolic plastic materials contain asbestos and are no longer manufactured. There is therefore a demonstrated need for an advancement in the art of electrical cable connectors that solves the problems discussed above.
It is an object of the present invention to provide a novel locking sleeve connector for a conductor cable.
It is an object of the present invention to provide a novel locking sleeve connector that may readily be applied to standard conductor plugs.
It is also an object of the present invention to provide a locking sleeve connector that fixedly retains the conductor plugs in electrical contact and provides a moisture barrier.
It is a further object of the present invention to provide a locking sleeve connector that is economical and easy to use.
The present invention is directed toward an insulated locking sleeve connector disposed about mating male and female conductor plugs to fixedly retain the conductor plugs in mating relationship and to isolate the conductor plugs from the environment. A heat shrinkable tubing may also be applied over the locking sleeve connector to act as a moisture barrier and also to relieve strain between the conductor cable and the locking sleeve connector.
These and other objects, features and advantages will become apparent upon consideration of the following DETAILED DESCRIPTION OF THE INVENTION and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a locking sleeve connector applied to a single mating conductor cable.
FIG. 2 is an exploded perspective view of the locking sleeve connector of FIG. 1.
FIG. 3 is a sectional view of FIG. 1.
FIG. 3A is a sectional view of FIG. 1.
FIG. 4 is an alternative embodiment of the locking sleeve connector of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side view of a locking sleeve connector 1 applied to a mating conductor cable 14 and FIG. 2 is an exploded perspective view of the locking sleeve conductor of FIG. 1 generally comprising a flanged connector 2, a threaded connector 3 and a connector coupling 4. The locking sleeve connector 1 is preferably formed of an electrical and thermal insulating material with strong mechanical properties and a low moisture absorbing characteristic. The locking sleeve connector 1 may for example be made from VALOX® manufactured by General Electric Company and comprised of a 45% glass/mineral reinforced polyester having a high tensile and flexural strength and UL® approved electrical and thermal insulating properties. The locking sleeve connector 1 may also be color coded to assist in identifying the conductor cable 14 when more than one cable comprises a network of conductor cables.
The mating conductor cable 14 generally comprises conductive wires 15 encased by a protective insulating sheath 16. FIG. 3 is a sectional view of FIG. 1 showing the conductive wires 15 interconnected by a pair of mating male and female conductor plugs 17 and 18 each having a base 27 with a plug recess 19 for fixedly receiving an end of the conductive wire 15. The male conductor plug 17 also has a protruding member 28 that is removably disposed in a complementary cavity 29 of the female conductor plug 18. A frictional force retains the male and female conductor plugs 17 and 18 in mating relationship. The conductor cable 14 may for example comprise a braided copper wire encased by a UL® approved insulator although other insulated conducting cables known in the art may also be used. The mating male and female conductor plugs 17 and 18 are for example brass single pole separable connectors NEC CODE 520-53(K).
The flanged connector 2 comprises a cylindrical body 6 having an annular flange 5 including a side surface 13 extending substantially radially outward from an end of the cylindrical body 6. The threaded connector 3 comprises a cylindrical body 9 having an annular flange 8 extending radially outward from an intermediate portion of the cylindrical body 9. The threaded connector 3 also comprises a screw thread 7 disposed about an end of the cylindrical body 9. The flanged connector 2 and the threaded connector 3 each have a conductor bore 10 extending concentrically through the cylindrical body portions 6 and 9, respectively. The flanged connector 2 and the threaded connector 3 each may have a knurled outer surface 12 to assist in handling the locking sleeve connector 1. The connector coupling 4 is comprised of a cylindrical body 11 having a connector bore 26 and an annular flange 21 including an inner side surface 22 extending substantially radially inward from one end of the cylindrical body 11. A screw thread 25 is disposed on an inner surface of cylindrical body 11 and is threadedly engageable with the screw thread 7 of the threaded connector 3. The connector coupling 4 may also have a knurled outer surface 23 to assist in handling the locking sleeve connector 1.
In an alternative embodiment of the locking sleeve connector 1 the flanged connector 2 may be connected to one or more flanged connectors in a "Y" or "Star" configuration to form a junction at which a plurality of conductor cables may be interconnected by a corresponding number of threaded connectors 3. In a further alternative embodiment, the threaded connector 3 may be connected to one or more threaded connectors to form a junction similar to that formed by the flanged connectors discussed above. FIG. 4 is a 4-way flanged connector junction having one flanged connector and three threaded connectors. It is noted that the disclosure is not limited to the 4-way connector, and in fact the multiple connectors may include various numbers of both male and/or female connectors.
In operation, the base 27 of the male conductor plug 17 is disposed in the conductor bore 10 of the flanged connector 2 so that the protruding member 28 extends outwardly from the conductor bore 10 beyond the annular flange 5. The female conductor plug 18 is disposed in the conductor bore 10 of the threaded connector 3 so that the female conductor plug 18 is positioned flush with the threaded end of the threaded connector 3. The male and female conductor plugs 17 and 18 are press-fit in the conductor bores 10 of the flanged connector 2 and the threaded connector 3, respectively, and are fixedly retained therein by frictional forces. Alternatively, the male conductor plug 17 may be disposed in the bore 10 of the threaded connector 3 and the female conductor plug 18 may be disposed in the bore 10 of the flanged connector 2.
The connector coupling 4 is concentrically disposed about the cylindrical body 6 of the flanged connector 2 so that the inner side surface 22 of the annular flange 21 may be disposed toward and in contact with the side surface 13 of the annular flange 5. The connector coupling 4 is most conveniently disposed about the flanged connector 2 before the male or female conductor plug 17 or 18 is press-fit into the bore 10 of the flanged connector 2 as discussed above. When the male and female conductor plugs 17 and 18 are engaged in mating relationship, the flange 5 of the flanged connector 2 will be proximate the threaded end of the threaded connector 3 so that the inner screw thread 25 of the connector coupling 4 may engage the screw thread 7 of the threaded connector 3 by rotating the connector coupling 4. As the screw thread 25 of the connector coupling 4 is engaged with the screw thread 7 of the threaded connector 3, the inner side surface 22 of the annular flange 21 will engage the side surface 13 of the annular flange 5 and displace the flanged connector 2 toward the threaded connector 3 so that the male and female conductor plugs 17 and 18 fully engage in mating relationship. The male and female conductor plugs 17 and 18 are then fixedly retained in mating relationship by the insulated locking connector sleeve 1.
The engagement of the male and female conductor plugs 17 and 18 may be provided with an additional degree of moisture protection by applying a section of heavy-duty polyolefin shrink tubing 45 over the locking connector sleeve 1 and a section of conductor cable 14 on both sides of the locking connector sleeve 1. The application of heat to the shrink tubing will create a skin-tight moisture seal over the locking sleeve connector 1 and conducting cable 14 and substantially relieve any strain between the conductor cable 14 and the locking sleeve connector 1.
Additionally, flexible O-ring type seals may be employed for moisture protection.
The foregoing is a description enabling one of ordinary skill in the art to make and use the preferred embodiments of the present invention. It will be appreciated by those skilled in the art that there exists variations, modifications and other equivalents to the embodiments disclosed. The present invention therefore is to be limited only by the scope of the appended claims. | An insulated locking sleeve arrangement including a connector disposed about mating male and female conductor plugs to fixedly retain the conductor plugs in mating relationship and to isolate the conductor plugs from the environment. A heat shrinkable tubing may also be applied over the locking sleeve connector to act as a moisture barrier and also to relieve strain between the conductor cable and the locking sleeve connector. | 8 |
This is a continuation of application Ser. No. 07/435,376, filed Mar. 8, 1990, abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a sensing element for an alarm system, and more particularly to a sensing element of the type which can be associated with a flexible closure to sense attempts of an unauthorised person to cut through or disturb the closure.
BRIEF DESCRIPTION OF THE PRIOR ART
There have been several proposals for alarm systems for flexible closures such as `curtainsider` lorry sides; usually these systems are based upon a network of conductive sensing elements which are attached to or otherwise incorporated into the flexible closure and which form part of an alarm circuit carrying a small electric current. The network is so arranged that, if the closure is cut to any significant extent, the elements will be disturbed or broken. This causes the current to vary or to stop flowing altogether, a variation which can be used to trigger an alarm thereby preventing unauthorised access to the area enclosed by the closure means. In other alarm systems, the alarm can be triggered by `making` a circuit between two normally unconnected sensing elements, the elements being deflected into contact with one another by disturbance or cutting, or being connected by a conductive cutting implement.
Although most known alarm systems provide a reasonable measure of protection, these systems can often be overcome by a determined and resourceful person. A major problem is that an unauthorised person can readily gain access to the sensing elements and tamper with them so that the system fails to trigger an alarm when other elements are subsequently cut or disturbed. In particular, certain sensing elements of the network can be connected to one another so that the current continues to flow steadily through the alarm circuit, thereby maintaining a non-alarm condition even when elements in other parts of the network are being cut or disturbed.
SUMMARY OF THE PRESENT INVENTION
An object of this invention is to provide an improved sensing element for an alarm system, which overcomes or mitigates the disadvantages of known sensing elements.
According to one aspect of this invention there is provided a sensing element for connection into an alarm system, the element including a plurality of conductors, wherein at least one of the conductors is a decoy conductor.
The decoy conductor may be a dummy conductor, or may be connected into an alarm device for sensing and alerting against attempts to tamper with the sensing elements. It is preferred that the conductors are braided, twisted or plaited together to form a wire, and the conductors are advantageously substantially identical in appearance to one another. Each conductor is preferably sheathed with insulating material before being formed into the wire, and the wire may itself be sheathed with insulating material. In preferred embodiments the sensing element also includes a flexible backing strip to which the wires are attached, the strip being for attachment to flexible closure means.
According to another aspect of this invention there is provided an alarm system for preventing unauthorised access to an area protected by flexible closure means, the system comprising a plurality of sensing elements for association with the closure means, wherein at least some of the elements each include at least two conductors and at least one of the condutors is a decoy conductor.
According to a further aspect of this invention there is provided a closure for use in an alarm system, the closure including a sheet having a plurality of sensing elements associated therewith for connection into an alarm system whereby disturbance of the sheet may be sensed, wherein at least some of the elements each include at least two conductors and at least one of the conductors is a decoy conductor.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of this invention will now be described; by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a part-sectioned elevational view illustrating aspects of an alarm system which can incorporate a sensing element according to this invention;
FIG. 2 is a perspective view showing a preferred embodiment of a sensing element according to this invention;
FIG. 3 is a part-sectioned detail view showing aspects of part of the sensing element shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, an alarm system incorporating the sensing element of this invention is shown in relation to "curtainsider" goods vehicle, although this type of alarm system can be applied to any of a variety of flexible closures such as car hoods or boat covers as will be clear to those skilled in the art.
In FIG. 1, a flexible protective sheet 10 extends over substantially all of the area of the side openings defined by the vehicle's support structure 12. The sheet 10 is of the type conventionally used in a curtainsider vehicle, hanging as a curtain by its upper edge from the support structure 12 and being made of canvas, p.v.c., or other flexible sheeting material. A similarly-sized inner sheet 14, which can also be made of canvas; p.v.c. or the like, is bonded, welded or stitched to the inner surface of sheet 10 in such a position that sheet 10 completely overlays the inner sheet 14.
The inner sheet 14 carries a network 16 of closely-spaced conductive sensing elements 18 extending over substantially all of its area, the elements 18 preferably being stitched to the inner sheet 14 although they may be attached thereto by any suitable means such as adhesive or welding. The network 16 is arranged such that making a cut of significant length anywhere on sheet 10 will also cut sheet 14 thereby disturbing or breaking at least one sensing element 18. The network 16 carries a small electric current, and disturbing or breaking an element 18 varies this current which can be used to activate an alarm.
Further details of the alarm system outlined above are contained in the Applicants co-pending International Patent Application No. PCT/GB87/00289, published under number WO87/06749, details of which are incorporated herein by reference.
FIG. 2 of the drawings illustrates a preferred embodiment of sensing element 18, which comprises a backing strip 20 of p.v.c. or other suitable flexible material. Backing strip 20 is preferably reinforced with laminated crisscross nylon strands 22 as shown, and is suitably about 32 mm wide by about 0.30 mm thick although its dimensions can be chosen to suit any particular application.
Extending longitudinally along, and attached to, the central portion of one side of backing strip 20 are two insulated wires 24 which lie substantially parallel to and separate from one another. The wires 24 may be attached to the backing strip 20 by any suitable means such as bonding, welding or laminating. It is preferred that the wires 24 are connected to each other in series as part of the same electrical circuit, although the wires 24 could alternatively be connected in parallel or could belong to different electrical circuits.
In use, the sensing element 18 is bonded, welded, stitched or otherwise attached to the inner face of inner sheet 14, with the wires 24 facing the sheet 14 and with the points of attachment extending along the backing strip 20 on either side of the wires 24 such that the wires 24 are shrouded in a protective pocket between the backing strip 20 on either side of the wires 24 such lengths of the sensing element 18 can be arranged and attached to the inner sheet 14 so as to build up a network of elements as desired. The wires 24 associated with the various lengths of sensing element 18 can be connected together at their ends to form an electrical circuit for triggering an alarm in case of unauthorised tampering.
A preferred embodiment of wire 24 is illustrated in detail in FIG. 3 and includes three inner conductors 26 contained within an insulating outer sheath 28. Each inner conductor 26 is made up of three strands 30 of conductive tinsel wire twisted about a polyester or cotton thread 32 and is shrouded by an insulating inner sheath 34. The inner conductors 26 are plaited, twisted or braided together and are substantially identical in appearance to one another so that they cannot be distinguished between.
In one embodiment of this invention, at least one of the inner conductors 26 (A) is not part of the main alarm circuit but is instead a dummy carrying no current. Therefore, if an unauthorized intruder should make a connection to the dummy inner conductor A in an attempt to circumvent the alarm, the alarm will not be disabled because the remaining `live` inner conductor (B) will be unaffected. If a large number of inner conductors 26 are employed, the intruder will find it difficult or impossible to pick out the live conductor(s) from the dummy conductors, which will delay and therefore help to deter the intruder. Moreover, as the number of inner conductors 26 increases it becomes more impractical for the intruder to make connections to all of the inner conductors 26 if he tries to ensure that he has made connections to the live inner conductors B.
In other embodiments, at least one of the inner conductors 26 (C) is again separate from the main alarm circuit, but instead of being a dummy the conductor is connected into a further alarm circuit. If an intruder should connect an inner conductor 26 from another sensing element 18 to conductor C, the voltage of, or current within conductor C will change. These effects can be positively sensed by the further alarm circuit so that any connection to conductor C triggers an alarm. One of the dummy inner conductors 26 could be earthed so as to cause a voltage drop if connected to a `live` conductor 26; this voltage drop can be sensed and used to trigger an alarm.
It is envisaged that tampering with the main alarm system itself can be sensed by sensing means which detect certain changes in the voltage or current characteristics of the circuit, thereby sounding an alarm in the unlikely event that an intruder should succeed in making connections to the live inner conductors B without being caught.
It will be clear that the inner conductors 26 can be a mixture of types A and B, or B and C, or A, B and C. It is possible for wires 24, or even entire sensing elements 18 to be dummies or to be capable of sensing attempts to short-circuit the network by interconnection of sensing elements. There may be any number of wires 24 and they may contain any suitble number of inner conductors 26 having any number of tinsel-wire strands 30. It will be clear that the conductors 26 need not actually be conductive if they are dummies, it being more important that the dummy conductors are substantially indistinguishable from the live conductors.
A further feature of this invention is that an unauthorised intruder is deterred by having to cut through two layers of sheath material to gain access to each inner conductor; the sheath material may be reinforced to hamper access still further by acting as a barrier. | A sensing element (18) for use in an alarm system for protecting an area enclosed by flexible closure device (10). The element includes a plurality of conductors (16), at least one of which is a decoy conductor intended to prevent circumvention of the alarm system by short-circuiting or the like. The decoy conductor can be a dummy conductor carrying no current, or can be connected into an alarm circuit arranged to sense attempts to connect the decoy conductor to another conductor. | 6 |
FIELD OF THE INVENTION
The present invention, in the field of electronic circuit board technology, relates to methods and apparatus for machine processing and installation of insulated hookup wire, especially in twisted pairs, in a manner to provide integrally interconnected component contact receptacles, formed from the wire, installed in a circuit board.
BACKGROUND OF THE INVENTION
In electronic circuit boards, even though the great majority of interconnections may be implemented as printed conductive traces, there are special circumstances in which it would be advantageous to interconnect particular components through insulated hookup wire. For example, the usual printed traces often prove unsatisfactory for routing a high speed digital signal from one region of the circuit board to another region due to inherent properties of printed traces which severely limit attempts to utilize them as high frequency transmission lines. The main shortcoming is susceptibility to crosstalk and r.f. interference even in attempts to form a "balanced" line from a pair of parallel traces, especially if they are unshielded at the circuit board surface in a usual microstrip configuration.
A classic solution to this type of problem is to form integral pseudo-coaxial signal paths within the circuit board by adding several additional circuit board layers to form buried stripline printed traces as signal paths sandwiched between ground plane shield layers in a multilayer circuit board configuration, imposing as a tradeoff penalty the greatly increased cost, complexity, fabrication difficulty and potential unreliability of a multilayer circuit board.
An alternative classic solution involves the addition of discrete runs of rigid or flexible coaxial cable: this is also costly and complex, usually entailing a great deal of skilled manual fabrication and assembly, and often suffers from impedance compromises along printed trace interface runs between the ends of the coaxial cables and the actual component terminals involved.
A third alternative, which has not been fully exploited heretofore, utilizes an unshielded twisted pair of insulated hookup wires serving as a balanced transmission line. The twisted pair configuration, by virtue of an inherent antenna effect cancellation property, provides superior crosstalk isolation over a single unbalanced line or parallel pair configuration such as microstrip lines formed on the surface of a circuit board, and, while not fully equivalent to shielded coaxial cable, twisted pair transmission lines, particularly in the novel implementation of this invention, will in many instances provide fully satisfactory signal transmission performance along with considerable cost, simplification, producibility and reliability benefits by avoiding the need for multilayer circuit boards and/or coaxial cables.
There are other situations where it may be preferable to fabricate a circuit board utilizing point-to-point hookup wiring throughout, for example, in realizing a preliminary "breadboard" model for evaluation and/or experimentation in advance of the availability of a "tooled-up" printed circuit version.
Point-to-point hand wiring as sometimes practiced in low volume production of circuit boards is generally tedious and costly, particularly where wire ends must be individually wrapped manually onto pins or terminal lugs and soldered individually.
As an alternative to hand wiring, a well known "wire wrap" technique involves wrapping the stripped ends of special hookup wire in a long tight spiral around special square elongated contact posts; frequently it is necessary to mount components such as DIP (dual inline packaged) devices, in special sockets having the required square posts, which, when wired correctly with a wrap of sufficient length, are supposed to provide reliable connections without soldering. "Wire wrap" is generally incompatible with standard dip or wave soldering since the presence of wiring on the side opposite the "component" side, i.e. on the "trace" side, which is normally immersed in molten solder at a temperature which would destroy the hookup wire insulation; therefore, any connections requiring soldering must be done individually, typically by hand.
"Wire wrap" is generally useful only at relatively low digital rates or frequencies, having proven unsuitable for handling some families of high speed logic such as ECL (emitter coupled logic) due to degradation of rise and fall times due to signal line termination impedance mismatches introduced by the elongated square posts.
The present invention provides a beneficial supplement, and in some instances a viable alternative, to a range of conventional circuit board practices including printed circuitry as well as hand wiring and wire wrapping.
OBJECTS OF THE INVENTION
It is a primary object of the present invention to provide a novel method for providing point-to-point wiring on a circuit board, utilizing insulated hookup wire to form integrally interconnected component contact receptacles installed in circuit board holes.
It is a further object to provide fabrication apparatus for implementing the primary object by forming helical shaped terminals from stripped portions of hookup wire and pressing the terminals into circuit board holes, the helical terminals being made capable of serving as receptacles for component terminal pins.
It is a further object that circuit boards may be fabricated in accordance with the foregoing objects in a manner to be compatible with normal dip or wave soldering techniques.
It is a still further object to provide such apparatus with capability of stripping portions of insulated hookup wire, twisting a pair of insulated wires together and installing a run of the twisted pair into a circuit board including pairs of terminals formed integrally from the hookup wires in accordance with the aforementioned objects.
Still further to the foregoing object, it is an object to provide capability of forming and installing such pairs of terminals at intermediate points along a run of twisted pair hookup wire as well as at the ends of the run.
An understanding of how the present invention has accomplished these and other objects and advantages will become apparent from a study of the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a three part machine tool set for forming and installing hookup wire in accordance with the present invention.
FIG. 2 is a cross section of a mandrel portion of FIG. 1.
FIG. 3 is a side elevation of the mandrel portion of FIGS. 1 and 2.
FIGS. 4a-4e show cross-sections of the tool set of FIG. 1 in a series of steps in the process of forming a length of hookup wire into a helical terminal and installing the terminal in a circuit board in accordance with the present invention.
FIG. 5a shows two pairs of helical terminals interconnected by a twisted pair of hookup wires in accordance with the present invention.
FIG. 5b shows a multiple interconnection of three pairs of helical terminals in a run of twisted pair hookup wire in accordance with the present invention.
FIG. 6 shows an example of implementing the present invention in a typical manner with a twisted pair of hookup wires disposed on the component side of a circuit board interconnecting a group of components.
FIG. 7 shows an alternative implementation of the present invention with hookup wiring disposed on the circuit board side opposite the components.
FIGS. 8a-8b illustrate process steps and related machine elements in stripping, twisting and installing hookup wire in accordance with the present invention.
DETAILED DESCRIPTION
The perspective view of FIG. 1 shows a three piece tool set which is understood to be mounted in an arbor type fabrication machine generally similar to a common type of vertical press in which a workpiece is normally placed on a platform disposed between upper and lower regions of the arbor configuration. Power manipulation of the tools is provided in a known conventional manner, typically via pneumatic or hydraulic mechanisms under automated or semi-automated control.
A main mandrel shaft 10 is made capable of both vertical travel and rotation about its vertical axis within a cylindrical sleeve guide 12 which is capable of vertical travel but constrained against rotation. Sleeve guide 12 is fitted with a pair of diametrically opposed vertical wire guide slots 14, one of which is visible in this view, extending to the bottom end and sized in width to clear the stripped diameter of the hookup wire to be used: the optional flared bottom region as shown facilitates wire capture.
The mandrel shaft 10 is configured to have at its lower end, starting at shoulder 16, a forming portion 18 of reduced diameter containing a wire holding recess 20 which extends at least diametrically across the bottom end and, in the preferred embodiment shown, part way upward on diametrically opposite sides toward shoulder 16.
Beneath the mandrel forming portion 18 is a forming cavity tool part 22 having an upward facing cylindrical cavity 24, coaxial with mandrel 10, dimensioned to accept the lower end of the mandrel forming portion 18. The cavity tool part 22, which is mounted in the lower arbor portion of the host machine, is made capable of vertical travel and is provided with freedom to rotate about its vertical axis; rotation normally occurs only as engagedly driven from rotation of mandrel 10.
For clarity of illustration, the mandrel 10 is shown with shoulder 16 exposed at the lower end of sleeve guide 12; in operation, mandrel 10 will travel within a range above the position shown such that shoulder 16 will remain inside sleeve guide 12. The mandrel 10 and sleeve guide 12 are mounted in the upper arbor portion of the host machine.
FIG. 2 is a cross-section of the forming portion 18 of mandrel 10 taken through axis 2--2' of FIG. 1, showing the shoulder 16 and end-surround recess 20.
FIG. 3 is a side elevation of the forming portion 18 of mandrel 10 as viewed at an angle of 90 degrees from the view of FIG. 2, showing the the shoulder 16 and end-surround recess 20.
FIGS. 4a-4e show a series of cross-sections of the tool set of FIGS. 1, 2 and 3 in five steps during the process of forming a length of hookup wire into a helical terminal and installing it into a circuit board in accordance with the present invention.
In FIG. 4a, beneath the upper tool assembly comprising mandrel 10 and sleeve guide 12, a circuit board 26 having a hole 28 is placed on a work platform 30 and x-y positioned to center the hole 28 on the vertical axis of mandrel 10 and cavity tool 22 which is located below the circuit board 26 in a clearance opening provided in the work table 30.
Above circuit board 26 a length of insulated hookup wire 32, of which a bare wire portion 34 has been stripped of insulation 36, is centrally positioned across the vertical axis of mandrel 10.
The preliminary positions shown of the mandrel 10 and sleeve guide 12 above wire 32 and the cavity tool 22 below circuit board 26 permit initial placement of the wire 32 and circuit board 26 as workpieces.
In FIG. 4b, the cavity tool 22 has been raised to protrude through the circuit board hole 28, and the sleeve guide 12 has been lowered onto the top surface of circuit board 26, capturing the stripped wire 34 in guide slots 14, following which the mandrel 10 has been lowered to capture wire 34 in recess 20 (refer to FIGS. 2 and 3) and then force the wire 34 into cavity 24 of tool 22, forming a U shaped wire loop 38 as shown. At this point, mandrel 10 is driven rotationally so as to wind the remaining adjacent portions of stripped wire 34 into a double interleaved helix while the rotationally driven mandrel 10 and and the cavity tool 22, driven rotationally from mandrel 10, are made to travel downwardly in accordance with the buildup of wire turns on the helix in the open region between portion 18 of the mandrel 10 and the inner wall of sleeve guide 12.
In FIG. 4c, at the completion of winding, the turns of wire 34 are seen in cross section forming a dual interleaved helix 40 extending upward toward the limits of slots 14; it is noted that winding the helix has drawn most of the stripped wire 34 inwardly from both directions through guide slots 14 so that the end points of insulation 36 now approach close to the helix 40, which is at this point ready to be installed into hole 28 of circuit board 26 as a helical terminal.
In FIG. 4d, mandrel 10 and cavity tool 22 have been lowered simultaneously and shoulder 16 has pressed helix 40 into hole 28 of circuit board 26 which now has insulation 36 of wire 32 resting on its upper surface, and the U shaped wire loop 38 protruding downward below its bottom surface.
In FIG. 4e, the helical terminal 40 is seen in its installed position in hole 28 of circuit board 26 as in FIG. 4d but with the machine tools moved away, the mandrel and the sleeve guide having been retracted upwardly and the cavity tool retracted downwardly so as to allow removal or x-y repositioning of circuit board 26.
The dimensions of mandrel 10 and the wire size are chosen to make the outside diameter of helix 40 a light friction fit in the circuit board hole 28 while its inside diameter allows the helical terminal 40 to serve as a receptacle for insertion of a contact pin of a component such as a DIP IC (dual inline package integrated circuit), or for insertion of a stripped hookup wire end, for example in interconnecting to another circuit board.
In some instances it may be desired to subsequently solder the helical terminal 40 and the inserted pin or wire: this may be done individually or in a dip or wave soldering operation along with other printed circuit board pads.
FIG. 5a shows a typical twisted pair interconnection between two pairs of helical terminals 42a, 42b and 42c, 42d, formed in accordance with the present invention as described above in conjunction with configuring the interconnecting wires 44a and 44b as a twisted pair.
FIG. 5b shows a typical multiple twisted pair interconnection of three pairs of helical terminals: 42e, 42f and 42i, 42j being formed at the ends of hookup wires 44c, 44d while 42g, 42h are formed from an intermediate stripped portion of the continuous run of wires 44c, 44d.
In FIGS. 5a and 5b it is assumed that the helical terminals are installed in holes in a circuit board; for clarity of illustration the circuit board is not shown. Typically the terminals of a pair are spaced 0.1" apart on a standard 0.1" grid pattern for circuit board hole locations.
FIG. 6 illustrates a typical implementation of a multiple twisted pair run (as described in connection with FIG. 5b) exemplifying the manner in which components on a circuit board may be interconnected in accordance with the practice of this invention in its preferred embodiment. A pair of discrete components 46a, 46b which may be resistors, each has one of its contact pins retained in one of a pair of helical terminals formed from hookup wires 44k, 44l which connect components 46a, 46b through a length of twisted pair to a pair of helical terminals retaining a pair of contact pins of a DIP IC (dual in-line package integrated circuit) 48a, then continuing similarly through another segment of the twisted pair run to a pair of pins on a second IC 48b. It should be noted that the wire remains on the top side of circuit board 26a which is assumed to provide solder pads and conductive traces in the normal manner of well known printed circuit board technology for soldering from the bottom side by conventional dip or flow soldering methods. In the case of conventional double sided printed circuit boards, the presence of circuit traces on the top side of the board would in no way interfere with the practice of the present invention; of course the effective inside diameter of circuit board holes, whether plated-through or not, must be suitable to accept the helical terminals.
As shown in FIG. 7, an alternative embodiment of this invention may locate the wiring on the side of the circuit board opposite the components, as illustrated by twisted hookup wire pairs 44m, 44n, shown dashed beneath the circuit board 26b, interconnecting DIP ICs 48c and 48d which are mounted on the top side of the circuit board 26b. For this type of mounting, the helical terminals would be inserted from the side of the circuit board opposite the component side so that the loop portion extends upwardly on the component side. This configuration enables a special fastening arrangement for DIP components: with appropriate sizing and shaping of the loop, it may be placed over the component lead 50 as shown in enlarged inset 52, to enhance retention of the component.
FIGS. 8a-8h illustrate process steps and related mechanism for stripping, twisting and installing hookup wire interconnections in accordance with this invention.
FIG. 8a illustrates a basic method of stripping insulation from the ends of a pair of hookup wires simultaneously. In a wire feed mechanism 54, a pair of hookup wires 44p, 44q from spools 56a, 56b pass through a pair of wire guide jaws 58a, 58b in which the wires feed through a pair of guide openings formed from approximately half round grooves on each jaw. The feed mechanism 54 is adapted to provide three controlled modes: a clamping mode in which guide jaws 58a, 58b are clamped firmly onto the hookup wires 44p, 44q, a slipping mode wherein the clamping force is relaxed to allow the wires to be drawn through the guide jaws 58a, 58b, and an opened mode wherein the guide jaws may be fully disengaged by opening wide apart (as shown in FIG. 8d). In a stripping mechanism 60 (FIG. 8a), a pair of notched stripping jaws 62a, 62b are caused to close onto the insulated hookup wire as shown, severing the insulation at that point, then the stripping jaws 62a, 62b are moved toward the right so as to strip a length of insulation off the right hand end of the wires 44q, 44p while they are held in the clamped mode by guide jaws 58a, 58b.
Then (as described in connection with FIGS. 4a-4e) each stripped end portion is formed into a helix and installed as a helical terminal with a single hookup wire attached, the pair appearing as at the right hand end of FIG. 8b installed in circuit board 26c.
Referring further to FIG. 8b, the wire feed mechanism 54 is made to rotate as indicated by the curved arrows shown on guide jaws 58a, 58b and to simultaneously travel toward the left relative to circuit board 26c as indicated so as to twist the wires 44p, 44q together uniformly as shown over any required length as they feed though guide jaws 58a, 58b, operating in the slipping mode.
FIG. 8c shows the additional incorporation of two sets of wire grabbers 60a, 60b which are adapted to close onto the wires 44p, 44q respectively and retain them in place. Like the guide jaws 58a, 58b, grabbers 60a, 60b are fitted with wire guiding grooves and are enabled to operate in three different modes: clamping, slipping and opened. Thus with grabbers 60a, 60b clamping the wires 44p, 44q as shown, guide jaws 58a, 58b may be opened wide as shown in FIG. 18d, so that they can moved leftward as indicated, past the grabbers 60a, 60b and then, as shown in FIG. 8e, clamp the wires 44p, 44q at a new location, at left, in preparation for stripping a non-end portion of the hookup wire for forming a pair of helical terminals intermediate along a twisted pair run, such as terminals 42g, 42h in FIG. 5b.
Referring now to FIG. 8f, stripping jaws 62a, 62b are closed onto the hookup wires 44p, 44q, severing the insulation, and then moved toward the right to strip the insulation from a designated portion of wire as shown in FIG. 8g. For some types of wire insulation, this operation may also require utilizing some form of longitudinal slitting blade (not shown) to facilitate non-end insulation stripping.
In FIG. 8h (as in FIG. 8g but with stripping jaws 62a, 62b removed) wires 44p, 44q are held in place by guide jaws 58a, 58b (in the clamped mode) and grabbers 60a, 60b (in the slipping mode). Recalling that the right hand end of wires 44p, 44q, as shown, are an end part of a partially installed twisted pair run (refer to FIGS. 8b-8d), a degree of slack will appear in the twisted pair run at this point as an allowance for terminal formation as follows. Mandrel 10 and sleeve guide 12 are shown, positioned over the stripped portion 34p of wire 44p. It is assumed that, as in FIG. 4a, a circuit board 26 is x-y positioned on a work platform 30 so as to align a designated hole 28 between mandrel 10 above and cavity tool 22 beneath. Mandrel 10 is lowered until its lower end captures stripped wire portion 34 at midpoint; then as cavity tool 22 moves up from below and contacts the wire 34, guide jaws 58a, 58b (FIG. 8h) are placed in the slipping mode and the cavity tool 22 moves further upward to form the loop 38 as shown in FIG. 4b. Then mandrel 10 is rotated to wind a helix and the helix is inserted into the circuit board hole to form a helical terminal as described in detail in connection with FIGS. 4b-4e. Referring once again to FIG. 8h, during the winding of the helix, insulated wire 44p is allowed to be pulled inwardly toward the helix from both directions since guide jaws 58a, 58b and grabbers 60a are in the slippage mode.
The arbor machine carrying the work table and the tool set comprising mandrel 10, guide sleeve 12 and the cavity tool is preferably made such that the vertical axis of the tool set may be set to either of two operating positions spaced apart a designated distance, such as 0.1". Thus, in a continuation of the process described in connection with FIG. 8h, the tool set would be stepped to the alternate position to engage stripped portion 34q of hookup wire 44q and the above process repeated to form the second in the pair of helical terminals. Then, if the twisted wire interconnection is to be continued on to additional terminal locations, the entire process as described in connection with FIGS. 8b-8h is repeated as required. When the pair of terminals being formed are at the end of a run, the two wires 44p, 44q (FIG. 7h) are cut off at the left hand end of the stripped regions 34p, 34q (FIG. 7h) by a wire shearing tool before forming each corresponding terminal.
Dimensioning the tool parts and specifying the circuit board hole diameter and number of turns in the helix depend on wire size and circuit board thickness. Using #30 AWG (American wire gage) wire, which has a diameter of 0.0125", a circuit board thickness of approximately 0.06" accommodates a five turn helix, 0.0625" in height. Referring to FIG. 1, to provide clearance for 0.07" diameter at the upper portion of mandrel 10, sleeve guide 12 is made to have an inside diameter of 0.075", which, with 0.042" diameter at mandrel forming portion 18, provides a space of 0.0165" for winding the 0.0125" diameter wire.
The inside diameter of the helix will be 0.042" as determined by the forming portion 18 of mandrel 10: this size easily accepts DIP contact pins which may be 0.015" to 0.02" in width, and is suited to other common component contact pins and hookup wire as large as #20 AWG (0.0375").
The outside diameter of the helix will be 0.042"+0.0125"+0.0125"=0.067", which dictates the required circuit board hole size.
The outside diameter of cavity tool 22 is made 0.06" to easily clear a circuit board hole diameter of 0.067", and the cavity 24 is made 0.05" deep by 0.045" diameter to accept the lower end of mandrel 10. The end-surround recess 20 on mandrel 10 is made 0.015" in depth to accept the 0.0125" wire, and typically extends 0.06" upward on each side of the forming portion 18 of mandrel 10.
The foregoing tool dimensions are suitable for terminal spacing as close as 0.1"; closer spacing, such as 0.05", may be provided by suitably scaling the tool dimensions and hookup wire size.
Long runs of twisted pair hookup wire may be secured to the circuit board by a fast curing adhesive cement.
A helical terminal may be utilized in conjunction with printed circuitry; if a terminal retaining a component pin is located in a circuit board hole which has a corresponding printed circuit pad on the foil side, regular dip or wave soldering will form a three way connection between the associated hookup wire, the pin and the pad.
There exists an option of utilizing the helical terminal, without any component being directly involved, to simply connect the associated hookup wire on the component side of the circuit board to a printed circuit pad on the opposite side, where the terminal would be dip or wave soldered in place along with the pad.
The U-shaped loop 38 (FIG. 4e) protruding below the circuit board may serve in some instances to provide clearance for the end of a component contact pin and/or it may serve as a terminal lug to which another component lead or hookup wire may be connected by through-insertion and/or wrapping, and then soldered. The size and shape of the loop may be modified by special shaping of the mandrel and cavity tools and/or the shape of the loop may be modified by post-forming in place on the circuit board. There also exists the option of eliminating the loop by configuring the mandrel, and controlling its vertical travel, so as to form only a straight run across the diameter of the helix at its lower end.
The above described preferred embodiment of fabrication apparatus of the present invention provides capability of processing a pair of hookup wires in a manner to provide a multiple terminal twisted pair configuration. It is to be understood that the apparatus described may be be easily operated in a simpler manner by the omission of particular process steps, for example when only a single wire, rather than a twisted pair, is to be processed and/or where terminals are to be formed only at wire ends. Similarly, for such less complex operations, it would be a simple matter to reduce the complexity of the apparatus accordingly to any of a number of more simplified embodiments utilizing only those essential elements of the apparatus required for particular wiring configurations.
The invention may be embodied and practiced in other specific forms without departing from the spirit and essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description; and all variations, substitutions and changes which come within the meaning range of equivalency of the claims are therefore intended to be embraced therein. | Insulated hookup wire is processed to provide point-to-point interconnections on a circuit board, including helical terminals formed integrally from stripped portions of the hookup wire and set into circuit board holes; the helical terminals serve as receptacles for contact pins of components such as DIP ICs, leads of components such as resistors or capacitors, or even for stripped ends of additional hookup wire, for example in interboard wiring. Regular dip or wave soldering may be performed subsequently. For special purposes, the wiring system of this invention may be utilized throughout a circuit board, or else it may be utilized strategically to supplement regular printed circuitry. In a three piece machine tool set, a shaped mandrel rotates to wind a portion of stripped wire into a dual interleaved helix and then press the helix into place as a helical terminal/receptacle in a circuit board hole, with one or two insulated hookup wires integrally attached for interconnection. A dual wire handling mechanism implements the installation of twisted pair runs which may include pairs of terminals at intermediate locations as well as at each end of a run. Such twisted pairs utilized as balanced transmission lines outperform unshielded printed circuit parallel microstrip lines in suppressing crosstalk and r.f. interference, and may enable transmission of critical digital and high frequency signals between widely separated regions of a circuit board while avoiding the cost, complexity, producibility and reliability penalties involved in the classic alternatives of adding several layers in a multilayer circuit board to provide buried stripline transmission paths or handwiring flexible or rigid coaxial cable runs with associated interfacing difficulties. | 7 |
This is a continuation of copending application Ser. No. 279,529, filed on Dec. 2, 1988, now abandoned.
This invention is in the field of chemical synthesis and is directed to a method for the preparation of monohalogenated nitroalkanes substantially free of polyhalogenated nitroalkanes.
BACKGROUND OF THE INVENTION
Halogens are known to react readily with nitroalkanes. This reaction occurs with respect to the hydrogens bonded to the same carbon as the nitro group. In the presence of an alkaline catalyst, complete halogenation of the nitroalkane is easily achieved. Thus, nitromethane reacts readily to produce chloropicrin in high yield as illustrated below. ##STR1##
Due to the ease with which complete halogenation takes place, however, it is difficult to prepare monohalogenated nitroalkanes in high yield. This difficulty is compounded by the difficulty in separating the monohalogenated product from any polyhalogenated product formed in the halogenation reaction.
A method of preparing monochlorinated nitromethane is described in U.S. Pat. No. 2,309,806. In this process, approximately equivalent quantities of aqueous solutions of nitromethane and a basic alkali metal hydroxide are reacted to form an alkali metal salt of the nitromethane which is, in turn, reacted with gaseous chlorine at a temperature not substantially in excess of 50° C. to produce monochlorinated nitromethane. The monochlorinated nitromethane is subsequently recovered by distillation.
More recent U.S. Pat. No. 3,096,378 describes a method of preparing monochlorinated nitroethane. The described process consists of a rather rigidly controlled chlorination of nitroethane with a special emphasis being placed on the control of reaction vairiables such as agitation, temperature, and time of reaction. An aqueous solution of the sodium salt of nitroethane is prepared by adding a solution of sodium hydroxide to a slurry of nitroethane in water with cooling. Sodium chloride is added to the solution to decrease the solubility of the monochlorinated nitroethane to be formed in the aqueous solution. The solution of the sodium salt of nitroethane is then cooled to 0° C. Chlorine is bubbled through the solution while avoiding stirring, and the monochlorinated nitroethane is formed and removed from the reaction mixture.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of preparing and recovering a high yield of high purity monohalogenated nitroalkane.
It is a further object of this invention to provide a means of preparing monohalogenated nitroalkanes of high purity and in high yields without the use of salt additives to control solubility or the need to avoid stirring the reaction mixture.
Yet another object of this invention is to provide a method of preparing monohalogenated nitroalkanes which employs a relatively simple recovery procedure.
A still further object of this invention is to provide a process for the preparation of monochlorinated nitroalkanes which can be operated in either a batch or a continuous process.
These and other objects and advantages of this invention, as well as additional inventive features, will become apparent from the description which follows.
Monohalogenated nitroalkanes are prepared in accordance with the present invention by reacting equal molar quantities of an alkaline material and a nitroalkane in a suitable medium to form a nitronate salt therein, immediately mixing the medium containing the nitronate salt with an equal molar quantity of a halogen to form monohalogenated nitroalkane in the medium, optionally and promptly adding a compound such as sodium bisulfite to the medium to destroy any unreacted halogen therein and thereby to terminate any further halogenation reaction, and recovering the monohalogenated nitroalkane from the medium. By alkaline material is meant an alkali metal salt or an amine. The recovery may be accomplished by distillation of a water azeotrope of the monohalogenated nitroalkane and separation of the monohalogenated nitroalkane layer from the remainder of the distillation product.
DETAILED DESCRIPTION OF THE INVENTION
While the invention will be described in connection with certain preferred embodiments, it is not intended to limit the invention to the particular embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalent processes as may be included within the spirit and scope of the invention as defined by the appended claims.
The present invention constitutes a method of preparing monohalogenated nitroalkanes of the formula: ##STR2## where R is hydrogen or an alkyl group and X is a halogen. The inventive method involves the reaction of a mono alkali salt of a nitroalkane, i.e., a nitronate salt, with a halogen to form the monohalogenated nitroalkane which is subsequently recovered from the reaction mixture.
The nitronate salt is prepared by reacting essentially equal molar quantities of an alkali metal hydroxide and a primary nitroalkane such as nitromethane, nitroethane or 1-nitropropane. The reaction may take place in any suitable vessel equipped with an agitator and cooling jacket or may be performed in a continuous reactor consisting of a tube containing a static mixer. The reaction takes place at temperatures below about 40° C. and when in a batch operation at low temperature, e.g., 0° C.±10° C., and preferably in an aqueous medium in which an aqueous solution of the nitroalkane is mixed with an aqueous solution of the alkali metal hydroxide, resulting in an aqueous solution of the nitronate salt. Other solvents can also be used. The preferred alkali metal hydroxide is sodium hydroxide, but other alkali metal hydroxides can be utilized in the practice of the present invention.
The nitronate salt thus formed is promptly mixed with a halogen in equal molar quantities. Again, the reaction may take place in any suitable vessel. Preferably, an aqueous nitronate salt solution is charged into a reactor containing a solution of the halogen. Cooling is supplied to maintain the vessel at temperature as recited in the preceding paragraph, with agitation. If a continuous system is desired, anhydrous halogen or a halogen solution can be fed into a tube reactor equipped with a static mixer simultaneously and in equal molar quantity with the nitronate salt solution. The process is preferably operated in an aqueous system, although other solvent systems can also be utilized. For example, if the halogen is not sufficiently water-soluble, a different, more suitable, solvent for the halogen may be used.
Immediately following formation of the monohalogenated nitroalkane, the solution is treated with a compound to destroy any unreacted halogen in the reaction mixture. The compound employed to destroy any unreacted halogen is preferably sodium bisulfite and is preferably added to the reaction mixture in the form of a saturated solution.
The resulting monohalogenated nitroalkane is recovered from the reaction mixture, preferably by distillation of a solvent azeotrope of the desired product and separation of the bottom product layer by decantation from a suitable distillation trap. The monohalogenated nitroalkane produced by this process will be on the order of 90-95% pure.
The following examples further illustrate the present invention but, of course, should not be construed as in any way limiting its scope.
EXAMPLE 1
This example illustrates the batch conversion of nitromethane to monobromonitromethane.
An aqueous nitromethane solution (10% wt/wt) was prepared from nitromethane (500 g, 98.4%, 8.06 moles) and water (4,500 g). The aqueous nitromethane solution and an aqueous sodium hydroxide solution (1,638.3 g, 20% wt/wt, 8.2 moles) were pumped into a four-neck, 500 ml, round-bottom flask equipped with a mechanical stirrer, thermometer, overflow tube, and immersed in a dry ice-acetone bath. The two streams were controlled with precision metering pumps and were contacted just prior to entering the vessel in a mixing T through which nitrogen was sparged to facilitate mixing and remove air. The rate of pumping was controlled so that nitromethane and caustic were reacted in a 1:1 molar ratio to form a nitronate salt and the net out fall from the overflow tube was 50.85 cc/min. The liquid level in the flask was controlled by raising or lowering the overflow tube so the vessel was half full. The pot temperature was maintained at -5° to 0° C. with cooling.
The nitronate salt solution overflow from this 500 ml flask was directed through a polypropylene tube subsurface into a four-neck, 12 liter, roundbottom flask equipped with a mechanical stirrer, thermometer, and dry ice vapor trap and which was charged with water (1,000 g) and bromine (8.2 moles, 1,310.6 g). The pot temperature in the 12 liter vessel was maintained at -5° to 0° C. by immersion in a dry ice-acetone bath.
Following completion of the nitronate salt solution addition to the bromine solution, the dark red monobromonitromethane solution was stirred for 15 minutes. A charge of saturated sodium bisulfite solution (25 cc) was then added to destroy the unreacted bromine, whereupon the reaction mixture turned colorless.
Agitation was then stopped and the entire reactor contents were transferred to a 12 liter round-bottom flask equipped with a mechanical stirrer, thermometer, and a Vigreux distillation column topped with a Dean-Stark trap and a cold water condenser.
An impure azeotropic forecut was taken (head temperature was 90°-94° C.) and the main product cut was collected as a 1:1 water azeotrope (head temperature=94°-101° C., pot temperature=100°-105° C., 760 mm Hg). The colorless lower monobromonitromethane layer was drawn off semicontinuously during the course of distillation and the upper aqueous layer was allowed to overflow back to the pot.
The product thus collected (1,088.3 g) was assayed by GLPC internal standard analysis as consisting of 90.5 wt.% monobromonitromethane, approximately 1.4 wt.% bromonitroethane, and approximately 2.4 wt.% dibromonitromethane. The conversion of nitromethane (500 g, 98.4%, 8.06 moles) to monobromonitromethane (985 g, 7.03 moles) was 87.28 mole percent.
EXAMPLE 2
This example illustrates a continuous process for the preparation of monobromonitromethane.
The reaction system consisted of a pair of static mixers, connected in series, immersed in a dry ice-acetone bath. The nitronate reactor was 0.7 meter section of Kimax process pipe (2 cm ID). The reactor contained a 21 element Teflon static mixer. The working volume of the reactor was 0.185 liter. Connecting lines to the reactor were 0.95 cm Teflon. Tubing connectors were made of either Teflon or Kynar. The nitromethane solution and sodium hydroxide were fed to the reactor using FMI Metering pumps (Model RP-B). The nitromethane pump was equipped with a #2, 316 SS pump head (0.95 cm od piston). The sodium hydroxide pump was a #2, ceramic pump head (0.95 cm od piston). The effluent from the reactor was passed to the inlet of the bromination reactor. Bromination of the nitronate solution was conducted in a second static mixer reactor. The bromination reactor was constructed of Kimax process pipe (0.5 m long, 1.25 cm ID, 51 cc volume). The reactor contained a 24 element Teflon static mixer. Anhydrous bromine was fed to the reactor by an FMI metering pump (Model RP-B) equipped with a #2 ceramic head pump. The effluent from the bromination reactor was sent to a polyethylene holding tank.
A solution of nitromethane (98 wt.%, 50 Kg) in 450 Kg of condensate water was prepared. The solution was mixed for fifteen minutes and then discharged to steel drums. A commercial solution of 50% NaOH was also employed in this process. The caustic was titrated with 1N HCl to confirm concentration.
The feed pumps for the three reactant streams were calibrated to give a 1:1:1 mole ratio of nitromethane, sodium hydroxide, and bromine. Typical flow rates for the reactants are shown below.
______________________________________ Volume Weight MolesComponent (cc/min) (g/min) (moles/min)______________________________________nitromethane 1013.17 1031.61 1.690(10% Aq.)sodium hydroxide 87.82 134.65 1.683(50% Aq.)bromine 86.10 271.48 1.699(Anhyd.)______________________________________
The above flow rates led to a residence time in the nitronate reactor of 10.08 seconds. The residence time in the bromination reactor was 2.58 seconds.
The flow rates for the three reactant streams were checked against the pump calibration. The temperature of the cooling bath was lowered to 0° C. using ice water. The nitromethane and sodium hydroxide pumps were switched on simultaneously, and the bromine pump was switched on ten seconds later. The temperature of the cooling bath was adjusted to -20° to -30° C. with dry ice pellets. The temperature of the reactor outfall and the pH were monitored every five minutes. Typical outlet temperature from the bromination reactor was +42° C. The pH of the effluent was typically pH 0.1 or less. The bromonitromethane product and aqueous phase were treated with small quantities of sodium bisulfite to destroy excess bromine. These layers were also sampled and tested for nitromethane and bromonitromethane content. The layers were then azeotropically distilled to obtain the monobromonitromethane.
This continuous reactor was operated for a five day period. Typical runs were of 30 minutes or less duration. The typical assay of the product was 92-94 wt.% monobromonitromethane, 4-6 wt.% nitromethane, 1-2 wt.% dibromonitromethane, and a trace amount of tribromonitromethane.
EXAMPLE 3
This example illustrates a batch process suitable for the preparation of monobromonitroethane.
In a suitable vessel equipped with an agitator, 24 grams of nitroethane and 600 grams of water were added. The reaction mixture was cooled to 0° C., and 26 grams of 50% sodium hydroxide solution were added slowly over a five minute period. The resulting nitronate solution was fed to a solution of 52 grams of bromine and 300 grams water, which was prepared in a second round bottom flask equipped with an agitator. Addition of the nitronate solution was accomplished in seven minutes. The temperature of the reaction mixture was maintained at 0° C.±10° C. Following the addition, the resulting solution was agitated for thirty minutes and treated with 25 ml of saturated sodium bisulfite solution to remove any residual bromine.
When agitation was stopped, a Vigreux column was added to the flask along with a Dean-Stark trap and cold water condenser. A water product azeotrope was removed at 94°-101° C., and product was recovered as it separates in the Dean-Stark trap.
EXAMPLE 4
This example sets forth an illustrative procedure for the preparation of monochloronitromethane.
The apparatus used to prepare monochloronitromethane included three reactors: a nitronate reactor, a chlorination reactor, and a distillation reactor. The nitronate reactor was a 500 ml, roundbottom flask equipped with a thermometer, agitator, two feed reservoirs and pumps, and a nitrogen purge line. The chlorination reactor was a 12 liter, round-bottom flask equipped with a dry ice reflux condensor, inlets for chlorine and nitronate, an agitator, and a scrubber (10% NaOH/10% NaHSO 3 ). The distillation reactor was a 12 liter, round-bottom flask equipped with a thermometer, agitator, 1.5 feet Vigreux column, a Dean-Stark trap, and a scrubber (10% NaOH/10% NaHSO 3 ).
The following procedure was followed in preparing the monochloronitromethane. 6,100 grams of a 10 percent aqueous nitromethane (10 moles) solution was charged to the feed tank of the nitronate reactor, and 2,000 grams of a 20 percent sodium hydroxide (10 moles) solution was charged to the second feed tank of the nitronate reactor. The overflow nitronate reactor (500 ml) was charged with 150 ml of DI water and then cooled to 0° C. with a dry ice-acetone bath. The dip pipe of the nitronate reactor was adjusted to give a residence time of three minutes at a feed rate of 53.3 cc per minute. The chlorination reactor was charged with one liter of methylene chloride and then cooled to -5° C. with a dry ice-acetone bath. The agitator was then started. Chlorine was sparged into the methylene chloride until a gentle reflux of liquid chlorine was apparent in the dry ice reflux condensor. At that time, the flow of nitrogen was started to the nitronate reactor (20 cc/minute). After two minutes, the nitromethane feed pump was started (41.5 ml/ minute) along with the sodium hydroxide feed pump (11.8 ml/minute). The temperature in the nitronate reactor was continuously monitored and maintained at 0°-5° C.
The flow of chlorine to the chlorination reactor was then started (feed rate: 8.5 grams/minute for the first 40 minutes, 5.95 grams/minute for the next 30 minutes, 2.55 grams/minute for the final 55 minutes). The sodium nitronate solution (yellow) overflowed continuously to the chlorination reactor, and the temperature in the chlorination reactor was maintained at 0°-5° C. A total of 760 grams of chlorine was fed to the reactor (10.7 moles) over the 2.6 hour nitronate feed period.
Upon completion of the feed addition, the nitronate pumps were stopped. The reaction mixture was allowed to warm to 25° C. and then stirred for one hour. The solution was cloudy yellow with a bright yellow organic phase at the bottom.
The entire contents of the reaction flask was transferred to the distillation reactor. The reaction mixture was heated to boiling (atmospheric pressure), and a bisulfate scrubber was used to remove chlorine evolved during the heating. A forecut was collected up to a head temperature of 91° C. The product cut was collected as the bottom layer of the azeotrope between 91°-101° C. (head; 94°-104° C. pot).
By following the foregoing procedure, 824 grams of product was recovered containing 88 wt.% monochloronitromethane, 2-3 wt.% dichloronitromethane, 1-2 wt.% trichloronitromethane, and 5-7 wt.% nitromethane. It is believed that the nitromethane in the product could have been removed from the recovered product by increasing the temperature of the forecut to 94° C. | A method of preparing a monohalogenated nitroalkane which comprises reacting equal molar quantities of an alkali metal hydroxide and a nitroalkane in a suitable medium to form a nitronate salt therein, promptly mixing the medium containing the nitronate salt with an equal molar quantity of a halogen to form a monohalogenated nitroalkane in the medium, promptly adding a material to the medium containing the monohalogenated nitroalkane to terminate any further halogenation therein, and recovering the monohalogenated nitroalkane from the medium. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a combination self-retracting, wall-mounted desktop and chart holder having a slim profile and being adapted for mounting in a hospital or nursing home hallway outside a patient's room to provide a decentralized nurses' station. More particularly, it is concerned with a chart holder having at least one open sided slot oriented and configured to receive and retain a medical chart standing on one edge so that at least a portion of the chart is visible to display, at-a-glance, information about a particular patient.
2. Description of the Prior Art
In hospitals, patient charts are generated for each patient by doctors, nurses, and other hospital staff for record keeping purposes. Once generated, and when not in use, all patient charts for the floor or section of the hospital are typically stored and maintained at a single centralized nurses' station. A centralized nurses' station may serve any number of patient rooms located at varying distances from the station. If a doctor or nurse wishes to use or consult a patient's chart while visiting the patient, a trip must first be made to the centralized nurses' station to obtain the chart. Further, when the doctor or nurse completes their use of the chart, it must be returned to storage by making another trip to the centralized nurses' station.
As can be appreciated, the obvious expedient of providing a conventional centralized nurses' station for chart and medication storage, use and management, will inevitably lead to a waste of valuable time associated with unnecessary trips by staff back and forth between the centralized nurses' station and patient rooms. Having all charts at one place also consumes a considerable amount of valuable floor space.
Decentralized chart racks having retractable desktops have been proposed in the past for mounting on walls outside patient rooms. In general, however, these units have not been acceptable because they are bulky and may unacceptably encumber the flow of traffic in hallways.
SUMMARY OF THE INVENTION
The problems outlined above are in large measure solved by the self-retracting wall-mounted desk and chart holder in accordance with the present invention. That is to say, the chart holder hereof is of slim profile, compact construction, and is specifically designed for mounting on walls outside patient rooms to provide a decentralized nurses' station.
The slim profile chart holder in accordance with the present invention broadly includes a body having structure for defining a side entry storage slot of sufficient width to receive a medical chart only when it is standing on edge and extending generally parallel to the wall on which the holder is mounted. The slot is sized so that portions of the chart may project above and out beyond the slot to make it visible at-a-glance.
In particularly preferred forms, the structure that defines the slot includes a chart retaining shelf having a rear edge that lies up against the hallway wall when the holder is mounted in place, and a retaining wall extending upwardly from said shelf and set back from said edge. The chart wall and shelf cooperate with the hallway wall to define the slot when the holder is in place.
When a medical chart is standing on edge in the slot, a portion of the chart hangs out beyond the slot and another portion extends above the slot for clear display of any tagged or flagged medical or doctor's orders, and to facilitate communication of information at-a-glance. The chart holder of the present invention also provides the hospital staff with the tools and office supplies they need outside the patient's room during any particular shift, to fulfill their required tasks without the need of making unnecessary trips to a centralized nurses' station.
The chart holder of the invention further includes a desktop which is swingably attached to the body for movement of the desktop between a horizontal open position for use as a work surface, and a vertical closed position. The desktop and body have a geometric relationship such that when the desktop is in the vertical closed position, the chart holder has a slim profile so as not to present any appreciable obstruction to traffic passing by.
These and other objects of the invention will be appreciated from an examination of the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a chart holder in accordance with the invention, shown in an upright orientation and mounted to a hallway wall or other upright surface with the desktop shown extending in the horizontally open position;
FIG. 2 is a similar view of the chart holder showing the desktop in the vertically closed position;
FIG. 3 is a rear elevational view of the devices;
FIG. 4 is a frontal elevational view of the chart holder with the desktop shown in the vertical closed position;
FIG. 5 is a top plan view of the chart holder with a portion broken away to reveal the desktop fold-up cylinder;
FIG. 6 is a vertical sectional view taken substantially along the line 6--6 of FIG. 3 and illustrating the internal construction of the chart holder;
FIG. 7 is a fragmentary isometric view of an alternative embodiment showing a chart retaining slot which includes first and second chart retaining walls;
FIG. 8 is a side elevational view of a medical chart shown standing on a side edge;
FIG. 9 is a perspective view of an alternative chart holder having lockable medicine cabinets attached to the chart holder side walls, shown with the desktop extended in the horizontally open position; and
FIG. 10 is a similar view of an alternative chart holder with the desktop in the vertically closed position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated a decentralized nurses' station in the form of a combination desktop and chart holder 10 adapted for mounting to upright surface 12, that embodies the features of the invention.
The combination desk and chart holder 10 broadly includes a cabinet body 16 and a retractable desktop 18. The cabinet body 16 and desktop 18 may be formed of wood, metal or molded plastic components. Cabinet body 16 includes a vertically disposed rear wall 20, a top wall 22, a bottom wall 24 and side portions or upright side walls 26, all extending forwardly from rear wall 20 to form therewith a hollow compartment 28 that is open at the front. An upper rear edge 30 is presented at the intersection of top wall 22 and rear wall 20.
A vertical chart retaining wall 32 extends upwardly from top wall 22, is spaced forwardly of the upper rear edge 30, is generally parallel to rear wall 20 and extends between side walls 26. A pair of upright, relatively closely spaced, centrally disposed, transverse abutment walls 34 extend rearwardly from the retaining wall 32 and are in general parallel relationship to one another. Abutment walls 34 cooperate with the retaining wall 32 and top wall 22 to form a pair of oppositely facing nooks 36. Nooks 36 are mirror images of one another, but in all other respects are identical. Nooks 36 are configured to receive and retain patient medical charts, which will now be generally described.
A medical chart 40, of the type which the chart holder 10 is configured to receive and retain, is of conventional design and typically comprises a ring binder including a spine 42, and top and bottom protective covers, 43 and 44. The covers are attached at one end to spine 42, and have their opposite ends 45 and 46 free to move toward and away from one another. Top cover 43 is shown in FIG. 1 with a name tag 47 affixed thereto. Chart 40 is configured to confine and store medical records and documents created and used by doctors, nurses and other hospital staff in connection with the administration of health care to a particular patient. Such records and documents include physicians' orders, medication records, lab reports, and the like. Such medical records and documents, usually an 81/2×11 inch format, are bound in the chart by conventional means such as binder rings associated with spine 42. The length and width of the chart top and bottom covers 43, 44, are typically slightly greater than that of the records the chart 40 is intended to contain. The width of the chart spine 42 may vary, but typically has a dimension of two inches. Top cover 43 and bottom cover 44, when closed on one another, cooperate to define opposite chart side edges 48.
One important purpose of chart 40 is to serve as a means to communicate information, including, physicians orders, between a doctor who prescribes medical care and nursing staff who implement the prescribed care. To enhance such communication between doctors and nurses, doctors often employ either a tagging or flagging techniques. Tags 47 may be affixed to the portion of chart 40, such as spine 42, hanging out end opening 52, as shown in FIG. 1. The flagging technique is used to bring recently prepared orders to nurses' attention. That technique simply involves the diagonal folding of a document bound in a chart to cause the non-bound end of the document to extend outwardly from either chart side edge 48, as illustrated in FIG. 1 with respect to "flag" 49. The length of each nook 36 is less than the length of chart side edges 48 so that a portion of the chart 40 hangs out beyond the nook 36.
Returning now to the description of cabinet body 16, each nook 36 presents a shelf 38 of sufficient width to receive the medical chart 40 standing on side edge 48, as shown in FIG. 1. Each nook 36 further includes an end opening 52 extending generally parallel to upright surface 12. An office supply storage shelf 54 (FIGS. 3 and 6) extends between the abutment walls 34 and is spaced upwardly from and generally parallel to the top wall 22.
The cabinet body 16 is provided with desktop 18 which presents desktop side edges 56 a desktop front edge 57, a desktop rear edge 58, upper surface 59 and lower surface 60. Desktop 18 is swingably attached by hinge means 62 to cabinet body 16 so that desktop 18 is movable with respect to the cabinet body 16 by the application of external force between an open horizontal position (FIG. 1), an intermediate position, and a vertical closed position (FIG. 2). In the preferred embodiment, hinge means 62 includes openings 64 in the two side walls 26 that pivotally receive pivot pins 66 extending outwardly from desktop side edges 56 in the proximity of desktop rear edge 56, as shown in FIGS. 1 and 3. Openings 64 and projections 66 are positioned so that when desktop 18 is in the vertical closed position, it completely conceals hollow compartment 28, as shown in FIG. 2.
Retaining wall 32 presents a forward facing surface 68 which defines a depression 70 for receiving the upper portion of desktop 18 when it is in the vertical closed position, as shown in FIG. 2. In the vertical closed position, desktop 18 cooperates with depression 70 so that the cabinet body 16 presents a slim profile.
A rail 74 is horizontally disposed in hollow compartment 28 and extends between and is secured to side walls 26. Rail 74 presents a lower flange surface 76 (FIG. 6) extending between side walls 26 for abutting engagement with desktop rear edge 58 when the desktop is down. Thus, flange surface 76 cooperates with rear desktop edge 58 to maintain desktop 18 in the horizontal open position for use as a working surface, when desired. Rail 74 is also provided with recesses or pockets 78 which cooperate with rear wall 20 to provide spaces for receipt and storage of documents or other materials 104 within hollow compartment 28.
Referring now to FIGS. 1 and 6, a spring means is provided in the form of telescoping cylinder 82 (gas or spring operated) which is pivotally attached at one end to the desktop upper surface 59 in the proximity of rear desktop edge 58. As shown in FIG. 6, the rod end of cylinder 82 extends through an opening 86 in top wall 22 and is attached by means of a swivel fastener 90 to a reinforcing member 94 which is secured to the rearward surface 69 of retaining wall 32 between the abutment walls 34 and below the office supply storage shelf 54. The geometric relationship between the cylinder 82 and the pivot pins 66 is such that upon removal of the external force, the desktop 18 will move down to the horizontal open position if the desktop is positioned between the intermediate position and the horizontal open position. Conversely, the desktop 18 will move up to the vertical closed position if the desktop 18 is positioned between the intermediate position and the vertical closed position. Cylinder 82 may, in the alternative, be adjustable so that if all external force is removed from the desktop when in its horizontal open position, the desktop will self-retract into its upright vertical closed position.
A fastener means, in the form of screws 96, secures the cabinet body 16 to upright surface 12 with the open end 52 of each nook 36 facing generally horizontally. Once the cabinet body 16 is secured to the upright surface 12, the chart retaining wall 32, chart shelf 42 and abutment walls 34 cooperate with the upright surface to define mutually opposed chart slots 100. It is to be understood, however, that chart holder 10 need only be provided with a single slot 100. Each slot 100 is configured to receive and retain a chart 40 standing on edge, such as chart side edge 48, and the length of slots 100 is such that chart cover ends 45, 46, extend outwardly through open end 52, as shown in FIG. 1, to display tagged information to enhance communication of information at-a-glance. Further, office supply storage shelf 54 and abutment walls 34 and a centrally disposed portion of rear wall 20 cooperate with the upright surface 12 to define a office supply storage slot 102.
The use of chart holder 10 will now be described. In use, chart holder 10 is mounted on the wall outside a patient's room, nursing home room, or the like for the purpose of providing a decentralized nurses' station for storage and use of medical charts 40, medication and the like. From this location, a doctor or nurse intending to visit or check on a patient may conveniently obtain the patient's chart without the need to make the trip to a centralized nurses' station where charts are otherwise stored. Further, following the patient visit, the chart may simply be returned to the slot 100 and the chart holder 10, again limiting the need to make an additional trip to the centralized nurses' station. In the case when a physician has generated and flagged physician's orders as described above, the physician needs simply to place the chart on side edge 48 in slot 100 to visually bring the orders to the attention of attending nurses who pass by the patient's room. Chart holder 10 may also be used to make various types of patient information, such as a patient's name, visible at-a-glance, by printing the information (such as indicia 83 as shown on tag 47 in FIG. 1) on the chart cover extending through an opening 52.
Another unique feature of the invention is that because of its slim profile when desktop 18 is in the vertical closed position, the chart holder 10 does not present any appreciable obstruction to traffic passing by. In fact, the chart holder 10 is sufficiently slim in profile that the distance it extends outwardly from the vertical surface or walls upon which it is mounted does not exceed that of conventional hand rails which may be installed (which are usually required by fire code not to exceed about 41/2 inches).
In an alternative embodiment, cabinet body 16 includes a second chart retaining wall 108 which is parallel to and extends upwardly from rear wall 20. Retaining wall 108 cooperates with chart retaining wall 32, chart shelf 38, and abutment walls 34 to define chart slots 200 and medicine storage slot 202.
In yet another alternative embodiment shown in FIGS. 9 and 10, chart holder 300 is shown with a pair of lockable medicine cabinets 302,304 attached to and extending outwardly from sidewalls 26. Medicine cabinets 302,304 include hollow enclosures 306,308, respectively, and doors 310,312 hingeably secured thereto, as shown in FIGS. 9 and 10. Each door 310,312 is provided with locks 314,316, to prevent unauthorized access into medicine cabinets 302,304. In all other respects, chart holder 300 is identical to chart holder 10, as described above.
Thus, it should be understood that the invention provides a relatively inexpensive slim profile and extremely efficient decentralized nurses' station adapted for mounting on a wall in the proximity of a patient's room to provide for the readily accessible storage of charts, medication, and other printed material. | A self-retracting, wall-mounted desk and chart holder especially useful as a decentralized nurses' station is provided having a slim profile, compact construction, and being specifically designed for mounting on walls outside patient rooms. The chart holder includes a body having structure for defining a side entry storage slot of sufficient width to receive a medical chart standing on edge and extending parallel to the wall on which the chart holder is mounted. The slot is shorter than the chart so that a portion of the chart may project out beyond the slot and above the slot to make it visible at-a-glance. The chart holder further includes a desktop which is swingably attached to the body for movement of the desktop between a horizontal open position for use as a work surface, and a vertical closed position. | 0 |
FIELD OF THE INVENTION
[0001] The present invention is directed to a method and apparatus for indicating the type of call being sent from a first radio-communication device to a second radio-communication device, and in particular, a method and apparatus for indicating the type of call being sent from a first radio-communication device to a second radio-communication device with the second radio-communication device in a disadvantaged mode of operation relative to the first radio-communication device.
BACKGROUND OF THE INVENTION
[0002] Conventionally, a radio-communication system has a small number of large transmitter/receivers which are in communication with a large number of small transmitter/receivers which are designed to be carried by hand. For simplicity, the large transmitter/receivers will be referred to as first radio-communication devices, while the smaller transmitter/receivers will be referred to as second radio-communication devices.
[0003] A characteristic common to radio-communication systems is that they have a limited range. That is to say, for any two radio-communication devices, the maximum distance at which the radio-communication devices are able to communicate with each other (i.e. maintain a communications link) is limited by the coding gain and transmission power of the devices.
[0004] Quite obviously, to maximize the portability of the second radio-communication devices, it is necessary to minimize the size of the device. Because of this need to decrease the size of the device, it is necessary to use a smaller transmitter and power supply in the second radio-communication device than can be used in the first radio-communication device. In doing so, the maximum range at which the first and second radio-communication devices can transmit messages back and forth may be decreased.
[0005] However, not all communications to be carried on between the second radio-communication device and the first radio-communication device require a two-way communication link. For example, the first radio-communication device can transmit broadcast information to the second radio-communication device on a one-way communication link. Not limited by the size of the transmitter or power supply of the second radio-communication device, the maximum distance for this communication between the first and second radio-communication devices is only limited by the size of the transmitter and power supply of the first radio-communication device, which is typically several orders of magnitude larger than that used in the second radio-communication device.
[0006] Within the industry, the two-way and one-way communication links are termed the “advantaged and disadvantaged” modes of operation. Specifically, the advantaged mode of operations occurs where the second radio-communication device can receive both low and high power signals from the first radio-communication device, and can communicate with the first radio-communication device along a return low-power channel. The disadvantaged mode of operations occurs where the second radio-communication device can receive only the high power signals, and cannot communicate with the first radio-communication device along a return low-power channel.
[0007] While a considerable number of communications could occur between the first and second radio-communication devices even in the disadvantaged mode of operation, a significant obstacle exists to utilizing this potential fully. Conventionally, in the advantaged mode of operation, the second radio-communication device receives information from the first radio-communication device indicating which type of message (voice call, fax call, data call, etc.) is being transmitted from the first radio-communication device. In the disadvantaged mode, however, no call-type indicator is typically provided, such information usually being transmitted to the second radio-communication device only after the second radio-communication device sends a response signal along a return channel to the first radio-communication device in response to a paging signal.
[0008] Consequently, a user of a second radio-communication device which is in the disadvantaged mode must move the second radio-communication device so that it can achieve an advantaged mode of operation in order to determine whether the incoming call is of a voice, fax, or data type. However, upon arrival at a position sufficient to permit advantaged mode operation, the user may not have the necessary peripherals (fax machine or computer or other accessories) with him or her to receive the incoming call or message. Consequently, the user may be required to return to the previous location to receive the call from the first radio-communication device. Quite obviously, this can be frustrating for the user, and diminish the user's satisfaction with the cellular system which he or she has contracted to use.
SUMMARY OF THE INVENTION
[0009] According to an aspect of the present invention, a method is provided for use in a radio-communication system having a first radio-communication device and a second radio-communication device, the second radio-communication device capable of operating in a disadvantaged mode wherein only a one-way communication link is possible from the first radio-communication device to the second radio-communication device. The method includes the steps of transmitting a paging message from the first radio-communication device to the second radio-communication device with the second radio-communication device operating in the disadvantaged mode, receiving the paging message at the second radio-communication device, and activating a user indicator at the second radio-communication device representative of a request to establish a particular type of communication between the first and second radio-communication devices as an incident of receiving the paging message.
[0010] The step of transmitting a paging message may include the step of transmitting a paging message having a first string which is representative of a request to establish a particular type of communication between the first and the second radio-communication devices.
[0011] Moreover, the step of transmitting a paging message may include the step of transmitting a paging message having a first string which is representative of a request to establish a facsimile communication between the first radio-communication device and the second radio-communication device, and the step of activating a user indicator may include the step of activating a facsimile communication user indicator at the second radio-communication device.
[0012] Moreover, the step of transmitting a paging message may include the step of transmitting a paging message having a first string which is representative of a request to establish a data communication between the first radio-communication device and the second radio-communication device, and the step of activating a user indicator may include the step of activating a data communication user indicator at the second radio-communication device.
[0013] Additionally, the step of transmitting a paging message may include the step of transmitting a paging message having a first string which is representative of a request to establish a voice communication between the first radio-communication device and the second radio-communication device, and the step of activating a user indicator may include the step of activating a voice communication user indicator at the second radio-communication device.
[0014] Also, the step of transmitting a paging message may include the step of transmitting a paging message having a first string which is representative of a request to establish a particular type of communication between the first and the second radio-communication devices and a second string which is representative of a first identification code, and the step of activating a user indicator may include the step of activating a user indicator at the second radio-communication device representative of a request to establish a particular type of communication between the first and the second radio-communication devices only if the first identification code contained in the paging message matches a second identification code stored in the second radio-communication device.
[0015] According to another aspect of the present invention, a receiving radio-communication device is provided. The receiving radio-communication device includes a receiver to receive a paging message from a sending radio-communication device with the receiving radio-communication device operating in a disadvantaged mode relative to the sending radio-communication device wherein only a one-way communication link is possible from the sending radio-communication device to the receiving radio-communication device. Further, the receiving radio-communication device has a programmable computational apparatus selectively coupleable to the receiver, and an output assembly device selectively coupleable to the programmable computational apparatus. A program operates in the programmable computational apparatus to control the programmable computational apparatus to control the receiver to receive a paging message from a sending radio-communication device, and to control the output device to activate a user indicator representative of a request to establish a particular type of communication between the sending and receiving radio-communication devices as an incident of receiving the paging message.
[0016] With the paging message including a first string which is representative of a request to establish a particular type of communication between the sending radio-communication device and the receiving radio-communication device, the program may operate in the programmable computational apparatus to control the programmable computational apparatus to control the output device to activate a user indicator representative of a request to establish a particular type of communication between the sending and receiving radio-communication devices.
[0017] With the paging message including a first string which is representative of a request to establish a particular type of communication between the sending radio-communication device and the receiving radio-communication device and a second string which is representative of a first identification code, the radio-communication device may include a memory selectively coupleable to the programmable computational apparatus and having a site in which is stored a second identification code. The program may operate in the programmable computational apparatus to control the programmable computational apparatus to retrieve the second identification code from the memory, to determine if the first identification code matches the second identification code, and to control the output device to activate a user indicator representative of a request to establish a particular type of communication between the sending and receiving radio-communication devices only if the first identification code matches the second identification code.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a schematic representation of a system with a first radio-communication device and a second radio-communication device capable of operating in a disadvantaged mode and an advantaged mode relative to the first radio-communication device;
[0019] [0019]FIG. 2 is a block diagram illustrating a method according to the present invention for informing the user of a second radio-communication device what type of call is being received with the second radio-communication device in a disadvantaged mode of operation relative to a first radio-communication device;
[0020] [0020]FIG. 3 is a schematic representation of a second radio-communication device used in the method according to the present invention;
[0021] [0021]FIG. 4 is a schematic representation of a second radio-communication device displaying an alpha-numeric indication of a request for a voice call with the second radio-communication device in a disadvantaged mode relative to a first radio-communication device; and
[0022] [0022]FIG. 5 is a schematic representation of a second radio-communication device displaying an alpha-numeric indication of a request for a non-voice type of communication, e.g., short message or data or fax call, with the second radio-communication device in a disadvantaged mode of operation relative to a first radio-communication device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] [0023]FIG. 1 shows a system 20 for radio communication between a first radio-communication device/satellite 22 and a second radio-communication device 24 . The first radio-communication/satellite 22 may be part of a cellular satellite communication system, such as the Asia cellular satellite communication system. The second radio-communication device 24 shown may be one of a plurality of second radio-communication devices which are in communication with the first radio-communication device 22 .
[0024] Communication occurs between the first radio-communication device 22 and the second radio-communication device 24 in one of two modes: advantaged and disadvantaged. The difference between the advantaged and disadvantaged modes of operation, as explained before, is dependent upon whether one-way or two-way communication is possible between the second radio-communication device 24 and the first radio-communication device 22 . In FIG. 1, an advantaged mode of operation is shown by a double-headed arrow 26 , wherein two-way communication is possible between the second radio-communication device 24 and the first radio-communication device 22 . A one-way, disadvantaged mode of operation is shown by a single-headed arrow 28 in FIG. 1, indicating that transmission is possible only from the first radio-communication device 22 to the second radio-communication device 24 .
[0025] Assuming that the second radio-communication device 24 is at a position 30 , and a paging signal is sent from the first radio-communication device 22 to the second radio-communication device 24 , the user has several options. First, the user could move, as indicated by a dashed line 32 , to a position 34 , wherein two-way, advantaged mode communication is possible between the first radio-communication device 22 and the second radio-communication device 24 . This would be particularly necessary if the incoming call type is a voice call or other call which does not require the use of special accessories between the second radio-communication device 24 and the first radio-communication device 22 . Second, the user could move the second radio-communication device 24 into association with a computer 38 , as represented by a dashed arrow 36 , and then activate an advantaged mode of operation so as to receive, for example, a data call. Third, the user could move the second radio-communication device 24 , as shown by a dashed arrow 40 , into association with a fax machine 42 , and then achieve an advantaged mode of operation to receive an incoming fax call.
[0026] Conventionally, a user could decide whether he or she wanted to receive the call, and if so whether it was necessary to move to its position 34 or to associate the second radio-communication device 24 with either a computer 38 or a fax machine 42 only after the user had moved the second radio-communication device 24 to the position 34 so as to achieve an advantaged mode of communication with the first radio-communication device 22 . The method according to the present invention, as illustrated in FIG. 2 and as performed by a program operating in a microprocessor 43 of the second radio-communication device 24 as shown in FIG. 3, allows a user to determine whether it is necessary to move to the position 34 or obtain peripherals 38 , 42 without having to first move to the position 34 .
[0027] In general terms, the method for use in a radio-communication system (such as 20 ) including a first radio-communication device (such as 22 ) and a second radio-communication device (such as 24 ) capable of operating in a disadvantaged mode of operation with the first radio-communication device has three steps. First, the first radio-communication device 22 transmits a paging message to the second radio-communication device 24 operating in the disadvantage mode. Second, the second radio-communication device 24 receives the paging message. Third, the second radio-communication device 24 activates a user indicator representative of whether the first radio-communication device 22 is requesting a voice or non-voice (e.g., data or fax) radio-communication with the second radio-communication device 24 .
[0028] Specifically, the method requires that the second radio-communication device 24 acquire a communication with the first radio-communication device 22 at a block 44 . The second radio-communication device 24 remains in an idle state at a block 46 until a paging message is received from the first radio-communication device 22 .
[0029] At a block 48 , the second radio-communication device 24 receives a paging message from the first radio-communication device 22 . The paging message may contain one or more bits indicating the identification number of the second radio-communication device 24 with which the first radio-communication device 22 wishes to communicate. According to the present invention, the paging message will also include one or more bits indicating a particular type of communication that the first radio-communication device 22 wishes to establish with the desired second radio-communication device 24 .
[0030] In particular, a high powered alerting channel may be used to transmit a 53 bit paging message. As will be recognized by one of ordinary skill in the art, the first 50 bits of such a paging message are conventionally devoted to the identification code or number of the second radio-communication device paged, leaving the last three bits for use as the call-type indicator. To promote standardization, the information transfer capability values for the cellular system used (in this case, the Asia cellular satellite system) are used for the call-type indicator values. Accordingly, a three bit string of 000 indicates a speech call, a string of 001 indicates an unrestricted digital information signal, a string of 010 indicates an audio message, and a string of 011 indicates a fax call.
[0031] Referring additionally to FIG. 3, when an antenna 50 and transmitter/receiver 52 receive a paging message from the first radio-communication device 22 , they pass this message along to the microprocessor or programmable computational apparatus 43 , which first determines the identification number associated with the paging message at a block 56 . The microprocessor 43 then retrieves a second identification number from a memory 58 in the second radio-communication device 24 and compares this second radio-communication device identification number with the identification number associated with the paging message. The microprocessor 43 makes the determination at a block 60 whether the message identification number and the second radio-communication device identification number match. If the identification number associated with the paging message does not match the identification number for the specific second radio-communication device unit 24 , then the microprocessor would return the second radio-communication device 24 to the idle state at the block 46 until a new message is received at the block 48 .
[0032] If the identification number for the paging message matches the identification number for the second radio-communication device 24 , then the microprocessor 43 determines at block 62 whether the second radio-communication device 24 is in an advantaged or a disadvantaged mode of operation, a condition updated continuously by the second radio-communication device 24 according to the received signal strength. If the phone is already in an advantaged mode of operation, then the call will be processed at a block 64 .
[0033] If, however, the microprocessor 43 determines that the second radio-communication device 24 is in a disadvantaged mode of operation, then at a block 66 , the microprocessor 43 analyzes the incoming paging message for the three bit call-type indicator associated therewith. Dependent upon the call-type indicator received, the microprocessor 43 controls an output assembly 68 to activate one of a variety of call-type user indicators at a block 70 . The output assembly 68 may activate either an audio or a video display of the incoming call. For example, the output assembly 68 may use light, sound, or an alpha-numeric message, as an indicator that the incoming call is either a voice, data, or fax call.
[0034] As illustrated in FIGS. 4 and 5, the second radio-communication device 24 has an output assembly 68 including an alpha-numeric display or LCD crystal 72 . When the second radio-communication device 24 is in a disadvantaged mode of operation, and the incoming call is a voice call, then as shown in FIG. 4, the second radio-communication device 24 may display a message “RECEIVING VOICE MESSAGE . . . PLEASE MOVE TO RECEIVE” on the display 72 . The user will then know that he or she merely needs to adjust the antenna 50 or move from the position 30 to the position 34 wherein an advantaged mode of operation can be achieved with the second radio-communication device 24 . On the other hand, if the incoming call is a non-voice call, such as a fax call, then the second radio-communication device 24 displays a message such as in FIG. 5; “RECEIVING FAX MESSAGE . . . PLEASE CONNECT FAX”.
[0035] After reviewing the message displayed, the user of the second radio-communication device 24 can determine at a block 74 whether or not to receive the call. For example, if the message displayed is that in FIG. 5, the user can move to associate the phone with the fax machine 42 and achieve an advantaged mode of operation. On the other hand, if the user does not have access to a fax machine 42 , for example, the user can ignore the call.
[0036] As a consequence of the foregoing method, it is not necessary for the user to move from the position 30 , wherein the second radio-communication device 24 is in a disadvantaged mode of operation with the first radio-communication device 22 , to a position 34 , wherein the second radio-communication device 24 is in an advantaged mode of operation with the first radio-communication device 22 , just to determine what type of incoming call is being processed. As a further consequence, the full potential of the operation in the disadvantaged mode may be realized.
[0037] Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. | A method is provided for use in a radio-communication system having a first radio-communication device and a second radio-communication device, the second radio-communication device capable of operating in a disadvantaged mode wherein only a one-way communication link is possible from the first radio-communication device to the second radio-communication device. The method includes the steps of transmitting a paging message from the first radio-communication device to the second radio-communication device with the second radio-communication device operating in the disadvantaged mode, receiving the paging message at the second radio-communication devices, and displaying a user prompt at the second radio-communication device representative of a request to establish a particular type of communication between the radio-communication devices as an incident of receiving the paging message. A radio-communication device is also provided having a program operating in a programmable computational apparatus to operate the programmable computational apparatus to carry out the method. | 7 |
PRIORITY
This application claims priority under 35 U.S.C. § 119 to an application entitled “Method for Providing Broadcast Service in a CDMA Mobile Communication System” filed in the Korean Intellectual Property Office on May 13, 2002 and assigned Serial No. 2002-26290, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to broadcast services, and in particular, to a method for more efficiently providing broadcast services in a mobile communication system using code division multiple access (hereinafter referred to as “CDMA”) technology.
2. Description of the Related Art
In the future, communications environments will undergo rapid changes regardless of wired/wireless region or country. In particular, the communications environment, such as IMT-2000 (International Mobile Telecommunication-2000), tends to synthetically provide users with various information needs including image and voice information on a real-time basis. With the development of mobile communication technology, even in a cellular wireless communication system or PCS (Personal Communications System) mobile communication system, a mobile station (MS) has the ability to not only simply perform voice communication but also to transmit text information and to receive broadcast services.
At present, 3GPP2 (3 rd Generation Partnership Project 2) considers the efficient utilization of various service media and resources for a broadcast service in a mobile communication system. Such a broadcast service is performed by unidirectionally transmitting high-speed forward data without receiving reverse feedback information from a mobile station. A broadcast service in a mobile communication system is characterized in that a plurality of base stations (BSs) simultaneously transmit the same data stream. This is conceptually similar to a general television broadcasting service.
If a common channel is designed so as to guarantee the same performance even at a cell boundary, cell capacity is excessively wasted. Therefore, in a 3 rd generation mobile communication system, a structure of a supplemental channel proposed as a dedicated channel for a packet data service is partially modified to realize high-speed transmission for a broadcast service. The supplemental channel uses a common long code mask instead of a long code mask dedicated to a user, for a broadcast service. During a broadcast service, autonomous handoff not requiring feedback information from a mobile station and outer coding are performed to guarantee performance higher than or equal to that of an existing common channel.
In an existing wireless broadcast service under discussion, a broadcast service provider is limited to a specific broadcast server or a contents server designated by a common carrier, so mobile stations can only passively receive the broadcast service. Therefore, the service provider cannot charge for the broadcast service according to its service time or quantity. In addition, because the same data stream is simultaneously transmitted from several base stations as stated above, network resources for a broadcast service must be assigned to all the base stations, preventing efficient utilization of resources.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a broadcast service method for simultaneously transmitting and receiving voice, text and image data between mobile stations in a mobile communication system.
It is another object of the present invention to provide a broadcast service method for forming a group of mobile stations in a network, and simultaneously transmitting and receiving voice, text or image data between the mobile stations in the group.
It is further another object of the present invention to provide a broadcast service method capable of efficiently using wired/wireless resources of a base station and a network.
It is still another object of the present invention to provide a broadcast service method capable of controlling a transmission time of a base station and assignment of network resources.
According to one aspect of the present invention, there is provided a method for receiving a broadcast service by a mobile station in a wireless broadcast service system including the mobile station existing in a service area, a base station capable of connecting a wireless channel, a packet data serving node for connecting the base station to a packet communication network, a broadcast server connected to the packet communication network, and an authentication server connected to the packet communication network. The method comprises the steps of: performing user authentication by setting up a connection with the authentication server, and receiving, if the user authentication is passed, information on available broadcast services from the broadcasting server; registering a desired broadcast service in the packet data serving node based on the received information so that the packet data serving node assigns a network resource for the desired broadcast service; if the desired broadcast service is authorized by the packet data serving node, registering the desired broadcast service in the base station so that the base station assigns a wireless broadcast supplemental channel and a network resource for the desired broadcast service; and receiving broadcast data for the desired broadcast service over the broadcast supplemental channel assigned to the base station.
According to another aspect of the present invention, there is provided a method for providing a broadcast service to a mobile station by a base station in a wireless broadcast service system including the mobile station existing in a service area, the base station capable of connecting a wireless channel, a packet data serving node for connecting the base station to a packet communication network, a broadcast server connected to the packet communication network, and an authentication server connected to the packet communication network. The method comprises the steps of: upon receiving a broadcast service registration request from the mobile station, determining whether the requested broadcast service is already being provided; if the requested broadcast service is not being provided, registering the requested broadcast service in the packet data serving node so that the packet data serving node assigns a network resource for the requested broadcast service; and if the requested broadcast service is authorized by the packet data serving node, assigning a wireless broadcast supplemental channel for the broadcast service and transmitting broadcast data for the requested broadcast service received from the packet data serving node to the mobile station over the assigned broadcast supplemental channel.
According to another aspect of the present invention, there is provided a method for providing a broadcast service to a mobile station by a packet data serving node in a wireless broadcast service system including the mobile station existing in a service area, a base station capable of connecting a wireless channel, the packet data serving node for connecting the base station to a packet communication network, a broadcast server connected to the packet communication network, and an authentication server connected to the packet data communication network. The method comprising the steps of: receiving information on broadcast services available for the mobile station from the authentication server; upon receiving a registration request for a broadcast service desired by the mobile station, assigning a network resource for the requested broadcast service based on the received information on the available broadcast services; and upon receiving a registration request for the requested broadcast service from the base station, transmitting broadcast data for the requested broadcast service received from the broadcast server to the mobile station through the base station, using the assigned network resource.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates the entire configuration of a common broadcast service system;
FIG. 2 illustrates the configuration of a broadcast service system in which an authenticated mobile station serves as a source of a broadcast service according to an embodiment of the present invention;
FIG. 3 illustrates configuration of a broadcast service system in which an authenticated broadcast server serves as a source of a broadcast service according to another embodiment of the present invention;
FIG. 4 is a message flow diagram illustrating a procedure for registering a broadcast service desired by a mobile station in a packet data serving node (PDSN) via a base station to thereby assign system and network resources according to an embodiment of the present invention;
FIG. 5 is a flowchart illustrating an operation performed by a mobile station to initiate a broadcast service as illustrated in FIG. 4 ;
FIG. 6 is a flowchart illustrating an operation performed by a base station to initiate a broadcast service as illustrated in FIG. 4 ;
FIG. 7 is a flowchart illustrating an operation performed by a packet data serving node to initiate a broadcast service as illustrated in FIG. 4 ;
FIG. 8 is a message flow diagram illustrating a procedure for returning system resources by a mobile station after leaving (or terminating) a broadcast service according to an embodiment of the present invention;
FIG. 9 is a flowchart illustrating an operation of leaving a broadcast service by a base station as shown in FIG. 8 ;
FIG. 10 is a message flow diagram illustrating a procedure for performing accounting on a broadcast service of a mobile station according to an embodiment of the present invention;
FIG. 11 is a flowchart illustrating an operation of performing accounting on a broadcast service by a base station and a packet data serving node as shown in FIG. 10 ;
FIG. 12 is a message flow diagram illustrating a procedure for assigning broadcast service resources using a registration message according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Several preferred embodiments of the present invention will now be described in detail with reference to the attached drawings. In the drawings, it should be noted that the same or similar elements are denoted by the same reference numerals even though they are depicted in different drawings. In the following description, a detailed description of known functions and configurations incorporated herein has been omitted for conciseness.
The disclosed embodiments of the present invention are characterized in that in a mobile communication system supporting a broadcast service, a broadcast server or a specific mobile station provides a broadcast service to registered mobile stations constituting a logical group. A packet data serving node (PDSN) authenticates mobile stations registered in a broadcast service receiving group, and controls base stations servicing corresponding mobile stations to assign a forward broadcast supplemental channel (hereinafter referred to as “F-BSCH”). Herein, reference will be made to a structure of a mobile communication system and a wireless channel based on 3GPP2 in order to describe an operating principal of the present invention. However, it should be readily understood by those of skill in the art that the present invention is not limited to 3GPP2 implementations.
FIG. 1 illustrates a common broadcast service system. Referring to FIG. 1 , a broadcast server or contents server (CS) 14 generates an IP packet by compressing image and/or voice data for a broadcast service, i.e., broadcast data, according to an Internet protocol (IP), and delivers the IP packet to base stations (BS) 12 a , 12 b and 12 c via packet data serving nodes (PDSNs) 13 a and 13 b over a packet communication network such as the Internet. Each of the base stations 12 a , 12 b and 12 c are comprised of a base transceiver subsystem (BTS), a base station controller (BSC), and a packet control function unit (PCF), and thus, they are represented by BS/PCF.
In order to deliver the broadcast data generated by the broadcast server 14 to the base stations 12 a , 12 b and 12 c , IP multicast technology is used. The base stations 12 a , 12 b and 12 c form a multicast group which is provided with IP multicast data from the broadcast server 14 . Membership information of the multicast group is retained by an undepicted multicast router (MR) connected to each of the base stations 12 a , 12 b and 12 c . That is, IP multicast data including the image and/or voice data generated by the broadcast server 14 is broadcasted to the base stations 12 a , 12 b and 12 c forming the multicast group, and the base stations 12 a , 12 b and 12 c convert the IP multicast data into a radio frequency (RF) signal, and then transmit the RF signal in their service areas.
In FIG. 1 , however, the base stations 12 a , 12 b and 12 c always transmit the broadcast data regardless of whether a mobile station exists in their service areas. Thus, the base stations 12 a , 12 b and 12 c may unnecessarily waste wired and wireless resources, and mobile stations 11 a, 11 b and 11 c located in the service areas of the base stations 12 a , 12 b and 12 c must passively receive the broadcast data.
FIG. 2 illustrates the configuration of a broadcast service system in which an authenticated mobile station serves as a source of a broadcast service according to an embodiment of the present invention. Referring to FIG. 2 , a mobile station 21 a , serving as a broadcast service source authenticated by an authentication server (or an Authentication, Authorization and Accounting (AAA) server) 24 , has been registered in a packet data serving node (PDSN) 23 a to provide a broadcast service. Broadcast data transmitted over a reverse fundamental channel (hereinafter referred to as “R-FCH”) established between the mobile station 21 a and its associated base station 22 a is provided to base stations 22 b and 22 c by packet data serving nodes 23 a and 23 b . The base stations 22 b and 22 c provide the broadcast data to mobile stations 21 b and 21 c in their service areas over forward broadcast supplemental channels (F-BSCHs). The broadcast data is transmitted in the form of IP multicast data. The mobile stations 21 b and 21 c provided with the broadcast data have been registered in the corresponding packet data serving nodes 23 a and 23 b for broadcast reception, forming a logical group. The authenticated mobile station 21 a can transmit broadcast data to the registered mobile stations 21 b and 21 c.
FIG. 3 illustrates configuration of a broadcast service system in which an authenticated broadcast server serves as a source of a broadcast service according to another embodiment of the present invention. Referring to FIG. 3 , a broadcast server 36 serves as a broadcast service source authenticated by an authentication server (or an AAA server) 34 , and broadcast data transmitted in the form of IP multicast data by the broadcast server 36 is directly delivered to an adjacent packet data serving node 33 b and also delivered to a packet data serving node 33 a of another network via a multicast router (MR) 35 . The packet data serving nodes 33 a and 33 b transmit the broadcast data to base stations 32 a , 32 b and 32 c that service mobile stations 31 a, 31 b and 31 c registered for a broadcast service. The base stations 32 a , 32 b and 32 c provide the broadcast data to the mobile stations 31 a , 31 b and 31 c over forward broadcast supplemental channels (F-BSCHs). The mobile stations 31 a , 31 b and 31 c provided with the broadcast data have been registered in the corresponding packet data serving nodes 33 a and 33 b for broadcast reception, forming a logical group. As a result, the authenticated broadcast server 36 can transmit broadcast data to the registered mobile stations 31 a , 31 b and 31 c.
With reference to FIGS. 4 to 12 , a description will now be made of an operation of providing a broadcast service in a mobile communication system according to an embodiment of the present invention.
FIG. 4 is a message flow diagram illustrating a procedure for registering a broadcast service desired by a mobile station in a packet data serving node (PDSN) via a base station to thereby assign system and network resources according to an embodiment of the present invention. As shown in FIG. 4 , a packet data serving node and a base station start providing a broadcast service only at the request of a mobile station, rather than always providing the broadcast service.
Referring to FIG. 4 , in step 100 , a mobile station (MS) sets up a connection to an authentication server (AAA) according to a point-to-point protocol (hereinafter referred to as “PPP”), and then sends a user authentication request to the authentication server (AAA) through the set connection in order to request a broadcast service. If the authentication is passed, the authentication server delivers information on broadcast services that the mobile station can receive to a corresponding packet data serving node (PDSN) in step 102 , the information being stored in its database through a service authorization procedure.
The delivered information includes broadcast multicast service identifiers (hereinafter referred to as “BCMCS_IDs”) for identifying broadcast services, multicast IP addresses and source IP addresses for identifying sources that provide a broadcast service, or includes a table identifier by which the above parameters can be searched from a database of the packet data serving node (PDSN).
In step 104 , the mobile station connects a call to a broadcast server (or a contents server (CS)) using a hypertext transfer protocol (HTTP) or a session description protocol (SDP), and receives session information related to broadcast services from the broadcast server. This is achieved through a dedicated channel by using a call based on Service Option 33 (hereinafter referred to as “SO33”) designating a packet data service. In step 106 , the mobile station sends an IGMP (Internet Group Management Protocol) message to the packet data serving node along with a multicast IP address corresponding to a desired broadcast service. The packet data serving node analyzes the requested multicast IP address included in the IGMP message.
In the case where the packet data serving node is already servicing the corresponding broadcast contents while the multicast IP address requested in step 104 by the mobile station is identical to a multicast IP address authorized in step 102 by the authentication server, the packet data serving node does not require new management such as system and network resource assignment for providing a broadcast service. On the other hand, in the case where the requested multicast IP address is identical to the authorized multicast IP address but the packet data serving node is not performing the service, the packet data serving node registers the requested multicast IP address in a multicast IP routing table of its internal database.
If the requested multicast IP address is not identical to the authorized multicast IP address, the packet data serving node inquires of the authentication server about whether the requested multicast IP address is available, through an optional service authentication procedure, in step 108 . If it is determined that the requested multicast IP address is available, the packet data serving node registers the requested multicast IP address in the multicast IP routing table, and builds a multicast IP spanning tree by communicating a routing message indicating the particulars registered in the routing table with neighboring routers.
After the requested multicast IP address is analyzed, the packet data serving node transmits an IGMP message to the mobile station in response to the IGMP message in step 110 . In step 112 , the broadcast server starts transmitting broadcast data for the corresponding broadcast service to the packet data serving node.
At this moment, the mobile station has already received all information necessary for reception of a broadcast service, and in particular session information, BCMCS_ID, and multicast IP address. Therefore, in step 114 , the mobile station sends a registration request for the desired broadcast service corresponding to the BCMCS_ID and the multicast IP address to a base station (BS) over an access channel, using the session information. The base station then analyzes the BCMCS_ID and the multicast IP address, registration of which was requested by the mobile station.
If a broadcast service corresponding to the BCMCS_ID and the multicast IP address is not currently being provided by the base station, the base station must newly assign wired and wireless resources for the broadcast service. Thus, in step 116 , the base station sends a packet control function unit (PCF) a call setup message (A 9 -Setup-A 8 ) carrying the BCMCS_ID and the multicast IP address. In step 118 , the packet control function unit sends the packet data serving node a registration request message (A 11 -Registration Request) carrying the BCMCS_ID and the multicast IP address, in response to the call setup message.
In step 120 , the packet data serving node transmits to the packet control function unit a registration response message (A 11 -Registration Reply) indicating that a broadcast service corresponding to the BCMCS_ID and the multicast IP address was authorized, in response to the registration request message. In step 122 , the packet control function unit (PCF) determines from the registration response message that the broadcast service was authorized, and then delivers a connection message (A 9 -Connect-A 8 ) for notifying this situation, to the base station. The base station then assigns wired and wireless resources as well as a forward broadcast supplemental channel (F-BSCH) for the broadcast service, and starts the broadcast service. That is, the base station receives broadcast data from the broadcast server via the packet data serving node, and starts transmitting the received broadcast data over the forward broadcast supplemental channel (F-BSCH).
In step 124 , the mobile station receives the broadcast data by tuning to the forward broadcast supplemental channel corresponding to the BCMCS_ID. A plurality of mobile stations desiring to receive the same broadcast service are registered as a broadcast service receiving group, and the broadcast service in the packet data serving node and the base station continues until a predetermined broadcast timer expires or all mobile stations terminate (or leave) their broadcast services.
FIG. 5 is a flowchart illustrating an operation performed by a mobile station to initiate a broadcast service as shown in FIG. 4 . Referring to FIG. 5 , a mobile station desiring to receive a broadcast service sends a user authentication request to an authentication server through PPP connection in step S 100 , and receives service authorization information for the user in response to the user authentication request in step S 102 . If the user is not authorized in step S 102 , the flow ends. In step S 104 , if session information for broadcast services is received from a broadcast server, the mobile station requests, in step S 106 , the desired broadcast service by transmitting information related to the desired broadcast service, i.e., BCMCS_ID and multicast IP address, to a packet data serving node.
If a broadcast service authorization response is received in step S 108 in response to the broadcast service request, the mobile station transmits in step S 110 a registration request for the desired broadcast service corresponding to the BCMCS_ID and the multicast IP address to a base station in order to register the desired broadcast service. If the service is not authorized in step S 108 , the flow ends. The base station then transmits broadcast data for the broadcast service in response to the registration request. In step S 112 , the mobile station receives the broadcast data for the desired broadcast service.
FIG. 6 is a flowchart illustrating an operation performed by a base station to initiate a broadcast service as shown in FIG. 4 . Referring to FIG. 6 , if a registration request for a broadcast service that a mobile station desires to receive is received in step S 200 , a base station determines in step, S 202 whether the broadcast service is already being provided. If the broadcast service is currently in operation, the base station proceeds to step S 210 where it continues to transmit broadcast data for the broadcast service. However, if the broadcast service is not being provided, the base station sends a broadcast service request to a packet data serving node in step S 204 . If it is determined in step S 206 that the broadcast service was authorized, the base station assigns a wireless broadcast supplemental channel and a network resource for the broadcast service in step S 208 , and then transmits broadcast data for the broadcast service over the assigned broadcast supplemental channel in step S 210 .
FIG. 7 is a flowchart illustrating an operation performed by a packet data serving node to initiate a broadcast service as shown in FIG. 4 . Referring to FIG. 7 , if information on broadcast services available for a mobile station is received from a broadcast server in step S 300 , and BCMCS_ID and a multicast IP address for a broadcast service desired by the mobile station is received in step S 302 , a packet data serving node determines in step S 304 whether the multicast IP address is identical to a multicast IP address for the broadcast services available for the mobile station. Here, the multicast IP address for the broadcast services available for the mobile station is included in the information received from the broadcast server.
If the multicast IP addresses are not identical to each other, the packet data serving node inquires, in step S 316 , of an authentication server about whether the multicast IP address for the desired broadcast service is available. If it is determined in step S 318 that the multicast IP address for the desired broadcast service is not available, the packet data serving node ends the operation, and otherwise, proceeds to step S 308 .
If the multicast IP addresses are identical to each other in step S 304 , the packet data serving node determines in step S 306 whether the desired broadcast service corresponding to the multicast IP address is currently being provided. If the desired broadcast service corresponding to the multicast IP address is currently not in operation, the packet data serving node registers in step S 308 the multicast IP address for the desired broadcast service in a multicast IP routing table. However, if the desired broadcast service corresponding to the multicast IP address is currently in operation, the packet data serving node proceeds to step S 310 . In step S 310 , the packet data serving node starts receiving broadcast data for the registered broadcast service from the broadcast server.
If a registration request for the broadcast service corresponding to the multicast IP address registered in the multicast IP routing table is received from a base station in step S 312 , the packet data serving node delivers the corresponding broadcast data received from the broadcast server to the base station in step S 314 .
FIG. 8 is a message flow diagram illustrating a procedure for returning resources by a mobile station after leaving (or terminating) a broadcast service according to an embodiment of the present invention. Referring to FIG. 8 , in step 200 , a plurality of mobile stations (MSs) registered as a broadcast service receiving group receives broadcast data for a broadcast service from a broadcast server (or a contents server (CS)). In step 202 , one of the mobile stations sends a broadcast service leave request to a packet data serving node (PDSN) through a leave procedure based on IGMP. In step 204 , the mobile station sends a BCMCS de-registration message to a base station (BS). The base station determines whether each of the mobile stations registered as the broadcast service receiving group has left its broadcast service, depending on whether the BCMCS deregistration message was received or whether a broadcast timer has expired.
If the mobile station that transmitted the BCMCS de-registration message is the last mobile station that was using a corresponding broadcast supplemental channel in its service area, the base station stops in step 206 the use of resources (i.e., broadcast supplemental channel and network resource), and then transmits in step 208 a release message (A 9 -Release-A 8 ) to a packet control function unit (PCF) in order to return the resources. In this case, the packet control function unit does not send a response for the release message. This is because when a plurality of base stations are connected to one packet control function unit, there may exist other base stations, which are providing a corresponding broadcast service.
If all of the base stations connected to the packet control function unit determine that all mobile stations that were receiving the broadcast supplemental channel have left the broadcast service, the packet control function unit transmits in step 210 a release complete message (Complete A 9 -Release-A 8 ) to all the base stations connected thereto. Then, the packet control function unit and the packet data serving node release all network resources related to the broadcast service.
FIG. 9 is a flowchart illustrating an operation of leaving a broadcast service by a base station as illustrated in FIG. 8 . Referring to FIG. 9 , in step S 400 , broadcast data for a broadcast service desired by a mobile station is transmitted from a base station to the mobile station. If a broadcast service leave request is received in step S 402 , or a broadcast service of a particular mobile station is left as a broadcast timer expires, the base station determines in step S 404 whether the particular mobile station is the last mobile station that uses the corresponding broadcast supplemental channel. If the particular mobile station is the last mobile station, the base station releases the broadcast channel and withdraws the network resource in step S 406 . Otherwise, if the particular mobile station is not the last mobile station, the base station maintains the broadcast supplemental channel.
FIG. 10 is a message flow diagram illustrating a procedure for performing accounting on a broadcast service of a mobile station according to an embodiment of the present invention. Referring to FIG. 10 , in step 300 , a mobile station (MS) desiring to receive a broadcast service connects a call based on Service Option 33 (hereinafter referred to as “SO33”) through a dedicated channel assigned between the mobile station and a base station (BS), establishes PPP connection with a packet data serving node (PDSN), and then receives information for the broadcast service from a broadcast server (or a contents server (CS)) through the PPP connection. Thereafter, if the broadcast service is registered, the dedicated channel is released and the SO33-based call transitions to a dormant state, in step 302 .
In the dormant state, a broadcaster service parameter message (BSPM) is transmitted from the base station to the mobile station through an overhead message. The overhead message includes a physical channel parameter, a logical parameter and mapping information for a broadcast service.
In step 304 , the mobile station registers the desired broadcast service in the base station through an access channel. In step 306 , the base station transmits a call setup message (A 9 -Setup-A 8 ) to a packet control function unit (PCF) in response to a broadcast service registration request from the mobile station. In this case, the call setup message includes information on a time when the mobile station registered the broadcast service, i.e., information on a service start time.
In step 308 , the packet control function unit receives the call setup message, searches a packet data serving node that can provide the desired broadcast service, based on IMSI (International Mobile System Identifier) of the mobile station, and then transmits a registration message (All Registration) with service start time information to the packet data serving node. The packet data serving node then assigns system and network resources for the broadcast service in response to the registration message, and generates accounting information based on the IMSI and the service start time information.
If the mobile station transmits a de-registration message to the base station in step 310 or the broadcast service of the mobile station is left as a broadcast timer expires, the base station transmits in step 312 a release message (A 9 -Release-A 8 ) including IMSI of the mobile station and service leave time information (i.e., information on a time when the mobile station deregistered the broadcast service) to the packet control function unit. In step 314 , the packet control function unit searches corresponding connection information of the mobile station according to the IMSI in response to the release message, and transmits a registration message (A 11 Registration) with service leave time information to the packet data serving node according to the searched connection information. In this case, the connection information means connection information based on an interface set during S 033 setup in step 300 , rather than an interface set for broadcasting.
FIG. 11 is a flowchart illustrating an operation of performing accounting on a broadcast service by a base station and a packet data serving node as shown in FIG. 10 . Referring to FIG. 11 , if a base station receives in step S 500 a broadcast service registration request from a mobile station, the base station generates in step S 502 broadcast service registration time information (i.e., service start time information) and transmits the generated broadcast service registration time information to a packet data serving node. In step S 504 , the packet data serving node starts generating accounting information, using the broadcast service registration time information. In step S 506 , the broadcast service is performed. If the broadcast service is left in step S 508 , the base station generates information on a time when the broadcast service is left in step S 510 , and transmits the generated broadcast service leave time information to the packet data serving node. In step S 512 , the packet data serving node generates accounting information related to the broadcast service, using the broadcast service registration time information and the broadcast service leave time information.
FIG. 12 is a message flow diagram illustrating a procedure for assigning broadcast service resources using a registration message according to another embodiment of the present invention. In FIG. 12 compared with FIG. 4 , a mobile station registers a broadcast service using a registration message instead of using an IGMP message.
Referring to FIG. 12 , in step 400 , a mobile station (MS) sends a user authentication request to an authentication server (AAA) through PPP connection in order to request a broadcast service. If the user authentication is completed, the authentication server delivers in step 402 to a corresponding packet data serving node (PDSN) information on broadcast services that the user can receive, the information being stored in a database of the authentication server.
The delivered information includes broadcast multicast service identifiers (BCMCS_IDs) for identifying broadcast services, multicast IP addresses and source IP addresses for identifying sources that provide a broadcast service, or includes a table identifier by which the above parameters can be searched from a database of the packet data serving node (PDSN).
In step 404 , the mobile station sets up a call based on Service Option 33 (SO33) designating a packet data service through a dedicated channel, and receives session information related to broadcast services from a broadcast server (or a contents server (CS)), using HTTP or SDP. In step 406 , the mobile station transmits a registration message with BCMCS_ID and multicast IP address corresponding to a desired broadcast service, to a base station (BS) over an access channel.
In step 408 , the base station sends a packet control function unit (PCF) a call setup message (A 9 -Setup-A 8 ) carrying the BCMCS_ID and the multicast IP address. In step 410 , the packet control function unit sends the packet data serving node a registration request message (A 11 -Registration Request) carrying the BCMCS_ID and the multicast IP address in response to the call setup message. The packet data serving node then analyzes the requested multicast IP address in response to the registration request message.
In the case where the packet data serving node is already servicing the corresponding broadcasting contents while the multicast IP address requested by the mobile station is identical to the multicast IP address authorized in step 402 by the authentication server, the packet data serving node does not require new management such as system and network resource assignment for providing a broadcast service. On the other hand, in the case where the requested multicast IP address is identical to the authorized multicast IP address but the packet data serving node is not performing the service, the packet data serving node registers the requested multicast IP address in a multicast IP routing table.
If the requested multicast IP address is not identical to the authorized multicast IP address, the packet data serving node inquires of the authentication server about whether the requested multicast IP address is available, through an optional service authentication procedure, in step 412 . If it is determined that the requested multicast IP address is available, the packet data serving node registers the requested multicast IP address in the multicast IP routing table, and builds a multicast IP spanning tree by communication a routing message indicating the particulars registered in the routing table with neighboring routers.
After the requested multicast IP address is analyzed, the broadcast server starts transmitting broadcast data for the corresponding broadcast service to the packet data serving node, in step 414 . Subsequently, in step 416 , the packet data serving node transmits to the packet control function unit a registration response message (A 11 -Registration Reply) indicating that a broadcast service corresponding to the BCMCS_ID and the multicast IP address was authorized, in response to the registration request message. In step 418 , the packet control function, unit determines from the registration response message that the broadcast service was authorized, and then delivers a connection message (A 9 -Connect-A 8 ) for notifying this situation, to the base station. In step 420 , the mobile station receives the broadcast data by tuning to the forward broadcast supplemental channel corresponding to the BCMCS_ID.
The disclosed embodiments of the present invention control transmission of a broadcast service data stream according to base station areas through registration of a broadcast service of a mobile station, thereby minimizing a waste of wired/wireless resources. Therefore, embodiments of the present invention can efficiently use base station resources by controlling broadcast service times of base stations, and efficiently use resources of the base stations and a network when a plurality of mobile stations simultaneously request broadcast services.
While the invention has been shown and described herein with reference to a certain preferred embodiment 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. | Disclosed is a method for providing a broadcast service in a mobile communication system using code division multiple access (CDMA) technology. The novel method controls transmission of broadcast service data according to base station areas by registering a mobile station with a broadcast service. For that purpose, the mobile station requests an authentication server to authenticate a desired broadcast service, and registers the authenticated broadcast service in a packet data serving node via a base station so that the base station and the packet data serving node can set up a transmission path for the broadcast service. The method increases the efficiency of base station resources by controlling transmission times of base stations, and the packet data serving node can perform accounting on the broadcast service of the mobile station. Further, a plurality of registered mobile stations constitute a group, and broadcast service data is transmitted from one mobile station to other mobile stations within the group. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates generally to measurement of surface deflection of vertical surfaces and, more specifically, to measurement of deflection of a window or door frame.
BACKGROUND OF THE INVENTION
[0002] In many fields, it is often necessary to measure the amount that a vertical surface or frame has been bent or deflected. Such a situation arises in disaster recovery in response to wind damage or other accidents or natural disasters. Measurement of damage is necessitated by retrofit procedures which may be required as well as insurance recovery and insurance adjustment.
[0003] One of the major problems in measuring the deflection over longs spans, such as in large window frames, is the lack of convenient, portable tools to measure the deflection. A typical tool available is a masons bubble level as well known in the art. A bubble level determines whether a surface is level and plumb (truly vertical or horizontal), but does not quantify the deflection of the surface.
[0004] U.S. Pat. No. 5,388,338 to Majors discloses an expandable screed level. The level has an open rectangular cross section and uses liquid bubble levels to determine slope. The device is expandable by adding additional sections at either end. The additional sections attach by means of a smaller rectangular cross section that fits inside the main body. The additional sections are retained in position by use of a latching mechanism. However, Majors makes no provision for measuring the displacement of a warp in a frame.
[0005] U.S. Pat. No. 5,433,011 to Scarborough et al discloses an expandable level. The level is expandable as a straight level, a square, a T-square and other shapes. Additional sections are added to the main body through a tongue and groove arrangement. A pressure screw is tightened to lock the pieces together. The device measures slope through use of liquid bubble levels. Each expansion piece contains at least one level. However, no provision for measuring deflection of a frame is provided.
[0006] U.S. Pat. No. 4,939,848 to Armstrong discloses an improved alignment gauge to check misalignment of the body of a vehicle. The device determines the distance between various physical points on the vehicle in order to aid in proper alignment. The device consists of a needle indicator attached at one end of a beam. The beam supports a horizontal and vertical liquid bubble level. The invention produces a precise result, but does not address the problems of ease of transport and use. It does not measure deflection along a long linear surface, but rather at specific points.
[0007] U.S. Pat. No. 7,497,022 to Aarhus discusses an extendable level. Telescopic extensions are contained within a main body of the level extension. Each terminates in an end piece. The extensions are supported by cross members. Each cross member and the main body includes a liquid bubble level. The invention facilitates viewing but does not measure depth or deflection.
[0008] US 2003/0033722 to Lanham discloses a telescopic leveling instrument having a body and telescopic extensions. The telescopic extensions are oriented horizontally or vertically. The extensions are marked to allow distance measurement. The main body includes a bubble level. The device measures distance but does not measure depth or deflection perpendicular to the surface.
[0009] U.S. Pat. No. 5,303,480 to Chek discloses a device to measure the amount of deviation of a patient's facial symmetry from a “standardized norm.” The device consists of a rod shaped base and a portable probe that is movable horizontally. The base is placed against a patient's sternum and maintained at horizontal by monitoring a liquid bubble level. The probe is then set against various facial features and the horizontal and radial distance from the sternum to the probe is measured. However, the device does not provide a means to measure depth between two points on a particular surface or over long distances. Further, the device is incapable of measuring multiple points of deflection at the same time.
[0010] U.S. Pat. No. 4,691,443 to Hamilton et al discloses a vehicle alignment system. The system includes fittings connected to beams that allow access to a vehicle, while maintaining the measurement surfaces in horizontal or vertical orientation. Lasers are used to project X, Y and Z coordinates. The device is not portable. The device also does not provide a means to measure deflection of a freestanding vertical beam.
[0011] U.S. Pat. No. 5,388,338 to Majors describes an extendable screed level. The level includes extensions that mount to a main body. The extensions enter a channel in the main body and are locked into position with releasable catches. The extensions produce an increase in length that allows the level to span retaining walls of various widths, forming a barrier to hold wet cement. The level of Majors includes a bubble level to ensure the surface of the wet cement is horizontal. However, Majors does not provide for determining a measurement of deflection of vertical surfaces.
[0012] Additionally, prior art does not address the problem in measuring deflection in a vertical beam by a single individual. Often the window frames are quite large, requiring spanning eight or more feet in order to determine the deflection. It is difficult and unwieldy for a single individual to hold prior art levels against such a window frame and measure the deflection accurately or consistently.
[0013] Therefore, a need exists for an economical device for measuring deflection of large surfaces, including window frames, which can be operated single-handedly. A need also exists for a deflection measurement device which is portable and may be used in the field. Still further, a need exists for a simple uncomplicated device to measure deflection of a vertical beam at or around its center point. A further need exists for a device which is expandable to fit both large and small spans, without the need for additional tooling or calibration. A still further need exists for a device to measure many points of deflection over a surface simultaneously between a pair of reference points.
SUMMARY OF THE INVENTION
[0014] The preferred embodiment includes a device and method for determining the deflection of a long freestanding vertical beam. A common use would be measuring the deflection of frames of large windows or doors.
[0015] One embodiment includes of an elongate frame having an adjustable reference assembly located at each end. A gauge is located centrally in the elongate frame and positioned to measure a deflection from two calibrated reference assemblies. A centrally located handle is provided for ease of use, allowing a single individual to hold the device and manipulate the measurement gauge.
[0016] Expansion sleeves are provided which can be attached precisely and rigidly to each end of the frame in order to expand the span of the device. The reference assemblies are then removed and placed at the end of the additional lengths. The reference assemblies are designed and constructed so that re-calibration is not required. Alternatively, the additional lengths incorporate additional pre-calibrated reference assemblies.
[0017] In another embodiment, the deflection at several locations along a given frame may be measured by repositioning the support frame, or, in another preferred embodiment, by several gauges simultaneously.
[0018] In use, the device is first calibrated. Then, the reference assemblies are positioned against a span of window frame or other surface by manipulation of the elongate frame. The gauge in the elongate frame provides a reading of deflection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0020] FIG. 1 is a side view of a preferred embodiment.
[0021] FIG. 2 is a cross sectional side view of a preferred embodiment.
[0022] FIG. 3 a is a side view of a preferred embodiment that includes expansion sleeves.
[0023] FIG. 3 b is a side view of several expansion sleeves of different lengths.
[0024] FIG. 3 c is an assembly view of the elongate frame and an expansion sleeve.
[0025] FIG. 3 d is a partial cross-sectional view of the elongate frame and an expansion sleeve.
[0026] FIG. 3 e is a partial cross-sectional view of the adjustable reference assembly.
[0027] FIG. 3 f is a top view of a mounting block.
[0028] FIG. 4 is a detailed view of a latch mechanism.
[0029] FIG. 5 is a side view of an alternative embodiment.
[0030] FIGS. 6 a and 6 b show a side view of a preferred embodiment resting against a surface, shown in two deflection states.
DETAILED DESCRIPTION
[0031] The present invention now will be described more fully with reference to the accompanying drawings in which various embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0032] Referring to FIGS. 1 and 2 , the preferred embodiment includes elongate frame 1 . Elongate frame 1 is a rectangular tube having a base length of approximately three feet. Bottom surface 1 a of elongate frame 1 in the preferred embodiment is machined flat. The flat surface forms a first datum surface. End caps 30 and 31 are solid aluminum billets that are sized to fit precisely into the ends of the rectangular channel of elongate frame 1 . In the preferred embodiment, the end caps are epoxied in place and machined flat and perpendicular to bottom surface 1 a . Perpendicularity is important. In the preferred embodiment the end caps are generally perpendicular to bottom surface 1 a . End caps 30 and 31 each contain holes 31 a and 31 b , sized so that threaded bolts 17 and 18 may extend into the end caps without interference (shown in detail in FIG. 3 e ). End caps further include guide holes 125 and 130 . Recesses 47 a and 48 a are located at each end of elongate frame 1 . Catch support 225 a resides in recess 47 a . Catch support 226 a resides in recess 48 a . Each catch support is secured to the elongate frame by way of retaining screws 235 and 240 . Each catch support includes a catch 230 (shown in detail in FIG. 4 ).
[0033] By way of example, FIG. 5 shows the construction of catch support 226 a and catch 230 as well as the location of the retaining screws 235 . Catch support 226 a and catch 230 are formed from stamped steel plate in the preferred embodiment.
[0034] Returning to FIGS. 1 and 2 , a number of weight reduction holes 4 pass through elongate frame 1 . Center cavity 6 is supplied for mounting of gauge 2 . Elongate frame 1 also includes a set of threaded holes for receiving mounting screws for a set of reference assemblies 15 and 16 . The threaded holes are shown by way of example in FIG. 3 e as 120 and 121 .
[0035] Elongate frame 1 may be made from an extrusion, milled from stock or cast. An aluminum magnesium alloy is preferred for cost and weight considerations. However, elongate frame 1 may be constructed of other rigid materials capable of maintaining a very low central beam deflection for moderate to light loads, on the order of 25 pounds. Lighter weight materials are preferred. For extremely high precision applications, stainless steel or titanium may be employed, resulting in extremely low deflections over large spans. Cross sectional shapes can vary. In one preferred embodiment an “I” beam extrusion is employed having the highest rigidity to weight ratio available. Rectangular and box extrusions are also preferred as having high rigidity.
[0036] Handle 8 extends from the center of elongate frame 1 . The handle is centrally positioned between the reference assemblies to provide equal pressure to the reference assemblies when in use and to facilitate ease of positioning by a single user. Handle 8 is attached to the elongate frame 1 using screws 8 a and 8 b passing through the inside of elongate frame 1 or by welding. Other methods of removable or permanent attachment may be employed as known in the art. A removable handle is preferred to aid in compact storage for shipment.
[0037] Elongate frame 1 includes two reference assemblies 15 and 16 . Reference assemblies 15 and 16 include mounting blocks 3 and 5 . The top surface of each mounting block (shown by example as 50 of FIG. 3 f is machined flat to match the bottom surface 1 a of the elongate frame. The flat surfaces form second and third datum surfaces from which the device is calibrated. The mounting blocks are removably attached to elongate frame 1 as shown with reference to FIGS. 1 , 2 , and 3 e . The mounting blocks include holes 107 and 108 . Bolts 52 and 54 pass through holes 107 and 108 in mounting blocks 3 and 5 and thread into holes 120 and 121 in end cap 31 . Each mounting block includes a threaded hole shown as 17 a for receiving a threaded contact support, shown as 18 . The threaded contact support 18 is retained in threaded hole 17 a by locking nut 14 . The threads are standard ASTM pitch. In high precision embodiments, threads with lesser pitch may be employed.
[0038] Each reference assembly further includes contact pad, shown by example as 9 . In the preferred embodiment, each contact pad includes a flexible neoprene gasket. In other embodiments requiring greater accuracy, each contact pad may be comprised of a suitable rigid material such as nylon, delrin, aluminum or polished stainless steel. In applications where static discharge or contact with high voltage is a concern, the contact assemblies can be formed of bakelite or asbestos.
[0039] Returning to FIGS. 1 and 2 , Gauge 2 is operatively positioned in mounting hole 6 . Gauge 2 includes deflection probe 12 , retention knob 10 a and data read out 10 b . Probe 12 extends radially from the bottom of gauge 2 through access hole 12 a in elongate frame 1 . Hole 12 a is sized to avoid interference with the radial movement of probe 12 . Similarly, retention knob 10 a extends radially through access hole 12 b in the top of elongate frame 1 . Access hole 12 b is sized to allow free motion of the retention knob. Probe 12 is spring loaded to facilitate ease of use. Retention knob 10 a follows the movement of probe 12 . Retention knob 10 a secures probe 12 to gauge 2 preventing over-extension or loss of probe 12 due to the spring.
[0040] Gauge 2 in the preferred embodiment is a 543 - 683 B electronic digital indicator manufactured by Mitutoyo of Tokyo, Japan. Another viable option is a depth gauge manufactured under part number CEN44345 and offered for sale by Central Tools/Central Lighting. In another preferred embodiment, the gauge can include an electronic memory including time and date indexing so that the time and date of measurements taken can be recorded. Furthermore, gauge 2 may include a memory for alphanumeric tagging of each measurement so that notes may be made as to the location of the window frame being measured. In this embodiment, electronic downloading of this data is provided to a laptop computer for later use. An RFID tag may be applied to the physical window frame corresponding to the deflection tagging for later positive location and correlation with the deflection measurement.
[0041] Additionally, gauge 2 may be an optical or acoustic distance measuring device. An example of an optical measuring device is Leica Disto's model 740690, which measures distance via a laser. An example of an acoustic measuring device is the Intellimeasure model 77-018 from Stanley Tools, which measures distance via ultrasonic waves. Other such measuring devices are known in the art and may include wireless data capture via a computer. Gauge 2 may also include a button to zero the readout at a given height during calibration.
[0042] FIGS. 3 a - 3 d and 4 show features extensions 100 , 105 and 110 . In the preferred embodiment, the extensions are different lengths of 3 inches, 6 inches and 12 inches, respectively. Other lengths of extensions may be utilized. The extensions are attached to the elongate frame singularly or in groups, thereby variably extending the length spanned by the device. Extensions 100 , 105 and 110 are constructed of hollow rectangular channel having solid ends 101 a and 101 b , 106 a and 106 b , and 111 a and 111 b . The solid ends are epoxied into each end of each extension, respectively. Bottom surfaces 1009 , 1089 and 1109 are each machined flat to match bottom surface 1 a of elongate frame 1 . The bottom surfaces form datum surface for calibration. Each solid end is also machined to be perpendicular with the bottom surfaces.
[0043] Each extension includes a set of guide pins 115 and 120 and a set of guide holes 116 and 121 . Guide holes 116 and 121 are sized to provide a close fit with guide pins 115 and 120 . Guide pins 115 and 120 are different diameters and different lengths so that the extensions may be assembled with the elongate frame in the proper orientation.
[0044] In an alternate embodiment, each extension includes a pre-calibrated reference assembly as previously described in relation to elongate frame 1 .
[0045] As shown in reference to FIGS. 3 d and 4 , toggle support 205 resides in recess 47 a located on each extension. Toggle support 205 is secured in recess 47 a with bolts 235 a and 240 a . Toggle arm 245 is pivotally supported by toggle support 205 through hinge pin 215 . Toggle arm 245 includes toggle pin 220 which pivotally supports latch 210 .
[0046] In situations where a vertical surface has been deflected in more than one plane and/or in more than one location, additional deflection measurements must be taken. FIG. 5 shows an alternate embodiment which accomplishes this goal. In this embodiment, gauges 51 , 53 , 55 , 57 , and 59 reside in holes 91 , 93 , 95 , 97 , and 99 , respectively. Each gauge includes a retention knob 61 , 63 , 65 , 67 , and 69 , respectively, and a probe 71 , 73 , 75 , 77 , and 79 , respectively. In use, once contact pads 7 and 9 have been positioned, readings from each of the gauges may be taken and recorded simultaneously.
[0047] The span of the invention may be increased by adding extensions 40 , 41 at each end of elongate frame 1 . In this case, the guide pins are engaged with corresponding guide holes until one or more extensions meets elongate frame 1 . In order to removably engage an extension with the elongate frame, toggle arm 245 is advanced allowing latch 210 to engage catch 230 . Toggle arm 200 is then rotated forcing latch 210 under catch support 225 , thereby releasably securing the extension to the elongate frame. The mounting blocks, along with the contact assemblies 15 and 16 are removed from elongate frame 1 and attached to extension 40 by use of threaded bolts 52 and 54 . Movement of contact supports 17 and 18 with respect to mounting blocks 3 and 5 is not required and their calibrated height is retained by locking nut 14 . Thus relocation of contact assemblies 15 and 16 onto the extension without recalibration of gauge 2 is accomplished. Other extensions are added in a similar manner.
[0048] Before use, the device must be calibrated. To calibrate the device, contact pads 7 and 9 are positioned on a flat calibration surface. A gauge block of known height, typically half of the probe's travel distance, is placed on the flat calibration surface and under the machined bottom surface 1 a of elongate frame 1 . Contact supports 17 and 18 are adjusted until elongate frame 1 comes to rest on the gauge block. Probe 12 of gauge 2 is spring loaded and provides a measurement of deflection when contact pads 7 and 9 come to rest against the surface. Gauge 2 is adjusted so that the gauge provides a neutral reading of the calibration surface. If additional contact assemblies are included on the extensions, they are attached to elongate frame 1 and calibrated in a similar fashion.
[0049] Alternatively, the gauge blocks may be replaced by a measurement device. A measurement device, such as a machinist square or a set of calipers is used to determine the distance between contact pads 7 , 9 and machined bottom surface 1 a . Pads 7 and 9 are then placed against a flat calibration surface and gauge 2 is zeroed against the surface. Alternatively a measuring device may be used to set probe 12 at the same distance as pads 7 and 9 . Probe 12 is then zeroed.
[0050] FIGS. 6 a and 6 b show an embodiment of the invention in use. The device is positioned on a vertical, free standing surface, such as frame 26 . Contact pads 7 and 9 are located at the extremities of the vertical surface and positioned by manipulating the elongate frame by the handle. Spring loaded probe 12 meets frame 26 prior to either contact pad 7 or 9 . As contact pads 7 and 9 move toward the surface, gauge 2 makes a measurement. Generally, the device will be located so that probe 12 meets frame 20 in the center, as this is often the area of greatest deflection. However, the device may be used to measure multiple locations along frame 26 .
[0051] Where gauge 2 has been properly calibrated, a positive displacement reading will show a deflection of frame 20 inward 22 (away from the device), a negative reading will show a deflection outward 24 (toward the device) and a reading of zero will show no deflection. Where an RFID tag 20 a is to be employed, it is affixed to frame 20 and its serial number is recorded and correlated with the deflection reading.
[0052] While preferred embodiments of this device are described as having a manually adjustable gauge, other gauges and measurement devices may be utilized. Further, seals for moving parts are not required for all uses and types of gauges. Finally, zeroing of the gauge and extensions may be accomplished utilizing many methods without departing from the intent and scope of the invention.
[0053] In the drawings and specification, there have been disclosed embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. | A portable device for measuring deflection of a surface, comprising an elongate frame having a first end and a second end and a first datum surface, a first removable reference assembly adjacent the first end, a second removable reference adjacent the second end, a deflection gauge attached to the elongate frame between the first removable reference assembly and the second removable reference assembly, and wherein the deflection gauge engages and measures a deflection of the surface relative to the first removable reference assembly and the second removable reference assembly. | 6 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.