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[0001] The present application for patent claims priority to Provisional Application No. 60/791,490 entitled “Unifile Healthcare Management System” filed Apr. 12, 2006, and assigned to the assignee hereof and hereby expressly incorporated by reference herein.
BACKGROUND
[0002] 1. Field
[0003] The presently disclosed embodiments relate generally to patient and healthcare information identification, storage, and retrieval, and more specifically to apparatus and methods for secured patient identification, and information storage and access.
[0004] 2. Background
[0005] The quality of care offered to patients (subjects) by healthcare providers is largely dependent on the quality and completeness of patient information available at the time. Because patient medical information often is fragmented across multiple organizations and held in a variety of formats (paper-based and electronic), inefficiencies arise that may adversely affect the care provision process. For example, basic patient information (such as blood type and drug prescriptions) is often collected multiple times by different practitioners. Furthermore, due to the lack of electronic sharing of information, requesting patient information by one party (e.g., HMO) from another (e.g., physician) is typically lengthy, labor-intensive, and costly. The impact of these inefficiencies is particularly significant in emergency situations (e.g., an unconscious car accident victim).
[0006] Methods have been proposed to facilitate the sharing of patient information in electronic format. These methods typically involve the storing of patient information in a centralized database and/or using a device, such as a smart card issued to patients, to store personal details and important medical facts (such as blood type, immunization history, and drug prescriptions).
[0007] There are many practical drawbacks to these approaches. Lack of an open design for a centralized database imposes significant constraints on access. Use of a software application designed specifically to interact with the central database is typically how the information is accessed. This results in lower take-up by the health industry which, in turn, diminishes the value of the central database. This proprietary design approach also creates considerable fragmentation in the healthcare industry. Often, even hospitals across the street from each other use different medical databases and software applications for accessing these databases so that and data transfer between various hospitals is costly and time consuming.
[0008] Another drawback is the use of security devices (such as smart cards) which are easily lost or may be unavailable when needed. This hampers access to vital medical information, especially in emergency situations. Further, the information on these devices can be compromised such as if they were lost or stolen.
[0009] There is therefore a need in the art for techniques and architecture to securely access patient information with high availability and minimal information fragmentation or inconsistencies.
SUMMARY
[0010] Techniques for securely storing and accessing patient information, and for patient identification are described herein.
[0011] In accordance with one aspect a method of providing secure access to stored medical information regarding at least one subject, comprises: accepting unique biometric information from a subject; accepting a command from a user for accessing at least a portion of a medical record associated with the subject, the subject's medical record identified using the subject's biometric information; accessing at least the portion of the medical record securely; and executing the user's command on at least the portion of the medical record.
[0012] In accordance with another aspect a method of securely storing subject information, comprising: using one or more databases to securely store subject biometric information, subject information, and user authentication information; accepting unique biometric information from a subject; accepting a command from a user for accessing at least a portion of a record associated with the subject, the record stored in the subject information database, the subject's medical record identified using the subject's biometric information stored on the subject biometric information database; accessing at least the portion of the medical record securely using the user authentication information; and executing the user's command on at least the portion of the medical record.
[0013] In accordance with yet another aspect a system configured to provide secure access to medical information regarding at least one subject, comprises: a first input configured to accept unique biometric information from a subject; a second input configured to accept a command from a user for accessing at least a portion of a medical record associated with the subject, the subject's medical record identified using the subject's biometric information; and an access device configured so as to access at least the portion of the medical record securely in response to the execution of a user's command.
[0014] In accordance with still another aspect a system configured to secure access to medical information regarding at least one subject, comprises: at least one database configured to store subject biometric information, subject information, and user authentication information; a first input configured to accept unique biometric information from a subject; a second input configured to accept a command from a user for accessing at least a portion of a record associated with the subject, the record stored in the subject information database, the subject's medical record identified using the subject's biometric information stored on the subject biometric information database; and an access device configured to allow secure access to at least the portion of the medical record using the user authentication information in response to the execution of the user's command on at least the portion of the medical record.
[0015] Various aspects and embodiments of the invention are described in further detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a block diagram of an exemplary embodiment of a healthcare management system;
[0017] FIG. 2 is a block diagram of an exemplary embodiment of a software architecture of an information server of the healthcare management system;
[0018] FIG. 3 is a block diagram of an exemplary embodiment of a information client of the healthcare management system;
[0019] FIG. 4 is a frontal view of an exemplary embodiment of an information client device;
[0020] FIG. 5 is a rear view of the embodiment shown in FIG. 4 ;
[0021] FIG. 6 is a perspective view of an exemplary embodiment of a cradle for use with the embodiment of the information client device shown in FIGS. 4 and 5 ;
[0022] FIG. 7 is a perspective view of an exemplary embodiment of a client system;
[0023] FIG. 8 is a block diagram of an exemplary embodiment of components of the information client device;
[0024] FIG. 9 is a block diagram of an exemplary embodiment of components of the information client device;
[0025] FIG. 10 is a flow diagram illustrating a typical use of the healthcare management system; and
[0026] FIG. 11 is a flow diagram illustrating a second typical use of the healthcare management system.
DETAILED DESCRIPTION
[0027] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs.
[0028] The record access techniques described herein may be used for various applications such as retrieving and writing to patient records, medical history, drugs and medication history, drug allergies, and so on.
[0029] The transmission medium described herein may be a wireless or wired communication system or a combination of both. Communication and transmission systems include cellular systems, broadcast systems, wireless local area network (WLAN) systems, Wi-Fi systems, LAN, Internet, and so on, as well as a wide area network (WAN) system used to access a secured network.
[0030] Generally, interfaces with a transmission medium include hardware and software interfaces. Hardware interfaces described herein include wireless broadcast antennas, RJ-45 connectors, DB-9, hermaphroditic connectors, and so on. Software interfaces include TCP/IP, NetBEUI, XMODEM, IPX, MODEM7, token ring, and so on.
[0031] Block diagrams described herein may be implemented using any known methods of implementing computational logic. Examples of methods of implementing computational logic include use of field-programmable gate arrays (FPGA), application-specific integrated circuits (ASIC), complex programmable logic devices (CPLD), integrated optical circuits (IOC), microprocessors, and so on.
[0032] The generalization of this healthcare management architecture, also within the scope of this disclosure, can incorporate other stage orders and combinations. For example, some embodiments of the healthcare management architecture may incorporate additional layers of security and authentication protocols or techniques.
[0033] Referring to FIG. 1 , an exemplary embodiment of a healthcare management system is shown. In some embodiments of a healthcare management system 100 , such as the one illustrated in FIG. 1 , the healthcare management system's architecture is structured as a client-server model. Other embodiments also within the scope of this disclosure include other computer architectures and computer network architectures such as a peer-to-peer network, and so on.
[0034] Referring to the exemplary embodiment of the healthcare management system 100 shown in FIG. 1 , the system includes a client 110 (via a client interface 112 ) connected to a server 120 (via a server interface 122 ) over a transmission medium 130 such as the Internet. The server 120 acts as a central repository for maintaining patient medical information and oversees access to three separate databases 124 , 126 , 128 , a security database 124 , a biometrics database 126 , and a medical records database 128 . Through the server 120 , the client 110 may access to three underlying database 124 , 126 , 128 .
[0035] The security database 124 typically stores details of individuals (users) who can access the system 100 , including type, name, profession, user ID, password, contact details, access privileges, and so on. Healthcare professionals as well as patients are usually captured in this database. Patients are typically not allowed direct access to the system 100 and, therefore, are not provided with a password, although permission from the patients for accessing the individual patients records would likely be necessary under current HIPAA rules and regulations. Passwords in the security database 124 are usually stored in encrypted format.
[0036] The biometrics database 126 stores personal and unique biometric information for each patient, such as fingerprint images and pre-analyzed fingerprint data. Typically, personal information (such as name or address) of the patient is not stored in this database, unless it is considered necessary for the particular application. Instead, a unique numeric identifier is usually used to link records in the security database 124 to corresponding images in the biometrics database 126 .
[0037] The medical records database 128 stores medical information for each patient, such as medical history, hospital records, administered drugs, x-rays, MRI scans, and so on. Typically, personal patient information is not stored in this database either, unless it is considered necessary for the particular application. A unique numeric identifier is also usually used to link records in the security database 124 to corresponding records in the medical database 128 .
[0038] The use of a plurality of databases to store information is more desirable since such an architecture enhances security and availability. Should intruders or computer viruses gain access to one database, the data integrity and availability of the others remains intact.
[0039] The server 120 makes its services available through a Web Services Interface 122 . This interface 122 can be accessed by a variety of client devices 110 across the Internet 130 using a suitable protocol, as for example Simple Object Access Protocol (SOAP). SOAP is a technology for invoking methods of remote objects in Internet-based client-server applications. Client devices 110 use a client interface 112 to establish an asynchronous connection with the server 120 . Through this connection, client devices 110 may exchange information with the server 120 . This architecture decouples the design of client devices from the server 120 enabling third-party suppliers to create new client devices that will inter-operate with the server 120 . Examples of client devices 110 are described in later figures.
[0040] For security, data exchanged between a client 110 and the server 120 is typically transported via HTTPS and is usually subject to encryption, such as 128-bit encryption. In other embodiments, other transport protocols and/or encryption techniques are possible and are within the scope of this disclosure.
[0041] This approach of using patient biometrics (e.g. fingerprints) avoid the problems associated with smart cards, and allows medical care professionals to access patient data in the event of emergencies when the patient can not communicate.
[0042] Referring to FIG. 2 , an example of basic modules of a software architecture 200 of the server 120 are shown. A web services interface 220 provided by the server 120 comprises one or more of the following or similar services:
[0043] User administration 222 supports creation of new users and modification of existing users. It verifies that the connected user has the necessary administrative access privileges to perform these operations. A newly-created user is usually assigned a user ID and password for accessing the system. The password may be user chosen at the time of the account creation.
[0044] User authentication 224 supports a user login process. Users may login using a user ID and password (typically for computer based users) or scanned fingerprint or other biometric image (typically for data pad users, a device further described in subsequent figures).
[0045] Patient registration (subject registration) 226 supports registration of new patients and modification of existing patients. Personal patient information (including biometric information such as a fingerprint image) is captured and stored in the system 200 .
[0046] Patient authentication 228 supports authentication of a patient using a scanned fingerprint or other biometric information. Once a patient is authenticated using the biometric information, the current user (e.g. practitioner) is granted access to the patient's medical information.
[0047] Medical record management 230 supports storage and retrieval of patient records. If the patient has been authenticated and the current user has appropriate access privileges through his/her unique access information, using for example his/her biometric information, then the patient's medical records can be accessed and information can be added to it in a secure manner.
[0048] Data mining 232 supports searching of medical records in anonymous format (i.e., without patient personal information). This can, for example, be used to generate statistical clinical reports for research purposes.
[0049] Document management 234 supports storage and retrieval of document images (e.g., x-rays, MRI scans, scanned paper documents) as a part of the process of updating a patient's medical records.
[0050] An access manager module 240 controls retrievals and updates of the security database 124 . If access involves biometrics information, this is handled by a biometrics manager module 242 , which controls retrievals and updates of the biometrics database 126 . The biometrics manager 242 also performs recognition of the biometric information, such as a finger print image, during an authentication process. The techniques and algorithms for fingerprint recognition are known to those skilled.
[0051] A transaction manager module 244 handles updates for the medical records database 128 , and ensures the atomicity, consistency, isolation, and durability (ACID properties) of transactions, such that concurrent updates by multiple users are correctly handled. The query processor module 246 handles read-only access to the medical records database 128 .
[0052] An image storage module 248 and compressor module 250 handle adding of images to the medical records database 128 . Each image is usually indexed by a unique ID and compressed before being stored. Conversely, an image retrieval 252 and decompression 254 modules typically handle retrieval of an image (using its ID) and decompress the image before passing it on.
[0053] Referring to FIG. 3 , an illustrative range 300 of client devices 110 which can connect to and exchange information with the server 120 is shown. A data pad 310 is a specialized handheld device designed for use in medical facilities, such as hospital, clinics, and emergency rooms. This device 310 is compact and may be carried by a practitioner while attending to a patient's needs (see FIG. 4 ). In other embodiments, the data pad may be implemented as software incorporated into PDAs with fingerprint scanning capabilities as well as add-on attachments to PDAs.
[0054] An emergency medical system 312 is an example of a mobile client device, suitable for use in an ambulance, for example. The hardware platform in this case may be a laptop computer with wireless Internet access.
[0055] Remaining client devices 314 - 326 are all PC or laptop based, typically operated on a desk in office environment (see FIG. 7 ). The physician office system 314 enables doctors to register new patients and keep their medical records up-to-date in subsequent visits. One benefit here is instantaneous access to a patient's full medical records, regardless of geographic location and without having to request paper-based medical records from other organizations.
[0056] A hospital healthcare system 316 and patient system 318 are examples of existing administrative systems in hospitals and clinics, which can be extended to act as client devices 110 .
[0057] A HMO system 320 provides HMOs and health insurance companies electronic access to medical records, thus eliminating the costly and time-consuming process of having to obtain paper-based medical records from individual facilities.
[0058] A pharmacy system 322 streamlines drug prescription process. Pharmacy staff can access up-to-date prescription records for a patient, without having to call a physician to verify unreadable or suspect prescriptions. The system 322 can also help track those abusing, are known to abuse, or have a potential to abuse prescription drugs. For example, certain drugs have a higher incidence of abuse and the pharmacy system 322 can help monitor patients on those medications.
[0059] A medical research system 324 and law enforcement system 326 are examples of systems that can use data mining to look for information patterns in large population samples, without compromising patients' identifies and privacy.
[0060] Referring to FIGS. 4 and 5 , a front 400 and a back 500 view of a data pad (DP) 310 are respectively shown. FIG. 6 refers to a cradle housing system 600 for the device 310 . In this exemplary embodiment, the data pad 310 is used by physicians and is installed in medical facilities (such as hospitals and clinics) where patients are examined and cared for. In other embodiments, the data pad may be used by other users and/or in other settings. Continuing with this embodiment, the device 310 is wall-mounted using a cradle 610 (see FIG. 6 ). DP 310 is wireless and uses radio signals to communicate with its cradle 610 which, in turn, is Internet-enabled through a Local Area Network (LAN) connection. The wireless communication employs an antenna 450 which may or may not be concealed depending on the embodiment or implementation.
[0061] The DP 310 has a Liquid Crystal Display (LCD) screen 410 which is touch sensitive. The screen typically functions acts as both output and input devices. A touch pen 420 is provided so that the user can accurately point and click on tokens displayed on the LCD, thus invoking functions. Tokens are understood by those skilled to include icons, images, words, features, and so on. Additionally, the DP 310 has a fingerprint scanner 430 . During an authentication process, the screen 410 prompts the user to place their index finger on the scanner 430 . A short beep confirms the completion of the scanning. A barcode scanner 440 , positioned on the side of the device, allows users to quickly enter IDs (e.g., user ID, document ID) by scanning a barcode rather than entering it alphanumerically. In addition, or as an alternative, an input device, such as a keyboard can be provided for aiding in the entering and accessing of information. The user may enter information via the touch screen by clicking on tokens, employing graffiti, or employing handwritten character recognition.
[0062] A small camera 510 can be positioned at the back of the device and can be used to take photographs. This is useful during the patient registration process, where a facial photograph of the patient is required. It is also useful when the physician needs to record visual information (e.g., injuries suffered in an accident). In some embodiments, the camera may also be used for patient or user identification. For example, the camera may be used for iris recognition, facial recognition, and so on. Further, these various methods of patient/user recognition may be used in combination to better positively identify the individual.
[0063] The DP 310 has a serial number 530 to identify the specific unit. The serial number can be used to identify the specific unit making command requests as well as identify units in need of repair or user attention. The DP 310 has a power switch-power indicator 470 to indicate that it is on.
[0064] The DP 310 can be powered by a rechargeable battery 520 . While the device is not in use, it can be placed in its cradle 610 to recharge. One or more attachments (e.g. clamps 620 ) around a cradle 610 keep the device 310 securely in place and ensure that the contact points 460 on the device 310 and contact points 630 cradle 610 align correctly. When secured in its cradle 610 , the device 310 may communicate with the cradle 610 through the contact points 460 630 rather than radio signals via an antenna 640 .
[0065] In some embodiments, operation of the DP 310 can include one or more of the following or similar illustrative steps.
A physician removes the DP 310 from its cradle 610 . At this point, the device 310 is automatically switched on, and displays a logo and the organization at which it is installed. The user is prompted to login to the device 310 . The device 310 cannot be operated without authentication and may include an inactivity time out where the user is required to log in again. The user can either input a user ID and password (using the touch pen) or place a finger on the fingerprint scanner. A short beep is emitted upon successful authentication, and the device 310 displays the list of functions available to the user. The latter is dependent on the user's access privileges. To access a patient's medical records, the user chooses the patient authentication function and, for example, asks the patient to place their right index finger on the fingerprint scanner. Upon successful patient authentication, the screen displays the patient's records as a menu. The user can navigate through patient information by drilling down this menu. The user can also add to patient's records by entering new information. Once the physician has finished with the patient, s/he will choose the exit function, which will clear the patient menu from the screen. Accessing the records of this patient or another patient will require authentication (e.g. fingerprint). Additionally, the device will have a timeout function which, after a period of inactivity, will automatically require re-authentication. To register a new patient, the physician chooses the ‘register new patient’ function. The device then prompts the user to enter patient's personal details, scan the patient's fingerprint, and capture a photograph of the patient's face. The user can then review the entered information and choose the ‘submit’ function to complete the registration process. Alternatively, the information can be entered into a computer or other input device, and subsequently downloaded to the DP, as described below in connection with FIG. 7 . If the user leaves the DP idle for 5 minutes or places it back in its cradle, the device will auto-logout. Subsequent use will require user authentication.
[0072] Referring to FIG. 7 , a client system 700 (e.g., physician office system) deployed on conventional hardware is shown. The PC 710 is connected to the Internet 130 via a network interface 720 (or modem) and runs client software. It is also connected to a camera/fingerprint scanner 730 and a document scanner 740 . The user interface provided by this system 700 would be similar to the DP 310 , but because this setup includes a conventional keyboard, it is better suited to entering a lot of textual information, as well as adding scanned documents to a patient's records. The use of camera and fingerprint scanner 730 is similar to the DP 310 scenario and supports the registration and authentication processes.
[0073] Referring to FIG. 8 , an exemplary design 800 of the DP 310 is shown. The device 310 is driven by a microprocessor 810 connected to a bus 812 to communicate with various components. In some embodiments, the device 310 utilizes two types of memory: a flash memory 814 stores the client software deployed on the device 310 , and the random access memory 816 stores transient information when the device is in use. In other embodiments, different types of memories are used and it is within the scope of this disclosure. The software can be upgraded by storing a newer version in flash memory 814 , or replacing the flash memory chip. A display controller 818 manages the display of digital data on the LCD Touch Screen 410 , and passes input operations back to the software.
[0074] A fingerprint scanner 820 , barcode scanner 822 , and camera 824 are examples of input devices and can be implemented in various embodiments. Examples include the scanners in previously described figures. An RF transceiver 826 translates requests raised by the DP 310 into radio signals and sends them to the DP Cradle 610 . It also does the reverse by translating information returned by the cradle 610 as radio signals back into their original format.
[0075] A DP port 828 provides a physical interface between the DP 310 and its cradle 610 .
[0076] Referring to FIG. 9 , an exemplary design 900 of the DP cradle 610 is shown. The DP cradle 610 has a similar (but simpler) design to the DP 310 . The software deployed within the cradle manages translation of data exchanged between the cradle 610 and the DP 310 , to/from radio signals and SOAP requests. When the DP 310 is secured in its cradle 610 , radio signals are not used and the communication is direct over the contact points 630 (in other embodiments, the radio signals may still be used). In both cases, however, the cradle software implements the client interface 112 (see FIG. 1 ) to communicate with the server 120 . A network interface 910 provides the necessary Internet connectivity. A battery charger 912 manages the recharging of the DP battery 520 when it is secured in its cradle 610 .
[0077] The DP cradle 610 also includes various memories 920 922 , a microprocessor 924 , an RF transceiver 926 , a DP port 928 , and a bus 930 connected these various modules.
[0078] Referring to FIG. 10 , an exemplary embodiment of a patient registration process 1000 as exercised by a physician or other health care professional using a client device is shown. The patient is interviewed by the physician who then enters the patient personal details into the system (step 1010 ). Next the physician is prompted by the system to scan the patient's fingerprint and capture a facial photograph (steps 1020 and 1030 ). This information is then submitted to the server (step 1040 ). The latter validates the information by cross-checking it against the information it has already in store (step 1050 ). For example, if the patient is already registered in the database, the new registration will be rejected. Once validates, the server permanently stores the patient details for subsequent use.
[0079] Referring to FIG. 11 , a process 1100 for a subsequent visit by a registered patient is shown. The physician scans the patient fingerprint (step 1110 ). The server compares the fingerprint image against the registered patients and retrieves the records of the matching patient, if any (step 1120 ). The physician can view these records (step 1130 ) and, as a result of the consultation, add new information (step 1140 ).
[0080] Information added to the system (during registration or subsequent consultation) is immediately available to other users (although a delay can be incorporated in some embodiments). Because the system operates over the Internet, the information can be instantaneously accessed anywhere in the world.
[0081] This healthcare management system provides healthcare professional with a range of remote units (client devices) to access patient medical records maintained in a secure central system (server) over the Internet. The server provides a range of web services, through a well-defined interface, such that new client devices can be added by third-party providers. Security measures such as patient biometrics and data encryption are used to secure the whole system against unauthorized access.
[0082] The healthcare management system can also be used as an effective advertising tool, with paid advertising services offered to, for example, pharmaceutical companies. The advertising mode can be configured to kick in when the device has been idle for a pre-specified length of time and/or when user places the device in its cradle. Examples of two advertising formats that can be supported:
Full graphics and hyper-linked pages rendered in HTML, allowing the use to interact with the ads and drill down to the advertisers web site for more information. Ticker-tape information running at the bottom of the screen, providing up-to-the-minute accurate information about the latest medical and pharmaceutical alerts.
[0085] The healthcare management system described addresses these difficulties by promoting a central system that has an open design, thus making it feasible for third-party software and hardware developers to offer applications and devices that can access the central system, in a secure manner, and exchange information with it. Further, this approach of using patient biometrics (e.g. fingerprints) avoid the problems associated with smart cards, and allows medical care professionals to access patient data in the event of emergencies when the patient can not communicate.
[0086] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | Systems for and methods of providing secure access to and storing patient medical information are described. In accordance with one aspect a method is described as a method of providing secure access to stored medical information regarding at least one subject, comprising: accepting unique biometric information from a subject; accepting a command from a user for accessing at least a portion of a medical record associated with the subject, the subject's medical record identified using the subject's biometric information; accessing at least the portion of the medical record securely; and executing the user's command on at least the portion of the medical record. In accordance with another aspect a system a system is configured to provide secure access to medical information regarding at least one subject, comprising: a first input configured to accept unique biometric information from a subject; a second input configured to accept a command from a user for accessing at least a portion of a medical record associated with the subject, the subject's medical record identified using the subject's biometric information; and an access device configured so as to access at least the portion of the medical record securely in response to the execution of a user's command. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This Continuation application claims the benefit of U.S. Ser. No. 13/046,124 filed Mar. 11, 2011, which is a continuation application which claims the benefit of U.S. Ser. No. 12/417,067 filed Apr. 2, 2009, now abandoned, which is a Continuation application which claims the benefit of U.S. Ser. No. 11/452,782 filed Jun. 14, 2006, now U.S. Pat. No. 7,550,445, which is a Continuation application which claims the benefit of U.S. Ser. No. 10/642,366 filed Aug. 14, 2003, now U.S. Pat. No. 7,115,587, which claims the benefit of U.S. Provisional Application Ser. No. 60/404,713 filed Aug. 20, 2002, now expired.
FIELD OF THE INVENTION
[0002] The present invention relates to an aripiprazole inclusion complex with a substituted-β-cyclodextrin, an aripiprazole formulation which includes aripiprazole in the form of the above inclusion complex, an injectable formulation which contains the above complex of aripiprazole, a method for reducing irritation normally caused by aripiprazole at an intramuscular injection site employing the above injectable formulation and a method for treating schizophrenia employing the above formulation.
BACKGROUND OF THE INVENTION
[0003] U.S. Pat. No. 5,006,528 to Oshiro et al. discloses 7-[(4-phenylpiperazino)-butoxy]carbostyrils, which include aripiprazole, as dopaminergic neurotransmitter antagonists.
[0004] Aripiprazole which has the structure
[0000]
[0000] is an atypical antipsychotic agent useful in treating schizophrenia. It has poor aqueous solubility (<1 μg/mL at room temperature). When formulated as an intramuscular (IM) injectable solution, aripiprazole has been found to cause unacceptable (moderate to severe) tissue irritation at the muscular site with many water-miscible co-solvent systems, and water-immiscible solvent and co-solvent systems such as hexonoic acid:medium chain triglyceride (10:90), polyethylene glycol 400:ethanol:lactic acid (35:15:50), benzyl alcohol:sesame oil (10:90), benzyl alcohol:medium chain triglyceride (10:90), benzyl alcohol:tributyrin (5:95), and polysorbate 80 in 25 mM tartaric acid.
[0005] Cyclodextrins are known for their use in increasing solubility of drugs. They function by forming inclusion complexes with hydrophobic molecules. Unfortunately, there are many drugs for which cyclodextrin complexation either is not possible or produces no apparent advantages as disclosed by J. Szejtli, Cyclodextrins in Drug Formulations: Part II, Pharmaceutical Technology, 24-38, August, 1991.
[0006] U.S. Pat. Nos. 5,134,127 and 5,376,645 each to Stella et al. disclose sulfoalkyl ether cyclodextrin derivatives and their use as solubilizing agents for water-insoluble drugs for oral, intranasal or parenteral administration including intravenous and intramuscular. Stella et al. disclose an inclusion complex of the water-insoluble drug and the sulfoalkyl ether cyclodextrin derivative and pharmaceutical compositions containing same. Examples of sulfoalkyl ether cyclodextrin derivatives disclosed include mono-sulfobutyl ether of β-cyclodextrin and monosulfopropyl ether of β-cyclodextrin. Examples of water-insoluble drugs are set out in column 7 starting at line 25 and include, among others, benzodiazepines, chlorpromazine, diazepam, mephorbarbital, methbarbital, nitrazepam, and phenobarbital.
[0007] U.S. Pat. No. 6,232,304 to Kim et al. discloses inclusion complexes of aryl-heterocyclic salts such as the tartrate salt of ziprasidone in a cyclodextrin such as β-cyclodextrin sulfobutyl ether (SBECD), and hydroxypropyl-β-cyclodextrin (HPBCD), and use of such inclusion complexes in oral and parenteral formulations.
[0008] Japanese Patent Application No. 09301867A2 dated Nov. 25, 1997 discloses antidepressant compositions in the form of tablets containing aripiprazole.
[0009] EP1145711A1 dated Oct. 17, 2001 (based on U.S. Application Serial No. 2000-547948 filed Apr. 12, 2000) discloses flash-melt oral dosage formulations containing aripiprazole.
[0010] U.S. Pat. No. 5,904,929 to Uekama et al. discloses trans-mucosal and transdermal pharmaceutical compositions containing a drug and a peracylated cyclodextrin as a solubilizing agent. Examples of drugs include antidepressants such as amitriptyline HCl, amoxapine, butriptyline HCl, clomipramine HCl, desipramine HCl, dothiepin HCl, doxepin HCl, fluoxetine, gepirone, imipramine, lithium carbonate, mianserin HCl, milnacipran, nortriptyline HCl and paroxetine HCl; anti-muscarinic agents such as atropine sulphate and hyoscine; sedating agents such as alprazolam, buspirone HCl, chlordiazepoxide HCl, chlorpromazine, clozapine, diazepam, flupenthixol HCl, fluphenazine, flurazepam, lorazepam, mazapertine, olanzapine, oxazepam, pimozide, pipamperone, piracetam, promazine, risperidone, selfotel, seroquel, sulpiride, temazepam, thiothixene, triazolam, trifluperidol and ziprasidone; anti-migraine drugs such as alniditan and sumatriptan; beta-adrenoreptor blocking agents such as atenolol, carvedilol, metoprolol, nebivolol and propranolol; anti-Parkinsonian drugs such as bromocryptine mesylate, levodopa and selegiline HCl; opioid analgesics such as buprenorphine HCl, codeine, dextromoramide and dihydrocodeine; parasympathomimetics such as galanthamine, neostigmine, physostymine, tacrine, donepezil, ENA 713 (exelon) and xanomeline; and vasodilators such as amlodipine, buflomedil, amyl nitrite, diltiazem, dipyridamole, glyceryl trinitrate, isosorbide dinitrate, lidoflazine, molsidomine, nicardipine, nifedipine, oxpentifylline and pentaerythritol tetranitrate.
BRIEF DESCRIPTION OF THE INVENTION
[0011] In accordance with the present invention, there is provided an inclusion complex of aripiprazole in a substituted-beta-cyclodextrin. It has been found that the inclusion complex of aripiprazole is substantially more water-soluble relative to the non-complexed aripiprazole.
[0012] Surprisingly and unexpectedly, it has been found that when aripiprazole is complexed with a substituted β-cyclodextrin such as sulfobutyl ether-β-cyclodextrin, it may be formulated as an injectable which delivers aripiprazole to the muscular site with unexpectedly diminished irritation as compared to injectables containing uncomplexed aripiprazole.
[0013] In addition, in accordance with the present invention, a pharmaceutical formulation is provided which is formed of an inclusion complex of aripiprazole and a substituted-β-cyclodextrin, and a pharmaceutically acceptable carrier therefor.
[0014] In a preferred embodiment, the pharmaceutical formulation of the invention will be in the form of an aqueous parenteral or injectable formulation. However, the pharmaceutical formulation of the invention may be in other dosage forms such as lyophilized injectable, oral (for example tablets, capsules, elixirs and the like), transdermal or transmucosal forms or inhalation forms.
[0015] Further, in accordance with the present invention, a method is provided for administering injectable aripiprazole without causing unacceptable irritation at the site of injection wherein the above described injectable formulation is administered, preferably intramuscularly, to a patient in need of treatment.
[0016] Still further in accordance with the present invention, a method is provided for treating schizophrenia which includes the step of administering to a patient in need of treatment the above described formulation, preferably in injectable form, without causing undue irritation at the site of injection, whether it be at a muscular site or other site.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Aripiprazole has poor water solubility and thus is difficult to formulate as an aqueous injectable. In accordance with the present invention, it as been found that the water-solubility of aripiprazole may be sufficiently increased to allow it to be formulated as an aqueous injectable by complexing aripiprazole with a substituted-β-cyclodextrin. In effect, the cyclodextrin inhibits precipitation of the aripiprazole at the site of injection. The aqueous injectable formulation containing the complex of aripiprazole and the substituted-β-cyclodextrin may be administered preferably intramuscularly without causing unacceptable irritation at the muscular site. This is indeed surprising and unexpected since, as indicated above, a host of water-miscible co-solvent systems and water-immiscible co-solvent systems have been found to be unacceptable as carriers for injectable aripiprazole formulations because of the unacceptable irritation profile of such formulations. On the other hand, the aqueous injectable formulation of the invention delivers aripiprazole without causing unacceptable irritation at the site of injection.
[0018] As will be seen hereinafter, the aripiprazole formulation in the form of an aqueous injectable will include an acid buffer and a base to adjust pH to desired levels.
[0019] The substituted-β-cyclodextrin suitable for use herein refers to sulfobutyl ether β-cyclodextrin (SBECD) and hydroxypropyl-β-cyclodextrin (HPBCD), with SBECD being preferred.
[0020] The term “undue irritation” or “unacceptable irritation” at the site of injection or at the muscular site refers to moderate to severe irritation which is unacceptable to the patient and thereby impacts unfavorably on patient compliance.
[0021] The term “reduced irritation” at the site of injection or at the muscular site refers to generally minimal to mild irritation which is acceptable to the patient and does not impact unfavorably on patient compliance.
[0022] The aripiprazole will form a complex with the substituted-β-cyclodextrin which complex may be dissolved in water to form an injectable formulation. However, physical mixtures of aripiprazole and the substituted-β-cyclodextrin are within the scope of the present invention as well.
[0023] The complex or the physical mixture may also be compressed into a tablet or may be filled into capsules.
[0024] The aripiprazole formulations of the invention may be formed of dry physical mixtures of aripiprazole and the substituted-β-cyclodextrin or dry inclusion complexes thereof which upon addition of water are reconstituted to form an aqueous injectable formulation. Alternatively, the aqueous injectable formulation may be freeze dried and later reconstituted with water. Thus, the inclusion complex in accordance with the invention, may be pre-formed, formed in situ or formed in vivo (in the gastrointestional tract or the buccal cavity). All of the above are contemplated by the present invention.
[0025] The aripiprazole formulation of the invention in the form of an aqueous injectable will include an acid buffer to adjust pH of the aqueous injection within the range from about 3.5 to about 5. Examples of acid buffers suitable for use herein include acids such as hydrochloric acid, sulfuric acid, phosphoric acid, hydrobromic acid and the like, and organic acids such as oxalic acid, maleic acid, fumaric acid, lactic acid, malic acid, tartaric acid, citric acid, benzoic acid, acetic acid, methanesulfonic acid, toluenesulfonic acid, benzenesulfonic acid, ethanesulfonic acid and the like. Acid salts of the above acids may be employed as well. Preferred acids are tartaric acid, citric acid, and hydrochloric acid. Most preferred is tartaric acid.
[0026] The injectable formulation of the invention will have a pH within the range from about 3.5 to about 5, preferably from about 4 to about 4.6, and most preferably about 4.3. In formulating the injectable, if necessary, the pH may be adjusted with a base such as an alkali metal hydroxide such as NaOH, KOH, or LiOH, preferably NaOH, or an alkaline earth metal hydroxide, such as Mg(OH) 2 or Ca(OH) 2 .
[0027] In preparing the aqueous injectable formulation of the invention, the substituted-β-cyclodextrin will be employed in a weight ratio to the aripiprazole within the range from about 5:1 to 400:1, preferably from about 10:1 to about 100:1. Each type of cyclodextrin employed requires a different ratio to inhibit or prevent precipitation of aripiprazole at the injection site. In preferred embodiments of the aqueous injectable of the invention, the substituted-β-cyclodextrin will be SBECD which will be employed in a weight ratio to aripiprazole within the range from about 5:1 to about 400:1, preferably from about 20:1 to about 40:1. The cyclodextrin may be present in an amount greater than that needed to complex the aripiprazole since the additional cyclodextrin could aid in dissolution of the aripiprazole.
[0028] The aripiprazole will be present in the aqueous injectable formulation in an amount within the range from about 0.1 to about 2.5% by weight, preferably from about 0.2 to about 1.5% by weight based on the total injectable formulation.
[0029] In preferred embodiments, the aripiprazole will be present in the aqueous injectable formulation to provide from about 1 to about 20 mg/mL of formulation, preferably from about 1.5 to about 8 mg/mL of formulation.
[0030] In more preferred embodiments, the formulations of the invention will provide 2 mg aripiprazole/mL, 5 mg/mL and 7.5 mg/mL. Fill volumes will preferably be 0.5 mL and 2 mL.
[0031] A preferred injectable formulation is as follows:
(1) aripiprazole—in an amount to provide from about 1.5 to about 8 mg/mL of solution. (2) SBECD—in an amount from about 100 to about 200 mg/mL of solution. (3) acid buffer (preferably tartaric acid)—in an amount from about 7 to about 9 mg/mL of solution to adjust pH from about 3.5 to about 5. (4) base to adjust pH, preferably an alkali metal hydroxide, preferably NaOH—in an amount to adjust pH from about 4 to 4.6 (5) water qs to 1 mL.
[0037] The aripiprazole injectable formulation of the invention may be prepared as follows: Tartaric acid or other acid buffer is dissolved in water for injection. The substituted-β-cyclodextrin (preferably SBECD) is dissolved in the acid buffer-water solution. Aripiprazole is then dissolved in the solution. The pH of the solution is adjusted to within the range from about 3.5 to about 5, preferably about 4.3 by adding base, such as sodium hydroxide or other alkali metal hydroxide or alkaline earth metal hydroxide. Additional water for injection is added to obtain the desired batch volume.
[0038] The resulting solution is aseptically filtered, for example, through a 0.22μ membrane filter and filled into vials. The vials are stopped and sealed and terminally sterilized.
[0039] The aqueous injectable formulation of the invention will provide an amount of aripiprazole of at least 2 mg aripiprazole/mL, preferably at least 5 mg aripiprazole/mL, when the amount of aripiprazole provided by the complex is measured at a cyclodextrin concentration of 5% w/v in water.
[0040] The aripiprazole formulations of the invention are used to treat schizophrenia in human patients. The preferred dosage employed for the injectable formulations of the invention will be a 2 ml injection containing 7.5 mg aripiprazole/mL or a dose of 15 mg given three times daily at two hour intervals. The injectable formulation is preferably administered intramuscularly although subcutaneous and intravenous injections are effective as well.
[0041] The following example represents a preferred embodiment of the invention.
Example
[0042] A clear colorless aripiprazole injectable solution (2 mg aripiprazole/mL, 4 mg/vial) essentially free of particulate matter by visual inspection was prepared as follows.
[0043] A stainless steel batching vessel was charged with an appropriate amount of water for injection USP.
[0044] With continuous stirring, 78 g tartaric acid granular USP and 1500 g sulfobutyl ether β-cyclodextrin (SBECD) was added to the batching vessel and was dissolved in the water.
[0045] Aripiprazole 20 g was added to the batching vessel and stirring was continued until the aripiprazole was dissolved.
[0046] Sodium hydroxide 1N was added to the above solution to adjust the pH thereof to about 4.3.
[0047] Additional water for injection USP was added to the above solution to adjust to the final batch size to 10 L with stirring.
[0048] The above solution was aseptically filtered through a 0.22 μM membrane filter into a sterilized container 4 mg amounts of the above solution were aseptically filled into sterilized vials which were then aseptically stoppered with sterilized stoppers to seal the vials. | An aripiprazole formulation is provided which includes the antipsychotic agent aripiprazole in the form of an inclusion complex in a β-cyclodextrin, preferably, sulfobutyl ether β-cyclodextrin (SBECD), which in the form of an injectable produces reversible generally minimal to mild irritation at the intramuscular injection site. A method for minimizing or reducing irritation caused by aripiprazole at an intramuscular injection site and a method for treating schizophrenia employing the above formulation are also provided. | 0 |
GOVERNMENTAL INTEREST
The invention described herein may be manufactured, used, and licensed by or for the Government for Governmental purposes without the payment to us of any royalties thereon.
BACKGROUND OF THE INVENTION
The present invention relates generally to a novel method for preparing 2,2',4,4',6,6'-hexanitrostilbene (HNS), an important thermally stable explosive material which is also useful as a nucleant for promoting optimum trinitrotoluene-crystallization.
The discovery and an early synthesis for preparing HNS is disclosed in U.S. Pat. No. 3,505,413 to K. Shipp. That reference teaches adding 2,4,6-trinitrotoluene (TNT) dissolved in an appropriate solvent to a metal hypochlorite solution to form trinitrobenzychloride (TNBCl), which will then react with the metal hydroxide normally present in the hypochlorite solution to form HNS. The reaction can be controlled by drowning the reaction mixture with an acid such as HCl during the TNBCl transition stage to obtain TNBCl and then reacting the TNBCl with a metal hydroxide such as NaOH to form HNS.
This reference also discloses a method for preparing 2,2',4,4',6,6'-hexanitrobibenzyl (HNB), a starting material necessary in the instant process, which will be more fully explained below.
Unlike the Shipp process, the instant method for preparing HNS involves the reaction of HNB and a quinone in a suitable solvent. This type of reaction can best be described as dehydrogenation by a quinone and is discussed by H. O. House in Modern Synthetic Reaction, 2nd Edition, 1972, W. A. Benjamin, Menlo Park, California, pp 37-44. However, the instant process operates under conditions different from those set forth by House. For example, House states that operative solvents include xylene and orthodichlorobenzene. However, as will be seen below these solvents do not work in the instant method whereas other solvents not previously disclosed for this type synthesis work quite well. Also, the quinones previously found operative with this type synthesis were those containing chlorine or cyano and chlorine groups. However, it has been discovered that benzoquinone, naphthoquinone and others also work while anthraquinone does not.
SUMMARY OF THE INVENTION
An object of the instant invention is to provide a method for producing HNS from HNB.
Another object of the instant invention is to provide a method for promoting the process for producing HNS by reaction of HNB with a quinone.
Yet another object of the instant invention is to be able to use normally inoperative reaction solvents in the process by adding pyridine or other suitable bases to the reaction mixture.
These and other objects that will be made apparent in the detailed description to follow are accomplished by reaction HNB and a quinone in a suitable solvent according to the following reaction scheme, wherein the quinone is illustrated by p-benzoquinone: ##STR1##
DETAILED DESCRIPTION OF THE INVENTION
As explained previously, the primary starting material is HNB, which can be prepared in accordance with the process set forth in Shipp U.S. Pat. No. 3,505,413. The process entails adding a dilute hypochlorite aqueous solution, to which has been added a small amount of sodium hydroxide, to a solution of trinitrotoluene. Yields of about 79% of the theoretical yield have been obtained. Of course, other processes can be used to obtain HNB as will be readily apparent to those skilled in the art.
Quinones useful in the present process are those which have an oxidation-reduction potential (E o ) of at least 0.4 volt to about 1 volt, and preferably in the range of from about 0.7 volt to about 1.0 volt, as determined according to J. B. Conant, and L. F. Fieser, J. Am. Chem. Soc. 45, 2194 (1923); 46, 1858 (1924). Suitable quinones include o- and p- benzoquinones, and 1,2- and 1,4-napthoquinones, which are unsubstituted or substituted by one or more radicals selected from the group consisting of methyl, phenyl, cyano and halogen, including fluoro, chloro and bromo radicals, such as methyl-p-benzoquinone, 2,3-dichloro-5,6-dicyano-p-benzoquinone, tetrachloro-p-benzoquinone (chloranil), tetrafluoro-p-benzoquinone, tetramethyl-p-benzoquinone, 2,5-diphenyl-p-benzoquinone, and tetrachloro-o-benzoquinone (o-chloranil). It has been found that quinones having an oxidation-reduction potential below about 0.4 volt, e.g. 9, 10-anthraquinone and tetrahydroxy-p-benzoquinone, will not produce HNS when reacted with HNB.
As shown in the reaction scheme above, one mole of benzoquinone or equivalent is theoretically required per mole of HNB in the process of the present invention. Generally a molar excess of the quinone over the HNB is employed to ensure maximum yields of HNS. Significantly, lower yields of HNS are obtained when the amount of quinone is reduced significantly below one mole per mole of HNB.
The solvent employed should be capable of dissolving the reactants and promoting the dehydrogenation of HNB to HNS with a quinone according to the process of the present invention. In general, suitable solvents include those having average beta values within the range of about 0.75 to 1.0 on the beta-scale of solvent hydrogen bond acceptor (HBA) basicities according to page 382, Table III of the article by M. J. Kamlet and R. W. Taft in J. Am. Chem. Soc. 98, 377 (1976). Examples of such solvents include hexamethylphosphoric triamide (HMPT), dimethyl sulfoxide (DMSO), and 1-methyl-2-pyrrolidinone, of which HMPT is preferred. Such solvents are viewed as proton acceptors strong enough to induce the formation of an incipient carbanion of HNB, thus facilitating the removal of hydrogen by the quinone. Solvents having average beta values below those noted above, e.g. dimethylformamide (DMF) and tetrahydrofuran (THF), are not effective for promoting the dehydrogenation of HNB. However, the latter solvents, e.g. DMF, are effective for promoting the dehydrogenation of HMB to HNS with quinones and hence constitute suitable reaction solvents, providing they dissolve the reactants, do not produce unwanted side reactions, and have suitable boiling points, when employed in combination with an organic amine having a pKa value within the range of about 4.5 to about 6.5, such as pyridine, aniline, N,N-dimethylaniline, 2- and 4-picolines and quinoline. Also, by employing an organic amine of pKa of about 4.5 to 6.5 in mixture with a solvent having an average beta value between 0.75 and 1.0 (defined above), the yield of HNS obtained according to the present process may be further increased over that obtained in the absence of such an amine.
After the introduction of the reagents, the mixture is heated while being stirred to accomplish the dehydrogentation of the HNB. The reaction is accomplished at temperatures of about 50° C. to 110° C. and preferably about 65° C. to 90° C. The reaction will proceed, although more slowly, at still lower temperatures. To increase the degree of completion of the reaction, the mixture is heated for about 1 to about 5 hours and preferably from 0.5 to 3 hours. However, excessive heating periods in the presence of an added base such as pyridine will decrease the yield of HNS. It is believed that the reason for this is that the HNS will form by-products via competing side reactions in the presence of such bases when subjected to excessive heating.
The HNS is then recovered from the reaction mixture in accordance with procedures well known to those skilled in the art. For example, the reaction mixture can be diluted with water and the solid precipitate filtered from the mixture. The precipitate can then be extracted with acetone to dissolve impurities and the insoluble HNS filtered from the acetone solution of impurities and dried.
The following examples will more fully illustrate the embodiments of the invention. Unless otherwise specified, all parts and percentages are by weight.
EXAMPLE I
1.2 grams (0.0027 mole) of 2,2',4,4',6,6'-hexanitrobibenzyl (HNB) and 1.5 grams (0.0061 mole) of chloranil (tetrachloro-p-benzoquinone) are mixed in 15 mls of hexamethyl phosphoric triamide (HMPT). This mixture is heated for 3 hours at a temperature of 70° C. while stirring. The reaction mixture is then diluted with water and the solid precipitate filtered from the mixture. The precipitate is then dried to give 2.4 grams of solids. The dried solids are then extracted with acetone. The acetone insoluble HNS is separated by filtration and dried to yield 1.05 grams (87% of theoretical) of a grey insoluble solid having a melting point of 315° C. and identified as 2,2',4,4',6,6'-hexanitrostilbene (HNS) as determined by infrared spectrum.
The above example was repeated four times with an average yield of 80% of theoretical.
EXAMPLE II
1.2 grams (0.0027 mole) of HNB and 0.57 gram (0.0053 mole) of p-benzoquinone are mixed in 15 mls of HMPT. The mixture is heated for 3 hours at a temperature of 70° C. while stirring. The reaction mixture is then diluted with water and the solid precipitate is filtered from the mixture. The precipitate is then extracted with acetone, and the acetone insoluble HNS is separated by filtration and dried to yield 0.93 gram (78% of theoretical) of HNS as determined by infrared spectrum.
EXAMPLE III
1.2 grams (0.0027 mole) of HNB and 1.31 grams (0.0053 mole) of tetrachloro-o-benzoquinone (ortho-chloranil) are mixed in 15 mls of HMPT. The mixture is heated for 3 hours at a temperature of 70° C. while stirring. The reaction mixture is then diluted with water and the solid precipitate filtered from the mixture. The precipitate is then purified by extraction with acetone and dried as described in Example I to yield 1.00 gram (83% of theoretical) of HNS as determined by infrared spectrum.
EXAMPLE IV
1.2 grams (0.0027 mole) of HNB and 0.84 gram (0.0053 mole) of 1,4-naphthoquinone are mixed in 15 mls of HMPT. The mixture is heated for 3 hours at a temperature of 70° C. while stirring. The reaction mixture is then diluted with water and the solid precipitate is filtered from the mixture. The precipitate is then purified by extraction with acetone and dried to yield 0.85 gram (71% of theoretical) of HNS.
EXAMPLE V
1.2 grams (0.0027 mole) of HNB and 1.20 grams (0.0053 mole) of 2,3-dichloro-5,6-dicyano-p-benzoquinone are mixed in 15 mls of HMPT. The mixture is heated for 3 hours at a temperature of 70° C. while stirring. The reaction mixture is then diluted with water and the solid precipitate is filtered from the mixture. The precipitate is then purified by extraction with acetone and dried to yield 1.07 grams (89% of theoretical) of HNS.
EXAMPLE VI
Example I is repeated but 9,10-anthraquinone is used in place of chloranil. The process produced no HNS.
EXAMPLE VII
Example II is repeated but the solvent N,N-dimethylformamide (DMF) is used in place of HMPT. The process produced no HNS.
EXAMPLE VIII
1.2 grams (0.0027 mole) of HNB and 0.57 gram (0.0053 mole) of p-benzoquinone are mixed in 15 mls of dimethyl sulfoxide (DMSO). The mixture is heated for 3 hours at a temperature of 70° C. while stirring. The reaction mixture is then diluted with water and the solid precipitate is filtered from the mixture. The precipitate is then purified by extraction with acetone and dried to yield 0.22 gram (18% of theoretical) of HNS.
EXAMPLE IX
Example VIII is repeated except that the mixture is heated for 3 hours at a temperature of 95° C. while stirring. The yield is 0.39 gram (33% of theoretical) of HNS.
EXAMPLE X
1.2 grams (0.0027 mole) of HNB and 0.57 gram (0.0053 mole) of p-benzoquinone are mixed in 15 mls of 1-methyl-2-pyrrolidinone. The mixture is heated for 3 hours at a temperature of 70° C. while stirring. The reaction mixture is then diluted with water and the solid precipitate is filtered from the mixture. The precipitate is then extracted with acetone and dried to yield 0.27 gram (23% of theoretical) of HNS.
EXAMPLE XI
Example II is repeated except the solvent orthodichlorobenzene is substituted for HMPT and the mixture is heated for 3 hours at 150° C. The process produced no HNS.
EXAMPLE XII
0.45 gram (0.001 mole) of HNB and 0.50 gram (0.002 mole) of orthochloranil are mixed in 50 mls of tetrahydrofuran. The mixture is heated at reflux (65° C.) for 3 hours while stirring. The process produced no HNS.
EXAMPLE XIII
0.90 gram (0.002 mole) of HNB and 0.50 gram (0.002 mole) of chloranil are mixed in 50 mls of xylene. The mixture is heated at reflux (130° C.) for 2 hours while stirring. The process produced no HNS.
EXAMPLE XIV
1.2 grams (0.0027 mole) of HNB, 0.57 gram (0.0053 mole) of p-benzoquinone and 0.5 gram (0.0063 mole) of pyridine are mixed in 15 mls of DMF. The mixture is heated for 3 hours at 70° C. while stirring. The mixture is then diluted with water and the precipitated solid is filtered from the mixture. The precipitate is then extracted with acetone and dried to yield 0.76 gram (63% of theoretical) of HNS.
EXAMPLE XV
Example XIV is repeated except the mixture is heated for 5 hours instead of 3 hours. The yield of HNS is 0.61 gram (51% of theoretical).
EXAMPLE XVI
1.2 grams (0.0027 mole) of HNB, 0.57 gram (0.0053 mole) of p-benzoquinone and 1.0 gram (0.0126 mole) of pyridine are mixed in 15 mls of DMF. The mixture is heated for 3 hours at 70° C. while stirring. The mixture is then diluted with water and the precipitated solid is filtered from the mixture. The precipitate is then extracted with acetone and dried to yield 0.66 gram (55% of theoretical) of HNS.
EXAMPLE XVII
Example XIV is repeated except 0.25 gram (0.0032 mole) of pyridine is used. The yield of HNS is 0.78 gram (65% of theoretical).
EXAMPLE XVIII
1.2 grams (0.0027 mole) of HNB, 0.57 gram (0.0053 mole) of p-benzoquinone and 0.25 gram (0.0032 mole) of pyridine are mixed in 15 mls of DMF. The mixture is heated at 70° C. for 11/2 hours. The mixture is then diluted with water and the precipitated solid is filtered from the mixture. The precipitate is then extracted with acetone and dried to yield 0.89 gram (74% of theoretical) of HNS.
EXAMPLE XIX
Example XVII is repeated except DMSO is used in place of DMF. The yield of HNS is 0.84 gram (70% of theoretical).
EXAMPLES XX-XXII
In accordance with the procedure set forth in Example I, the following quinones are mixed with HNB in the solvent HMPT. The mixture is heated for 3 hours at 70° C. The molar ratio of quinone to HNB is 2.
______________________________________Quinone HNS % Yield______________________________________2,5-diphenylbenzoquinone 70%Methyl-p-benzoquinone 72%tetramethyl-p-benzoquinone 46%______________________________________
EXAMPLES XXIII-XXVII
In accordance with the procedure set forth in Example XIV, p-benzoquinone, HNB and the following organic bases are mixed in the solvent DMF. The mixture is heated for 3 hours at 70° C. The molar ratio of benzoquinone to HNB is 2 and the molar ratio of base to HNB is 1.2.
______________________________________Base HNS % Yield______________________________________Aniline 53%Quinoline 73%N,N-DiMethylaniline 21%2-Picoline 68%4-Picoline 70%______________________________________
This invention has been described with respect to certain preferred embodiments and various modifications. Variations in the light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims. | 2,2',4,4',6,6'-hexanitrostilbene, a thermally stable explosive material, isrepared by reacting 2,2',4,4',6,6'-hexanitrobibenzyl with a quinone in a suitable reaction solvent such as hexamethyl phosphoric triamide, dimethyl sulfoxide and N-methyl-pyrrolidinone. The use of organic bases to promote the reaction and to allow the use of normally inoperative reaction solvents is also disclosed. | 2 |
BACKGROUND OF THE INVENTION
A reactor core, of a nuclear reactor, is typically located in a containment vessel having predetermined operating pressure and temperature ranges for normal safe operation of the reactor. The containment vessel is typically provided with heat-transferring fluid coolant which is pumped into the containment vessel adjacent the reactor core, heated by the reactor core, with said heat being utilized in a steam turbine for the generation of electricity.
Under certain conditions, the heat-transfer fluid coolant to the core could be interrupted. In this event, the temperature of the core would continue to rise, resulting in a preliminary melting of the core, and upon uninterrupted continuous temperature increase, would cause a complete melt down of the core to a molten bolus of radioactive fuel. This fuel would flow by gravity downwardly from said core and could melt through the bottom of the containment vessel, causing great damage to the nuclear reactor and create extreme danger to public health and environmental safety.
Presently, known types of nuclear reactors can be provided with core melt down accepting fluxing or eutectic solute material or device beneath the core to receive the molten bolus of atomic fuel in the event of a melt down; however, presently there is no device which is retrofitable to the primary heat-transfer fluid system to automatically provide the containment vessel with a molten core fuel catcher. Moreover, no such safety device is provided in this manner through the heat-transfer fluid system or by a supplemental system connected to the containment vessel.
SUMMARY OF THE INVENTION
In the present art of nuclear reactor systems, a failure in the heat-transfer coolant system could cause a melt down of the reactor fuel elements, resulting in the formation of a molten bolus in the bottom of the reactor containment pressure vessel as an immediate prelude to burn through of the vessel by the molten bolus. This bolus presents a large thermal assault on any available materials which would most likely not be sufficient to neutralize the bolus under these conditions. This invention provides a device for preventing the emission of radioactive material into the environment in the event of a melt down and to limit damage to the nuclear power plant.
OBJECTS OF THE INVENTION
The primary object of this invention is to provide a device which is retrofitable to a nuclear power plant to limit the damage to a nuclear power plant and the environment in the event of a fuel core melt down.
It is another object of this invention to provide a fuel element core catcher to receive initial bits and drops of molten fuel as it begins to melt down from the fuel core to provide a gradual thermal assault, shock or challenge to the eutectic solute material, as is calculatedly provided by this invention, and thereby avoiding the otherwise massive thermal shock assault or challenge to the accepting material, device or containment vessel, otherwise accompanying the melt down of the fuel system in the present art of nuclear fuel power plants.
It is a further object of this invention to provide a device which is specifically retrofitable to existing nuclear reactor power generating plants to provide the means for preventing the escape of radioactive material and damage to the nuclear plant in the event of a core melt down accident which is not otherwise provided by the original structure of the plant, or which is retrofitable to said plant to augment an existing melt down retainer.
An additional object of this invention is to provide a fuel core melt down catcher which is not otherwise provided by the state of the art and existing nuclear energy power plants.
Another object of this invention is to provide an emergency melt down core catcher for a nuclear reactor core containment vessel which is responsive to temperature and/or pressure to be operable to provide and position supplemental core melt down catching material within the containment vessel.
Other advantages and novel aspects of this invention will become apparent from the following detailed description, in conjunction with the accompanying drawings wherein:
FIG. 1 is a vertical sectional representation of a primary portion of a nuclear power plant showing a nuclear reactor core containment vessel, associated steam generators and pressurizers as found in existing known types of nuclear power plant installations.
FIG. 2 is a vertical sectional representation of the portion of a nuclear power plant shown in FIG. 1 showing a cross sectional view of the emergency eutectic solute and coolant holding vessel with storage and discharge chambers and with chamber and discharge valves retaining eutectic solute and transfer fluid, of this invention, retrofitably connected to the primary heat-transferring fluid system of the containment vessel and steam generators, in the normally unactivated condition precedent to any emergency melt down situation.
FIG. 3 is a sectional representation of the portion of a nuclear power plant shown in FIG. 2 showing the transferring fluid and eutectic material expelled from the holding vessel into the primary cooling system and with the solid eutectic solute material particles settled out of the fluid heat transfer fluid in the bottom of the core containment vessel forming a core catcher for any partial or full melt down of the fuel core.
FIG. 4 is a detailed sectional view of the eutectic solute and coolant holding vessel of this invention showing the cold shutdown position thereof with the chamber and discharge valves closed.
FIG. 5 is a sectional view of the eutectic solute holding vessel of this invention attached to the fluid-transfer system with a thermal responsive discharge valve in the normal open operating position with the coolant under pressure in the discharge chamber of the vessel and against a pressure responsive chamber valve.
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5 showing the configuration of the holding vessel of this invention and the pressure responsive chamber valve thereof.
FIG. 7 is a sectional view of the holding vessel of this invention showing the condition thereof in the event of pressure and temperature failure within the nuclear reactor coolant system resulting in the full open of the thermal responsive exhaust valve and the pressure responsive chamber valve with the material held thereby exhausted into the fluid coolant passing to the core containment vessel.
DESCRIPTION OF THE INVENTION
Referring to the drawings, and particularly FIG. 1, there is illustrated a primary portion of a nuclear power plant generally represented by the numeral 10, and generally includes a reactor core containment vessel 11 (FIGS. 1-3), associated multiple steam generators 12 (only two shown), and pressurizing vessels 13. The typical nuclear reactor core containment vessel 11 of a nuclear power plant 10 is provided with a nuclear reactor core 14, a main containment portion 15 and a top 16. The heat producing atomic reaction is provided by atomic fuel elements 17 of core 14.
Heat transferring coolant fluid is presented to containment vessel 11 by pumps 21 (FIGS. 1-3) through respective entry conduits or system 22 and downwardly through an inner annular plenary conduit 23 in vessel 11 into a lower chamber 24 in bottom portion 25 of the containment vessel 11. The heat absorbing and transferring fluid thereafter passes upwardly through the center of the containment vessel 11 past the reactor cores 14 to absorb the heat generated by the cores 14. The heated fluid is thereafter similarly forced by pumps 21 and thermal action, through exhaust conduits 26 to respective steam generators 12 by conduits 28.
The heated fluid is transferred through heat transfer coils 31, of the respective steam generators 12, into chambers 32 thereof containing water 34 and returned to the pump by respective conduits 33. Water 34 of steam generators 12 is thus transformed into steam in the steam generators 12 in the upper portion of chamber 32 as a result of the heat of the heat-transfer fluid passing in coils 31. The steam is then fed from the steam generator chambers 32 to a steam turbine (not shown) by conduits 35 to operate a turbine and generator for the production of electricity. The steam is condensed through the operation of the turbine and returned to steam generator by condenser water return inlet conduits 36 to respective steam generators 12.
Existing types of nuclear reactor power plants as generally referred to above (FIG. 1) are sometimes provided with a supplemental, fixed quantity, emergency coolant containers containing emergency core cooling liquids such as borated water. In the event of an emergency caused by a predetermined drop in pressure, or increase in temperature, in the primary coolant supply, emergency core coolant fluid could be expelled into respective conduits leading to the core containment vessel 11 through conduits 22. The purpose of this would be to try to reduce the temperature of fuel core 14 to prevent a melt down of individual fuel elements 14a. In this situation, the emergency core cooling fluid would pass from the emergency coolant container into the coolant fluid conduit 22 and into and through the containment vessel 11, to provide whatever cooling effect it might be able to provide to attempt to lower the temperature of the fuel elements 14a.
Above and beyond the elements of a conventional nuclear power plant as previously generally described, this invention provides a eutectic solute holding vessel 41 to provide emergency melt down core catching capacity. Holding vessel 41 has a storage chamber 42 and a discharge chamber 43 interconnecting storge chamber 42 with conduit 22 of core containment vessel 11.
Vessel 41 (FIGS. 2-6) is further provided with a valve means which includes a normally closed chamber pressure valve 45 between storage chamber 42 and discharge chamber 43, and a normally open heat responsive discharge valve 46, positioned in an exhaust outlet 47 of discharge chamber 43, and fluid conduit 22.
Chamber valve 45 (FIGS. 2-7) is illustrated to include a valve seat opening 51 (FIG. 6) between storage chamber 42 and discharge chamber 43. A valve plate 52 is pivotally connected to a straight internal surface 53 within holding vessel 41. Plate 52 is complementary in shape to the cross sectional area of discharge chamber 43 (FIG. 6), and is adapted to be pivoted at 54 to upwardly engage a valve seat surface 55 whereby when valve plate 52 is pivoted clockwise about 54 (FIG. 7), plate 52 will ultimately seat against valve seat surface 55 (FIGS. 4-6) to seal exhaust chamber 43 from storage chamber 42. Plate is biased to be releasably retained in the closed position (FIGS. 4-6), and is similarly positioned by force of normal pressure from fluid system in conduit 22.
Normally closed discharge valve 46 (FIG. 4) is provided with a heat expansion stem 61 connected to the far or bottom side of conduit 22 and a valve ball 62 on the upper end of stem 61 adapted to seat against tapered seat surface 63 of discharge chamber 43 to normally seal discharge chamber 43 from exhaust outlet 47 and fluid conduit 22.
In operation, and in a situation of cold shutdown, (FIG. 4), discharge valve 46 will be normally closed, sealing the pressure of the fluid system in discharge chamber 43 to maintain chamber valve plate 52 in the up or seated and sealed position (FIGS. 4 and 5). In normal operation, stem 61 (FIGS. 5 and 7) will be elongated by virtue of the coefficient of expansion resulting from operating temperatures and will maintain discharge chamber 43 open into discharge outlet 47 and conduit 22 by unseating ball 61 from seat 62, thus maintaining discharge chamber 43 open to conduit 22.
However, in the event of malfunction in a fluid system of conduits 22 causing a large reduction in pressure, stem 61 will be maintained elongated as above set forth to allow the discharge from chamber 43 into respective conduits 22.
When the pressure in discharge chamber 43 is thus lowered, during operating conditions, the greater pressure in storage chamber 42 will urge the contents thereof downwardly against valve plate 52 causing plate 52 to be pivoted counterclockwise and downwardly (FIG. 5) to the open position (FIG. 7). In this instance, the contents of storage chamber 42 will be released, by the pressure thereof, from storage chamber 42 through the discharge chamber 43, discharge outlet 47, into the coolant system of conduit 22, and into the bottom chamber 24 of containment vessel 11 through inner conduit 23.
Storage chamber 42 (FIGS. 4 and 5) is normally filled with fluxing eutectic solute of flux material granules 65 and coolant 66 and, as generally set forth above, maintained at a pressure significantly greater than outside air pressure and significantly lower than that of the fluid system in conduit 22, by a gas 67 such as nitrogen or argon.
Eutectic solute material has a eutectic 65 in granular form adapted to mix with the plant coolant in exhaust chamber 43 and is propelled as a slurry through the conduits 22 and 23 to chamber 24 of primary containment vessel 11. Eutectic 65 is deposited as core catching mass or deposit 68 in the bottom of vessel 11 (FIG. 3) as the coolant vaporizes or otherwise rises through vessel 11 past core elements 14a. In the event of a core melt down, causing eutectic solute 66 to thus be passed from holding vessel 13 to containment vessel 11 to form core catching deposit 68, the molten fuel that starts to form from cores 14, as the melt down progresses, will gradually drop and eventually slump as a bolus into the mass of eutectic solute material 68 formed from granular eutectic 65 which is acting as a catcher for the core melt down material.
Eutectic solute 65 as mass 68, will thereby dissolve the beginning droplets and eventual mass of any full scale or partial melt down, to cool the molten fuel thereof by the eutectic effect of solute mass 68, and by being dissipated over a large volume, creating a larger area for heat exchange, and thus also inhibiting nuclear heat production by absorption and dispersal.
The eutectic solute material 65 can be any granular matter capable of being mixed with coolant 66 and dissolving with reactor fuel. For example, if a reactor is fueled with UO 2 and cooled with liquid sodium, then anhydrous basalt granules could be used as solute material 67. Alternatively, if the reactor is fueled with metallic uranium and cooled with water, filings or shot of relatively carbon free iron could be used. It is desirable to provide a surfeit of eutectic solute material 67 and several routes of access to the primary containment vessel to allow for losses through ruptures in the system. The eutectic materials 67 may be maintained apart, shielded and even at points remote from core 14, thereby eliminating uncertainties involving prolonged exposure. The measures to prevent spurious triggering of current emergency core cooling systems can be applied to this system.
A further refinement of this invention involves the use of a poison control substance with the eutectic solute 67. In this form, one could use boron compounds in conjunction with the borosilicate mixture used in uranium glass for a UO 2 water cooled reactor. If, on the other hand, the reactor were fueled with metallic uranium, one could use filings of iron alloyed with cadmium. This embodies the added benefits of neutron absorption via fission poisoning. In these cases, the eutectic solute material 67 dissolves with control substance as well as fuel. In all embodiments, this system can effectively alleviate the damage to plant and environment by its immediate dissipative eutectic solute action, and if enough eutectic solute or poisoned eutectic solute 67 is present, the integrity of the primary containment vessel 11 may be significantly preserved. This invention is designed to be easily adaptable and retrofitable to existing reactors and many proposed designs.
An appropriate glass, for the above referred to, can be a borosilicate glass. A specific example of an appropriate glass for this purpose is a glass of 80%, SiO 2 ; 14%, B 2 O 3 ; and 4%, Na 2 O; and 2%, Al 2 O 3 . This formula, is fused into glass, and then ground or otherwise formed into pellets, particulate or granules of the proper size and a density greater than that of coolant 66 to allow transport through conduit systems 22 in suspension and under turbulence thereof, but dense enough to precipitate out of the coolant in the less turbulent area of the bottom of vessel 11, to form the core catcher or mass 68, it could be used as the eutectic solute to dissolve molten UO 2 .
Additional coolant can be applied through conduits 49 under the control of valve 48 of respective holding vessels 41. This provides an additional option of pressurized coolant to force the discharge of the contents of storage chambers 42 through and past chamber valve 45 to discharge the contents of chamber 42 through discharge chamber 43 and exhaust conduit 47 into coolant system of conduits 22. Thus, an ejection system is provided upon command by the manipulation of valve 40 to provide the ability to discharge the vessels 41, on operator command, by raising the pressure in the storage chamber 42. Alternatively, conduit 35 can be linked with existing emergency core cooling systems such as borated water systems to initiate the discharge.
Therefore, it should be noted that this invention provides a fuel core melt down catcher which is not otherwise provided by the state of the art and that is, moreover, readily deployable to existing systems in various altered forms or applications.
It is to be understood that the invention is not to be limited to the specific constructions and arrangements shown and described, as it will be understood to those skilled in the art that certain changes may be made without departing from the principles of the invention. | An emergency melt down core catcher apparatus for a nuclear reactor having a retrofitable eutectic solute holding vessel connected to a core containment vessel with particle transferring fluid and particles or granules of solid eutectic solute materials contained therein and transferable by automatically operated valve means to transport and position the solid eutectic solute material in a position below the core to catch and react with any partial or complete melt down of the fuel core. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to diversity and more particularly to wireless receivers using noise levels for combining multiple signals, using noise levels for dynamic scaling of an equalized signal, and having a method for determining noise levels.
[0003] 2. Description of the Prior Art
[0004] There is an escalating demand for wireless systems such as cellular telephones and wireless local area networks (LAN)s. This demand and economic factors are driving requirements for ever higher data throughput and greater range for these systems. However, as data rate and range is increased the wireless signals in these systems are increasingly degraded by burst noise and by time-varying frequency selective attenuation (fading) and delay distortion. This fading and distortion, generally caused by having multiple signal paths or channels between a transmitter and receiver, is known as multipath fading or multipath distortion or simply multipath.
[0005] A technique called equalization is commonly used for compensating for the effects of the multipath in order to estimate the bits that were actually transmitted. Most modem systems also use error detection and correction encoding where the transmitter encodes the bits that are transmitted with extra information that enables the receiver to use a decoding algorithm to detect and correct errors in the received bits after equalization.
[0006] Recent systems have improved upon standard or hard bit decision equalization with soft equalization where probabilities of transmitted bits are estimated. Where soft equalization is used, the receiver decoding algorithm operates on the probabilities of the equalized transmitted bits for error detection and correction.
[0007] In addition to equalization and encoding, wireless systems sometimes use other techniques, such as temporal diversity and spatial diversity, for combating burst noise and multipath. For temporal diversity, transmitted bits are interleaved into time-separated packets at a transmitter, spreading and thereby reducing the effect of burst noise or multipath fading in particular packets. The interleaved bits are then deinterleaved at the receiver to recreate their original order. However, in known systems where soft equalization is used, the reliability of the error detection and correction decoding process in the receiver is limited by changes in noise and multipath during the time separation.
[0008] Multiple antennas are used for spatial diversity for transmitting or receiving the wireless signals. Because the multiple antennas have different spatial locations, the signal paths are different and therefore the multipath is different. The multiple signals are combined at the receiver. A wireless receiver can use the idea that the multipath is different in the different signal paths in order to reduce the degradation that the multipath causes. Several combining methods, such as maximal ratio combining and equal gain combining are known in the prior art. However, none of the known methods combine the signals in an optimum way in the presence of equalization.
[0009] There remains a need for improved methods using spatial diversity and temporal diversity with equalization for reducing multipath effects.
SUMMARY OF THE INVENTION
[0010] It is therefore an object of the present invention to provide a spatial diversity receiver and method where multiple signals are weighted and combined according to their noise levels for providing an optimal composite equalized signal.
[0011] Another object of the present invention is to provide a temporal diversity receiver and method using noise scaling of a soft equalized signal before the signal is deinterleaved.
[0012] Another object of the present invention is to provide a simple apparatus and convenient method for determining a representation of signal noise level.
[0013] Briefly, a method and a receiver of the present invention determines ratios of noise levels of received signals and then uses the noise level ratios for determining noise-based scale factors. For spatial diversity, the noise-based scale factors are used for weighting multiple received signals inversely according to their respective noise levels for providing a composite equalized signal. For temporal diversity, the noise-based scale factors are used for dynamically scaling an equalized signal in order to compensate for time variations in noise and multipath. For temporal diversity and spatial diversity used together, the equalized signal that is scaled is the composite equalized signal.
[0014] In a preferred embodiment, for spatial diversity a receiver of the present invention includes multiple receiver chains and a noise-based spatial diversity combiner. For temporal diversity a receiver of the present invention includes a noise postscaler. For combined spatial and temporal diversity, the receiver includes the multiple receiver chains, the spatial diversity combiner, and the noise postscaler.
[0015] For spatial diversity, the receiver chains receive an incoming signal and provide sampled receiver chain signals to the spatial diversity combiner. The spatial diversity combiner scales and equalizes the sampled receiver chain signals by computing a set of composite equalizer branch metrics t n (s→s′) as shown in an equation 1 and then uses the composite equalizer branch metrics t n (s→s′) for providing a composite equalized signal u i as shown in an equation 2.
t n ( s → s ′ ) = 1 p a 2 r n , a - h o , a x n ( s → s ′ ) - ∑ k = 1 K h k , a x n - k ( s ) 2 + 1 p b 2 r n , b - h o , b x n ( s → s ′ ) - ∑ k = 1 K h k , b x n - k ( s ) 2 ⋯ + 1 p m 2 r n , m - h o , m x n ( s → s ′ ) - ∑ k = 1 K h k , m x n - k ( s ) 2 ( 1 )
u i =F ({{ t n ( s→s ′)}, s,s′} n=0 N−1 ) (2)
[0016] In the equation 1, the n is the time index of the received symbols, the r n,a, r n,b through r n,m represent nth symbols received in receiver chains denoted “a”, “b” through “m”, respectively; the h k,a , h k,b through h k,m represent kth of 0 to K coefficients of channel impulse response sets for the “a”, “b” through “m” receiver chains, respectively; the x n (s→s′) represents a symbol uniquely determined by an equalizer transition from an originating state s to a new state s′ for the nth symbol; the x n−k (s) represents symbols uniquely determined by the state s for the nth symbol and the kth of said of 1 to K coefficients; the p a 2 , p b 2 through p m 2 are quantities that represent the noise variances in the “a”, “b” through “m” receiver chains, respectively; and the t n (s→s′) represents composite equalizer branch metrics corresponding to the equalizer transitions for the nth received symbols. The K most recent symbols {x n−k (s)} k=1 K are uniquely determined by the originating state s. The 1/p a , 1/p b through 1/p m or their squares are noise-based scale factors.
[0017] There are S=P K+1 state s to state s′ equalizer transitions for each index n where “P” is the number of modulation states in the transmitted signal and “K+1” is the length or number of coefficients in the channel impulse response. For example for BPSK, “P” is two. For a P of two and a K of five, the number S of equalizer branch metrics t n (s→s′) is 64 for each index n.
[0018] In the equation 2, the composite equalized signal u i is the ith index for a function of all equalizer branch metrics. The composite equalized signal u i has the form of a sample stream of bit probabilities for the i=0 . . . (N−1)th received symbol where N is the total number of received symbols over which the equalizer operates. This is the “soft” information that feeds an error correcting decoder.
[0019] The present invention can be implemented by noise scaling each of the composite equalizer branch metrics t n (s→s′) as shown in equation 1, as it is being computed within an equalizer. However, this would require several multiplications per index n, the number of multiplications dependent on the total number of state transitions within the equalizer trellis (64 in the example above). In a preferred embodiment, the spatial diversity combiner therefore includes noise prescalers for prescaling the receiver chain signals r n,a , r n,b through r n,m and channel impulse response sets h k,a , h k,b through h k,m according to equations 3A-C and 4A-C.
r ~ n , a = ( p min / p a ) r n , a ( 3 A ) r ~ n , b = ( p min / p b ) r n , b ( 3 B ) r ~ n , m = ( p min / p m ) r n , m ( 3 C ) h ~ k , a = ( p min / p a ) h k , a ( 4 A ) h ~ k , b = ( p min / p b ) h k , b ( 4 B ) h ~ k , m = ( p min / p m ) h k , m ( 4 C )
[0020] In the equations 3A-C and 4A-C, the p min =min(p a ,p b . . . p m ) where p min is the smallest of the p a and p b through p m ; the {tilde over (r)} n,a , {tilde over (r)} n,b through {tilde over (r)} n,m represent prescaled receiver chain signals; and the {tilde over (h)} k,a , {tilde over (h)} k,b through {tilde over (h)} k,m represent the prescaled channel impulse response sets. The p min /p a , p min /p b through p min /p m are noise-based scale factors. An equation 5 shows composite equalizer branch metrics {tilde over (t)} n (s→s′) determined from the prescaled receiver chain signals {tilde over (r)} n,a , {tilde over (r)} n,b through {tilde over (r)} n,m and the prescaled channel impulse response sets {tilde over (h)} k,a , {tilde over (h)} k,b through {tilde over (h)} k,m .
t n ~ ( s → s ′ ) = r ~ n , a - h ~ o , a x n ( s → s ′ ) - ∑ k = 1 K h ~ k , a x n - k ( s ) 2 + r ~ n , b - h ~ o , b x n ( s → s ′ ) - ∑ k = 1 K h ~ k , b x n - k ( s ) 2 ⋯ + r ~ n , m - h ~ o , m x n ( s → s ′ ) - ∑ k = 1 K h ~ k , m x n - k ( s ) 2 ( 5 )
[0021] Because it is the ratio of the scale factors and not their actual values that is necessary for the optimal combining of the receiver chain signals, the p min in the numerator of the scale factors can be replaced by an arbitrary constant. However, an advantage of the use of the p min is that the signal level after automatic gain control (AGC) of the dominant receiver chain signal is retained while the signal levels of the other receiver chains are lowered, thereby retaining the use of the dynamic range of the equalizer. An equation 6 shows a composite equalized signal ũ i of a sample stream of bit probabilities that is analogous to the composite equalized signal u i of the equation 2.
ũ i =F ({{ {tilde over (t)} n ( s→s ′)}, s,s′} n=0 N−1 ) (6)
[0022] In a system using temporal diversity, the noise postscaler dynamically scales packets of the composite equalized signal ũ i by 1/p min 2 in order to eliminate the effect of packet-to-packet changes in noise level.
[0023] It should be noted that the composite equalizer branch metrics {tilde over (t)} n (s→s′) scaled by 1/p min 2 are equal to the composite equalizer branch metrics t n (s→s′) shown in the equation 1 and that the composite equalized signal ũ i times 1/p min 2 is the composite equalized signal u i . However, the prescaling and postscaling of the present invention have substantially reduced the number of multiplications that are required.
[0024] For an alternative embodiment the equation 1 may be reformatted as shown in an equation 7.
t n ″ ~ ( s → s ′ ) = 1 p a 2 p b 2 … p m 2 product ( p 2 a ) r n , a - h o , a x n ( s → s ′ ) - ∑ k = 1 K h k , a x n - k ( s ) 2 + 1 p a 2 p b 2 … p m 2 product ( p 2 b ) r n , b - h o , b x n ( s → s ′ ) - ∑ k = 1 K h k , b x n - k ( s ) 2 ⋯ + 1 p a 2 p b 2 … p m 2 product ( p 2 m ) r n , m - h o , m x n ( s → s ′ ) - ∑ k = 1 K h k , m x n - k ( s ) 2 ( 7 )
[0025] In the equation 7 the product(p {overscore (a)} 2 ) is the product of all the noise representations p a 2 , p b 2 through p m 2 except the noise representation p a 2 ; the product(p {overscore (b)} 2 ) is the product of all the noise representations p a 2 , p b 2 through p m 2 except the noise representation p b 2 ; the product(p {overscore (m)} 2 ) is the product of all the noise representations p a 2 , p b 2 through p m 2 , except the noise representation p m 2 ; and the {tilde over (t)} n ″(s→s′) represents the equalizer branch metrics corresponding to the trellis transition from state s to state s′, for the nth index. The product(p {overscore (a)} )/p a p b . . . p m , product(p {overscore (b)} )/p a p b . . . p m through product(p {overscore (m)} )/p a p b . . . p m or their squares are noise-based scale factors. For only two receiver chains “a” and “b”, the product(p {overscore (a)} 2 ) is p b 2 and the product(p {overscore (b)} 2 ) is p a 2 . For this alternative embodiment, the spatial diversity combiner includes noise prescalers for implementing equations 8A-C, 9A-C and 10 for determining composite equalizer branch metrics {tilde over (t)} n ″(s→s′) for the spatial diversity combiner with the prescaling for the receiver chains “a”, “b” through “m”.
{tilde over (r)}″ n,a =product( p {overscore (a)} /p max ) r n,a (8A)
{tilde over (r)}″ n,b =product( p {overscore (b)} /p max ) r n,b (8B)
{tilde over (r)}″ n,m =product( p {overscore (m)} /p max ) r n,m (8C)
{tilde over (h)}″ k,a =product( p {overscore (a)} /p max ) h k,a (9A)
{tilde over (h)}″ k,b =product( p {overscore (b)} /p max ) h k,b (9B)
{tilde over (h)}″ k,m =product( p {overscore (m)} /p max ) h k,m (9C)
[0026] [0026] t ~ n ″ ( s → s ′ ) = r ~ n , a ″ - h ~ o , a ″ x n ( s → s ′ ) - ∑ k = 1 K h ~ k , a ″ x n - k ( s ) 2 + r ~ n , b ″ - h ~ o , b ″ x n ( s → s ′ ) - ∑ k = 1 K h ~ k , b ″ x n - k ( s ) 2 ⋯ + r ~ n , m ″ - h ~ o , m ″ x n ( s → s ′ ) - ∑ k = 1 K h ~ k , m ″ x n - k ( s ) 2 ( 10 )
[0027] In the equations 8A-C and 9A-C, the p max =max(p a ,p b . . . p m ) where p max is the largest of the noise representations p a and p b through p m ; the {tilde over (r)}− n,a , {tilde over (r)}″ n,b through {tilde over (r)}″ n,m represent prescaled receiver chain signals; the {tilde over (h)}″ k,a , {tilde over (h)}″ k,b through {tilde over (h)} k,m represent the prescaled channel impulse response sets; and the {tilde over (t)} n ″(s→s′) represents composite equalizer branch metrics for the receiver chain signals {tilde over (r)}″ n,a , {tilde over (r)}″ n,b through {tilde over (r)}″ n,m and the channel impulse response sets {tilde over (h)}″ k,a , {tilde over (h)}″ k,b through {tilde over (h)}″ k,m . The product(p {overscore (a)} /p max ) is the product of the noise representations for all the receiver chains except the receiver chain “a” divided by the largest noise representation, the product(p {overscore (b)} /p max ) is the product of the noise representations for all the receiver chains except for the receiver chain “b” divided by the largest noise representation, product(p {overscore (m)} /p max ) is the product of the noise representations for all the receiver chains except for the receiver chain “m” divided by the largest noise representation. The product(p {overscore (a)} /p max ), product(p {overscore (b)} /p max ) through product(p {overscore (m)} /p max ) are noise-based the scale factors. For only two receiver chains “a” and “b”, the product(p {overscore (a)} /p max ) is p b /p max and the product(p {overscore (b)} /p max ) is p a /p max . For three receiver chains “a”, “b” and “c”, the product(p {overscore (a)} /p max ) is p b p c /p max the product(p {overscore (b)} /p max ) is p a p c /p max 2 and the product(p {overscore (c)} /p max ) is p a p b /p max 2 . Because it is the ratio of the scale factors and not their actual values that is necessary for the optimal combining the receiver chains, the p max in the denominator of the scale factors may be replaced by an arbitrary constant. However, an advantage of the use of the p max is that the signal level after automatic gain control (AGC) of the dominant receiver chain signal is retained while the signal levels of the other receiver chains are lowered, thereby retaining the use of the dynamic range of the equalizer.
[0028] In a system using temporal diversity, the noise postscaler in the alternative embodiment scales the composite equalizer branch metrics {tilde over (t)} n ″(s→s′) by a postscale factor of p max 2(M−1) /p a 2 p b 2 . . . p m 2 in order to eliminate packet to packet changes in noise level where the M is the total number of receiver chains and the p a 2 p b 2 . . . p m 2 is the product of the quantities that represent the noise variances of all the receiver chains “a”, “b” through “m”. For only two receiver chains “a” and “b” the postscale factor is p max 2 /p a 2 p b 2 . It should be noted that the composite equalizer branch metrics {tilde over (t)} n ″(s→s′) scaled by p max 2 /p a 2 p b 2 are equal to the composite equalizer branch metrics t n (s→s′) shown in the equation 1. Hence the two systems provide the same results.
[0029] In a system using spatial diversity but not temporal diversity, the postscaler is not required. In a system using temporal diversity but not spatial diversity, only one receiver chain, denoted by “a”, is needed and the spatial diversity combiner is an equalizer for equalizing the receiver chain signal r n,a with the channel impulse response set h k,a without the need for noise-based prescaling. For a receiver with only the single receiver chain “a”, the postscaler uses a scale factor of 1/p a 2 for scaling the equalized signal in each data packet.
[0030] The true noise variances for the receiver chain signals r n,a , r n,b through r n,m can be computed and used for the quantities p a 2 , p b 2 through p m 2 , respectively. However, the calculation of such noise variances requires the computationally intensive operations of squaring real and imaginary noise components and then taking a square root of the squared real and imaginary components to compute the prescale factors required for the equations in 3A-C and 4A-C or 8A-C and 9A-C. The noise estimators of the present invention avoid the squaring and square root operations by using real and imaginary cyclic finite impulse response (FIR) filters for determining real and imaginary noises by comparing the symbols of the receiver chain signals r n,a , r n,b through r n,m to a known preamble as dispersed according to the calculated channel impulse response coefficients. The noise estimators then simply add the real and imaginary noises for determining the noise representations p a , p b through p m . An equation 11 shows the determination of the noise representation p a for the receiver chain “a”. The noise representations p b through p m are calculated in an identical manner for a receiver having multiple receiver chains “b” through “m”.
p a = 〈 Re { r n + ξ , a - ∑ k = 0 K h k , a w n - k } 〉 + 〈 Im { r n + ξ , a - ∑ k = 0 K h k , a w n - k } 〉 ( 11 )
[0031] In the equation 11, the w n−k represents the symbols corresponding to a known training sequence in the incoming signal, the ξ is the time index offset of the first received symbol corresponding to the training sequence received in the receiver chain “a”, and the outer brackets “< >” denote averaging. It should be noted that the method of the present invention takes advantage of the fact that the noise on the incoming signal is approximately uncorrelated between real and imaginary and both the real and imaginary noises have approximately a Gaussian distribution.
[0032] In a preferred embodiment for a Global System for Mobile Communication (GSM) system, the cyclic FIR filters take advantage of the fact that a 26 bit preamble includes a pre-pended 5 bits that duplicate the last 5 bits of a 16 bit mid-section and a post-pended 5 bits that duplicate the first 5 bits of the 16 bits of the mid-section for operating in a circular manner.
[0033] These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read this summary and the following detailed description of the preferred embodiments which are illustrated in the various figures.
IN THE DRAWINGS
[0034] [0034]FIG. 1 is a block diagram of a receiver of the present invention for determining a noise representation and then using the noise representation for combining signals having temporal and spatial diversity;
[0035] [0035]FIG. 2 is a diagram of a system showing multiple signals channels with multiple antennas in the receiver of the present invention;
[0036] [0036]FIG. 3 is another block diagram of the receiver of FIG. 1;
[0037] [0037]FIG. 4 is a block diagram of a noise estimator of the receiver of FIG. 1;
[0038] [0038]FIG. 5 is a flow chart of a method for determining a noise representation and then using the noise representation for combining signals having temporal and spatial diversity of the receiver of FIG. 1;
[0039] [0039]FIG. 6 is a flow chart for combining signals in the method of FIG. 5; and
[0040] [0040]FIG. 7 is a flow chart for determining the noise representation in the method of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] [0041]FIG. 1 is a block diagram of a preferred embodiment of a receiver of the present invention referred to by a general reference number 10 . The receiver 10 includes a receiver chain 12 A for processing signals received in an antenna A a , denoted by 14 A, and a receiver chain 12 B for processing signals received by an antenna A b , denoted by 14 B. Although the receiver 10 is illustrated and described for two channels, the idea may extended to any number of channels.
[0042] The receiver chain 12 A includes analog circuits G a , denoted by 24 A; an analog-to-digital converter A/D a , denoted by 26 A; and digital circuits g a ; denoted by 28 A. Similarly, the receiver chain 12 B includes analog circuits G b , denoted by 24 B; an analog-to-digital converter A/D b , denoted by 26 B; and digital circuits g b , denoted by 28 B. The antennas A a 14 A and A b 14 B convert incoming radio frequency (RF) signals from an airwave to a conducted form. The analog circuits G a 24 A and G b 24 B filter, amplify, and downconvert the conducted RF signals to a lower frequency. The analog circuits G a 24 A and G b 24 B also provide automatic gain control (AGC) for the signals. The A/D a 26 A and A/D b 26 B convert the lower frequency signals from an analog form to a digital form. The digital circuits g a 28 A and g b 28 B apply further filtering, amplification, frequency conversion, and AGC to the digitized signals and issue sampled receiver chain signals r n,a and r n,b where n is the index of the nth signal symbols received in the receiver chains 12 A and 12 B, respectively. The antenna A a 14 A has a different spatial location than the antenna A b 14 B, thereby providing spatial diversity.
[0043] Referring to FIG. 2, the receiver 10 receives a signal 30 from a transmitter 31 through a signal transmission channel A, denoted by 32 A; and a signal transmission channel B, denoted by 32 B, to antennas A a 14 A and A b 14 B, respectively. Because antennas A a 14 A and A b 14 B are physically separated, the signal transmission channels A 32 A and B 32 B are different and in general have different multipath. For temporal diversity, the transmitter 31 interleaves information bits into time-separated packets according to a system specification. The transmitter 31 also encodes and frames the information bits with an error detection/correction algorithm into packets. The encoded interleaved framed packets of transmitted bits are carried on the signal 30 .
[0044] Returning to FIG. 1, the receiver 10 also includes a summer 34 , a timing recovery circuit 36 , a noise comparator 37 , a diversity processor 38 , and a postprocessor 39 . The diversity processor 38 weights, combines and equalizes the receiver chain signals r n,a and r n,b by determining effective equalizer branch metrics according to the equation 1 or the equation 10.
[0045] The diversity processor 38 preferably includes a noise-based spatial diversity combiner 40 and a noise postscaler 41 . The spatial diversity combiner 40 includes a noise prescaler 42 A, a noise prescaler 42 B, and an equalizer 43 . The noise prescaler 42 A can also be considered a part of the receiver chain 12 A and similarly the noise prescaler 42 B can be considered a part of the receiver chain 12 B.
[0046] The receiver chain 12 A also includes a channel estimator 44 A, a squarer 45 A, a noise estimator 46 A, and buffers 48 A and 49 A. Similarly, the receiver chain 12 B includes a channel estimator 44 B, a squarer 45 B, a noise estimator 46 B, and buffers 48 B and 49 B. For the purpose of the present invention, there is no significant difference whether the analog circuits G a ,G b 24 A,B, the analog-to-digital converters A/D a ,A/D b 26 A,B, the digital circuits g a ,g b 28 A,B, and the channel estimators 44 A,B, the squarers 45 A,B, and the noise estimators 46 A,B are constructed separately for the receiver chains 12 A, 12 B; or are constructed so as to span the receiver chains A,B 12 A, 12 B.
[0047] The noise estimator 46 A determines a representation p a of the noise variance for the noise, including signal interference, for the receiver chain signal from the digital circuit g a 28 A and passes the noise representation p a to the noise comparator 37 . Similarly, the noise estimator 46 B determines a representation p b of the noise variance for the noise, including signal interference, for the receiver chain signal from the digital circuit g b 28 B and passes the noise representation p b to the noise comparator 37 . It is not necessary that the noise representations p a and p b be actual noise variances but only that they each have a relationship or ratio that can be directly to the actual noise variance ratio. The noise comparator 37 determines the smallest of the noise representations p a and p b as a minimum noise representation p min , and then computes a noise-based scale factor p min /p a for the receiver chain 12 A and a noise-based scale factor p min /p b for the receiver chain 12 B.
[0048] The channel estimators 44 A and 44 B use a training sequence embedded in the frames of the receiver chain signals from the digital circuits g a 28 A and g b 28 B, respectively, for estimating channel impulse response sets h k,a and h k,b , respectively. The squarers 45 A and 45 B square absolute values of the channel impulse responses h k,a and h k,b and issue squared outputs H a and H b to the summer 34 . The summer 34 adds the squared channel impulse responses H a and H b and then issues summed squared channel impulse responses to the timing recovery circuit 36 . The timing recovery circuit 36 uses the summed squared channel impulse responses for providing a symbol synchronization index. The buffers 48 A and 48 B use the symbol synchronization index for buffering the receiver chain signals r n,a and r n,b , respectively. The buffers 49 A and 49 B synchronize the channel impulse response sets h k,a and h k,b , respectively.
[0049] The noise comparator 37 passes the scale factors p min /p a and p min /p b to the noise prescalers 42 A and 42 B, respectively. The noise prescaler 42 A includes a signal prescaler 52 A and a transmission channel prescaler 54 A. The signal prescaler 52 A multiplies the buffered received signal samples r n,a by p min /p a for providing a prescaled receiver chain signal {tilde over (r)} n,a as shown in the equation 3A. The transmission channel prescaler 54 A multiplies the buffered channel impulse response set h k,a by p min /p a for providing a prescaled channel impulse response set {tilde over (h)} k,a as shown in the equation 4A. Similarly, the noise prescaler 42 B includes a signal prescaler 52 B and a transmission channel prescaler 54 B. The signal prescaler 52 B multiplies the buffered receiver chain signal r n,b by p min /p b for providing a prescaled receiver chain signal {tilde over (r)} n,b as shown in the equation 3B. The transmission channel prescaler 54 B multiplies the buffered channel impulse response set h k,b by p min /p b for providing a prescaled channel impulse response set {tilde over (h)} k,b as shown in the equation 4B. The noise postscaler 41 uses a scale factor of 1/p 2 min received from the noise comparator 37 for dynamically scaling the composite equalized signal ũ i .
[0050] [0050]FIG. 3 is a block diagram of the receiver 10 showing the receiver chains 12 A and 12 B through to a receiver chain 12 M for providing signals to the noise prescalers 42 A and 42 B through to a noise prescaler 42 M. The noise prescalers 42 A-M pass signals to the equalizer 43 as described above. The receiver chain 12 M is similar in all respects to the receiver chains 12 A and 12 B, and the noise prescaler 42 M is similar in all respects to the noise prescalers 42 A and 42 B, described above. The receiver 10 may have many receiver chains 12 A-M for spatial diversity or spatial and temporal diversity, or only one receiver chain 12 A for temporal diversity but not spatial diversity. The receiver chains 12 A, 12 B through 12 M provide squared channel impulse responses H a , H b through H m to the summer 34 and receive the index from the timing recovery circuit 36 . The noise prescalers 42 A-M receiver prescale scale factors from the noise comparator 37 . The equalizer 43 is preferably a soft equalizer for providing bit probabilities as opposed to a hard equalizer where the actual bits are estimated.
[0051] The equalizer 43 includes functional blocks for a branch metric calculator 62 , a combiner 64 , and a probability calculator 66 preferably implemented together in a digital signal processor (DSP) integrated circuit where the DSP circuit is constructed as a single physical block. Because the DSP circuit is constructed as a single block it may not be possible to separate the functional blocks physically.
[0052] The branch metric calculator 62 uses prescaled channel impulse response sets {tilde over (h)} k,a , {tilde over (h)} k,b through {tilde over (h)} k,m for equalizing prescaled receiver chain signals {tilde over (r)} n,a , {tilde over (r)} n,b through {tilde over (r)} n,m for providing respective noise weighted terms of equalizer branch metrics for the receiver chains 12 A, 12 B through 12 M, respectively. The combiner 64 adds the noise weighted terms for providing the composite equalizer branch metrics {tilde over (t)} n (s→s′) as shown in the equation 5. The probability calculator 66 uses the composite equalizer branch metrics {tilde over (t)} n (s→s′) for providing the composite equalized probability signal ũ i as shown in the equation 6. Technical information for determining an equalized probability signal from equalizer branch metrics is shown by Gordon L. Stüber in “Principles of Mobile Communication, Second Edition” published 2001 by Kluwer Academic Publishers on pages 329-335, and by Gerhard Branch and Volker Franz in “A Comparison of Soft-In/Soft-Out Algorithms for “Turbo-Detection” published in the Proceedings of the International Conference on Telecommunications, ICT-98, on pages 259-263 in June, 1998. In a preferred implementation using a DSP integrated circuit the composite branch metrics {tilde over (t)} n (s→s′) are intermediate results that are used in the equalizer 43 but are not necessarily available outside the equalizer 43 .
[0053] The post processor 39 includes a deinterleaver 74 and a decoder 76 . The noise postscaler 41 issues the postscaled composite equalized probability signal to the deinterleaver 74 . The deinterleaver 74 reverses the interleaving of the system specification for placing the samples back into the order that they would have had without the interleaving performed by the transmitter 31 and passes a deinterleaved signal to the decoder 76 . The decoder 76 uses a decoding algorithm according to a system specification for detecting and correcting errors in the deinterleaved signal in order to recover information bits. The information bits may receive further higher level processing in order to pass information for an application to its intended user.
[0054] The receiver 10 has been described in a detailed embodiment using prescale noise-based scale factors of p min /p a , p min /p b through p min /p m , and a postscale noise-based scale factor of 1/p 2 min as shown in the equations 3A-C, 4A-C, 5, and 6. In an alternative embodiment, a receiver 110 of the present invention uses prescale noise-based scale factors of product(p {overscore (a)} /p max ), product(p {overscore (b)} /p max ) through product(p {overscore (m)} )/p max , and a postscale noise-based scale factor of p max 2(M−1) /p a 2 p b 2 . . . p m 2 as shown in the equations 8A-C, 9A-C and 10.
[0055] In the receiver 110 a noise comparator 137 receives the noise representation p a from the noise estimator 46 A, the noise representation p b from the noise estimator 46 B, and determines the largest of the noise representations p a , p b as a maximum noise p max and then computes the scale factor p b /p max for the receiver chain 12 A and the scale factor as p a /p max for the receiver chain 12 B. The noise comparator 137 passes the scale factor p b /p max to the noise prescaler 42 A, passes the p a /p max to the noise prescaler 42 B, and passes the scale factor p max 2(M−1) /p a 2 p b 2 . . . p m 2 to the noise postscaler 41 .
[0056] For two receiver chains 12 A and 12 B the noise prescaler 42 A uses the scale factor p b /p max for prescaling the buffered receiver chain signal r n,a for providing a prescaled receiver chain signal {tilde over (r)}″ n,a as shown in the equation 8A and prescaling the buffered channel impulse response set h k,a for providing a prescaled channel impulse response set {tilde over (h)}″ k,a as shown in the equation 9A; similarly, the noise prescaler 42 B uses the scale factor p a /p max for prescaling the buffered receiver chain signal r n,b for providing a prescaled receiver chain signal {tilde over (r)}″ n,b as shown in the equation 8B and prescaling the buffered channel impulse response set h k,b for providing a prescaled channel impulse response set {tilde over (h)}″ k,b as shown in the equation 9B. The branch metric calculator 62 of the equalizer 43 uses the prescaled channel impulse response set {tilde over (h)}″ k,a , {tilde over (h)}″ k,b through {tilde over (h)}″ k,m for equalizing the prescaled receiver chain signals {tilde over (r)}″ n,a , {tilde over (r)}″ n,b through {tilde over (r)}″ n,m and the combiner 64 adds the terms for issuing values of composite branch metrics as shown in the equation 10. The probability calculator 66 uses the composite equalizer branch metrics {tilde over (t)} n ″(s→s′) for providing the composite equalized probability signal ũ″ i analogous to the composite equalized signal ũ i shown in the equation 6.
[0057] [0057]FIG. 4 is a block diagram of the noise estimator 46 A of the present invention for the receiver chain 12 A where the receiver 10 , 110 is a Global Systems for Mobile Communications (GSM) cellphone receiver. The GSM system specifies a 26-symbol training sequence of the form w 11 , w 12 , w 13 , w 14 , w 15 , w 0 , w 1 , w 2 , w 3 , w 4 , w 5 , w 6 , w 7 , w 8 , w 9 , w 10 , w 11 , w 12 , w 13 , w 14 , w 15 , w 0 , w 1 , w 2 , w 3 , w 4 . The noise estimator 46 A uses the GSM training sequence in real and imaginary cyclic finite impulse response (FIR) filters for providing the noise representation p a as shown in the equation 11. Block diagrams for the noise estimator 46 B for the receiver chain 12 B or for additional noise estimators for additional receiver chains 12 B through 12 M are the same.
[0058] The noise estimator 46 A includes a cyclic inter-symbol interference (ISI) sequence generator 102 implemented with shift registers, a convolver implemented with real and imaginary convolvers 104 I and 104 Q, a comparator implemented with real and imaginary signal comparators 106 I and 106 Q, and a linear noise combiner 108 . The ISI sequence generator 102 shifts and recycles the sixteen central symbols w 0 through w 15 of the 26-symbol GSM training sequence that are known according to the GSM system specification.
[0059] The 26-symbol GSM training sequence includes a pre-pended section of five symbols w 11 through w 15 followed by a center section of sixteen symbols w 0 through W 15 followed by five post-pended section of five symbols w 0 to w 4 . The pre-pended five symbol section is a duplicate of the last five symbols (w 11 to w 15 ) of the center sixteen symbol section and the post-pended five symbol section is a duplicate of the first five symbols (w 0 to w 4 ) of the center sixteen symbol section. The convolver 104 I is shown for an impulse response set of six coefficients h 0,a to h 5,a . Other numbers of coefficients may be used. At the start, the receiver chain signal r n+ξ,a =r ξ,a for the index n=0 is synchronized with the w 0 as shown at the start of the ISI sequence generator 102 .
[0060] The convolver 104 I includes multipliers 112 I and a convolution summer 114 I. For the index n=0, the multipliers 112 I multiply the first six symbols w 0 , w 15 through w 11 in the generator 102 by the six impulse response coefficients h 0,a , h 1,a through h 5,a , respectively, for providing six products. The six products are added in the convolution summer 114 I and the convolution result of the real n=0 channel dispersed training symbol is passed to the signal comparator 106 I. The signal comparator 106 I determines a difference between the n=0 channel dispersed training symbol and the receiver chain symbol r ξ,a and determines the absolute value of the difference as a real symbol noise amplitude for the first training symbol. The real first symbol noise amplitude is passed to the linear noise combiner 108 . It should be noted that the real symbol noise amplitude is an absolute value.
[0061] This is repeated for the indexes n equal to 1 through 15 while the ISI sequence generator 102 cycles at the same rate, and the results are passed to the linear noise combiner 108 . For example, for the next index (n=1) the generator 102 is cycled so that its first symbol is w 1 , its second symbol is w 0 , and so on so that its fifteenth symbol is w 2 . The multipliers 112 I multiply the first six symbols w 1 , w 0 through w 12 in the generator 102 by the six impulse response coefficients h 0,a , h 1,a through h 5,a , respectively, for providing six new products. The six new products are added in convolution summer 114 I and the real n=1 channel dispersed training symbol is passed to the signal comparator 106 I. The signal comparator 106 I subtracts the n=1 channel dispersed training symbol from the receiver chain symbol r ξ+1,a and passes the absolute value of the difference as a real second symbol noise amplitude to the linear noise combiner 108 .
[0062] The linear noise combiner 108 includes real and imaginary accumulators 122 I and 122 Q and a real imaginary adder 124 . The accumulator 122 I receives the real symbol noise amplitudes. When the accumulator 122 I has accumulated the real symbol noise amplitudes for n from 0 to 15, it passes the accumulated result to the adder 124 . The imaginary convolver 104 Q, the imaginary signal comparator 106 Q, and the imaginary accumulator 122 Q operate in an identical manner.
[0063] The adder 124 adds the accumulated results from the real and imaginary accumulators 122 I and 122 Q for providing the noise representation p a as shown in the equation 11. In an equivalent alternative block diagram, the real and imaginary symbol noise amplitudes are added and then the sum is accumulated for providing the noise representation p a . It should be noted that the averaging shown in the equation 11 is equivalent to adding all the real and imaginary symbol noise absolute amplitudes divided by the number of symbols, sixteen in the above description, that were used in the addition. It should also be noted that the noise representation p a is determined without any requirement for squaring the real and imaginary noise components or for taking a square root of any combination of real and imaginary noise components.
[0064] [0064]FIG. 5 is a flow chart of a method in the receiver 10 , 110 for diversity processing of the incoming signal 30 . In a step 202 the receiver 10 , 110 receives the signal 30 and provides receiver chain signals. In a step 210 noise representations for noise levels of the receiver chain signals are determined. There is a noise representation for the receiver chain signal for each receiver chain, respectively. In a step 212 the noise-based scale factors for each of the receiver chain signals are calculated from the noise representations. Then, in a step 220 the scale factors are used for effectively weighting equalizer branch metrics that represent the receiver chain signals in order to determine the composite equalized signal. In a step 224 , for temporal diversity, the composite equalized signal is deinterleaved. Then, in a step 226 the deinterleaved composite equalized signal is decoded for providing a best estimate of the information bits that were transmitted by the transmitter 31 and carried in the form of coded, interleaved symbols modulated onto the signal 30 .
[0065] [0065]FIG. 6 is a flow chart of a preferred embodiment for the step 220 for determining the composite equalized signal. In a step 232 the channel impulse response coefficients are determined for the receiver chain signal for the receiver chains 12 A-M, respectively. There is a set of channel impulse response coefficients for each receiver chain signal, respectively. In a step 234 the channel impulse response coefficients for each of the receiver chain signals are prescaled with the prescale factor for that receiver chain signal. In a step 242 the receiver chain signals are prescaled with the respective prescale factors. In a step 250 the prescaled receiver chain signals are equalized with the prescaled channel impulse response coefficients for determining a composite equalized signal. Where temporal diversity is used, the composite equalized signal is a preliminary composite equalized signal. In a step 260 , for temporal diversity the preliminary composite equalizer signal is postscaled with the postscale factor for providing the composite equalizer signal.
[0066] The step 250 for equalizing the receiver chain signals functionally includes steps 262 , 264 , and 266 . In the step 262 prescaled equalizer branch metrics are determined from the prescaled receiver chain signals and the prescaled channel impulse response coefficients. In the step 262 , for spatial diversity, the prescaled equalizer branch metrics for the receiver chains 12 A-M are combined for providing the composite equalizer branch metrics. In the step 266 the composite equalizer branch metrics are processed for determining the composite equalized signal. It should be emphasized that the steps 262 - 266 are functional operations that may be performed in various ways by digital signal processing techniques where the functions may or may not be physically separable.
[0067] [0067]FIG. 7 is a flow chart of a preferred embodiment for the step 210 for determining the noise representations. In the step 232 the channel impulse response coefficients are determined for the receiver chain signals for the receiver chains 12 A-M, respectively. In a step 272 a stored replica sequence of predetermined training symbols are continuously shifted and the replica symbols of the shifting sequence are issued in parallel. For the example of GSM the training symbols are shifted in as a circulating cycle. However, the symbols could be shifted in different ways for different system specifications. Real shifting replica symbols are convolved with real channel impulse response coefficients in a step 274 ; and imaginary shifting replica symbols are convolved with imaginary channel impulse response coefficients in a step 275 for providing real and imaginary channel dispersed replica symbols. In a step 276 real symbols noise amplitudes are determined from the absolute values of the differences between the real dispersed replica symbols and the real symbols in the corresponding receiver chain signals. In a step 277 imaginary symbols noise amplitudes are determined from the absolute values of the differences between the imaginary channel dispersed replica symbols and the imaginary symbols in the corresponding receiver chain signals. Each symbol in a receiver chain signal has an unsigned real noise value and an unsigned imaginary noise. In a step 280 the real and imaginary symbol noise values for a receiver chain signal are accumulated over a certain number of symbols for determining the noise representations for that receiver chain signal.
[0068] Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that such disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention. | A wireless receiver for receiving an incoming signal having spatial and temporal diversity. The receiver uses noise-based prescaling of multiple receiver chain signals for optimally combining the receiver chain signals in a composite equalized signal and uses noise-based time-varying postscaling the equalized signal. The receiver determines noise-based scale factors by comparing signal symbols to dispersed replica symbols of a training sequence for the incoming signal. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from Provisional Patent Application No. 60/238,907, filed on Oct. 10, 2000.
BACKGROUND
[0002] The invention generally relates to wireless communication systems. In particular, the invention relates to an improved automatic gain control (AGC) circuit for a time division duplex (TDD), time division multiple access (TDMA) or time division-code division multiple access (TD-CDMA) receiver. For simplicity, the receiver shall be referred to as TDD throughout.
[0003] It is well known in the art that power varies significantly between adjacent time slots in a TDD frame, due to variable data rates or variable number of active users in a time slot. In order to determine the correct AGC gain, the AGC circuit estimates symbol power of the first N symbols as they are received. During this estimation process, the symbols may be lost for data estimation due to imperfect gain control during this time. Depending on the initial accuracy of the gain estimate, this estimation procedure may take a long time.
[0004] A typical TDD frame generally comprises fifteen time slots. Each of the time slots comprises two data bursts, that are separated by a midamble, followed by a guard period which forms the end of the frame. The data bursts transmit the desired data, and the midamble is used to perform channel estimation. Since the midamble is used to perform channel estimation, gain must be constant over the entire time slot in order to get an accurate estimation of the channel.
[0005] Prior art AGC methods have drawbacks. Since both the number of codes and their relative power in the received TDD frame is unknown, the AGC circuit takes unnecessarily long to adjust to the correct level of gain. To determine the estimated symbols, the receiver receives a time slot's worth of data and performs a channel estimation based on the midamble. The channel estimation assumes there is a constant gain and that the power of the symbols is known for the duration of the estimation process. Interference with channel estimation can occur if the AGC is active during the midamble or either data burst. If the first few data symbols have a signal strength that is significantly less than the remainder of the symbols in the TDD frame, these data symbols may not be properly received due to the weakness of the symbols. Accordingly, channel estimation under this prior art AGC method ultimately results in a channel estimation that is slow and not very accurate.
SUMMARY
[0006] The present invention is an enhanced TDD frame structure which includes a preamble for gain estimation, and includes a method and apparatus for using this enhanced TDD frame. The preamble enables the AGC circuit to quickly estimate the power level of the received signal and to adjust the gain level accordingly. This permits all data symbols within the data burst to be correctly received, and results in a midamble channel estimate that is much more accurate. It also allows the AGC circuit within the TDD receiver to be greatly simplified. Further improvements are afforded by utilizing a preamble having a binary phase shift keying (BPSK) format.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is an illustration of an enhanced TDD communication burst with a preamble.
[0008] [0008]FIG. 2 shows a block diagram of an AGC circuit that processes the communication burst of FIG. 1.
[0009] [0009]FIG. 3 shows a method flowchart for channel estimation using the circuit of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] [0010]FIG. 1 shows an improved TDD communication burst 10 having a preamble 11 , two data bursts 12 , 16 , a midamble 14 , two transport format combination indicator (TFCI) periods 15 , 17 and a guard period 18 . As shown, the communication burst 10 comprises one time slot of the TDD signal architecture. The two data bursts 12 , 16 are separated by the midamble 14 and the two TFCI periods 15 , 17 .
[0011] Each portion of the TDD communication burst 10 supports a different function. The midamble 14 facilitates estimation of the transmitter channel. The two data bursts 12 , 16 comprise the data carrying portion of the communication burst 10 , and are used to transport the desired data. Administrative functions of the communication system are handled using transport sets. The TFCI periods 15 , 17 store the information bits associated with these transport sets and instruct the receiver as to how the data is partitioned within the communication burst 10 . The guard period 18 is void of information and is provided as a demarcation gap between consecutive time slots.
[0012] In accordance with the present invention, the preamble 11 comprises one or more symbols. Preferably the preamble 11 is in binary phase shift keying (BPSK) format, although this is not required. A BPSK symbol format is preferably used since power estimation can be simply determined by squaring the BPSK signal. The remainder of the communication burst 10 is formatted as a quadrature phase shift keying (QPSK) signal. The inclusion of the preamble 11 allows for an easier estimation of the power level of the signal. The preamble 11 is preferably a pseudo-random sequence, randomly generated and then maintained as a fixed sequence. Since the pseudo-random sequence is the same for every time slot, synchronization is simplified by requiring only a single correlator for the system. A pseudo-random signal also provides for maximum spreading, thereby avoiding a concentrating of power which is unfavorable. In addition, using a pseudo-random signal allows for the elimination of a DC bias in the signal.
[0013] [0013]FIG. 2 shows a simplified automatic gain control (AGC) circuit made in accordance with the present invention, which takes advantage of the preamble 11 . The AGC circuit 30 comprises a voltage variable attenuator (VVA) 39 , an analog-to-digital (A/D) converter 34 , a switch 41 , a power estimation unit 35 , a power reference 47 , a summer 36 , a feedback filter 37 , and a digital-to-analog (D/A) converter 38 . The switch 41 , power estimation unit 35 , power reference 32 , summer 36 , feedback filter 37 and D/A converter 38 together form a feedback loop 43 .
[0014] The VVA 39 is a standard electronic device used in AGC circuits for receiving an input signal and adjusting the amplifier gain to maintain a constant output signal level for further receiver processing. The A/D converter 34 accepts the analog signal output from the VVA 39 and outputs a digital signal 33 . The power estimation unit 35 accepts the digital signal 33 and mathematically processes the digital signal with a predetermined algorithm to average the power level of the sequence of symbols that form the communication burst 10 . Preferably, the power is estimated using the following formula:
P est = 1 N ∑ J = 1 N I J 2 + Q J 2 Equation ( 1 )
[0015] This average power level is provided to the first input of the summer 36 as a power estimation signal 43 . The summer 36 performs a simple sum of the two signal inputs: 1) the power estimation signal 43 output from the power estimation unit 35 ; and 2) the power reference signal 32 output from the power reference unit 47 . Since the power reference signal 32 output from the power reference unit 47 is preferably a negative signal, the power reference signal 32 is essentially subtracted from power estimation signal 43 to generate an error signal 40 . The error signal 40 is then input to the feedback filter 37 . The feedback filter 37 is an integrator, or alternatively, a low pass filter. The feedback filter 37 sets the time constant of the feedback loop to ensure stability and smooth out variations of the error signal 40 . The filtered output signal 48 is input into the switch 41 .
[0016] The switch 41 determines whether the filtered output signal 48 is within a predetermined tolerance threshold. If so, the switch 41 holds the filtered output signal 48 , thereby maintaining a switch output signal 49 at the same level as the filtered output signal 48 when the switch was opened. If the filtered output signal 48 is not within the predetermined tolerance threshold, the filtered output signal 48 is permitted by switch 41 to fluctuate from the previous pass through the feedback filter 37 . The switch output signal 49 is then converted to an analog signal 50 by the D/A converter 38 , and this analog signal 50 is used as a control signal to adjust the gain of the VVA 39 . The A/D and D/A converters 34 , 38 are well known and widely used in the art and need not be described in detail herein.
[0017] Referring to FIG. 3, a preferred method 100 in accordance with the present invention is shown. The method is initiated when the communication burst 31 initially passes through the VVA 39 in step 101 and is then digitally converted by the A/D converter 34 . The digital signal 33 enters the feedback loop 43 and is next processed by the power estimation unit 35 in step 102 . The negative predetermined power reference signal 32 is added to the power estimate at summer 36 , resulting in an error signal 40 (step 103 ). The error signal 40 is averaged by the feedback filter 37 (step 104 ). A decision step 105 is performed to determine whether the error signal 40 is low enough (i.e. lower than a threshold) to complete the channel estimation process. If the error signal 40 is less than the error threshold, the channel estimation process is complete, and the feedback loop 43 is set by switch 41 to hold the VVA 39 control signal constant (step 106 ) for the remainder of the time slot.
[0018] However, if the error signal 40 is greater than the tolerance, the control signal from the filter 37 is converted by the D/A converter 38 and is used as a control signal to the VVA 39 (step 107 ), and the channel estimation is repeated. The power estimation and attenuation adjustment process may be repeated for a second symbol of the preamble, or more, until the error is reduced to an acceptable level and the switch 41 is activated. The attenuation provided by the VVA 39 is then fixed for the remainder of the time slot (step 106 ). This process is preferably repeated for each time slot.
[0019] One advantage of using the preamble in accordance with the present invention, with respect to hardware, is in reducing the required size of the A/D converter 34 . A typical size for A/D converter 34 in accordance with the present invention is six (6) to ten (10) bits, depending on requirements. | A method and system for automatic gain control (AGC) in a TDD communication system, wherein each time slot of the communication signal contains a preamble in binary phase shift keying (BPSK) format, located at the beginning of the time slot. The channel estimation by the receiver is improved since the preamble allows AGC to quickly estimate the signal strength and adjust the gain accordingly. This permits all data symbols within the data burst, which follows the preamble, to be correctly received, and results in a midamble channel estimate that is much more accurate. It also allows the AGC circuit within the TDD receiver to be greatly simplified. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to a rubber band machine for processing a rubber band into a rubber ring.
BACKGROUND OF THE INVENTION
[0002] During the production of rubber rings, the common manufacturing process is as follows: taking bundles or rolls of rubber bands as raw materials, cutting them into segments and sewing them into rings. During the production, those operations are accomplished manually or by a plurality of single machines with different functions. Chinese Utility Model Patent No. 201020269752.5 titled Rubber Band Feeding Device for Automatic Rubber band Machines, Chinese Utility Model Patent No. 201020269792.X titled Rubber Band Length Control Device for Automatic Rubber Band Machines, Chinese Utility Model Patent No. 201020269783.0 titled Cutting Device for Automatic Rubber Band Machines, Chinese Utility Model Patent No. 201020269797.2 titled Rubber Band Looping Device for Automatic Rubber Band Machines, and Chinese Utility Model Patent No. 201020269802.X titled Pulling Device for Automatic Rubber Band Machines disclosed a full-automatic rubber band processing equipment integrating sorting, feeding, length controlling, cutting, splicing and sewing in one equipment. Such a full-automatic rubber band processing equipment can automatically accomplish the whole production procedure of processing rubber bands into rubber rings. However, the processability and production assembly of such a full-automatic rubber band processing equipment can be further improved.
SUMMARY OF THE INVENTION
[0003] In view of the status of the prior art, the present invention provides a rubber band machine with higher processing efficiency.
[0004] To solve the above technical solution, the present invention employs the following technical solution: a rubber band machine is provided, comprising a feeding device, a cutting device and a looping device, characterized in that the feeding device comprises a first rack and a second rack arranged at intervals, the first rack being provided with a first feeding drive wheel driven by a first motor, the second rack being provided with a second feeding drive wheel driven by a second motor; the looping device comprises a first gripper capable of rotating around a first axis, a second gripper capable of rotating around a second axis, a bracket disposed between the first gripper and the second gripper, and a third gripper capable of rotating around a third axis; the first feeding drive wheel rotates and inputs a predetermined length of rubber band between the first feeding drive wheel and the second feeding drive wheel, the third gripper grips one end of the rubber band at the discharge port of the second feeding drive wheel and rotates around the third axis under the auxiliary feeding of the second feeding drive wheel to allow a predetermined length of the rubber band to pass through the first gripper and the second gripper, and then the rubber band at the discharge port of the second feeding drive wheel is cut by the cutting device; after gripping two ends of the cut rubber band, the first gripper and the second gripper rotate around the first axis and the second axis, respectively, to fix the two ends of the rubber band onto the bracket.
[0005] To optimize the above technical solution, the present invention further comprises the following improved technical solution.
[0006] The rubber band input by the first feeding drive wheel is suspended between the first feeding drive wheel and the second feeding drive wheel; a stock sensor for detecting the suspension state of the rubber band is disposed below the first feeding drive wheel; the second feeding drive wheel conveys the suspended rubber band when the third gripper moves rotationally; and, the first motor controls the first feeding drive wheel to convey a next predetermined length of the rubber band after the stock sensor detects that the rubber band in the suspended state is straightened.
[0007] The first rack is provided with a first feeding driven wheel fitted with the first feeding drive wheel; the second rack is provided with a second feeding driven wheel fitted with the second feeding drive wheel; a rubber band conveying passage is disposed above the first feeding drive wheel, and a heating plate for ironing the rubber band and a heating cylinder for controlling the heating plate to move close to or move away from the rubber band conveying passage are provided on one side of the rubber band conveying passage.
[0008] A joint sensor for detecting the thickness of the rubber band is provided on one side of the rubber band conveying passage, and the joint sensor controls the first motor to stop working when detecting that the thickness of the rubber band becomes larger.
[0009] The cutting device comprises a moving cutter and a stationary cutter disposed at the discharge port of the second feeding drive wheel, the moving cutter being connected to the drive rod of a cutting cylinder.
[0010] The looping device comprises a third rack on which a slidable base is disposed, the base being connected to the drive rod of a sliding cylinder; and, the first gripper, the second gripper and the bracket are all disposed on the base.
[0011] The base is provided with a first rotating cylinder for driving the first gripper to rotate around the first axis and a second rotating cylinder for driving the second gripper to rotate around the second axis at intervals, and the distance from the first axis to the second axis is adjustable.
[0012] The third rack is provided with a third drive shaft capable of rotating, and one end of the third drive shaft is connected to the third gripper via a third connecting arm while the other end thereof is linked to a third rotating cylinder on the third rack.
[0013] A second guide rail, on which the bracket is slidably disposed, is disposed on the base, and a tension spring is disposed between the bracket and the base.
[0014] Compared with the prior art, the rubber band machine provided by the present invention can allow the first feeding drive wheel to convey a predetermined length of rubber band by controlling the angle of rotation of the first motor, and each segment of the rubber band input by the first feeding drive wheel is stored between the first feeding drive wheel and the second feeding drive wheel so that the second feeding drive wheel coordinates with a looping device to output the rubber band continuously. During feeding, the rubber band machine may perform joint examination and ironing to the rubber band, and automatically cut the rubber band off at the discharge port of the second feeding drive wheel via the cutting device. The looping device grips the rubber band via the third gripper and moves rotationally to convey two ends of the rubber band to the first gripper and the second gripper, respectively. After the first gripper and the second gripper have gripped the two ends of the rubber band, the rubber band forms a rubber ring by rotational motion of the first gripper and the second gripper, and the two jointed ends of the rubber ring are fixed on the bracket for subsequent sewing and fixation. The looping device has the advantages of simple structure and automatic control, and the looping speed of rubber bands is thus greatly improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a stereoscopic/three dimensional structure diagram according to an embodiment of the present invention;
[0016] FIG. 2 is a stereoscopic structure diagram of a feeding part of FIG. 1 ;
[0017] FIG. 3 is an exploded assembly view of a first rack part of FIG. 2 ;
[0018] FIG. 4 is an exploded assembly view of a second rack part of FIG. 2 ;
[0019] FIG. 5 is a stereoscopic structure diagram of a looping device of FIG. 1 ;
[0020] FIG. 6 is a rear stereoscopic structure diagram of FIG. 5 ; and
[0021] FIG. 7 is an exploded assembly view of FIG. 6 .
[0022] In the drawings, the meanings of the reference numerals are as follows: 1 —First rack; 11 —Heating plate; 11 a —Heating guide rail; 11 b —Electrical heating rod; 12 —Heating cylinder; 12 —Stock sensor; 14 —Third motor; 15 —Material sorting roller; 16 —Backup plate; 17 —Adjusting and limiting stopper; 18 —Joint sensor; 18 a —Sensing flap; 2 —Second rack; 21 —First mounting substrate; 22 —Second mounting substrate; 23 —Third mounting substrate; 24 —Feeding carrier; 25 —Driven wheel shaft; 26 —Adjusting block; 3 —First feeding drive wheel; 31 —First motor; 32 —First feeding driven wheel; 33 —First driven wheel mounting support; 34 —First spring; 4 —Second feeding drive wheel; 4 a —Rotary drive shaft; 41 —Second motor; 41 a —First synchronous wheel; 41 b —Second synchronous wheel; 41 c —First synchronous belt; 42 —Second feeding driven wheel; 43 —Second driven wheel mounting support; 44 —Second spring; 5 —Third rack; 5 a —Bedplate; 5 b —Support frame; 51 —Sliding cylinder; 52 —Third drive shaft; 52 a —Third synchronous wheel; 53 —Third connecting arm; 54 —Third rotating cylinder; 54 a —Fourth synchronous wheel; 54 b —Second synchronous belt; 55 —First guide rail; 57 —Third gripper; 6 —Base; 61 —Bracket; 61 a —Material support frame; 62 —Second gripper; 63 a —Second cylinder mounting plate; 63 b —Second drive shaft; 63 c —Second connecting arm; 63 d —Second rotating cylinder; 64 —Second guide rail; 65 —Tension spring; 66 —Support plates; 67 —Connecting plate; 67 a —Carrier mounting frame; 67 b —Carrier; 68 —Air pipe mounting support; 68 a —Air blowpipe; 68 b —Mounting shaft; 68 c —Positioning backup plate; 7 —Moving cutter; 71 —Stationary cutter; 72 —Cutting cylinder; 73 —Moving cutter mounting frame; 74 —Moving cutter arm; 8 —Gripping cylinder; 81 —Fixed arm; and, 82 —Moving arm.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Embodiments of the present invention will be further described as below in details with reference to the accompanying drawings.
[0024] As shown in FIG. 1 , the rubber band machine provided by the present invention comprises a feeding device, a cutting device and a looping device. The feeding device comprises a first rack 1 and a second rack 2 arranged at intervals. The first rack 1 is provided with a first feeding drive wheel 3 driven by a first motor 31 . The second rack 2 is provided with a second feeding drive wheel 4 driven by a second motor 41 . The looping device comprises a first gripper 62 capable of rotating around a first axis, a second gripper 63 capable of rotating around a second axis, a bracket 62 disposed between the first gripper 62 and the second gripper 63 , and a third gripper 57 capable of rotating around a third axis. The first feeding drive wheel 3 rotates and inputs a predetermined length of rubber band between the first feeding drive wheel 3 and the second feeding drive wheel 4 . The third gripper 57 grips one end of the rubber band at the discharge port of the second feeding drive wheel 4 and rotates around the third axis under the auxiliary feeding of the second feeding drive wheel 4 to allow a predetermined length of the rubber band to pass through the first gripper 62 and the second gripper 63 , and then the rubber band at the discharge port of the second feeding drive wheel 4 is cut by the cutting device. After gripping two ends of the cut rubber band, the first gripper 62 and the second gripper 63 rotate around the first axis and the second axis, respectively, to fix the two ends of the rubber band onto the bracket 61 .
[0025] As shown FIG. 2 , the feeding device of the rubber band machine comprises a first rack 1 and a second rack 2 spaced apart from each other. The first rack 1 is provided with a first feeding drive wheel 3 driven by a first motor 31 . The second rack 2 is provided with a second feeding drive wheel 4 driven by a second motor 41 . The first feeding drive wheel 3 inputs a predetermined length of rubber band under the control of the first motor 31 , and the rubber band is suspended between the first feeding drive wheel 3 and the second feeding drive wheel 4 . A stock sensor 13 for detecting the suspension state of the rubber band is disposed below the first feeding drive wheel 3 . The second feeding drive wheel 4 conveys the suspended rubber band under the control of the second motor 41 . The first motor 31 controls the first feeding drive wheel 3 to convey a next predetermined length of the rubber band after the stock sensor 13 detects that the rubber band in the suspended state is straightened.
[0026] FIG. 3 shows an exploded assembly view of the first rack 1 part. A rubber band conveying passage is disposed above the first feeding drive wheel 3 . A material sorting roller 15 driven by the third motor 14 is disposed above the first feeding drive wheel 3 . The rubber band conveying passage is vertically disposed between the material sorting roller 15 and the first feeding drive wheel 3 .
[0027] In this embodiment, the first rack 1 is fixedly connected with a backup plate 16 , and the rubber band conveying passage is vertically disposed on the backup plate 16 . An adjusting and limiting stopper 17 for adjusting the width of the rubber band conveying passage is disposed on the backup plate 16 .
[0028] A heating plate 11 for ironing the rubber band and a heating cylinder 12 for controlling the heating plate 11 to move close to or move away from the rubber band conveying passage is disposed on one side of the rubber band conveying passage.
[0029] When the first motor 31 works, the heating cylinder 21 controls the heating plate 11 to move close to the rubber band inside the rubber band conveying passage, and irons the rubber band being conveyed. When the first motor 31 stops working, the heating cylinder 12 controls the heating plate 11 to move away from the rubber band conveying passage.
[0030] The first rack 1 is provided with a heating guide rail 11 a on which the heating plate 11 is slidably disposed. An electrical heating rod 11 b is provided in the heating plate 11 .
[0031] A joint sensor 18 for detecting the thickness of the rubber band is disposed on one side of the rubber band conveying passage. The rubber band may have joints which cannot be allowed during the manufacturing of rubber rings. As the thickness of the rubber band at a joint becomes larger, the first motor 31 and the second motor 41 are controlled to stop conveying the rubber band when the joint sensor 18 detects the thickness of the rubber band becomes larger, so that it is convenient for workers to remove the joints of the rubber band.
[0032] The joint sensor 18 is provided with a freely suspended sensing flap 18 a . One bent portion of the sensing flap 18 a is fitted with the vertical rubber band in the rubber band conveying passage, while the other bent portion of the sensing flap 18 a is positioned in the vicinity of a contact point of the joint sensor 18 . When there is a joint on the rubber band, the sensing flap 18 a comes into contact with the contact point of the joint sensor 18 , so that the joint sensor 18 detects the joint of the rubber band and timely controls the feeding device to stop working.
[0033] The first feeding drive wheel 3 is provided with a first feeding driven wheel 32 clung thereto due to elasticity. A first driven wheel mounting support 33 capable of rotating is disposed on the other side of the backup plate 1 . The first feeding drive wheel 3 is rotatably disposed on the first driven wheel mounting support 33 . The backup plate 16 is provided with a first spring 34 fitted with the first driven wheel mounting support 33 . One end of the first spring is fitted with a mounting rod on the backup plate 16 , while the other end thereof is fitted with a connecting member on the first driven wheel mounting support 33 . The first driven wheel mounting support 33 enables in the aid of the elasticity of the first spring 34 the first feeding driven wheel 32 to cling to the first feeding drive wheel 3 .
[0034] FIG. 4 shows an exploded assembly view of the second rack 2 part. The second rack 2 comprises a first mounting substrate 21 and a second mounting substrate 22 which are provided in parallel, and a third mounting substrate 23 vertically connected to the first mounting substrate 21 and the second mounting substrate 22 , respectively.
[0035] A rubber band conveying passage is provided between the first mounting substrate 21 and the second mounting substrate 22 . A feeding carrier 24 is fixed between the first mounting substrate 21 and the second mounting substrate 22 . A driven wheel shaft 25 is disposed above the feeding carrier 24 . The rubber band conveying passage is positioned between the feeding carrier 24 and the driven wheel shaft 25 .
[0036] After conveyed by the first feeding drive wheel 3 , the rubber band passes between the driven wheel shaft 25 and the feeding carrier 24 and is then conveyed by the second feeding drive wheel 4 . An adjusting block 26 capable of adjusting the width of the rubber band conveying passage is disposed on the driven wheel shaft 25 in order to adapt for conveying rubber bands in different width.
[0037] The second feeding drive wheel 4 is rotatably disposed between the first mounting substrate 21 and the second mounting substrate 22 . The second motor 41 and the second feeding drive wheel 4 are positioned on two sides of the first mounting substrate 21 , respectively. A power output shaft of the second motor 41 is connected with a first synchronous wheel 41 a . The rotary drive shaft 4 a of the second feeding drive wheel 4 passes through the first mounting substrate 21 , and the outgoing end thereof is connected with a second synchronous wheel 41 b . A first synchronous belt 41 c is disposed between the first synchronous wheel 41 a and the second synchronous wheel 41 b . The second motor 41 drives the second feeding drive wheel 4 to move via the first synchronous wheel 41 a , the first synchronous belt 41 c and the second synchronous wheel 41 b.
[0038] A moving cutter 7 and a stationary cutter 71 for cutting the rubber band off are disposed at the discharge port of the second feeding drive wheel 4 . The moving cutter 7 cuts off the rubber band at the discharge port via a cutting cylinder 72 after the second feeding drive wheel 4 completes the feeding of the rubber band.
[0039] In this embodiment, a moving cutter mounting frame 73 is fixedly connected to one side of the third mounting substrate 23 close to the first feeding drive wheel 3 . The moving cutter mounting frame 73 is provided with a moving cutter arm 74 capable of rotating. The moving cutter 7 is fixed on the moving cutter arm 74 and positioned below the second feeding drive wheel 4 .
[0040] The cutting cylinder 72 for driving the moving cutter 7 to rotate is movably mounted on the first mounting substrate 21 , and positioned below the second motor 41 . The drive rod of the cutting cylinder 72 drives the moving cutter arm 74 to rotate via a connecting rod.
[0041] The second feeding drive wheel 4 is provided with a second feeding driven wheel 42 clung thereto due to elasticity. A second driven wheel mounting support 43 capable of rotating is disposed on the outer side of the third mounting substrate 23 , and the second feeding driven wheel 42 is rotatably disposed on the second driven wheel mounting support 43 . The third mounting substrate 23 is provided with a second spring 44 fitted with the second driven wheel mounting support 43 . One end of the second spring 44 is fitted with a mounting rod on the third mounting substrate 23 , while the other end thereof enables due to the elasticity the second feeding driven wheel 42 on the second driven wheel mounting support 43 to compress the second feeding drive wheel 4 .
[0042] When in work, the rubber band passes between the first feeding drive wheel 3 and the first feeding driven wheel 32 at first, and then passes between the second feeding drive wheel 4 and the second feeding driven wheel 42 . A stock sensor 13 is fixedly disposed below the first feeding drive wheel 3 . The length of the rubber band conveyed by the first feeding drive wheel 3 may be controlled by controlling the rotating revolutions of the first motor 31 . After the first feeding drive wheel 3 conveys a predetermined length of rubber band, the rubber band is suspended between the first feeding drive wheel 3 and the second feeding drive wheel 4 , and the suspended rubber band coordinates with the stock sensor 13 to enable the stock sensor 13 to detect that the rubber band is in the suspended state.
[0043] When the third gripper 57 grips and rotates the rubber band, the second motor 41 controls the second feeding drive wheel 4 to feed quickly and output the rubber band for subsequent looping operation. The rubber band suspended between the first feeding drive wheel 3 and the second feeding drive wheel 4 is straightened gradually. The rubber band after straightened is separated from the stock sensor 13 , and the stock sensor 13 controls the first motor 31 to make the first feeding drive wheel 3 convey a next segment of the rubber band after detecting that the rubber band is separated from it.
[0044] As shown in FIG. 5 , the looping device of the rubber band machine comprises a third rack 5 and a base 6 disposed on the third rack 3 . In this embodiment, the third rack 5 is a composite member consisting of a bedplate 5 a and a support frame 5 b . The third rack 5 is positioned below the second rack 2 , so that it is convenient for the third gripper 4 57 to grip the rubber band at the discharge port of the second feeding drive wheel 4 .
[0045] A first guide rail 55 is provided on the bedplate 5 a of the third rack 5 , while the base 6 is slidably disposed on the first guide rail 55 . A sliding cylinder 51 for driving the base 6 to slide is disposed on the third rack 5 . By controlling the base 6 to move via the sliding cylinder 51 , the looped rubber band may be conveyed to a sewing position for sewing.
[0046] The first gripper 62 and the second gripper 63 for gripping the rubber band are disposed on the base 6 at intervals, and may rotate around the first axis and the second axis, respectively. In this embodiment, a first cylinder mounting plate 62 a and a second cylinder 63 a are fixed on the base 6 at intervals, with a first rotating cylinder 62 d and a second rotating cylinder 63 d being mounted on the first cylinder mounting plate 62 a and the second cylinder 63 a , respectively.
[0047] The first rotating cylinder 62 d is provided with a first drive shaft 62 b connected to the first gripper 62 via a first connecting arm 62 c . The first axis is coincided with the axis of the first drive shaft 62 b . The second rotating cylinder 63 d is provided with a second drive shaft 63 b connected to the second gripper 63 via a second connecting arm 63 c . The second axis is coincided with the axis of the second drive shaft 63 b.
[0048] The first rotating cylinder 62 d may drive the first gripper 62 to rotate around the first drive shaft 62 where the first axis is located. The second rotating cylinder 63 d may drive the second gripper 63 to rotate around the second drive shaft 63 b where the second axis is located.
[0049] The first cylinder mounting plate 62 a and the second cylinder mounting plate 63 a are formed with adjustable mounting grooves, respectively. The positions of the first cylinder mounting plate 62 a and the second cylinder mounting plate 63 a on the base 6 may be adjusted by the adjustable mounting grooves, thereby adjusting the distance from the first axis to the second axis.
[0050] A bracket 61 is disposed between the first gripper 62 and the second gripper 63 , and fixed on the base 6 via a material support frame 61 a.
[0051] The material support frame 61 a has an extended end which is positioned between the first gripper 62 and the second gripper 63 . The bracket 61 is fixed on the end of the material support frame 61 a . The first rotating cylinder 62 d and the second rotating cylinder 63 d may drive the corresponding first gripper 62 and second gripper 63 to rotate, respectively, to fix the gripped rubber band onto the bracket 61 .
[0052] In this embodiment, the extended end of the material support frame 61 a is protruded relatively. The bracket 61 will run into a sewing device in the process of moving the base 6 to the sewing position. Therefore, during the movement of the base 6 , the movement stroke of the bracket 61 is less than that of the base 6 . To make the movement stroke of the bracket 61 less than that of the base 6 , a second guide rail 64 is disposed on the base 6 . The second guide rail 64 is positioned between the first cylinder mounting plate 62 a and the second cylinder mounting plate 63 a . The material support frame 61 a is slidably disposed on the second guide rail 64 , and a tension spring 65 is provided between the material support frame 61 a and the base 6 . In this way, the bracket 61 may stop moving when running into the sewing device, and the base 6 continues to move and convey the looped rubber band to the sewing position.
[0053] The base 6 is connected to a connecting plate 67 via two support plates 66 . An air pipe mounting support 68 is fixed at the upper part of the connecting plate 67 . The air pipe mounting support 68 is provided with two air blowpipes 68 a connected to an air pump. The outlets of the air blowpipes 68 a are positioned above the bracket 61 . A mounting shaft 68 b is fixed between the two air blowpipes 68 a , and fixedly provided thereon with a positioning backup plate 68 c for positioning the rubber band. A carrier mounting frame 67 a , fixed with a carrier 67 b , is fixed on the side wall of the connecting plate 67 . The carrier 67 b is positioned above the bracket 61 . When rotating to the position of the bracket 61 , the first gripper 62 and the second gripper 63 are rightly positioned on two sides of the carrier 67 b.
[0054] The third rack 5 is provided with the third gripper 57 capable of rotating around the third axis, and a third rotating cylinder 54 for driving the third gripper 57 to rotate around the third axis.
[0055] Before looping the rubber band, the first gripper 62 and the second gripper 63 are positioned on two sides of the bracket 61 , and the third axis is positioned between the first axis and the second axis. The radius, by which the third gripper 57 rotates around the third axis, is rightly fitted with the distance from the third gripper 57 to the first gripper 62 and the second gripper 63 . Thus, the third gripper 57 may pass through the unfolded first gripper 62 and second gripper 63 , respectively, while rotating around the third axis.
[0056] The third rotating cylinder 54 may directly drive the third gripper 57 to move rotationally, or may drive the third gripper 57 to move rotationally via a transmission structure.
[0057] In this embodiment, the support frame 5 b of the third rack 5 is provided with a third drive shaft 52 capable of rotating, with the axis of the third drive shaft 52 being coincided with the third axis. The third drive shaft 52 is connected to the third gripper 57 via a third connecting arm 53 . The third gripper 57 may rotate around the third drive shaft 52 where the third axis is located. A third synchronous wheel 52 a is fixed on the third drive shaft 52 . A fourth synchronous wheel 54 a is fixedly provided on the drive shaft of the third rotating cylinder 54 . The third synchronous wheel 52 a is linked to the fourth synchronous wheel 54 a via a second synchronous belt 54 b.
[0058] In this embodiment, with a similar structure, the first gripper 62 , the third gripper 63 and the third gripper each comprises a fixed arm 81 , a moving arm 82 and a gripping cylinder 8 for driving the moving arm 82 to coordinate with the fixed arm for gripping. The fixed arm 81 is mounted on the body of the gripping cylinder 8 , while the moving arm 82 is connected to the piston rod of the gripping cylinder 8 . The moving arm 82 may be controlled to coordinate with the fixed arm 81 for gripping under the drive of the gripping cylinder 8 .
[0059] When in work, the first gripper 62 and the second gripper 63 are positioned on two sides of the bracket 61 , respectively, and are unfolded for gripping. The third gripper 57 grips an end of the rubber band at the discharge port of the second feeding drive wheel 4 , and rotates around the third axis to allow the end of the end of the rubber band to pass through the unfolded first gripper 62 and second gripper 63 . After the first gripper 62 and the second gripper 63 have gripped corresponding portions of the rubber band, the cutting device cuts off the segment of rubber band gripped by the first gripper 62 and the second gripper 63 . At this time, two ends of this segment of rubber band have been gripped by the first gripper 62 and the second gripper 63 . Subsequently, the first gripper 62 and the second gripper 63 move rotationally to the position of the bracket 61 , respectively, where the two ends of the rubber band are fixedly joined on the bracket 61 , and the rubber band is spliced into a ring. The sliding cylinder 51 controls the base 6 to move to convey the first gripper 62 , the second gripper 63 and the bracket 61 to the sewing position for sewing. The air blowpipes 68 a and the positioning backup plate 68 c may assist in positioning the looped rubber band, thereby conveying the rubber ring to the sewing device.
[0060] The distance from the first axis to the second axis can be adjusted by adjusting the mounting positions of the first cylinder mounting plate 62 a and the second cylinder mounting plate 63 a . During looping a rubber band, the connecting parts are overlapped or spliced as required. When the distance from the first axis to the second axis shortens, two ends of the rubber band are overlapped after the first gripper 62 and the second gripper 63 rotate and fold the rubber band. When the distance from the first axis to the second axis increases, two ends of the rubber band are spliced after the first gripper 62 and the second gripper 63 rotate and fold the rubber band.
[0061] The preferred embodiment of the present invention has been described above. Various changes or variations made by an ordinary person of skill in the art shall not depart from the scope of the present invention. | The present invention discloses a rubber band machine. The length of a rubber band to be conveyed may be set by controlling the angle of rotation of a first motor. The rubber band input by a first feeding drive wheel is stored between the first feeding drive wheel and a second feeding drive wheel so that the second feeding drive wheel coordinates with a looping device to continue to output the rubber band. During feeding, the rubber band machine can perform joint examination and ironing to the rubber band, and automatically cut the rubber band off at the discharge port of the second feeding drive wheel via a cutting device. The looping device grips the rubber band via a third gripper and moves rotationally to convey two ends of the rubber band to a first gripper and a second gripper, respectively. After the first gripper and the second gripper have gripped the two ends of the rubber band, the rubber band forms a rubber ring by rotational motion of the first gripper and the second gripper, and the two jointed ends of the rubber ring are fixed on a bracket for subsequent sewing and fixation. The looping device has the advantages of simple structure and automatic control, and the looping speed of rubber bands is thus greatly improved. | 8 |
TECHNICAL FIELD
[0001] The invention relates to the in-flight relighting of an aircraft turbofan engine.
BACKGROUND
[0002] FIG. 1 schematically illustrates a typical turbofan engine 10 for subsonic flight. The engine 10 generally comprises in serial flow communication a fan 12 through which ambient air is propelled, a multi-stage compressor 14 for pressurising the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating a stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases. The engine 10 also comprises an auxiliary or accessory gearbox (AGB) 20 on which are located mechanical and electrical systems, such as fuel pumps, oil pumps, generators and a starter/generator. The main rotating parts of the engine 10 are connected in two subgroups, the low pressure (LP) spool and the high pressure (HP) spool, which are coaxially disposed. In use, the engine 10 is started by the starter which is mechanically connected to the HP spool using a set of gears and a tower shaft 22 . Once the desired HP spool speed is reached, fuel is provided into the combustor 16 and is ignited to start or “light” the engine 10 .
[0003] When the engine 10 is mounted on an airplane, in the unlikely event of a flame out or engine shutdown, dynamic pressure due to forward speed of the airplane creates a windmill effect to spin the LP and HP spools. This spinning is then further assisted by the starter to spin the HP spool up to the starting speed so that relight can successfully occur. In other arrangements, a shaft power transfer arrangement is provided to transfer windmilling energy from the LP spool to the HP spool to assist acceleration of the HP spool to relight speed. However, there is a continuing need for simpler and better systems.
SUMMARY
[0004] In one aspect, the present invention provides a method for in-flight relighting a turbofan engine of an aircraft, the engine having at least two shafts, one of which is a high-pressure shaft mounted to a high-pressure compressor and a high-pressure turbine, the high-pressure shaft drivingly connected to an accessory load, the method comprising the steps of: disconnecting the accessory load from the high-pressure shaft to substantially eliminate a parasitic drag load on the high-pressure shaft; permitting ram air to rotate the high pressure shaft; and relighting the engine.
[0005] In another aspect, the present invention provides a method for in-flight relighting an aircraft turbofan engine, the engine having at least two shafts, one of which is a high-pressure shaft mounted to a high-pressure compressor, a high-pressure turbine and an electrical generator, the generator electrically driving an accessory load, the method comprising the steps of: determining the presence of an engine-out condition of the engine; using the generator to reduce the rate of rotation of the high-pressure shaft to a desired rate within a relight envelope; and relighting the engine.
[0006] In another aspect, the present invention provides a method for in-flight relighting an aircraft accessory gearboxless turbofan engine, the engine having at least two shafts, one of which is a high-pressure shaft mounted to a high-pressure compressor, a high-pressure turbine and a concentrically-mounted electrical generator, the generator electrically driving an accessory load, the method comprising the steps of: using exclusively ram air through the engine to rotate the high-pressure shaft; and then relighting the engine.
[0007] In another aspect, the invention provides a method of relighting a gas turbine engine of a fixed-wing aircraft after an in-flight engine-out condition, the engine having at least one electromagnetic bearing apparatus and at least a bladed propulsor mounted to a first shaft and a compressor and turbine mounted to a second shaft, the first shaft drivingly connected to an electric generator, the method comprising the steps of: using windmill rotation of the bladed propulsor to drive the generator; using electricity from the windmill-driven generator to provide power to the electromagnetic bearing apparatus; and relighting the engine.
BRIEF DESCRIPTION OF THE FIGURES
[0008] For a better understanding of the present method, and to show more clearly how it may be carried into effect, reference will now be made by way of example to the accompanying figures, in which:
[0009] FIG. 1 schematic view of a typical turbofan gas turbine engine according to the prior art;
[0010] FIG. 2 is a schematic side view of an example of a turbofan gas turbine engine for use with the present method; and
[0011] FIG. 3 is block diagram illustrating the present method.
DETAILED DESCRIPTION
[0012] FIG. 2 shows a turbofan gas turbine engine 20 which generally comprises a low-pressure (LP) spool 21 supporting at least a fan and a turbine, and a concentric high-pressure (HP) spool 24 supporting at least a compressor and a turbine. An embedded or integrated generator or starter/generator 22 is coaxially mounted on the HP spool 24 of the engine 20 , and preferably a second generator or motor/generator 23 is mounted on the LP spool 21 of the engine 20 . Starter-generator 22 may be operated as a motor to light engine 20 , and also preferably as a generator to generate electricity, which a controller 26 may then provide in form suitable for driving accessories 28 such as electrically-driven pumps and other engine and aircraft services. Generator 23 may be used likewise to generate electricity for controller 26 to provide to accessories 28 (but are not necessarily the same controller or accessories/services as driven by generator 22 ), and if a motor/generator, may be used to selectively drive the LP spool 21 . Consequently, the need for an accessory gearbox is obviated, and is thus not present in engine 20 . The design of engine 20 is not new, however the present invention offers new functionality to the engine 20 to provide improved in-flight relighting, as will now be described.
[0013] After a flame-out or other shut-down of engine 20 occurs requiring the engine to be relit, in-flight windmilling causes the LP spool 21 and HP spool 24 to rotate, which thus rotates starter-generator 22 . During in-flight windmilling, controller 26 preferably partially or completely disconnects or stops supplying electricity to accessories 28 , so there is substantially no electrical load drawn from starter-generator 22 , and thus there is substantially no parasitic drag on the HP spool 24 caused by starter-generator 22 . For example, in one embodiment shown in FIG. 3 , a flame-out (or other engine-off) condition is initially detected by the controller 26 , which controls the fuel and oil pumps 28 . The controller also monitors electrical output from the generator(s), and includes suitable means to prevent power output to the aircraft electrical bus (also represented by 28 ) which does not meet the specification requirements—i.e. the controller 26 has control over whether the starter-generator 22 is connected to the bus in the ‘generate’ and ‘start’ modes. In a flame-out condition, an appropriate sensor signals the controller to stop the fuel pump from pumping fuel, and preferably also stops the oil pump, and the electrical output of the starter-generator 22 is also disconnected from the aircraft bus. Thus, electromagnetic drag on the HP spool 24 is reduced, and preferably effectively eliminated. Consequently, unlike the prior art, the accessories 28 are disconnected from the HP spool 24 , preferably prior to relight.
[0014] Referring again to the engine 10 of FIG. 1 , during in-flight windmilling AGB 20 remains drivingly connected to the HP spool, and thus a plurality of gears and accessories continue to be driven by the HP spool, which creates a parasitic mechanical drag on the HP spool which tends to decelerate the HP spool windmilling speed. As previously described, another energy source is required to overcome this drag and accelerate the engine to its relight speed. However, by disconnecting the load from the HP spool 24 of engine 20 , the parasitic drag of the accessory system is virtually eliminated and, in the right conditions, windmill speed alone becomes sufficient to spin the HP spool 24 at a desired starting speed, using only aircraft attitude if necessary to control windmill speed. Another external power source is not required, thereby simplifying the engine system. This greatly facilitates relighting of the engine 20 by extending the in flight relight envelope of the engine.
[0015] Therefore, the windmilling effect of ram air though the high spool may be used to rotate the engine to relight speed, particularly in very small turbofans having low inertia. Thus relight is achieved by disconnecting accessories and then using windmilling power, preferably alone and without the input of additional rotation energy from the starter-generator 22 , or any other power transfer mechanism, to increase the speed of the HP spool.
[0016] In fact, conversely to the prior art, in some situations such as when descending rapidly on flame out conditions, the rotor may tend to spin too quickly, and thus prevent optimum relight conditions (e.g. lean blow out may occur if there is too much speed at the low fuel flows generally desired for starting), adjustable “drag” may be provided to the high rotor, e.g. by providing a braking force to slow the HP spool speed down. In one approach, this is achieved by operating the starter/generator 22 as a sort of electromagnetic brake, for example by controlling the current of the starter-generator via the controller 26 . In another aspect, a mechanical braking arrangement may be employed to retard spool rotation. This may be used to put an upper limit on windmill speed under conditions requiring a specific relight speed, without requiring the pilot to set a different decent rate than was required for other reasons (for example, in the case where both engines flame out, descending to an altitude where there is air to breathe is often high on the pilot's list of priorities). Thus, controlling the windmill speed to an optimum value for relight, whether increasing or decreasing the rotor speed as necessary, is available with the present concept.
[0017] In another aspect of the present invention, in the case of flame-out, generator 23 may provide self-contained back-up electrical to power during windmilling to a magnetic bearings power system (indicated as among the elements of 28 ) to support the required shafts or spools during power-out situations. The LP spool generator does not induce parasitic drag on the HP spool, and thus no hamper relighting of the HP spool.
[0018] The above description is meant to be exemplary only, and one skilled in the art will recognize that other changes may also be made to the embodiments described without departing from the scope of the invention disclosed. For instance, the starter-generator can be any suitable design, and may in fact be provided by two different units (e.g. separate starter and generator). Although it is desirable to adjust parasitic drag (e.g. by disconnecting accessories and/or reducing rotor speed) prior to commencing relight procedures, the operations may be performed in any desired order. Although electrically disconnecting of the HP spool from accessory drive systems is preferred, any suitable selectively operable disconnect system may be employed. Still other modifications may be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. | The method and apparatus for in-flight relighting of a turbofan engine involve in one aspect selectively controlling an accessory drag load on one or more windmilling rotors to permit control of the windmill speed to an optimum value for relight conditions. | 5 |
RELATED APPLICATIONS
This application is a continuation of application Ser. No. 12/634,407 filed Dec. 9, 2009, now U.S. Pat. No. 8,026,807, which is a continuation of application Ser. No. 12/125,215 filed May 22, 2008, now U.S. Pat. No. 7,636,041, which is a continuation of application Ser. No. 11/317,606 filed Dec. 23, 2005, now U.S. Pat. No. 7,378,961 which is a continuation-in-part of application Ser. No. 10/789,341 filed Mar. 1, 2004, now U.S. Pat. No. 7,002,477, which is a division of application Ser. No. 09/294,034 filed Apr. 19, 1999, now U.S. Pat. No. 6,762,684, all of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for monitoring a remote subject and more particularly to a system for identifying a monitored subject, ascertaining an out of boundary condition and transmitting event data pertaining to the monitoring activities to a central station.
2. Antecedent History
Various monitoring devices for promotion of safety and security of persons and property have been described in U.S. Pat. No. 5,825,283 entitled System for the Security and Auditing of Persons and Property, issued to Applicant herein on Oct. 20, 1998 and incorporated herein by reference.
While the previously known monitoring systems were capable of ascertaining the physical location of a subject as well as monitoring the status of vehicular functions and the like, e.g. U.S. Pat. No. 5,450,321, and were further capable of reducing the number of out of boundary condition reports by, for example, providing a time window within which an out of boundary condition may be corrected, as illustrated in U.S. Pat. No. 5,430,432 entitled Automotive Warning and Recording System, issued Jul. 4, 1995 to Applicant herein, there was a perceived need to provide a monitoring system with remote monitoring stations capable of monitoring an identifying physiological parameter associated with the subject, determining whether an out of boundary condition exists and conveying event data to a central station.
SUMMARY OF THE INVENTION
A processor implemented monitoring system includes one or more monitoring stations capable of monitoring an identifying physiological parameter of a subject such as a retinal scan, fingerprint scan, voice recognition, digital image, DNA characteristics, etc.
The monitoring station scans or otherwise receives subject definition data, i.e. an identifying physiological parameter and physical location boundary definition data relating to the identified subject, such as geographic areas where access is permitted or denied.
The monitoring station loads the definition data from a card or other device carried by the subject into a memory and then determines whether a physiological parameter sampling submitted by the subject is within boundary limits of the loaded physiological parameter data residing in the memory. If the physiological parameter is within boundary limits, the monitoring station processor then determines if the location of the monitoring station is within limits of the subject's location parameter data residing in the memory. If the monitoring station is associated with a controlled area entrance or exit portal, the processor then actuates an access to control to permit the monitored subject to enter or exit the controlled premises.
Each transaction is stored in an event log, with the event log data being transmitted to a central station via radio, cellular telephone, global communication network or other wired or wireless communications link. The event log data includes unique monitoring station identification data, such that the central station determines the specific geographic location of the occurrence reported.
The central station is also in communication with the monitoring station for loading or revising program software and optionally loading subject definition data.
The card or device carried by or attached to the subject may comprise a smart card, radio frequency transponder, inferred transmission device etc. for loading definition data, i.e. the subject physiological parameter data and the subject physical location boundary data into the monitoring station memory.
From the foregoing compendium, it will be appreciated that it is an aspect of the present invention to provide a monitoring system of the general character described which is not subject to the disadvantages of the antecedent history aforementioned.
It is a feature of the present invention to provide a monitoring system of the general character described which monitors a physiological parameter of a subject, ascertains the location of the subject and transfers event log information to a central station.
A consideration of the present invention is to provide a monitoring system of the general character described which monitors a unique identity parameter of a subject and ascertains whether the subject is seeking access to an authorized location.
Another aspect of the present invention to provide a monitoring system of the general character described which monitors a physiological parameter of a subject, ascertains whether the subject is at a permitted location and transfers event log information to a central station.
A still further feature of the present invention is to provide a monitoring system of the general character described which assures that only authorized personnel are within a monitored area.
To provide a monitoring system of the general character described which includes a processor implemented monitoring station capable of monitoring a number of subjects with relatively low memory requirements is yet another consideration of the present invention.
Yet another aspect of the present invention is to provide a monitoring system of the general character described which employs a plurality of monitoring stations to control access to premises having internal areas where access is permitted to only certain individuals among those who have been permitted access to the overall premises.
Other aspects, features and considerations of the present invention in part will be obvious and in part will be pointed out hereinafter.
With these ends in view, the invention finds embodiment in various combinations of elements, arrangements of parts and series of steps by which the above-mentioned aspects, features and considerations and certain other aspects, features and considerations are attained, or with reference to the accompanying drawings and the scope of which will be more particularly pointed out and indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings in which is shown one of the various possible exemplary embodiments of the invention:
FIG. 1 is a schematized view of a monitoring system constructed in accordance with and embodying the invention depicted in simplified block format with a monitoring station comprising a station processor coupled to a card reader, a parameter sensor and an access control and also coupled to a remote central station by a communications link,
FIG. 2 is a reduced scale schematized illustration of the monitoring system at a controlled premises having a plurality of internal areas with access to the premises and each of the internal areas being controlled by a monitoring station and with a communications link interconnecting each monitoring station and a remote central station, and
FIG. 3 is a schematized diagrammatic representation of a typical routine for a monitoring station processor pursuant to which a subject is identified and access to a controlled area is granted only after the subject's identity and authorization to access the controlled area have been verified.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings, the reference numeral 10 denotes generally a monitoring system constructed in accordance with and embodying the invention. The monitoring system 10 includes at lease one monitoring station 12 coupled to a remote central station 14 by a communications link 16 .
The monitoring station 12 includes a station processor 18 . The processor 18 is interconnected to an input device 20 which may comprise a card reader, to an input device 22 , which may comprise a physiological parameter sensor and to a peripheral device 24 , which may comprise an access control, such as a gate or door mechanism. There is also associated with the station processor 18 a memory 26 which stores data representative of the physical location of the monitoring station.
In accordance with one aspect of the invention, the memory 26 is not required to store subject definition data for all monitored subjects because the definition data pertaining to each monitored subject is carried with or affixed to the subject in a smart card 28 or other portable memory device such as a flash memory card, a radio tag or transponder or may be directly coupled to the processor through a suitable port, such as a USB port. Accordingly, the input device 20 , should not be construed as solely a card reader but may encompass any other data input device capable of receiving subject definition data.
The operation of the monitoring station 12 may be more readily appreciated from an examination of FIG. 3 wherein a typical processor routine 30 is depicted.
Upon entry into the routine 30 , the processor 18 ascertains whether or not there is an input signal at the input device 20 , as indicated in an inquiry box 32 . If an input is present, the processor 18 obtains the subject definitions, i.e. physiological parameter data and location parameter data, as indicated in a block 34 . Thereafter, the processor 18 loads the subject definition data into the memory 26 as indicated in a block 36 . If the memory 26 has stored previous subject definition data, the processor 18 may overwrite such previous data to conserve memory requirements.
Thereafter, a subject physiological parameter sample is taken at the parameter sensor 22 , as indicated in a block 38 . It should be appreciated that the physiological parameter sensor 22 will input to the processor 18 unique subject identification data obtained as a result of a retinal scan, fingerprint scan, etc.
The processor 18 then ascertains whether or not the physiological parameter sample data obtained is within the boundary limits of the physiological parameter definition data residing in the memory 26 , as indicated at a box 40 . In the event the physiological sample data is not within the boundary limits, the processor stores the transaction in an event log as indicated at a block 46 and may immediately transmit the event log data to the remote central station 14 , as indicated in a block 48 , before returning.
Optionally, the processor 18 may permit a given number of physiological parameter samples to be submitted before storing the transaction in the event log and/or transmitting the event log data and returning to the inquiry box 32 .
In the event the physiological parameter sample falls within the limits of the stored data, the processor 18 then proceeds to a further inquiry to determine whether the location of the monitoring station 12 is within the limits of the subject location parameter definition data. If the monitoring station location or the entrance or exit portal controlled by the monitoring station is not a permitted location for the subject, the processor stores the transaction in the event log, as indicated in the block 46 and returns to the inquiry box 32 or may immediately transmit the event log data to the remote central station 14 , as indicated in the block 48 and then return to the inquiry box 32 .
In the event the station location is a permitted location for the subject and the monitoring station is controlling an entrance or exit portal, the processor then actuates the access control 24 to permit the subject to pass beyond the entrance or exit portal, as indicated at a block 44 . The processor 18 then stores the transaction in the event log, as indicated in the block 46 and may transmit the event log data to the remote central station, as indicated in the block 48 before returning to the inquiry box 32 .
It should be appreciated that the transmission of the event log of each event to the remote central station may be immediate, upon the occurrence of each event or the processor may store event log transactions over a period of time and then transmit a group of transactions to the remote central station 14 .
The advantage to immediately transmitting each event log occurrence is that personnel or processor implemented oversight systems at the remote central station will have a real time knowledge of monitoring station transactions and may take immediate action as deemed necessary in the event of irregular or inappropriate activities.
The central station 14 may forward all or selected event log occurrences to a distribution list of computers, e-mail address or the like. Well known encryption technologies may be employed for communications on the communications link 16 and from the central station 14 to entities on the distribution list.
In FIG. 2 there is depicted a monitoring system wherein a plurality of monitoring stations are deployed throughout a controlled premises 50 , which might comprise a building or portion thereof operated by a business dealing in sensitive information, a correctional institution or an apartment dwelling, for example.
The premises 50 includes a main entrance doorway 52 , as well as a plurality of interior entrances 54 , 56 , and 58 . The premises 50 may also include exit portals through interior spaces such as exit portals 60 , 62 , 64 and 66 .
There is also provided a monitoring station 102 associated with the entrance 50 , a monitoring station 104 associated with the interior entrance 54 , a monitoring station 106 associated with the interior entrance 56 and a monitoring station 108 associated with the interior entrance 58 .
Each exit portal may also have an associated monitoring station, for example, a monitoring station 110 associated with the exit portal 60 , a monitoring station 112 associated with the exit portal 62 , a monitoring station 114 associated with the exit portal 64 and a monitoring station 116 associated with the exit portal 66 .
Each of the monitoring stations 102 , 104 , 106 , 108 , 110 , 112 , 114 , and 116 is substantially identical to the monitoring station 12 previously described and depicted in FIG. 1 and include a linked input device or card reader, a linked parameter sensor and a linked access control coupled to the associated entrance or exit portal.
Additionally, as will be noted in FIG. 2 , each of the monitoring stations is coupled by a communications link to a remote central station 118 .
In operation, a subject would present his or her own definition data card 28 to be scanned or otherwise read by the input device 20 and thereafter submit an identifying physiological sample at the parameter sensor. The station processor then proceeds with the routine 30 and either permits or denies access through each of the successive entrances. Thus for example, in a secure establishment requiring clearance to enter various interior areas, the subject will gain access to a common interior room 120 and one or more successive interior rooms denoted by the reference numerals 122 , 124 and 126 , only as authorized by the subject's security clearance, i.e. location parameter definition data. Entry or denial of entry into each of the interior rooms is logged and a report is transmitted to the remote central station 118 . Further, although a subject may exit an interior room through the entrance controller by a first monitoring station, in some instances, the subject exits through a separate exit portal controlled by a separate monitoring station and the transaction is entered in the appropriate transaction log.
In an environment such as a multiple dwelling structure, each subject's card 28 will permit access to a main lobby 120 and the subject's individual apartment 122 , 124 , for example, and also permit access to controlled semipublic areas such as a laundry room, gym, etc. 12 only if such access is authorized. A monitoring station may also be employed to gain access to specific equipment within the controlled premises such as, for example, gym equipment or laundry machines, or, computer terminals, etc. with the access control 24 coupled to an equipment switch.
It should also be noted that monitoring stations may be deployed in situations wherein access control is not required. For example, monitoring stations may be employed within or at peripheral locations of an area wherein a subject is confined, with the subject being required to submit a physiological parameter specimen at preset time intervals. If relatively few subjects are being monitored, the employment of a card 28 or the like for retrieval of the subject definition data may not be necessary, since the definition data of a limited number of subjects may be stored in the station processor memory 26 . An aspect of the invention however, is the ability to utilize relatively little memory for monitoring a relatively large number of subjects, since the subject card 28 carries each subject's definition data which is loaded into the memory and thereafter overwritten.
A further aspect of the invention is the ability to utilize the input device 20 to retrieve limited or incomplete definition data. For example, the input device 20 may comprise a keypad or scanner which just retrieves subject identification data, e.g. a pin number, without the definition data. The processor 18 then requests complete definition data attributable to the subject having the pin number from the central station 14 and retrieves the definition data over the communications link 16 .
Thus it will be seen that there is provided a monitoring system which achieves the various aspects, features and considerations of the present invention and which is well adapted to meet the conditions of practical usage. | A monitoring system includes at least one fixed location monitoring station, a remote central station and a communications link interconnecting the monitoring station with the remote central station. The monitoring station includes a processor coupled to an input device for retrieving subject identification definition data and subject location definition data. The processor also retrieves physiological parameter sampling data from the subject and determines whether the physiological parameter sampling data lies within boundary limits of the identification definition data and also determines whether the location of the monitoring station lies within boundary limits of the location definition data. In the event the sampling data and the fixed location are within boundary limits, the processor may actuate an access control to permit the subject to enter or exit a controlled premises. Transaction logs including out of boundary conditions as well as in boundary conditions and the location of the monitoring station are transmitted to a remote central station. | 8 |
This application claims the benefit of 60/238,739 filed on Oct. 6, 2000.
This application is a 317 of PCT/US01/42521 filed Oct. 5, 2001
FIELD OF THE INVENTION
The invention relates to neuroprotectants. In particular, the invention relates to a peptide-free N-methyl-D aspartate (NMDA) receptor open channel blocker, which mitigates excitotoxicity to aid in preventing neuronal cell death.
BACKGROUND OF THE INVENTION
NMDA receptor activity produces synaptic plasticity in the central nervous system that affects processes for learning and memory, including long-term potentiation and long-term depression (Dingledine R., Crit. Rev. Neurobiol., 4(1):1–96, 1988). However, prolonged activation of NMDA receptor under pathological conditions (such as cerebral ischaemia and traumatic injury) causes neuronal cell death (Rothman S. M. and Olney J. W., Trends Neurosci., 18(2):57–8, 1995). NMDA receptor-mediated excitotoxicity may contribute to the etiology or progression of several neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease. Since open channel blockers of NMDA receptors were shown, in the late 1980s, to have potential for therapy of ischemic stroke, the receptor has been considered an attractive therapeutic target for the development of neuroprotective agents. Unfortunately, the development of these compounds as neuroprotectants is often limited by their psychiatric side-effects associated with their undesired pharmacodynamic properties such as slow dissociation from the receptor (Muir K. W. and Lees K. R., Stroke, 26(3):503–13, 1995).
The advent of combinatorial chemistry technology in recent years has greatly facilitated the process of drug discovery. For example, a set of arginine-rich hexapeptides, which potently blocked NMDA receptor, have recently been identified from a peptide combinatorial library (Ferrer-Montiel A. V., et al., Nat. Biotechnol., 16(3):286–91, 1998). However, development of peptides as drugs is often hampered by their lack of oral bioavailability due to enzymatic degradation before entry into systemic circulation.
SUMMARY OF THE INVENTION
The invention provides open-channel blockers for NMDA receptor which do not contain peptides. As such, the compounds are protected from the degradation that limits the use of peptide-based drugs in systemic circulation. The compounds are of the formula:
The most potent of the inventive compounds is NBTA:
The inventive compounds protect neurons from NMDA neurotoxicity, without affecting other receptors, including glutamate receptors not of the NMDA subtype. It protects neurons in cultured hippocampal neurons from NMDA receptor-mediated excitotoxic cell death, and exerts non-competitive NMDA receptor blockade which is use- and strongly voltage-dependent, exhibiting fast offset kinetics.
Compounds with such fast offset kinetics and strong voltage-dependence often offer better therapeutic profile with fewer adverse-effects. The strong voltage-dependence of block enhances the ability of this compound to differentiate between transient physiological from sustained pathological activation of NMDA receptor because it allows the compound to leave the NMDA receptor channel rapidly upon normal transient activation by high concentration of glutamate at the synapse but to block the sustained activation by low concentrations of glutamate under certain pathological conditions. Recovery from the blocked state can be prompt and complete, allowing the channel block to be effective only during a brain insult, but not during normal synaptic activity.
These characteristics endow NBTA with properties of significant therapeutic potential. Thus, NBTA and its related compounds are efficacious, selective agents for highly targeted neuroprotection.
DESCRIPTION OF THE DRAWINGS
FIG. 1 . Mixtures of dipeptidomimetic combinatorial library blocks recombinant NMDA receptor expressed in Xeniopus laevis oocytes. (A) Representation of the N-alkylated triamine positional screening-synthetic combinatorial library (PS-SCL). O represents a defined functionality derived from a single building block; X represents a mixture of functionalities derived from a mixture of all the building block used to generate the relevant diversity position. (B) A representative trace showing the glutamate and glycine-activated inward current through NMDA receptor is reversed by 10 μM of one mixture library with L-isoleucine and benzyl defined at position 1 and 2, respectively.
FIG. 2 . The blocking profile of each of the mixture comprising the dipeptidomimetic combinatorial library on recombinant NMDA receptor expressed in Xenopus laevis oocytes. Each bar represents the blocked response by each of the 364 dipeptidomimetic mixtures at 10 μM. Values are given as mean±s.e. of 3–6 oocytes.
FIG. 3 . The blocking activities of a series of 21 compounds were tested, the compounds having been synthesized based on the blocking profile of the library from the primary screening, and the results for 14 of the compounds are shown. (A) The amino acids and alkyl groups defined at each of the four positions of these compounds. Abbreviations: Bz: benzyl; Et: ethyl; ile: D-isoleucine; Ile: L-isoleucine; leu: leucine; lys(Boc): ε-t-butyloxycarbonyl-D-lysine; Me: methyl; nal: D-naphthylalanine; Tyr(2BrZ): 2-bromobenzyloxycarbonl-L-tryosine; Tyr(tBu): t-butyl-L-tyrosine; Val: L-valine. (B) The blocking activities of these compounds were performed as described in Method. Values are expressed as mean±s.e. of 3–6 oocytes.
FIG. 4 . Structure and LC-MS of NTA. Total ion counting is shown in (A), the UV absorbance in (B), the mass spectra and structure in (C). The mass spectral analysis was performed using a Finnigan Mat LCQ interfaced with a Waters analytical HPLC and a short Keystone C 18 column (3 μm, 4.6 mm×50 mm).
FIG. 5 . The blocking action of NBTA is specific. 1 μM NBTA blocks NMDA receptors (A) but not non-NMDA glutamate receptor GluR1 (B). (C) Concentration-inhibition curves for antagonism of NMDA and GluR1 channels by NBTA, memantine, MK-801, and PCP. Data are fitted with the Hill equation. (D) Blocking activity of NBTA on wild-type NMDA receptors (NR1/NR2A (□))-IC 50 =80+/−10 nM (n=6), n H =0.8; and of indicated mutants, data for the latter as shown in the Figure.
FIG. 6 . NBTA is an open-channel blocker of NMDA receptor. (A, B) The NBTA does not affect the IC 50 of L-glutamic acid or glycine for the NMDA receptors. Dose-response curves of L-glutamic acid (plus 20 μM glycine) or glycine (plus 200 μM L-glutamic acid) were obtained by activation of NMDA receptors in the absence (□) or presence (Δ) of 0.2 μM NBTA, n=4 oocytes. (C) NMDA current blockade by NBTA is voltage-dependent, as illustrated by currents evoked by 200 μM L-glutamic acid (plus 20 μM glycine) during a voltage-ramp protocol performed when currents reached a steady state. (D) Use dependence of NMDA receptor block by NBTA, at −80 mV. Pulse duration is indicated by the horizontal bar. Two pulses of 200 μM L-glutamic acid (plus 20 μM glycine) were first delivered as control, and then followed by a co-application the agonist with 0.1 μM NBTA. The NBTA induces a progressive block of the NMDA-receptor mediated currents. A complete recovery is observed at the second pulse of 200 μM L-glutamic and 20 μM glycine following the washout of NBTA.
FIG. 7 . NBTA protects cultured hippocampal neurons from NMDA receptor-mediated excitotoxic cell death. Trypan blue exclusion assays of (A) control neurons and neurons exposed to 200 μM NMDA in the absence (B) or presence of 10 μM memantine (C); and in the presence of 10 μM NBTA (D). (E) Normalized cell death in the absence and presence of the lead. (F) Neuronal death induced by kainate in the absence or presence of 20 μM CNQX, 10 μM MK-801, 10 μM memantine or 10 μM NBTA. Data are mean±s.e., n=2000.
DETAILED DESCRIPTION OF THE INVENTION
A. NBTA and Related NMDA Open Channel Blockers
1. Identification.
To identify NMDA receptor channel blockers, a N-alkylated triamine SCL generated in a dual defined positional scanning (PS) format was screened for block on recombinant NMDA receptors expressed in Xenopus oocytes. The PS-SCL consists of two sublibraries, as shown in FIG. 1A . Each sublibrary has two positions defined with a given amino acid (O 1 or O 3 for sublibrary 1 or 2) or a given alkyl group (O 2 or O 4 for sublibrary 1 or 2). The remaining two diversity positions were close to equimolar mixtures of amino acids or alkyl groups (X positions). Sublibrary 1 consists of 184 mixtures, while sublibrary 2 consists of 180 mixtures. Each mixture contains 230 compounds, for a total of 42,320 individual compounds in the entire library.
FIG. 1B shows the effect of a representative active mixture: coperfusion of the actile Ile(benzyl)XX library mixture at 10 μM with the agonist drastically diminishes the invoked current by 70%. Mixtures with O 4 defined with a methyl were among the most active compounds (blocked responses between 70 and 80%), while none of the mixtures having a methyl at O 2 showed a blocked response greater than 50%. All of the mixtures from sublibrary 1 showing responses greater than 60% were defined with a benzyl group at positions O 2 , while other alkyl groups defined the active mixtures from sublibrary 2. These results indicate that not only the nature of the amino acid and the alkyl group are important for activity, but also their location within the molecule. Based on these screening results, 21 compounds were synthesized, based on the formula:
wherein the R substituents varied as follows: R 1 is a S-4-hydroxylbenzyl or a S-2-butyl; R 2 is a benzyl; R 3 is selected from the group consisting of N-methyl, N-benzylaminobutyl, S-4-hydroxybenzyl; R-2-naphthylmethyl, S-isopropyl, R-isobutyl and R-2-butyl; and R 4 is selected from the group consisting of benzyl, methyl, naphthylmethyl and ethyl.
Compound #10 (NBTA) is the most potent N-benzylated triamine derivative of the 21 compounds tested, exerting 70±3% of NMDA current at 1 μM ( FIG. 3B ). The structural and analysis spectra of NBTA are shown in FIG. 4 . NBTA has an S-2-butyl at R 1 , a benzyl at R 2 , a S-4-hydroxybenzyl at R 3 , and a benzyl at R 4 , as follows:
2. NBTA Activity.
The blocking action of NBTA is specific, and is representative of all of the inventive compounds, although it possesses greater potency than its 20 relatives described in FIG. 3A . 1 μM NBTA blocks ˜95% NMDA current but had no effect on the non-NMDA receptor glutamate receptor (GluR1), even at 1 mM ( FIGS. 5B and C). Concentration-inhibition data fitted with a Hill equation yielded a mean IC 50 of 80±10 mM and a Hill coefficient close to unity (about 0.8) suggesting that NBTA binds to a single site ( FIG. 5C ).
The remarkable selectively of NBTA for NMDA receptors is underscored by the data shown in FIG. 5C . Phencyclidine (PCP), sizolcipine (MK-801) and memantine (1-amino-3,5-dimethyladamantane) are high affinity, open channel blockers of the NMDA receptor. By contrast, non-NMDA receptors are only weakly responsive to these compounds. For example, they display 1,000 to 10,000 higher affinity for NMDA receptors than for AMPA receptors ( FIG. 5C ).
NBTA sharply discriminates between these two types of receptors, displaying high blocking potency for NMDA receptors, but no effect at all on AMPA receptors, even in the mM concentration range. This combination of potency and selectivity make NBTA a uniquely efficacious neuroprotectant.
B. Mechanism of Action of NBTA
NMDA receptor mediated inward current can be attenuated by a number of mechanisms, depending on the site of action of the ligand at the receptor protein. NMDA receptor activity can be reduced by acting at various sites of the channel proteins, for instances, competitive antagonism at the glycine or glutamate binding sites, or allosteric modulating the proton and polyamines sites. The concentration-response curves L-glutamic acid (with glycine at 20 μM) dose-response curves performed in the absence or presence of 0.2 μM NBTA were similar (gives a mean EC 50 of 2.08±0.2 μM and 1.91±0.3 μM, respectively ( FIG. 6A )). The EC 50 of glycine determined in the absence and presence of 0.2 μM compound were 2.22±0.21 μM (n=4) and 1.95±0.18 μM (n=4), respectively ( FIG. 6B ). The results suggest that NBTA is a non-competitive antagonist of NMDA receptor.
NBTA is an open-channel blocker for NMDA receptor. One of the key features of open-channel block is voltage-dependence. In general, open channel blockade exhibits marked voltage-dependent inhibition, that is, in the presence of a fixed concentration of blocker, the fraction of inhibited NMDA-evoked current increased with more negative membrane holding potentials. The active NBTA reduced more NMDA current at more hyperpolarized membrane potential, indicating that current reduction by NBTA is voltage-dependent ( FIG. 5C , being more pronounced at more negative membrane potential than at positive membrane potential. A δ of 0.56 suggests that the compound transverses ˜56% of the transmembrane electric field to reach its binding site(s) and this site is probably located in the pore. The observed current reduction presumably reflects occlusion of the channel pore.
Another feature of open channel block is the use-dependence, at a fixed concentration of the open channel blocker, the fraction of current blockade increases with repetitive activation of the receptors. 0.1 μM NBTA induces a progressive blockade of the currents elicited by repetitive pulses of glutamate (200 μM) and glycine (20 μM) ( FIG. 5E ). A full recovery of responses was observed in the subsequent receptor activation following the washout of the compound ( FIG. 6D ). These results demonstrate that NBTA acts as an open-channel blocker at recombinant NMDA receptor.
C. Site of Action of NBTA on NMDA Receptors
A critical asparagine, the N-site of NR1 subunit of NMDA receptors, is a structural determinant of ion permeation and channel blockade at the receptor pore. The N-site specifies the action of a wide array of open-channel blockers, including memantine, phencyclidine and MK-801 (Ferrer-Montiel A. V., et al., Neuropharmacology, 37(2):139–47, 1998), as well benzyl-polyamine derivatives. Examination was therefore made regarding whether NBTA binds to this critical asparagine (N-site). Substitution of the N-site to arginine (N616R) reduces the blocking activity of NBTA by 275 fold ( FIG. 5D ). In contrast, replacement of N616 for glutamine, which contains a similar functional group, only slightly reduces blocking activity ( FIG. 5D ), indicating that NBTA binds to the N-site of NR1.
A tryptophan to leucine substitution at the corresponding position of the NR2A subunit reduces the blocking activity of NBTA by 4.7 fold ( FIG. 5D ), suggesting that tryptophan 606 also contributes to the binding pocket for NBTA. In contrast, mutations at N614G, N615G and S616G in the M2 segment had no effect on NBTA binding. Furthermore, NBTA binding in the face of coexpression of N616Q (NR1 mutant) with N614G (NR2 mutant) was similar to binding achieved with N616Q alone, indicating that NBTA does not bind to asparagine 614 of NR2 ( FIG. 5D ). It is possible that the side-chains of the 614 and 615 asparagines of the NR2 subunit do not lie on the same level of the receptor as the NR1 N-site.
D. NBTA Exerts a Neuroprotective Effect Against NMDA-Receptor Mediated Cell Death
To determine whether NBTA has neuroprotective effect against NMDA-receptor mediated neurotoxicity, a model of excitotoxicity was employed. Cultured rat hippocampal neurons exposed to 200 μNMDA and 20 μM glycine for 20 min induced 50±3% of cell death ( FIG. 7B ). At 10 μM, NBTA protects hippocampal neurons from NMDA receptor-mediated cell death (83±2%) ( FIG. 7D ) to an extent comparable to that exerted by conventional NMDA blockers, such as memantine (93±1%) ( FIGS. 7C and 6E ) and MK-801 (89±1%) ( FIG. 7E ).
To evaluate the specificity of the neuroprotective effect of NBTA<its activity against kainate induced neuronal cell death was assessed. 6-cyano-7 nitroquinoxaline-2,3-dione (CNQX), an AMPA/kainate receptor antagonist, protects neurons from cell death induced by kainate ( FIG. 7F ). The NMDA blockers memantine and MK-801 protect neurons as well, though not as effectively as CNQX. In sharp contrast, NBTA has no effect on cell death mediated by the kainate receptor, demonstrating the specificity of NBTA for NMDA receptors ( FIG. 5C ).
The voltage-dependence of block produced by NBTA at the voltage-dependent site provides insight into the dimension of the NMDA receptor channel pore. It has been shown that both Mg 2+ and memantine has a δ of ˜0.77 (21, 29, 30, 31, 32) and that the N-site located at the tip of M2 segment is their binding site. Because the N-site is not the binding site for NBTA, the vestibule of the receptors probably provides the binding site(s) for the compound. The blocking effect exhibited by this compound is characterized by a deep electrical depth (δ=0.56). The result implies that, unlike potassium channel pore where the majority of the transmembrane voltage (˜80%) is imposed across the short selectivity filter (33, 34), a significant voltage drop occurs in the outer vestibule of the. NMDA channel pore.
The phenolic hydroxyl and the benzyl group define the structure-activity relationship of NBTA and are probably involved in interaction with amino residues in the outer vestibule of the channel. These two groups are separated apart by ˜8.8 Å, implying that the outer vestibule of the NMDA pore right must be ˜9 Å in order to accommodate the molecule. The size and configuration of NBTA therefore likely contribute to its greater potency as compared to the other inventive compounds described herein, although they also exert open channel blocking activity.
E. Pharmaceutical Compositions of NMDA Open Channel Blockers and Uses therefor
Any of the NMDA open channel blockers of the invention may be prepared in a pharmaceutically acceptable composition. Pharmaceutically acceptable carriers preferred for use in the invention may include sterile aqueous of non-aqueous solutions, suspensions, and emulsions.
Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's or fixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers (such as those based on Ringer's dextrose), and the like. Preservatives and other additives may also be present such as, for example, antimicrobials, antioxidants, chelating agents, and inert gases and the like. A composition of the invention may also be lyophilized using means well known in the art, for subsequent reconstitution and use in neuroprotection according to the invention.
Clinically, the neuroprotectants of the invention will be useful in the same therapies which are or may be practiced with known neuroprotectant agents which block NMDA receptor-mediated activity, with suitable adjustment for side effects and dosage (see, e.g., clinical reports regarding use of such agents as reported in Carter, A J, J. Pharmacol. Exp. Ther., 269:573–580, 1994). Protocols for administering the neuroprotectants of the invention (including dosing schedules and concentrations) will depend on the patient's condition and the medical judgment of the clinician (see, use-dependence curve set forth in FIG. 5E ). The concentration of neuroprotectants of the invention in a pharmaceutically acceptable carrier which produces a therapeutic benefit in a host is considered a “therapeutically effective dosage” of the neuroprotectant.
The invention having been fully described, examples illustrating its practice are provided below. These examples are non-limiting of the scope of the invention, whose scope will be defined by claims thereto.
Standard abbreviations used in the examples will be understood to have their common meaning ascribed in the art.
EXAMPLE I
Synthesis of the Library and Individual N-Alkylated Triamines
The N-alkylated triamine mixtures and individual compounds were synthesized on the solid phase using the “tea-bag” methodology (Houghten R. A., Proc. Natl. Acad. Sci. USA, 82:5131–5135, 1985) by selective alkylation and exhaustive reduction as described elsewhere (Dorner B., et al., Bioorg. Medicinal Chem., 4:709–715, 1996; Ostresh J. M., et al., J. Org. Chem., 63:8622–8623, 1998; Nefzi A., et al., Tetrahedron, 55:335–344, 1999). The mixtures were prepared using the divide, couple and recombine method (Houghten R. A., et al., Nature, 354(6348):84–6, 1991; Dorner B., et al., Bioorg. Medicinal Chem., 4:709–715, 1996). In brief, the first amino acid was coupled using conventional Fmoc chemistry, and following removal of the Fmoc group, the N-terminal amino group was tritylated by reaction with a solution of trityl chloride (5 molar excess over the total free N-α-amino groups) for 3 hours at room temperature. N-alkylation was then performed by treatment of the resin packet with 1M lithium t-butoxide in tetrahydrofuran under a nitrogen atmosphere and strictly anhydrous conditions. Excess base was removed by cannulation, followed by addition of the individual alkylating agent in dimethylsulfoxide. The solution was vigorously shaken for 2 hours at room temperature. Upon removal of the trityl group with 2% trifluoroacetic acid in dichloromethane (2×10 min), the resin was washed, neutralized, and the second amino acid coupled and selectively alkylated as described above.
Exhaustive reduction was carried out in 50 ml kimax tubes under nitrogen (Ostresh J. M., et al., J. Org. Chem., 63:8622–8623, 1998; Nefzi A., et al., Tetrahedron, 55:335–344, 1999) by addition of boric acid (40×) and trimethylborate (40×), followed by 1M borane in tetrahydrofuran (40×). The solutions were heated at 65° C. for 72 h, decanted, and quenched with methanol. Following overnight treatment with piperidine at 65° C., the mixtures or individual compounds were cleaved from the resin with anhydrous hydrogen fluoride, extracted, and lyophilized. The purity of the compounds was revealed by reverse phase high pressure liquid chromatography (HPLC) and the identity of each compound were confirmed by reverse phase HPLC and matrix assisted laser desorption ionization-mass spectroscopy (MALDI-MS). Results are as described in the Detailed Description of the Invention.
EXAMPLE II
Expression of NMDA Receptors in Xenopus Oocytes
Recombinant NMDA receptor subunits, NR1 (Planells-Cases R, et al., Proc. Natl. Acad. Sci. USA, 90(11):5057–61, 1993) and NR2A (Le Bourdelles B, et al., J. Neurochem., 62(6):2091–8, 1994) was used for screening the dipeptidomimetic combinatorial library. cDNAs of NR1 and NR2A were linearized with NOT1. cRNAs encoding NR1 and NR2A were synthesized from the linearized cDNAs templates according to manufacturer specifications (Ambion). NR1 mutant (N616Q) was used to examine the site of action of the identified lead. The NR1A mutants were linearized with NOT1 and use of T7 for sense. cDNA of human glutamate receptor/GluR1 (Sun W., et al., Proc. Natl. Acad. Sci. USA, 89:1443–1447, 1992) was linearized with Hind III and the use of T3 promoter for the synthesis of its cDNA. cDNAs were quantified by spectroscopy and the quality were assessed by gel electrophoresis.
Oocytes of stage V and VI were surgically removed from the ovaries of Xenopus oocytes anesthetized with 0.4% ethyl 3-amino-benzoate methanesulfonic acid-Clusters of oocytes were incubated with 2 mg/ml collagenase (Life Technologies, Gaithersburg, Md.) for 1 hour 20 min in Ca 2+ -free solution comprised of (mM) 82.5 NaCl, 2.5 KCl, 1 MgCl 2 , 5 HEPES, pH 7.4 with vigorous agitation to remove the follicular cell layer. Oocytes were then washed extensively with the Ca 2+ -free solution to remove the collagenase. Oocytes were eventually incubated in Barth's solution consisted of (in mM): 96 NaCl, 2 mM KCl, 1.8 CaCl 2 , 1 MgCl 2 , 5 HEPES supplemented with 100U/ml penicillin and 100 ug/ml streptomycin, pH 7.4 at 17° C. Oocytes were injected with 5–15 ng of cRNA encoding NR1 or its mutant premixed with three-fold amount of cRNA encoding NR2A.
Results are as described in the Detailed Description of the Invention.
EXAMPLE III
Electrophysiology of the NMDA Receptor
On days two to six following injection of cRNAs, whole oocyte currents were recorded with standard two-electrode voltage-clamp. All electrophysiological studies, unless otherwise stated, were performed in Ba 2+ /flufenamic-Ringer's solution (in mM: 10 HEPES pH7.5, 115 NaCl, 2.8 KCl, 2.0 BaCl 2 , 0.1 flufenamic, 0.1 niflumic acid) at ambient temperature as previously described (Ostresh J. M., et al., J. Org. Chem., 63:8622–8623, 1998; Nefzi A., et al., Tetrahedron, 55:335–344, 1999). Both current and voltage electrodes were filled with 3M KCl and have a tested resistance of 0.5–1 MOhm. The blocking activities of the library were assessed at 10 μM (assuming the molecular weight is ˜500). The screening of the subsequent twenty one compounds synthesized based on the primary screening were performed at 1 μM. Inward currents were elicited from a holding potential of −80 mV except where indicated. NMDA receptors were activated by abruptly exposing oocytes to 200 μM L-glutamic acid and 20 μM glycine followed by coperfusion with the library at indicated concentration. Blocking activity of the mixture is expressed as fraction of response blocked by the mixture. Dose-response curves were fitted to the Hill equation:
y = 1 1 + [ [ x ] IC 50 ] n H
where y is the ratio of current in the presence and presence of blocker, [x] is the blocker concentration, and IC 50 and n H represent the concentration blocks 50% of response and Hill coefficient, respectively. Current-voltage relationships were measured first in the absence and then in the presence of a given concentration of lead at a specified membrane holding potential, and the ratio of these currents was plotted as a function of the holding potential. Analysis of the voltage dependent block current was performed according to the model proposed by Woodhull (Woodhull A. M., J. Gen. Physiol., 61:687–708, 1973). Data were fitted with the equation according to Zarei and Dani (Zarei M. M. and Dani J. A., J. Gen. Physiol., 1103(2):231–48, 1994):
I b I c = 1 1 + [ B ] K d · ⅇ [ δ · F · V / R · T z ]
where I b and I c are currents recorded during the blockade and control, respectively; [B] is the concentration of the blocker; K d is the dissociation constant of the blocker at 0 mV; δ is the fraction of the membrane field sensed by the blocker as it binds to its site; V is the command voltage; R is the gas constant; T is the absolute temperature; F is the Faraday's number; z is the valence of the blocker. Current signals were digitized and recorded using pClamp (version 6) software (Axon Instruments, Foster City, Calif.). Results are as described in the Detailed Description of the Invention.
EXAMPLE IV
Excitotoxic Assays in Hippocampal Cultures
Mixed hippocampal neuron/glia primary cultures were employed to assess the neuroprotective activities of the identified lead against NMDA receptor-mediated excitotoxic cell death. Primary culture of rat hippocampal neurons were prepared as previously described (Ferrer-Montiel A. V., et al., Nat. Biotechnol., 16(3):286–91, 1998; Schinder A. F., et al.; J. Neurosci., 16(19):6125–33, 1996). In brief, hippocampi from E17–E19 rat embryos were first taken out and incubated at 4° C. in a saline (BSS) containing (mM): 137 NaCl, 3.5 KCl, 0.4 KH 2 PO 4 , 0.33 Na 2 HPO 4 .7H 2 O, 5 TES, and 10 glucose, pH 7.4. Hippocampi were then incubated in 0.25% trypsin (1×) solution from Hyclone at 37° C. for 15 min. Tissues were then washed and resuspended in minimal essential medium (Earle's salt) supplemented with 10% heat-inactivated horse serum (Hyclone), 10% fetal bovine serum (Hyclone), 1 mM glutamate, 22 mM glucose, 20U/ml penicillin and 20 ug/ml streptomycin. Digested hippocampi were eventually dissociated by pipetting through a Pasteur pipette. Cells were plated at a density of 5×10 4 cells/cm 2 .
Neurons cultured 14–17 days were used for the excitotoxic assays. Cultured medium was first removed and rinsed with BSS supplemented with 1 mM CaCl 2 , and 20 μM glycine. Neurons were challenged with 200 μM NMDA in the absence and presence of 10 the identified lead for 20 min at room temperature. The insults were terminated by removing the BSS containing NMDA. To reduce the excitotoxic effect due to the residual NMDA, the culture medium was supplemented with 20 μM MK-801. Cell cultures were returned to the incubator (37° C., 5% CO 2 ). Cell death was assessed 20–24 hours after the challenge with trypan blue (0.04%) exclusion assays. Fraction of dead cells in cultures treated with control buffer (8±3%, n=2000) was subtracted as background.
NMDA insult alone caused significant cell death of 45±6% (n=2000). Neuroprotective activities as described in the Detailed Description of the Invention were expressed as percentage of net cell death in the absence and presence of 10 μM of the known NMDA receptor blockers and the identified compound. Cell death elicited by NMDA alone was considered as 100%. The assays were repeated in 4 separated occasions with different culture preparations. | Neuroprotectant agents are provided which do not contain peptides and axe protected from the degradation that limits the use of peptide-based drugs in systemic circulation. With great selectivity for NMDA receptors, the agents exert an open channel block on NMDA receptors, and protect neuronal cells containing such receptors from excitatoxic cell death. | 2 |
BACKGROUND OF THE INVENTION
The disclosed invention is advantageously utilized to provide automatic control for achieving the optimal distribution of electric power within an electrostatic precipitator while maintaining acceptable environmental standards. An electrostatic precipitator utilizes high voltage electrodes to charge particulate matter in a high voltage or corona field. The charging voltage is further used to collect the charged particles on the oppositely charged electrodes of the precipitator. Periodic rapping of the electrodes is usually required to loosen the particulates and to thereby maintain the operating efficiency of the precipitator.
A typical electrostatic precipitator utilizes a plurality of paired oppositely charged electrodes disposed, at least in part, in the flue gas flow path. The electrodes are usually arranged in groups or fields. A transformer-recitifer (T-R) set provides power to a field, to several fields or to a portion of a field and is used to generate the corona power between the paired electrodes.
Field voltage, hence corona power, is regulated and controlled by the amount of current provided by a regulator to each T-R set. Dedicated control for each T-R set is normally provided. Dedicated control of each T-R set permits independent energization of each field in order to enhance the collection of the particulates. Additionally, independent energization of the fields permits profiling of the precipitator fields in order to optimize the collection of particulates by the various fields.
Prior art control techniques have frequently sought to maintain the field voltage at a high voltage that is close to the "sparking limit" of the field. The field voltage is thereby maintained at maximun power regardless of whether maximum power is necessary. Consequently, the extra power is wasted and needlessly increases the operating costs of the precipitator. Experience has shown that the power requirement is related to many factors, such as: flue gas flow, particulate loading and the temperature of the flue gas, among others.
The continuing increase in the cost of electricity, which is utilized to energize the individual fields of the precipitator, has brought forth a need to optimize power consumption while still attaining particulate emission levels at their design limits and as mandated by environmental regulations. Manual adjustment of the individual T-R sets can provide some power reduction but control by this means is extremely inexact.
Reese, et al., U.S. Pat. No. 4,284,417, discloses one method for controlling the electric power supplied to an electrostatic precipitator. Reese discloses the utilization of an opacity transducer adapted for monitoring the opacity of the flue gas exiting the precipitator. Reese discloses that the power to the precipitator may be regulated so that the opacity remains just below the established environmental guidelines. Reese fails to realize, however, that major reductions in opacity are achieveable for minor increases in corona power to a point of optimum power utilization. Consequently, relatively minor increases in power can provide a cleaner environment at a reasonable cost. Reese attempts to achieve an opacity level just short of that required rather than attempting to remove the maximum amount of particulates from the stream. Reese fails to appreciate the downstream effects and costs occasioned by the large quantity of particulates remaining in the flue gas stream.
OBJECTS AND SUMMARY OF THE INVENTION
The primary object of the disclosed invention is to provide a method and appartus for optimizing the power consumption of electrostatic precipitators through utilization of a load indexed feed forward signal and a particulate loading feedback signal.
A further object of the disclosed invention is to provide means for accommodating linear and non-linear load transients.
Yet a further object of the disclosed invention is to provide a method and apparatus for automatically seeking the optimal power level.
Still a further object of the disclosed invention is to utilize the particulate loading feedback signal to trim the power of the field wherein the power is primarily derived from the load indexed feed forward signal.
Yet another object of the disclosed invention is to provide automatic means for determining the buildup of particulates on the electrodes and for providing automatic means for cleaning the electrodes while simultaneously compensating for any out of service electrodes.
Still yet another object of the disclosed invention is to provide a precipitator control apparatus and method adapted for minimizing particulate emissions and simultaneousy optimizing power consumption while still attaining environmental guidelines.
Yet a further object of the disclosed invention is to provide an apparatus and method for controlling a precipitator which may be retrofitted to an existing precipitator control apparatus.
Another object of the disclosed invention is to provide a precipitator control apparatus and method which is expandable and which may be assembled from a minimum number of readily available parts.
A further object of the disclosed invention is to provide a method and apparatus for profiling the precipitator fields.
Another object of the disclosed invention is to provide a method and apparatus which automatically trims the field voltage until the opacity increases by more than a preselected amount.
In summary, the disclosed invention is advantageously adapted for controlling the power consumption of an electrostatic precipitator utilized in conjunction with a boiler, or the like, which discharges particulate laden flue gas to a smokestack. A transformer-rectifier set provides the corona power for the precipitator and an adjustable primary controller is connected to the transformer-rectifier set in order to regulate the power output thereof. A load indexed signal is fed forward from the boiler to the primary controller in order to establish the primary corona power. A particulate loading signal is fed back from the smokestack to the primary controller in order to trim the corona power to a level where the particulate loading of flue gas increases by more than a predetermined amount. The offset limit is normally set at the point of optimization, but the level can be set so as to be just sufficient to permit the precipitator to attain the particulate emission standards. The invention achieves the stated objectives of minimizing particulate emission while optimizing the power consumption through utilization of a low seeking algorithm which cooperates with the opacity monitor.
A power to voltage or current comparator compares the corona voltage to the voltage demand indicated by the transformer-recitifier set in order to monitor the build-up of particulates on the electrodes of the various fields. An increase in current or a decrease in voltage while field power is held constant provides an accurate means for determining particulate build-up. When the particulates have built up beyond a predetermined level, then means are initiated for automatically rapping or cleaning the electrodes.
These and other objects and advantages of the invention will be readily apparent in view of the following description and drawings of the above-described invention.
DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages and novel features of the present invention will become apparent from the following detailed description of the preferred embodiment of the invention illustrated in the drawings, wherein:
FIG. 1 is a schematic diagram of the invention;
FIG. 2 is a functional block diagram of the invention;
FIGS. 3 and 4 are functional logic diagrams illustrating the algorithms utilized by the invention:
FIG. 5 is a plot of several opacity versus power curves; and,
FIG. 6 is a plot disclosing the effects of profiling of the precipitator fields.
DESCRIPTION OF THE INVENTION
As best shown in FIG. 1, coal fired boiler B has an exhaust duct 10 communicating particulate laden flue gas to precipitator P. Stack or exhaust device S is in communication with precipitator P by means of duct 12 which conveys the cleaned flue gas from precipitator P to stack S.
While the boiler B has been disclosed as being a coal fired boiler, one skilled in the art can appreciate that various other particulate and energy sources are known in the art for powering a boiler, a generator, a kiln, a smelter or the like. The boiler B, regardless of the media being combusted, is adapted for combusting the material in order to achieve a desired purpose, such as the generation of electric power, steam or the like. The combustion of the energy source requires the utilization of air, as is well known, with the result that large quantities of particulate laden flue gas are generated.
Environmental regulations and statutes limit the overall quantity and the loading of particulates emitted from any particulate source, such as from boiler B. Control of particulates exhausted through stack S is therefore of prime concern to the operators of boiler B, whether it be a boiler or other particulate source.
The precipitator P is, preferably, divided into a plurality of fields P1, P2 and P3. Those skilled in the art can appreciate that the precipitator P will typically have more than three fields and that the fields P1, P2 and P3 are merely illustrative. Each field includes at least one pair of oppositely charged electrodes which generate the corona power for charging the particulate material. Field P1 has electrodes 14 and 16 while field P2 has electrodes 18 and 20 and field P3 has electrodes 22 and 24. Each of the electrodes 14-24 is connected one of to a transformer-rectifier (T-R) sets 26, 28 and 30, respectively. Leads 32 and 34 connect electrodes 14 and 16. respectively, to T-R set 26. Similarly, leads 36 and 38 connect electrodes 18 and 20, respectively, to T-R set 28 while leads 40 and 42 connect electrodes 22 and 24, respectively, to T-R set 30. Those skilled in the art can appreciate that each of the pair of leads 32-42 are utilized to provide voltage to the associated electrodes 14-24. The electrodes 14-24 of each field P1, P2 and P3 each have their own voltage sign and thereby provide oppositely charged paired electrodes. Charging of particulates by one of the electrodes of a pair causes the particulates so charged to be attracted to the oppositely charged electrode with the result that particulates are removed from the flue gas stream.
The charging voltage between each of the cooperating pairs of electrodes 14-16, 18-20 and 22-24 must be sufficiently high to charge and collect the charged particulates on the oppositely charged electrodes within the precipitator fields P1, P2 and P3. For this reason, adjustable output primary controller 44 is connected to each of the T-R sets 26-30 by means of leads 46, 48 and 50. In this way, the primary controller can direct current to each of the T-R sets 26-30 in order to regulate the power
to the fields P1, P2 and P3. Regulation and adjustment of the current fed to each of the T-R sets 26-30 results in the regulation and adjustment of the corona power between the electrodes 14-24 of the fields P1, P2 and P3.
As best shown in FIG. 1, primary supervisory controller 44 is in electrical connection with transformer-rectifiers sets 26-30. The transformer-rectifier sets 26-30 each includes a voltage, current, or phase angle control adapted for energizing the electrodes of the fields P1, P2 and P3 of the precipitator P by generating a field voltage in response to a control signal sent by the primary controller 44.
Load indexed transducer 52 is operatively associated with boiler B and is in electrical connection with primary controller 44. One or more transducers 52, which is of a type well known in the art, is adapted for monitoring any one or all of the following load transients: volumetric flue gas flow, volumetric steam flow, volumetric air flow and volumetric fuel flow. Similarly, transducer 52 or an additional transducer or controller may be utilized to correct the load indexed signal for particulate resistivity, ash loading, and flue gas temperature. The above cited transients and input to boiler B are only a representative list of the parameters which may be monitored. Those skilled in the art can appreciate that the significance of these, as well of other parameters, is, to a large extent, dependent upon the application to which the boiler B is placed.
Additionally, the above and other load parameters or transients may be of a linear or a non-linear relationship. That is, particulate loading is based, at least in part, on fuel loading and fuel loading is not necessarily continuous and uniform. Consequently, particulate loading may exhibit both linear and non-linear relationships at various times.
The transducer 52 monitors the parameters or transients and feeds forward a dynamic signal to the controller 44 which signal is indicative of, and generally proportional to, the parameter or parameters being monitored. The transducer 52, preferably, includes means for providing a time delay to permit a lag time to be built into the monitoring system. It should be obvious that, due to the large number of parameters being monitored, a modern electronic digital or analog data collection system is preferred for use with the transducer 52 to facilitate data collection.
An optical transducer 54 is operatively associated with stack S and is adapted to monitor the opacity of the flue gas exiting precipitator P through stack S. The transducer 54 generates a dynamic signal indicative of, and preferably proportional to, the opacity level or particulate loading of the flue gas issuing from stack S. The transducer 54 is in electrical communication with primary controller 44 and is adapted for transmitting the dynamic signal to controller 44. Consequently, the transducer 54 feeds back a particulate loading signal to the controller 44. While an opacity transducer 54 has been disclosed, those skilled in the art can appreciate that other particulate loading monitor means may be adapted for utilization with the invention.
A power monitor 56 is in electrical connection with the electrodes 14-24 of the precipitator P and with the primary controller 44. The power monitor 56 monitors the corona power between the paired electrodes 14-24 of the precipitator fields P1, P2 and P3. The charged particulates are drawn to and attached to the electrodes 14-24 of each of the precipitator P and thereby affect the voltage and current relationship existing between the electrodes as the power is held constant.
Monitoring the voltage or current change for each field in relation to the power permits a determination to be made of the quantity of particulates which have become attached to the electrodes 14-24 of the precipitator P. Also, monitoring of the voltage or current rate of change in comparison with the power permits an accurate determination of the rate of particulate build-up to be made. The comparison of the rate of particulate build-up in one of the fields P1, P2 and P3 with a similar measurement in the other parallel flow path fields permits a determination to be made of any flow or particulate loading imbalance between the flow paths. This in turn permits the power to each flow path to be biased in order to compensate for the flow imbalances.
The load indexed transducer 52 transmits its dynamic signal to primary controller 44. Controller 44 interprets the received signal and directs T-R sets 26-30 to provide a particular corona power dependent upon the signal received. Consequently, the initial corona power is proportional to the initial load parameter or parameters being monitored. The primary controller 44 receives the load indexed signal from transducer 52 and interprets the signal received with regard to the particulate level which must be achieved by the precipitator P and determines the power necessary for the precipitator P to attain that level.
The Deutsch-Anderson model is one means which may be utilized to approximate the corona power which is required. The Deutsch-Anderson model may be mathematically expressed as:
β=100(1-e(-AW/V))K
where β=particulate removal efficency (%)
A=total collecting area (FT 2 )
V=volumetric flow (FT 3 /min)
W=migration velocity (FT/min)
K=empirical correlation factor
The Deutsch-Anderson model determines particulate removal efficiency based upon the total area of the electrodes, the volumetric flow rate, the migration velocity and an empirical correlation factor.
The migration velocity may be determined from Cunningham's correction to Stoke's law. Cunningham's correction may be mathematically expressed as:
W=(qEp/6πθ)a (1+α(λ/a))
where
W=migration velocity
q=particle charge
Ep=precipitator field voltage
θ=gas viscosity
a=particle radius
λ=mean free path length
αdimensionless parameter
Cunningham's correction bases migration velocity on the particle charge, the precipitator field voltage, the gas viscosity, the particle radius, the mean free path length and a dimensionless parameter. Consequently, the primary controller 44, which preferably includes a microprocessor or other modern electronic computing means adapted for performing the necessary arithmetic operations, calculates and determines the required corona power taking into account the Deutsch-Anderson model and Cunningham's correction.
The inventors have learned, through experimentation, however, that the Deutsch-Anderson model suffers from a lack of accuracy as the corona power increases. Specifically, the Deutsch-Anderson model suggests that the removal efficiency increases with increasing corona power. Consequently, increasing corona power should result in increasing removal efficiency. Unfortunately, the results indicate otherwise.
For instance, the empirical correlation factor K permits the reentrainment of particulates due to electrode cleaning to be taken into account. Additionally, the empirical correlation factor K also takes into account turbulence or other flow disturbing occurences. Since cleaning occurs periodically, the Deutsch-Anderson model need only take those factors into account during the cleaning period. The Deutsch-Anderson model also fails to take into account electrode end sneakage and rear field reentrainment. The latter two deviations account for a substantial portion of the stack particulates and cannot be overcome by increasing the corona power.
A more accurate approximation of the required corona power can be obtained by an empirical determination based upon repeated testing, particularly at high voltages, and monitoring of the obtained load indexed and particulate loading signals. The particulate testing required is of a type well known in the art and merely requires a manual adjustment of T-R sets 26-30 in cooperation with the feedback signal from the transducer 54 and the feed forward signal from transducer 52. A sufficient number of tests at various load levels permits accurate power approximation to be made for those ranges where the Deutsch-Anderson model breaks down. These tests can also be utilized with modern computer techniques in order to fit the Deutsch-Anderson model and to provide for proper nominal power distribution within the precipitator.
The opacity transducer 54 feeds back a signal to primary controller 44 which is utilized for trimming the corona power of the electrodes 14-24 of the precipitator P. The primary controller 44 utilizes a low-seeking algorithm in order to adjust the corona power based upon particulate loading the measured opacity as monitored by the transducer 54. The corona power is decreased by the controller 44 until such time as a marginal decrease in corona power results in the opacity increasing by more than a predetermined particulate offset amount. The controller 44 monitors the resulting opacity and compares that opacity to both an environmental limit for particulates a setpoint which is derived by adding together a previously obtained low opacity with the offset. The controller 44 adjusts the corona power of the electrodes 14-24 based upon the results of the comparison with the result that the corona power is again incrementally reduced if the opacity is less than the setpoint. On the other hand, should the measured opacity exceed the setpoint or the environmental limit, for particulates then the corona power is incrementally increased. Consequently, the measured opacity is capable of being maintained at an optimal level well below the environmental limit for particulates and thereby provides maximum environmental protection. Consequently, the primary controller 44 will reduce the corona power in order to conserve electricity. Additionally, should the measured opacity exceed the environmental limit, then a backup in the primary controller 44 will raise the corona power. One skilled in the art can appreciate that monitoring of the opacity in cooperation with the load indexed transducer 52 results in the corona power being continuously adjusted in order to achieve the minimal power level required for obtaining the maximum environmental protection.
As best shown in FIG. 1, data input device 58 is in electrical connection with controller 44. The data input device 58 is utilized by the operator (not shown) in order to input the particulate offset and the environmental limit for particulates. Consequently, the operator (not shown) can select the amount of offset which is to be utilized by the controller 44 in determining whether or not to increase or decrease the corona power. Typically, the particulate offset should be set in a range of approximately 0.25%, for reasons to be explained herein later.
Storage device 60 is in electrical connection with controller 44 and is utilized by the controller 44 to store the particulate offset and the environmental limit for particulates, among other things. Additionally, the storage device 60, which preferably is a volatile memory, is utilized to store a previously achieved low opacity level utilized in calculating the setpoint. The controller 44 stores in the storage device 60 the lowest previously obtained opacity level in order to provide a target or reference level. The storage device 60 must permit the stored opacity level to be replaced, it must be writeable, due to the fact that marginal changes in the corona power and transients in the boiler load parameters may result in the stored low opacity being subject to change. Those skilled in the art can appreciate that the storage device 60 and data input device 58 can, preferably, be integrated into the controller 44. Specifically, a modern computing system can be advantageously utilized to effect such integration.
FIG. 5 discloses curves 62, 64 and 66 which relate the opacity to field power. Curve 62 is representative of opacity readings obtained when a precipitator, such as precipitator P, is operating at 60% load. Similarly, curves 64 and 66 relate to precipitator loadings of 80% and 100%, respectively. Obviously, these curves are illustrative as the actual curves will be related to the precipitator being operated. It can be noted that each of the curves 62-66 has a relatively flat portion at high power inputs. Each of the curves 62 through 66 has a knee associated with a dramatic change in opacity rating for a marginal change in power input. Consequently, the power which is input to the precipitator P can be continually decreased until the knee of the curve is reached. Once the knee is reached, the opacity increases greatly for each marginal decrease with the result that particular care must be taken to make sure that the power is not reduced below that level required to attain the environmental limit. It can be seen that the flat part of the curve extends over a wider power range as the load factor decreases. Additionally, the opacity increases dramatically as the power approaches zero due to the fact that few particles are being removed from the flue gas stream. This it to be expected in view of the denseness of the particulates exiting the boiler B.
The primary controller 44 directs the T-R sets 26-W-30 to provide a predetermined amount of power for charging the discharge electrodes of precipitator P. The accumulation of particulates on the electrodes of precipitator P affects the voltage and current of the collecting electrodes. Consequently, while the primary controller 44 may direct the T-R sets 26-30 to provide a certain power level, the accumulation of particulates results in a different voltage and current level being actually realized because the T-R sets 26-30 tend to hold the current, voltage or phase angle constant for the particular idealized power demanded. The power monitor 56, which is of a type well known in the art, monitors the power between the electrodes of the precipitator P, or the electrodes of each field P1, P2 and P3, and communicates the measured power or voltage to the primary controller 44. The controller 44 continuously compares the idealized or theoretical voltage or current for a given power level versus the actual field voltage or current as a means for monitoring the accumulation of particulates on the electrodes. After a sufficient number of particulates have accumulated on the electrodes 14-24 of the precipitator P, then the electrodes must be cleaned or rapped, in a way well known in the art, in order to restore the precipitator P, or at least the individual fields P1, P2 and P3, to efficient operation.
As best shown in FIG. 1, each of fields P1, P2 and P3 has a rapper mechanism 68 which is in electrical connection with rapper controller 70. Rapper controller 70 is in electrical connection with primary controller 44 and the rapper controller 70 is responsive to control signals directed from the primary controller 44 for causing the rappers 68 to selectively rap the fields P1, P2 and P3.
A transient monitoring transducer 72 is preferably operatively associated with boiler B, preferably through duct 10. Transducer 72 is adapted for providing a signal indicative of any one of flue gas temperature, particulate resistivity, field dielectric strength and electrode cleaning. The transducer 72 directs a signal indicative of the variable being monitored to the primary controller 44 to permit the primary controller 44 to regulate the field voltage in response to fluctuations in the signal.
The logic sequence utilized for operating the invention is best shown in FIGS. 3 and 4. The logic sequence may be thought of as an algorithm which is utilized to obtain the necessary data, to perform the necessary functions on the data and to utilize the processed data for the purpose of regulating the power output of the T-R sets 26-30.
Initially, the environmental limit for particulates and the particulate offset are input through the data input device 58. The environmental limit permits primary controller 44 to determine a minimum field power. The feed forward load indexed signal produced by the transducer 52, in cooperation with the preestablished environmental limit, permits the primary controller 44 to determine the appropriate power needed to assure that the precipitator P adequately cleans the flue gas, particularly during start-up of the boiler B.
The feed forward load indexed signal of transducer 52 is input to the primary controller 44 at step 74, as best shown in FIG. 3. The overall field power required is determined, as previously described, based upon the load indexed signal which is fed forward from transducer 52. Generally, a precipitator, such as precipitator P, includes a number of cooperating pairs of electrodes, such as electrode pairs 14-16, 18-20 and 22-24. The cooperating pairs of electrodes each serve to define a field, such as fields P1, P2 and P3, respectively. The primary controller 44 establishes the total field power which is necessary for the combination of the fields, P1, P2 and P3.
The overall field power is corrected at 76 for any one of flue gas flow, casing particulate loading, flue gas temperature, or resistivity. Generally, the correction for variations in flue gas flow will be based upon analysis of historical data. Typically, manual correction will be provided, the amount of which will be determined from the data and which will be related to the precipitator P being utilized. The flue gas temperature correction, on the other hand, is based upon a realization that a higher temperature will result in a higher volumetric flow. This data is relatively easy to collect. Finally, the correction for ash resistivity will also be historically based and will be dependent, at least in some part, on the particulate material being combusted. Those skilled in the art know that coal, as an example of one particulate source, is an amorphous material which consists essentially of numerous organic constituents. The resistivity of the ash of the coal will depend, to a large extent, on the grade and type of coal being combusted. The overall field power can also be corrected at 78 by a manual bias. The manual bias will be based, at least in part, upon operator experience with the particular precipitator P being utilized.
The algorithm next corrects the overall power demand signal at 80 based upon the feedback signal from the transducer 54. The signal from the transducer 54 is manipulated by the algorithm of FIG. 4, and will be further explained, and is input to the logic sequence at 80. Suffice it to say at this point, that the signal of the transducer 54 is operated on by an integrating controller.
The integrating controller is best shown in FIG. 4 and is utilized for correcting the overall demanded power signal by biasing the signal up or down to maintain the opacity at a particular level. The opacity setpoint signal is determined by the low-seeking algorithm of FIG. 4 and optimizes the power/particulate level relationship. This low-seeking algorithm incorporates an allowable offset limit setpoint. The environmental limit setpoint overrides the low-seeking algorithm of FIG. 4 in the event that the precipitator P performance is in the vicinity of the environmental limit. The environmental limit setpoint and the allowable offset limit setpoints are, as previously discussed, input to primary controller 44 by data input device 58.
The algorithm of FIG. 4 determines, at 82, whether or not the loop is in automatic control or on manual by interpreting a signal from switch controller 83. The algorithm next receives the particulate signal at 84 from the opacity transducer 54. Comparator 86 manipulates the signal from the transducer 54 and compares that signal with a prevously stored minimum particulate limit signal related to a previously achieved low opacity level. The comparator 86 determines whether the particulate loading signal transmitted by the transducer 54 is less than the stored particulate limit signal. Should the particulate loading signal be less than the stored particulate limit then the algorithm at 88 sets the stored particulate limit signal as being equal to the particulate loading signal. Basically this operation indicates that the particulate loading signal is less than the previously achieved stored minimum particulate level. Consequently, function 88 indicates that the particulate loading signal is less than that previously obtained, although not necessarily the lowest obtained level, and indicates that a reduction in corona power of the electrodes has not deleteriously affected the measured opacity.
Should the particulate loading signal be greater than or equal to the previously stored minimum particulate signal, then the operation of function 88 will be bypassed. The algorithm next calculates a setpoint signal which is equal to the particulate limit signal plus the previously input particulate offset signal. The particulate limit, as previously described, represents a previously obtained low opacity level which has been stored in storage device 60. The setpoint signal is then transmitted to comparator 92 where the particulate loading signal is compared with the setpoint signal. Should the particulate loading signal be less than the setpoint signal then the comparator 92 outputs the resulting signal to 94 and replaces the previously stored minimum particulate limit signal with the particulate loading limit. In other words, the previously stored low opacity value has been replaced due to the fact that the particulate loading signal is less than the setpoint signal. This indicates that the opacity did not increase more than the acceptable range which is established by the particulate offset signal.
Should the particulate loading signal be greater than or equal to the setpoint signal, then the algorithm bypasses the operation of 94 and the signal is transmitted to comparator 96 wherein the setpoint is compared with the environmental limit which has been input through by data input device 58. Should the setpoint exceed the environmental limit signal then the setpoint is set equal to the environmental limit at 98.
The algorithm next compares the particulate loading signal to the setpoint signal at comparator 100. Should the particulate loading signal exceed the setpoint signal then the algorithm at 102 directs that the corona power be increased by a uniform increment voltage amount at 102. The increased corona power signal is then output to the particulate detection correction at 80, FIG. 3.
Should the particulate loading signal not exceed the setpoint, then the algorithm compares the particulate signal to the setpoint at comparator 104. Should the particulate loading signal be less than the setpoint signal then the algorithm, at 106, directs that the corona power be decreased by a uniform voltage amount. The output of the algorithm of FIG. 4 is input to the particulate detection correction 80 of FIG. 3, as previously described.
The low-seeking algorithm, as best shown in FIG. 4, optimizes the particulate level setpoint by adjusting the power level down until the predetermined offset in particulate loading has been obtained. Should the particulate loading exceed the maximum allowable particulate level, then the setpoint directs that the corona power be increased. The low particulate level previously obtained is stored in storage 60 for reference as a target particulate level. The process and the control are both dynamic and cycling occurs. Cycling is used to assure that the minimum power level for the target particulate level is achieved. As the cycling occurs, the stored minimum particulate level is continually updated from the particulate detection signal.
Should the load increase, or other factor, cause the target opacity to be exceeded for more than predetermined period of time, while the primary controller 54 has increased power to a predetined limit, then the stored target particulate level is replaced by the actual particulate level plus the predetermined allowable offset. This action resets the algorithm which again performs the low-seeking power routine. This method prevents the particulate control from oscillating between the predefined particulate limits and permits continual operation very near the optimal level.
The particulate detection correction can be placed into or taken out of service by a manual or an automatic selector station. This capability permits operation in accordance with the load indexed feed forward signal when the opacity transducer 54 is being maintained or is not operating properly.
One skilled in the art can appreciate that various upsets and transient distortions may occur in the operation of boiler B with the result that the emissions from stack S may be non-linear. The particulate sampler, such as optical transducer 54, therefore preferably includes means for averaging the measured particulate level over a preselected period of time in order to minimize temporary distortions and transients. Consequently, the dynamic signal being transmitted by the optical transducer 54 is not a real time signal but is actually an averaged signal. A similar feature may also be provided for the load indexed transducer 52 to also minimize the distortions and fluctuations of the parameters being measured. Furthermore, the lead time from input upset to its effect on the stack S may be compensated for by the controller 44 means of a time delay.
The primary controller 44 determines the flow path power levels at 106 and directs the individual T-R sets 26-30 to provide the necessary power for obtaining that total corona power. A manual flow path bias at 108 may be adjusted for each flow path. The primary controller 44 also includes means for automatically biasing the flow path at 110 for achieving the maximum removal effect in each flow path.
The particulate buildup detection algorithm, at 112, is used for automatic correction of the effects of particulate accumulation through monitoring the rate of build-up in the front fields for each flow path. The power level demanded for each flow path is compared to the actual power utilized in the flow paths at 114. An integrating controller assures that the feed back signal representing the power utilized is equal to the power demanded signal. The power to the flow paths is distributed at 116.
The flow control also includes means for biasing the individual fields, P1, P2 and P3, from the front of the flow path to the rear at 118. This helps to achieve the optimal removal effect in each flow path. FIG. 6, which discloses the effects of profiling, shows that biasing of the T-R fields depends upon the actual precipitator used. The biasing is based upon modeling utilizing the Deutsch-Anderson model in conjunction with historical data. The particulate build-up detection algorithm 112 is used for automatically correcting the demanded power distribution within the flow path.
The individual demanded power levels can be manually biased, at 118, for operational flexibility. A manual bias is provided at 120 and permits manual adjustment in the event of transient distortions.
The primary controller 44 utilizes the algorithm at 112 for monitoring the particulate build-up of the electtrodes 14-24 in the precipitator P. A voltage or current monitor, such as monitor 56, is connected between each pair of oppositely charged electrodes 14-16, 18-20 and 22-24, and monitors the voltage between the electrodes. Experience has indicated that the accumulation of particulates on the electrodes 14-24 results in a decreasing resistance between the electrodes. Consequently, while the primary controller 44 is directing individual T-R sets 26-30 to provide an amount of power previously determined to be sufficient to generate a predetermined field power, the accumulation of particulates results in the actual voltage level being less than the idealized voltage. Consequently, the current level is greater than the idealized current. At some point, the resistance decreases to such a point that the electrodes 14-24 must be cleaned. Those skilled in the art realize that the rate of particulate build-up on the cooperating pairs 14-16, 18-20 and 22-24 uniform with the result that one pair of electrodes, such as 14-16 may require cleaning prior to the remaining electrodes 18-24. Consequently, monitoring the field voltage or current of the individual fields P1, P2 and P3 provides an accurate measurement for determining when the electrodes 14-24 must be cleaned. Also, a comparison of the idealized voltage or current versus the actual utilized voltage or current permits a determination to be made as to whether or not the cleaning process was sucessful or the field is operating properly. Failure of the voltage or current to return to the idealized level after cleaning generates a cleaning failure alarm.
A power increase for one of the pairs of electrodes 14-24 permits an accurate measurement to be made of when the electrodes 14-24 must be cleaned. The means for rapping or cleaning the electrodes are well known in the art and the rapper controller 70 is directed at 122 to cause rapping by one or several of the rappers 68. Further discussion of the rapper mechanism 68 is not deemed necessary. The power level of the fields P1, P2 and P3 being cleaned is maintained, reduced or deenergized depending upon the characterics of the particulates being removed.
Should the utilized voltage after cleaning be less the idealized voltage determined by the T-R set excitation, then the algorithm provides for an alarm to be transmitted in order to notify the appropriate personnel. A system of alarms permits ready determination of the malfunction.
The algorithm, at 124, outputs a control signal to each T-R set 26-30. The signal is normally a current limit, a voltage limit, or a firing angle limit override which regulates the power output of the T-R sets 26-30 at 126.
The functional diagram disclosed in FIG. 2 indicates in block form the various functions and corrections provided by the algorithms of FIGS. 3 and 4. A master control, such as the main control of the precipitator P, is in electrical connection with primary controller 44. Primary controller 44, which includes a microprocessor or the like, directs the field series biasing and correction for the individual fields of the paired electrodes 14-16, 18-20 and 22-24 of the precipitator P. The primary controller 44 includes means for correcting the primary field power for flow measurement of flue gas, for casing particulate measurement in the flue gas, for temperature of the flue gas and provides manual bias based upon empirical relationships. The primary controller 44 also includes a flue gas correction to accomodate the build-up of particulates on electrodes 14-24. As can be appreciated, the primary controller 44 provides means for automatically arithmetically accurately approximating the overall field power which the precipitator P must have if the measured particulate level is to be approximately that of the target level with the lowest power input. It is important that the initial primary field power be close to the required field power if the algorithms of FIGS. 3 and 4 are to be accurately and efficiently utilized for minimizing the power consumption of the precipitator P.
The field controls also include an upscale override in the event one of the upstream fields is being cleaned. One skilled in the art can appreciate that rapping of the electrodes 14-24 by the rapper mechanism 68 results in the evolution of large amounts of particulates. These particulates could result in a spurious signal directing the primary controller 44 to unnecessarily increase the field voltage by a large amount. The upscale overrides are only operational during the cleaning of the individual electrodes. The field controls also contain a downscale override for power off or reduced power rapping.
The field controller includes means for transmitting the particulate build-up to the primary controller 44 so as to rap or clean the individual electrodes 14-24 when that becomes necessary.
The primary controller 44 also controls the total power to be given any flow path. Thus, the primary controller 44 automatically adjusts the total power in a given flow path to compensate for action taken in cleaning. Additionally, the primary controller 44 compensates in the event that a T-R set 26-30 is lost for any reason. It can be seen in FIG. 2 that a number of paired electrodes 14-24 are provided in the precipitator P. The primary controller 44 is adapted for monitoring each of the individual field controls and for summing and scaling the results obtained therefrom so as to optimally provide the requisite power for precipitator P. Each of the field controllers is in communication with the field controllers of the other electrodes so that a working network is provided.
FIG. 6 discloses the effects of profiling or biasing fields P1, P2 and P3 in a flow path for a specific precipitator P. The ideal profile would be determined for each precipitator by tests and computer modeling.
Curve 128 represents a uniform power reduction curve. Curve 130, on the other hand, represents the effect of profiling the fields P1, P2 and P3 in a certain way. Similarly, curves 132 and 134 likewise show the effects of profiling.
A review of FIG. 6 discloses the beneficial effects of profiling the fields P1, P2 and P3. It can be seen that curve 132 provides a greatly improved removal efficiency at a voltage level wherein the remaining curves 130 and 134 provide for a reduced removal. Similarly, curve 134 provides for reduced removal efficiency at relatively low power levels but removal efficiency is greater increased at higher levels. It can be noted, however, that all curves 128-134 eventually obtain the same removal efficiency at maximum field power. Consequently, the effects of profiling are more substantial at low power operation.
OPERATION
Utilization of the invention is relatively straightforward and is readily adapted for both new installations and retrofitting. The primary controller 44, the data input device 58 and the storage device 60 may, preferably, be integrated into a single unit which may also have the capability for handling the data collection from transducers 52 and 54 and the transient transducer 72. Consequently, the space requirements are relatively small.
The system operator (not shown) inputs the particulate offset level and the environmental limit into the primary controller 44 through the data input device 58. Typically, precipitators, such as precipitator P, are designed to remove in excess of 99.6% of the particulates and therefore it is not necessary to input a removal efficiency parameter. The removal efficiency parameter may, however, be included in the algorithm. After the particulate offset and the environmental limits have been received and stored in the storage device 60, then the system is ready for operation.
The feed forward lead indexed transducer 52 transmits its signal to the primary controller 44. The primary controller 44 determines the field power which is required in order that the flue gas exiting the stack S not exceed the precipitator's capability and be less than the environmental limit. The primary controller utilizes the algorithm of FIG. 3 for determining the field power and directs the T-R sets 26-30 to provide the requisite power. This demanded power is sufficient to permit the flue gas exiting the stack S to not exceed the environmental limit. The demanded power may, however, be more than is optimally required with the result that the trim algorithm of FIG. 4 is then utilized.
The opacity transducer 54 feeds back a particulate loading signal to the primary controller 44 which utilizes the algorithm of FIG. 4 to trim the power. The power is continually uniformly incrementally decreased until such time as the opacity exceeds the previously obtained opacity by more than the allowable offset. The primary controller, once beyond or less than the power level associated with the knee of the curves of FIG. 5, directs the T-R sets 26-30 to increase the power and thereby bring the opacity into range. The algorithm of FIG. 4 causes the T-R sets 26-30 to follow the base or flat portion of the curves 62-66 until such time as a marginal decrease in power causes the opacity to increase by a large amount.
The algorithm of FIG. 4 stores a low opacity level which has been obtained at a particular power input. The algorithm then lowers or incrementally decreases the power and then compares the measured opacity to the stored opacity. Should the measured opacity be less than the stored opacity plus the particulate offset, then the measured opacity replaces the stored opacity. The algorithm continues to repeat this process until the measured opacity exceeds the stored opacity by more than the particulate offset.
It can be seen, therefore, that the load indexed transducer 52 provides an accurate determination of the power required by the electrodes 14-24 to clean the flue gas so as to obtain at least the environmental limit. The feed back particulate loading transducer, on the other hand, causes the field power to be trimmed or incrementally decreased so that the resulting opacity is, generally, much better than the environmental limit but, on the other hand, the power required may be greater than the power required to attain the environmental limit. The use of the feed back particulate loading transducer, therefore, represents a tradeoff between reduced power consumption and a cleaner environment. The cleaner environment also, however, results in decreased operating costs for the precipitator P and stack S. The reduced operating costs are due to the fact that a cleaner flue gas stream causes less damage to the induced draft fans and other operating components.
While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, uses and/or adaptions of the invention following in general the principles of the invention and including such departures from the present disclosures as come with the known or customary practice in the art to which the invention pertains and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention of the limits of the appended claims. | A process for optimizing the power consumption of electrostatic precipitators communicating with a boiler or the like includes a load indexed signal fed forward to a field power controller to approximate the required power levels. An optical transducer is provided in the boiler stack for monitoring the emissions therefrom and feeds back a signal to the controller proportional to the emission from the stack to trim the power level. The controller incrementally adjusts the field power by comparing the opacity generated signal to a continuously optimized limit in order to thereby optimize the power consumption by lowering and raising the field power in response to changes in the opacity. The measurement of power permits the process to be extended to include supervision of electrode cleaning, compensation for fields out of service and flow balancing. | 8 |
The present application claims priority on co-pending U.S. Provisional Patent Application Serial No. 60/240,006 filed Oct. 12, 2000. The entire text of the above-referenced disclosure is incorporated by reference herein without discretion.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to shock absorbing components and to methods of manufacturing shock absorbing components. More particularly, the invention relates to flexible shock absorbing components used to provide cushioned surfaces or surface coverings.
2. Description of Related Art
There are many cushioning surfaces that have been used for athletic and recreational activities in indoor as well as outdoor facilities. For example, cushioned surfaces have been used for floor coverings or wall surfaces in indoor gymnasiums for indoor sports, as well as for home gyms and exercise mats. Examples of outdoor athletic and recreational areas where cushioned surfaces have been used to cover the ground include football fields, children's playgrounds, and running tracks. Not only have cushioned surfaces been used for floor coverings and/or wall surfaces in athletic and recreational fields, but they also have been used in medical and health-related areas including nursing homes, hospitals and rehabilitation centers, and for animal enclosures to aid in animal comfort and safety.
There are three principle types of prior art cushioning structures used in flooring or wall surfaces for recreational use. First, there are cushioning structures that use solid materials such as rubber or rubber particles to provide the shock absorbing characteristics. A wearcourse is the term for outermost layer that comes into contact with the user and the elements. For example, wearcourses that have been used include rubber particle surfaces for tracks, nylon fibers and other materials used for synthetic grass.
Second, wood chips or sand have been used to provide cushioning of the ground surfaces in outdoor areas such as playgrounds to help reduce the impact from falls as a result of the activity, thereby reducing the risk of injury.
Third, mechanical means have been used to cushion the impacts. For example, one such mechanical means used in cushioned floor surfaces is vertical I beams. For example, the I-beam structure has been used in shock absorbing structures where honeycomb surfaces made from rubber provide support between the ground and the upper or outer surface. The I-beams in these structures are perpendicular to the surface.
Each of the three main types of prior art cushioning structures have certain disadvantages.
The first type of cushioned surface, made from solid materials such as rubber (i.e., foam rubber) or rubber particles, has the advantage of all weather use, but also has several disadvantages. The first disadvantage relates to the cost of manufacturing and adhering two layers of material together. Two layers are typically needed because the cushioning requirements are substantially different from the surface requirements. For example, in floor coverings, the bottom layer of material typically provides the cushioning features and the top layer of material provides comfort, traction and durability. The layers must have different structures and are manufactured from different materials having different characteristics.
A second disadvantage with prior art cushioned surfaces made from rubber or rubber particles is that they do not adequately cushion a fall. This is because the prior art cushioned structures made from rubber or rubber particles do not provide adequate impact management over the range of force exerted on the surface. For example, the impact absorption is not predictable throughout the surface and, especially at high impacts, the structures fail to provide sufficient cushioning.
A third disadvantage of prior art cushioning structures made from rubber or rubber particles is their lack of durability. In the past, many of these materials, such as foam rubber, used for the bottom layer of a two-layer cushioning structure lost their cushioning ability quickly and, failed to provide adequate cushioning for a sufficiently long period of time.
Wearcourse outdoor surfaces have additional disadvantages, primarily related to installation and durability. For example, wearcourse installation is tedious, labor intensive, and fraught with human error. Installation involves precise chemical mixing and handling of chemicals, often in less than optimum conditions or in the presence of children. Additionally, the range of colors available and customization is very limited. Lateral shock dispersion, which can reduce or prevent minor injuries such as broken fingers or skin abrasion, also is severely lacking.
As discussed above, the second type of cushioning surface is wood chips or sand, which typically have been used in outdoor areas such as playgrounds to provide cushioning. Although wood chips or sand are low cost alternatives, they also have disadvantages. One problem is that they do not provide uniformly adequate depth to provide adequate cushioning. For example, the loose particles move around so that the actual thickness of the cushioning layer varies significantly depending upon the level of usage and maintenance in a given area. Wood chips or sand fail to provide adequate cushioning for impacts where the loose fill particles do not have sufficient depth.
A second disadvantage with the loose fill materials is that the surface may not be solid enough to permit wheel chair access, especially where the loose fill material has substantial depth. Therefore, the use of wood chips or sand in outdoor recreational facilities may present a problem in satisfying the Americans with Disabilities Act access standards.
Mechanical cushioning structures in the prior art also have disadvantages. Although they may provide acceptable cushioning at low impacts, their cushioning ability is reduced at higher and more dangerous higher impacts. That is due to the tendency of prior art structure to buckle at high levels of impact. Specifically, we have found that prior art I-beam cushioning structures tend to buckle at a high level of impact, rendering this cushioning structure ineffective at some point during the impact.
SUMMARY OF THE INVENTION
This invention overcomes the above mentioned problems and disadvantages by providing a cushioning surface especially suited for recreational use, for both indoor and outdoor activities. The cushioning structure of the invention provides a surface having improved lateral shock dispersion, and improved impact protection. For example, the present invention provides superior impact protection for impacts due to falls of six feet or more onto the surface.
The invention provides a cushioning structure made of interconnected tiles that are fastened together to provide a continuous and smooth cushioning surface. Each tile is made from one or more sheets of thermoplastic material. In a preferred embodiment, two thermoplastic sheets are used. The thermoplastic material is preferably in the range of 0.005 to 0.100 inches, and most preferably about 0.050 inches. Thermoset elastomers or other thermoplastic rubber materials may be used for the sheets to handle larger temperature ranges.
Each sheet of thermoplastic material has a number of indentations therein, each indentation having a hemispherical or elliptical cross section. The hemispherical or elliptical shape of each indentation provides shock absorbing characteristics having a number of advantages in cushioning and durability. The indentations are made by thermoforming each sheet in a mold having hemispherical or elliptical protrusions. Each tile, after the indentations are thermoformed therein, will have a thickness of preferably about one inch in its non-compressed state. When two sheets are used, the thickness of a tile is preferably about two inches. In the two sheet configuration, indentations in each sheet face inwardly and may abut or be joined together. Two inches is preferred as the thickness, and it has been determined that a thickness of two inches will comply with ASTM playground standards. However, the thickness of the two sheets, when they are combined together, may be 12 inches or more in thickness.
One advantage of the present invention is that the top surface spreads the impact or load over a large cross sectional area of the cushioning layer. Another advantage of the present invention is that cushioning tiles may be manufactured and shipped at one location, and then installed at the desired site. Another advantage of the present invention is that the installation of the cushioning tiles requires far less labor than the prior art rubber or rubber particle cushioning structures. Another advantage of the present invention is that tiles having varied properties can be connected together at the installation site to accommodate different cushioning needs. For example, tiles having greater cushioning ability can be installed at equipment locations where risks are higher, while tiles having less impact protection can be installed in other lower risk areas.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.
FIG. 1 is a perspective view of the twin sheet cushioning structure of the present invention.
FIG. 2 is a cross section view of the twin sheet cushioning structure with a layer of rubber particles applied to the outer surface of the top sheet according to a first preferred embodiment of the present invention.
FIG. 3 is a perspective view of the twin sheet cushioning structure with a layer of rubber particles applied to the outer surface of the top sheet, plus a moderator, according to a second preferred embodiment of the present invention.
FIG. 4 is a perspective view of the twin sheet cushioning structure with a layer of fiber particles applied to the outer surface of the top sheet according to a third preferred embodiment of the present invention.
FIGS. 5 and 5A are a perspective view and expanded perspective view of the twin sheet cushioning structure with an additional cushion layer applied to the outer surface of the top sheet according to a fourth preferred embodiment of the present invention.
FIG. 6 is a perspective view, partially in cross section, of the twin sheet cushioning structure of the present invention interlocking tiles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a twin sheet structure specifically adapted for floor or wall cushioning. The twin sheet structure includes a first sheet with indentations and a second sheet with indentations that abut the indentations extending from the first sheet. A twin sheet structure having hemispherical indentations is shown in U.S. Pat. No. 6,029,962 to Joseph J. Skaja and Martyn R. Shorten. The '962 patent shows a twin sheet structure having hemispherical indentations in the sheets. The present invention provides a number of improvements that allow that structure of the '962 patent to be advantageously used for cushioning of floor and wall surfaces.
The present invention improves on the twin sheet structure of the '962 patent by adding an additional layer of material, also referred to as a wearcourse, to the outer surface of one of the sheets. The wearcourse layer provides traction, wear resistance, and resistance to temperature extremes and weather conditions. For example, the wearcourse layer may consist of rubber granules, thermoplastic, or thermoset rubber applied and adhered to the outer surface of a sheet. Although a number of other materials may be used to form the wearcourse layer according to the present invention, several materials that have been tried are described below.
As shown in FIG. 1, the twin sheet cushioning structure includes a first or upper sheet 11 and a second or lower sheet 21 . The first sheet has hemispherical or hemi-ellipsoidal indentations 12 and the second sheet also has hemispherical or hemi-ellipsoidal indentations 22 . Each indentation in the first sheet abuts a corresponding indentation in the second sheet. Drainage connectors 26 may extend between the indentations. The drainage connectors not only allow water to drain from the top sheet to the bottom sheet, but also between adjacent hemis or ellipses in the same layer. Sidewalls 13 and 23 at the perimeter of each sheet may be joined at a seam.
FIG. 2 shows a first preferred embodiment of the present invention. In the first embodiment, the wearcourse layer consists of rubber particles 40 applied to the outer surface of sheet 11 . The rubber particles may partially or completely fill indentations 12 . The rubber particles in each indentations may be loose or may be adhered together with a binder such as a urethane binder. The rubber particles may have irregular dimensions or may be spherical or some other shape if desired. Preferably, the rubber particles are elastic and each will have outward dimensions of less than 0.25 inches. Use of rubber granules to partially or completely fill some or all of the indentations helps make the cushioning structure of the invention effective and consistent across the typical temperature range for the outdoor activities.
FIG. 3 shows a second preferred embodiment of the present invention. In the third embodiment, the wearcourse layer consists of moderator 50 , which is a sheet of plastic or rubber material applied to the outwardly facing surface of sheet 11 . The moderator may be adhered to sheet 11 with adhesive or spot welded to the outer surface of sheet 11 . As shown in FIG. 3, moderator 50 may cover a layer of rubber particles 41 that partially or completely fill indentations 12 . Alternatively, the moderator and sheet each may have mating protrusions and holes to fit over the protrusions, so that the moderator is engaged to the sheet. Optionally, the moderator may have additional cushioning members with a regular grid or pattern, and hemispherical protrusions that extend into indentations. The protrusions may be integral to the moderator. Optionally, fiber particles also may be applied to the outer surface of the moderator.
FIG. 4 shows a third preferred embodiment of the present invention. In the third embodiment, the wearcourse layer consists of fiber particles 30 applied to the outer surface of sheet 11 . This process is generally known as flocking. The fiber particles (i.e., nylon, acrylic, etc.) are applied to the outwardly facing surface of one of the sheets in the twin sheet cushioning structure. Optionally, the outer surface of sheet 11 may be electrically charged to attract and adhere the fibers. If desired, adhesive also may be applied to sheet 11 to adhere the flocking material to that sheet.
A fourth preferred embodiment of the invention is shown in FIG. 5 . In this embodiment, the wearcourse layer consists of moderator 59 which is a third thermoplastic cushioning sheet applied to the outer surface of top sheet 11 . Moderator 59 includes a grid of raised polygonal structures 60 with interconnecting channels therebetween. Each polygonal structure has an indentation in the top surface thereof, preferably a hemispherical or hemiellipsoidal indentation, as shown in the expanded view of FIG. 5 A.
After the floor or wall cushioning structure of the present invention has been manufactured, it can be easily transported and assembled at another location, as will be described below with reference to FIG. 6 . The twin sheet structure and wearcourse layer can be produced in lengths and widths limited only by the dimensions of the production equipment, which is described in U.S. Pat. No. 5,976,451 to Joseph J. Skaja and Martyn R. Shorten. For floor and wall cushioning structures of the present invention, however, it is advantageous to have the twin sheet structure and wearcourse layer sized into symmetrical tiles, and preferably square tiles. The tiles may be 12 inches on each side, for example, facilitating their shipment to the assembly site. Each tile is locked to the adjacent tiles by male and female seam locks 25 , 26 .
Additionally, the present invention contemplates the use of double sided tape applied to urethane film to seal the edges of each tile in the cushioning structure. Double sided tape attached to the urethane film may be used for sealing up the side of a tile, or for the seams. To apply the cushioning structure of the present invention around an obstacle, one can simply cut a hole to fit around the obstacle, take the double sided tape and attach it to urethane film, then put it around the opening in the cushioning structure. | A flexible shock absorbing component providing cushioning for surfaces, especially wall and floor surfaces, is described. The shock absorbing component includes two sheets of thermoplastic, each sheet with inwardly facing, opposing, resiliently compressible indentations extending into a cavity between the two sheets. The shock absorbing component also includes a layer of particulate matter applied to and adhered to the outer surface of one of the sheets, to provide wear and weather resistance. A moderator may also be attached to the outer surface of the sheet. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a method for making a nonwoven web from polymer filaments and more particularly to a method in which continuous filaments of thermoplastic polymer are continuously extruded and subjected to an electrostatic charge to cause separation of the filaments before they are formed into a web.
Spunbonded webs are typically made by continuously extruding a bundle of monofilaments, quenching and attenuating the filaments, and then depositing the filaments on a moving support to form a web.
The application of a uniform electrostatic charge to the filaments to cause repulsion and separation and to provide for better web uniformity is well known. U.S. Pat. No. 3,338,992 describes a process in which a multifilament strand, while under tension, is electrostatically charged by a corona discharge device. The charged filaments are then forwarded by means of a jet toward a web laydown zone, with the tension on the filaments being released upon exist from the jet, permitting the filaments to separate due to the repelling effect of the applied electrostatic charge. Related techniques are described in U.S. Pat. Nos. 3,163,753, 3,341,394 and 4,009,508, in which the filaments are attenuated in round tubes.
In order to improve productivity of the spunbond process, more recent improvements in spunbond technology have involved the use of slot attenuators, such as described in U.S. Pat. No. 3,502,763. In a slot drawing process, the filaments pass through a tapered slot, which is coextensive with the width of the machine or take off conveyor. The filaments produced by the spinnerets are fed into the slot and are attenuated by a high flow of air in which a venturi effect is created to accelerate the air flow and cause elongation of the filaments. The filaments then exit the slot and are deposited on a moving conveyor in the form of a web.
U.S. Pat. No. 5,397,413 discloses a slot drawing device in which electrodes are mounted within the body of the attenuator near the outlet exit of the slot. A uniform electrostatic charge is applied to the filaments while under tension within the attenuator, and the filaments tend to separate upon exit from the slot. While some improvements are afforded, the filaments nearest the electrodes block the filaments in the middle, and this results in the application of a non-uniform charge. Also, the filaments tend to be deposited more in the machine direction, resulting in less strength in the cross machine direction.
Manufacturers of spunbonded nonwoven fabrics have long sought to achieve high production speeds without sacrifice to web uniformity. Non-uniformity is especially a troublesome problem when producing low basis weight fabrics. The most desirable fabrics have good strength in the machine and cross machine direction, uniform and even spacing of the filaments, and a random laydown in which the filaments do not extend in parallel to a significant degree.
In view of the fact that the filaments are extruded and drawn in parallel, many other proposals have been advanced to disrupt the parallel pattern into a more random or oscillating pattern, especially to improve strength in the cross machine direction. Various mechanical and pneumatic methods have been proposed, such as described in U.S. Pat. Nos. 3,296,678, No. 3,485,428 and 4,163,305. These devices, however, generally increase the complexity and cost of the manufacturing process and may impose a limit on production speeds.
SUMMARY OF THE INVENTION
In accordance with the present invention, a nonwoven web is made from a plurality of extruded polymer filaments, and the filaments are randomized by subjecting them to a pulsed or irregular electrostatic charge. The filaments, which are moving in a primary direction toward a collection zone, are passed adjacent high voltage electrodes having a pulsed signal. This results in intervals of greater and lesser charge on the filaments and random deflection of the filaments at angles relative to the primary direction. The filaments are repeatedly deflected to cause sinusoidal motion of the filaments and oscillation of the filament stream.
Preferably, adjacent groups of filaments are provided with pulsed charges of the same polarity but at different phases such that the oscillation of one group is out of phase with an adjacent group. This provides better interdispersion between adjacent groups and even better uniformity and distribution of filaments in the resulting web. Also, preferably, the filaments are provided with some degree of constant (DC) charge to provide some basic amount of constant repulsion.
The electrostatic charge is provided across the moving filaments simultaneously by a plurality of high voltage electrodes which are preferably located downstream of the zone in which the filaments are being attenuated by air flow or otherwise. The pulse frequency and amplitude can be adjusted to vary the period or degree of oscillation of the filaments. The randomized filaments are then deposited on a moving support to provide a continuous flat web.
The method of the present invention provides a relatively simple and inexpensive way to produce nonwoven webs of extremely good uniformity at lower basis weights and high production speeds, allowing significant reductions in direct production costs. The method and apparatus of the invention also avoids the need to employ complicated auxiliary devices to control filament distribution, such as mechanical and air jet devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective schematic view of the apparatus for carrying out the method of the present invention.
FIG. 2 is a side view of the apparatus shown in FIG. 1.
FIG. 3 is a partial front view of the apparatus shown in FIG. 1.
FIG. 4 is a schematic of a circuit for providing a pulsed voltage to a plurality of electrodes.
FIG. 5 is a schematic view of an electrode array which may be employed in connection with the present invention.
DETAILED DESCRIPTION
FIGS. 1-3 schematically show a slot drawing device used in a process for making spunbonded nonwoven webs. Such devices are described in detail in U.S. Pat. Nos. 3,302,237, 3,325,906, 3,655,305, 3,502,763 and 5,397,413, incorporated herein by reference.
In general, a solid granulated thermoplastic resin such as polypropylene is introduced into a heated and pressurized extrusion device 2 through an inlet or hopper 4, and the molten thermoplastic is fed under pressure into a head 6 having a plurality of lines and rows of orifices or spinnerets, causing extrusion of a plurality or bundle of spaced filaments 8. The filaments are introduced into the inlet opening 12 of a slot draw attenuator 10. The attenuator 10 comprises a downwardly tapering passage, and a high velocity flow of air is also forced downwardly, causing elongation or attenuation of the filaments, which are shown beyond the exit 14 of the slot 10 at 16. Upon exit from the slot device 10, the solid filaments are free of any substantial tension and are deposited on a moving conveyor 18 to form a continuous web 20. The web 20 is typically further processed, such as by bonding and by rolling up into a finished roll.
The present invention is not limited to any particular method of filament formation, as long as the filaments to be processed are arranged in a generally parallel arrangement and preferably in one or more lines, such as is available from the slot drawing device. As will be described hereinafter in detail, the electrostatic treatment of the filaments can take place in a zone after the filaments have been completely attenuated and are not under any significant tension. The invention is also applicable to any polymer capable of being spun into filaments and capable of holding an electrostatic charge, with polyolefins such as polyethylene and polypropylene and polyesters being most commonly employed.
As shown in FIGS. 1-3, an electrode bar 22, made of a high dieletric material, such as a polycarbonate resin, is positioned beyond or beneath the slot exit 14 and is coextensive with the width of the row of filaments 16. The bar 22 has an electrode face 24 which is slightly spaced from the filaments 16 on a first side thereof. A grounded conductive element or bar 26 is spaced from the row of filaments 16 on the other side thereof, said conductive element being opposed to and coextensive with the electrode bar 22. The two parts 22 and 26 therefore provide an open gap through which the filaments 16 may pass and receive a charge during passage. Preferably, the entrance to the gap is at a distance in the order of from about 0.25 to about 5 inches below the exit 14 of the attenuator 10.
As shown in FIG. 1, the electrode bar 22 is electrically connected to a high voltage power supply 28 through a control unit 30. The power supply 28 preferably has a variable voltage setting of up to 30 kv with negative polarity. The control unit 30 includes a pulse control with variable pulse frequency and a splitter to divide the pulse into at least two different phases. The control unit 30 also provides an adjustable degree of a constant DC negative voltage and a pulsed negative voltage. Preferably, the AC or pulsed voltage is about 40 to 60 percent of the constant DC voltage.
FIGS. 4 and 5 show the elements for providing a corona discharge. As shown in FIG. 5, the electrode block 22 includes at least one row of electrodes 31 asegregated into a plurality of cells, such as 32a, 32b and 32c. The electrodes in each cell are preferably in a saw tooth or w-shaped pattern and are closely spaced to provide a high charge density. Second and additional lines of cells may be provided, beneath the first line, such as the line formed by cells 34a, 34b and 34c. Each electrode 30 and its associated series resistor 36 of each cell in each line is alternatively connected to the pulsed power supply at the same intensity but at different phases. If the two phases are identified as A and B as shown in FIG. 5. The outermost cells in the first line, 32a and 32c, are connected to phase A, and the central cell 32b is connected to phase B. In the second line 34, the phase connections are reversed, and the outer cells are connected to phase B.
From initial studies, it has been found that most satisfactory results are obtained if the pulses in lines A and B are 180° out of phase. The pulse frequency can be widely adjustable, e.g., from about 0.5 Hz to 100 Hz. From initial studies, good results on polypropylene filaments are obtained in the range of from about 2 to about 10 Hz. Obviously, various groups of electrodes could be caused to operated at different frequencies and phases to cause a variety of types of movements of the filaments.
Since the power supply 28 is a DC source, only a portion of the voltage is pulsed, so that a constant DC is supplied to the electrodes with the added pulsed supply. Thus, the filaments will be provided with a constant base charge as well as an added pulsed charge of the same polarity.
In operation, the electrode bar 22 is supplied with high voltage, and an electrostatic field is established between the bar and ground 26. If the field is pulsed, the filaments 16 are deflected at an angle away from the normal line of travel. Repeated pulsing causes the filaments to oscillate back and forth by an electric wind. A substantial amount of this movement is in the cross machine direction, or in a direction perpendicular or at obtuse angles relative to the direction of movement of the conveyor 18 as shown in FIG. 1. By oscillating the filaments in the cross machine direction, the tensile strength of the resulting fabric in the same direction is greatly improved.
In addition, if adjacent groups are pulsed at opposite phases, they will oscillate toward and away from each other, which results in better interdispersion and improved uniformity. The use of two or more rows of electrodes in this fashion results in a laydown of the filaments in a randomized uniformly spaced manner solely by use of electrostatic forces.
With reference to FIG. 5, it may be seen that the second row 34 of electrode cells are in staggered relation with the first row 32, with a reversed order of phase. This causes additional overlap or mixing of the filaments between cells by dividing the previously charged filaments in one phase into charges of opposite phases. The treatment easily allows enhancement of the CM/MD tensile strength ratios, with a 2.6:1 ratio being obtained at 5 Hz.
In summary, the electrostatic treatment of the filaments comprises three components. A constant DC charge is applied to the filaments to cause constant repulsion therebetween, irrespective of position. A pulsing charge of the same polarity as the DC charge is applied to deflect the filaments back and forth at angles relative to the normal path of travel. The charge applied to one group of filaments is out of phase with the charge applied to a second adjacent group, causing the groups to deflect toward and away from each other.
As a result of the above electrostatic treatment, the filaments are uniformly repelled from each other and are also oscillated, with adjacent groups being oscillated in different directions. | A method and apparatus is provided to cause deflection or oscillation of a bundle of spun thermoplastic filaments. A pulsing electrostatic charge and optionally an additional constant charge is applied to attenuated filaments prior to deposit of the filaments on a conveyor in the form of a web. Adjacent sections of filaments may be charged with different phases, and multiple pulsed charges may be applied. The pulsed charges cause movement or oscillation of the filaments resulting in better web uniformity. | 3 |
This is a division of application Ser. No. 07/759,095, filed Sep. 6, 1991 now U.S. Pat. No. 5,177,224, which is a continuation of application Ser. No. 07/399,100, filed Aug. 28, 1989 abandoned.
BACKGROUND OF THE INVENTION
The invention concerns a catalytic process for the preparation of halogenated 2,2-bis(trifluoromethyl)-1,3-dioxolanes.
2,2-Bis(trifluoromethyl)-1,3-dioxolane is a known compound which may be halogenated according to a number of known methods to produce various halo-isomers at the 4,5 or 4 and 5 positions. For example, U.S. Pat. No. 2,925,424 describes a batch photochemical chlorination of 2,2-bis(trifluoromethyl)-1,3-dioxolane. The reaction was conducted at 50° C. for 2.5 hours. A 68% yield of 2,2-bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-dioxolane was obtained upon fractionation of crude product. See Example 9.
U.S. Pat. No. 4,535,175 discloses a batch photochemical chlorination of 2,2-bis(trifluoromethyl)-1,3-dioxolane to yield a mixture of di-, tri- and tetra-chloro derivatives. The reaction proceeds rather slowly. Example 1 of the patent details the production of 2,2-bis(trifluoromethyl)-4,4,5-trichloro-5-fluoro-1,3-dioxolane by reacting 2,2-bis(trifluoromethyl)-4,4,5,5,-tetrachloro-1,3-dioxolane, HF and antimony chloride at 70° C. for 5 hours.
U.S. Pat. No. 3,794,791 discloses a batch photochlorination of 2,2-bis(trifluoromethyl)-1,3-dioxolane at -15° C. Example 1 describes the synthesis of 2,2-bis(trifluoromethyl)-4-chloro-1,3-dioxolane. Example 2 of the patent describes the synthesis of 2,2-bis(trifluoromethyl)-4,5-dichloro-1,3-dioxolane.
G.B. 1,361,346 discloses the preparation of 2,2-bis(trifluoromethyl)-4,5-dichloro-4,5-difluoro-1,3-dioxolane by fluorinating 2,2-bis(trifluoromethyl)-4,4,5, 5,-tetrachloro-1,3-dioxolane with SbF 3 /SbCl 5 at 120° C.
SUMMARY OF THE INVENTION
The invention provides a process for the preparation of 2,2-bis(perhaloalkyl)-4,4,5,5-tetrachloro-1,3-dioxolane by chlorinating 2,2-bis(perhaloalkyl)-1,3-dioxolane with a source of chlorine in the presence of a catalyst which contains at least one of La, Ni, Sn, Zn Co, Fe, or Cu.
The invention also provides a process for the preparation of fluorinated 2,2-bis(perhaloalkyl)-1,3-dioxolanes of the formula ##STR4## wherein X is Cl, each Y is independently Cl or F and at least one Y is F, and each R f is independently perhaloalkyl in which the alpha carbon is substituted by at least one fluorine atom.
The process comprises fluorinating 2,2-bis(perhaloalkyl)-4,4,5,5-tetrachloro-1,3-dioxolane with a source of fluorine under fluorination conditions, so as to effect fluorine-chlorine exchange, in the presence of a catalyst which is a catalyst as noted above in the chlorination reaction or is chromium (III) oxide, i.e., Cr 2 O 3 or one or more of a metal supported on carbon wherein the metals are chosen from Cr, Co, La, Fe, Ni, Cu, Sn, or Zn.
DETAILED DESCRIPTION
Preferably, R f is trifluoromethyl. The 2,2-bis(perhaloalkyl)-1,3-dioxolane starting material for the chlorination is a known compound which may be readily prepared by reacting perfluoroacetone and ethylene chlorohydrin under basic conditions as described in U.S. Pat. No. 2,925,424.
The chlorination is preferably conducted in the vapor phase, and is preferably conducted continuously. However, the reaction may be conducted in the liquid phase using the reactants as solvents, at the same temperatures noted for the vapor phase, under autogenous pressure. Preferred temperatures for the reaction are 250°-300° C. The molar ratio of chlorine to 2,2-bis(perhaloalkyl)-1,3-dioxolane is preferably about 4:1 to 10:1, more preferably about 4:1 to 5:1. The reaction time is generally about 1 to 120 seconds, and is preferably about 30 to 60 seconds. The reaction pressure is preferably about 1 to 20 atmospheres, more preferably about 10 to 20 atmospheres. The preferred source of chlorine is chlorine gas. The catalyst metal may be in the form of any soluble compound of the metal such as the oxide, oxyhalide, halide, pseudohalide, nitrate, sulfate, or organic salt such as acetate and propionate. The halides include chlorides, fluorides and bromides. The pseudohalides include cyanides, cyanates and thiocyanates. The form of the catalyst is not critical and may be pellets, powders or granules. Preferably, the catalysts are used in a fixed bed; however, fluidized bed reactors may also be used. Preferably, the catalysts are in the form of their chlorides, and preferably are supported on carbon. The preferred catalyst for the chlorination is CuCl 2 /C.
General Procedure for Preparing Catalysts MCl x /C
The desired amount of metal chloride was dissolved in water (35 to 75 mL) and the entire solution poured over 40 g of commercial carbon granules (Girdler 411, 0.32 cm pellets). The resulting mixture was allowed to stand at room temperature for one hour and was then placed in a vacuum oven at 110° C. for 16 to 24 hours to remove the water. The catalyst was then pretreated by heating in an atmosphere of nitrogen gas at 400° C. followed by heating in HF at 400° C. prior to its use as a fluorination catalyst. For chlorination reactions, the catalyst was heated in an atmosphere of nitrogen gas at 400° C. followed by adjusting the temperature to the desired value and treatment with chlorine gas. Preferably, 0.1-30% b.w. based on the support of active metal is incorporated in the catalyst.
Catalyst Preparation
The following catalysts were prepared by the general procedure for MCl x /C:
______________________________________CoCl.sub.2 /C 35 g CoCl.sub.2.6H.sub.2 O/35 mL H.sub.2 OFeCl.sub.3 /C 39.7 g FeCl.sub.3.6H.sub.2 O/35 mL H.sub.2 OZnCl.sub.2 /C 20.44 g ZnCl.sub.2 /75 mL H.sub.2 ONiCl.sub.2 /C 34.94 g NiCl.sub.2 2.6H.sub.2 O/35 mL H.sub.2 OLaCl.sub.3 /C 62.43 g LaCl3.7H.sub.2 I/75 mL H.sub.2 OCrCl.sub.3 /C 39.17 g CrCl.sub.3.6H.sub.2 O/60 mL H.sub.2 OSnCl.sub.2 /C 38.36 g SnCl.sub.2.2H.sub.2 O/70 mL H.sub.2 OCuCl.sub.2 /C 25.06 g CuCl.sub.2.2H.sub.2 O/70 mL H.sub.2 O______________________________________
Cr 2 O 3 is commercially available and was treated with HF as described above prior to its use as a fluorination catalyst.
The catalysts having differing anions are prepared analogously.
The fluorination is preferably conducted in the vapor phase, and is preferably conducted continuously. The reaction may be conducted in the liquid phase as indicated for the chlorination. The reaction temperature is preferably 150° to 350° C., more preferably 150° to 200° C. The preferred source of fluorine is HF. The molar ratio of HF to 2,2-bis(perhaloalkyl)-4,4,5, 5-tetrachloro-1,3-dioxolane is preferably about 2:1 to 10:1, more preferably about 2:1 to 5:1. Preferred reaction time is about 1 to 120 seconds, more preferably about 30 to 60 seconds. The preferred catalyst for the fluorination is Cr, more preferably unsupported Cr 2 O 3 .
The production of the fluoro-compounds may be conducted in two steps, with, e.g., isolation of a 2,2-bis(perhaloalkyl)-4,4,5,5-tetrachloro-1,3-dioxolane intermediate, or may be conducted in one enclosure with the addition of the fluorine source preferably after substantial completion of the first reaction.
The catalysts of the invention are extremely active and selective. In the fluorination, where Cr 2 O 3 is the catalyst, the ratio of trans to cis isomers is desirably high.
The products of the process of the invention are useful as intermediates in the production of perhalodioxoles of the formula ##STR5## by dehalogenation of the appropriate precursor according to conventional processes, for example, as disclosed in U.S. Pat. Nos. 4,535,175, 3,865,845, and 3,978,030.
Preferably, trans-2,2-bis(perhaloalkyl)-4,5-difluoro-4,5-dichloro-1,3-dioxolane is used to produce the dioxole. A multi-plate distillation column may be used to separate the cis and trans isomers. Preferably, the cis isomer as well as 2,2-bis(perhaloalkyl)-4,4,5, 5-tetrachloro-1,3-dioxolane and -4-fluoro-4,5,5-trichloro-1,3-dioxolane are recycled to the fluorination step.
The dioxole in turn may be used to prepare homopolymers and copolymers which possess advantageous properties such as chemical inertness to hydrogen fluoride, optical clarity and film-forming ability.
For example, the dioxoles may be copolymerized under standard polymerization conditions with tetrafluoroethylene to form crystalline copolymers suitable for use as a dielectric in electronic equipment. Preferably, in these applications the dioxole is employed in an amount of about 12 mole % or less.
Polymers having more than about 12% dioxole are more generally amorphous, and are soluble in various organic liquids, e.g., 1,1,2-trichloro-1,2,2-trifluoroethane. These polymers are useful in the production of chemically inert, stain and weather resistant coatings and finishes.
Further, the dioxoles may be reacted with vinylidene fluoride or tetrafluoroethylene to produce plastic and/or elastomeric terpolymers useful in the production of corrosion-resistant seals, gaskets or linings.
Finally, the dioxoles may be homopolymerized to produce amorphous resins suitable for use as transparent glazing materials and sight glasses in apparatuses employed in handling chemically corrosive materials.
In particular, the amorphous polymers are useful in the production of optical fiber cladding materials, e.g., in accordance with U.S. Pat. Nos. 4,530,569 and 4,754,009.
Various fluoropolymers have been proposed from time to time for this purpose, mainly because of their good performance under a variety of temperature and atmospheric conditions and resistance to many chemicals. A good polymeric cladding material for optical fibers should be completely amorphous because crystallites present in polymers would cause light scattering. Further, it should have a high glass transition temperature, Tg, especially if intended for use at high temperatures because above its Tg, it would lose some of its desirable physical properties; and, in particular, it would be unable to maintain good bonding to the fiber core. A desirable Tg would be above 85° C., preferably above 120° C.
As the amount of dioxole in the copolymer increases, the Tg also increases, although not necessarily in a linear fraction.
A homopolymer of dioxole appears to be amorphous and has a high Tg. However, dioxole is a much more expensive monomer than tetrafluoroethylene so that use of dioxole homopolymers, rather than of dioxole/tetrafluoroethylene copolymers, is economically much less attractive. Furthermore, the copolymers are easier to fabricate. The dipolymers have low refractive indices, which is a particularly desirable feature for optical fiber cladding. Furthermore, films of these copolymers are clear and transparent, compared with hazy or translucent films of crystalline polymers. For this reason, the amorphous copolymers of the present invention are suitable for such applications as, for example, windows for chemical reactors, especially for processes using or manufacturing hydrogen fluoride.
Amorphous terpolymers can be made by copolymerizing certain ethylenically unsaturated monomers with perfluoro-2,2-dimethyl-1,3-dioxole and tetrafluoroethylene. These include selected olefins, vinyl compounds, and perfluoromonomers. Typical olefins are, for example, ethylene, propylene, 1-butene, isobutylene, trifluoropropene, and trifluoroethylene. Vinyl monomers can be, for example, vinyl fluoride, vinylidene fluoride, and chlorotrifluoroethylene. Perfluoromonomers may be of different chemical types, for example, perfluoropropene, perfluoro(1,3-dioxole), perfluoro(alkyl vinyl ethers), methyl 3-[1-[difluoro(trifluoroethenyl)oxy]methyl]-1,2,2, 2-tetrafluoroethoxy]-2,2,3,3-tetrafluoropropanoate ##STR6## and 2-[1-[difluoro[(trifluoroethenyl)oxy]methyl]-1,2,2,2-tetrafluorooethoxy]-1,1,2, 2-tetrafluoroethanesulfonyl fluoride ##STR7##
The proportion of dioxole in the amorphous terpolymers of this invention should preferably be at least 12 mole percent of the tetrafluoroethylene content, while the mole percent content of the third monomer should be the smallest of all three monomers. Outside these limits, either an amorphous terpolymer may not be obtained; or, if made, its maximum tensile modulus and strength may not be realized.
Copolymerization is carried out in the presence of a free radical generator, preferably at a slightly elevated temperature, for example, 55°-65° C. Well-agitated pressure equipment should be used.
In addition to tetrafluoroethylene, amorphous copolymers may be fabricated from the dioxole and chlorotrifluoroethylene; vinylidene fluoride; hexafluoropropylene; trifluoroethylene; perfluoro(alkyl vinyl ethers) of the formula CF 2 ═CFOR F , where R F is a normal perfluoroalkyl radical having 1-3 carbon atoms; fluorovinyl ethers of the formula CF 2 ═CFOQZ, where Q is a perfluorinated alkylene radical containing 0-5 ether oxygen atoms, wherein the sum of the C and O atoms in Q is 2 to 10, and Z is a group selected from the class consisting of --CN, --COF, and --OCH 3 , where R is a C L-C4 alkyl; vinyl fluoride; and (perfluoroalkyl)ethylene, R f CH═CH 2 , where R f is a C L-C8 normal perfluoroalkyl radical.
The maximum preferred mole percentage of the comonomer in the copolymers are as follows:
for tetrafluoroethylene, 35;
for chlorotrifluoroethylene, 30
for vinylidene fluoride, 20;
for hexafluoropropylene, 5;
for trifluoroethylene, 30;
for CF 2 ═CFOR F , 30;
for CF 2 ═CFOQZ, 20;
for vinyl fluoride, 25; and
for R f CH═CH 2 , 10.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative and not limitative of the remainder of the disclosure in any way whatsoever.
In the preceding text and the following examples, all temperatures are set forth uncorrected in degrees Celsius and all parts and percentages are by weight, unless otherwise indicated. Amounts of compounds listed in the Tables are given in area %. C.T. represents contact time.
In the following examples, the numbers identifying the compounds in the tables are as follows:
D456 - 2,2-Bis(trifluoromethyl)-1,3-dioxolane
D436 - 2,2-Bis(trifluoromethyl)-4,5-dichloro-1,3-dioxolane
D436a - 2,2-Bis(trifluoromethyl)-4,4-dichloro-1,3-dioxolane
D426 - 2,2-Bis(trifluoromethyl)-4,4,5-trichloro-1,3-dioxolane
D416 - 2,2-Bis(trifluoromethyl)-4,4,5, 5-tetrachloro-1,3-dioxolane
D417 - 2,2-Bis(trifluoromethyl)-4-fluoro-4,5, 5-trichloro-1,3-dioxolane
D418a - 2,2-Bis(trifluoromethyl)-4,4-difluoro-5,5-dichloro-1,3-dioxolane
D418 - 2,2-Bis(trifluoromethyl)-4,5-dichloro-4,5-dichloro-1,3-dioxolane
D419 - 2,2-Bis(trifluoromethyl)-4,4,5-trifluoro-5-chloro-1,3-dioxolane.
E X A M P L E S
General Procedure for Chlorination
The reactor (0.5 inch ID Inconel nickel alloy pipe) was charged with the designated amount of catalyst, sealed and placed into a sand bath. The bath was heated to 400° C., at which time nitrogen gas at a flow rate of 50 ml/minute was passed through the reactor to remove all traces of water. Chlorine gas at a flow rate of 25.7 cc/min was passed through the reactor and the temperature adjusted to the desired value. The flow of nitrogen gas was turned off and the flow of D456 started. The flow of chlorine and D456 were adjusted to give the desired molar ratio.
The reactor effluent was scrubbed with aqueous potassium hydroxide to remove Cl 2 , HCl and HF and sampled on line by a HP 5890 gas chromatograph using a 5 foot Krytox perfluorinated polyether column. Conditions were 70° C. for 3 minutes followed by temperature programming to 180° C. at a rate of 6° C./minute. Helium flow was 35 cc/minute.
General Procedure for Fluorination
The reactor (0.5 inch ID Inconel nickel alloy pipe) was charged with the designated amount of catalyst, sealed and placed into a sand bath. The bath was heated to 400° C., at which time nitrogen gas at a flow rate of 50 ml/minute was passed through the reactor to remove all traces of water. The temperature was lowered to 200° C., and HF and nitrogen gas (1:4 molar ratio) was passed through the reactor, and the nitrogen flow was decreased with time until neat HF was being passed through the reactor. At this point, the temperature is raised to 350° C. and maintained there for 15 to 30 minutes. The temperature is then decreased to the desired temperature, and the D416 flow is started. The flow of HF and D416 were adjusted to give the desired molar ratio.
The reactor effluent was scrubbed with aqueous potassium hydroxide to remove Cl 2 , HCl and HF and sampled on line by a HP 5890 gas chromatograph using a 5 foot Krytox perfluorinated polyether column. Conditions were 70° C. for 3 minutes followed by temperature programming to 180° C. at a rate of 6° C./minute. Helium flow was 35 cc/minute.
Examples 1-16
______________________________________Chlorination of 2,2-Bis(trifluoromethyl)-1,3-Dioxolane (D456)CuCl.sub.2 /C 19.7 grams (30 cc)Exp Temp Cl.sub.2 /D456 C.T. D436 D426 D416 Unk______________________________________ 1 225 6/1 30 14 40 43 3 2 235 6/1 30 5 29 62 3 3 245 6/1 30 3 21 74 2 4 255 6/1 30 1 9 88 2 5 265 6/1 30 0 5 93 2 6 195 6/1 60 43 33 16 8 7 205 6/1 60 25 44 24 5 8 215 6/1 60 10 44 42 4 9 225 6/1 60 5 34 57 310 235 6/1 60 1 18 80 111 245 6/1 60 0 7 90 312 255 6/1 60 0 2 95 313 265 6/1 60 0 0 97 314 275 6/1 60 0 0 96 415 285 6/1 60 0 0 95 516 285 4/1 60 0 1 95 4______________________________________
The conversion of D456 to products was 100%, as shown in the Table.
EXAMPLES 17-23
______________________________________Chlorination of 2,2-Bis(trifluoromethyl)-1,3-Dioxolane (D456)CuCl.sub.2 /C 19.7 grams (30 cc)Exp Temp Cl.sub.2 /D456 C.T. D426 D416 D417 Unk______________________________________17 265 6/1 60 1 97 0 218 265 6/1 60 1 97 0 119 265 6/1 60 1 97 0 320 265 5/1 75 1 97 1 021 265 4/1 75 3 95 0 222 265 5/1 60 2 95 0 323 275 5/1 60 0 97 0 2______________________________________
The conversion of D456 to products was 100%, as shown in the Table.
EXAMPLES 24-28
______________________________________Chlorination of 2,2-Bis(trifluoromethyl)-1,3-Dioxolane (D456)LaCl.sub.3 /C 4.25 grams (5 cc) Cl.sub.2 /Exp Temp D456 C.T. D456 D436 D426 D416 D417 Unk______________________________________24 200 6/1 10 3 74 12 10 0 125 225 6/1 10 4 64 11 18 0 326 250 6/1 10 1 43 9 43 1 227 275 6/1 10 0 22 6 67 1 428 300 6/1 10 0 9 3 72 3 13______________________________________
EXAMPLES 29-32
______________________________________Chlorination of 2,2 Bis(trifluoromethyl)-1,3-Dioxolane (D456)SnCl.sub.2 /C 4.0 grams (5 cc) Cl.sub.2 /Exp Temp D456 C.T. D436 D426 D416 D427 D417 Unk______________________________________29 225 6/1 10 36 37 23 1 0 230 250 6/1 10 13 29 53 1 1 331 275 6/1 10 2 8 74 1 2 832 275 5/1 10 2 9 70 0 2 12______________________________________
The conversion of D456 to products was 100%, as shown in the Table.
EXAMPLES 33-37
__________________________________________________________________________Chlorination of 2,2-Bis(trifluoromethyl)-1,3-Dioxolane (D456)FeCl.sub.3 /C 3.4 grams (5 cc)Exp Temp Cl.sub.2 /D456 C.T. D456 D436 D426 D416 D427 D417 Unk__________________________________________________________________________33 200 6/1 10 11 36 2 8 4 0 3934 150 6/1 10 36 51 1 0 3 0 935 200 6/1 1 67 21 1 1 2 1 736 250 6/1 1 37 25 1 6 3 0 2837 250 4/1 1 42 19 1 5 2 0 31__________________________________________________________________________
EXAMPLES 38-41
______________________________________Chlorination of 2,2-Bis(trifluoromethyl)-1,3-Dioxolane (D456)ZnCl.sub.2 /C 3.8 grams (5 cc) Cl.sub.2 /Exp Temp D456 C.T. D456 D436 D426 D416 D417 Unk______________________________________38 200 6/1 10 27 62 5 4 0 239 225 6/1 10 15 70 10 4 0 140 250 6/1 10 7 66 15 11 0 141 275 6/1 10 1 28 13 50 2 6______________________________________
EXAMPLES 42-51
__________________________________________________________________________Fluorination of2,2-Bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxolaneCr.sub.2 O.sub.3 28.9 g (30 cc) -12 + 20 meshExp Temp HF/D416/HCl C.T. D419 tD418 cD418 D418a D417 D416 Unk__________________________________________________________________________42 175 2/1/0 60 2 74 18 0 4 0 143 200 2/1/0 60 37 10 3 36 10 1 044 165 2/1/0 60 19 37 9 13 20 1 145 175 2/1/0 60 15 62 16 2 5 0 046 175 3/1/0 45 3 77 19 0 0 0 147 175 3/1/4 45 13 66 18 1 2 0 048 175 4/1/4 40 4 75 20 0 2 0 049 175 5/1/4 35 3 75 20 0 1 0 150 175 5/1/4 40 3 75 20 0 1 0 151 175 5/1/4 40 4 74 20 0 1 0 1__________________________________________________________________________ t = trans c = cis
EXAMPLES 52-54
______________________________________Fluorination of 2,2-Bis-trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxalaneCoCl.sub.2 /C 12.3 g (30 cc) HF/Exp Temp D416 C.T. tD418 cD418 D417 Unk______________________________________52 200 10/1/0 30 44 35 8 753 200 5/1/0 60 39 33 16 654 165 10/1/0 30 47 37 8 3______________________________________
EXAMPLES 55-59
______________________________________Fluorination of 2,2-Bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxolaneCr.sub.2 O.sub.3 14.4 g (15 cc) -12 + 20 mesh HF/Exp Temp D416 C.T. D419 tD418 cD418 D417 Unk______________________________________55 200 3/1/0 30 1 72 22 0 556 200 3/1/0 30 0 71 26 0 357 210 3/1/0 30 1 73 24 0 258 220 3/1/0 30 1 72 24 0 359 230 3/1/0 30 l 73 23 1 2______________________________________
COMPARATIVE EXAMPLES 60-68
______________________________________Fluorination of2,2-Bis(trifluoromethyl)-4,4,5,5,-tetrachloro-1,3-DioxolaneLaCl.sub.3 /C 4.25 g (5 cc) HF/Exp Temp D416 C.T. tD418 cD418 D417 D416 Unk______________________________________60 225 2/1/0 10 2 4 85 3 661 250 2/1/0 10 14 13 67 0 562 275 2/1/0 10 26 27 0 0 463 300 2/1/0 10 34 33 26 0 764 300 2/1/0 20 43 35 11 0 1065 300 2/1/0 20 44 36 9 0 1166 250 2/1/0 40 41 38 14 0 767 250 2/1/0 40 38 35 20 0 768 300 2/1/0 40 46 31 4 0 11______________________________________
EXAMPLES 69-72
______________________________________Fluorination of2,2 Bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxolaneFeCl.sub.3 /C 3.4 g (5 cc) HF/Exp Temp D416 C.T. tD418 cD418 D417 D416 Unk______________________________________69 200 2/1/0 5 0 0 24 71 570 225 2/1/0 5 0 0 42 54 871 275 2/1/0 10 7 8 76 1 872 275 3/1/0 10 9 10 70 0 11______________________________________
EXAMPLES 73-79
______________________________________Fluorination of2,2-Bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxolaneNiCl.sub.2 /C 1.66 g (3 cc)1/8-inch Pellets HF/Exp Temp D416 C.T. tD418 cD418 D417 D416 Unk______________________________________73 200 2/1/0 5 0 0 5 91 474 220 2/1/0 5 0 0 7 88 575 240 2/1/0 5 0 0 13 80 776 260 2/1/0 5 0 0 31 61 677 280 2/1/0 5 1 2 45 39 1078 280 4/1/0 5 5 4 66 10 1379 325 4/1/0 5 8 7 34 2 48______________________________________
EXAMPLES 80-83
______________________________________Fluorination of2,2-Bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxolaneCuCl.sub.2 /C 19.7 g (30 cc) HF/Exp Temp D416 C.T. tD418 cD418 D417 D416 Unk______________________________________80 200 3/1/0 30 2 2 66 13 1681 200 3/1/0 30 6 5 73 3 1382 250 3/1/0 30 4 4 85 0 583 250 3/1/0 30 4 4 85 0 6______________________________________
EXAMPLES 84-85
______________________________________Fluorination of2,2 Bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxolaneSnCl.sub.2 /C 4.0 g (5 cc) HF/Exp Temp D416 C.T. tD418 cD418 D417 D416 Unk______________________________________84 275 2/1/0 10 9 10 74 2 585 275 2/1/0 20 19 17 60 0 4______________________________________
EXAMPLES 86-87
______________________________________Fluorination of2,2 Bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-DioxolaneZnCl.sub.2 /C 3.8 g (5 cc) HF/Exp Temp D416 C.T. tD418 cD418 D417 D416 Unk______________________________________86 300 2/1/0 10 6 7 73 10 487 250 2/1/0 10 1 2 53 44 1______________________________________
EXAMPLE 88
Examples Describing the Rearrangement of Cis-D418 to Trans-D418
A mixture of 150 g D-418 (65.5% trans isomer), 6.0 g antimony pentachloride, and 20 g anhydrous hydrogen fluoride was heated at 100° for one hour and 135° for five hours. The reaction mixture was added to ice/ice water and the lower layer washed with 400 ml ice water to give 139.3 g of product. Analysis showed this product to contain 1.3 g D-419 and 138.0 g D-418 (79.8% trans isomer). Thus the amount of trans D-418 rose from 98.3 g to 110.1 g, while the amount of cis isomer fell from 51.7 to 27.9 g.
A mixture of 40.5 g D-418 (53.5% trans isomer), 4.0 g antimony pentachloride, and 20 g anhydrous hydrogen fluoride was heated at 100° for one hour and 135° for four hours. The reaction mixture was added to ice/ice water and the lower layer separated to give 35.4 g of product containing 26.7 g trans D-418 and 8.5 g cis D-418 (78.4% trans isomer). Thus the amount of trans D-418 rose from 21.7 g to 26.7 g, while the amount of cis D-418 declined from 18.8 g to 8.5. g.
EXAMPLE 89
Variation in Yield of Perfluoro-2,2-bistrifluoromethyl-1,3-dioxole (PDD) with cis/trans bis-2,2-trifluoromethyl-4,5-dichloro-4,5-difluoro-1,3-dioxolane (D418)
A mixture of 24.9 g magnesium turnings and 395 ml tetrahydrofuran was heated 60°. After addition of 2.75 ml, 1,2-dibromoethane approximately 4.5 g bis-2,2-trifluoromethyl-4,5-dichloro-4,5-difluoro-1,3-dioxolane (D418) was added. The reaction mixture was cooled to 35°-40° and a total of 133 g cis/trans D418 added. After stirring for 15 minutes, the mixture was distilled until the pot temperature reached 70°. The distillate boiling to 45° was washed with 100 ml of ice water. Gas chromatographic analysis of the lower layer showed it to be greater than 99% PDD.
______________________________________Percent Trans Isomer Yield of PDDin Startinq D418 Percent______________________________________97.7 60 783.6 51.764.7 40.2______________________________________
The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. | A process for the production of a halogenated 2,2-bis(trihaloalkyl)-1, 3-dioxolane of the formula ##STR1## wherein R f is perhaloalkyl comprising a 2,2-bis(trihaloalkyl)-1,3-dioxolane in the presence of at least one of La, Ni, Sn, Zn Fe, Co or Cu is disclosed.
A process for the production of a halogenated 2,2-bis(trihaloalkyl)-1,3-dioxolane of the formula ##STR2## wherein X is Cl and each Y is independently Cl or F and wherein at least one Y is F, comprising fluorinating a halogenated 2,2-bis(trifluoromethyl)-4,4,5,5-tetrachloro-1,3-dioxolane in the presence of a catalyst which is preferably Cr 2 O 3 is disclosed.
A process for the production of a 2,2-bis(trihaloalkyl)-1,3-dioxole of the formula ##STR3## comprising dehalogenating substantially only a corresponding trans-2,2-bis(perhaloalkyl)-4,5-difluoro-4, 5-dichloro-1,3-dioxolane is disclosed. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Application Ser. No. 12/537, 208 filed on 6 Aug. 2009 entitled RAILING SYSTEM, which is a continuation of U.S. application Ser. No. 10/547,183 filed on 11 Mar. 2004 entitled RAIL AND RAILING SYSTEM, which is US national stage of PCT International Application No. PCT/CA2004/000378 which has an international filing date of 11 Mar. 2004 and entitled RAIL AND RAILING SYSTEM, which claims the benefit of the filing date of Canadian Application No. 2,422,750 filed on 12 Mar. 2003 and entitled RAIL AND RAIL SYSTEM. The content of the applications referred to in this paragraph is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to the field of railings and in particular to an aluminum rail and railing system.
BACKGROUND OF THE INVENTION
[0003] Railing systems for any number of outdoor applications are well known. For example, residential decks, pool decks, playgrounds, etc., all utilize any number of conventional railing systems. Such railing systems are typically made of pressure treated lumber or aluminum particularly suited for outdoor use.
[0004] Typically, aluminum railing systems utilize spacers which snap onto top and bottom rails to space out railing pickets. Although such systems adequately space out the pickets, the overall appearance of the system is less than desired given that the spacers necessarily protrude away from the railings. Furthermore, as the spacers merely snap onto the top and bottom rails, the spacers are susceptible to removal after the railing system has been assembled. Consequently, thieves may easily remove the spacers leaving the railing system vulnerable to failure. These systems are undesirable, particularly in the residential railing industry wherein homeowners frequently install or build their own rail systems.
[0005] Accordingly, a need exists for an improved rail and railing system which provides an aesthetically pleasing result and which overcomes the deficiencies noted above.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention there is provided a rail for a picket railing system having a plurality of spacers for spacing a plurality of railing pickets. The rail may include a substantially elongated planar member and first and second substantially parallel elongated side-walls perpendicularly connected to the planar member. The side walls may each comprise opposing grooves running substantially parallel to the elongated planar member. The grooves may be adapted to receive the plurality of spacers and may be formed within each of the side walls.
[0007] Each of the grooves may comprise a first elongated groove member and a second elongated groove member. The first elongated groove member may be connected adjacent an end of the side wall and extend perpendicularly from the side-wall. The second elongated groove member may be connected adjacent the end of said side wall and run parallel to the first groove member. The second elongated groove member may be spaced away from the first elongated groove member to permit snug insertion of the plurality of spacers between the first and second groove members.
[0008] According to another aspect of the invention there is provided a rail system for holding picket railings. The rail system may include a plurality of spacers adapted to space the picket railings apart and a rail adapted to internally receive the plurality of spacers and to secure the picket railings.
[0009] Each of the plurality of spacers may include a top member and first and second parallel wings connected to the top member. The first and second wings may be shaped to be received in grooves located within the railings.
[0010] According to yet another aspect of the invention there is provided a rail system which includes a top rail and bottom rail, a post adapted to receive the top and bottom rails, a plurality of pickets for placement between the top and bottom rails, and a plurality of spacers adapted to be inserted into the top and bottom rails for spacing the plurality of pickets apart.
[0011] The post may include an open ended head to receive the top rail and an opening for receiving the bottom rail. Alternatively, the post may include connectors to receive the top and bottom rails. The connectors may include universal angle brackets. The post may also include post supports.
[0012] Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Embodiments of the invention will be described by reference to the accompanying drawings.
[0014] FIG. 1 is a perspective view of a rail and railing system made in accordance with a first embodiment of the present invention;
[0015] FIG. 2 a is a perspective view of a section of top rail of FIG. 1 ;
[0016] FIG. 2 b is a perspective view of a section of bottom rail of FIG. 1 ;
[0017] FIG. 3 a is a cross-sectional view along line 3 a - 3 a of FIG. 1 ;
[0018] FIG. 3 b is a cross-sectional view along line 3 b - 3 b of FIG. 1 ;
[0019] FIG. 4 is a perspective view of a post and a section of top and bottom rails of FIG. 1 ;
[0020] FIG. 5 . is a perspective view of an alternative embodiment of the post of FIG. 4 ; and
[0021] FIG. 6 . is a perspective exploded view of the railing system of FIG. 1 .
DETAILED DESCRIPTION
[0022] Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a third embodiment. It is intended that the present invention include such modifications and variations as come within the scope and spirit of the present invention.
[0023] An outdoor railing system, generally 10 , according to the invention is illustrated in FIG. 1 . Railing system 10 is illustrated as a section of a complete rail for purposes of illustration. The present invention includes such sections as well as a complete railing system constructed in accordance with the invention. The present invention also includes top and bottom rails 12 and 14 separately for use in such railing systems.
[0024] Conventional outdoor railing systems are typically made from aluminum. The present invention includes rails and railing systems made of aluminum, but is not limited to any particular material. For example, the components of the railing system 10 or rails 12 and 14 may be fabricated from any conventional construction material, including plastic, wood, cementious materials, and the like. Any and all such materials suitable for railing systems are within the scope and spirit of the invention.
[0025] Referring again to FIG. 1 , railing system 10 includes top and bottom rails 12 and 14 , posts 16 , pickets 18 and picket spacers 20 in between adjacent pickets. The pickets 18 are of sufficient length to span the distance between the top and bottom rails 12 and 14 .
[0026] Referring to FIGS. 2 a , 2 b , 3 a and 3 b , each rail includes a substantially elongated planar member 22 and first and second substantially parallel elongated side walls 24 and 26 perpendicularly connected to the planar member 22 . The side walls 24 and 26 each include opposing grooves 28 running substantially parallel to the elongated planar member 22 .
[0027] The grooves 28 are adapted to receive the spacers 20 and include a first elongated groove member 30 and a second elongated groove member 32 . The first elongated groove member 30 is connected adjacent an end of the side walls 24 and 26 and extends perpendicularly from the side-walls 24 and 26 . The second elongated groove member 32 is also connected adjacent the same end of the side walls 24 and 26 and runs parallel to the first groove member 30 . The second elongated groove member 32 should be spaced away from the first elongated groove member 30 to permit snug insertion of the spacers 20 between the first and second groove members 30 and 32 .
[0028] The first and second side walls 24 and 26 may be connected to the planar member 22 via spot welding in the case of aluminum. Similarly, the first and second groove members 30 and 32 may be connected to the side walls 24 and 26 via spot welding in the case of aluminum. As those skilled in the art will appreciate other methods of connecting the first and second side walls 24 and 26 to the planar member 22 and the groove members 30 and 32 to the side walls 24 and 26 are contemplated, for example, adhesive, fasteners etc. Preferably, each of the top and bottom rails 12 and 14 is a unitary structure which may be accomplished via an aluminum extrusion for instance or by other means known in the art.
[0029] The spacers may include a top member 34 and first and second parallel wings 36 shaped to be received in the grooves 28 . The first and second parallel wings 36 may be connected to the top member 34 via spot welding in the case of aluminum. As those skilled in the art will appreciate other methods of connecting the first and second wings 36 to the top member 34 are contemplated, for example, adhesive, fasteners etc. Preferably, the first and second parallel wings 36 are integrally formed with the top member 34 via an aluminum extrusion for instance or by other means known in the art.
[0030] As best shown in FIGS. 3 a and 3 b , once spacers 20 are inserted into top and bottom rails 12 and 14 , the first and second parallel wings 36 abut the first and second groove members 30 and 32 . In so doing, the spacers 20 snugly fit into grooves 28 , thus preventing the spacers 20 from being removed from the railing system 10 after assembly. To provide for an aesthetically pleasing result, the top member 34 may be spaced away from the first and second parallel wings 36 so that the top member 34 lies flush with the first elongated groove member 30 . However, in another embodiment, those skilled in the art will also appreciate that parallel wings 36 may be flush with top member 34 providing an overall flat surface.
[0031] FIG. 3 a also shows that top rail 12 comprises a handgrip portion 60 . Handgrip portion 60 has first and second edges 60 A and 60 B that respectively join to first and second side walls 24 and 26 . FIG. 3 a also shows that side walls 24 and 26 and planar member 22 form an elongated, downwardly opening channel 62 . Downwardly opening channel 62 is dimensioned to receive the top ends of pickets 18 (not shown in FIG. 3 a ) which may project into channel 62 during assembly of railing system 10 (see FIG. 6 ).
[0032] As illustrated, channel 62 is generally square in cross-section. In the illustrated embodiment, handgrip portion 60 connects to the components which define channel 62 (i.e. first and second side walls 24 , 26 and planar member 22 ) to define an elongated bore 64 . Bore 64 may be defined by an exterior surface of channel 62 and an interior surface of handgrip portion 60 . In the illustrated embodiment, bore 64 has the shape of an inverted U in cross-section.
[0033] In the illustrated embodiment, handgrip portion 60 comprises generally planar elongated sections 65 A and 65 B that are respectively adjacent to first and second edges 60 A and 60 B of handgrip portion 60 . Sections 65 A, 65 B define a portion of bore 64 . Sections 65 A, 65 B extend generally perpendicularly to side walls 24 , 26 respectively. In the illustrated embodiment, lower edges of side walls 24 and 26 project downwardly past edges 60 A and 60 B of handgrip portion 60 and upper edges of side walls 24 , 26 project upwardly past edge 60 A, 60 B of handgrip portion 60 —i.e. edges 60 A, 60 B of handgrip portion 60 are connected to side walls 24 , 26 in locations spaced apart from the upper and lower edges of side walls 24 , 26 . In the illustrated embodiment, edges 60 A, 60 B join to side walls 24 , 26 substantially along longitudinal mid-lines of side walls 24 , 26 .
[0034] In the illustrated embodiment, handgrip portion 60 has opposed generally planar faces 66 A and 66 B that extend along the length of handgrip portion 60 and a top section 68 which extends laterally between faces 66 A, 66 B. Faces 66 A, 66 B and top section 68 define a portion of bore 64 .
[0035] Referring to FIG. 4 , the post 16 includes an open ended head 38 shaped to receive the top rail 12 . In this embodiment, the post 16 may also include an opening 40 to receive the bottom rail 14 . Preferably, the open ended head 38 and opening 40 are shaped to snugly fit top and bottom rails 12 and 14 to secure the top and bottom rails to the post 16 . As those skilled in the art will appreciate, other methods may be used to further secure the top and bottom rails 12 and 14 to the post 16 , such as fasteners.
[0036] Referring to FIG. 5 , in another embodiment, the post 16 includes connectors to receive the top and bottom rails 12 and 14 . The connectors comprise universal angle brackets 42 as known to those skilled in the art. Universal angle brackets are particularly useful for railing applications requiring non-conventional angles, such as following a flight of steps. Alternatively, the connectors may simply be a U-bracket 44 as illustrated in FIGS. 1 and 6 . As those skilled in the art will appreciate, several connectors are contemplated and may be used in different combinations for use with the top and bottom rails 12 and 14 without departing from the scope and spirit of the present invention.
[0037] As best illustrated in FIGS. 1 and 6 , to provide additional support to the posts 16 , the posts may include post supports 46 . Preferably, the post supports 46 include a base 48 which can be connected to a deck surface for instance. A sleeve 50 may be attached to the base 48 to snugly receive the posts 16 . The post supports 46 may be separately fabricated and attached to the posts 16 during installation of the railing system or may be integrally fabricated with the posts.
Operation
[0038] The top and bottom rails 12 and 14 are connected to a post 16 . At least one spacer 20 is inserted into each of the top and bottom rails 12 and 14 . A picket 18 may then be installed between the top and bottom rails 12 and 14 by simply placing the ends of the picket into the top and bottom rails and abutting the picket next to the spacers 20 . Further spacers 20 and pickets 18 may be inserted until a desired number of pickets has been installed. A second post 16 may then be connected to the top and bottom rails 12 and 14 to complete the assembly resulting in an aesthetically pleasing and secure railing system. Alternatively, the top and bottom rails 12 and 14 may first be attached to a wall without the need for a first post 16 and then assembled as discussed above.
[0039] It should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents. | A railing system is disclosed having spacers for spacing apart railing pickets, and a rail which engages the spacers and secures the railing pickets. The spacers are made up of a planar top member, side members extending from longitudinal edges of the top member, and wings extending outwardly from a central position of the side members. The rail comprises a substantially elongated planar member and first and second substantially parallel elongated side-walls perpendicularly connected to the planar member. The side-walls each comprise first and second groove members, which are spaced apart to form grooves running substantially parallel to the elongated planar member. The grooves are adapted to receive the plurality of spacers such that the wings of the spacers abut against the first and second groove members when the spacers are assembled in the railing system. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to floral display holders. In particular, the invention is directed towards a floral display holder resting on top of a funeral casket displaying the floral arrangement in an inclined elevation. Of course, the floral display holder described herein may be used in other circumstances as well as funeral caskets where the inclination of the floral arrangement is desired.
2. Description of the Prior Art
Many floral display holders today utilize a water-retaining foam (hereinafter referred to as the "floral foam" or foam") to attach flowers thereon in a desired arrangement and at the same time provide water to the stems of the flowers to prevent wilting. Prior to piercing the floral foam with the desired flower arrangement, the floral foams are saturated with water. The foams are then placed onto a floral display holder and locked into place by retaining clips. The floral foam when fully saturated retains approximately five cups of water. Despite this initial saturation the floral foam gradually dries as a result of both evaporation into the ambient air and absorption by the flower arrangement.
The floral display holder of the inclined double-dept saddle variety displays a floral arrangement by resting on top of a funeral casket. It is desired that the floral foams are inclined towards the audience so as to heighten the quality view of the floral arrangement. Generally, at least two foams sit side by side along their length. In some prior art, it is taught that at least one foam must be trimmed before inserting it into the housing of the floral display holder. Once a wedge-like portion is removed with a knife, the foam is inserted into the holder alongside an uncut foam. The prior art allowed only the foam nearest to the front area of the displayer holder ("front foam") to be inclined while the rear foam remained horizontal. As a result of trimming the front foam and inclining the floor surface area just below the front foam a desired inclination of the front foam was achieved. The overall appearance of this layout is known as a `cascade` display. However, there remained the problem that labour was needed in trimming the foam and that only one foam was inclined. Morever, because the prior art taught one foam being inclined while the other remained horizontally disposed, occasionally the foams did not abut continuously throughout their length either because of poor trimming or because of saturation of the front foam tending to sway the foam away from the horizontally disposed foam.
In the case of a floral display holder of the inclined double-depth saddle variety, there is generally more than one foam utilized in the holder; therefore, there is additional surface area for ambient air to come into contact with the foam because more than one foam is generally used. This would inherently increase the evaporation rate of the water in the foam. Further, when the foam is in an inclination, the force of gravity causes a gradual migration of the water retained in the foam to migrate from the upper portions of the foam to the bottom. As the inclination from the horizontal increases, the migration becomes more exaggerated. As the flowers inserted in the now dried-up portion may wilt earlier than those flowers inserted at the moister bottom portion of the foam. Currently, a user must, therefore, occasionally attend the floral display arrangement with a watering vessel in hand to re-saturate the floral foam. When water is simply added to the top portion of the floral foam, excess water begins to undesirably accumulate in the lower portion near the bottom of the foam. In U.S. Pat. No. 4,058,929 to O'Connell, there is at least one aperture along the connecting edge of the upper bottom wall and the lowermost side wall to drain this excess water into the hollow interior of the product.
However, currently available inclining floral display holders fail to address the need to conveniently re-saturate a dried foam without a watering vessel. Morever, a completed flower arrangement is difficult to handle, especially when fully loaded. A completed flower arrangement may weigh in the range of 40 to 50 pounds; therefore, a means to comfortably transport the holder is desired.
SUMMARY OF THE INVENTION
It is an object of the invention to overcome some of the drawbacks and disadvantages of currently available inclined floral display holders.
It is another object of the invention to provide for inclined foams without the need to trim or cut them.
It is another object of the invention to provide for a continuously abutting foams that do not tend to separate from each other even when saturated.
It is another object of the invention to minimize the need for a user to attend the inclined floral display holder with a flower watering vessel to re-saturate the floral foam.
It is another object of the invention to drain and re-circulate excess water accumulating at the bottom end of the inclined foam back to the upper portion of the foam.
It is another object of the invention to allow the user to easily transport by hand a completed flower arrangement.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, the preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of the display holder with two floral foams and U-clips attached.
FIG. 2 is a rear view of the display holder with two floral foams and U-clips attached;
FIG. 3 is a side view of FIG. 2;
FIG. 4 is a plan view of the display holder with the floral foam inserted and U-clips attached;
FIG. 5 is a cross-sectional view along line A--A of FIG. 4;
FIG. 6 is a plan view of the display holder without the floral foams inserted and U-clips attached;
FIG. 7 is a bottom view of FIG. 2;
FIG. 8 is a front view of FIG. 2;
FIGS. 9, 10 and 11 are illustrations of how the prior art required the floral foam to be trimmed; and,
FIG. 12 is a perspective view of the cascading prior art floral display holder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The accompanying drawings show the preferred embodiment of the floral display holder, generally referenced by numeral 1, formed from a hollow housing (as shown in FIG. 1) by any suitable process such as blow molding. With reference to FIG. 6, the housing 1 has a foam receiving recess 2 on its top surface to allow the insertion of floral foams 4 as shown in FIG. 1. The foams rest side by side abutting each other along their length.
Returning to FIG. 6, each front and rear wall of recess 2 has, in the preferred embodiment, two lateral half-cylindrical protrusions 8 extending from the recess floor 9 approximately half way up the walls. Directly opposite to one set of protrusions 8 are another set of corresponding protrusions located on the opposing wall. Each protrusion has clip receiving apertures 10. As shown in FIGS. 4 and 5, a pair of opposing protrusions receive the ends of U-shaped clips 11 into the apertures. The end of the U-shaped clips are locked into the protrusions by applying pressure onto thumb rests 3. As a result of the pressure the one-way inserts 6 snap into the apertures. The head of insert 6 has a slightly larger diameter than the aperture diameter while the diameter of the neck of the insert is slightly smaller than the apertures diameter. This shape of the insert securely retains the floral foams in the recess despite a heavy load applied on the U-shaped clips. The U-shaped clips also have teeth 18 disposed along the horizontal bar. The teeth assist in preventing the foam from shifting down the inclined surface.
In the preferred embodiment, the floral foams are of a size, as shown in FIG. 4, to allow the outer side surfaces of the foams when inserted into the recess to be pinched by protrusions 8 and lateral protrusions 5, but of a size so as not to come into contact with any wall. The pinching effect assists in securing the position of the floral foams and provides for additional narrow lateral pockets to collect and pool excess water from the foams.
As shown in FIG. 4, a filling area 20 is provided in the preferred embodiment at the top rear portion of the housing. The filling area 20 is concave in shape and is adapted to merge with the planar floor surface 9. The shape and location of the filling area advantageously allows: water to be added to the floral foams without necessarily wetting the floral arrangement directly; for an even distribution of water to the floral foams; and, for the top foam, which generally is the foam that dries first, to be replenished with water first.
With reference to FIG. 5, the planar floor surface is at a higher elevation along the rear of the recess area than at the front of the recess area. This continuous planar inclination of the floor surface of the recess is essential to the invention. The resulting profile provides for a desirable preset in inclined display for more favourable viewing of the floral arrangement when the display rests on a casket. The drainage openings 14 allow excess water to drain into the water reservoir 15. In addition, the planar inclination overcomes the drawback in the prior art of having a broken cascade of floral foams as shown in FIG. 12. To achieve the inclined appearance of the floral foam, the prior art required the foam to be trimmed as shown in FIGS. 9 to 11. In contrast, the present invention advantageously allows the user to set up the display holder without the hassle and additional labour of cutting and trimming the floral foams. Furthermore, the present invention advantageously allows the foams to consistently rest side by side without forming an undesirable gap between the foams. FIG. 12 illustrates the undesirable gap between the saturated foams that occurs in the prior art.
In the preferred embodiment, the floor surface 9, as shown in FIG. 6, has a series of reservoir channels 16 recessed therein. The channels allow any excess water in one area of the foam to flow to a drier portion, and to allow water to wick upwardly into the block from the channels. When the reservoir area of any one channel cannot accommodate any further volume of water to store, the excess water simply migrates down the inclined surface floor 9 towards the drainage openings 14.
With reference to FIG. 5, the hollow housing defines a reservoir 15. The reservoir has a capacity to store, in the preferred embodiment, at least one cup of water 12. Initially, the reservoir is filled with water for saturation purposes. Once a saturated foam is inserted into the recess 2 the reservoir begins to collect excess water from drain openings 14. Water stored in the reservoir may be advantageously pumped out of the housing through a tube 27 extending to the bottom of the reservoir. The other end of the tube connects to a manual pump dispenser 13 screwed onto a threaded pump opening (not shown) located on the rear surface of housing.
When the floral foams requires additional water, the user simply pumps pump 13 and the pump draws the water from the reservoir and re-saturates the foams 4 by spraying water directly onto the upper portion of the rear most foam. If the reservoir is depleted, additional water may be added into the reservoir by first unscrewing and removing the pump 13. The pump 13 is then reconnected and ready to dispense water again.
The profile view of the housing is best shown in FIG. 3. The profile is adapted to allow the floral display holder to rest or straddle the top of a funeral casket. Since most casket tops are of a convex shape the bottom surface off the housing, in the preferred embodiment, is concave in shape to allow it to securely rest on the casket top. As shown in FIGS. 2, 3, 7, and 8 the handgrips 26 consists of four finger rests integrally formed on the rear edge of the bottom surface of the housing. The floral display holder may be conveniently carried by slipping a hand into either or both the handgrips.
As result of the unique housing shape, more foam exposure allows for better design capabilities such as easier insertion and angling of flowers and greens.
It will be appreciated that the above description relates to the preferred embodiment by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described.
In another embodiment of the invention a new floral display arrangement may call for an alternative shape of the floral foams such as an oval floral arrangement. In such a situation the housing will be of another shape to accommodate the foam insert. Despite a change in the shape of the housing the scope of this invention will encompass such change. Hence, the shape and proportions of the housing may vary widely depending on what the needs of the particular application calls for.
Another variation of the preferred embodiment may have the dispenser pump located in another location besides the top surface of the housing. In addition, instead of only one pump on the holder perhaps two pumps may be required in larger flower arrangements. | A floral display holder to be used on a funeral casket has a hollow body with an inclining recess for receiving water-absorbing foams, and a manual pump to draw water from a lower portion defining a liquid reservoir. The floral display holder has U-shaped clips to secure the foams generally against an inclined floor surface of the recess. The water drawn with the pump is directed onto the foam, thereby replenishing the foam with additional water. | 0 |
PRIORITY
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/223,589, filed Sep. 10, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to pollution control devices for diesel engines.
BACKGROUND
[0003] NO x and particulate matter (soot) emissions from diesel engines are an environmental problem. Several countries, including the United States, have long had regulations pending that will limit NO x and particulate matter emissions from trucks and other diesel-powered vehicles. Manufacturers and researchers have put considerable effort toward meeting those regulations. Diesel particulate filters (DPFs) have been proposed for controlling particulate matter emissions. A number of different solutions have been proposed for controlling NO x emissions.
[0004] In gasoline-powered vehicles that use stoichiometric fuel-air mixtures, NO x emissions can be controlled using three-way catalysts. In diesel-powered vehicles, which use compression ignition, the exhaust is generally too oxygen-rich for three-way catalysts to be effective.
[0005] One set of approaches for controlling NO x emissions from diesel-powered vehicles involves limiting the creation of pollutants. Techniques such as exhaust gas recirculation and partially homogenizing fuel-air mixtures are helpful in reducing NO x emissions, but these techniques alone are not sufficient. Another set of approaches involves removing NO x from the vehicle exhaust. These approaches include the use of lean-burn NO x catalysts, selective catalytic reduction (SCR), and lean NO x traps (LNTs).
[0006] Lean-burn NO x catalysts promote the reduction of NO x under oxygen-rich conditions. Reduction of NO x in an oxidizing atmosphere is difficult. It has proven challenging to find a lean-burn NO x catalyst that has the required activity, durability, and operating temperature range. Lean-burn NO x catalysts also tend to be hydrothermally unstable. A noticeable loss of activity occurs after relatively little use. Lean-burn NO x catalysts typically employ a zeolite wash coat, which is thought to provide a reducing microenvironment. The introduction of a reductant, such as diesel fuel, into the exhaust is generally required and introduces a fuel economy penalty of 3% or more. Currently, peak NO x conversion efficiencies for lean-burn NO x catalysts are unacceptably low.
[0007] SCR generally refers to selective catalytic reduction of NO x by ammonia. The reaction takes place even in an oxidizing environment. The NO x can be temporarily stored in an adsorbent or ammonia can be fed continuously into the exhaust. SCR can achieve high levels of NO x reduction, but there is a disadvantage in the lack of infrastructure for distributing ammonia or a suitable precursor. Another concern relates to the possible release of ammonia into the environment.
[0008] To clarify the state of a sometimes ambiguous nomenclature, in the exhaust aftertreatment art, the terms “SCR catalyst” and “lean NO x catalyst” are occasionally used interchangeably. Where the term “SCR” is used to refer just to ammonia-SCR, as it often is, SCR is a special case of lean NO x catalysis. Commonly, when both types of catalysts are discussed in one reference, SCR is used with reference to ammonia-SCR and lean NO x catalysis is used with reference to SCR with reductants other than ammonia, such as SCR with hydrocarbons.
[0009] LNTs are devices that adsorb NO x under lean exhaust conditions and reduce and release the adsorbed NO x under rich exhaust conditions. A LNT generally includes a NO x adsorbent and a catalyst. The adsorbent is typically an alkaline earth compound, such as BaCO 3 and the catalyst is typically a combination of precious metals, such as Pt and Rh. In lean exhaust, the catalyst speeds oxidizing reactions that lead to NO x adsorption. In a reducing environment, the catalyst activates reactions by which adsorbed NO x is reduced and desorbed. In a typical operating protocol, a reducing environment will be created within the exhaust from time-to-time to remove accumulated NO x and thereby regenerate (denitrate) the LNT.
[0010] Creating a reducing environment for LNT regeneration involves eliminating most of the oxygen from the exhaust and providing a reducing agent. Except when the engine can be run stoichiometric or rich, a portion of the reductant reacts within the exhaust to consume oxygen. The amount of oxygen to be removed by reaction with reductant can be reduced in various ways. If the engine is equipped with an intake air throttle, the throttle can be used. However, at least in the case of a diesel engine, it is generally necessary to eliminate some of the oxygen in the exhaust by combustion or reforming reactions with reductant that is injected into the exhaust.
[0011] The reactions between reductant and oxygen can take place in the LNT, but it is generally preferred that the reactions occur in a catalyst upstream from the LNT, whereby the heat of reaction does not cause large temperature increases within the LNT at every regeneration.
[0012] Reductant can be injected into the exhaust by the engine fuel injectors or by separate injection devices. For example, the engine can inject extra fuel into the exhaust within one or more cylinders prior to expelling the exhaust. Alternatively, or in addition, reductant can be injected into the exhaust downstream of the engine.
[0013] U.S. Pat. No. 7,082,753 (hereinafter “the '753 patent”) describes an exhaust treatment system with a fuel reformer placed in the exhaust line upstream from a LNT. The reformer includes both oxidation and reforming catalysts. The reformer both removes excess oxygen and converts the diesel fuel reductant into more reactive reformate.
[0014] The operation of a fuel reformer can be modeled in terms of the following three reactions:
0.684CH 1.85 +O 2 →0.684CO 2 +0.632H 2 O (1)
0.316CH 1.85 +0.316H 2 0→0.316CO+0.608H 2 (2)
0.316CO+0.316H 2 O→0.316CO 2 +0.316H 2 (3)
wherein CH 1.85 represents an exemplary reductant, such as diesel fuel, with a 1.85 ratio between carbon and hydrogen. Reaction (1) is exothermic complete combustion by which oxygen is consumed. Reaction (2) is endothermic steam reforming. Reaction (3) is the water gas shift reaction, which is comparatively thermal neutral and is not of great importance in the present disclosure, as both CO and H 2 are effective for regeneration.
[0015] The inline reformer of the '753 patent is designed to be rapidly heated and to then catalyze steam reforming. Temperatures from about 500 to about 700° C. are said to be required for effective reformate production by this reformer. These temperatures are substantially higher than typical diesel exhaust temperatures. The reformer is heated by injecting fuel at a rate that leaves the exhaust lean, whereby Reaction (1) takes place. After warm up, the fuel injection rate is increased to provide a rich exhaust.
[0016] Depending on such factors as the exhaust oxygen concentration, the fuel injection rate, and the exhaust temperature, the inline reformer of the '753 patent tends to either heat or cool as reformate is produced. In theory, heating can be limited by increasing the fuel injection rate and thereby increasing the rate of endothermic reaction (2). In practice, due to differences in the locations at which reactions (1) and (2) occur and limitations on one more of heat transfer rates, reformer reaction rates, and the efficiency with which an LNT can use reformate, the reformer cannot always be cooled in this manner. As an alternative, the '753 patent suggests pulsing the fuel injection to the reformer during LNT regenerations. The reformer cools between fuel pulses and thereby remains within an acceptable operating temperature range.
[0017] During denitrations, much of the adsorbed NO x is reduced to N 2 , although a portion of the adsorbed NO x is released without having been reduced and another portion of the adsorbed NO x is deeply reduced to ammonia. The NO x release occurs primarily at the beginning of the regeneration. The ammonia production has generally been observed towards the end of the regeneration.
[0018] U.S. Pat. No. 6,732,507 proposes a hybrid system in which a SCR catalyst is configured downstream from the LNT in order to utilize the ammonia released during denitration. The LNT is provided with more reductant over the course of regeneration than is required to remove the accumulated NO x in order to facilitate ammonia production. The ammonia is utilized to reduce NO x slipping past the LNT and thereby improves conversion efficiency over a stand-alone LNT.
[0019] U.S. Pat. Pub. No. 2004/0076565 (hereinafter “the '565 publication”) also describes hybrid systems combining LNT and SCR catalysts. In order to increase ammonia production, it is proposed to reduce the rhodium loading of the LNT. In order to reduce the NO x release at the beginning of the regeneration, it is proposed to eliminate oxygen storage capacity from the LNT.
[0020] In addition to accumulating NO x , LNTs accumulate SO x . SO x is the combustion product of sulfur present in ordinarily fuel. Even with reduced sulfur fuels, the amount of SO x produced by combustion is significant. SO x adsorbs more strongly than NO x and necessitates a more stringent, though less frequent, regeneration. Desulfation requires elevated temperatures as well as a reducing atmosphere. In the case of a lean-burn gasoline engine, the temperature of the exhaust can generally be elevated by engine measures. In the case of a diesel engine, however, it is generally necessary to provide additional heat. Typically, this heat can be provided through the same types of reactions as those used to remove excess oxygen from the exhaust. Once the LNT is sufficiently heated, the exhaust is made rich by measures like those used for LNT denitration. If an inline reformer is used to make the exhaust rich for LNT desulfation, it may be necessary to pulse the fuel injection over the course of desulfation to prevent the fuel reformer from overheating.
[0021] In spite of advances, a long felt need exists for an affordable and reliable exhaust treatment system that is durable, has a manageable operating cost (including fuel penalty), and is practical for reducing NO x emissions from diesel engines to an extent that meets U.S. Environmental Protection Agency (EPA) regulations effective in 2010 and other such regulations.
SUMMARY
[0022] One of the inventor's concepts relates to a power generation system, comprising a diesel engine and a fuel reformer configured to receive the exhaust from the diesel engine. Two or more separate LNT bricks are configured in a parallel valveless arrangement so that each simultaneously receives a separate portion of the exhaust leaving the fuel reformer. The LNTs are each adapted and configured to simultaneously store NO x when the exhaust from the fuel reformer is lean and to simultaneously reduce stored NO x and regenerate when the exhaust from the fuel reformer contains reformate. This parallel multi-brick arrangement reduces the effective length to width ratio of the LNTs as a group without the packaging difficulties that occur when equivalently reducing the length to width ratio with a single LNT brick.
[0023] A small length to width ratio is particularly useful in this system for reducing axial temperature gradients within the LNTs during desulfation. When fuel injection is pulsed to limit the inline reformer temperature, it has been observed that significant axial temperature gradients develop within the downstream LNTs; their temperatures increase along the direction of flow. Desulfation rates are highly sensitive to temperature. Having the temperatures increasing along the direction of flow can substantially prolong desulfation and concomitant thermal degradation of the LNTs, particularly considering that sulfur deposits primarily at the fronts of the LNTs, where the LNTs are coolest. Reducing the length to width ratio ameliorates these gradients. Multiple LNT bricks in a parallel valveless arrangement are largely equivalent to a single LNT with a very small length to width ratio, but can be packaged more easily than the single brick.
[0024] Another concept relates to a method of operating a power generation system. The method comprises operating a diesel engine to produce an exhaust containing NO x and SO x . The exhaust is channeled through a plurality of LNTs, each comprising a separate brick and each receiving a separate portion of the exhaust flow. The LNTs adsorb and store a first portion of NO x and a portion of the SO x from the exhaust. The exhaust from these LNTs is passed through one or more SCR catalysts that reduce a second portion of NO x in the exhaust by reactions with ammonia under lean conditions. The method further comprises generating a first control signal to denitrate one or more of the LNTs. In response to the control signal, a rich exhaust is supplied to the one or more of the LNTs, whereby adsorbed NO x is reduced producing ammonia-containing exhaust. The ammonia containing exhaust is passed through one or more of the SCR catalysts, whereby the SCR catalysts adsorb and store ammonia. A second control signal to desulfate one or more of the LNTs is also eventually generated. In response to the second control signal, one or more LNTs are regenerated by heating them and making the exhaust supplying them rich. The manner of making the exhaust rich is such that the temperatures in the LNTs being desulfated increase in the direction of the exhaust flow. The provision of multiple LNTs each receiving a separate portion of the exhaust flow mitigates the temperature gradients that develop in the LNTs during desulfation.
[0025] The primary purpose of this summary has been to present certain of the inventor's concepts in a simplified form to facilitate understanding of the more detailed description that follows. This summary is not a comprehensive description of every one of the inventor's concepts or every combination of the inventor's concepts that can be considered “invention”. Other concepts of the inventor will be conveyed to one of ordinary skill in the art by the following detailed description together with the drawings. The specifics disclosed herein may be generalized, narrowed, and combined in various ways with the ultimate statement of what the inventor claims as his invention being reserved for the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a schematic illustration of an exemplary power generation system.
[0027] FIG. 2 is a plot of temperatures and reductant concentration in a comparison power generation over the course of LNT desulfation.
[0028] FIG. 3 is a schematic of the power generation system that produced the data plotted in FIG. ( 2 ).
[0029] FIG. 4 is a schematic illustration of another exemplary power generation system.
[0030] FIG. 5 is a schematic illustration of yet another exemplary power generation system.
[0031] FIG. 6 is a schematic illustration of a further exemplary power generation system.
DETAILED DESCRIPTION
[0032] FIG. 1 is a schematic of an exemplary power generation system 100 embodying one of the inventor's concepts. The power generation system 100 comprises an engine 101 and an exhaust aftertreatment system 102 . The exhaust aftertreatment system 102 includes a controller 103 , a fuel injector 104 , a fuel reformer 105 , a plurality of lean NO x -traps (LNT) 106 (including at least two LNTs 106 more specifically identified as 106 a and 106 b ), and a plurality of ammonia-SCR catalysts 107 . The controller 103 may be an engine control unit (ECU) that also controls the exhaust aftertreatment system 102 or may include several control units that collectively perform these functions.
[0033] During lean operation (a lean phase), the LNTs 106 adsorb a first portion of the NO x from the exhaust. The ammonia-SCR catalysts 107 may have ammonia stored from a previous regeneration of the LNTs 106 (a rich phase). If the ammonia-SCR catalysts 107 contain stored ammonia, they remove a second portion of the NO x from the lean exhaust.
[0034] From time to time, the LNTs 106 must be regenerated in a rich phase to remove accumulated NO x (denitrated). Denitration may involve heating the reformer 105 to an operational temperature and then injecting fuel using the fuel injector 104 to make the exhaust rich. The fuel reformer 105 uses the injected fuel to consume most of the oxygen from the exhaust while producing reformate. The reformate thus produced reduces NO x adsorbed in the LNTs 106 . Some of this NO x is reduced to NH 3 , most of which is captured by the ammonia-SCR catalysts 107 and used to reduce NO x during a subsequent lean phase.
[0035] From time to time, the LNTs 106 must also be regenerated to remove accumulated sulfur compounds (desulfated). Desulfation involves heating the reformer 105 to an operational temperature, heating the LNTs 106 to a desulfating temperature, and providing the heated LNTs 106 with a rich atmosphere. Desulfating temperatures vary, but are typically in the range from about 500 to about 800° C., with optimal temperatures typically in the range of about 650 to about 750 ° C. Below a minimum temperature, desulfation is very slow. Above a maximum temperature, the LNTs 106 may be damaged.
[0036] The primary means of heating the LNTs 106 is heat convection from the reformer 105 . To generate this heat, fuel can be supplied to the reformer 105 under lean conditions, whereby the fuel combusts in the reformer 105 . Once the reformer 105 is heated, the fuel injection rate can be controlled to maintain the temperature of the reformer 105 while the LNTs 106 are heating.
[0037] The LNTs 106 can also be heated in part by combustion within them. Heating the LNTs 106 in part in this way reduces the peak temperatures at which the reformer 105 must be operated. One method of achieving combustion within the LNTs 106 is to design and operate the fuel reformer 105 in such a way that a portion of the fuel supplied to the fuel reformer 105 slips to the LNTs 106 . For example, the catalyst loading of the fuel reformer 105 or its mass transfer coefficient can be kept low to facilitate this mechanism. Another method of achieving combustion in the LNTs 106 is to use rapid cycling between rich and lean phases. Oxygen for the lean phases can mix with fuel or reformate from the rich phases to combust in the LNTs 106 . This mixing and combustion can be facilitated by a capacity of the LNTs 106 to adsorb reductants or oxygen.
[0038] Even when the LNTs 106 are not specifically designed to adsorb either reductants or oxygen, it has become evident that when fuel is pulsed to the fuel reformer 105 in order to maintain its temperature over the course of a desulfation, reductant and oxygen mix and combust in the LNTs 106 . Data regarding this phenomenon are provided in FIG. 2 .
[0039] The data in FIG. 2 were gathered for a power generation system 300 configured as illustrated in FIG. 3 . In the system 300 of FIG. 3 , two LNT bricks 106 a and 106 b are arranged in series. The LNTs 106 are provided in two separate bricks in the system 300 to give a target total LNT volume using conventionally sized LNT bricks. During desulfation, the fuel injection is pulsed to give the reformate concentration profile illustrated by line 201 (CO) and line 202 (H 2 ) in FIG. 2 . Line 203 plots temperature readings obtained from a thermocouple in the LNT brick 106 a 2.5 cm from its entrance. Line 204 plots temperature readings obtained from a thermocouple in the LNT brick 106 i a 2.5 cm from its exit. Line 205 plots temperature readings obtained from a thermocouple in the LNT brick 106 b 2.5 cm from its exit. Both LNTs were about 24 cm long and 15 cm in diameter. The plots show that peak temperatures increase along the direction of flow, with peak temperatures near the exit of the two brick system being about 150° C. higher than peak temperatures near the front of the system.
[0040] The inventor's concept is to replace a series arrangement of LNTs such as illustrated by FIG. 3 with a parallel arrangement of LNTs such as illustrated by FIG. 1 . By reducing the collective lengths of the LNTs 106 , the axial temperature gradients can be ameliorated. Temperatures still increase along the direction of flow when fuel injection is pulsed, but to a lesser degree. Axial conduction through the substrates of the LNT bricks smoothes the temperature profiles. The area available for this transport is increased and the distance over which heat must be transported is reduced when the LNTs 106 are arranged in parallel.
[0041] For simplicity of representation, FIG. 1 shows only two separate LNT bricks arranged in parallel. Preferably, however, more than two separate LNT bricks are used in order to achieve a very small overall effective length to width ratio for the LNT in comparison to the length to width ratios of the individual LNT bricks. Preferably, three or more LNTs bricks are used. More preferably, four or more separate LNT bricks are used.
[0042] Preferably, the equivalent diameter to equivalent length ratio of the LNTs 106 collectively is at least about two, more preferably at least about three, and still more preferably at least about four. Equivalent diameter and equivalent length are calculated on the basis of a single cylindrical LNT brick having the same total frontal area and total volume as the LNTs 106 collectively. The equivalent diameter is obtained by dividing the total frontal area of the LNTs 106 by pi, taking the square root, and multiplying by two. The equivalent length is obtained by dividing the total volume of the LNTs 106 by the total frontal area of the LNTs 106 .
[0043] Each of the LNTs 106 is preferably a separate monolith brick. A monolith is a structure providing an array of parallel passages. A brick is a cohesive unit, for example, an extruded structure or a structure formed by rolling one or more stacked sheets of metal into a cylinder. Monolith bricks generally have aspect ratios from about 0.5 to about 2.0, with a 1.0 aspect ratio being typical. These dimensions provide structural stability. Bricks with aspect ratios greater than 2.0 are less strong and are more difficult to manufacture and effectively can. Typical diameters and lengths of monolith bricks range from about 15 cm to about 36 cm. According to the present concept, shorter bricks are preferable, e.g., bricks from about 7 cm to about 15 cm in length.
[0044] Each brick preferably provides a high degree of axial heat conduction per unit of surface area. Combustion that produces heat occurs at a rate proportional to the surface area whether the rate of combustion is kinetically or mass transfer rate controlled. For high porosity monoliths, increasing the wall thickness increases the degree of axial heat conduction. Metal conducts heat better than ceramic. A preferred LNT brick according to the inventor's concept is constructed with relatively thick metal walls. A thick metal wall is about 100 μm or thicker, preferably about 200 μm or thicker, more preferably about 400 μm or thicker.
[0045] The benefit of arranging LNTs 106 in parallel can be realized whether or not the LNTs 106 are desulfated one at a time. In the power generation system 100 , the LNTs 106 are desulfated simultaneously using a single reductant source. One advantage of the power generation system 106 is that it can be constructed and operated without exhaust system valves. Exhaust valves are undesirable because they lack durability and reliability. Mobile dampers are within the scope of valves for the purpose of this description. The system 106 divides the flow among the various branches passively; the division of flow is independent of the control signals that trigger regeneration.
[0046] FIG. 4 is a schematic of an exemplary power generation system 400 illustrating a second embodiment of the inventor's concept. The most significant difference between this embodiment and that exemplified by the power generation system 100 is that in the power generation system 400 each LNT 106 is provided with an independent mechanism for making the exhaust supplying it rich, in this case a separate inline reformer 105 for each of the exhaust branches 109 . This configuration allows one or more of the LNTs 106 to be regenerated independently of the others.
[0047] A significant advantage of independently regenerating the LNTs 106 is that rich exhaust from LNTs 106 being regenerated can be combined with lean exhaust from LNTs 106 not being regenerated. Oxygen from the lean exhaust can be used to oxidized residual reductants, slipping NO, and H 2 S in the rich exhaust.
[0048] NO tends to slip from the LNTs 106 being regenerated, particularly at the start of a regeneration. Some of this NO may be reduced in the SCR catalysts 107 . Some, however, is not so reduced either because of limitations on the catalyst efficiency or on the amount of available ammonia. NO is environmentally more harmful than NO 2 . Oxidizing untreated NO to NO 2 improves the overall performance of the exhaust treatment system.
[0049] H 2 S may slip from the LNTs 106 during desulfation. H 2 S has an offensive odor even in very small concentrations. By oxidizing this H 2 S to SO 2 , the unpleasant odor can be avoided.
[0050] Additional benefits are realized if the SCR catalysts 107 are arranged after the point in the exhaust line where the lean and rich flows are combined. FIG. 5 is a schematic of an exemplary power generation system 500 in which the flow is combined while the SCR catalyst 107 still consists of multiple separate bricks in a parallel arrangement. This embodiment realizes the benefits of a combined flow and an arrangement of SCR catalysts 107 that fits compactly with the arrangement of LNTs 106 contemplated by the inventor.
[0051] One benefit of combining the flows of separately regenerated LNTs 106 prior to supplying the combined flow to SCR catalysts 107 is that ammonia produced by the LNTs 106 during the regenerations is distributed to SCR catalysts 107 more evenly in time. This more even distribution in time increases the efficiency with which the ammonia is used. In the case of a single LNT 106 followed by a single SCR catalyst 107 , the ammonia concentration in the SCR catalyst 107 is highest immediately following regeneration. Immediately following regeneration, NO x slip from the LNT 106 is generally at its lowest. As a result, much of the ammonia remains in the SCR catalyst 107 for an extended period prior to being used to reduce NO x . Over this period, a significant portion of the stored ammonia can be lost to decomposition. By staggering the regenerations and spreading out the times over which the LNT bricks 106 are regenerated and ammonia is produced, the average time that ammonia must be stored in the SCR catalysts 107 is significantly reduced, which results in increased ammonia utilization.
[0052] Another benefit is that the environment of the SCR catalysts 107 can be maintained continuously lean. SCR catalysts function more effectively in the presence of oxygen. Maintaining a continuously lean environment in the SCR catalyst 107 can improve its performance and reduce NO x slip during regenerations.
[0053] In the exemplary power generation systems 100 , 400 , and 500 , the exhaust is made rich using inline reformers 105 . The concepts, however, extend to methods of making the exhaust rich that do not include or entirely rely upon inline reformers. The engine 101 can be used remove excess oxygen from the exhaust: the engine 101 could be operated with a stoichiometric or rich fuel-air mixture, if the engine is of such a design that this is possible. Reformate or another reductant other than diesel fuel can be injected into the exhaust. Excess oxygen can be removed by combustion of reductant in a device other than a fuel reformer 105 , such as an oxidation or three-way catalyst. In addition, it should be noted that diesel fuel can be injected into the exhaust by an engine fuel injector rather than by an exhaust line fuel injector.
[0054] At least one DPF will typically be included in a diesel exhaust aftertreatment system. The DPF can be placed at any suitable location. Examples of suitable locations are upstream from the fuel reformer 105 , between the fuel reformer 105 and the LNTs 106 , between the LNTs 106 and the SCR catalysts 107 , and downstream from the SCR catalysts 107 . A potential advantage of placing the DPF upstream from the LNTs 106 is that NO x concentrations are high, facilitating continuous regeneration. A potential advantage of placing the DPF downstream from the fuel reformer 105 is that oxidation of NO to NO 2 in the fuel reformer 105 can facilitate DPF regeneration. Also, if placed downstream from the fuel reformer 105 , the fuel reformer 105 can be used to heat the DPF for intermittent regeneration.
[0055] If the DPF is placed between the fuel reformer 105 and the LNTs 106 , the DPF can provide a thermal mass ameliorating temperature excursion in the LNTs 106 during denitrations. Repeated exposure to high temperatures can reduce the life of the LNTs 106 . Between the LNTs 106 and the SCR catalysts 107 , the DPF can have a similar effect: protecting the SCR catalysts 107 from desulfation temperatures; some SCR catalysts undergo degradation if exposed to desulfation temperatures. Downstream from the SCR catalysts 107 may be a preferred location if the DPF has a catalyst that could oxidize NH 3 . The preferred location for the DPF depends on the type of DPF and other particulars of the various system components.
[0056] FIG. 6 provides a schematic illustration of an exemplary power generation system 600 comprising an exhaust treatment system 602 in which a DPF 108 is configured. Other components of the system 600 are the same as described for the system 500 . The DPF 108 is placed downstream from the LNTs 106 at a point where the exhaust flow is unified. This configuration allows a continuously lean environment to be maintained in the DPF 108 , provided the LNTs 106 are not all regenerated simultaneously. The environment in the SCR catalyst 107 would also be continuously lean. A lean environment allows the DPF 108 to be regenerated simultaneously with desulfation of one or more of the LNTs 106 . Heat from the desulfations helps achieve soot combustion. Consumption of oxygen in one or more of the LNTs 106 reduces the risk the DPF 108 will overheat at internal hot spots.
[0057] A DPF can be a wall flow filter or a pass through filter and can use primarily either depth filtration or cake filtration. Cake filtration is the primary filter mechanism in a wall flow filter. In a wall flow filter, the soot-containing exhaust is forced to pass through a porous medium. Typical pore diameters are from about 0.1 to about 1.0 μm. Soot particles are most commonly from about 10 to about 50 nm in diameter. In a fresh wall flow filter, the initial removal is by depth filtration, with soot becoming trapped within the porous structure. Quickly, however, the soot forms a continuous layer on an outer surface of the porous structure. Subsequent filtration is through the filter cake and the filter cake itself determines the filtration efficiency. As a result, the filtration efficiency increases over time.
[0058] In contrast to a wall flow filter, in a flow through filter the exhaust is channeled through macroscopic passages and the primary mechanism of soot trapping is depth filtration. The passages may have rough walls, baffles, and bends designed to increase the tendency of momentum to drive soot particles against or into the walls, but the flow is not forced though micro-pores. The resulting soot removal is considered depth filtration, although the soot is generally not distributed uniformly with the depth of any structure of the filter. A flow through filter can also be made from temperature resistant fibers, such as ceramic or metallic fibers, that span the device channels. A flow through filter can be larger than a wall flow filter having equivalent thermal mass
[0059] Diesel particulate filters must be regenerated from time-to-time to remove accumulated soot. Two general approaches to DPF regeneration are continuous and intermittent regeneration. In continuous regeneration, a catalyst is provided upstream from the DPF to convert NO to NO 2 . N 0 2 can oxidize soot at typical diesel exhaust temperatures and thereby effectuate continuous regeneration. Intermittent regeneration involves heating the DPF to a temperature at which soot combustion is self-sustaining in a lean environment. Typically this is a temperature from about 400 to about 600° C., depending in part on what type of catalyst coating has been applied to the DPF to lower the soot ignition temperature.
[0060] While the engine 9 is preferably a compression ignition diesel engine, the various concepts of the inventor are applicable to power generation systems with lean-burn gasoline engines or any other type of engine that produces an oxygen rich, NO x -containing exhaust. For purposes of the present disclosure, NO x consists of NO and NO 2 .
[0061] The power generation system can have any suitable type of transmission. A transmission can be a conventional transmission such as a counter-shaft type mechanical transmission, but is preferably a CVT. A CVT can provide a much larger selection of operating points than can a conventional transmission and generally also provides a broader range of torque multipliers. The range of available operating points can be used to control the exhaust conditions, such as the oxygen flow rate and the exhaust hydrocarbon content. A given power demand can be met by a range of torque multiplier-engine speed combinations. A point in this range that gives acceptable engine performance while best meeting a control objective, such as minimum oxygen flow rate, can be selected. In general, a CVT prevents or minimizes power interruptions during shifting.
[0062] Examples of CVT systems include hydrostatic transmissions, rolling contact traction drives, overrunning clutch designs, electrics, multispeed gear boxes with slipping clutches, and V-belt traction drives. A CVT may involve power splitting and may also include a multi-step transmission.
[0063] A preferred CVT provides a wide range of torque multiplication ratios, reduces the need for shifting in comparison to a conventional transmission, and subjects the CVT to only a fraction of the peak torque levels produced by the engine. These can be achieved using a step-down gear set to reduce the torque passing through the CVT. Torque from the CVT passes through a step-up gear set that restores the torque. The CVT is further protected by splitting the torque from the engine, and recombining the torque in a planetary gear set. The planetary gear set mixes or combines a direct torque element transmitted from the engine through a stepped automatic transmission with a torque element from a CVT, such as a band-type CVT. The combination provides an overall CVT in which only a portion of the torque passes through the band-type CVT.
[0064] The fuel reformer 105 is a device that converts heavier fuels into lighter compounds without fully combusting the fuel. The fuel reformer 105 can be a catalytic reformer or a plasma reformer. Preferably, the fuel reformer 105 is a partial oxidation catalytic reformer comprising a steam reforming catalyst. Examples of reformer catalysts include precious metals, such as Pt, Pd, and Rh, and oxides of Al, Mg, and Ni, the latter group being typically combined with one or more of CaO, K 2 O, and a rare earth metal such as Ce to increase activity. The fuel reformer 105 is preferably small compared to an oxidation catalyst that is designed to perform its primary functions at temperatures below 450° C. The reformer 105 is generally operative at temperatures within the range of about 450to about 1100° C.
[0065] The LNTs 106 can comprise any suitable NO x -adsorbing material. Examples of NO x adsorbing materials include oxides, carbonates, and hydroxides of alkaline earth metals such as Mg, Ca, Sr, and Ba or alkali metals such as K or Cs. Further examples of NO x -adsorbing materials include molecular sieves, such as zeolites, alumina, silica, and activated carbon. Still further examples include metal phosphates, such as phosphates of titanium and zirconium. Generally, the NO x -absorbing material is an alkaline earth oxide. The adsorbent is typically combined with a binder and either formed into a self-supporting structure or applied as a coating over an inert substrate.
[0066] The LNTs 106 also comprise a catalyst for the reduction of NO x in a reducing environment. The catalyst can be, for example, one or more transition metals, such as Au, Ag, and Cu, group VIII metals, such as Pt, Rh, Pd, Ru, Ni, and Co, Cr, or Mo. A typical catalyst includes Pt and Rh. Precious metal catalysts also facilitate the adsorbent function of alkaline earth oxide adsorbers.
[0067] Adsorbents and catalysts according to the present invention are generally adapted for use in vehicle exhaust systems. Vehicle exhaust systems create restriction on weight, dimensions, and durability. For example, a NO x adsorbent bed for a vehicle exhaust system must be reasonably resistant to degradation under the vibrations encountered during vehicle operation.
[0068] The ammonia-SCR catalysts 107 are catalysts functional to catalyze reactions between NO x and NH 3 to reduce NO x to N 2 in lean exhaust. Examples of SCR catalysts include oxides of metals such as Cu, Zn, V, Cr, Al, Ti, Mn, Co, Fe, Ni, Pd, Pt, Rh, Mo, W, and Ce, zeolites, such as ZSM-5 or ZSM-11, substituted with metal ions such as cations of Cu, Co, Ag, Zn, or Pt, and activated carbon. Preferably, the ammonia-SCR catalysts 107 are designed to tolerate temperatures required to desulfate the LNTs 106 .
[0069] Although not illustrated in any of the figures, a clean-up catalyst can be placed downstream from the other aftertreatment device. A clean-up catalyst is preferably functional to oxidize unburned hydrocarbons from the engine 101 , unused reductants, and any H 2 S released from the LNTs 106 and not oxidized by the ammonia-SCR catalyst 107 . Any suitable oxidation catalyst can be used. To allow the clean-up catalyst to function under rich conditions, the catalyst may include an oxygen-storing component, such as ceria. Removal of H 2 S, when required, may be facilitated by one or more additional components such as NiO, Fe 2 O 3 , MnO 2 , CoO, and CrO 2 .
[0070] The invention as delineated by the following claims has been shown and/or described in terms of certain concepts, components, and features. While a particular component or feature may have been disclosed herein with respect to only one of several concepts or examples or in both broad and narrow terms, the components or features in their broad or narrow conceptions may be combined with one or more other components or features in their broad or narrow conceptions wherein such a combination would be recognized as logical by one of ordinary skill in the art. Also, this one specification may describe more than one invention and the following claims do not necessarily encompass every concept, aspect, embodiment, or example described herein. | A power generation system comprises a diesel engine and a fuel reformer configured to receive the engine exhaust. Two or more separate LNT bricks are configured in a parallel valveless arrangement wherein each simultaneously receives a separate portion of the exhaust leaving the fuel reformer. The LNTs are each adapted and configured to simultaneously store NO x when the exhaust from the fuel reformer is lean and to simultaneously reduce stored NO x and regenerate when the exhaust from the fuel reformer contains reformate. This parallel multi-brick arrangement reduces the effective length to width ratio of the LNTs as a group without the packaging difficulties associated with a single LNT having an equivalently reduced length to width ratio. Axial temperature gradients that develop in the LNTs during desulfation are thereby mitigated. | 8 |
SUMMARY OF THE INVENTION
This invention relates to an improved journal bearing and has specific but not limited application to a bearing having a length which is less than one-half its inside diameter.
In the bearing of this invention a support member is formed with a bore which receives the rotatable shaft. The sidewall of the support member bore is formed by a load carrying part and a shaft control part which is offset radially from the load bearing part by a shoulder. The load carrying part of the bore sidewall includes a segment which directly bears the shaft load. The control part of the bore sidewall includes a segment which is located generally oppositely across the bore from the segment of the load carrying part of the bore sidewall which bears the shaft load. This segment of the control part of the bearing is for restricting lateral movement of the shaft within the bearing bore so as to control the location of the shaft. Through the use of radially offset or eccentric bore sidewall parts sufficient radial clearance between the rotatable shaft and load carrying part of the bearing can be designed so as to provide an increased load bearing capacity for the bearing while maintaining shaft control through the use of the close fitting control part of the bearing.
Accordingly, it is an object of this invention to provide a journal bearing having a high load capacity and accurate shaft location.
Another object of this invention is to provide a journal bearing having a high load capacity with accurate shaft location for a bearing length to bore diameter ratio of less than 1 to 2.
Other objects of this invention can become apparent upon a reading of the invention's description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of one embodiment of this invention.
FIG. 2 is a cross sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a cross sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is a longitudinal sectional view of another embodiment of this invention.
FIG. 5 is a cross sectional view taken along line 5--5 of FIG. 4.
FIG. 6 is a cross sectional view taken along line 6--6 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments illustrated are not intended to be exhaustive or to limit the invention to precise forms disclosed. They are chosen and described in order to best explain the principles of the invention and its application and practical use to thereby enable others skilled in the art to best utilize the invention.
In the embodiment of this invention shown in FIG. 1--3, the bearing includes a support member 10 which is sleevelike in form and whose bore receives a shaft 12 shown rotating in the direction of arrow 13. Support member 10 is retained against movement by being secured to an exterior housing 14. The means of securing support member 10 to housing 14 may vary. In some applications of the bearing an interference fit between the support member and housing will be sufficient to secure the support member to the housing while in other applications lock rings or set screws could be utilized to accomplish the same purpose. Support member 10 is formed of a metallic material whose composition will vary depending upon the intended use of the bearing.
The bore sidewall of support member 10 includes a circular shaft load bearing part 16 and a circular shaft control part 18 which is offset radially, so as to be eccentric, from load carrying part 16 by a shoulder 20. In comparing the clearance of shaft 12 within the support member bore, it will be noted that there is substantially more clearance between shaft load carrying part 16 (see FIG. 2) than there is between shaft control part 18 (see FIG. 3) of the bearing. During rotation of shaft 12 in the operation of the bearing of this invention, a suitable lubricant, such as oil, is introduced between support member 10 and the shaft. The diametrical clearance 22 between shaft 12 and load carrying part 16 is designed to be sufficient for the desired load carrying capabilities of the bearing to allow a hydrodynamic pressure of lubricant wedge to be formed along segment 24 of part 16. This lubricant wedge, as is well known in the lubricating art, serves to support shaft 12 and its load during operation of the bearing. The diametrical clearance between shaft 12 and control part 18 of support member 10 is minimal so as to restrict radial movement of the shaft relative to support member 10. Because of this minimal clearance, a suitable shaft-supporting lubricant wedge will generally not be formed between the shaft and control part 18. The lubricant wedge formed in the general area of load carrying part segment 24 will force shaft 12 upwardly where the shaft is restricted from further upward movement by segment 26 of control part 18.
In the embodiment of this invention shown in FIGS. 4-6, the bearing is modified so as to include an oil wick 28 which serves to feed the lubricant into space 30 created by the clearance between shaft 32 shown rotating in the direction of arrow 33 and circular shaft load carrying part 34 and into the slight spacing between the shaft and circular shaft control part 36 of support member 38. Control part 36 is offset radially from load carrying part 34 by a shoulder 40. A hydrodynamic pressure or lubricating wedge will be formed in the general area of the load bearing segment 42 of load carrying part 34. This lubricating wedge will force shaft 32 upwardly where further upward movement of the shaft is restricted by segment 44 of control part 36 of the bearing.
Other than lubricating wick 28 which could be incorporated in either of the embodiments shown in the description of this invention, the bearing deplicted in FIGS. 1-3 is similar to that shown for the bearing deplicted in FIGS. 4-6 except for the size and location of the shaft control parts 18 and 36. In the bearing of FIGS. 1-3 it will be observed that the bottom of load carrying part 16 which includes load bearing segment 24 and the bottom of control segment 18 are colinear. In the embodiment of the bearing of FIGS. 4-6, the bottom of control part 36 extends below the bottom of load carrying part 34 which includes load bearing segment 42 as will be observed by space 46 in FIG. 6. Generally the shaft control part of the bearing of this invention will be narrower than the shaft load carrying part of the bearing, although this relationship can vary depending upon use, peak loads, safety and other operating conditions of the bearing. Additionally, the shaft load carrying and control parts of the bearing need not be circular. The configuration of such parts may be elliptical, oval, or some other suitable shape so long as a lubricating wedge can be formed between the shaft and the load carrying part of the bearing and a generally oppositely located portion of the control part of the bearing can be utilized to locate the shaft within the bearing. The bearing of this invention may also be designed for a high load capacity with the length of the bearing as measured between end faces 48 of support members 10 and 38 being less than one-half of the maximum transverse dimensions of the shaft load carrying parts 16 and 34 and shaft control parts 18 and 36.
It is to be understood that the invention is not to be limited to the details above given but may be modified within the scope of the appended claims. | A bearing having a sleeve-like support member with a bore therethrough which receives a rotatable shaft. The sidewall of the support member bore is formed into an annular shaft load carrying part and an annular shaft control part which is offset radially from the load bearing part by a shoulder. | 5 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation in part of prior U.S. patent application, Ser. No. 07/426,567, entitled "Weir construction for Liquid Distributors" filed by the applicant herein, Richard F. Plachy, on Oct. 23, 1989 now abandoned. The entire disclosure of this earlier application is incorporated into this specification by reference.
BACKGROUND OF THE INVENTION
The proposed invention is a device whose sole purpose is to evenly divide a flow into two or more equal streams. This invention is only for free flows in pipes or containers having a liquid/gas interface under the influence of gravity, centrifugal force, or acceleration.
When a subsistence farmer in Asia wishes to divide the irrigation water into two or more parts, he simply hoes out a shallow trough in the sides of the main irrigation ditch to conduct water to lateral irrigation ditches. If two of the shallow troughs are near each other and about the same shape, length and depth (as measured from the water surface), the flow will be divided more or less evenly. This sort of liquid flow dividing is what the proposed invention is for, but the proposed invention has unique features that make it vastly superior to these hoed troughs. Both this invention and the hoed troughs are simply types of weirs, however and thus are variants on a very old concept.
The primary use for this invention is when the head at the two weirs is different. This difference might be due to vertical misalignment of the weirs, surging due to flow patterns, or other causes. In such a case division of the flow by a V-notch weir or a rectangular notch weir is generally unsatisfactory due to the large difference in the flow over the two weirs. This is especially true at low flows where there may be little or no flow over the weir with the lower head. A normal "V" notch weir will almost triple the flow if the head above the notch bottom changes by a factor of 1.5. This implies that even a slight vertical misplacement of one of the weirs would result in a considerable difference in the amount of flow through that weir. This is one of the central problems in using weirs to divide the flow.
Prior art efforts to solve these problems have included narrow notch weirs. This does minimize the problem at low flows because the total head is raised making the head differences small compared to the total head. There are at least two significant problems with this approach. First, the narrow opening is quite subject to clogging in many (if not most) open channel applications. Second, it has a very small dynamic range. That is, if it is accurate in dividing the flow at, say, 0.2 gallons per minute, the maximum flow for a device with reasonable total height might be only 0.5 gallons per minute.
In order to overcome these disadvantages prior art includes the modified combination V-notch and narrow rectangular notch weir. The lower portion of the "V" in a V-notch weir ends in a narrow rectangular notch weir which goes still lower (mainly for use at low heads). This device does solve the problem in part, but also has some disadvantages. The low flow portion (the narrow slot) is still subject to clogging. The high flow region uses the inaccurate V-notch so that a small error in vertical alignment or head will cause a significant error in flow dividing for medium flows. The present invention solves these problems in flows subject to weir clogging such as wastewater flow division, cooling water flow division, irrigation water flow division or slurry flow division.
In flows containing a clogging agent, such a buildup of the clogging agent can cause uneven distribution or malfunction of some sort. With the present invention, however, this buildup is actually used to perfect the division of flow!
This invention has particular application in septic systems. A typical system consists of a septic tank, a distribution box or "Tee", two or more subsurface absorption areas, and the associated piping. Flow division takes place in the distribution box, often made of concrete. The walls of this box have holes or knockouts through which four inch distribution pipes are inserted. The open ends of the four inch pipes serve in lieu of flow dividing weirs.
Thus if one distribution pipe is higher than another--an inevitable occurrence--the flows will be unequal. The flow rate through the lower pipe will have to reach some minimum value before the head inside the box rises enough for there to be any flow at all through higher pipes. This means that any distribution box is a very poor divider for low flow rates. Unfortunately, since the boxes are always installed so that they are downstream from a large reservoir (the septic tank), the average flow rate is very low in practice and the resulting distribution poor. Even if perfect flow is achieved when the system is first installed, later movement and settling will cause a variation in the outlet pipe elevations.
Prior art has tried to solve these problems in septic systems by dropping the effluent over a knife edge as a means of flow division as shown in U.S. Pat. No. 4,605,501 to Tyson and U.S. Pat. No. 3,497,067 to Tyson, by using dosing systems which thereby transiently increase the flow rate, and by using orifices whose height is adjustable over the pipe as shown in U.S. Pat. No. 4,298,470 to Stallings. None of these options have been successful enough to be generally accepted.
BRIEF SUMMARY OF THE INVENTION
After much study and research into the above mentioned problems and possible solutions therefore, applicant has developed an improved distribution means which will allow division of a liquid stream into two or more equal parts with relative accuracy, even when some the outlet pipes from the distribution means were initially displaced a substantial amount vertically, and even at low flow rates. The invention is also useful when the distribution means is a pipe fitting such as a "Tee". The primary use for this invention is in flow distribution for flow streams containing elements which adhere to parts of the system or which support a growth adhering to parts of the system.
It is, therefore, an object of the present invention to provide an improved means for division of a liquid flow stream into equal parts.
Another object of the present invention is to provide a flow distribution means that will provide good flow division in spite of any initial or subsequent vertical misplacement of the outlets.
Another object of the present invention is to provide a flow distribution means that will provide good flow division at low flows.
Another object of the present invention is to provide a process for creating an improved distribution means as related above.
Another object of the present invention is to provide a process for dividing a flow such that the process will tend to maintain the equal division even if one or more outlets are raised or lowered before or during the process.
Another object of the present invention is to provide an apparatus for flow division based on these principles and having the same advantages.
Another object of the present invention is to provide such distribution means or device or process or apparatus specifically to solve the problem of equal flow division of septic tank effluent.
Another object of this invention is to provide a weir shape for use in attempting to equally divide flows containing elements which will adhere to the weirs, and wherein the outlet elevations with respect to the flowing liquid surface are unequal, such that the range of elevation difference for which a set of weirs might be used to try to compensate for these differences in outlet elevations is greatly extended over any prior art.
Another object of this invention is to provide a range of weir shapes for use in attemting to equally divide flows containing elements which will adhere to the weirs, and wherein the outlet elevations with respect to the flowing liquid surface are unequal, such that the range of elevation difference for which a set of weirs might be used to try to compensate for these differences in outlet elevations is greatly extended.
Another object of this invention is to provide a means of improving the performance of these composite weirs by causing the edges of the weir opening to be artificially ridged or roughened for better shape and adhesion for the secondary weir.
Another object of this invention is to provide a means of improving the performance of these composite weirs by making the material of the original weir much thicker, thus allowing more reliable secondary weir buildup with larger weir openings.
Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings.
To accomplish these objects, a new type of weir is proposed. This weir is designed so that the lowest portion will be narrow enough to clog with adherent elements from the flow or growths supported by the flow. The upper portions of the weir are designed so that the opening is too wide to be bridged by these same elements or growths. There will then be a part of the opening that may or may not be clogged depending on the elevation of the particular weir relative to the average flow and depending on the maximum flow rate experience at that weir. This adjustable clogging region is a large fraction of the total height of this weir opening, thereby differing significantly from any prior art. This specially designed weir is a useful new device in that it allows us to create what might be called a "secondary weir" which is the weir formed within the opening of the original weir. This secondary weir is formed from the adherent elements or growths. Any flow then takes place over this secondary weir. This secondary weir will tend to grow or shrink in such a way as to keep the flow channel over its upper surface just below the level of the fluid in the container means during low flows. Thus it forms a self-adjusting weir system when two or more weirs of this type are used to divide the flow. This then involves novel devices such as the original weir, and the composite weir having both original weir and secondary weir; novel processes such as the process for forming and adjusting the secondary weirs on all weirs or the process for dividing a flow stream in a self-adjusting way so that the outputs will remain equal in spite of moving outlet positions up or down; and, apparatus such as flow dividing apparatus based on any of these as a means of dividing a flow of liquid into equal parts though the outlets are at somewhat different or changing elevations.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the weir construction for liquid distributors in accordance with the present invention are set forth with particularly in the appended claims, a full and complete understanding of the invention may be had by referring to the detailed description of the preferred embodiment which is presented subsequently, and as illustrated in the accompanying drawing figures in which:
FIG. 1 is a perspective view of a preferred embodiment of a weir in accordance with the present invention;
FIG. 2 is a perspective view of the weir of FIG. 1 and showing the weir after clogging by elements associated with the flow of material through the weir;
FIG. 3 is a perspective view of a distribution box for subsurface wastewater disposal utilizing weirs in accordance with the present invention;
FIG. 4 shows a preferred shape of a weir opening of the present invention and its theoretical boundaries;
FIGS. 5A-5F show the formation and self-adjustment of a composite weir in accordance with the present invention;
FIGS. 6A-6C show further formation and adjustment of a composite weir;
FIG. 7 is a perspective view of a weir opening in accordance with the present invention; and
FIGS. 8A and 8B are front elevational views of a composite weir in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
This detailed description will use the preferred embodiment shown in FIG. 3. This figure shows a distribution box 2 of the type customarily used in conventional septic systems in order that the inlet flow coming from the septic tank via the inlet pipe 17 might be equally divided among the outlet pipes 13 14 15 16, each outlet pipe usually bringing the flow to a separate drainage area. FIG. 3 shows caps 12 over the ends of the outlet pipes 13 14 15 16, each said cap containing a weir of the type disclosed herein 10 11. This weir shape being shown in more detail in FIG. 1 at 5, and in FIG. 4. A prior art distribution box would not have these weirs. It should be noted that either through mismounting of the pipes or box, or subsequent settling of the box, the outlet pipes 13 14 (and the associated weirs 10 11) are at differing heights with respect to the effluent liquid inside the box 2.
Flow division in a septic system is a particularly apt use for this invention because the effluent from a septic tank contains finely divided organic matter which tends to form a thick adherent layer over all parts of the system contacted by said effluent. This adherent layer has little structural strength, and will not span wide gaps to form dams holding back the flow appreciably. It will span narrow gaps, however, and has enough strength to maintain a plug or dam across a narrow opening in spite occasional high heads and high flow rates.
The proposed invention begins with a multiple weir construction, as in the said distribution box, using weirs shaped like those shown in FIG. 1, which are (or might be) at differing heights with respect to the effluent liquid. These I will call the "original weirs". I will refer to the notches in the "original weirs" as the "original notches". The exact shape for each application must be determined, but the device is quite tolerant in most applications and will operate well though the exact best shape may not be used.
The operating principle involves a synergistic use of the clogging mechanism. After installation of the original weirs and clogging by the flow, the combination of original weir 5 and clogging medium 6 might appear as in FIG. 2. The clogging will not occur above the water line, so that the level of clogging will tend toward the average water line. Further filling will now raise the water level. It may be seen that the clogging agents will usually form a new "weir" 7 held at the edges by our original weir. This new weir is herein called a "secondary weir".
The process of forming the composite weirs (the combination of the original weirs and the secondary weirs formed from adherent elements from the fluid), and the subsequent self adjustment if the vertical positions of the weirs are changed proceeds as follows. The process will begin with weirs mounted at substantially different heights as shown by weirs 20 and 21 in FIG. 5A. As the liquid level rises in the container means, the process for generating a weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained will begin; said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which a fluid is flowing,
B. said fluid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing fluid at each weir,
D. the fluid is then allowed to flow so that said accretions build up on the weirs, with the fluid flowing over the accretions (accretions shown as 22 and 23 in FIG. 5B), (24 is the low flow liquid level in the container means for flow apparatus with variable input flow rates, or the equilibrium flow rate for flow apparatus wherein incoming the flow rate is constant)
E. the accretions then block the lower part of the weirs, causing an increase in the head of fluid in the container means and against the weirs (accretions 24 and 25 in FIG. 5C), (27 is the--now higher--low flow liquid level in the container means for flows with variable input flow rates)
F. this increased head then causing the accretions to occur at still higher levels on the weirs (FIG. 5D),
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the fluid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away (top of accretion 32 in FIG. 5E),
I. the fluid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little accretions occurring on the higher weirs during this time (FIG. 5F),
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the water line at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally (FIG. 5F), in spite of the original construction having one weir lower that the others, and this condition remains until one or another weir moves so as to become lower than the formerly lowest weir thereby causing (in FIG. 6A, opening 20, the left hand weir opening, has suddenly moved lower than weir opening 21, the right hand weir opening-though it had been higher in FIG. 5)
M. that new lowest weir to undergo the same process of adjustment as did the original lowest weir (FIG. 6B), while
N. any accretions on other weirs above the fluid line dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the fluid at the same elevation (FIG. 6C), thereby causing the fluid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change substantially.
The lower portion of the original weirs must have a narrow shape like that in FIG. 1, or the clogging material will either break off where it attaches to the original weir or be unable structurally to maintain the span across the gap during occasional higher flows. After partial clogging, the new composite weir is formed from the original weir as modified by the clogging agent. The new composite weir has all the high flow rate advantage of a V-notch weir so that high flows would still be divided evenly in spite of slight vertical misalignment of some weirs. Surprisingly, however, we can see that the "weir" 7 formed by the clogging agent will usually be at the same head level on each weir, in spite of the fact that the original weir heights are substantially different. Thus the composite weir has corrected for any original differences in head between weirs. This means that this composite device will also be accurate for division of low flow rates containing a clogging agent, even when the outputs are misaligned vertically. This is a critical point wherein this invention improves over prior art. Some prior art weirs would allow adjustment by formation of a secondary weir as described above; but, these prior art weirs would have negligible range of adjustment. They would work only so long as all the weirs were mounted at substantially the same elevation with respect to the surface of the liquid flow being divided.
It is necessary that the original weir be carefully designed. If it widens too slowly, the entire notch may become clogged from bottom to top. But, if it widens too rapidly, it will be too wide just above the desired bridging level and the clogging material will not have the structural strength to maintain itself hanging across the gap. As with any weir used in such a fashion, there will be some slight ability to self-adjust to follow changing weir elevations, but the range of elevation differences that can be corrected with such a misdesigned weir will be negligible. Above the height of anticipated clogging, the original weir could widen more quickly with increasing height. This extra widening would be to accommodate a greater range in flow rates than would be obtained with a very acute V-notch, for example. FIG. 4 shows how--in the preferred embodiment--the shape for the weir opening is formed by curves that are monotonically increasing and the shapes of these curves are such that the curves are bound between x=by 1 .3 and x=by 4 , where x is the abcissa (increasing half notch width) and y is the ordinate (increasing height above the bottom of the notch.
If a thicker material is used for the weir, this would allow the opening width across the lower part of the weir to be somewhat larger. This would have some advantage. This is shown in FIG. 7.
Similarly, if the edges of the weir opening are rough, it will allow better adhesion of the clogging or growing elements forming the secondary weir. This will allow a more desireable "U" shape in the resulting secondary weir. FIG. 8B shows the sort of shape expected for the secondary weir 60 when the weir 58 has edges 56 that are very smooth. FIG. 8A shows the sort of shape expected for the secondary weir 59 when the edges 55 of the opening 57 are rough enough for good adhesion.
One of the novel improvements claimed here is for a weir modified structurally to cause a clogging agent to form a structure across the lower portion of the original weir. The upper part of this structure made by the clogging material will then act as a new weir. The bottom of the "notch" of this new weir formed by the clogging agent is more accurately placed (with respect to the average head) than was the original weir. A variety of shapes may be used to do this in various applications, and it is not intended that this claim be limited as to the original weir shape (except as already indicated), the nature of the clogging agent, or the purpose for which the flow is divided.
Also claimed is the process of forming these composite weirs and the process of dividing a flow stream using these composite weirs, this process utilizing the wide range of vertical self-adjustment possible with these weirs.
Also claimed are the apparatuses to divide a liquid stream into equal parts based on the employment of these devices or processes.
Also claimed are septic tank systems using these devices, processes or apparatus.
Thus this invention makes it possible to have accurate flow division with relatively inaccurate vertical placement of the flow dividing weirs. In the preferred embodiment shown, it does this and yet allows accurate flow division over two orders of magnitude in flow rate for flow containing a clogging agent.
This type of weir may be formed in the walls of a flow dividing container (as in a cooling tower), at the entrance to pipes leading from a flow dividing container (as in a septic system distribution box), or as an insert placed in pipes, conduits, pipe fittings, or flow channels.
An example of an application for this device is found in the distribution boxes used to divide the flow in septic systems 2 (see FIG. 3. These boxes are usually made of rough concrete with areas for the pipes knocked out of thin areas of the sidewalls using a hammer. The four inch pipes are then pushed through the holes and the open ends of the pipes form the flow dividing weirs. Obviously significant vertical alignment errors are virtually inevitable. An end cap 12 having a weir 10 11 of the type described for this invention can be installed at the end of each pipe. This will have a dramatic effect on the accuracy of flow division between the pipes in this application.
The novel elements that comprise this invention may be described in various ways. These novel elements include:
1. A multiple weir construction for providing division of a flow of liquid into equal parts, said construction comprising a flow delivery means delivering liquid to a liquid containing means, from which means two or more flow receiving means conduct liquid, and including a system of nearly identical flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs being a multiple weir construction adapted to equally divide flows in liquid handling equipment; said multiple weir construction providing a set of weirs such that at least one weir will be between said flow delivery means and each of said flow receiving means, said weirs comprising an opening through a generally vertical wall member, said opening beginning at the bottom with a narrower width measured parallel to the wall and perpendicular to the flow, this narrower width being small enough to always become clogged by elements in the flow or by concommitant processes such as algae growth, the edges of the opening being such that the opening gradually gets wider toward the upper portions with this increase in width being at a rate slow enough to permit the accretion of the clogging agent to be capable of acting as a secondary weir across the opening at a variety of levels, and said increase in width being fast enough that there will always be a large fraction of the upper weir with a width too large for the said accretions to span without being torn away by the flow, and said width such that in those parts of the weir where the top of a secondary weir might be expected to form, the rate of said increase in width will increase with increasing height as measured from the bottom of the weir opening so that the accumulation of the clogging agent is able to grow or shrink gradually as the average liquid level in the container means rises and falls, at least one of said weirs being in the flow path between the said liquid supply means and each of said flow receiving means; thereby creating a multiple weir construction with weirs capable of supporting a secondary set of weirs derived from contaminants in the flow such that the flow over each said secondary weir in the said set of weirs will become nearly the same though the original weirs were mounted at differing elevations; also thereby providing a multiple weir construction which will provide substantially equal flows at various outlets though the vertical positions of the flow controlling weirs, with respect to the liquid surface, change slowly with time; also providing a set of weirs wherein the secondary weirs can not grow to fill the entire weir opening; and also providing a set of weirs wherein there will be a larger opening at the upper part of the weir capable of handling occasional high flow rates.
2. A multiple composite weir construction for providing division of a flow of liquid into equal parts, said construction comprising a flow delivery means delivering liquid to a liquid containing means, from which means two or more flow receiving means conduct liquid, and including a system of nearly identical flow dividing weirs such that at least one weir will be between the flow delivery means and any flow receiving means, said system of flow dividing weirs being a multiple weir construction adapted to equally divide flows in liquid handling equipment; said multiple weir construction providing a set of weirs such that at least one weir will be between said liquid supply means and each of said flow receiving means, said weirs comprising an original weir and a secondary weir grown in place, said original weir being an opening through a generally vertical wall member, said opening beginning at the bottom with a narrower width measured parallel to the wall and perpendicular to the flow, this narrower width being small enough to always become clogged by elements in the flow or by concommitant processes such as algae growth; the edges of the opening being such that the opening gradually gets wider toward the upper portions with this increase in width being at a rate slow enough to permit the accretion of the clogging agent to be capable of acting as a secondary weir across the opening at a variety of levels, and said increase in width being fast enough that there will always be a large fraction of the upper weir with a width too large for the said accretions to span without being torn away by the flow, and said width such that in those parts of the weir where the top of a secondary weir might be expected to form, the rate of said increase in width will increase with increasing height as measured from the bottom of the weir opening so that the accumulation of the clogging agent is able to grow or shrink gradually as the average liquid level in the container means rises and falls, the combination of the said original weir and the said secondary weir now being called a composite weir, at least one of said composite weirs being in the flow path between the said liquid supply means and each of said flow receiving means; and, thereby creating a multiple composite weir construction with original weirs capable of supporting a secondary set of weirs derived from contaminants in the flow such that the flow over each said secondary weir in the said set of weirs will become nearly the same though the said original weirs were mounted at differing elevations; also thereby providing a multiple weir construction which will provide substantially equal flows at various outlets though the vertical positions of the said original flow controlling weirs, with respect to the liquid surface, change slowly with time; also providing a set of composite weirs wherein the secondary weirs can not grow to fill the entire original weir opening; and also providing a set of weirs wherein there will be a larger opening at the upper part of the composite weir capable of handling occasional high flow rates.
3. A septic tank system comprising a septic tank, a distribution means receiving effluent from said tank, and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas; and, in the flow path from the interior of said distribution means to the interior of said pipes, a multiple weir construction adapted to equally divide flows in liquid handling equipment such that at least one weir will be in the flow path between the distribution means and each said subsurface absorption area, said weirs comprising an opening through a generally vertical wall member on or operatively attached to the said distribution means, said opening being called the original weir and said opening beginning at the bottom with a narrower width measured parallel to the wall and perpendicular to the flow, this narrower width being small enough to always become clogged by elements in the flow or by concommitant processes such as algae growth, the edges of said opening being such that the opening gradually gets wider toward the upper portions, with this increase in width being at a rate slow enough that the accumulation of the clogging agent is capable of acting as a secondary weir across the opening, said secondary weir growing or shrinking gradually as the fluid level rises and falls by a substantial amount, but said increase in width being fast enough that the upper portions of the opening will be too wide to allow maintenance of said secondary weir, thereby creating a set of weirs such that the secondary weir of each of weir opening will tend to adjust for the fact that the said original weir opening might have been higher or lower, relative to the surface of the flowing liquid, than the other weir openings and thus causing equal flow division in spite of original vertical misalignment, and also thereby creating an apparatus which will provide substantially equal flows at various outlets though the original flow controlling weirs are at substantially different elevations relative to the liquid surface; thereby causing equal distribution to the various subsurface absorption areas in spite of sustantial vertical misalignment of the weirs or later tipping of the distribution means due to settling.
4. A septic tank system comprising a septic tank, a distribution means receiving effluent from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas, and, in the flow path from the interior of said distribution means to the interior of said pipes, a composite multiple weir construction adapted to equally divide flows in liquid handling equipment such that at least one of of these weirs will be in the flow path between the distribution means and each said subsurface absorption area, said weirs comprised of an original weir and a secondary weir grown in place, such that the original weir is an opening through a generally vertical wall member on or operatively attached to the container means, said opening beginning at the bottom with a narrower width measured parallel to the wall and perpendicular to the flow, this narrower width being small enough to always become clogged by elements in the flow or by concommitant processes such as algae growth, the edges of said opening being such that the opening gradually gets wider toward the upper portions, this increase in width being at a rate slow enough to permit the accretions of the clogging agent to be capable of acting as a secondary weir across the opening; said rate of increase in width at the same time being fast enough that the accretions forming the secondary weir will be structurally unable to maintain such a secondary weir in the wider upper part of said opening, and such that said secondary weir will grow or shrink gradually as the average fluid level rises and falls, said growing and shrinking taking place over a substantial fraction of said weir opening; thereby creating a set of weirs, such that the secondary weir of each of which will tend to adjust for the fact that one original weir opening might have been substantially higher or lower than the other weir openings and by said adjustment these weirs will cause equal flow division, and thereby cause equal distribution of effluent to each subsurface wastewater disposal area.
5. A multiple weir construction for providing division of a flow of liquid into equal parts comprising a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate liquid flow in fluids handling equipment and each weir comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed such as to form curves which are monotonically increasing and curves such that the increase in opening width, x, at any point will be at least By 1 .3 where y is increasing notch width above the bottom of the opening and B is some constant and x will be at most By 4 .
6. A multiple composite weir construction for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a composite weir construction adapted to regulate flow in fluids handling equipment; said composite weir comprising an original weir and a secondary weir grown in place, such that the original weir is an opening through a generally vertical wall member having an opening therethrough extending longitudinally down said wall, the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed so that the edges of the opening leading upward from the bottom of the opening form curves such that the increase in opening width, x, at any point will be an least By 1 .3 where y is increasing height above the bottom of the opening and B is some constant, and x is at most by 4 ; this weir then supporting a secondary weir formed by accretions of some elements from the liquid having adhered to the opening, said secondary weir tending then to slowly follow any changes in fluid head by increasing its height for increasing average head, thereby creating an apparatus which will provide approximately equal flows at various outlets though the original flow controlling weirs are at substantially different elevations relative to the liquid surface.
7. A process for generating a weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlets from some container means into which a liquid is flowing,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing liquid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away and
I. the liquid level drops slightly essentially stopping the accretion on all other weirs, but this fluid level allows the accretions to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little accretions occurring on the higher weirs during this time, until
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the water line at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower that the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the liquid line dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the liquid at the same elevation, thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change substantially.
8. A process for generating a multiple weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained; said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlets from some container means into which a liquid is flowing, each weir of which assembly being described as follows: a weir construction adapted to regulate liquid flow in fluids handling equipment comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed such as to form curves which are monotonically increasing and curves such that the increase in opening width, x, at any point will be at least By 1 .3 where y is increasing notch width above the bottom of the opening and B is some constant and x will be at most By 4 ,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing liquid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away and
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the top of the accretion across the others is largely confined to being just below the surface of the liquid at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower that the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the surface of the liquid dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the liquid at the same elevation, thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the original weir elevations change substantially.
9. An apparatus for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs having been generated by a process for generating a weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir opening such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which a liquid is flowing,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but said accretions will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing fluid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away and
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little additional accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again thereby providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the surface of the liquid at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower than the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. the accretions on that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the surface of the liquid dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the weir openings at the same elevation thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change;
thereby resulting in an apparatus which self-adjusts for substantially altered elevation of one of the outlet weirs so that the flows to various outlets will again be nearly equal.
10. An apparatus for providing division of a flow of liquid into equal parts comprised of a flow delivery means or pipe delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs having been generated by a process for generating a multiple weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which a liquid is flowing, each weir of which assembly being described as follows: a weir construction adapted to regulate liquid flow in liquids handling equipment comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall the lowest portion of said opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed such as to form curves which are monotonically increasing and curves such that the increase in opening width, x, at any point will be at least By 1 .3 where y is increasing notch width above the bottom of the opening and B is some constant and x will be at most By 4 ,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing liquid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little additional accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again thereby providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the liquid surface at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower that the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the liquid surface dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the liquid at the same elevation thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change;
thereby resulting in an apparatus which self-adjusts for substantially altered elevation of one of the outlet weirs so that the flows to various outlets will again be nearly equal.
11. In a septic tank system comprising a septic tank, a distribution means receiving effluent from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas, in the flow path from the interior of said distribution means to the interior of said pipes, a composite multiple weir construction adapted to equally divide flows in fluid handling equipment said weir construction is generated by a process for generating a weir construction capable of adjusting to compensate for substantial errors in the vertical placement of one or more weir openings such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which the effluent liquid is flowing,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but said accretions will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing liquid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block stillmore of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again thereby providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the water line at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower that the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the surface of the liquid dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the middle of the weir openings at the same elevation thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change;
thereby resulting in an apparatus which self-adjusts for substantially altered elevation of one of the outlet weirs so that the flows to various outlets will again be nearly equal, and thereby causing equal flow to each subsurface absorption area in the septic system.
12. A method for providing division of a flow of liquid into equal parts using a process which both establishes the final apparatus shape and adjusts that shape for later changes in outlet elevations, said method employing an apparatus comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs having been generated by a process for generating a weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which a liquid is flowing,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but said accretions will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing fluid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away and
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little additional accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again thereby providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the surface of the liquid at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower than the others, and this conditions remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. the accretions on that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the surface of the liquid dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the weir openings at the same elevation thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change;
thereby resulting in a process which self-adjusts for substantially altered elevation of one of the outlet weirs so that the flows to various outlets will again be nearly equal, this same process thereby causing the original flow to be equally divided in spite of changes in outlet elevations.
13. A multiple weir construction for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate flows in liquid handling equipment and comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall, said opening being such that when said weir construction is used with other similar weir constructions to divide the flow into equal parts, the lower portion of said weir constructions will become partially clogged by contaminants in the fluid such that the contaminants will modify the shape of the opening in such a way as to compensate for any substantial initial difference in elevations of the weirs, thereby making the flow division more nearly equal over a wide range of flows.
14. A septic tank system comprising a septic tank, a distribution means receiving effluent from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas, and, in the flow path from the interior of said distribution means to the interior of said pipes, a composite multiple weir construction adapted to equally divide flows in liquid handling equipment, said weir construction comprising a weir construction adapted to regulate liquid flow in liquids handling equipment, each weir of said multiple weir construction comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall, said opening being such that when said weir construction is used with other similar weir constructions to divide the flow into equal parts, the lower portion of said weir constructions will become partially clogged by contaminants in the fluid such that the contaminants will modify the shape of the opening in such a way as to compensate for substantial difference in elevations of the weirs; thereby making the flow division more nearly equal over a wide range of flows, thereby causing nearly equal flow to each subsurface absorption area in the septic system.
15. A method for providing division of a flow of liquid into equal parts using a process which both establishes the final apparatus shape and adjusts that shape for later changes in outlet elevations, said method employing an apparatus comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs having been generated by a process for generating a weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which a liquid is flowing,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but said accretions will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing fluid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away and
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little additional accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again thereby providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the surface of the liquid at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower than the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. the accretions on that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the surface of the liquid dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the weir openings at the same elevation thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change;
thereby resulting in a process which self-adjusts for substantially altered elevation of one of the outlet weirs so that the flows to various outlets will again be nearly equal, this same process thereby causing the original flow to be equally divided in spite of changes in outlet elevations.
16. In a septic tank system comprising a septic tank, a distribution means receiving effluent liquid from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent liquid from the distribution means into pipes leaning to subsurface absorption areas, and in which the vertical placement of the outlets of said distribution means are relatively inaccurate or changing with time, a process for providing division of a flow of effluent liquid from the septic tank into equal parts using a process which both establishes the final apparatus shape and adjusts that shape for later changes in outlet elevations, said process employing an apparatus comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs being capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained and having been generated as a part of the said process, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which a liquid is flowing,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but said accretions will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing liquid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away and
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little additional accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again thereby providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the surface of the liquid at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower than the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. the accretions on that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the surface of the liquid dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the weir openings at the same elevation thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change;
thereby resulting in a process which self-adjusts for substantially altered elevation of one of the outlet weirs so that the flows to various outlets will again be nearly equal, this same process thereby causing the original flow to be equally divided in spite of changes in outlet elevations.
17. In a septic tank system comprising a septic tank, a distribution means receiving effluent liquid from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent liquid from the distribution means into pipes leaning to subsurface absorption areas, and in which the vertical placement of the outlets of said distribution means are relatively inaccurate or changing with time, a process for generating a weir construction capable of adjusting to compensate for errors in the vertical placement of one or more weir openings such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlets from some container means into which a liquid is flowing,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing liquid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away and
I. the liquid level drops slightly essentially stopping the accretion on all other weirs, but this liquid level allows the accretions to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little accretions occurring on the higher weirs during this time, until
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the water line at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower that the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the liquid surface dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the effluent liquid at the same elevation, thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change substantially.
18. A multiple weir construction for providing division of a flow of liquid into equal parts comprising a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate liquid flow in fluids handling equipment and comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of said opening being formed such that the width of said opening is an increasing function of distance from the bottom of said opening, and formed such that the rate of increase in said width is itself an increasing function of distance from the bottom of said opening.
19. A multiple composite weir construction for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a composite weir construction adapted to regulate flow in liquids handling equipment; said composite weir comprising an original weir and a secondary weir grown in place, such that the original weir is an opening through a generally vertical wall member having an opening therethrough extending longitudinally down said wall, the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed such that the width of said opening is an increasing function of distance from the bottom of said opening, and formed such that the rate of increase in width of the opening is also an increasing function of the distance from the bottom of said opening; this weir then supporting a secondary weir formed by accretions of some elements from the liquid having adhered to the opening, said secondary weir tending then to slowly follow any changes in fluid head by increasing its height for increasing average head, thereby creating an apparatus which will provide approximately equal flows at various outlets though the original flow controlling weirs are at substantially different elevations relative to the liquid surface.
20. In a septic tank system comprising a septic tank, a distribution means receiving effluent liquid from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas; a multiple weir construction for providing division of a flow of liquid into equal parts, said multiple weir construction comprised of a flow delivery means delivering liquid to a flow containing means from which flow containing means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate flow in liquids handling equipment; each of said weirs comprising an opening through a generally vertical wall member on or attached to the container means, having an opening therethrough extending longitudinally down said wall, the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of said opening, said dam having a vertical dimension three or more times that width, and with the rest of said opening being formed such that the width of said opening is an increasing function of distance from the bottom of said opening, and formed such that the rate of increase in width of the opening is also an increasing function of the distance from the bottom of said opening; this weir then supporting a secondary weir formed by accretions of some elements from the liquid having adhered to the opening, said secondary weir tending then to slowly follow any changes in fluid head by increasing its height for increasing average head; thereby creating an apparatus which will provide approximately equal flows at various outlets though the original flow controlling weirs are at substantially different elevations relative to the liquid surface, and thereby separating the septic tank effluent into equal parts for distribution to various subsurface absorption areas.
21. In a septic tank system comprising a septic tank, a distribution means receiving effluent from said tank, and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas; in the flow path from the interior of said distribution means to the interior of said pipes, a composite multiple weir construction adapted to equally divide flows in liquid handling equipment; said weir construction is generated by a process for generating a weir construction capable of adjusting to compensate for substantial errors in the vertical placement of one or more weir openings such that equal flow division is maintained, said process comprising the following steps:
A. having a multiple weir assembly all the weirs of which are similar, said weirs providing the outlet from some container means into which a liquid is flowing, each weir of which assembly being described as follows: a weir construction adapted to regulate liquid flow in liquids handling equipment comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall the lowest portion of said opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed such as to form curves which are monotonically increasing and curves such that the increase in opening width, x, at any point will be at least By 1 .3 where y is increasing notch width above the bottom of the opening and B is some constant and x will be at most By 4 ,
B. said liquid having some elements therein which are capable of adhering to or growing on said weirs,
C. said weirs having been so constructed that the accretions of adherent elements from the flow can partially block the lower portion of the weirs, but will not have the structural strength to maintain a blockage across the upper part of the weirs, the width of the weir openings increasing steadily from the lowest part of the weirs to the highest part of the operating portion of the weirs, said weirs being described as higher or lower meaning the relative elevations of the bottom of each weir as measured from the surface of the flowing liquid at each weir,
D. the liquid is then allowed to flow so that said accretions build up on the weirs, with the liquid flowing over the accretions,
E. the accretions then block the lower part of the weirs, causing an increase in the head of liquid in the container means and against the weirs,
F. this increased head then causing the accretions to occur at higher levels on the weirs,
G. these accretions then block still more of the weir, until
H. the greater weir opening width for the lowest weir as measured at the liquid surface causes the uppermost part of that weir to lack the strength to bridge the gap and it breaks away
I. the liquid level drops very slightly essentially stopping the accretion on all other weirs, but allowing it to continue to rebuild the small top portion of the accretions that broke away on the lowest weir, very little additional accretion occurring on the higher weirs during this time,
J. this accretion on the lowest weir again loses a small amount of the top of the accretion across the opening,
K. steps I and J are repeated again and again thereby providing a condition where the top of the accretion across the opening in the lowest weir varies only slightly up and down, and the accretion across the others is largely confined to being just below the liquid surface at low flows, this negative feedback mechanism then provides a set of weirs with their attendant accretions that operate so that
L. the flows are divided essentially equally, in spite of the original construction having one weir lower that the others, and this condition remains until one or another weirs moves so as to become lower than the formerly lowest weir, said movement thereby causing
M. that new lowest weir to undergo the same process of adjustment as did the original lowest weir, while
N. any accretions on other weirs above the liquid surface dry up, wither and otherwise become less so that
O. the steps I and J will be repeated so that steps K and L are repeated for this new configuration so that this continuing process based on negative feedback continually adjusts to keep the tops of the accretions in the liquid at the same elevation thereby causing the liquid flowing out of the container means over these accretions to be divided into equal streams though the weir elevations change;
thereby resulting in an apparatus which self-adjusts for substantially altered elevation of one of the outlet weirs so that the flows to various outlets will again be nearly equal, and thereby providing equal distribution of effluent to the outlets leading to the various subsurface absorption areas.
22. In a septic tank system comprising a septic tank, a distribution means receiving effluent liquid from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas; a multiple composite weir construction for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a composite weir construction adapted to regulate flow in liquids handling equipment; said composite weir comprising an original weir and a secondary weir grown in place, such that the original weir is an opening through a generally vertical wall member having an opening therethrough extending longitudinally down said wall, the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed so that the edges of the opening leading upward from the bottom of the opening form curves such that the increase in opening width, x, at any point will be an least By 1 .3 where y is increasing height above the bottom of the opening and B is some constant, and x is at most by 4 ; this weir then supporting a secondary weir formed by accretions of some elements from the liquid having adhered to the opening, said secondary weir tending then to slowly follow any changes in fluid head by increasing its height for increasing average head, thereby creating an apparatus which will provide approximately equal flows at various outlets though the original flow controlling weirs are at substantially different elevations relative to the liquid surface, and thereby causing the flow of effluent from the septic tank to be equally divided among the various subsurface absorption areas.
23. In a septic tank system comprising a septic tank, a distribution means receiving effluent liquid from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas; a multiple weir construction for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate flow in liquids handling equipment; said weirs each comprising an opening through a generally vertical wall member having an opening therethrough extending longitudinally down said wall, such that the average height of said opening is at least three times the average width of said opening; thereby providing a means for reducing the effect on the outlet flows of vertical misplacement of the outlets from the said distribution means so that the flows to the various subsurface absorption areas will be more nearly equal in spite of vertical misalignment of the outlets.
24. In a septic tank system comprising a septic tank, a distribution means receiving effluent liquid from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent from the distribution means into pipes leading to subsurface absorption areas; a multiple weir construction for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate flow in liquids handling equipment; said weirs each comprising an opening through a generally vertical wall member having an opening therethrough extending longitudinally down said wall, such that the average height of said opening is at least three times the average width of said opening and such that the portion of the opening experiencing the flow of liquid has an increase in width with increasing height as measured from the bottom of said opening, said increase in width being equal to or greater than zero; thereby providing a means by which the effect on the outlet flows of vertical misplacement of the outlets from the said distribution means so that the flows to the various subsurface absorption areas will be more nearly equal in spite of vertical misalignment of the outlets.
25. In a septic tank system comprising a septic tank, a distribution means receiving effluent liquid from said tank and multiple discharge means operatively connected into said distribution means for discharging effluent liquid from the distribution means into pipes leading to subsurface absorption areas; a multiple weir construction for providing division of a flow of liquid into equal parts; said multiple weir construction comprising a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate liquid flow in fluids handling equipment, each weir of said multiple weir construction comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall the lowest portion of the opening having a width determined to be at most 0.8 times the width across which contaminants in a flow through the opening could support a dam by adhering to the edges of the opening, said dam having a vertical dimension three or more times that width, and with the rest of the opening being formed such as to form curves which are monotonically increasing and curves such that the increase in opening width, x, at any point will be at least By 1 .3 where y is increasing notch width above the bottom of the opening and B is some constant and x will be at most By 4 ; thereby providing a flow division means which will provide approximately equal flows at various outlets though the original flow controlling weirs were at substantially different elevations relative to the liquid surface and thereby separating the septic tank effluent into equal parts for distribution to various subsurface absorption areas.
34. A multiple weir construction for providing division of a flow of liquid into equal parts comprised of a flow delivery means delivering liquid to a flow containing means from which means two or more flow receiving means conduct liquid, and including a system of flow dividing weirs such that at least one weir will be in the flow path between the flow delivery means and any flow receiving means, said system of flow dividing weirs employing a weir construction adapted to regulate flows in liquid handling equipment and comprising a generally vertical wall member having an opening therethrough extending longitudinally down said wall, said opening being such that when said weir construction is used with other similar weir constructions to divide the flow into equal parts, the lower portion of said weir constructions will become partially clogged by contaminants in the fluid such that the contaminants will modify the shape of the opening in such a way as to compensate for any substantial initial difference in elevations of the weirs, thereby making the flow division more nearly equal over a wide range of flows. Obviously, this invention is not limited in terms of the materials from which it is fabricated, flexible or otherwise. It is not limited in terms of the devices or processes in which it can be used except as already described. | A composite weir construction for evenly dividing liquid flows in conduits or containers having a liquid-gas interface under the influence of gravity or accelleration is presented. In particular, this device is for flows wherein clogging of narrow weirs is a problem, and where weir elevation differences are also a problem. When these weirs are placed in the flow, new weirs are gradually formed which is are composites made from the clogging agent and the original weirs. These new composite weirs are very accurate in flow division over a wide range of flows in spite of substantial vertical misalignment of the original weirs. | 4 |
FIELD OF THE INVENTION
The present invention relates to a shaftless spinning rotor for an open-end spinning machine, which is embodied as the rotor of an axial field motor with means for creating a magnetic field for driving rotation of the spinning rotor and another magnetic field for guiding the spinning rotor. More particularly, the spinning rotor of the present invention has a bearing face remote from the spinning chamber of the spinning rotor adapted to form a combined magnetic and gas bearing and means for conducting the magnetic flux for the driving and guiding magnetic fields.
BACKGROUND OF THE INVENTION
As development of rotor spinning machines progresses, the goal is not only to improve the quality of the yarns produced, but above all to increase production capacity. A key factor in increasing production capacity is the rotary speed of the spinning rotor. For this reason, varied kinds of drives and bearings for spinning rotors have been developed, in order to reach rotary speeds of markedly over 100,000 rpm. Reducing the rotor diameter and mass and lowering friction losses enables not only greater rotary speed but also reduced energy consumption when driven.
In this respect, a shaftless spinning rotor, which is embodied as the rotor of an axial field motor, can be considered especially advantageous by providing a combined magnetic and gas bearing which assures relatively low friction losses.
A shaftless open-end spinning rotor of the above-described type having a combined magnetic and gas bearing is known from International PCT Patent Reference WO 92/01097, which discloses a rotor having a bearing face, remote from the spinning chamber of the spinning rotor, and means for conducting the magnetic flux for the driving and guiding magnetic fields. By means of the guiding magnetic field, the rotational axis of the open-end spinning rotor is to be rigidly defined and maintained during rotation. However, it has been found impossible to achieve significant suppression of impermissible vibratory, wobbling and oscillating motions that occur particularly in critical rpm ranges. Moreover in the central region of the stator of the axial field motor, overheating tends to occur which causes thermal expansion and can ultimately lead to problematic warping.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to improve the known type of shaftless spinning rotor described above to achieve a smoother, balanced rotational operation without problematic vibration, oscillation or wobbling and with reduced generation of heat in the region of the rotational axis.
Briefly summarized, this object is attained in accordance with the present invention in a shaftless spinning rotor for an open-end spinning machine of the type adapted to be operable in an axial field motor to be driven rotatably by a stator of the motor. The rotor comprises a body defining a spinning chamber and an opening into the chamber, with a bearing face disposed opposite the rotor opening. Means are provided for producing a combined magnetic and gas bearing for supporting the rotor relative to the stator, including means for producing a first field of magnetic flux for orienting and maintaining a rotational axis of the rotor in a stationary disposition and means for producing a second field of magnetic flux for driving rotation of the rotor about the axis. A first means is provided for conducting the magnetic flux for the guiding magnetic field, while a second means conducts the magnetic flux for the driving magnetic field. According to the present invention, a generally nonmagnetic barrier layer is disposed between the first and second flux conducting means for decoupling of the respective fluxes.
The invention is based on the recognition that the magnetic fields of the axially symmetrical driving magnets have a component that changes with time and spatially which impairs the constant magnetic field of the guiding magnets. Superimposing the fields on one another, as in the prior art, results in an asymmetrical field intensity distribution in the center of the spinning rotor. For example, while the magnetic field lines between the driving magnets extend in the same direction over the central region in which the guiding magnets are disposed, the direction of the magnetic field lines of the guiding magnets is opposite on opposed sides of the axis of rotation. This causes a backup of magnetic flux on one side, and possibly even a magnetic saturation, while on the opposite side mutual attenuation of the magnetic fields occurs. By coupling the magnetic fluxes of the drive and guide magnet fields, the action of the stator current causes a constant magnetic reversal in the region of the guide magnets.
In contrast, by providing a barrier layer for decoupling the respective magnetic fluxes, the influence of the alternating component of the driving magnetic field in the central region, i.e., in the region of the guiding magnetic field, is minimized. As a result, eddy currents in the rotational frequency of the rotor, particularly on the stator side, can be reduced significantly. Such eddy currents can become dangerous especially if the central part of the stator gas bearing has metal elements. Moreover, an asymmetrical magnetization of the central region of the guiding magnetic field, and hence an undesirable shift in the magnetic axis, is avoided. Such a shift leads directly to a deviation between the mechanical axis of rotation about the center of gravity of the rotor and the magnetic axis intended to be defined by adjusting the rotor to a minimum of the magnetic potential of the field. In turn, any deviation between the two axes leads to the wobbling and oscillatory motion found in the prior art.
Advantageously, separate yokes, which are separated from one another by the aforementioned barrier layer, are used to conduct the respective magnetic fluxes of the driving magnets and the guiding magnets. Although hysteresis material can also be used on the rotor in order to effect rotational guiding and driving thereof, it is advantageous to use a concentric or symmetrical arrangement of permanent magnets for the drive and guide magnet fields. The respective yokes may be spaced apart both axially and radially from one another, with the barrier layer disposed in the space therebetween.
In one embodiment, the arrangement of magnets that generate the guiding magnetic field protrude from the flat bearing face of the spinning rotor and extends into a corresponding recess in the stator, which advantageously allows a reduction in the axial length of the main body of the spinning rotor, even if the two yokes for the guiding and driving magnets are spaced apart axially. With respect to the magnetic flux of the magnetic field of the drive magnets, a yoke that extends past the central region has more favorable properties. Moreover, in this case the yoke toward the rotor for the driving magnetic field is located closer to the stator windings, with the overall result that the length of the magnetic field lines is shortened. An especially favorable configuration of the magnets for generating the guiding magnetic field is obtained by the disposition of one central, disklike magnet, and one concentric, annular magnet of opposite polarity spaced annularly therefrom. In this manner, the guiding magnetic arrangement can cooperate with an identical magnet arrangement but of reverse polarity to achieve both good holding action and good centering action.
The invention also contemplates joining the yokes directly to their respective magnets without anything between them to minimize any hindrance on, and thereby optimize the strength of, their magnetic flux.
The arrangement of magnets protruding from the bearing face of the rotor for generating the guiding magnetic field can be achieved especially favorably if the associated yoke is located in the same plane with the main portion of the bearing of the spinning rotor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross-section through an assembly of a shaftless open-end spinning rotor as preferably embodied according to the present invention as the rotor in an axial field motor;
FIG. 2 is another cross-section axially through a shaftless spinning rotor according to an alternate embodiment of the present invention; and
FIG. 3 is another axial cross-section of a shaftless spinning rotor according to a further embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the accompanying drawings and initially to FIG. 1, a shaftless spinning rotor 1 according to the present invention is embodied as the rotor of an axial field motor in assembly with a stator 2 of the motor. The main body of the spinning rotor 1 forms a spinning cup 3 open at its top with a circular disk-like base 3' from which an annular outer wall extends to define a spinning chamber therewithin with an annular fiber collecting groove 3" extending circumferentially at the juncture of the base 3' and the annular wall, this structure of the rotor 3 being concentric about and defining an axis of rotation 11. As is known in open-end spinning, opened individualized fibers are fed into the chamber to collect centrifugally in the groove 3" as a result of driven rotation of the rotor 3 and the collected fibers are progressively drawn from the spinning chamber to form a yarn or thread. The means by which fibers are delivered into the chamber and the means by which the yarn is withdrawn from the chamber are known but are not shown for the sake of simplicity in that elements do not have any influence on the subject of the present invention.
Drive magnets 4 and 4', which by way of example may comprise segmental axially symmetrical magnet plates of alternating polarity, are mounted concentrically about the rotational axis between the underside of the rotor base 3' and a magnet carrier 5 affixed thereto, which forms a bearing face of the rotor. The magnet carrier 5 may be made up for example of solid laminates as known from International PCT Patent Disclosure WO 92/01097. In the simplest case, two drive magnets 4,4' suffice, which are magnetically insulated from one another in the plane of the bearing face. However, since this magnet arrangement is already described in WO 92/01097, it need not be described in further detail herein.
An assembly of a centering magnet 7 and a magnet ring 8, supported in spaced relation from one another by an insulating holder 19, is mounted to the underside of the magnet carrier 5 on the spinning rotor 1 to protrude downwardly from the bearing face into a recess of the stator 2, forming therebetween an axial air gap 14 and a radial air gap 15.
Axially adjacent the air gap 14 toward the stator is a corresponding magnet arrangement comprising a central magnet 22 and a ring magnet 21 supported in spaced apart relation to one another by an insulating holder 20. The polarity of the magnets 21,22 in the region of the air gap 14 is opposite the polarity of the magnets 7,8 on the rotor side resulting in mutual attraction of the magnets, whereby the magnets create magnetic fields adapted to guide or retain the rotor 1 axially aligned with the stator 2.
Yoke disks 6,23 are disposed to extend radially with respect to the magnet assemblies at the sides of the respective magnet assemblies opposed to the air gap 14, for conducting the magnetic fluxes. At least on the side toward the stator, the yoke disk 23 can rest directly on the magnets 21,22, because this magnet arrangement is stationary, and accordingly no special demands for retention need to be made of its supporting and insulating layer 20. However, it is also possible on the side toward the rotor to secure the magnets 7,8 to their yoke 6 by an adhesive bond. In that case it is not necessary for a portion of the supporting and insulating layer 19 also to extend between the magnets 7,8 and the yoke 6.
The yoke 6 for the guiding magnetic fields of the spinning rotor 1 is joined to the spinning cup 3 via the aforementioned magnet carrier 5 together with the drive magnets 4,4'. For soft-magnetic short circuiting of the drive magnets 4,4', the base 3' of the spinning cup 3 is used directly as a yoke for conducting the magnetic flux of the magnets 4,4' and therefore comprises a ferromagnetic material. The drive magnets 4,4' are glued to the rotor base 3'. The yoke 6 for the magnets 7,8 of the guiding magnetic field is spaced axially from the rotor base 3 acting as a yoke for the drive magnets 4,4' by means of a suitably wide air gap 9 to form a barrier layer which is adequate to decouple the driving and guiding magnetic fields from one another. The alternating component of the rotary driving magnetic field therefore has no significant influence on the guiding magnetic field. This decoupling of the magnetic fields not only markedly reduces the production of eddy currents in the region of the rotational axis 11 but also prevents the magnetic and the mechanical axes of rotation from "moving apart", which would lead to oscillation of the rotor 1.
The main component of the stator 2 is a stator winding 25 with an annular soft iron core 24. As already mentioned, the magnet arrangement on the stator side of the magnets 21,22 for the guide magnet fields is provided inside this ring formed by the soft iron core 24 and stator winding 25. Air nozzles 16 open axially through the holder 20 into the air gap 14 to inject air. thereinto. The air nozzles 16 are supplied with air through an annular conduit 17 which communicates with a source of compressed air, not shown, via a connecting line 18. As a result of the outflowing air, the air gap 14 is always maintained appropriately between the spinning rotor 1 and stator 2 counter to the magnetic force of attraction of the magnets 7,8,21,22 for averting direct contact between their opposed bearing faces. The air emerging from the air nozzles 16 flows from the axial gap 14 annularly into the radial gap 15 and outwardly therefrom radially through an air gap 10 between the rotor 1 and the stator 2, thereby achieving a uniform air cushion over the entire bearing face 5 of the rotor 1. The air pressure and air quantity should be adapted to the magnetic force so that, in the main bearing region, i.e., between the annular arrangement of the stator winding 25 and the opposite face 5 of the spinning rotor 3, the air gap 10 is maintained at a width in the range of a few hundredths of a millimeter. In this manner, the air consumption can be kept within feasible limits, and the magnetic interaction between the spinning rotor 1 and the stator 2 can be maximized, while achieving adequate security against direct contact of the bearing faces.
The air gap 14, which is somewhat wider than the air gap 10, prevents dimensional deviations in the magnet arrangements for the guide magnet fields, resulting for instance from heating due to eddy currents induced by way of harmonics, from having any negative consequences on the operation of the rotor 1. Above all, however, it can be assured that the vulnerable nozzle arrangement of the air nozzles 16 is protected in every case.
The radial air gap 15 is defined by two security faces 12,13 formed respectively as wearproof surfaces on the radially outward surface of the holder 19 and the radially inward surface of the stator 2, to be operative upon startup of the rotor 1 to serve the purpose of radially securing the position of the spinning rotor 1.
Although normally the guiding magnetic fields reliably assure centering of the spinning rotor 1, a sudden imbalance of the rotor or soiling in the region of the bearing face 5 can cause shifting of the axis of rotation under extreme conditions. In that case, the startup security faces 12,13 assure that the deflection of the rotor will be kept within narrow limits. The annular arrangement of the air nozzles 16 and the emergence of the air into the air gap 15 assure that, beyond the magnetic centering, centering of the spinning rotor takes place without contact of the startup security faces 12,13 with one another.
Compared with a known arrangement of annular startup security faces surrounding the outer periphery of the rotor, the advantage in the present invention is that the peripheral speed of the startup security face 13 on the rotor is markedly lower at the same rpm because of the substantially smaller radius, and accordingly the coefficients of friction are significantly lower than those in the known rotors.
The width of the air gap 14 should not be substantially greater than that of the air gap 10, because of the magnetically insulating properties of the air in the gap 14. However, opposed magnet poles can be expected normally to face one another and there should not be any preconditions for deflecting the magnetic flux by means of some other soft magnetic short circuit. Accordingly, the air gap 9 has a substantially greater magnetic insulative effect than the air gap 14, since the air gap 9 separates self-contained magnetic fields by means of magnetic short circuiting.
In the embodiment of the invention shown in FIG. 2, the base of the spinning cup 27 of the spinning rotor 26 does not serve as a yoke for the drive magnets 29,29', in contrast to the first embodiment. The spinning cup 27 can therefore be entirely made of a material that has no magnetic conductivity, such as aluminum.
The drive magnets 29, 29', guide magnets in the form of a central magnet 30 and a ring magnet 31, as well as a yoke 32 for the drive magnets 29, 29' and a yoke 33 for the guide magnets 30, 31, are all embedded in a layer of a supporting and insulating material 28. The insulating function of this supporting and insulating layer 28 is to decouple from one another the respective magnetic fields of the drive magnets 29,29' and the guiding magnets 30,31 that perform different tasks. The yoke 32 is annular in design, so that it is disposed in the same plane as the yoke 33 for the guide magnet fields, and there is merely a mutual radial spacing between the respective yokes 32,33 within which the supporting and insulating layer 28 is disposed. The spacings between the magnets and their respective yokes are very slight, so that the supporting and insulating layer 28 located between them does not significantly impair the magnetic flux in that region. Moreover, no other kind of soft magnetic short circuiting is present, and the magnetic flux takes the shortest course.
In a third embodiment shown in FIG. 3, another spinning rotor 34 is shown which is formed with a spinning cup 35 made of a magnetically nonconductive material. A separate yoke 36 for the driving magnetic field of the drive magnets 38,38' is secured to the underside of the rotor base, preferably by means of an adhesive bond.
By means of an insulating layer 39, the yoke 36 for the drive magnets 38,38' is separated both axially and radially from guide magnets, i.e., a central magnet 40 and a ring magnet 41, and their associated yoke 42. An annular magnetically insulating layer 43 is also provided between the two guide magnets 40 and 41. These components, i.e., the drive magnets 38,38', the guide magnets 40,41, the yoke 42 and the insulating layer 43, are positioned relative to one another and secured to the yoke 36 for the driving magnetic fields by means of a supporting layer 37.
In the last two exemplary embodiments, a continuously flat bearing face is provided which advantageously faces toward the stator which, in turn, likewise has an entirely flat bearing face. Depending on the number and disposition of magnets, one or more self-contained driving magnetic fields and one or more guiding magnetic fields are produced. As will thus be understood, it is possible within this scope of the invention to dispose a plurality of sectorlike pairs of driving magnets on the spinning rotor. It is also possible to expand the concentric arrangement of the guiding magnets.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | A shaftless spinning rotor for an open-end spinning machine is adapted to operate as a rotor driven by a stator in an axial field motor supported thereon by a combined magnetic and gas bearing producing separate magnetic fields for guiding orientation of the rotational axis of the rotor and for driving rotation thereof which achieves smooth substantially non-oscillating operation with minimal heating in the region of the axis of rotation by interposing a barrier layer with nonmagnetic properties between respective means for conducting the magnetic flux of the driving and guiding magnetic fields for decoupling the magnetic fields. In particular, separate yokes are utilized for conducting the fluxes of the driving and guiding magnetic fields and permanent magnets are primarily used to generate the magnetic fields. | 5 |
RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Application 60/444, 502, filed Feb. 3, 2003, entitled “Silicon Nitride/A110 Capping Bi-Layer in Copper-Polyimide Systems for 3 D Integration Applications”.
FIELD OF THE INVENTION
[0002] The present invention relates to the integration of circuit components into a 3 D structure using a wafer-level layer transfer process based on the incorporation of capping bi-layers for reliable connection of integrated circuits, components, and other semiconductor components.
BACKGROUND OF THE INVENTION AND DESCRIPTION OF THE PRIOR ART
[0003] In recent years, a variety of three-dimensional (3 D) integration and packaging techniques have been examined. The main considerations behind the use of 3 D integration are: 1) minimization of the wire length, 2) incorporation of new back-end-of-the-line (BEOL) processes that are currently limited by conventional planar technology, and 3) implementation of related design flexibility. Items 1-3 mentioned above would allow significantly reduced interconnect delay as well as a complex system integration to increase both performance and functionality.
[0004] Approaches to 3 D integration at either the chip or wafer level have been described in the prior art. For example, wafer level bonding can be achieved via an assembly approach. In such a method, layers are transferred one by one, on top of each other, and attached by a bonding process. The prior art layer transfer process is realized using carrier wafers, most often a glass substrate.
[0005] In such a scheme, the glass substrate is attached to the structure by an adhesive bonding process and released after the layer transfer is completed. One of the methods to release glass is based on laser ablation, which entails irradiating the glass/adhesive interface through the back surface of the glass substrate. In order to accomplish the ablation process, polyimide materials are typically used as a sacrificial adhesive layer in prior art 3 D integration schemes. The polyimide sacrificial adhesive layers are deposited on top of the layer that will be subsequently transferred. During ablation, the deposited energy is contained within a shallow (submicron) surface layer for an approximate 50 ns duration of the excimer laser pulse due to the polyimides strong absorption properties of ultraviolet laser radiation and poor thermal conductivity. When the absorbed energy density exceeds a certain threshold value, a surface layer having a thickness of less than 1 μm is photo-ablated and the laser separation of the glass carrier substrate is realized. The laser ablation process using polyimides has been reported and a comprehensive summary has been provided by Srinivasan, et al., “Ultraviolet Laser Ablation of Organic Polymers”, Chem. Rev. 990, 1303-1316 (1989).
[0006] The assembly approach in which laser ablation is used is only one of the examples in which the polyimide material is used in a 3 D integration scheme. In general, in 3 D structures, the polyimide layer is deposited on an already processed and tested device layer terminated with at least one Cu-based wiring layer. When a polyamic acid (PAA) solution, which is the precursor for the formation of polyimide films, is spin applied to the Cu surface and subsequently cured at a temperature between 350′-400° C., Cu reacts with the polyamic acid during the curing step to form salts which diffuse into the polyimide layer to form copper oxide precipitates. This is disclosed, for example, in Kim, et al., “Adhesion and Interface Investigation of Polyimides on Metals”, J. Adhesion Sci. Technol., Vol. 2, No. 2, pp. 95-105 (1988). As demonstrated by Kowalczyk, et al., “Polyimide in Copper: The Role of Solvent in the Formation of Copper Precipitates”, Appl. Phys. Lett., Vol. 52, No. 5, pp. 375-376, (1988), the polyimide precursor solvent, n-methyl pyrrolidone (NMP), provides mobility for the aggregation of Cu precipitates.
[0007] This situation is worsened when photosensitive polyimides are used since reacted Cu leaves a residue upon development, which is very difficult to clean; see, in this regard, Perfecto, et al. “Evaluation of Cu Capping Alternatives for Polyimide-Cu MCM-D”, ECT. '01 (2001). In the case of a preimidized polyimide, Cu diffusion has been observed and documented in U.S. Pat. No. 5,081,005. Over the years, the copper-polyimide interface has been well studied. Copper-polyimide technology has been successfully used in the form of multi-level thin film structures for over two decades now. It has been primarily developed for use in the cost/performance SCM's and high end MCM's applications; see, for example, Prasad, et al., “Multilevel Thin Film Applications and Processes for High and Systems”, IEEE Transactions and Components, Packaging, and Manufacturing Technology-Part B, Vol. 17, No. 1, pp. 38-49 (1994).
[0008] In these applications, to prevent copper diffusion into the polyimide, various metal capping layers have been used. Illustrative examples of prior art polyimide capping layers include, for example, Cr, Pt, Pd, Ti, Co (P), and chromate treatment; see, in this regard Matienzo, et al., “Adhesion of Metal to Polyimides, in Polyimides: fundamentals and applications”, K. K. Ghosh and K. L. Mittal Eds., Marcel Dekker, NY, N. Y. (1996); Shih, et al., “Cu passivation: a method of inhibiting copper-polyamic acid interactions”, Appl. Phys. Lett., Vol. 59, No. 12, pp. 1424-1426 (1991); Ohuchi, et al., “Summary Abstract: Ti as a diffusion barrier between Cu and polyimide”, J. Vac. Sci. Technol. A, Vol. 6, No. 3, pp. 1004-1006 (1988); O'Sullivan, et al., “Electrolessly deposited diffusion barriers for microelectronics”, IBM J. Res. Develop., Vol. 42, No. 5, pp. 607-619 (1998).
[0009] Also, baseline requirements for a capping layer in the Cu-polyimide system used for various packaging structures have been established. Namely, any Cu passivation metal should be chemically inert and insoluble in PAA; and the passivation metal should be a good diffusion barrier against Cu outdiffusion at temperatures less than 100° C. when the solvent NMP is present (above this temperature the Cu transports into the polyimide via solid-state-diffusion). Moreover, the passivation metal should not diffuse into Cu to cause resistivity increase.
[0010] In addition to copper diffusion barrier properties, metal caps were found to enhance adhesion between Cu and a polyimide. The shortcoming of this Cu/metal cap/polyimide is based on the processing limitation, for example, when the metal wiring is defined by the subtractive etching of a Cr/Cu/Cr sputtered film, Cr protection only occurs on the top of the wiring. Similar problems take place when a metal is deposited by a lift-off process. Hence, this solution has been limited to pattern electroplated films, where Co or chromate treatments have been shown to successfully encapsulate the Cu wiring.
[0011] However, in case of 3 D integration applications, the concern about metal capping layers is based on compatibility of these materials with various heterogeneous structures involved in future 3 D integration schemes. The capping could be introduced as a continuous layer across the whole wafer. In this case, after the layer transfer and ablation of the glass substrate is completed, this layer would be exposed to the removal of the polyimide (the removal step is not present in the aforementioned packaging applications). Wet and dry methods have been used to remove polyimides, but oxygen-plasma based removal has been proven most effective, and it is also is a well understood process.
[0012] Therefore, in case of 3 D structures, requirement of good Cu-diffusion barrier (specially against activated oxygen in a plasma etching environment) is additionally mandated of the capping layer. Since titanium is prone to oxidation in an oxygen-plasma, it cannot be considered as a candidate for a capping layer. Even if other capping metal candidates are stable in the oxygen-plasma environment, once the polyimide stripping process has been completed, the additional step of removing the sacrificial capping layer would have to be implemented in order to provide electrical separation between Cu wires. This removal process needs to be CMOS compatible, and preserve the structural, mechanical and electrical stability of the underlying patterned structures. Selective etching of such capping metals without degrading (etching or damaging) the underlying copper wires makes the choice of such a metal cap layer even more difficult. Taking all these restrictions into consideration, the metal capping-sacrificial coating of a full wafer is not likely to be feasible from the manufacturing point of view.
[0013] The metal capping in the form of a selective cap, such as electroless Co on the top of Cu structures, could be implemented in a 3 D integration scheme. However, application of such a cap will be limited, as 3 D structures may implement various heterogeneous materials and their compatibility with Co, or other relevant selective metal caps would have to be established.
[0014] The organic copper-capping technology for the Cu-polyimide system was also developed for thin film packaging. It has been shown that a thin organic coating, such as poly(arylene ether benzimidazole) (PAEBI), silane-modified polyvinylimidazole, or polybenzimidazole, can be applied directly to a wiring layer for enhancing adhesion to both the copper wiring and the polymer dielectric surface. These materials provide 100% protection for copper wiring, eliminating the need for metal capping, but at the expense of adding a thermal treatment step prior to the coating of the polyimide. This is described, for example, in Lee, et al., “Adhesion of poly (arylene ether benzimidazole) to copper and polyimides”, J. Adhesion Sci. Technol., Vol. 10, No. 9, pp. 807-821 (1996); and Ishida, et al., “Modified Imidazoles: degradation inhibitors and adhesion promoters for polyimide films on copper substrates”, J. Adhesion, Vol. 36, pp. 177-191 (1991). Such predominantly organic caps will be attacked by oxygen plasma exposure and will not protect the copper wires during the post ablation cleaning step of plasma ashing.
[0015] Organic caps that do not require additional thermal treatments have been evaluated by Perfecto, et al., “Evaluation of Cu capping alternatives for cu-Cu MCM-D, ECTC'01 (2001).
[0016] Two approaches were investigated in the Perfecto, et al. paper: 1) re-formulation of the PAA with an additive which will reduce the Cu diffusion and/or prevent Cu from complexing with the PAA, and 2) spun dry precoat of a Cu surface with an organic solution that reacts with Cu reducing the availability of Cu for diffusion. In the first method, 1% tetrazole in a polyimide solution, and 5% benzotriazole (BTA) in a polyimide solution were evaluated, while in the second method an amino silane, namely, 3-aminopropyl-trimethoxy silane diluted to 1% in deionized water, as well as BTA diluted to 1% NMP were studied. All systems showed degraded performance when compared to the simplest and most robust process of coating copper with 3-aminopropyl-trimethoxy silane. A layer of 3-aminopropyl-trimethoxy silane exhibited superior performance as an adhesion promoter in the Cu-polyimide system, and as a Cu-diffusion limiting layer, and its use as a capping layer in package-related applications has been described in U.S. Pat. Nos. 5,081,005 and 5, 194,928.
[0017] However, a coating of 3-aminopropyl-trimethoxy silane (usually a few monolayers) is not stable in the plasma-environment, and hence it cannot serve as an oxygen-diffusion barrier. Therefore, its use as a capping layer in the 3 D integration applications is limited to schemes when no oxygen-plasma processes are involved. However, other characteristics of 3-aminopropyl-trimethoxy silane, such as its ability to promote interfacial strength in both polyimide/silicon dioxide and silicon/silicon nitride laminates, make this system a great candidate in the scheme for capping layer discussed below.
[0018] In view of the above, there is a need for providing an improved capping layer which provides adhesion as well as protection to underlying layers such as metal-based semiconductor elements.
SUMMARY OF THE INVENTION
[0019] The present invention relates to the three-dimensional integration of semiconductor elements, such as devices and interconnections, using a novel layer transfer process. Moreover, the present invention overcomes the difficulties associated with the integration of various materials and devices through the use of a passivation capping coating to protect the underlying metal-based semiconductor elements. The inventive process provides a wafer-level layer transfer that is compatible with CMOS technology and enables integration of various active, passive and interconnecting circuit elements.
[0020] In particular, it is an object of this invention to provide a supporting structure for an integrated 3 D interconnect circuit for high frequency and high speed computing applications.
[0021] It is a further object of the present invention to combine the know-how of layer transfer technology to form a complete high density interconnect structure with integrated functional components.
[0022] It is a still further object of this invention to enable a low cost of ownership process based on a bi-layer capping coating using an adhesive component and a diffusion barrier component.
[0023] Specifically, and in broad terms, the present invention provides a structure for interconnecting semiconductor components comprising:
[0024] a layered substrate including, for example, semiconductor components, for transferring;
[0025] a bi-layer capping coating on top of the substrate, each layer of said coating provides adhesion and protection; and
[0026] a carrier assembly.
[0027] The inventive structure can be used for interconnecting various semiconductor components including, for example, semiconductor devices, semiconductor circuits, thin film layers, passive and/or active elements, interconnect elements, memory elements, micro-electro-mechanical elements, optical elements, optoelectronic elements, and photonic elements.
[0028] In addition to the above-mentioned structure, the present invention also provides a method for fabricating the same. Specifically, and in broad terms, the method of the present invention comprises the steps of:
[0029] providing a layered substrate for transferring;
[0030] forming a bi-layer capping coating on the substrate, each layer of coating providing protection and adhesion; and
[0031] forming a carrier assembly on the bi-layer capping coating.
[0032] The bilayer capping coating of the present invention is formed by depositing at least two consecutive layers, hence creating a bi-layer protecting the substrate to be transferred from negative effects of attachment and the later removal of the carrier assembly.
[0033] The present invention also provides a method for wafer-level transfer that comprises the steps of:
[0034] providing a layer to be transferred on a semiconductor substrate;
[0035] forming a first layer of a capping coating on the layer to be transferred, said first layer provides adhesion and protection from oxidation;
[0036] forming a second layer of a capping coating on said first layer, said second layer provides additional protection and adhesion to a carrier assembly;
[0037] adhering the carrier assembly to a carrier wafer by means of an adhesive; and
[0038] removing the semiconductor substrate whereby said layer to be transferred is attached to the carrier assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] [0039]FIG. 1 is a schematic representation of a prior art structure including a single-layer capping coating.
[0040] [0040]FIG. 2 is a schematic representation of a structure of the present invention including a bi-layer capping coating.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] The present invention relates to a method for manufacturing 3 D integrated structures based on an assembly approach in which a layer-to-be transferred is coated with a bi-layer capping stack, a polyimide layer, and an adhesive layer. That structure is then bonded to a glass carrier-wafer and upon removal of the bulk silicon, it is transferred to a new circuit, and attached to this new circuit using bonding techniques such as, for example, adhesive bonding. In the subsequent step, the glass layer is released (for example, by laser ablation), and the residual polyimide layer is removed by plasma ashing using oxygen.
[0042] The aforementioned protecting capping stack is comprised of two layers including a first layer of silicon nitride and a second layer of an amino silane deposited over the whole area of the wafer. Such a bi-layer cap provides not only protection from both Cu and oxygen diffusion, but it presents a SiCMOS-compatible and reliable solution for use in the 3 D applications where Cu-polyimide layers are present. The thickness of the first and second layers of the inventive bi-layer capping coating may vary depending on the conditions used for depositing each of the layers. Typically, the SiN layer has a thickness of from about 100 to about 1000 nm, while the amino silane has a thickness of a few monolayers. Other thickness besides the ranges mentioned herein are also contemplated herein
[0043] The term “amino silane” is used in the present invention to denote a compound that has the formula:
[0044] wherein R 1 , R 2 , R 3 , R 5 , and R 6 , independently of each other, can be hydrogen or an organic radical such as, for example, a lower alkyl radical containing from 1 to about 6 carbon atoms, an acyl radical containing 1 to 6 carbon atoms, or an allyl, alkenyl or alkynyl radical containing 2 to 6 carbon atoms and R 4 can be an organic radical such as, for example, a lower alkyl containing from 1 to about 6 carbon atoms or an aromatic system such as, for example, phenyl or benzyl derivative. Illustrative examples of amino silanes that can be employed in the present invention as the second layer of the bi-layer capping coating include, but are not limited to: 3-aminopropyl-trimethoxy silane, vinyl aminomethyl triacetoxysilane, and the like. Of the aforementioned amino silanes, it is highly preferred to use 3-aminopropyl-trimethoxy silane as the second layer of the bi-layer capping coating of the present invention.
[0045] As stated above, the first layer of inventive bi-layer capping coating is a silicon nitride layer. The process of depositing silicon nitride is well known. Illustrative methods that can be used in the present invention to deposit the silicon nitride layer of the bi-layer capping coating include, for example, spin-coating, chemical vapor deposition (CVD), plasma enhanced chemical vapor deposition (PECVD), chemical solution deposition, atomic layer deposition, evaporation, physical vapor deposition (PVP), and other like deposition processes.
[0046] The silicon nitride layer of the bi-layer capping coating of the present invention exhibits good adhesion properties to materials used in the back-end-of the-line (BEOL) processing, namely conductive materials such as Cu, and dielectric films including, for example, silicon dioxide, oxide films containing phosphorus or boron, such as phosphorus doped silicate glass (PSG), boron doped silicate glass (BSG), and boron-phosphorus doped silicate glass (BPSG), a silicon oxynitride, nitrides, and other low-k organic and non-organic films. Also silicon nitride allows for good chemical mechanical polishing (CMP) process selectivity to the aforementioned materials. Therefore, in Cu-dual damascene structures, it is used as a CMP hard mask.
[0047] The above characteristics of silicon nitride allow this insulating material to be utilized as a capping layer in applications in which metal capping layers failed. Namely, silicon nitride can be deposited over the surface of the to-be-transferred layer (with Cu patterned structure) followed by the amino silane deposition (formation of the bi-layer cap). Subsequently, the layer transfer steps are implemented (deposition of polyimide adhesives, attachment of glass, removal of the bulk silicon, bonding to a new substrate, release of glass carrier, strip of polyimide).
[0048] In embodiments wherein the silicon nitride is deposited over an interconnect structure containing Cu metallurgy, the silicon nitride serves as a Cu protection layer, preventing Cu oxidation. Depending on the processing scheme, the silicon nitride layer can be easily removed by well-known wet or dry etching processes, or simply (and preferably) by a CMP process. In such a scheme, silicon nitride would serve as a sacrificial layer. For other 3 D applications, the silicon nitride layer can be left on as a constituent of the structure, and it can be, for example, used as a passivation layer or as an etch stop layer to add additional wiring layers.
[0049] In this invention, the bi-layer capping layer is proposed for CMOS-compatible processes related to 3 D integration applications, hence it is expected that the thermal budget will not exceed 400° C. The thermal stability of silicon nitride has been well documented for such applications. On the other hand, thermal stability of the amino silane/polyimide system depends on the processing ambient. The degradation under nitrogen is minimal at 400° C. (16 hours), but air enriched nitrogen probably causes oxidation and decomposition of unreacted surface amino silane.
[0050] However, the application of present invention is related to polyimide materials which have to be cured in an oxygen-free ambient. Hence, without any added restrictions the stability of the amino silane-polyimide interface is insured. All of the above information leads to the conclusion that silicon nitride/amino silane system is an excellent capping bi-layer for 3 D integration applications when Cu-polyimide interfaces are involved.
[0051] The prior art structure of the assembly approach technique used in 3 D integration applications is shown in FIG. 1. The structure consists of: a layered structure-to-be transferred 100 , which includes bulk silicon 101 and device layer 102 terminated by the Cu patterned wiring level 103 ; capping layer 200 ; sacrificial polyimide layer 300 ; adhesion layer 400 ; and glass carrier 500 . In such a structure, only an amino silane, such as 3-aminopropyl-trimethoxy silane, is used as the capping layer 200 .
[0052] Amino silanes serve as adhesion promoters for patterned Si BEOL structures enabling increased strength in the Cu-polyimide and dielectric-polyimide interfaces. In addition, amino silanes serve as Cu diffusion barriers, limiting the creation of Cu-containing precipitates in the polyimide. However, upon plasma exposure the amino silane reduces simply to a layer of silicon oxide and electrical evaluation of the layer transfer process using this scheme showed increased Cu wire resistivity. Hence, it has been concluded that Cu surface degraded during the oxygen-plasma removal of the polyimide, caused by oxidation was not prevented by the silicon oxide layer resulting from the oxidized amino silane.
[0053] The present invention is based on a bi-layer approach, i.e., the previous single capping layer 200 in this scheme is substituted by a capping layer 200 ′ which is comprised of two films: silicon nitride 201 ′ underneath the amino silane layer 202 ′. The schematic diagram of the inventive structure is shown, for example, in FIG. 2. The combined properties of the silicon nitride 201 ′ (oxygen diffusion barrier layer with good adhesion properties to BEOL materials), and amino silane layer 202 ′ (adhesion promoter to polyimide) provides superior capping layer characteristics.
[0054] In FIG. 2, reference numeral 100 denotes a layered substrate to be transferred. The layered substrate 100 includes a semiconductor substrate 100 , device layer 102 which can be terminated with a layer 103 that comprises at least one metallic element such as Ti, Ta, Zr, Hf, silicides, nitrides and conducting siliconnitrides of the aforementioned elemental metals; Cu, W, Al, composites of these metals with glass; and any combination thereof. Preferably, layer 103 comprises Cu. The metallic element of layer 103 may be patterned, i.e., a patterned wiring level, or a blanket layer. When a patterned metallic element is present, portions of layer 103 may be comprised of an insulating material including oxides, nitrides, oxynitrides, polymeric dielectrics and inorganic dielectrics. The insulating material may be porous or non-porous. The layered substrate 100 is fabricated using any well-known semiconductor processing technique.
[0055] The semiconductor substrate 101 may be a bulk semiconductor including, for example, Si, SiGe, SiC, SiGeC, GaAs, InP, InAs and other III-V compound semiconductors, II-V compound semiconductors, or layered semiconductors such as silicon-on-insulators (SOI), SiC-on-insulator (SiCOI) or silicon germanium-on-insulators (SGOI). When the layered semiconductors are employed, the top layer of those substrates represent the device layer 102 .
[0056] [0056]FIG. 2 also shows an example of a carrier assembly that can be employed in the present invention. The carrier assembly may include a carrier wafer 500 , adhesion layer 400 and intermediate layer 300 . The carrier assembly is fabricated using techniques that are well-known in the art. For example, the carrier assembly can be formed by applying an adhesive coating atop a carrier wafer using a conventional deposition process such as spin-on coating, PECVD, CVD or physical vapor deposition (PVP). The intermediate layer is then applied by using one of the above mentioned deposition processes. In a preferred embodiment, the carrier assembly comprises glass and an intermediate layer of a polyimide.
[0057] Carrier wafer 500 may be comprised of a semiconductor including any group III-V or II-V semiconductor, SOI, SGOI, alumina, ceramics and the like. Intermediate layer 300 of the carrier assembly is any polyimide material, which is typically used as an adhesive coating in such a structure. Examples of polyimide materials that can be employed in the present invention include polyamic acid (PAA)-based polyimides, polyimic ester-based polyimides and pre-imidized polyimides.
[0058] Adhesion layer 400 includes coupling agents such as amino silanes. Adhesion layer 400 serves to bond the carrier wafer 500 to the intermediate layer 300 .
[0059] The 3 D structures transferred using this bi-layer (silicon nitride/amino silane) approach preserved circuit performance, indicating that the inventive bi-layer capping coating reliably performs its function.
[0060] This invention is based on the use of the wafer-level layer transfer process which incorporates the inventive bi-layer capping coating described above. This type of passivation material is proposed since it is compatible with current CMOS technology. Specifically, the wafer-level layer transfer method of the present invention includes first providing a layer to be transferred on a semiconductor substrate using well known CMOS process steps. The first layer of the inventive capping coating, e.g., silicon nitride, which provides good adhesion and protection from oxidation for the layer to be transferred is then formed using a conventional deposition process such as spin on coating, PECVD, CVD or PVP. Next, the second layer of the inventive capping coating, i.e., the amino silane, which serves as an additional diffusion barrier and provides adhesion to the carrier assembly is applied to the first layer using spin on coating, PECVD, CVD or PVP. The carrier assembly comprising the intermediate layer attached to a carrier wafer by means of suitable adhesive is then adhered to the second layer. After this step, the semiconductor substrate is removed such that the layer to be transferred is attached to the carrier assembly thus achieving layer transfer. The removal may be achieved by laser ablation or etching.
[0061] The method of the present invention may further comprise the steps of joining an exposed surface of the transferred layer to a top surface of a receiver substrate, and removing the carrier assembly to achieve further transfer of the transferred layer from the carrier assembly to the receiver substrate.
[0062] In this embodiment, the semiconductor and receiver substrates contain semiconductor components and the carrier assembly is used to enable the layer transfer of the semiconductor components from semiconductor substrate onto semiconductor components from the receiver substrate.
[0063] The focus of this invention is on ability to integrate multifunctional 3 D structures with active and passive components by coating their interconnecting elements with passivation layer to protect them from degradation during the layer transfer process.
[0064] The concepts disclosed in the present invention can be used to add functionality to the 3 D ICs without deviating from the spirit of the invention. For example, the methods can be applied to future optoelectronic device structures. In such cases, firstly the type of the material to create the layers can be replaced by other materials such as II-VI and 111 -V materials, (example: gallium arsenide or indium phosphide) and organic materials, and should be selected according to the specific application however similar bi-layer passivation can be used to preserve electrical and mechanical stability of the semiconductor elements. Secondly the functional bi-layer can be an integral part of an optoelectronic structure, including future 3-dimensional circuit stacks, allowing for integration of complex multifunctional and mixed-technology systems or elements on a single wafer.
[0065] While the present invention has been particularly shown and described with respect to preferred embodiments, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrates, but fall within the scope of the appended claims. | A structure for a semiconductor component is provided having a bi-layer capping coating integrated and built on supporting layer to be transferred. The bi-layer capping protects the layer to be transferred from possible degradation resulting from the attachment and removal processes of the carrier assembly used for layer transfer. A wafer-level layer transfer process using this structure is enabled to create three-dimensional integrated circuits. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a conversion of U.S. Provisional Application Ser. No. 62/255,557, filed Nov. 16, 2015, of which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to mechanisms for opening a hopper door on a trailer, and more particularly, to automated mechanisms for opening the hopper door for a particulate material trailer.
BACKGROUND OF THE INVENTION
[0003] A hopper trailer is a trailer that includes one or more hoppers defined within the trailer body. Each of the hoppers includes a discharge opening through which grain, or other loose granular material may flow in order to empty the trailer. The discharge opening at the lower end of the hopper is typically provided with a door that can be selectively opened and closed by a user to permit flow through the discharge opening or to prevent flow through the discharge opening. In a conventional design, the door slides in a generally horizontal plane to open and close the discharge opening.
[0004] One disadvantage of the conventional sliding door design is that it is difficult to move the door when the trailer is fully loaded with grain or other bulk materials. According to a conventional design a hand crank is provided to allow a user to move the sliding door back and forth between the open and closed positions. However, it can be difficult and inconvenient to manually provide the necessary force to move the sliding door.
[0005] Automated designs powered by hydraulics have been proposed. However, these hydraulic designs have some disadvantages. They require significant hardware and expertise to connect to a hydraulic system. They can be noisy during operation, and require pressure to be maintained in the hydraulic lines even when not in operation. There is a need for an improved automated design that does not utilize hydraulics.
[0006] Accordingly, a primary objective of the present invention is the provision of an improved door opening and closing apparatus for a particulate material trailer hopper door.
[0007] Another objective of the present invention is the provision of a motorized linear actuator connected to a door of a particulate material container to control opening and closing of the door.
[0008] A further objective of the present invention is the provision of a method of moving a granular material hopper door between open and closed positions.
[0009] Yet another objective of the present invention is the provision of a method and means for remotely operating a door of a grain trailer discharge chute.
[0010] Still another objective of the present invention is the provision of an apparatus for quickly, easily and safely opening and closing a discharge door of a particulate material container.
[0011] These and other objectives will become apparent from the following description of the invention.
SUMMARY OF THE INVENTION
[0012] According to one embodiment, the present invention relates to a hopper door opening and closing apparatus for opening and closing a door located at a lower opening of a granular or particulate material hopper. A pair of support rails are mounted to opposite sides of the hopper. A pair of linear actuators each having an electric motor electrically connected to a power source and each having an extendable and retractable actuator rod are mounted to the support rails. A bracket is operably attached to the door and has a central portion with end portions extending from the central portion. The end portions include vertically extending portions that extend from the central portion to a height above a top edge of the rails The end portions also include lateral portions that extent outward beyond outer faces of the rails, and tabs that the attach the lateral portions to the rods, such that the bracket connects the rods to the door. A controller selectively activates the linear actuators to extend the rods and thereby move the door to an open position that permits material to flow through the lower opening, and selectively activates the linear actuators to retract the rods and thereby move the door to a closed position covering the lower opening. The apparatus may include a remote control, wherein the linear actuators are controllable with the remote control. Motor guards may be mounted to the support rails to protect the motors.
[0013] The invention also encompasses a method of operating the door of a discharge chute on a particulate material hopper. The method involves actuating a motor to extend and retract a linear actuator connected to the door so as to move the door between open and closed positions. The method may be conducted remotely using a remote control device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is side elevation view of a truck trailer with an open top, and having a cover tarp and two discharge chutes and openings, and with the door opener of the present invention.
[0015] FIG. 2 is a close up view of a hopper door opening and closing apparatus according to one embodiment of the present invention, with the actuator extended to open the hopper door.
[0016] FIG. 3 is another close up view of the hopper door opening and closing apparatus of the present invention, with the door in an open position.
[0017] FIG. 4 is an enlarged view of the bracket of the apparatus.
[0018] FIG. 5 is another enlarged view of the electric motor of the door opener and closer apparatus.
[0019] FIG. 6 is a perspective view of the hopper door opening and closing apparatus, with the actuator in a retracted position to close the door.
[0020] FIG. 7 is a perspective view of an alternative embodiment of a hopper door opening and closing apparatus that includes a motor guard.
[0021] FIG. 8 is a left side perspective view of the hopper door opening and closing apparatus of FIG. 7 .
[0022] FIG. 9 is another perspective view of the hopper door opening and closing apparatus of FIG. 7 .
[0023] FIG. 10 is a right side perspective view of the door opening and closing apparatus shown in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] FIG. 1 shows a hopper trailer 10 including a storage compartment 12 that is suited for containing grain, coal, fertilizer, gravel, sand, or other loose, solid, flowable particulate or granular material. The lower portion of the storage compartment 12 is provided with hopper chutes 14 . The hopper chutes 14 act as funnels to guide the flow of granular material (not shown) within the storage compartment 12 through discharge openings (not shown) at the lower ends of the hopper chutes 14 . The hopper trailer 10 of FIG. 1 includes a kingpin structure 18 that is adapted to be connected to the fifth wheel of a truck (not shown) or other towing vehicle. Collapsible and foldable jacks 20 are provided to support the hopper trailer 10 when it is not connected to a towing vehicle.
[0025] The present invention is directed toward a hopper door opening and closing apparatus 16 provided on each of the hopper chutes 14 . The hopper door opening and closing apparatus 16 provides a mechanism for controlling the flow of the granular material through the discharge openings.
[0026] Additional details of the hopper door opening and closing apparatus 16 can be seen in FIGS. 2-6 . A pair of support rails 22 are mounted at a lower portion of each chute 14 on opposite lateral sides of the chute 14 . One of the rails 22 is mounted on the driver side of the chute 14 and the other is mounted on the passenger side. The rails 22 are elongated metal beams that act as mounting and support structures for linear actuators 24 . The rails 22 may be attached to the chutes by bolts, rivets, or the like. In many instances the rails 22 will be existing structure used to support the sliding hopper door 34 .
[0027] Electric motors 26 are provided at one end of each of the linear actuators to selectively extend and retract corresponding output rods or arms 28 . The free ends of the two output rods 28 are attached to a bracket 30 that extends between and connects the free ends of the two output rods 28 . The bracket 30 includes a lower central portion 32 that attaches to the hopper door 34 and end portions 36 that connect the central portion 32 with the output rods 28 . The end portions 36 extend vertically upward from the lower central portion 32 , laterally outward beyond the width of the support rails 22 and, and vertically downward to connect with the free ends of the output rods 28 . The end portions 36 attach to the rods 28 preferably by an easily detachable connector, such as a bolt. In the embodiment shown, the lower central portion 32 along with the adjacent vertical and lateral portions are formed from a single piece of metal bent to the desired shape, and separate metal tabs 38 are welded to that piece of metal to act as the connection to the rods 28 (See FIG. 4 ).
[0028] The linear actuators 24 may be screw-type electric linear actuators. According to a preferred embodiment, the linear actuators 24 have in input voltage of 12V DC such that they can be powered by a standard vehicle battery when the trailer 10 is attached to a towing vehicle. A wire harness 40 may be attached to each linear actuator 24 to connect with the electrical system of the towing vehicle, or other electrical power source. According to a preferred embodiment, the linear actuators 24 may include a 12 A motor and have a sixty (60) inch stroke. A linear actuator sold under the brand/model Progressive Automations PA-04 has been found to be suitable. The linear actuators 24 are preferably controllable with a remote control, such as an RF or Bluetooth controller. The linear actuators 24 may be provided with a smart controller that permits actuation through a mobile device application. The linear actuators 24 may include limit switches to stop the rods 28 in the fully open and fully closed positions. Alternatively, a user may stop the linear actuators 24 with the door in any desired position from fully opened to fully closed, or anywhere in between, using the remote controller, or other activator. Additionally, the controller may be programmable to stop the door 34 at pre-programmed or learned intermediate positions. As a still further option, the controller may be programmed to open the door 34 to a desired position and automatically move it back to a closed position after a set period of time to facilitate unloading a desired amount of material through the hopper.
[0029] The opening and closing apparatus 16 will operate without the need to disconnect the existing rack and pinion manual opening and closing systems 42 (see FIG. 9 ) on most trailers. However, in case the opening and closing apparatus 16 is not functioning, or there is no available electrical source, the rods 28 may be quickly and easily detached from the bracket 30 , so that the actuator 24 does not preclude or prevent manual movement of the door 34 .
[0030] FIGS. 7-10 show an alternative embodiment of the opening and closing apparatus 16 that also includes a motor guard 44 . The motor guard 44 may be formed of any appropriate material, such as from metal plates that are welded together, to form a shield that protects the motor 26 , especially during times when the trailer 10 is being transported. As best seen in FIG. 7 , the guard 44 may include a lower plate 46 that is bolted or otherwise secured to the rail 22 below the motor 26 , and a cover 48 that is welded to the plate 46 to protect the motor 26 , especially against contact that might occur during movement of the trailer 10 , and from weather and debris.
[0031] The opening and closing apparatus 16 improves upon existing hydraulic door options. The linear actuators 24 are smaller, simpler to install, and permits more accurate control of the door position. Unlike a hydraulic system, the linear actuators 24 do not require power input to hold their position. The actuators are also quieter and better for the environment.
[0032] The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives. | A hopper door opening and closing apparatus operates a door on a hopper discharge opening. A pair of motorized linear actuators, each having an extendable rod, are mounted to support rails on opposite sides of the door. A bracket connects the rods to the door. A controller selectively activates the linear actuators to extend the rods and thereby move the door to an open position that permits material to flow through the lower opening and selectively activates the linear actuators to retract rods and thereby move the door to a closed position covering the lower opening. | 4 |
FIELD OF THE INVENTION
The present invention relates to a new impregnating process and its use for the production of analytical test devices, such as, for example, diagnostic test strips. The invention preferably relates to a process for the production of test strips in which the reagent zone and the test strip holder form a plane, planar carrier film.
BACKGROUND OF THE INVENTION
The impregnation of absorbent materials, also called carrier matrices, is a common process which is frequently used, in particular, in the production of test strips. For example, test strips for diagnostic detection of glucose can be produced by impregnation absorbent paper first with the organic solution of a chromogen (for example 3,3',5,5'-tetramethylbenzidine in acetone) and then with an aqueous buffered enzyme solution (glucose oxidase or peroxidase) and drying the paper. The impregnated papers are then attached to carrier films, which function as the test strip holder.
The impregnating processes are usually carried out by an immersion method. Here, the absorbent substrate to be impregnated is conveyed at a constant rate through an immersion dish containing the impregnating solution to be impregnated and is then dried.
A serious disadvantage of this process is that during impregnation with multi-component impregnating solution systems, increasing concentration gradients develop in the impregnating solution or in the carrier matrix as the duration of the impregnation increases, since the various components are as a rule absorbed to different degrees by the matrix. The quality of the test strips and hence the accuracy of the analytical results obtained with the test strips is thereby impaired. Furthermore, precise metering of the amount of liquid to be impregnated is not possible with this process. The amount of liquid absorbed is rather determined by the absorbency of the carrier matrix.
Several successive impregnations of the same carrier matrix also present problems in the immersion impregnation process, since the components of the reagents impregnated beforehand can be extracted again by the subsequent impregnation, especially if the impregnations are carried out from the same solvent.
Another process for impregnation of absorbent substrates is the spraying process. Here, the impregnation liquid is sprayed from spray guns onto the continuously moving matrix material and the matrix material is then dried. Although the above- o mentioned disadvantages of the immersion process can be prevented here, this method is generally limited to liquids of low viscosity, which means that the field of application is restricted.
Impregnation of narrow, very sharply defined zones on a matrix also presents problems in the spraying process.
Test strips for the diagnostic field have been produced by a procedure in which the matrices, impregnated with the corresponding detection reagents, are cut into narrow strips and attached to polymer films or substrates, which function as the test strip holder. In addition to various adhesives used, which frequently have an adverse influence on the functioning of the detection reagents, the build-up of the test strips is also a disadvantage in carrying out the detection reaction. Thus, when blood is applied and is wiped off the reagent field after a defined residence time, complications arise on the one hand due to residues of blood and on the other hand the cottonball used to wipe off the blood remains stuck to the edges between the test strip holder and the reagent zone. In the case of urine test strips, which as a rule contain several different reagent zones (for example a glucose, pH, ketone, bilirubin, nitrite and hemoglobin zone) on one test strip holder, there are complications with the conventional systems in that residues of liquid remain between the attached reagent zones after immersion in the urine. In both cases, as well as aesthetic disadvantages, errors with respect to the accuracy of the test results frequently occur.
SUMMARY OF THE INVENTION
It has now been found, surprisingly, that impregnation of absorbent matrices can be carried out in a simple manner with the aid of extruder casting machines or cascade casting machines, with which the disadvantages and limitations described above do not occur. Test strips can be produced without separately attaching reagent zones. In particular, the present invention enables test strips to be produced in which the reagent zone forms a common surface with the remaining portion of the test strip.
Extruder casting machines are known systems for coating films. The extrusion coating process (DOS, German Published Specification, No. 2,521,608) is used, in particular, for producing photographic layers, aqueous gelatinous compositions within certain viscosity limits being applied to films of plastic or paper carriers. The viscosity of the coating mixture can thereby be varied within the limits of 5 to 1,000 mPas (millipascal).
It has now been found that extruder casting machines or cascade casting machines can also be used for impregnating absorbent carrier matrices, it also being possible for the viscosity of the impregnating liquid to have significantly lower values than in the case of the extrusion coating process. Thus, the viscosities of the impregnating solutions in the impregnating process according to, the invention can be in the range from 0.6 to 10 mPas. Viscosity ranges from 0.9 to 4 mPas are preferred.
Cascade casting machines have several casting units which are supplied and adjustable independently of one another. They are chiefly used for the production of multi-layered films in one operation. In the context of the present invention, an advantage of the cascade casting machine is that higher rates of impregnation can be achieved.
Moreover, the casting units can also be charged with different impregnating solutions. This may be necessary if individual substances which are to be introduced into the matrix are poorly compatible with one another or tend to undergo undesirable reactions. Cascade casting machines, moreover, have the advantage that the impregnated matrix can also be provided with one or more further layers in one operation.
Protective layers, spreading layers or other reagent layers are possible. Thus, for example, it is possible for the impregnated matrix to be coated with a layer which has filtering properties, for example in order to remove the cellular constituents of a blood sample from the plasma. The additional reagent layers can contain enzymes, antibodies, effectors, substrates, stabilizers, wetting agents and the like, which are important for the detection reaction. With suitable design of the additional layers, it is also possible to remove interfering substances, such as, for example, ascorbic acid. Such layers are known from the prior art.
As stated, it is advantageous that the impregnation be carried out rapidly without the disadvantages present with the conventional impregnating technique, and also multi-layered test strips can be produced in one operation with the impregnation.
The impregnating liquid can be a solution, dispersion or emulsion. To produce test strips, the impregnating solution contains the reagents necessary for detection of the analysis substance. Reagents are understood as substances such as enzymes, coenzymes, an enzyme substrate, activators, inhibitors, effectors, antigens, antibodies, haptens, indicators and the like. However, nonreacting substances, such as wetting agents, stabilizers or buffer substances, can also be included with the reagents.
The relationship between the surface tensions of the impregnating liquid and the surface of the matrix to be impregnated is of importance for uniform impregnation, and as far as possible similar values are to be aimed for.
Exact dosages can be established with the aid of suitable pumps in the case of impregnation by the process according to the invention. By using extruder casting machines or cascade casting machines with narrow slits, narrow, sharply defined reaction zones can be produced. If impregnations are to be carried out at defined temperatures, this is also possible by keeping the cascade or extruder system under thermostatic control.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects, advantages and features of the invention will be apparent to those skilled in the art from the following detailed description thereof, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a partial diagrammatic top view of substrate onto which has been cast layers in accordance with the impregnating process of the present invention; and
FIG. 2 is a diagrammatic side view of a test strip prepared in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
To produce test strips according to the invention with reagent zones integrated into the surface it is particularly preferable to use extruder casting machines or cascade casting machines with narrow casting slits. Thus, for example, test strips with an integrated reagent zone 1 cm wide can be produced by impregnating a 2 cm wide longitudinal strip in the middle of the matrix, in the case of carrier matrices such as are described, for example, in DE-OS (German Published Specification) No. 3,407,359, with the reagents required for the detection reaction, and drying the system. If the impregnated matrix is now cut through the center of the impregnated zone in the longitudinal direction and then at right angles thereto at distances of 5 mm, finished test strips are obtained directly; the reagent zone thereof being 1 cm long, the entire test strip having a common surface and the disadvantages described above with conventional test systems no longer occur when the strips are wiped. In the case of impregnation with colorless reagent liquids, dye stuffs, such as, for example, tartrazine, can also be used in the impregnating solution, if appropriate, in order to render the reagent zone visible.
The invention furthermore relates to test strips which have been produced by the impregnating process described. The test strips according to the invention can contain one or more reagent zones. If a test strip contains several reagent zones, these are usually different, that is to say they contain different reagents for the detection of various substances.
In order to prevent the individual zones from influencing one another, regions between the reagent zones can be impregnated or coated with hydrophobic substances. Hydrophobic substances such as, for example, oils, waxes, silicones or polymers, are suitable for such treatment.
The absorbent materials which are known per se for test strip systems, such as paper or microporous polymer films, can be employed for impregnation by the impregnating process according to the invention. Examples of suitable microporous polymer matrices are polymer dispersions, water-in-oil dispersions (P No. 34 34 822.0) or coagulated carrier membranes (DE-OS, German Published Specification, No. 3,407,359). Carrier-supported microporous polymer films are preferred for the production of the test strips according to the invention in which the reagent zone and test strip holder form a plane. Microporous matrix systems adhering to polymer films and produced by the coagulation process, such as are described in DE-OS (German Published Specification) 3,407,359, are especially preferred.
Impregnation of these carrier-supported polymer matrices by the zone impregnating process described above and corresponding cutting then gives the finished test strips directly, in which the carrier-supported polymer matrix on the one hand functions as the test strip holder and on the other hand contains the impregnated reagent zone.
If touching of the microporous polymer matrix is to be prevented when test strips according to the invention are used, carrier-supported polymer matrices which contain an uncoated matrix-free zone can be employed for the impregnation. The build-up of such test strip systems is illustrated in more detail in FIG. 1, wherein a 16 cm wide microporous polymer membrane is cast onto a 20 cm wide polymer film by the process described in DE-OS (German Published Specification) No. 3,407,359, a 2 cm wide edge remaining uncoated on both sides as a "handle". A 2 cm wide reagent zone is impregnated in the longitudinal direction in the middle of the porous polymer matrix by the impregnating process according to the invention.
If the impregnated matrix is now cut through the middle of the impregnated zone in the longitudinal direction (along line 1) and the separated halves are then cut in the transverse direction at suitable intervals (along lines 2), the finished test strips, having a substrate 3, an elevated portion 4 and a reagent matrix portion 5 of substantially the same height as elevated portion 4, are obtained directly (see FIG. 2).
Although the substrate 3 and the surface of the polymer matrix containing the reagent zone do not lie in a common plane in the test strip build-up described last, and illustrated in FIG. 2, the scope of the present invention should not thereby be limited. It is important that the portion of the test strip which comes into contact with the sample liquid or is required for wiping off the excess sample without interference forms a plane, so that the disadvantages described above for conventional test strip systems do not arise. The portion of the nonreacting layer 4 lying alongside the reagent zone 5 should be at least 1 cm, preferably 2-5 cm, for this.
The nonreacting portion 4 of the matrix as a rule contains no detection reagents. However, it is also possible for one or more components of the reagent system of reagent zone 5 to be present in this portion of the test strip.
The liquids used for impregnation consist of the reagents required for the desired detection reaction, which are dissolved in a suitable solvent. Surfactants are as a rule also added in order to improve wettability.
An impregnating solution for glucose detection contains, for example, the components described in the first example.
An impregnation solution of sodium nitroprusside, magnesium sulphate and phosphate buffer is used for the detection of ketones. The detection of bilirubin can be carried out, for example, with the aid of an impregnating solution of a 2,5-dichlorophenyl-diazonium salt in 0.1N hydrochloric acid.
One carrier matrix can also be impregnated several times in succession by the impregnating process according to the invention. The components of the impregnations previously carried out are not thereby extracted.
It is also possible for the impregnating liquid to contain other auxiliaries, such as, for example, water-soluble polymers. Such additives are of interest, above all, if the reagents of the individual impregnations are to remain separated within the matrix, especially in the case of multiple impregnations. For example, the detection reaction actually desired can in this manner be carried out after another reaction, in which interfering components are to be eliminated.
The process according to the inventions is also outstandingly suitable for the production of test strips which contain several different reagent zones on one carrier. If extruder casting machines or cascade casting machines with narrow slits which lie parallel to one another and are fed with the different reagent liquids are used for the impregnation, such detection systems can be produced in a single operation. The nonreacting matrix regions lying between the reagent zones can likewise be treated., for example rendered hydrophobic with corresponding impregnating solutions.
The process for the production of the detection elements according to the invention is described in more detail in the following examples, without limiting the scope of the present invention.
EXAMPLE 1
A 20 cm wide microporous polyurethane matrix adhering to a polyethylene terephthalate film was produced by a coagulation process following the method described in DE-OS (German Published Specification) No. 3,407,359.
A polyurethane casting solution of the following composition was used: 13.73 g (grams) of polyurethane (Desmopan 150 S, Bayer AG), 66.37 g of dimethylformamide (DMF), 7.24 g of polyurethane dispersion (Desmoderm, 28% in DMF/water, Bayer AG), 0.07 g of sodium dioctylsulphosuccinate and 11.01 g of titanium dioxide.
This polymer matrix was impregnated with a reagent system for glucose detection.
For the impregnation, the polymer matrix was first conveyed past an extruder casting machine on a continuous belt unit and was then passed through a drying zone.
During the impregnation with the impregnating solution described below, the following apparatus parameters were maintained:
Conveying speed of the belt unit: 10 m/minute
Conditions in the drying zone: warm air, 50° C., 2.5 minutes
Metering of the impregnating solution to the extruder casting machine: 20 ml/minute
______________________________________Impregnating Solution:______________________________________4-Aminoantipyrine 1 mmol/lNa 3,5-dichloro-2- 10 mmol/lhydroxybenzene sulphonateSaponin 100 mg/lGlucose oxidase 40 KU/lPeroxidase 5 KU/l______________________________________
in phosphate buffer (secondary phosphate, primary phosphate) pH 5.5
An extruder casting machine with a slit width of 2 cm was used for the impregnation, a sharply defined 2 cm wide impregnation zone, applied accurately as a central strip in the carrier matrix, being obtained.
To produce the final test strips, the impregnated matrix was first cut through the middle of the impregnated zone in the longitudinal direction and then cut at right angles thereto at 5 mm parallel distances. The test strips according to the invention were thereby obtained directly, the test stripholder and the reagent zone 1 cm wide integrated through the impregnation forming a plane.
The sample liquids applied to the reagent field (blood with different glucose contents) could be wiped off particularly advantageously in comparison with conventional test strip systems. Graduated color intensities were observed, corresponding to the increasing glucose contents
EXAMPLE 2
A polyurethane matrix containing a 3,3',5,5'-tetramethylbenzidine was produced from a casting solution of the following compositions: 13.73 g of polyurethane (Desmopan 150 S, Bayer AG), 66.37 g of dimethylformamide (DMF), 7.24 g of polyurethane dispersion (Desmoderm, 28% in DMF/water, Bayer AG), 0.07 g of sodium dioctylsulphosuccinate, 0.79 g of 3,3',5,5'-tetramethylbenzidine and 11.01 g of titanium dioxide.
A 16 cm wide microporous polyurethane matrix was produced on a 20 cm wide polyethylene terephthalate film with the aid of this casting solution analogously to Example 1 (see FIG. 1).
The remaining detection reagents required for glucose detection were impregnated as a 2 cm wide central strip analogously to Example 1 with the aid of the following impregnating solution: 150 KU of glucose oxidase, 150 IU of peroxidase and 0.2 g of Triton X 100 in 100 ml of 0.1M citrate buffer.
The impregnated matrix was cut analogously to Example 1, the finished test strips being obtained directly with the build-up shown in FIG. 2.
EXAMPLE 3
Test strips for nitrite: the polyurethane matrix from Example 1 was used as the absorbent material.
______________________________________Impregnating Solution:______________________________________Sulphanilamide 2.0 gα-Naphthylamine 1.2 gTartaric acid 25.0 gTriton X-100 2.0 gMethanol to 1,000 ml______________________________________
Impregnation Conditions analogous to Example 1
EXAMPLE 4
Test strips for urobilinogen: the polyurethane matrix from Example 1 was used as the absorbent material.
______________________________________Impregnating Solution:______________________________________4-cyclohexylaminobenaldehyde 1.0 gOxalic acid 200.0 gTriton X-100 2.0 gMethanol to 1,000 ml______________________________________
If these test strips were immersed in urine containing urobilinogen, a completely uniform red discoloration of the test area develops, permitting reproducible semi-quantitative determination of the uorbilinogen
EXAMPLE 5
Test strips for the pH value: the polyurethane matrix form Example 1 was used as the absorbent material.
______________________________________Impregnating solution:______________________________________Methyl red 13 mgBromoethylmol blue 250 mgTriton X-100 200 mgMethanol to 1,000 ml______________________________________
Impregnation conditions: analogous to Example 1
Test Results with the Test Strips
______________________________________pH of the test solution color of the test strip______________________________________ 9.4 yellow11.0 blue/green12.0 blue______________________________________
Although the examples specifically utilize polyurethane matrix material adhering to polyethylene terephthalate film, it is to be understood that other absorbent materials, as mentioned in the specification, can be applied to suitable substrates in similar manner.
Obviously, many modifications and variations of the invention as hereinbefore set forth can be made without departing from the spirit and scope thereof and therefore only such limitations should be imposed are indicated by the appended claims. | Process for the production of a test devices using extruder casting machines or cascade casting machines is disclosed in which reagent zones are produced on a common surface with remaining portion of test device such that reagent zone is protected by being in the same plane as a portion of the test device. The process permits application of reagent material to matrix areas without interaction of the reagents or the loss of reagents due to extraction during the process of forming the test device. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a washing machine.
2. Brief Description of the Related Art
The applicant proposed a conventional washing machine in the Japanese laid open patent No. 11-137895. The disclosed conventional washing machine is illustrated in FIGS. 5 and 6.
In these figures, a reference numeral “ 31 ” is a washing/dehydrating tank with a bottom, which is fixed to a first hollow cylindrical revolving axis 32 mounted for rotation in a bearing such that the journal 32 communicates with the washing/dehydrating tank 31 . A reference character “t” is protrusions formed on the inner wall of the washing/dehydrating tank 31 . A pulsator 34 is fitted to a second revolving conduit journal 33 arranged so as to rotate within and extending through the first cylindrical journal 32 . An annular drainage pipe 35 is co-axially arranged with the tank at the upper periphery of the washing/dehydrating tank 31 . A reference character “ 35 a ” is an annular drainage opening connected to the annular drainage pipe 35 .
A reference numeral “ 36 ”, arranged on the inner wall of the washing/dehydrating tank 31 for being pushed toward the center of the washing/dehydrating tank 31 , is loosners for loosening the washing in the dehydrating tank. These loosners, in the form of bent rod paddles, are contacted to the above-mentioned inner wall by springs. A reference character “g” is rubber cushions for relieving colliding impacts of the loosners 36 to the inner wall.
The loosners 36 are pushed toward the center of the washing/dehydrating tank 31 against forces from the springs, in accordance with pushing movements of pushing rods 37 driven by a movement of a roller 38 . The roller is moved in accordance with a revolving movement of the washing/dehydrating tank 31 and it is arranged at a corner of the annular drainage pipe 35 . Consequently, the loosners 36 revolve around axes 36 a attached to the inner wall of the washing/dehydrating tank 31 .
The annular drainage pipe 35 has the annular drainage opening 35 a on its inner wall and a plurality of drainage openings 31 a are arranged on the washing/dehydrating tank 31 at positions facing to the annular drainage opening 35 a.
On the upper side of the second cylindrical revolving axis 33 an opening 33 a communicating with the washing/dehydrating tank 31 is formed and to the lower side of the second cylindrical revolving axis, a three-way branched pipe 39 is co-axially and rotatably connected.
The three-way branched pipe 39 is capable of forming an air discharge passage for leading dehumidified air from a dehumidifier 41 , forming a drainage passage for draining washing water from the washing/dehydrating tank 31 and forming a closed passage for stopping the washing water from flowing out of the washing/dehydrating tank 31 by diverting a diverting valve 40 .
In the above-mentioned conventional washing machine, the loosners 36 are positioned at standby positions from pushed positions and the three-way valve 40 of the three-way branched pipe 39 is diverted so as to form the closed passage before starting a washing operation. Then water is supplied to the washing/dehydrating tank 31 , a detergent is added, the washing is put into the tank and the pulsator 34 is revolved.
During a rinsing operation, the pulsator 34 is revolved as water is being supplied into the washing/dehydrating tank 31 . Water in the washing/dehydrating tank 31 is discharged via the drainage openings 31 a to the annular drainage pipe 35 , wherefrom water is discharged to the outside via a drainage pipe 50 .
During a dehydrating operation, the three-way valve 40 of the three-way branched pipe 39 is diverted so as to form the drainage passage, the pulsator 34 is stopped and the washing/dehydrating tank 31 is revolved at a higher rate. In this operation, water in the washing/dehydrating tank 31 and included in the washing is moved upward along a slanted inner wall of the washing/dehydrating tank 31 by a centrifugal force and is discharged into the annular drainage pipe 35 via the drainage openings 31 a and also is discharged from the drainage passage. Washing/rinsing water stayed in the second annular axis 33 and the three-way branched pipe 39 during the washing/rinsing operations is discharged from the drainage passage.
When the dehydrating operation is finished, the washing in the washing/dehydrating tank 31 is moved to and annularly pressed against the inner wall of the tank, and an air passage is already formed during the dehydrating operation at the center portion of the washing.
After finishing the dehydrating operation, the loosners 36 are pushed toward the center of the washing/dehydrating tank 31 so as to loosen the stuck washing to the inner wall. Thus, air passages are formed among the washing and between the washing and the washing/dehydrating tank 31 .
After the air discharge passage is secured by diverting the three-way valve 40 of the three-way branched pipe 39 , a humidifier 41 is put into operation. Air bearing humidity in the outer case and in the washing/dehydrating tank 31 is sucked and dehumidified by the dehumidifier 41 . The washing is dried by repeated cycles of the above-mentioned sucking and dehumidifying procedures. The drying operations and above-described loosening operations can be properly and repeatedly carried out.
However, there are still the following problems in the conventional washing machine.
The washing operation is carried out according to a sequence consisting of securing the closed passage by diverting the three-way valve 40 of the three-way branched pipe 39 , supplying water, adding the detergent and putting the washing into the washing/dehydrating tank 31 , consequently the washing is washed as earth/sand, waste thread, dust and the like are being stuck to the washing, when the washing bears the above-mentioned foreign substances.
Floating earth/sand, waste thread, dust and the like are removed to a certain extent when a large quantity of water is used, since overflowed water from the washing/dehydrating tank 31 is discharged to the annular drainage pipe 35 as water being supplied to the washing/dehydrating tank 31 and the pulsator 34 being revolved during the rinsing operation. However this rinsing operation is not enough to remove the above-mentioned foreign substances completely.
Consequently, the washing is dehumidified and dried without removing stuck earth/sand, waste thread, dust and the like to the washing completely. Remaining earth/sand, waste thread, dust and the like can be removed afterward, but a further troublesome work is required to remove them.
SUMMARY OF THE INVENTION
The present invention is carried out in view of the above-mentioned problems. The objective of the present invention is to provide a washing machine capable of removing stuck earth/sand, waste thread, dust and the like to the washing effectively by arranging the washing machine such that overflowed or rinsing water from a washing/dehydrating tank is led to a side pipe, where water is filtered and circulated to the washing/dehydrating tank by a pump arranged in middle of the side pipe when washing and rinsing operations are executed by revolving the washing/dehydrating tank.
The washing machine provided by the present invention comprises: a cylindrical washing/dehydrating tank with its diameter gradually increasing from its bottom to its upper portion, having a bottom fixed to a cylindrical revolving journal arranged as a communicating pipe being communicated to the tank; an annular drainage pipe co-axially arranged with the tank at an upper periphery of the washing/dehydrating tank; loosners for loosening the washing attached to the inner wall of the tank so as to be pushed toward the center of the washing/dehydrating tank; a pushing means for pushing lossners toward the center of the washing/dehydrating tank; a dehumidifier; an annular opening formed on the inner wall portion of the annular drainage pipe; a plurality of drainage openings formed on the washing/dehydrating tank so as to face against the annular opening; a three-way branched pipe capable of forming an air supply passage for leading dried air from the dehumidifier to the washing/dehydrating tank, a drainage passage for discharging washing water from the washing/dehydrating tank to the outside or a closed passage for stopping washing water flowing out of the washing/dehydrating tank by diverting a three-way valve, co-axially and revolvingly connected to the lower portion of the cylindrical revolving journal; a side pipe arranged between the annular drainage pipe and the three-way branched pipe for circulating overflowed washing water from the washing/dehydrating tank to the annular drainage pipe via the three-way branched pipe to washing/dehydrating tank or for discharging washing water to the outside by a pump; and a demountable filter arranged in the side pipe.
Sensors for detecting the quantity of the overflowed washing water from the washing/dehydrating tank to the annular drainage pipe can be arranged in the side pipe and/or the annular drainage pipe so as to control revolution rates of the washing/dehydrating tank and the pump.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a longitudinal sectional view of an embodiment of a washing machine.
FIG. 2 is a cross sectional view of the washing machine sectioned at portion of a drainage pipe of a washing/dehydrating tank of the washing machine in FIG. 1 .
FIG. 3 is a partial view for explaining a movement of a loosner shown in FIG. 1 .
FIG. 4 is an exploded perspective view of a filter apparatus shown in FIG. 1 .
FIG. 5 is a longitudinal sectional view of a conventional washing machine.
FIG. 6 is a partial view for illustrating a loosner shown in FIG. 5 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter the embodiment according to the present invention is explained.
FIG. 1 is the longitudinal sectional view of the embodiment of the washing machine. FIG. 2 is the cross sectional view of the washing machine in the embodiment. FIG. 3 is the partial view for explaining the movement of the loosner shown in FIG. 1 . FIG. 4 is the exploded perspective view of the filter apparatus shown in FIG. 1 .
In these figures, a reference numeral “ 1 ” is a washing/dehydrating tank with a bottom plate, having a diameter gradually increasing from its bottom to its upper portion. The washing/dehydrating tank 1 is fixed to a cylindrical revolving axis 2 , which functions as a pipe led to the tank 1 . The cylindrical axis 2 is attached to an outer case 4 via a bearing 3 . The diameter at the upper portion of the washing/dehydrating tank 1 is required to set 5 to 10% larger than that of the bottom portion. In this embodiment it is 8% larger than that of the bottom portion. The washing/dehydrating tank 1 is forward or reciprocatingly revolved by a motor. A reference numeral “ 5 ” is a pulley for revolving the washing/dehydrating tank 1 . The motor is set at a reciprocating mode during washing and rinsing operations. Operational modes of the washing machine is set by inputting keys (not shown).
A reference character “ 1 a ” is drainage openings formed with a predetermined pitch at the upper peripheral wall of the washing/dehydrating tank 1 and a reference character “ 1 b ” is a flange-shaped drainage plate formed at lower sides of the drainage openings 1 a.
A reference numeral “ 6 ” is a cover for covering an opening portion of the cylindrical revolving journal 2 positioned at the bottom portion of the washing/dehydrating tank 1 . A lot of small drainage orifices 6 a are formed on the cover 6 as shown in FIG. 2 .
A reference numeral “ 7 ” is an annular drainage pipe co-axially formed with the washing/dehydrating tank 1 around the upper periphery of the tank 1 and a reference character “ 7 a ” is an annular opening formed on the inner wall of the annular drainage pipe 7 . A bottom plane 7 b of the annular drainage pipe 7 forms an inclined plane inclined toward a side pipe 8 , which is explained below. The above-mentioned drainage plate 1 b is fitted in the annular opening 7 a. The washing/dehydrating tank 1 and the annular drainage pipe 7 are arranged so as to attain the above-described fitting-in relation.
A reference numeral “8” is the side pipe linking the annular drainage pipe 7 with a three-way branched pipe 18 , which will be explained below, for circulating washing water flowing from the washing/dehydrating tank 1 via drainage openings la and the annular opening 7 a into the annular drainage pipe 7 to the washing/dehydrating tank 1 .
A reference character “ 1 c ” is convex columns with a semicircular cross section arranged on the inner wall of the washing/dehydrating tank 1 . Six convex columns 1 c are circularly arranged with a 60 degree angled pitch.
Although it is not illustrated, a means for preventing the washing/dehydrating tank from vibrating is also arranged, when the washing is unevenly placed during the dehydrating operation.
A reference numeral “ 9 ” is loosners for loosening the washing after the dehydrating operation, which are attached to revolving axes 10 arranged on the inner wall of the washing/dehydrating tank in the vicinity of the openings via a bracket (not shown). The loosners 9 are formed so as to have a shape and a size such that the lossners 9 are arranged along the inner wall of the washing/dehydrating tank and do not interfere with the cover 6 . More specifically, as shown in FIG. 3, the loosner 9 is formed out of a U-shaped rod, which is bent so as to be formed in an L-shape in its side view. Respective loosners 9 are arranged closely to respective convex columns 1 c such that the loosner surrounds the convex column. Six loosners 9 are arranged circularly with a 60 degree angled pitch.
A reference numeral “ 11 ” is springs for pressing the loosners 9 against the inner wall of the washing/dehydrating tank 1 such that the loosners 9 are positioned at idle positions.
A reference numeral “ 12 ” is pushing rods protrudingly attached to the loosners 9 . Each pushing rod 12 runs through a hole 1 d (FIG. 2) arranged between two drainage openings 1 a and protrudes into the annular drainage pipe 7 . The pushing rods 12 are pushed toward the center of the washing/dehydrating tank 1 against the forces from the springs, when a roller 13 arranged at the corner portion of the pipe 7 is moved from an idle position to an operating position and is contacted with the pushing rods 12 . A reference character “G” is rubber cushions, mated in concave portions formed on the washing/dehydrating tank 1 , for relieving impacts when the loosners 9 return to idle positions by applied forces from springs 11 .
As shown in FIG. 2, a reference numeral 13 is the roller arranged at the corner portion of the annular drainage pipe 7 for pushing loosners 9 , when it strikes pushing rods. The roller 13 is attached to a geared motor 15 via an arm 14 such that the roller can be moved rotatingly on a horizontal plane, where a roller depicted by a chained line shows the idle position and a roller depicted by a solid line shows the operational position. A control means (not shown) controls positioning to both positions. A reference numeral “ 16 ” is a stopper for holding the arm 14 at the operational position.
Hereinafter relations between the roller 13 and loosners 9 and their functions are explained.
After the roller 13 is positioned at the operational position, the washing/dehydrating tank 1 is slowly revolved in an R direction illustrated in FIG. 2 so that the pushing rod 12 is contacted with and pushed by the roller 13 . Respective loosners 9 are successively pushed into the center of the washing/dehydrating tank 1 . The washing after dehydrating operation is loosened by the pushed loosners 9 .
A reference numeral “ 17 ” is a humidifier and a reference numeral “ 18 ” is the three-way branched pipe arranged between the cylindrical revolving axis 2 and the humidifier 17 . The three-way branched pipe 18 comprises a first branched pipe 18 a, a second branched pipe 18 b and a third branched pipe 18 c. The first branched pipe 18 a and the cylindrical revolving journal 2 are connected such that they can be relatively revolved each other. The second branched pipe 18 b is connected to a dried air outlet (not shown) of the humidifier 17 . The third branched pipe 18 c is opened to the outside.
A reference numeral “ 19 ” is a three-way valve. When the three-way valve 19 is diverted to a position illustrated in a solid line in FIG. 1, the first branched pipe 18 a forms a closed passage, which stops water flowing from the washing/dehydrating tank 1 and the side pipe 8 . When the three-way valve 19 is revolved by 120 degrees in a right direction in FIG. 1, the first branched pipe 18 a and the third branched pipe 18 c are connected so that a drainage passage is formed. The three-way valve 19 is controlled by a valve control means (not shown). A reference numeral “ 20 ” is a cover of the washing machine, which covers an upper opening of the outer case 4 .
The above-mentioned side pipe 8 is connected to the first branched pipe 18 a. A reference character “P” is a pump arranged in the middle of the side pipe 8 .
Overflowed water from the washing/dehydrating tank 1 to the annular drainage pipe 7 due to the centrifugal force caused by the reciprocating revolutions of the washing/dehydrating tank 1 , is accelerated by the pump P and circulated to the washing/dehydrating tank 1 via the cylindrical revolving journal 2 .
The quantity of overflowed water from the washing/dehydrating tank 1 by the centrifugal forces caused by the reciprocating revolutions of the tank 1 during the washing or rinsing operation is increased in accordance with an increased extent of a reciprocating revolution rate of the tank 1 . Consequently, a revolution rate of the pump should be regulated in accordance with the revolution rate of the washing/dehydrating tank 1 in order to circulate the overflowed water from the washing/dehydrating tank 1 to the tank 1 .
A pressure sensor S 1 in the annular drainage pipe 7 near the side pipe 8 and a pressure sensor S 2 in the side pipe 8 are arranged for regulating the overflowed water circulation. Both pressure sensors S 1 and S 2 detect the quantity of the overflowed washing or rinsing water from the washing/dehydrating tank 1 and transmit outputted signals to the first control means (not shown) for controlling the reciprocating revolution rate of the washing/dehydrating tank 1 and to the second control means (not shown) for controlling the revolution rate of the pump P.
The first and second control means, to which detected signals by sensors S 1 and S 2 are respectively inputted, respectively control the reciprocating revolution rate of the washing/dehydrating tank 1 and the revolution rate of the pump P.
The washing/dehydrating tank 1 is arranged so as to set the revolution rate at a desired rate.
A reference character “F” is a filter apparatus comprising a filter 21 , a holder 22 for holding the filter and a pin 23 for securing the filter 21 to the holder 22 as shown in FIG. 4 .
The holder 22 is formed as a cylindrical body having slits 22 a with a 90 degree angled pitch on its side, a flange 22 b formed on its upper portion and bottleneck portion 22 c formed on its lower portion. The filter 21 is formed in a shape like a long test tube and its upper portion is mated to the bottleneck portion 22 c of the holder 22 and secured by the pin 23 mated to the bottleneck portion so as not to be disconnected from the bottleneck 22 c.
The filter apparatus F is inserted into and fitted in holes formed on the outer case 4 and the annular drainage pipe 7 . In a fitted status, the filter 21 is inserted into the side pipe 8 , the flange 22 b of the holder 22 is secured to the outer case 4 and the lower portion of the holder is inserted into and held by the annular drainage pipe 7 . Washing water flowing into the annular drainage pipe 7 flows into the filter 21 via slits 22 a of the holder 22 .
In the washing machine of the present embodiment arranged as mentioned above, the roller 13 is positioned at the idle position and the closed passage is formed by diverting the three-way valve 19 before starting the washing operation. Then the washing is put into the washing/dehydrating tank 1 . The quantity of the washing is measured by a revolving inertia generated by a dummy revolution of the washing/dehydrating tank 1 before water is supplied. After required water and detergent is supplied to the tank the washing operation is started. A distance between a water level in the tank and drainage openings 1 a is varied in accordance with the quantity of the supplied water. Consequently, in order to carry on the washing operation, the reciprocating revolution rate of the washing/dehydrating tank is fixed at a rate where the flowing quantity of the water into the annular drainage pipe reaches to a proper value, as the revolution rate being gradually increased.
The washing revolved by a revolving water stream is pushingly washed by convex columns 1 c of the washing/dehydrating tank 1 . Since the loosners 9 are arranged near the respective convex columns 1 c as if they surround the respective convex columns 1 c, these convex columns 1 c prevent the washing from strong strikes against the loosners 9 , thus the loosners are prevented from bending. As a result, stresses caused by reciprocating revolutions against supporting portions of the revolving axes 10 of the loosners 9 can be reduced. The overflowed water from drainage openings 1 a of the washing/dehydrating tank 1 by the reciprocating revolutions of the tank 1 is led through the side pipe 8 and the first branched pipe 18 a of the three-way branched pipe 18 and returned to the washing/dehydrating tank 1 by the pump P. Thus the washing water in the washing/dehydrating tank 1 is circulated. Earth/sand, waste thread, dust and the like floating on or being included in the washing water, are removed by the filter 21 when the washing water is circulated.
Before the rinsing operation, the three-way valve 19 is diverted so as to form the drainage passage for discharging contaminated water during the washing operation from the washing/dehydrating tank 1 . After forming the closed passage by diverting the three-way valve 19 and supplying the rinsing water, the first rinsing operation is executed as the rinsing water is being circulated a predetermined times by reciprocatingly revolving the washing/dehydrating tank 1 . In this operation earth/sand, waste thread, dust and the like floating on or being included in the rinsing water are also removed by the filter 21 .
When the first rinsing operation is finished, the three-way valve 19 is diverted so as to form drainage passage and to discharge the rinsing water.
Succeeding rinsing operations are executed in the same way as the first rinsing operation. The dehydrating operation is executed when a predetermined times of rinsing operations are finished.
After finishing discharging the rinsing water, the dehydrating operation is executed by revolving the washing/dehydrating tank 1 at a high rate (for example 1,000 r.p.m.) as the drainage passage is being formed in the three-way branched pipe 18 .
Water included in the washing is moved upward along the inclined inner wall of the washing/dehydrating tank 1 by the centrifugal force and flows into the annular drainage pipe 7 via drainage openings 1 a and discharged to the outside via the side pipe 8 . During the dehydrating operation, the washing in the washing/dehydrating tank 1 is annularly stuck to the inner wall of tank 1 and the loosners 9 by the centrifugal force so that an air passage is formed at the center of the washing.
In the drying operation of the washing, the cover 20 of the washing machine is put over the upper opening of the outer case 4 , the roller 13 is forwarded to the operational position, the three-way valve 19 is diverted so as to form an air supplying passage, the washing/dehydrating tank 1 is occasionally revolved in R direction shown in FIG. 1 and the washing is loosened by the loosners 9 . The humidifier 17 is operated as the washing is being loosened.
Humid air in the outer case 4 and in the washing/dehydrating tank 1 is sucked and dehumidified by the dehumidifier 17 during the drying operation. Dehumidified dried air is led thorough the air supplying passage and the cylindrical revolving axis 2 to the washing/dehydrating tank 1 and then passed through the air passages formed in the washing and between the washing and the tank 1 . The dried air removes humidity in the washing and returns to the dehumidifier 17 after passing through the outer case 4 . The washing is dried, when the above-described cycle is repeated.
As explained above, according to the present invention, the washing machine is arranged such that the overflowed washing or rinsing water from the washing/dehydrating tank to the annular drainage pipe by the reciprocating revolutions of the tank, is led to the side pipe where the water is filtered and is circulated to the tank by the pump arranged in the middle of the side pipe so as to be utilized for washing or rinsing water again. As a result, earth/sand, waste threads, dust and the like stuck to or included in the washing are effectively removed during the washing and the rinsing operations. | The objective of the present invention is to provide a washing machine capable of removing earth/sand, waste thread, dust and the like stuck to the washing. In order to realize the objective, the washing machine is constituted so as to be operated as follows: overflowed washing water or rinsing water from washing/dehydrating tank to an annular drainage pipe by reciprocating revolutions of the tank is led to a side pipe, where the water is filtered and circulated to the tank by a pump arranged in the middle of the side pipe for utilizing the washing or the rinsing operation. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to a sliding-tongue compound needle for a knitting machine comprising a needle equipped with a hook and a sliding tongue at least partially straddling the needle and equipped with at least one butt, with an end and with a shoulder, the bottom of this sliding tongue being longitudinally slotted in its distal region comprising the end and the shoulder so as to allow the end to be parted, by the needle or by an opposed needle or an opposed sliding tongue, the sliding tongue being movable relative to the needle so as to close and open the hook of the needle and so as to drive a stitch along via its shoulder.
A needle such as this is described in Patent Application EP 0 881 315, filed by the Applicant, the content of which is incorporated by reference hereto. In the embodiment described in that document, the bottom of the sliding tongue and the upper edge of the needle are rectilinear and parallel to the direction of travel of the needle. Movement of the sliding tongue is therefore also rectilinear and parallel to the direction of travel of the needle. Because of this configuration, when the needle advances relative to the sliding tongue to come into the position for preparing to transfer a stitch, the stitch that is to be transferred has to ride up a ramp on the needle until it is practically level with the bottom of the sliding tongue. This has the effect of exerting upward tension on the stitch and has the result of enlarging the stitch. This effect is further reinforced when the sliding tongue advances, carrying the stitch over the hook of the needle, the end and the shoulder of the sliding tongue passing very much over the hook of the needle. The fineness of the stitches that can be knitted is therefore limited.
In a compound needle of the conventional earlier type, that is to say in which the needle, in the form of a slider, equipped with a needle hook, lies under a slideway that closes and opens the hook, it has been proposed, in Patent FR 2 652 593, the content of which is incorporated herein by reference, that means be provided for raising and lowering the slideway relative to the bottom of the slot of the needle so as to reduce friction and tension on the stitch carried by the needle and obtain more even stitches. These means consist, on the one hand, of a bearing effect in the bottom of the slot of the needle and, on the other hand, of a lever effect exerted by the needle push rod. The path of the end of the slideway is not, however, governed tightly enough and, what is more, because of the general design of the needle, the slideway cannot move beyond the hook of the needle but merely moves back and forth between a lowered position and a raised position relative to the bottom of the sliding tongue.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to allow the knitting of finer and more even stitches and, in addition, to make the transfer of stitches to one or more receiving elements easier.
To this end, the sliding-tongue compound needle according to the invention is one which has means for the positioning and vertical guidance of the sliding tongue in all positions of the sliding tongue as it moves relative to the needle, these means for the guidance and vertical positioning consisting exclusively and wholly of special shapes of the needle and of the sliding tongue and such that the sliding tongue moves along a nonrectilinear path controlled at all points and having rising and falling movements.
By guiding the sliding tongue in a perfectly controlled way, these guide means have the effect of reducing as far as possible the vertical tension on the stitch and therefore its enlargement. It is thus possible to knit finer and more even stitches.
According to a preferred embodiment of the invention, the bottom of the sliding tongue is open between the butt and approximately the middle of the sliding tongue, and the needle has an arm extending from the rear forward roughly parallel to the body of the needle, this arm passing through the sliding tongue via its open bottom to extend over the solid part of the sliding tongue so as to form, with the body of the needle, a fork in which the sliding tongue is guided.
To provide guidance, the internal dimensions of said fork and the bottom and back of the solid part of the sliding tongue are advantageously in the shape of cams providing the nonrectilinear movement of the sliding tongue, that is to say causing it to rise and fall relative to the needle.
According to one embodiment, the sliding tongue has, at the rear, at least one bearing point collaborating with the body of the needle to prevent inadvertent rocking of the sliding tongue and/or to induce a movement of the rear of the sliding tongue in a vertical plane relative to the needle. In this last instance, at least one of the sides of the needle body against which the bearing point rests, is in the form of a cam.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended drawing depicts, by way of example, one embodiment of the invention.
FIG. 1 is a side view of the sliding-tongue compound needle.
FIG. 2 depicts the needle and the sliding tongue separate from one another.
FIG. 3 is a view from above, enlarged, of the front part of the sliding tongue.
FIGS. 4 to 11 show eight successive positions of the sliding tongue relative to the needle from one extreme position to the other, particularly in the case of the transfer of a stitch.
DETAILED DESCRIPTION
The shape of the needle and of the sliding tongue will first of all be described in relation to FIGS. 1 to 3 .
The compound needle consists of a needle 1 and of a sliding tongue 2 straddling the needle 1 in a way similar to the sliding tongue of the sliding-tongue needle described in document EP-A-0 881 315. For that purpose, the sliding tongue 2 has a profile in the shape of an inverted U, but over just part of its length for reasons which will become apparent later.
The needle 1 is equipped, in the conventional way, with a hook 3 . In the embodiment depicted, the needle 1 is equipped with a butt 4 for driving it via the cams of a cam carriage. The needle could, however, be driven by a drive bolt. Approximately at its middle, the needle is equipped with an arm 5 extending forward, above the needle proper, parallel to the longitudinal axis of the needle, that is to say to the direction of travel of this needle in its needle bed. The needle 1 and the arm 5 form a fork 6 , the internal sides 7 and 8 of which have a nonrectilinear contour in the form of a cam. The side 7 in the form of a cam extends beyond the fork 6 where it has a depression 9 followed by a ramp 10 rising up forward. Forward of this ramp 10 , the needle tapers, in a known way, in a downward ramp 11 as far as the hook 3 .
The sliding tongue 2 has, at the front, an end 12 situated in front of a shoulder 13 and is equipped at the rear with a butt 14 for driving it. The bottom of the sliding tongue 2 is eliminated at two points, on the one hand in its distal part, forward of a point 15 situated slightly to the rear of the shoulder 13 and, on the other hand, in its rear half 16 , between the butt 14 and a point 17 situated approximately mid-way along the sliding tongue.
Viewed from above, the distal part of the sliding tongue is depicted in FIG. 3 . The interruption of the U-shaped profile of the sliding tongue forms a slot 18 which narrows at the end of the sliding tongue to form the end 12 , at the end of which the sides of the slot 18 meet. The two sides of the slot 18 may be parted from one another elastically.
The interruption 16 of the bottom of the sliding tongue forms a cut-out of a width corresponding to the thickness of the needle. This cut-out has, passing through it, the arm 5 of the needle which extends above the sliding tongue proper, that is to say above the region 29 of the sliding tongue in which the bottom of the sliding tongue is uninterrupted. This region 29 externally, at the front, has a ramp 19 ending in a nose 20 and, at the rear, a small boss 21 . Internally, the bottom of the sliding tongue has a first boss 22 in its front part and a second boss 23 at the rear. Between these bosses, the bottom of the sliding tongue has a slight depression.
At the rear, at the height of the butt 14 , the sliding tongue 2 has two bearing points 33 and 34 collaborating respectively with the upper side 35 and lower side 36 of the bottom of the needle to prevent inadvertent rocking of the sliding tongue. These bearing points may furthermore be used to induce an additional movement of the sliding tongue relative to the needle, for example to retract its butt 14 relative to a cam of the cam carriage or to obtain a finer and more precise movement of its end 12 . In this case, at least one of the sides 35 , 36 of the needle body is nonrectilinear, that is to say is in the form of a cam. The bearing point 33 is formed by a boss in the bottom of the sliding tongue and the bearing point 34 is formed, for example, by the upsetting of material of the walls of the sliding tongue.
As regards the interior profile of the fork 6 of the needle, this has, starting from the end of the arm 5 , a disengagement ramp 32 followed by a boss 24 followed by a slight depression and a second, not very pronounced, boss 25 and, on the needle proper, a tall part 26 of constant height between the depression 9 and a ramp 27 ending at a depression 28 .
As can be seen in FIG. 1, when the needle is assembled, the region 29 of the sliding tongue lies in the fork 6 of the needle, which provides nonrectilinear guidance of the sliding tongue 2 as it moves. In FIG. 1, the sliding tongue is depicted in its rearmost position on the needle. In this position, the boss 24 of the arm S of the needle rests against the nose 20 of the sliding tongue and this has the effect of positioning the end 12 of the sliding tongue in a lowered position of minimal height relative to the needle. In this position, the two sides of the end 12 are parted by the needle 1 and so the end 12 and the depression situated behind this end are at all points below the upper edge of the needle.
The complete movement of the sliding tongue on the needle will now be described in relation to FIGS. 4 to 11 which depict eight successive positions of the sliding tongue relative to the needle starting from the position depicted in FIG. 1 which is the same position as the one depicted in FIG. 4 .
The sequence depicted illustrates the transferring of a stitch. In the position depicted in FIG. 4, the sliding tongue 2 is positioned in the fork 6 by its nose 20 and its boss 22 . The end 12 of the sliding tongue, which is open, is situated below the upper edge of the needle 1 . The two sides of the end 12 rest on the sides of the needle on two millings 30 which reduce the thickness of the needle and therefore the opening of the end 12 so as not to exceed the width of the sliding tongue. The stitch 31 that is to be transferred is carried by the needle 1 so that it exerts no pressure on the sliding tongue 2 which is supported cantilever fashion, and avoids slowing of the sliding tongue. The end 12 is at that moment at a height H 1 relative to the lower edge of the needle, that is to say relative to the bottom of the slot of the needle bed in which the needle slides. This level H 1 is the minimum level of the end 12 in the path of the sliding tongue.
As the sliding tongue 2 advances, its boss 22 rises up the ramp 27 of the needle to arrive on the tall part 26 (FIG. 5 ). Toward the top, the sliding tongue is retained and guided by the boss 24 of the arm 5 of the needle. This rise of the sliding tongue is just enough for the depression at the rear of the end 12 of the sliding tongue to come slightly above the level of the needle. During this rise of the sliding tongue, the end 12 closes again and the stitch 31 is carried along by the shoulder 13 of the sliding tongue. The level H 2 reached by the end 12 of the sliding tongue is the highest level relative to the needle reached by the sliding tongue in its movement.
The sliding tongue 2 continues its advance, resting on the top part of constant level 26 of the needle, that is to say maintaining the level H 2 , as depicted in FIG. 6 .
The boss 22 of the sliding tongue then leaves the part 26 of the needle so that the end 12 of the sliding tongue drops towards the hook 3 of the needle, as depicted in FIG. 7 .
Continuing its fall, the sliding tongue 2 caps the hook 3 of the needle with its end 12 , as depicted in FIG. 8 . This movement corresponds to the closure movement of a conventional latch needle by its latch.
With the sliding tongue continuing to move, its boss 22 arrives against the ramp 10 of the needle so that the sliding tongue 2 and its end 12 begin a rising movement (FIG. 9) which continues until the end 12 reaches a level H 4 (FIG. 10 ). This rising movement has the purpose of preventing the hook 3 of the needle from catching on filaments of the stitch 31 present on the sliding tongue.
Once the hook 3 has passed, the boss 22 of the sliding tongue 2 falls back down along the ramp 11 of the needle and leaves it while the boss 23 takes over on the face 26 of the needle and the end 12 reaches a low level H 5 and maintains this level to the end of its travel. This fall has the effect of avoiding deformation of the stitch 31 in tension (FIG. 11 ).
In the position depicted in FIG. 11, the stitch 31 can be grasped by an opposed needle (transfer) or by a sliding tongue (stitch transfer between neighbouring needles) as described in Patent EP 0 881 315, that is to say by introducing this needle or this sliding tongue into the end 12 .
In alternative forms of embodiment, the sliding tongue could completely straddle the needle and could be equipped with two or more butts. The sliding tongue could, at the rear, have a single bearing point, for example the bearing point 34 (FIG. 2 ).
Multiple variations and modifications are possible in the embodiments of the invention described here. Although certain illustrative embodiments of the invention have been shown and described here, a wide range of modifications, changes, and substitutions is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the foregoing description be construed broadly and understood as being given by way of illustration and example only, the spirit and scope of the invention being limited only by the appended claims. | Sliding-tongue compound needle comprising a needle ( 1 ) equipped with a hook ( 3 ) and with a sliding tongue ( 2 ) straddling the needle and equipped with an end ( 12 ) and with a shoulder ( 13 ), the bottom of the sliding tongue being longitudinally slotted in its distal region comprising the end ( 12 ) and the shoulder ( 13 ) so as to allow the end to be parted, the sliding tongue being movable relative to the needle to close and open the hook of the needle and to carry a stitch by its shoulder. This needle has means ( 6 ) for the vertical guidance of the sliding tongue ( 2 ) as it moves relative to the needle ( 1 ) so that the sliding tongue moves in a non-rectilinear path. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 07/359,728, filed May 31, 1989, pending, which is hereby incorporated by reference. Application Ser. No. 07/359,728 is a continuation of parent application Ser. No. 06/921,311, filed October 21, 1986, now U.S. Pat. No. 4,865,706. A related application, is Ser. No. 07/143,442, filed Jan. 12, 1988, now U.S. Pat. No. 4,865,707 which is another continuation-in-part application based on the same parent application.
FIELD OF THE INVENTION
This invention relates to electrophoresis, and more particularly, to gel-containing microcapillary columns for high performance analytical electrophoresis.
BACKGROUND OF THE INVENTION
Electrophoresis is one of the most widely used separation techniques in the biologically-related sciences. Molecular species such as peptides, proteins, and oligonucleotides are separated by causing them to migrate in a buffer solution under the influence of an electric field. This buffer solution normally is used in conjunction with a low to moderate concentration of an appropriate gelling agent such as agarose or polyacrylamide to minimize the occurrence of convective mixing.
Two primary separating mechanisms exist, separations based on differences in the effective charge of the analytes, and separations based on molecular size. The first of these mechanisms is limited to low or moderate molecular weight materials in the case of separations of oligonucleotides because in the high molecular weight range the effective charges of these materials become rather similar, making it difficult or impossible to separate them. In the case of proteins, charge and size can be used independently to achieve separations. Separations based on molecular size are generally referred to as molecular sieving and are carried out employing as the separating medium gel matrices having controlled pore sizes. In such separating systems, if the effective charges of the analytes are the same, the separation results from differences in the abilities of the different sized molecular species to penetrate through the gel matrix. Smaller molecules move relatively more quickly than larger ones through a gel of a given pore size. Oligonucleotides and medium to high molecular weight polypeptides and proteins are commonly separated by molecular sieving electrophoresis. In the case of proteinaceous materials, however, it is first generally necessary to modify the materials to be separated so that they all have the same effective charges. This is commonly done by employing an SDS-PAGE derivatization procedure, such as is discussed in "Gel Electrophoresis of Proteins," B. D. Hames and D. Rickwood, Eds., published by IRL Press, Oxford and Washington, D.C., 1981. The contents of this book are hereby incorporated herein by reference.
Sometimes it is desirable to separate proteinaceous materials under conditions which pose a minimal risk of denaturation. In such cases system additives such as urea and SDS are avoided, and the resulting separations are based on differences in both the molecular sizes and charges.
Most electrophoretic separations are today conducted in slabs or open beds. However, such separations are hard to automate or quantitate. Extremely high resolution separations of materials having different effective charges have been achieved by open tubular free-zone electrophoresis and isotachophoresis in narrow capillary tubes. In addition, bulk flow can be driven by electroosmosis to yield very sharp peaks. Such high efficiency open tubular electrophoresis has not generally been applied to the separation of medium to high molecular weight oligonucleotides, however, since these materials have very similar effective charges, as indicated above. In addition, open tubular electrophoresis does not provide size selectivity for proteinaceous materials. The questions thus arise whether electrophoresis on gel-containing microcapillaries can be employed to achieve high resolution separations of oligonucleotides, and whether the conventional procedure of SDS-PAGE can be accomplished on such microcapillaries. As demonstrated by the present disclosure, the answers to these questions are affirmative, although given its potential importance as a separating technique in the biological sciences, surprisingly little attention has been paid to microcapillary gel electrophoresis.
Hjerten has published an article in the Journal of Chromatography. 270, 1-6 (1983), entitled "High Performance Electrophoresis: The Electrophoretic Counterpart of High Performance Liquid Chromatography," in which he employs a polyacrylamide gel in tubes having inside dimensions of 50-300 micrometers, and wall thicknesses of 100-200 micrometers. However, this work suffers from limited efficiency and relatively poor performance due in part to the use of relatively wide bore capillaries, relatively low applied fields, high electrical currents, and insufficient suppression of electroendosmosis. He has also obtained U.S. Pat. No. 3,728,145, in which he discloses a method for coating the inner wall of a large bore tube with a neutral hydrophilic substance such as methyl cellulose or polyacrylamide to reduce electroendosmosis in free-zone electrophoresis in open tubes. In a later patent, No. 4,680,201, Hjerten discloses a method for coating the inner wall of a narrow bore capillary with a monomolecular polymeric coating of polyacrylamide bonded to the capillary wall by means of a bifunctional reagent. These capillaries are also open tubes to be used for free-zone electrophoresis. In the background section of the '201 patent, it is stated that coating the inner wall of the electrophoresis tube with a polymeric substance to reduce adsorption and electroendosmosis suffers from the drawbacks that the coating material must be renewed periodically since it apparently flushes out of the capillary during use, and that relatively thick layers necessary for complete coating cause zone deformation in electrophoresis. This '201 patent thus teaches away from coating the wall of a capillary with a polymeric substance applied as an adsorbed layer, and discloses instead that for suppression of electroendosmosis a monomolecular layer of polyacrylamide should be covalently attached to the tube wall.
The small amount of work in the field of gel electrophoresis in capillaries by researchers other than the present applicants has generally resulted in columns which were not highly stable and could not be subjected to sufficiently high electric fields to achieve high efficiencies and high resolution separations. Improved gel filled capillary columns for electrophoresis which provide superior stability, efficiency, and resolution would be of great value in bioanalytical chemistry.
SUMMARY OF THE INVENTION
The above-identified need for stable and efficient gel-filled capillary electrophoresis columns is answered by the present invention, which provides an improved gel-containing microcapillary for high performance electrophoresis. It includes a microcapillary, a thin layer of coating material covalently bonded to the inner surface of the microcapillary wall, a thin layer of hydrophilic polymer adsorbed on the layer of coating material, and a polymeric gel filling the interior cavity of the microcapillary.
The layer of coating material between the microcapillary wall and the layer of hydrophilic polymer is generally a hydrophobic material and originates as a reagent possessing a reactive functional group capable of reacting with reactive functionalities on the interior surface of the capillary wall, silanol groups, for example. The remainder of the reagent may include a second reactive group which is capable in principle of reacting with vinyl monomers and optional crosslinking agents which when polymerized constitute the polymeric gel.
The layer of hydrophilic polymer effectively reduces electroendosmosis, stabilizes the column, and unexpectedly enables operation of the microcapillary column in high electric fields (or more exactly, high power), resulting in high resolution separations.
The improved gel-containing microcapillary of the invention is prepared as follows: first, the interior surface of a microcapillary is contacted with one or both of a basic and an acidic material to activate it, then it is treated with a solution of an appropriate coating reagent capable of covalent bonding to the microcapillary wall, resulting in formation of a layer of the coating material covalently attached to the inner surface of the microcapillary wall. Following this operation, the coated microcapillary is treated with a solution of a hydrophilic polymer, and this is dried, leaving a layer of hydrophilic polymer adsorbed on the layer of coating material. Next, the microcapillary is filled with a solution containing at least one monomer, and optionally at least one crosslinking agent, plus at least one free radical source and an appropriate catalyst, and this mixture is allowed to polymerize in the tube, ultimately forming a polymeric matrix which fills the capillary bore. As a final step, one end of the gel-containing microcapillary is cut off cleanly and squarely.
The gel-containing microcapillaries of the invention are unusually stable and function well under applied electric fields typically of 300 volts/cm or higher, and with currents typically up to approximately 50 microamperes or above. Under these conditions, extremely high resolution separations are obtained on very small amounts of material. In addition, the microcapillaries of the invention have been demonstrated to resolve mixtures of analytes as a linear function of the logarithms of their molecular weights. Accordingly, they permit convenient and accurate molecular weight determinations on nanogram or lower amounts of unknown biopolymers.
DESCRIPTION OF THE DRAWING
The invention will be better understood from a consideration of the following detailed description taken in conjunction with the drawing in which:
FIG. 1 shows a magnified perspective view of the end of the gel-containing microcapillary of the invention;
FIG. 2 shows an SDS-PAGE separation of four standard proteins, cytochrome C, lysozyme, myoglobin, and trypsinogen, on a microcapillary column of the invention containing 7.5% total monomer, 3.3% crosslinker, and 0.1% (w/v) of SDS. The pH of the buffer was 8.6, and electrophoresis was conducted under an applied field of 300 volts/cm and a current of 12-15 microamperes, over a 20 centimeter migration distance;
FIG. 3 shows an electrophoretic separation of poly(deoxyadenylic acid) oligomers on a microcapillary column like that described with reference to FIG. 2, but without SDS, under the same electrophoretic conditions as were employed in the separation shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, the gel-containing microcapillary column of the invention includes a microcapillary 10, a layer 12 of coating material which is covalently bonded to the inner surface 14 of the microcapillary wall, a layer of hydrophilic polymer 16 adsorbed on layer 12, and a polymeric gel material 18 within the bore of this microcapillary.
The microcapillary may be made of any of a variety of materials provided that the detection system to be employed in the electrophoresis can function adequately with the particular material employed. Suitable materials include glass, alumina, beryllia, and TEFLON. Preferably, the microcapillary is made of fused silica.
The microcapillary dimensions are important because, for a given electric field, as the internal diameter of the microcapillary is reduced, the electric current and the resultant heating produced by a particular applied electric field is reduced. Thus, for highest resolution separations it is desirable that the microcapillary have a minimum internal diameter. With the improved hydrophilic polymer-containing microcapillaries of this invention, however, this factor is somewhat less important than formerly. Accordingly, microcapillaries having internal diameters in the range between 10 and 2000 micrometers function in the invention. A preferred range of internal diameters is 10 to 200 micrometers. A polyimide coating on the outer surface of the microcapillary permits easy handling of thin-walled microcapillaries.
The polymeric gel material 18 employed can be any polymer which has a pore structure which can be varied. It may or may not be crosslinked. Preferably, the polymeric gel is a crosslinked polymer whose pore structure is varied by varying the amounts of monomer and crosslinking agent, and the reaction conditions. Examples of suitable polymeric systems are polyacrylamide, agarose and mixtures of agarose and polyacrylamide. A preferred polymeric gel material is based on acrylamide and N,N' methylenebisacrylamide, the N,N'-methylenebisacrylamide serving as a crosslinking agent. Other possible crosslinking agents are N,N'(1,2-dihydroxyethylene)-bisacrylamide, N,N'-diallyltartardiamide, and N,N'-cystamine-bisacrylamide. Still other monomers and crosslinkers will suggest themselves to those skilled in the art.
The polymerization reaction is preferably initiated with ammonium persulfate or N,N,N',N'-tetramethyleneethylenediamine, though other free radical polymerization initiators may be employed, as known by those skilled in the art.
The layer 12 between the layer of hydrophilic polymer and the inner surface of the microcapillary wall is generally a hydrophobic material and is derived from a coating reagent which is capable of chemically bonding to the microcapillary wall. This reagent is generally a molecular chain having an appropriate reactive functional group at one end, though non-chain type molecules having appropriate functionalities will also serve. The end of the coating reagent which is to bond to the capillary wall carries a reactive functional group which can bond chemically to silanol groups or other reactive functionalities on the inner surface of the microcapillary. Such reactive functional groups of the reagent are typically reactive silanes such as trialkoxysilane, trichlorosilane, mono, di-, or tri-enolate silanes, and aminosilanes, where the silicon atom carries at least one group which may be readily displaced. Examples of suitable coating reagents are materials such as alkyl di- or tri- ethoxy or methoxy silanes, and alkylether di- or tri- ethoxy or methoxy silanes.
In a preferred embodiment, the coating reagent is a bifunctional material, which also contains a second functional group capable in principle of forming a covalent bond with the polymeric gel material. Such functional groups include vinyl, substituted vinyl, or any group which upon cleavage yields a free radical, but for practical purposes a vinyl group is preferred because it may then be possible to form the polymeric gel in the microcapillary and chemically bond it to the microcapillary wall simultaneously. Representative bifunctional reagents are 3-Methacryloxypropyl-trimethyoxysilane, and 3-Methacryloxypropyldimethylethoxysilane, shown as (a) and (b) below:
CH.sub.2 ═C(CH.sub.3)--CO.sub.2 --(CH.sub.2).sub.3 --Si(OCH.sub.3).sub.3
CH.sub.2 ═C(CH.sub.3)--CO.sub.2 --(CH.sub.2).sub.3 --Si(CH.sub.3).sub.2 OC.sub.2 H.sub.5
Other possible bifunctional reagents are vinyltriacetoxysilane, vinyltri(-methoxyethoxy)silane, vinyltrichlorosilane, and methylvinyldichlorosilane, this list being intended as illustrative but not exhaustive.
In the case of capillaries to which the bifunctional reagents do not bond, e.g., TEFLON, the capillaries may be employed without a coating layer 12, provided that the hydrophilic polymer adsorbs to the microcapillary wall, or a layer of a polymer possessing the ability to adsorb to the microcapillary wall and to the hydrophilic layer may be employed.
The hydrophilic polymers which are useful in the invention include polyoxides such as polyoxymethylene; polyethers such as polyethylene oxide; polyalkylimines such as polyethyleneimine; polyamides such as polyacrylamide, polymethylacrylamide, poly-N,N-dimethylacrylamide, polyisopropylamide, and polyacrylylglycinamide; polyalkylene glycols such as polyethylene glycol and polypropylene glycol; and polymers of vinylic materials such as polyvinyl alcohol, polyvinyl acetate, and polyvinyl pyrrolidone. The molecular weight of the hydrophilic polymer is 600-500,000 Daltons or higher, preferably in the range of approximately 5000 to 200,000 Daltons. The hydrophilic polymers are preferably linear polymers. Polyethylene glycol is a preferred hydrophilic polymer.
For the improved microcapillary in which polyethylene glycol is employed as the hydrophilic polymer, the polyethylene glycol preferably has an average molecular weight of about 8000 Daltons or above, though material having an average molecular weight in the range 600 to 35,000 Daltons will serve. Polyethylene glycol having an average molecular weight of about 8000 Daltons or above is preferred, and is well-suited for use in the aqueous systems which are employed in this invention.
For highest resolution it is necessary that at least the front end of the gel-containing microcapillary be cleanly and squarely cut perpendicular to the central axis of the microcapillary. If the surface of the polymeric gel material which is exposed at the end of the microcapillary is uneven, it is impossible to make an injection of a uniform narrow band of sample, with the result that broad peaks are obtained.
The gel-containing microcapillaries of the invention are generally prepared as follows. First, the column is activated by heating it in excess of 100° C., generally for several hours, and then bringing its interior surface into contact with an acidic material such as a dilute solution of hydrochloric or nitric acid, and/or a basic material such as ammonia gas or a solution of a base. In the heating step a temperature of 110° to 200° C. may be conveniently employed. The time of such heating can vary from a few hours to overnight or longer. In one procedure, the activating step is accomplished by flushing the microcapillary with dry ammonia gas, generally for approximately 2 hours at a temperature of approximately 20-35° C., preferably at room temperature. In an alternative and preferred procedure, the column may be activated by heating it as above, then filling it with a solution of a base such as an alkali metal hydroxide, e.g., an 0.1 to 1N NaOH solution, leaving this solution in the microcapillary for at least approximately 1-3 hours and conveniently overnight at a temperature typically in the range 20-35° C., preferably at room temperature, then flushing with water.
The time and temperature employed in activating the microcapillary are selected such that they are sufficient to activate the microcapillary so that good bonding between the microcapillary and the bifunctional reagent is achieved.
The activated microcapillary is then flushed with at least 20 tubing volumes of a solution of the reagent to be employed in coating the tubing wall, and this is left to react for at least 1 hour and preferably 2 hours or longer at a temperature of 20-35° C., preferably at room temperature, filled with this solution of coating reagent. An alternative procedure is to place the filled microcapillary column in a vacuum oven overnight at about 60° C.
The solution of coating reagent is prepared in a nonaqueous solvent such as an alcohol, an ether, a ketone, or a moderately polar halogenated solvent and typically contains between 4 and 60% coating reagent by volume. Representative solvents are methanol, dioxane, acetone, and methylene chloride. After the coating reagent has been allowed to react with the inner wall of the microcapillary, excess unreacted reagent is optionally removed by rinsing the column with a suitable solvent such as methanol, followed by a further rinsing with water. Typically at least 100 tubing volumes of solvent and water are employed.
To form the layer of hydrophilic polymer, the coated microcapillary is filled with a degassed solution of hydrophilic polymer containing the buffer which will be employed for preparation of the gel filling to be described below. The concentration of the polymer in this solution is typically about 5-10% (w/v). The microcapillary is then held for several hours or overnight in a vacuum oven maintained at a temperature of about 125° C., until the tube is dry. This may be determined readily by inspecting the microcapillary under a microscope. The microcapillary is finally flushed with one or two tubing volumes of the buffer solution to remove excess crystals of the buffer material from the tube wall, while leaving the coating of hydrophilic polymer largely undisturbed.
For the case in which the hydrophilic polymer is polyethylene glycol, the polyethylene glycol is combined with degassed triply distilled water which has been cooled to about 10° C., then stirred while the temperature is raised slowly to room temperature. A clear transparent solution with no precipitate results. This solution is used to prepare the buffered solution of hydrophilic polymer discussed above.
Next, separate stock solutions of the monomers, any cross-linkers, the initiators, and free radical sources for the polymerization reaction are prepared, typically in 7 to 8 molar aqueous urea, though higher and lower concentrations of urea may be used. Gels which are intended to be non-denaturing are prepared without urea or other denaturing additives, and function well. The concentrations of these reagents are selected such that convenient aliquots of the solutions may be taken and mixed together to form a polymerization mixture having predetermined concentrations of monomer, crosslinker (if employed), and polymerization catalysts. Before mixing aliquots of these reagents together, the solutions are separately degassed for at least one hour. This degassing operation may be conducted in any of the several ways known to the art, but basically involves stirring the solutions mechanically or agitating them with ultrasound while simultaneously applying a low vacuum of approximately 20 to 30 millimeters of mercury. The preparation of these solutions is as known to the art, for example, as shown by Hames and Rickwood.
The total concentration of monomer and the concentration of crosslinking agent in these sorts of systems are generally expressed respectively as %T and %C, employing the terminology of Hjerten. In this regard, see Hjerten, Chromatographic Reviews, 9, 122-219 (1967). For the acrylamide N,N'-methylenebisacrylamide system preferably employed in this invention, the definitions of %T and %C are given below. ##EQU1## The concentrations of monomer and any crosslinking agent are predetermined according to the porosity of the polymeric matrix desired. However, the concentrations of initiator and polymerization catalyst in the reaction mixture must be determined experimentally. This is done by preparing test solutions containing the desired %T and %C, but varying the amount of initiator and polymerization catalyst employed. In the event that SDS-PAGE electrophoresis is contemplated, sodium dodecylsulfate is also included in the reaction mixture in the requisite amount, typically 0.1%(w/v). These test solutions are allowed to polymerize at or below the temperature at which the electrophoresis is to be performed and the progress of the polymerization reaction is monitored by ultraviolet spectroscopy by observing the decrease in the absorbance of the vinyl double bond. Alternatively, the microcapillary may be observed visually. Levels of initiator and polymerization catalyst are selected which cause the polymerization to be essentially complete in a reasonable time, such as approximately 45 to 60 minutes.
Once the correct reagent concentrations have thus been determined, a fresh mixture of the polymerization reagents is prepared and injected into the microcapillary tube, taking care not to create bubbles. A small ID TEFLON tube is used to connect the microcapillary to the syringe employed to fill the microcapillary. When the microcapillary has been filled with polymerization mixture, the syringe is removed and both ends of the microcapillary are plugged by inserting them into septa, which are maintained while the polymerization reaction occurs.
The polymerization reaction is carried out at or below the temperature which is to be employed for subsequent electrophoresis on the microcapillary column. While the polymerization reaction is occurring, the reaction may be monitored separately in an aliquot of the reaction mixture by observing the loss of absorbance due to the vinyl groups by ultraviolet spectroscopy or visually. The polymerization reaction in the column and that in the separate monitor solution are the same, although the reaction in the capillary is much faster. When the test solution indicates the polymerization reaction is essentially over, which should be at a time between 45 and 60 minutes, the reaction is allowed to proceed for at least another two hours, preferably overnight, maintaining the temperature as indicated above.
An alternative and preferred polymerization procedure is to fill the microcapillary column with the solution of polymerization reagents as described above, then immediately place the column in a refrigerator at a temperature of 5-10° C. and allow the polymerization reaction to proceed overnight.
After the polymerization reaction in the microcapillary has gone essentially to completion, the caps are removed from the microcapillary ends and at least one end of the microcapillary is cut off cleanly and squarely. One way to accomplish this is to tightly sheath an end to be cut with small diameter TEFLON tubing, then cut the TEFLON-sheathed end cleanly and squarely perpendicular to the axis of the microcapillary using a microtome, which cuts through the TEFLON sheathing, the microcapillary material, and the polymeric gel, leaving a very smooth surface of gel material exposed at the end of the microcapillary. Alternatively and preferably, the capillary may be scored carefully at a right angle to its axis be means of a sapphire cleaver, and broken cleanly by bending it. The end of the microcapillary which has been thus cut is examined under a microscope to ascertain that the cutting operation in fact produced the requisite flatness of the exposed polymeric gel. If necessary, further cuts can be made until a suitably flat end is produced. Both ends of the microcapillary are generally treated in this fashion, although it is really only necessary to have a square cut end on the front of the microcapillary.
After its preparation, the column is placed in suitable electrophoresis apparatus and a low electric field of approximately 100 to 150 volts/cm is applied for a period of about one hour. If a very noisy baseline or a zero current condition is obtained, this indicates an improperly prepared column. In this event, a new microcapillary must be prepared.
In employing the gel-containing microcapillary column of the invention in electrophoresis, apparatus and techniques which are generally known to the those skilled in the art of open tube free zone microcapillary electrophoresis are employed. See, for example, B. L. Karger, A. S. Cohen, and A. Guttman, J. Chromatog. 492, 585 (1989); M. J. Gordon, X. Hung, S. L. Pentaney, Jr., and R. N. Zare, Science, 242, 224 (1988); and J. W. Jorgenson and K. D. Lukacs, Science, 222, 266-272 (1983). In capillary gel electrophoresis, resolution between two compounds is influenced by all the factors which affect band sharpness, including sample size, ionic materials in the samples, and the gel concentration. The latter factor is especially important, since if the gel concentration is too high the analytes are totally excluded from the column, while if it is too low little or no molecular sieving occurs. No single gel concentration is optimal for the resolution of all mixtures of proteinaceous materials or oligonucleotides. It is necessary to select appropriate gel concentrations for particular samples. Other important variables affecting electrophoresis in microcapillaries are the applied field and the electrical current employed. The sample is injected by the so-called "electrophoretic injection" technique, though other techniques known to the art, such as syringe layering injection, can serve. In the electrophoretic injection technique, the front end of the electrophoresis microcapillary is dipped into a sample solution containing an electrode of the appropriate polarity and an electric field of approximately 50 to 100 volts/cm is applied for a few seconds to cause electrophoresis of a small amount of the sample solution into the end of the microcapillary. The microcapillary is then transferred back to a solution of "running" buffer, the desired electrophoretic field is applied, and the electrophoresis is carried out in the normal way.
To aid in cooling and microcapillary, a cooling jacket or a related device is employed around the microcapillary over most of its length, excluding only the front and the rear ends of the microcapillary, which are respectively immersed in buffer solution and connected to the detector of the electrophoretic system. A cooling fluid is circulated through this jacket and maintained at whatever temperature is desired. Alternatively, an electrically controlled mechanical cooling device may be employed around the microcapillary column. Such "active " cooling is more effective in maintaining desired microcapillary temperatures than forced air or natural convection.
A method of performing high resolution molecular sieving electrophoresis for analytical purposes thus includes the steps of electrophoretically injecting an aliquot of a sample containing analytes to be separated into a gel-containing microcapillary column of the invention, applying an electric field of between 100 and 300 volts/cm or higher, allowing a current typically less than about 50 microamperes to pass through the microcapillary, and instrumentally detecting and measuring the separated analytes sequentially as they migrate past the detector.
The gel-containing microcapillaries of the invention separate analytes as a function of the logarithms of their molecular weights in a linear fashion. Accordingly, it is possible to determine molecular weights of unknown analytes by comparing their mobilities under standard electrophoretic conditions with a calibration chart plotting the log of the molecular weight of standard materials versus the mobilities of such standard materials.
A method of determining the molecular weight of an analyte therefore is to prepare a gel-containing microcapillary column according to this invention, select standard values of the electrophoretic operating parameters, the applied field being typically between 100 and 300 volts/cm or higher and the current being typically less than about 50 microamperes, injecting onto this microcapillary column an aliquot of a standard solution containing several standard analytes of known molecular weight, applying the selected standard values of the electrophoretic operating parameters to the microcapillary column to separate the standards, measuring mobilities of the known standards under the conditions of the electrophoresis, plotting the log of the molecular weight for each of the standard materials versus its mobility under the standard operating conditions, electrophoretically analyzing an unknown solution on the same column under the same conditions, measuring the mobilities of the analytes contained therein, and finally determining the molecular weights of these analytes from a comparison with the calibration plot.
The improved microcapillary columns containing a layer of hydrophilic polymer between the polymeric gel filling and the layer of wall coating material exhibit longer shelf lives and better stability in use than columns not containing such hydrophilic additives. Most importantly and unexpectedly, the improved microcapillary columns of the invention can be operated at high field strengths, which permit high resolution separations to be achieved in short analysis times.
The following experimental preparations are intended as exemplary only, and are not intended to limit or define the scope of the invention.
EXPERIMENTAL SECTION
Acrylamide, N,N'-methylenebisacrylamide, N,N,N',N'-tetramethyleneethylenediamine (TEMED), ammonium persulfate, sodium dodecylsulfate, TRIS buffer, and disodium hydrogen phosphate were all ultrapure or electrophoretic grade materials obtained from Swartz/Mann Biotech of Cleveland, Ohio. Somewhat less pure acrylamide from other sources could be suitably purified by recrystallizing three times and deionizing it by treatment with ion exchange resin. Urea was freshly obtained, and triply recrystallized from water/methanol. Proteins were obtained from the Sigma Chemical Company, St. Louis, Missouri and used as received. Water was triply distilled and deionized. Polyethylene glycol was obtained either from Aldrich or Sigma and was of analytical reagent grade. The fused silica microcapillary tubing preferably employed in the invention was obtained from Polymicro Technologies, Inc., Phoenix, Ariz. This company also supplies such tubing in various other dimensions. A sapphire cleaver useful in cutting off the ends of the microcapillaries was obtained from Ealing Electronics Corp., 22 Pleasant Street, South Natick, Mass. 01760.
Narrow bore TEFLON tubing (0.2-0.25 millimeters ID) was used for filling microcapillary tubes. All solutions were filtered through a nylon 66 or methylcellulose filter membrane having a 0.2 micrometer pore size. Analytical samples were kept frozen at -20° C. prior to use, and aliquots of these samples for experimental work were stored at 4° C. Proteins for SDS-PAGE work were prepared as known to the art.
A Soma S-3207 detector by Instrumentation for Research and Development, Inc., Kingston, Mass., was employed, and was modified for microcapillary work as described in the article by S. Terabe, et al, Anal. Chem., 56, 111-113 (1984). Data were converted to digital form using a Nelson Analytical A/D Interface model 762 SA, and stored using an IBM PC/XT computer. Other equipment known to the art will also serve.
Preparation and Testinq of Gel-Containing Microcapillary Having 7.5% T, 3.3% C, 0.1% SDS, and a Layer of Polyethylene Glycol Surrounding the Gel
Fused silica microcapillary tubing having an ID of 75 micrometers, a wall thickness of about 150 micrometers, and a polyimide coating was employed. A 40 to 45 cm length of this tubing was taken for preparation of the gel-containing microcapillary. The polyimide coating was removed from a 2 cm section of one end of the tubing by burning. This end was ultimately connected to the detector of the electrophoresis apparatus.
The microcapillary tubing was heated overnight at about 120° C. in air, then filled with 1 M KOH solution and left overnight at room temperature. Next, the microcapillary was rinsed with about twenty column volumes of a 50% solution of 3-Methacryloxypropyltrimethyoxysilane in HPLC grade methanol at room temperature. The microcapillary, filled with bifunctional reagent solution, was then placed in a vacuum oven maintained at a temperature of 125° C. and a vacuum of approximately 2 mm of mercury and left overnight.
The coated microcapillary was next carefully filled with a previously degassed solution containing 6% w/v polyethylene glycol having a nominal molecular weight of about 35,000 Daltons, 0.1 M Tris borate buffer (pH=8), and 7 M urea, and then left overnight in a vacuum oven at a temperature of about 125° C. and a vacuum of about 2 mm of mercury, after which the microcapillary was found to be dry by microscopic examination. The treated microcapillary was flushed with about 1-2 tube volumes of buffer solution (below) and then cut to a length of somewhat greater than 20 cm from the window.
Buffer solution was prepared by dissolving 1.1 g of TRIS buffer in 100 ml of 7 molar urea solution, adding 0.01 g of EDTA and 0.1 g of sodium dodecyl sulfate, and adjusting the pH to 8 by the addition of boric acid.
A solution of acrylamide and N,N'-methylenebisacrylamide was prepared by combining 29 g of acrylamide and 1 g of N,N'-methylenebisacrylamide in 100 ml of buffer solution, giving a solution having a %T of 30% and a %C of 3.3%.
A solution of ammonium persulfate was prepared by dissolving 0.2 g of ammonium persulfate in 2 ml of the buffer solution.
The solutions of buffer, monomers, and ammonium persulfate were separately filtered through 0.2 micrometer filters and degassed for 2 hours by applying a vacuum of 20-30 mm of mercury.
0.75 g of the acrylamide-bisacrylamide solution was added to 10 ml of buffer solution, giving a final solution having %T=7.5% and %C=3.3%. This solution was filtered through a 0.2 μm filter and degassed under vacuum overnight at a vacuum of about 20-22 mm of water.
To a 0.5 ml aliquot of the acrylamide-bisacrylamide solution were added 7.5μ1 of a 5% v/v solution of electrophoresis grade TEMED and 7.5 μ1 of 5% w/v ammonium persulfate solution, and in excess of 50 μl of this polymerization mixture was forced through the microcapillary until no bubbles were observed exiting the microcapillary. The injection syringe was carefully removed from the TEFLON tubing while continuing the injection, to prevent introduction of bubbles into the microcapillary. Finally, both ends of the microcapillary were plugged with septa and the column was placed in a refrigerator and maintained between 5 and 10° C. overnight, during which time the polymerization occurred. Finally, the front end of the microcapillary was cut off in a microtome at a microcapillary migration distance (front end to detector) of 20 cm. The final gel-containing microcapillary was evaluated for one hour under an applied field of 100 volts/cm, and found to be satisfactory.
A mixture of four proteins, cytochrome C, lysozyme, myoglobin, and trypsinogen, was prepared for SDS-PAGE electrophoresis in the standard manner known to the art, then a sample of this solution was electrophoretically injected onto the microcapillary column by application of an electrical field of 100 volts/cm for 15 seconds. Electrophoresis was conducted at 300 volts/cm and a current of 15-17 μA over the 20 cm migration distance. Results are shown in FIG. 2.
Preparation and Testing of Gel-Containing Microcapillary Having 7.5%T, 3.3%C and a Layer of Polyethylene Glycol Surrounding the Gel
A second microcapillary was prepared as above but without the inclusion of SDS. A mixture of poly(deoxyadenylic acid) was injected and separated by electrophoresis at 300V/cm with a current of 12-14 μA. Results are shown in FIG. 3.
Quality Control Testing of Microcapillary Columns
During their lifetimes, the gel-filled microcapillaries should be tested periodically for stability and reproducability by measuring the electrophoretic current at various applied fields. Well-made columns in good condition exhibit a constant resistance over a range of applied fields and this is repeatable over time. In this test the applied field (V/cm) is plotted against the measured current. A straight line with a constant slope (resistance) over time indicates the column is good. Typical experimental data for an SDS-gel capillary column are presented in Table I below.
TABLE I______________________________________ E (V/cm) I (μA)______________________________________ 100 6 200 12 300 18 400 22 500 28 600 33 700 40______________________________________
These data are indicative of a well-made column, and also demonstrate the column can be operated under an applied electric field of 700 V/cm.
Other embodiments of the invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention as disclosed herein. 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. | A microcapillary column for high performance electrophoresis. A preferred column includes a microcapillary, a thin layer of coating material covalently bonded to the inner surface of the microcapillary wall, a thin layer of a hydrophilic polymer absorbed on the layer of coating material, and a gel comprising polyacrylamide polymerized in the tube, filling it. The gel-containing microcapillary is prepared by covalently bonding a layer of a suitable coating material to the inner surface of the microcapillary wall, applying a layer of hydrophilic polymer, and then causing a mixture of monomer with or without crosslinking agent, initiator, and polymerization catalyst to react in the bore of the microcapillary to form a polymeric matrix. In electrophoresis, the gel-containing microcapillary provides peak efficiencies in excess of 100,000 theoretical plates and in some instances over 1,000,000 theoretical plates within separation times of less than thirty minutes, permits trace level determinations of molecular weights, and permits electrophoretic operation at fields of 300 V/cm or higher, resulting in extremely high resolution separations. | 6 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made with United States government support awarded by EPA R826289-01-1. The U.S. Government retains certain rights in this invention.
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
BACKGROUND OF THE INVENTION
Arsenic is one of the most abundant and widely distributed anthropogenic pollutants in many contaminated sites, and can be a significant source of poisoning in agricultural workers, smelters, miners, and chemical plant workers. Moreover, arsenic poisoning due to contamination of drinking water affects thousands of people worldwide. The common method of removing arsenic from water uses chlorine or ozone, and the waste products from such methods are harmful to people.
The chemistry of arsenic is very complex. While some forms of arsenic become tightly bound to surrounding matter, one of the more toxic forms, arsenite, is also the most mobile. For example, arsenite (AsIII) is more toxic than arsenate (AsV) and arsenite is more mobile in the environment than arsenate. Cullen, W. R., Reimer, K. J. Chem. Rev . 1989, 89, 713-764. In general oxidized forms of arsenic tend to be less mobile in, and easier to remove from, the environment. Thus, it is desirable to convert arsenite to arsenate.
The oxidation of arsenite to arsenate in the absence of catalyst is kinetically inhibited. Wilke and Hering reported that certain microorganisms may be able to catalyze the oxidization of arsenite to arsenate at 25° C. Wilkie, J. A., Hering, J. G. Rapid Oxidation of Geothermal Arsenic (III) in Streamwaters of the Eastern Sierra Nevada, Environ. Sci. Tehnol . 1998, 32, 657-662. However, the identity of the microorganisms in Wilke and Hering are not known. Id. Several microorganisms are known to be able to oxidize arsenite. These microorganisms include heterotrophs Pseudomonas putida and Alcaligenes faecalis as well as the chemolithoautotrophic arsenite-oxidizers Pseudomonas arsenitoxidans and “NT-26.” Turner., A. W. Aust. J. Biol. Sci . 1954, 7, 452-478.; Osborne, F. H., Ehrlich, H. L. J. Appl. Bacteriol . 1976, 41, 295-305.; Ilyaletdinov, A. N., Abrashitova, S. A. Mikrobiologiya 1981, 50, 197-204; Santini, J. M., Sly, L. I; Schnagl, R. D., Macy, J. M. Appl. Environ. Microbiol . 2000, 66, 92-97.
Arsenic is a common constituent of geothermal fluids with typical concentrations of 1-10 mg L −1 . Ballantyne, J. M., Moore, J. N. Geochim. Cosmochim. Acta 1988, 52, 475-483. As a result, levels of arsenic are often elevated in surface waters and aquifiers surrounding hot springs. Welch, A. H., Westjohn, D. B., Helsel, D. R., Wanty, R. B. Ground Water 2000, 38, 589-604. For example, at Yellowstone National park, over 100,000 kg of geothermally-derived arsenic is estimated to leave the western boundary each year, affecting water quality within a large region. Nimick, D. A., Moore, J. N. Dalby, C. E., Savka, M. W. Water Resour. Res . 1998, 34, 3051-3067. Stauffer, Jenne and Ball reported that rapid arsenite oxidation at high temperature was observed in the drainage of the Azure Hot Spring of Yellowstone but did not explain why. Stauffer, R. E., Jenne, E. A., Ball, J. W. Chemical Studies of Selected Trace Elements in Hot-Spring Drainages of Yellowstone National Park , 1980, Geological Survey Professional Paper1044-F.
Thermus species bacteria are Gram-negative aerobic rods found in warm waters such as hot springs, hot water tanks and thermally polluted waters. The Thermus species have been studied extensively in pursuit of novel enzymes and biochemical pathways for industrial applications. Alfredsson, G. A., Kristjansson, J. K. In Thermus species, Sharp, R., Williams, R. Eds., Plenum: New York, 1995; Chapter 2. For example, the Taq enzyme used in polymerase chain reaction was first isolated from Thermus aquaticus . So far, no information exists regarding Thermus species' interaction with arsenic-rich fluids.
BRIEF SUMMARY OF THE INVENTION
The present invention is summarized in that bacteria of a Thermus species can be used to convert arsenite to arsenate. An arsenic contaminated source containing arsenite can be detoxified by incubating bacteria of a Thermus species in the source at a temperature and under conditions in which the bacteria can convert at least some of the arsenite to arsenate.
It is an object of the present invention to detoxify arsenic using microorganisms.
It is another object of the present invention to detoxify arsenic with microorganisms at a relatively high temperature.
It is an advantage of the present invention that no harmful products are generated through the arsenic detoxification process.
Further objects, features and advantages of the invention will be apparent from the following detailed description when taken in conjunction with the accompanying claims and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows arsenic speciation and culture density during arsenite oxidation by Thermus aquaticus YT1 (A) and Thermus thermophilus HB8 (B).
FIG. 2 shows arsenic speciation and culture density during antibiotic-inhibited culturing of Thermus aquaticus YT1 (A) and Thermus thermophilus HB8 (B).
FIG. 3 shows quantification of the genus Thermus and the species Thermus aquaticus and Thermus thermophilus at each station, as determined by FISH.
DETAILED DESCRIPTION OF THE INVENTION
This invention is based on the finding that bacteria of the genus Thermus have the native ability to oxidize forms of arsenic to render them more susceptible to removal. The data presented below shows that three different bacterial strains from two different species of the Thermus genus, Thermus aquaticus YT 1 , Thermus aquaticus HR-13 and Thermus thermophilus HB8, oxidize the more toxic and more mobile form of arsenic, arsenite, to the less toxic and less mobile arsenate. Thus, these exemplary bacteria may be used directly to detoxify arsenic. All three strains from the Thermus genus tested so far were effective in oxidizing arsenite. It is expected that other strains of the Thermus genus also have such activity.
The examples described below show that the arsenite oxidization efficiency of the Thermus species was reduced when their growth of the bacterial culture was inhibited. Thus, it is preferable to use a Thermus species for arsenic detoxification under conditions and at a temperature that favors the growth of the bacteria. Generally speaking, the growth temperature range of Thermus species is higher than other bacteria. This can be an advantage of the present invention in that it allows efficient arsenic detoxification even if the target's temperature is relatively high. One of ordinary skill in the art either knows or can easily determine the growth temperature range of a Thermus species. For example, it is known that the growth range of Thermus aquaticus is from 40 to 79 degrees Celsius and the growth range for Thermus thermophilus is from 47 to 85 degrees Celsius. It is also contemplated that the bacteria can be subject to mutation and selection to lower the optimal growth temperature, or change other preferred culture conditions, to permit use of the bacteria in lower temperature processes.
Thermus species can be used to detoxify arsenic in any source that can support survival or preferably growth of Thermus species. If the source can not by itself support survival or growth of a Thermus species, the source may be mixed with a medium that can support such in order to detoxify the source. Examples of an arsenic source that needs to be detoxified include but are not limited to a water source or soil that is contaminated by arsenite.
Thermus species can be used to detoxify arsenite in situ when the in situ conditions support Thermus species' survival or preferably support their growth. For example, in a geothermal electrical plant, the spent fluid after it has been extracted and used to run the turbines may contain high levels of arsenic. Thermus species can be used to oxidize arsenite in the spent fluid in situ because the spent fluid's temperature is high enough to support Thermus species' growth. Otherwise, in order to detoxify a contaminated source, the source has to be brought into a treatment facility so that it can be heated up to a temperature that supports Thermus species' growth.
The present invention can also be used to reduce arsenic concentration in a source when combined with an arsenate adsorption method. Other people have developed methods to reduce arsenic level in a source by arsenate adsorption. Examples of such methods include U.S. Pat. Nos. 6,203,709 and 5,591,346, which are hereby incorporated by reference in their entirety. When the present invention is combined with an arsenate adsorption method, both detoxification and arsenic concentration reduction can be achieved. It is known that arsenate can be adsorbed to a substrate such as iron oxyhydroxides and many other mineral species better than arsenite. Bhumbla, D. K., Keefer, R. F. In Arsenic in the Environment, Part I: Cycling and Characterization , Nriagu, J. O. Ed., John Wiley: New York, 1994, Chapter 3. It is preferable to combine the present invention with an adsorption substrate that has a higher affinity for arsenate than arsenite.
EXAMPLES
Materials and Methods
1. Laboratory experiments.
Bacterial strains and growth conditions. The strains Thermus aquaticus YT1 (DSM 625) and Thermus thermophilus HB8 (DSM 579) were purchased from the German Collection of Microorganisms and Cell Cultures. Thermus aquaticus HR-13 was collected from a hot spring in northern California containing 0.12 mM arsenite. Growth medium contained 0.2% (w/v) yeast extract, 0.8 g L −1 (NH 4 ) 2 SO 4 , 0.4 g L −1 KH 2 PO 4 , 0.18 g L −1 MgSO 4 *7H 2 O, and 1.75 g L −1 NaCl adjusted to pH 7.5 at room temperature with NaOH and autoclaved. When required, 2× (double the concentration of constituents) growth medium was diluted to 1× with autoclaved de-ionized water and a stock of filter-sterilized 3750 mg L −1 arsenite (as arsenious acid; LabChem Inc.) adjusted to pH 7.5 with NaOH. Cultures of T. aquaticus and T. thermophilus were maintained in the presence of 75 mg L −1 arsenite and washed twice with fresh growth medium prior to subsequent culture inoculations. All culturing was carried out using tightly-sealed 125 mL screw-cap polycarbonate flasks to prevent evaporation.
Arsenite oxidation assay. To test for the ability to oxidize arsenite, T. aquaticus and T. thermophilus were inoculated into 60 mL of growth medium containing 75 mg L −1 arsenite and incubated at 70° C. with 125 RPM shaking. Experiments using uninoculated, sterile media with 75 mg L −1 arsenite were also incubated under the same conditions. One-mL samples from biological and abiotic experiments were taken over time for measurements of cell density and for determinations of arsenic speciation. Optical density was measured at 600 nm using a Perkin Elmer Lambda 3 UV/VIS spectrophotometer. Samples were centrifuged and the supernatants decanted. Samples were then acidified by adding the concentrated trace metal-grade HCl to 1% (v/v) and stored at 4° C. for less than 7 days prior to arsenic analyses.
Measurements of arsenic speciation in laboratory experiments followed the protocol of Howard and Hunt. Howard, A. G., Hunt, L. E. Anal. Chem . 1993, 65, 2995-2998. Arsenic species were chromatographically separated using a 53 mm×7 mm Alltech adsorbosphere reversed-phase C-18 Rocket Column (part number 50625). Isocratic elution was performed using a mobile phase consisting of 5.0 mM tetrabutylammonium hydroxide in H 2 O:methanol (95:5; v/v) adjusted to pH 7.0 with H 3 PO 4 . An injection volume of 20 μL and flow rate of 2.5 mL min −1 were used. After separation of As(III) and As(V), the post-column flow was routed to a Cetac HGX-100 hydride generator where 6 M HCl and sodium borohydride solution (1% (w/v) NaBH 4 , 0.5% NaOH (v/v), 0.3% (v/v) Antifoam A (Sigma); made fresh daily and filtered) were added, generating arsine (AsH 3 ). This mixture was pumped into a gas-liquid separator and the arsine was flushed with nitrogen gas (400 mL min −1 ) to a flame-heated silica T-tube. The atomic absorption was detected at 193.7 nm using a Unicam 969 flame atomic absorption spectrometer.
2. Field Studies.
Sample Collection. Fieldwork was carried out over a two-day period in September 2000 at the Twin Butte Vista Hot Spring in the Lower Geyser Basin of Yellowstone National Park. Five sampling stations were designated at intervals along the main overflow channel spanning an approximately 18.5 meter distance. Biological samples were collected using sterile forceps, placed in 15 ml screw-cap Falcon tubes containing 4% (w/v) paraformaldehyde in phosphate-buffered saline (PBS; 8.0 g L −1 NaCl, 0.2 g L −1 KCl, 1.44 g L −1 Na 2 HPO 4 *7H 2 O, 0.24 g L −1 KH 2 PO 4 , pH 7.2), and kept on ice. Within 8 hours of collection, samples were centrifuged, washed once with cold PBS, and resuspended in ethanol:PBS (1:1; v/v). Fixed biological samples were kept on ice during transport and stored at −20° C. in the laboratory.
Three sets of water samples were collected by syringe from each station and were filtered (0.2 μm Pall Acrodisc) into high-density polyethylene screw-cap bottles. Samples for As and Fe speciation determinations were acidified by 1% (v/v) additions of concentrated trace metal-grade HCl. Samples for cations measurements were acidified by 1% (v/v) additions of electronic-grade HNO 3 . The final set of water samples were left unacidified for anion analysis.
Laboratory determinations of inorganic constituents. All reagents were of purity at least equal to the reagent-grade standards of the American Chemical Society. Doubly-distilled de-ionized water and re-distilled acids were used in all preparations. USGS standard reference water samples were used as independent standards. Samples were diluted as necessary to bring the analyte concentration within the optimal range of the method. For elemental analyses, several dilutions of each sample were analyzed to check for concentration effects on the analytical method. Spike recoveries were also performed on several samples.
Concentrations of major cations and trace metals were determined using a Leeman Labs—DRE inductively-coupled plasma optical-emission spectrometer. Major cations were analyzed using the radial view while the axial view was used for trace metals. As (III/V) redox species were determined using a flow injection analysis system for the generation of arsine and detection using atomic absorption spectrometry (Perkin Elmer—Analyst 300). McCleskey, R. B., Nordstrom, D. K., and Ball, J. W. In U.S. Geological Survey Workshop on Arsenic in the Environment, Denver , CO, Feb. 21-22, 2000. Fe(II/III) redox species were determined using a modification of the FerroZine colorimetric method. Stookey, L. L. Anal. Chem . 1970, 42, 779-781. Concentrations of major anions were determined chromatographically, Brinton, T. I., Antweiler, R. C., Taylor, H. E. US. Geological Survey, Open-File Report 95-426A, 1995, using a Dionex 2010i ion chromatograph with 10-μL and 50-μL sample loops. Alkalinity (as HCO 3 − ) was determined using an Orion 960 autotitrator and standardized H 2 SO 4 . Barringer, J. L., Johnsson, P. A., US. Georlogical Survey, Water Resources Investigations Report 89-4029, 1989. Specific conductance was measured using an Orion conductivity meter (model 126).
Field geochemical analyses. Measurements of pH, Eh, and water temperature were made in the field using an Orion 290A portable meter and Orion 9107 pH/temperature and Orion 9678 redox electrodes. The pH electrode was calibrated with pH 4, 7 and 10 standard buffers (Fisher) heated to sample temperature by immersion of the buffer vials in the hot spring waters where sampling was performed. Preparation of the ZoBell's solution to calibrate the platinum electrode for Eh measurements and the values for the standard half-cell potentials used in calculating sample Eh are after the method in Nordstrom and White. Nordstrom, D. K., White, F. D. In US. Geological Survey Techniques of Water Resources Investigations Book 9, Wilde, F. D., Radtke, D. B. Eds; 1998, Chapter A6. The Zobell's solution was prepared immediately prior to use and brought to sample temperature by immersion of the sealed solution vial in the hot spring fluids before calibration of the meter. Sulfide was measured colorimetrically in the field using a Hach DR/2010 portable datalogging spectrophotometer after Hach method #690.
Fluorescence in-situ hybridizations (FISH). The 16S rRNA-targeted oligonucleotide probes Eub338, Arch915, S-G-Thus-0438-a-A-18, Taq1258, and Tth1258 were used in this study. Amann, R. I., Binder, B. J., Olson, R. J., Chislholm, S. W., Devereux, R., Stahl, D. A. Appl. Environ. Microbiol . 1990, 56, 1919-1925; Stahl, D. A., Amann, R. in Nucleic acid techniques in bacterial systematics, Stackebrant, E., Goodfellow, M. Eds., John Wiley: Chichester, UK, 1991, pp. 205-248; Harmsen, H. J. M., Prieur, D., Jeanthon, C. Appl. Environ, Microbiol . 1997, 63, 4061-4068; Byers, H. K., Patel, B., Stackebrandt, E. System. Appl. Microbiol . 1997, 20, 248-254. Probes were synthesized and labeled with fluorescein (Eub338 and Arch915) or Cy3 (Thus0438, Taq 1258, and Tth 1258) by the University of Wisconsin Biotechnology Center.
Hybridizations were performed according to the protocol of Bond et al. Bond, P. L., Banfield, J. F. Microb. Ecol. 2001, in press. Fixed environmental samples were homogenized by rigorous vortexing and spotted to gelatin-coated multiwell slides. The organisms Thermus aquaticus YT1 , Thermus thermophilus HB8 , Pseudomonas putida, Thermoplasma acidiphilum , and Sulfolobus sulfataricus were fixed and used as controls during the hybridizations. The hybridization buffer contained 20% formamide and each well was probed with Arch915 and Eub338, plus either Thus0438, Taq1258, or Tth1258.
Samples were examined using a Leica LEITZ DMRX epifluorescence microscope equipped with Chroma Technology filter sets 41007a for detection of Cy3 and 41001 for detection of fluorescein. The percentages of hybridized cells were quantified by comparing the total number of cells in a field of view labeled with the Arch915 and Eub338 probes relative to the number of cells labeled with either the Thus0438, Taq1258, or Tth1258 probes. For stations 2 - 5 , a minimum of 3,000 cells in at least 6 separate wells were counted for each sample. 697 cells in 4 separate wells were counted for station 1 . The sample in FIG. 5 was stained with DAPI (4′, 6′,-diamidino-2-phenylindole) and the image was captured using a Hamamatsu digital CCD camera (C4742-95) with AxioVision 2.0.5 software (Zeiss, N.Y., USA).
Results
1. Culturing Experiments.
Laboratory experiments conducted to examine Thermus aquaticus YT1 for the ability to oxidize arsenite to arsenate showed that within 12 hours after inoculation, arsenite oxidation was accelerated relative to abiotic controls (FIG. 1 A: Arithmetic plot: ▭, arsenite; ⋄, arsenate; ο, arsenite-abiotic control; †, arsenate-abiotic control. Logarithmic plot: X, optical density of culture). A lag period of slow oxidation during the first 16 hours of incubation was followed by rapid arsenite oxidation coinciding with the exponential phase of growth. Within 24 hours, 100 percent of arsenite was oxidized to arsenate by T. aquaticus YT1 at a rate of 0. 139 mg L −1 min − during exponential growth. Thermus thermophilus HB8 showed similar results (FIG. 1B: arithmetic plot: ▭, arsenite; ⋄, arsenate; ο, arsenite-abiotic control; †, arsenate-abiotic control; logarithmic plot: X, optical density of culture). Thermus thermophilus HB8 oxidized arsenite at a rate of 0.144 mg L −1 min −1 during exponential growth. In each of the abiotic control experiments, only about 5 percent of the arsenite was oxidized after 48 hours (FIG. 1) at an average rate of 0.001 mg L −1 min −1 (n=3; standard deviation=0.00036). Experiments carried out with Thermus aquaticus HR13 showed similar results to those with Thermus aquaticus YT1 and Thermus thermophilus HB8 described above.
To confirm arsenite was oxidized through the metabolic activity of T. aquaticus YT1 and T. thermophilus HB8, culturing experiments were carried out in which growth was inhibited by antibiotics (FIG. 2 : open arrows indicate the addition of 2.0 mg L −1 kanamycin and 2.0 mg L −1 ampicillin; filled arrows indicate the addition of 75 mg L −1 As(III); arithmetic plot: ▭, arsenite; ⋄, arsenate; logarithmic plot: X, optical density of culture). The rate of arsenic oxidation by antibiotic-treated cells was significantly reduced relative to untreated cells. Experiments carried out with Thermus aquaticus HR13 showed similar results.
Additional experiments were conducted to ascertain whether T. aquaticus and T. thermophilus are capable of chemolithoautotrophic growth by arsenite oxidation. Using low levels of yeast extract (0.020, 0.002, and 0.000%; w/v) as a carbon source, cultures were incubated with and without arsenite present. Growth in these experiments was extremely slow and cultures grown with arsenite showed no change in their growth rate compared to cultures grown in the absence of arsenite.
2. Field Investigations.
Physical and geochemical parameters. The Twin Butte Vista Hot Spring is comprised of a small pool with a vent at the western edge and overflow waters draining in 3 channels. The flow rate in the 2 western channels was irregular, increasing with sporadic surges from the vent, and samples from these drainages were not used in this study. Waters overflowed via the northern channel at a nearly constant rate, buffered by the deep pool between the vent and outlet. The north drainage channel was very well confined and the residence time for waters in the sampled region (flow from station 1 to 5 ) was estimated to be approximately 2 minutes.
Geothermal waters venting the Twin Butte Vista Hot Spring were alkaline, with an average pH of 8.8 throughout the north drainage channel (Table 1). Water temperatures decreased from 82.6 to 65.1° C. during flow from station 1 to 5 . Conditions were reducing at the pool, becoming more oxidizing with distance as Eh increased from −87.2 mV at station 1 to 3.3 mV at station 5 . Sulfide concentrations fell from 0.13 to 0.017 mg L −1 as sulfate remained nearly constant between the first and final sampling stations. Results of additional chemical analyses are shown in Table 1.
The total dissolved arsenic concentration was approximately constant at 2.5 mg L −1 throughout the north drainage channel (Table 2). While total As behaved conservatively, specification changed dramatically as waters flowed downstream. As(III) was highest at the first sampling station at 1.9 mg L −1 and decreased at each subsequent station to 0.61 mg L −1 at the final point. Correspondingly, As(V) was low near the pool at 0.6 mg L −1 and increased with distance to 1.9 mg L −1 at the final sampling station. The rate of arsenite oxidation between stations 1 and 5 was estimated to be approximately 0.5 mg L −1 min −1 .
Laboratory experiments were performed to test for catalysis of As(III) oxidation by mineral surfaces. Sediments collected from the north drainage channel near station 1 (150 mg) were autoclaved and placed in a flask with 10 mL of filter-sterilized fluids collected from the same location. A spike of 75 mg L −1 As(III) was added to the flask which was then incubated for 48 hours at 70° C. with 125 RPM shaking. The rate of arsenite oxidation in this experiment was linear at 0.002 mg L −1 min −1 .
Microbial characterizations. Pale-orange biofilms were visible beginning at ˜2 m downstream of station 1 and were evident in the remainder of the channel. These microbial streamers, attached to sediments and other surfaces, were often very dense and formed thick filaments up to 10 cm long. Microscopic observations revealed a very low cell density at station 1 consisting primarily of cocci. Stations 2 and 3 were dominated by dense, homogenous masses of thin filamentous rods. Samples from stations 4 and 5 also contained large accumulations of thin filamentous rods in addition to clusters of thick green rods (likely cyanobacteria).
To label individual cells and quantify their relative proportion of the microbial community at each station, fluorescence in-situ hybridizations were performed. Results of FISH analyses are shown in FIG. 3 (values are expressed as the percent of (Arch915+Eub338) hybridized cells; error bars represent one standard deviation; only the positive portions of error bars are shown). The probes Arch915 and Eub338, specific for the archaeal and bacterial domains respectively, were used to label all viable prokaryotic cells. Thus0438, specific at the genus level, was used to detect Thermus species. The species-specific probes Taq1258 and Tth1258 were used to identify and enumerate Thermus aquaticus and Thermus thermophilus respectively.
At station 1 , no cells were detected with the genus- or species-specific probes, indicating that Thermus species were not present in the pool. As the hot springs waters cooled with distance, Thermus aquaticus was found to be colonizing the drainage channel at stations 2 and 3 , occurring as nearly 100% of the microbial population. Stations 4 and 5 contained a lower percentage of Thermus aquaticus (80 and 42% respectively), although the species remained prominent. Thermus thermophilus was not detected in any of the drainage samples.
TABLE 1
Physical and Chemical Characteristics of the Twin Butte
Vista Hot Spring North Drainage Channel.
Field
Station Number
Blank b
1
2
3
4
5
Approx.
—
0
3.8
6
13.5
18.5
Distance
to pool (m)
Temperature
—
82.6
79.0
77.7
72.6
65.1
(° C.)
pH
—
8.7
8.7
8.7
8.8
8.9
Eh (mV)
—
−87.2
−76.6
−36.8
−62.1
3.3
Conductance
—
1449
1460
1471
1479
1497
(uS/cm)
Al a
<0.08
0.26
0.28
0.3
0.33
0.33
B
<0.003
3.2
3.2
3.2
3.1
3.2
Ba
<0.0005
<0.0005
<0.0005
<0.0005
<0.0005
<0.0005
Be
<0.0001
<0.0001
0.0004
0.001
0.002
0.002
Ca
<0.05
0.22
0.24
0.35
0.46
0.46
Cd
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
Co
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
Cr
<0.002
<0.002
<0.002
<0.002
0.002
0.002
Cu
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
K
0.012
12
12
12
13
13
Li
<0.008
3.2
3.5
3.5
3.6
3.7
Mg
<0.06
<0.0001
<0.0001
<0.0001
0.001
0.001
Mn
<0.001
<0.001
<0.001
0.001
0.002
0.002
Na
<0.04
320
310
310
330
340
Ni
<0.002
<0.002
<0.002
<0.002
<0.002
<0.002
Pb
<0.006
<0.006
<0.006
<0.006
<0.006
0.006
SiO 2
<0.01
190
270
240
170
190
Se
<0.04
<0.04
<0.04
<0.04
<0.04
<0.04
Sr
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
V
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
Zn
<0.001
<0.001
<0.001
<0.001
<0.002
0.001
Fe (Total)
0.004
0.046
0.016
0.015
0.014
0.002
Fe (II)
—
0.021
0.009
0.006
0.002
<0.002
F
<0.05
21
22
21
21
22
Cl
<0.4
280
280
280
280
280
Br
<0.1
0.99
0.86
0.94
0.97
0.96
NO 3
<0.5
<0.5
<0.5
<0.5
<0.5
<0.5
SO 4
<0.8
16
16
16
16
17
S 2−
—
0.13
0.13
0.10
0.04
0.017
Alkalinity
—
337
341
345
347
355
(as HCO 3 )
TABLE 2
Arsenic Measurements for the North Drainage channel of
the Twin Butte Vista Hot Spring.
As (Total) a , mgL −1
As (III) a , mg L −1
As (V), mg L −1
Sample
n
mean
±
n
mean
±
by difference
Field Blank b
3
<0.0001
2
<0.0002
Station 1
2
2.5
0.01
3
1.9
0.04
0.6
Station 2
2
2.5
0.02
3
1.7
0.05
0.8
Station 3
2
2.5
0.02
3
1.3
0.02
1.2
Station 4
2
2.5
0.00
3
1.0
0.04
1.5
Station 5
2
2.5
2.02
3
0.61
0.03
1.9 | A method for converting arsenite in a source to arsenate is disclosed. The method involves incubating bacteria of a Thermus species in the source at a temperature at which the bacteria can convert at least some of the arsenite to arsenate. | 8 |
[0001] This application claims the benefit of provisional application No. 60/429,602 filed on Nov. 27, 2002, the content of which is incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] This invention relates generally to a method for the synthesis of [ 18 F]-labeled trifluoromethyl ketones. The invention more particularly relates to a method for the synthesis of [ 18 F]-labeled trifluoromethyl ketones by [ 18 F]-labeled fluorination of 2,2-difluoroenol silyl ethers.
BACKGROUND ART
[0003] There has been increasing interest in biologically active compounds known as α-Trifluoromethyl ketones (TFMKs). It has been found that many TFMK compounds have unique properties due to its α-trifluoromethyl ketone functionality. In example, TFMK's have been found to be potential hydrolytic enzyme inhibitors. In particular, TFMK's have been found to be inhibitors of protease
[0004] Kawase has reported that the trifluoromethyl group in the α-position of the carbonyl of the TFMK facilitates the formation of tetrahedral hemiketals or hydrates with water. The hydrated molecule interacts with protease, and inhibits the enzyme activity Kawase, M. J. Syn. Org. Chem. Jpn. 2001, 59, 755, which is incorporated herein by reference thereto.
[0005] It has also been demonstrated that TFMK's are cytotoxic agents against human oral tumor cell lines, such as human squamous carcinoma cells HSC-2 and salivary gland tumor cells HSG. Kawase, M.; Sakagami, H.; Kusama, K.; Motohashi, N.; Saito, S. Bioorg. Med. Chem. Lett. 1999, 9, 3113, incorporated herein by reference.
[0006] Traditionally, TFMKs are prepared from inexpensive trifluoroacetic acid derivatives. See, Creary, X. J. Org. Chem. 1987, 52, 5026; Keumi, T.; Shimada M.; Takahashi, M.; Kitajama, H. Chem. Lett. 1990, 783. Both of which are incorporated herein by reference. Additionally, the present inventors have recently reported the direct preparation of TFMKs from carboxylic esters with (trifluoromethyl)trimethylsilane (TMS-CF 3 ). See, Wiedemann, J.; Heiner, T.; Mloston, G.; Prakash, G. K. S.; Olah, G. A. Angew. Chem. Int. Ed. 1998, 37, 820, which is incorporated herein by reference thereto.
[0007] Our reported method has been extended by others with CsF catalyzed trifluoromethylation of esters. Most recently we have developed a simple and convenient general synthesis of α-trifluoromethyl ketones by fluorination using elemental fluorine F 2 (Prakash, G. K. S.; Hu, J.; Alauddin, M. M.; Conti, P. S.; Olah, G. A. J. Fluorine Chem. 2003, 121, 239, incorporated herein by reference thereto.
[0008] There is a need for an expedient process for radioactive labeling of TFMKs. However, the current synthesis methods are not suitable for the synthesis of [ 18 F]-labeled TFMKs since it is difficult to prepare [ 18 F]-labeled trifluoroacetic acid derivatives or TMS-CF 3 due to the short half-life of 18 F (t 1/2 =110 min).
SUMMARY OF THE INVENTION
[0009] The aforementioned need has been satisfied by the present invention which discloses the first synthesis of [ 18 F]-labeled TFMKs by fluorination of 2,2-difluoro silyl enol ethers with radioactive fluorine [ 18 F]-F 2 .
[0010] The present invention is preferably directed to an expedient method for synthesizing [ 18 F]-labeled trifluoromethyl ketones from the fluorination of silyl enol ethers. Thus, it has now been discovered that TFMK compounds have the potential for radiolabeling with fluorine-18. Advantageously, the radiolabeled compounds can be used as markers for identification of cell proliferation, markers for identification of viral infection, or for PET imaging.
[0011] In accordance with the present invention, a method of synthesizing [ 18 F]-labeled α-trifluoromethyl ketones is provided by reacting [ 18 F]-F 2 under sufficient reaction conditions with a compound having the general formula 1, wherein R refers to an alkyl having 1 to 24 carbons or an aryl group having 6 to 24 carbon atoms.
[0012] In one aspect of the invention, the alkyl or aryl group includes a ring. In another aspect of the invention, the alkyl group is substituted with at least one halogen, nitro group, or alkoxy group. In yet another aspect of the invention, the alkoxy group has one to eight carbon atoms. In another aspect of the invention, the alkoxy group is substituted with at least one substituent including an alkyl group having 1 to 8 carbon atoms, a halogen, an amino group, or any combination thereof. Advantageously, the substituent does not participate in the reaction.
[0013] In a preferred embodiment, the method further comprises dissolving the silyl ether compound in acetonitrile to form a solution; cooling the solution to about −50° to about −15° C.; preparing a mixture of [ 18/19 F]-F 2 and nitrogen; and bubbling the mixture of [ 18/19 F]-F 2 and nitrogen into the solution for about 5 to 15 minutes to form a reaction mixture. [ 18/19 F]-F 2 can be prepared by bombardment with [ 18 O]O 2 in a cyclotron and mixing with non-radioactive F 2 .
[0014] The silyl ether is preferably 2,2-difluoroenol silyl ether and may be prepared by mixing magnesium, tetrahydrofuran, and chlorotrimethylsilane to form a reactant mixture; cooling the mixture to between about −15° C. to 5° C.; adding trifluoroacetophenone to the cooled mixture; and stirring the mixture for about 0.5 to 1.5 hours to produce the difluoroenol silyl ether.
[0015] The [ 18 F]-labeled trifluoromethylketones that are synthesized generally have a radiochemical purity greater than 99% and specific activities between about 15 to 20 GBq/mmol at the end of synthesis. They are produced at yields of between about 45 to 55%.
[0016] Several [ 18 F]-labeled α-trifluoromethyl ketones have been synthesized by the present method. Compounds 2a˜2d shown below have been successfully synthesized in accordance with the method of the invention.
[0017] Also in accordance with the present invention is an imaging agent comprising the [ 18 F]-labeled α-trifluoromethyl ketones synthesized from the method of the invention. In one aspect of the invention, the imaging agent is useful for positron emission tomography (PET) imaging.
[0018] The invention also relates to a marker that can be used for detecting cell proliferation or for detecting viral infection. The marker of the invention comprises the [ 18 F]-labeled α-trifluoromethyl ketones synthesized according to the method of the invention and preferably includes those having a radiochemical purity of about 99%.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention is better understood by reference to the drawings figures, wherein:
[0020] FIG. 1 illustrates a chromatogram of purified labeled trifluoromethyl ketones;
[0021] FIG. 2 illustrates a HPLC chromatogram of a labeled trifluoromethyl ketone; and
[0022] FIG. 3 illustrates a radio TLC of a labeled trifluoromethyl ketone of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention relates to a general and expedient method for the preparation of [ 18 F]-labeled trifluoromethyl ketones. In accordance with the method of the invention, a fluorination reaction between [ 18 F]-labeled F 2 and 2,2-difluoroenol silyl ether 1 produces [ 18 F]-labeled trifluoromethyl ketones 2 as shown below. The R group of 2,2-difluoroenol silyl ethers 1 preferably include an alkyl or aryl group.
[0024] As noted above, radiolabeled trifluoromethyl ketone compounds 2a˜2d, shown below, have been successfully synthesized in accordance with the method of the invention.
[0025] In accordance with one aspect of the invention, difluoroenol silyl ether compounds 2a-d, shown above, can be prepared from a mixture of compound 1, which is shown below, TMSCl, and Mg 11 in anhydrous THF or DMF. The mixture is stirred for about 15 to 30 minutes, preferably 20 minutes, at a temperature between about −10° C. to about 5° C., and preferably at 0° C.
[0026] Difluoroenol silyl ether is obtained after filtration. The R of compound 1 includes but is not limited to Ph, 4-MeOC 6 H 4 , 4-CF 3 C 6 H 4 , 4-ClC 6 H 4 , 2-furyl, 2-thienyl, C 6 H 13 , or Cy. The method is disclosed in Amii, H.; Kobayashi, T.; Hatamoto, Y.; Uneyama, K. Chem. Comm. 1999, 1323, the entire content of which is expressly incorporated herein by reference. Preferably, tetrabutylammonium fluoride with D 2 O is added to the THF or DMF for the preparation of the difluoro enol silyl ethers, as disclosed in Prakash, G. K. S.; Hu, J.; Olah, G. A. J. Fluorine Chem. 2001, 112, 357), the entire content of which is expressly incorporated herein by reference. It has been found that silyl enol ethers produced by this preferred method have greater stability for hydrolysis compared to other silyl enol ethers. Although the stability of the silyl ethers enable simple handling without decomposition, freshly prepared compounds were used for radiolabeling experiments.
[0027] The goal compounds, [ 18 F]-labeled trifluoromethyl ketones, were prepared by fluorination of 2,2-difluoroenol silyl ethers 1 with [ 18/19 F]-F 2 . The [ 18/19 F]-F 2 was produced in the cyclotron by bombardment of [ 18 O]O 2 followed by mixing the target gas with non-radioactive F 2 . The mixture of [ 18/19 F]-F 2 was bubbled into the solution of the substrates 2,2-difluoroenol silyl ethers at low temperature for efficient trapping of activity. Trapping of activity was quite efficient for 2-3 mg (˜10 μmol) of the precursors. Since the syntheses were carrier added, a sufficient amount of F 2 was present, resulting in absence of any unreacted starting material in the reaction mixture.
[0028] Reactions of 2,2-difluoro-1-aryl-1-trimethylsiloxyethenes with [ 18 F]-F 2 at low temperature produced [ 18 F]-labeled α-trifluoromethyl ketones. The radiolabeled products were isolated by purification with column chromatography in 22-28% yields, and were decay corrected (d. c.) in 3 runs per compound. The radiochemical purity was greater than 99%, with specific activities of 15-20 GBq/mmol at the end of synthesis (EOS). The synthesis time was 35-40 min from the end of bombardment (EOB). This one step simple method is highly useful for the radiochemical synthesis of potential biologically active [ 18 F]-labeled α-trifluoromethyl ketones for PET.
[0029] Trifluoromethyl ketones can form hydrated products in the presence of water which can cause difficulties during HPLC purification using MeCN/H2O solvent system. However, compound 2c was found to be relatively stable in aqueous system during HPLC purification and pure product was isolated in good yield (54%). Referring to FIG. 1 , purification of 2 c is represented by a chromatogram. The desired product was eluted in 13 to 15 minutes, which could then be isolated in pure form.
[0030] Referring to FIG. 2 , analysis of pure product 2 c by HPLC showed two radioactive and three UV active peaks. The UV peaks compared to the hydrated product (a), partial hydrated product (b), and trifluoromethyl ketone (c). Only two radioactive peaks were observed corresponding to the hydrated product (a) and the ketone (c) and the ratio between the ketone and hydrated product was approximately 10:90.
[0031] In order to verify the reactivity of the trifluoromethyl ketones with water a pure 18F-labeled product collected by HPLC in CH3CN/water was heated for a short time of 1 to 2 minutes. Analysis of the product by either HPLC and TLC demonstrated 100% hydrated compound.
[0032] Although the other radiolabeled ketones could not be purified by HPLC since the products readily converted to the hydrated compound and eluted much earlier than the desired ketones, the radiolabeled ketones were in fact purified by chromatography on a small silica gel column and eluted with the organic solvent mixture, ethyl acetate and hexane (10:90). Fractions (0.5 mL) of the product were collected and radioactivity was measured on a dose calibrator. The products were eluted in the earlier fractions with an r.f. value of approximately 0.8. Pure fractions after combining were analyzed by TLC and found to be co-eluted with authentic sample checked by both UV and radioactivity.
[0033] Referring to FIG. 3 illustrated is a representative radio TLC for the compound 2 b where a is the point of application and b is the solvent front.
[0034] In non-radioactive preparations excess F 2 was used and the chemical yields were greater than 80%. However, in the radiochemical syntheses only 50% of the activity is incorporated into the substrate resulting lower yields in the range of 22-28% (d. c.) from the EOB. The radiochemical purity was greater than 99% with specific activities of 15-20 GBq/mmol. The synthesis time was 35-40 min from the EOB. In a representative preparation of 2 b, 30 mCi of labeled product was obtained starting from 120 mCi of trapped activity [ 18 F]-F 2 .
[0035] The present invention will be further understood by the examples set forth below, which are provided for purpose of illustration and not limitation.
EXAMPLES
[0036] In the following examples, all reagents and solvents were purchased from Aldrich Chemical Co. (Milwaukee, Wis.), and used without further purification, unless otherwise specified. Dichloromethane (CH 2 Cl 2 ) and fluorotrichloromethane (CFCl 3 ) were distilled over calcium hydride (CaH 2 ), and acetonitrile (MeCN) was distilled over phosphorus pentoxide (P 2 O 5 ) prior to use.
[0037] 1 H, 13 C and 19 F NMR spectra were recorded on a Bruker 500 or 360 MHz NMR spectrometer in chloroform-D using tetramethysilane and trichlorofluoromethane as internal standards, respectively. Mass spectra were obtained on a Hewlett Packard 5890 Gas Chromatograph equipped with a Hewlett Packard 5971 Mass Selective Detector.
[0038] Column chromatography was performed using silica gel (60-200 mesh) and ethyl acetate/hexane (10:90) as eluent. Thin layer chromatography (TLC) was performed on a silica gel plate (1×10 cm) and developed in the appropriate solvent system ethyl acetate/hexane (10:90). Radioactivity on the developed TLC plate was scanned on a TLC scanner (Bioscan Inc., Washington D.C.) to obtain a radiochromatogram.
Example 1
Preparation of 2,2-difluoroenol silyl ethers (1a-d):
[0039] 2,2-difluoroenol silyl ethers ( 1 a - d ) were prepared from their respective ketones by magnesium metal mediated reductive defluorination.
[0040] To a dry 250 ml Schlenk flask the following compounds were added: magnesium turnings (1.45 g, 60 mmol), dry tetrahydrofuran (THF, 120 ml) and chlorotrimethylsilane (TMSCl, 13.0 g, 120 mmol). The flask was cooled to 0° C. 2,2,2-Trifluoroacetophenone (non-radioactive) 2a (5.2 g, 30 mmol) was added drop wise into the flask with a syringe. After addition of the 2,2,2-Trifluoroacetophenone, the reaction mixture was stirred for an additional 1 h. The completion of the reaction was monitored by 19 F NMR spectroscopy. The solvent and excess TMSCl were removed under vacuum, and hexane (50 ml) was added to the residue. Solid impurities were removed by suction filtration, and the solvent was evaporated to yield 2,2-difluoro-1-phenyl-1-trimethylsiloxyethene 1 a (6.8 g, 99% yield).
[0041] The product was characterized by 1 H and 19 F NMR spectroscopy and mass spectrometry. Spectroscopic data were consistent with the literature for 2,2-difluoro-1-phenyl-1-trimethylsiloxyethene. 1 H NMR: δ=0.60 (s, 9H), 7.38 (t, J=7.5 Hz, 1H), 7.47 (t, J=7.5 Hz, 2H), 7.61 (d, J=8.8 Hz, 2H); 13 C NMR: δ=0.02, 114.09 (q, 2 J C-F =18.0 Hz), 125.84, 127.72, 128.25, 132.71, 154.87 (t, 1 J C-F =286.8 Hz); 19 F NMR: δ=−100.39 (d, 2 J F-F =68.0 Hz), −112.16 (d, 2 J F-F =68.0 Hz). MS(70 eV, m/z): 228 (M + ), 213, 197, 186 (, 177, 131, 115, 105, 89, 81, 77, 73.
[0042] Compounds having the formulae 1b-d were also characterized by 1 H and 19 F NMR spectroscopy and mass spectrometry.
Example 2
Preparation of [ 18 F]-α-trifluoromethyl ketones (2a-d)
[0043] Experiments were performed under similar conditions as described in Example 1.
[0044] 2,2-Difluoro-1-phenyl-1-trimethylsiloxy-ethene 1a (2 μL, 11 μmol) was dissolved in dry acetonitrile (0.5 ml) and cooled to −45° C. A mixture of fluorine [ 18/19 F]-F 2 and nitrogen (F 2 /N 2 (v/v=⅛)) was bubbled into the solution for 10 min. Radioactivity was measured on a dose calibrator (Capintec Inc., Ramsey, N.J.), and the reaction mixture was warmed to room temperature.
[0045] The crude product was purified by chromatography on a silica gel column using 10% ethyl acetate in hexane as eluent. Fractions (0.5 mL) were collected and radioactivity was measured. Fractions containing radioactivity were combined and solvent was evaporated to obtain the pure product. The product was analyzed by TLC with an authentic compound as a reference. The TLC plate after development was scanned for radioactivity on a TLC scanner, checked under UV lamp and compared with the reference compound. Analysis of the TLC plate showed the material to be 99% pure. Radiochemical yield was 22% (d. c).
[0046] Compounds 2b-d were produced in similar radiochemical yields in the range of 22-28% (d. c).
[0047] It is understood that the foregoing detailed description and accompanying examples are merely illustrative and are not to be taken as limitations upon the scope of the invention, which is defined solely by the appended claims and their equivalents. Various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications, including without limitation those relating to the chemical structures, substituents, derivatives, intermediates, syntheses, and or methods of use of the invention, can be made without departing from the spirit and scope thereof. | The present invention is directed to a convenient method of synthesizing radiolabeled α-trifluoromethyl ketones by a fluorination reaction. The present invention also relates to imaging agents and markers for identifying cell proliferation, or viral infection. The markers and imaging agents including the radiolabeled α-trifluoromethyl ketones that are prepared by the present method. | 2 |
TECHNICAL FIELD OF THE INVENTION
The invention relates to a linear actuator for a vehicle occupant restraint system.
BACKGROUND OF THE INVENTION
A conventional linear actuator for a vehicle occupant restraint system comprises a cylinder, a piston shiftable therein and consisting of a locking part including a conical outer section and a sealing part coaxial with said locking part, and further a plurality of locking bodies shiftably arranged between said conical outer section of said locking part and the inner wall of said cylinder and a pulling element connected to said piston by means of a holding part.
Such a linear actuator serves to convert the energy of a highly pressurized gas into a tensioning stroke which may be used to eliminate the slack of a seat belt system by, for example, rotating the belt reel of a belt retractor in the coiling direction or by suitably displacing the buckle of a seat belt.
BRIEF DESCRIPTION OF THE INVENTION
The invention provides a linear actuator which features a particularly short overall length and which can be mounted particularly simple. For this purpose, a linear actuator for a vehicle occupant restraint system is provided, which comprises a cylinder and a pulling element connected to the cylinder by means of a holding part. The linear actuator further comprises a piston which is shiftable within the cylinder and has a locking part. The locking part includes a sealing part coaxial with the locking part and a conical outer section. The conical outer section has an axial end at a side facing the sealing part and is provided with a peripheral groove at this axial end. Still further, the linear actuator comprises a plurality of locking bodies shiftably arranged between the conical outer section of the locking part and the inner wall of the cylinder. Due to this configuration two arrangements of the locking bodies relative to the locking part are possible: a fitting position in the peripheral groove in which the locking bodies do not engage the inner wall of the cylinder and an operative position in which the locking bodies are in contact with the inner wall of the cylinder. In the fitting position the piston is shiftable in both directions along the longitudinal axis of the cylinder, this being especially of advantage for fitting. By contrast, in the operative position the piston is movable only in one direction in the interior of the cylinder.
It is preferably provided for that the sealing part includes a supporting lip for the locking bodies at its axial end facing the conical outer section and that at the locking part or at the holding part a cylindrical outer section is formed on which the sealing part is movable between a fitting position spaced in the axial direction from the conical outer section and an operative position approached to the conical section. Due to this configuration the piston can be translated by particularly simple means from the fitting position into the operative position. When the sealing part is located in the fitting position, the locking bodies are reliably held in the peripheral groove by the supporting lip of the sealing part. When the sealing part is moved from the fitting position into the operative position the supporting lip forces the locking bodies from the peripheral groove into a position on the conical section in which they come into contact with the inner wall of the cylinder, the linear actuator then being ready to function.
According to a further embodiment of the invention it is provided that said locking part is slipped onto said holding part, whereby said holding part is arranged in the interior of said locking part. This results in a particularly short overall length of the linear actuator since the pulling element is connected to the piston within the length required overall in any case for the piston.
It is preferably provided for that the holding part features a conical section, this resulting in a particularly uniform transfer of force between the piston and the pulling element and thus in a particularly high strength of the connection between the piston and the pulling element.
In accordance with a preferred embodiment it is provided for that the locking part is a cold extruded part, thus permitting particularly favorable manufacture of the locking part, for example, on the basis of a hollow cylindrical tubing section, and the work hardening of the locking part occurring during cold extrusion resulting in a particularly high strength of the locking part which may also be made of a non-tempered metal.
Details of the invention are evident from the sub-claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the attached drawing in which:
FIG. 1 is a schematic discontinued cross-section through a linear actuator in accordance with the invention as a first embodiment in a functioning position;
FIG. 2 shows the linear actuator of FIG. 1 in a fitting position;
FIG. 3 shows a linear actuator in accordance with the invention as a further variant of the linear actuator of FIGS. 1 and 2 in a fitting position;
FIG. 4 shows a linear actuator in accordance with the invention as a further variant of the linear actuator of FIGS. 1 and 2 in a functioning position;
FIG. 5 shows a second embodiment of a linear actuator in accordance with the invention; and
FIG. 6 shows a third embodiment of a linear actuator in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the FIGS. 1 and 2 a first embodiment of a linear actuator in accordance with the invention is illustrated. This linear actuator comprises substantially a cylinder 10, in the interior of which a piston 12 is shiftably arranged which is connected to a pulling element 14. On activation of the linear actuator the end of the piston, shown on the right in FIGS. 1 and 2, is impacted by a pressurized gas so that the piston 12 moves in the direction of the arrow A. This movement translated to the pulling element 14 may be employed to eliminate the slack in a seat belt system, by for instance the belt reel of the belt retractor being rotated in the coiling direction or by a fitting part of the seat belt system being moved in a suitable direction relative to other parts.
In the embodiment illustrated in FIGS. 1 and 2 the pulling element 14 is configured as a cable, at the end of which assigned to the piston 12 a holding part or holding element for the piston 12 is provided which in the embodiment illustrated is designed as a preform 16 crimped onto the cable. This preform 16 comprises a conical section 18 and a projection having a cylindrical outer surface 20, a thread being formed on the latter.
The piston 12 consists of a locking part 22, a plurality of locking bodies 24 and a sealing part 26. In the embodiment shown the locking bodies 24 are formed as balls which are movable on a conical outer section 28 of the locking part 22 between a starting position shown in FIG. 1 and a locking position in which they are wedged between the locking part 22 and the inner wall of the cylinder 10, whereby a movement of the piston 12 in the direction of the arrow B is prevented or retarding with energy conversion. At its axial end facing the sealing part the locking part 22 is provided with a peripheral groove 30.
The sealing part 26 includes a sealing lip 32 in contact with the inner wall of the cylinder 10 and a supporting lip 34. The sealing part 26 is screwable on the projection 20 between a fitting position illustrated in FIG. 2 and a functioning position illustrated in FIG. 1. In the fitting position the supporting lip 34 holds the locking bodies 24 in the peripheral groove 30 so that the locking bodies 24 do not engage the inner wall of the cylinder 10. In this condition the piston 10 is movable both in the direction of the arrow A and in the direction of the arrow B in the cylinder which constitutes a major advantage as regards freedom for fitting the linear actuator. When the sealing part 26 is screwed from the fitting position in the direction of the functioning position the locking bodies 24, by the supporting lip 34, are forced out from the peripheral groove 30 and forced onto the conical outer section 28 of the locking part 22 until they come into contact with the inner wall of the cylinder 10, the linear actuator then being ready to function, i.e. when the piston 12 is impacted by the pressurized gas it is able to move in the direction of the arrow A unhampered by the locking bodies 24, whereas a movement of the piston 12 in the direction of the arrow B is counteracted by the locking bodies 24. In translation of the sealing part 26 from the fitting position into the functioning position a deformation of the supporting lip 34 materializes, as a result of which the locking bodies reliably held in the peripheral groove 30 in the fitting position of the sealing part 26 are forced over the shoulder between the peripheral groove 30 and the conical outer section 28.
As a result of the design of the linear actuator in accordance with the invention a series of advantages is achieved. Since the locking bodies 24 can be retained in a fitting position spaced away from the inner wall of the cylinder 10, greater freedom is provided in fitting the linear actuator, since in the fitting position the piston 12 can be moved in both the direction of the arrow A and in the direction of the arrow B in the cylinder, this constituting a substantial advantage over prior art linear actuators in which the piston can be moved in the cylinder in one direction only, namely in the direction of the arrow A. Due to the nested configuration, i.e. the arrangement of the complete piston on the holding part of the cable, a particularly short overall length is achieved. By suitably selecting the material for the piston 12 in keeping with the requirements a low weight is achieved all-in-all. The sealing part 26, which is exposed to no high surface pressures, may be made of a plastics material, whilst the locking part 22 exposed to high point-concentrated loads is made of metal. By means of the conical section 18 high forces effective between the cable 14 and the piston 12 result in a clamping effect on the preform 16 which can thus be dimensioned relatively lightweight, it being even possible to use a preform 16 of aluminum. Furthermore, due to the favorable transfer of force between the piston and the cable 14 a lightweight dimensioned locking part 22 may be employed. Due to the favorable design of the locking part 16 void of any undercuts it is additionally possible to manufacture this as a cold extruded part. Since the cold working of the material occurring in cold extrusion adds to the strength of the locking part 22 it is thus possible to make use of a locking part made of a non-tempered metal.
In FIG. 3 a variant of the embodiment of a linear actuator in accordance with the invention illustrated in FIGS. 1 and 2 is shown. Like reference numerals are used to identify like elements already known from FIGS. 1 and 2 and as regards the function of these elements reference is made to the explanations regarding FIGS. 1 and 2.
The difference between the variant illustrated in FIG. 3 and the embodiment shown in FIGS. 1 and 2 is that in the case of the linear actuator shown in FIG. 3 a cylindrical outer surface 20 of the projection of the preform 16 is executed plain, i.e. without a thread and that a snap-lock connector 40 is provided with which the sealing part 26 is lockable in the operative position on the locking part 22. The sealing part 26 is press-fit on the cylindrical outer surface 20 of the projection so that it is reliably held in the fitting position shown in FIG. 3. To translate the sealing part 26 from the fitting position into the operative position the sealing part 26 merely needs to be shifted in the direction of the conical outer section 28 until the snap lock 40 latches in place. The splaying of the supporting lip 34 resulting during latching of the snap lock 40 facilitates translating the locking bodies 24 out of the peripheral groove 30 onto the conical outer section 28. Further, locking bodies 24 are illustrated in FIG. 3 which are in a position in which they counteract a movement of the piston 12 in the direction of the arrow B.
The advantages attainable with this variant substantially correspond to those of the embodiment according to FIGS. 1 and 2. In addition, the sealing part 26 permits particularly facilitated translation from the fitting position into the functioning position by, for instance, the piston being pulled by means of the pulling element 14 to the right, with reference to FIG. 3, up to the corresponding end face of the cylinder 10 so that the locking part 22 is forced into the sealing part 26, this being impossible with prior art linear actuators since the locking bodies 24 counteract such a movement of the piston 12.
In FIG. 4 a further variant of the embodiment of a linear actuator in accordance with the invention illustrated in FIGS. 1 and 2 is shown, the difference as regards the embodiment according to FIGS. 1 and 2 being that the holding part 16 includes a flange-like end section 50 received in a complementary recess in the interior of the locking part 22. In this variant the force between the piston 12 and the cable 14 is transferred by the contact surface extending perpendicular to the direction of force transfer between the end section 50 and the locking part 22, thus avoiding force components which tend to splay the locking part 22.
In FIG. 5 a second embodiment of a linear actuator in accordance with the invention is schematically illustrated. Here, the difference to the embodiment according to FIGS. 1 and 2 is that the pulling element is configured as a solid pull bar 114 at the one end of which the holding part 116 is integrally formed. Employing a solid pull bar instead of a pull cable is both possible and to advantage when the movement of the piston is able to be transferred without deflection.
Due to the high strength of a pull bar the weight as a whole is reduced.
In FIG. 6 a third embodiment of a linear actuator in accordance with the invention is illustrated. Here too in this embodiment, a solid pull bar 114 is employed as the pulling element, the holding part 216 of which is integrally connected to the locking part 22 of the piston 12. Due to the direct flow of force between the piston 12 and the pull bar 114 a particularly low weight is achieved. In addition, the cold working of the material resulting during manufacture of the pull bar together with the locking part can be made use of to advantage. | A linear actuator for a vehicle occupant restraint system is provided, which comprises a cylinder and a pulling element connected to the cylinder by means of a holding part. The linear actuator further comprises a piston which is shiftable within the cylinder and has a locking part. The locking part including a sealing part coaxial with to the locking part and a conical outer section. The conical outer section has an axial end at a side facing the sealing part and is provided with a peripheral groove at this axial end. Still further, the linear actuator comprises a plurality of locking bodies shiftably arranged between the conical outer section of the locking part and the inner wall of the cylinder. | 1 |
REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 09/444,666, filed Nov. 22, 1999, now U.S. Pat. No. 6,383,296, issued May 7, 2002.
BACKGROUND OF THE INVENTION
In the application of liquid substances to a moving web or successive sheets of material, it is considered well known in the art to apply the liquid using a rotating transfer roller, and to directly apply the liquid uniformly onto the roller by means of a doctor blade assembly. The doctor blade assembly generally includes a reservoir chamber extending the length of the transfer roller and in contact with the circumferential surface thereof, and a pair of doctor blades extending longitudinally on either side of the chamber. The doctor blades are angled obliquely toward the transfer roller surface, and serve both to seal the reservoir chamber to the roller and to form a uniform film of liquid on the roller transfer surface. The assembly also must include some means to seal the reservoir chamber at the ends of the roller, so that the liquid is not flung from the roller into the surroundings, and so that the liquid may be pumped through the reservoir during the transfer process. Such transfer systems are used in flexographic and gravure printing, adhesive applicators in the paper converting industry, coating applicators in many different industrial processes, and the like. An exemplary system is described in U.S. Pat. No. 4,821,672, issued to Nick Bruno on Apr. 18, 1989.
Chambered doctor blade devices are generally employed with large printing presses or paper converting machines, either of which comprising a substantial capital investment. The forces of economics dictate that these machines be used productively to the greatest extent possible. Any downtime is considered to be a diminishment of return on investment, to be avoided whenever possible.
It is often necessary to change the ink or coating compound that is applied by the chambered doctor blade apparatus, due to color change or alteration of the machine setup. Typically, the ink reservoir, supply lines, valves, and inking chamber must be drained, flushed, cleaned, and resupplied with a new ink or coating compound. The time spent in carrying out these tasks comprises machine downtime, a loss in productivity. Automated systems for supplying a doctor blade chamber are known in the prior art, and include some draining and flushing features. These systems also enable the transfer roller to be cleaned by the doctor blade assembly as it cleans itself, shrinking the labor requirement of the cleaning and refilling process. It is highly desirable for an automated system to drain, flush, and clean all of the supply lines and fittings, whereby contamination from a former machine setup is removed before a new setup is created. One such system, depicted in U.S. Pat. No. 5,683,508 describes a doctor blade coating system which purports to automate the wash and clean cycle in addition to supplying the coating chamber. However, this system typifies the prior art in that it does not route the washing and flushing liquids through the same lines and fittings that deliver the ink or coating substances. As a result, some components such as the supply pump and supply lines, and the associated connectors are not cleaned before a new ink color or coating is introduced into the system.
It is also known that chambered doctor blade devices rely on doctor blades impinging on a transfer (anilox) roller to form a smooth and uniform film of ink or coating substance on the roller. The doctor blades are required to present a highly linear edge that impinges on the transfer roller with a force that is very uniform along the entire length of the blades (which can extend over 170 inches). Due to vibration and wear, the doctor blade edges may develop areas where the contact force varies along the length thereof, causing uneven distribution of the ink or coating film on the transfer roller.
There is known in the prior art at least one system for urging the doctor blades toward the transfer roller that employs hydraulic cylinders spaced along the apparatus to distribute the loading force therealong. Moreover, the hydraulic system is energized by pneumatic pressure, which provides hydrostatic compensation in the hydraulic circuit that enables each hydraulic piston to advance or retract as necessary to maintain a constant loading pressure against the transfer roller. In addition, the system provides a restricted flow orifice at each hydraulic cylinder, so that each cylinder may resist rapid motion (vibration and the like) while enabling slower adjustability in response to wear conditions. Although this superior doctor blade loading system has been available in the prior art, it has not been integrated into an automatic cleanup and ink and coating replacement system.
SUMMARY OF THE INVENTION
The present invention generally comprises a chambered doctor blade apparatus that provides automatic system for cleanup and replacement of ink or coating substance. The automatic system also operates a hydraulic head loading system that includes hydrostatic compensation, and integrates the head loading mechanism into the automated cleaning, flushing and replacement cycle. (Hereinafter, reference will be made to the use of ink in a printing process, but it is understood that any coating substance is encompassed by this discussion.)
In one aspect, the invention includes a chambered doctor blade assembly having a supply line connected to one end and a return line connected to the other end. A return pump has an intake connected to the return line, and an output connected through a return valve to a changeable ink reservoir. A supply pump has an output connected to the chamber supply line, and an intake connected through a supply valve to the ink reservoir. The supply pump intake line is also connected to a vent valve, and to a first wash valve that is connected to a first wash tank. The line from the supply valve at the ink reservoir is connected through a first pair of valves to a main water reservoir and a second wash tank. The line from the return valve at the ink reservoir is connected through a second pair of valves to the second wash tank and to a waste discharge outlet. Actuation of these valves and pumps in various combinations and sequences enables all of the valves, fittings, pumps, the doctor blade chamber, and the anilox roller to be drained, flushed, cleaned, flushed, and recharged with fresh ink.
In a further aspect of the invention, the system includes an automated system for controlling the valves and pumps enumerated above to carry out the cleaning and recharging functions also described above. The automated system includes a programmable logic controller (PLC) connected through a display driver to a touch screen display that depicts system conditions and presents an interactive graphical user interface for control purposes. The PLC is connected to a non-volatile memory that stores programming and values to carry out sequentially the required steps for cleaning, refilling, and running the chambered doctor blade assembly. The PLC is connected to each of the pumps and valves, and to the head loading valve of a hydrostatically compensated hydraulic head loading system.
The hydrostatically compensated hydraulic head loading system includes a hollow pivot tube extending parallel to the length of the doctor blade chamber and mounted on a coaxial pivot shaft. A plurality of hydraulic cylinders, each having a rolling diaphragm piston mounted therein, are spaced along the back panel of the doctor blade chamber, with each piston secured to the back panel. Each cylinder is rigidly secured to the pivot tube, whereby the pivot tube supports the hydraulic cylinders and the doctor blade assembly. A handle secured to the pivot tube permits the assembly to be rotated to bring the doctor blades into and out of engagement with the adjacent anilox roller.
The pivot tube also serves as a manifold to supply hydraulic fluid to the cylinders. An hydraulic supply reservoir includes a head space that is connected through a head loading valve to a source of selectively controlled pneumatic pressure, and the fluid is connected to supply the interior of the hollow pivot tube. An hydraulic supply line extends from each hydraulic cylinder to an adjacent fitting extending from the pivot tube to pressurize the cylinders whenever the head loading valve is activated. The pneumatic loading of the hydraulic fluid supplies a constant and uniform pressure to all the cylinders, and further enables the hydraulic fluid to flow bidirectionally and allows each hydraulic piston to advance or retract as necessary to maintain a constant loading pressure against the transfer roller. In addition, the system provides a restricted flow orifice at each hydraulic cylinder, so that each cylinder may resist rapid motion (vibration and the like) while enabling low velocity adjustability in response to wear conditions.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a chambered doctor blade mounted on a hydrostatically compensated hydraulic head loading assembly and connected to an automatic cleaning and refilling system.
FIG. 2 is an enlarged partial plan elevation of the chambered doctor blade assembly as shown in FIG. 1 .
FIG. 3 is a schematic view of the hydrostatically compensated hydraulic head loading system combined with the automatic cleaning and recharging system of the invention.
FIG. 4 is a schematic representation of the active mechanical components of the automatic cleaning and recharging system of the invention.
FIG. 5 is a functional block diagram representation of the active electronic components of the automatic cleaning and recharging system of the invention.
FIG. 6 is a side elevation of the doctor blade assembly and the head loading system of the invention.
FIG. 7 is an enlarged cross-sectional detail of the doctor blade chamber connections to the return lines.
FIG. 8 is an enlarged top view of the drain reservoir valve of the automatic cleaning and recharging system of the invention.
FIG. 9 is a perspective view the console of the automatic cleaning and recharging system of the invention.
FIG. 10 is a chart depicting the operational status of each active mechanical component of the automated system in each step required for filling, running, and cleaning the chambered doctor blade assembly using non-water-based coatings.
FIG. 11 is a chart depicting the operational status of each active mechanical component of the automated system in each step required for filling, running, and cleaning the chambered doctor blade assembly using water-based coatings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention generally comprises a chambered doctor blade apparatus that includes an automatic system for cleanup and replacement of ink or coating substance. With regard to FIGS. 1, 2 , and 6 , the applicator portion of the invention includes a chambered doctor blade assembly 21 extending parallel to a transfer roller 22 (anilox or equivalent) that engages a printing press, coating applicator, or the like. The assembly 21 includes a longitudinally extending cavity, or chamber 24 , and a pair of doctor blades 23 that engage the surface of the transfer roller and form a uniform thin fluid film thereon. The chamber 24 is formed by a channel-like structure having a central web 26 and side walls extending therefrom in parallel, spaced apart relationship.
A hollow pivot tube 27 extends parallel to the central web 26 for substantially the entire length thereof, and is mounted on coaxial pivot shafts 28 which are rotatably supported at opposed ends. A plurality of hydraulic cylinders 31 are mounted rigidly on the pivot tube 27 and spaced longitudinally therealong. Each piston rod 32 of the cylinders 31 is secured to a mounting disk 33 , which in turn is slidably received in a receptacle in a bracket 30 secured to the back surface of the central web 26 . A lock-down screw 25 secures the disk 33 in the bracket 30 . Thus the entire structure 21 is supported by the piston rods 32 , which in turn are supported on the pivot tube 27 . A handle 34 is secured to the tube 27 to enable rotation of the tube to bring the chambered doctor blade assembly 21 into and out of engagement with the transfer roller 22 . At least one shaft lock 36 is also provided to lock the pivot tube 27 and pivot shafts 28 at a fixed angular orientation to secure the apparatus 21 in an engaged or disengaged disposition.
It may be appreciated that the entire head assembly 21 may be removed quickly and easily by loosening all of the screws 25 , and sliding the brackets 30 off of the disks 33 . Another head assembly 21 may be substituted by reversing this process.
The pivot tube 27 further serves as a manifold to supply low pressure hydraulic fluid to the cylinders 31 . An hydraulic supply reservoir 37 is disposed adjacent to the tube 27 , and includes a supply line 38 that delivers hydraulic fluid from the reservoir to the interior of the pivot tube 27 . The reservoir provides head space above the fluid charge therein, and a pneumatic line 39 connects the head space through a head loading valve to a pressurized gas source having a selectively adjustable pressure in a generally low pressure range. A plurality of supply lines 41 extend from a fitting on the pivot tube 27 to a respective one of the hydraulic cylinders 31 . Thus the hydraulic fluid supplied through the interior of the pivot tube 27 to each cylinder is under a constant and uniform pressure, and is free to flow bidirectionally between the reservoir, pivot tube, and cylinders. This feature enables all pistons to exert the same force on the central web of the doctor blade assembly, while each piston is able to extend a variable amount until it meets sufficient mechanical resistance that is equal and opposite to the hydraulic force of the piston. This attribute allows the doctor blade assembly to self-compensate for wear, expansion, and other physical variables in the relationship between the doctor blade assembly and the transfer roller.
With regard to FIG. 3, each cylinder 31 includes a piston 42 connected to the piston rod 32 , the piston 42 having a rolling diaphragm seal 43 . The driving chamber 44 of the cylinder 31 is connected through a restricted orifice 46 to the input of the supply line 41 . The restricted orifice 46 prevents the piston 42 from undergoing any high velocity translation, thereby minimizing any response to rapid motion of the doctor blade assembly, such as vibration and the like. On the other hand, the restricted orifice does not inhibit low velocity translation of the piston 42 , whereby the system provides self-compensating adjustment to wear and other long-term variables.
With regard to FIG. 4, the mechanical components 100 of the automated cleaning, filling, and operating system include an interchangeable coating supply reservoir 101 . A draw tube in the reservoir 101 feeds a coating substance (ink or UV coating or any other liquid) through a supply valve 102 to a supply line 131 . The supply line 131 extends to the intake port of supply pump 124 , the output of which is connected through line 132 to the doctor blade chamber. The system also includes a heated clean water reservoir 105 that is connected through supply valve 104 to the supply line 131 . The reservoir 105 is maintained at a fill level by a valve 110 connected to a clean water supply, using a level detector (as is known in the art) to operate the valve 108 . A heater 107 in the reservoir 105 heats and maintains the water at a preset temperature, and is thermostatically controlled.
In addition, the system includes a recirculation reservoir 109 that has an outlet connected through valve 103 to the supply line 131 . The inlet to reservoir 109 is connected through valve 106 to the return line 136 . A valve 107 connects the return line 136 to the inlet of coating supply reservoir 101 , and a valve 108 connects the return line 136 to a waste discharge receptor.
With reference to FIG. 5, the invention further includes an automatic system 51 for operating the valves and pumps described above to carry out all steps required for filling, running, and cleaning the chambered doctor blade assembly. The automated system 51 includes a programmable logic controller (PLC) 52 connected through a display driver 54 to a touch screen display 56 . The display 56 serves as a graphical user interface by presenting system functions that are selectable by a user. The display 56 further acts as an input device by enabling the user to tap the portion of a screen display that corresponds to a chosen function, and the touch screen feeds the selection information back to the PLC 52 . In addition, a non-volatile memory 53 that stores programming instructions and data values is connected to the PLC 52 to provide the proper screen displays and carry out the functions and choices portrayed by the screen displays.
The PLC 52 is also connected to operate the system pumps 57 (corresponding to the supply pump 124 and return pump 126 of FIG. 4 ), and the system valves (corresponding to the valves 102 - 104 , 106 - 108 , 110 , 123 , and 135 ). The PLC is also connected to operate the head loading valve 59 which, as described previously, controls the application of pneumatic pressure to the hydraulic fluid reservoir 37 that supplies the hydraulic cylinders 31 of the doctor blade mounting system. The PLC is further connected to the heater 107 and to appropriate sensors and limit switches that a prudent individual skilled in the art would include for safety and smooth operations. The stored programming of the PLC 52 is written to carry our the operating functions of the doctor blade system, including, but not limited to, the functions described in FIG. 10 (for UV cured coatings) and FIG. 11 (for water-based coatings). All of these functions may be carried out while the chambered doctor blade assembly 21 is engaged with the roller 22 , whereby the roller is cleaned, washed, and coated at the same time as the remainder of the system undergoes these processes. As a result, the head loading valve 59 is On for all of the procedures except the Stop and Unload condition.
The mechanical components depicted in FIG. 4 and the electronic system of FIG. 5 may be incorporated into a small, portable console 81 , as shown in FIG. 9 . The console 81 is supported on casters, and includes a tank 84 that comprises the heated water reservoir 105 , and a space for a removable container 86 that comprises the recirculation supply reservoir 109 . The coating supply reservoir 101 is maintained in separate tank 83 that is connected through removable lines to the console 81 . Note that the tank 83 is easily removed and replaced (swapped) to change the coating material that is applied by the system. A significant advantage of this system is that UV curable coatings (typically not compatible with water as a solvent) and water-based coatings may be alternated and are automatically accommodated, as described below.
The touch screen display 56 is supported in a handheld remote control 82 connected by cable to the console 81 , whereby the user may select a desired function for the system, and the function is carried out by the electronic system depicted in FIG. 5 . The desired function may include a plurality of the procedures listed in FIGS. 10 and 11, carried out sequentially to effect a complete job change for the transfer roller; i.e., coating purge and drain, recirculate wash and drain, and, thereafter, coating fill and run.
The apparatus may further include an ambient port 71 , as shown in FIGS. 1 and 2, that is disposed in a trough or channel 70 interposed between the return line 133 and the valve 127 . It has been observed that the chambered doctor blade assembly, when running against the transfer roller, may develop a suction adhesion to the transfer roller. When the system is switched to a function such as draining a liquid from the chamber 24 , the vacuum in the chamber may hamper complete pump-out of the liquid. To overcome this effect, the ambient port 71 includes a top opening 72 that is open to atmosphere, as shown in FIG. 9, to maintain the return line to atmospheric pressure and releases any vacuum suction effects. The return pump may be operated at a slightly greater rate than the supply pump to assure that the flow through channel does not overflow from opening 72 . Note that the trough 70 may extend substantially the entire length of the doctor blade chamber.
A significant advantage of this system is the capability to go from a water-based coating to a UV based coating and back again with little effort. This is successfully completed by the use of the coating purge step, followed by chamber filling of a different coating material. Thus, for example, a run of water based coating followed by a water based wash and drain routine could result in some residual water based fluids in the lines, valves, and fittings of the system. A subsequent run of UV coating could become contaminated by residual water based fluids in the system. To overcome this problem, a new coating run always begins with a coating purge step, in which the new coating is briefly pumped through the system and discharged to waste, thereby sweeping away the residual water based fluids. Thereafter, the coating fill and run routines are free of contamination. The same is true when switching from a UV coating to a water based coating.
The initial screen prompts the operator to select either water based coating or UV coating. When this selection is made the system selects the wash up procedure that is required. This is done due to the fact that water should not be used to wash UV coatings. Thus, as shown in FIG. 10, none of the wash steps for UV coatings involve opening the valve 104 to admit water to the system; rather, the recirc. supply tank 109 holds a solvent or the like that is fed through valve 103 to provide the fluid for the washing functions.
After the initial type of coating is selected there are only two choices that need to be selected. Start Coat and Start Wash. All the functions happen automatically after these selections are made. When Start Coat is selected the following process steps occur:
Chamber Load: The chamber will load against the anilox roll and the coating purge process will start after a given amount of time.
Coating Purge: The supply pump pulls material from the supply container, pumps it up to the chamber and through the bottom of the chamber. It then flows into the trough or reservoir 70 and is pulled out of the trough 70 by means of the return pump which is then pumped to waste for the given amount of time.
Coating Fill: The chamber drain valve is then closed, allowing the chamber to fill.
Coating Run: The chamber drain valve remains closed and the pumps automatically slow down for the duration of the coating job, after which the operator will select the automatic wash up. The Run Speed can be adjusted at the console for different flow rates.
At this point the operator may select Start Wash and the following steps will automatically occur:
Coating Wash: The first step when Coating Wash is selected is Coating Drain. It stops the supply of coating to the chamber by means of opening a pump vent valve. It also opens the chamber drain valve allowing the coating to drain from the chamber into the trough or reservoir. It returns as much residual coating back to the coating supply container as is set as a timing function by the installer.
Warm Water Rinse: (This rinse is only enabled when ‘water based’ is selected on the touch screen) Water is drawn with the supply pump from the water reservoir up to the chamber, through the chamber with the chamber drain valve closed at first to fill the chamber then opened to flush the bottom of the chamber. All of this flows into the trough where the return pump draws the material and sends it to waste.
Water Drain: The supply pump vent valve opens, stopping the supply of water to the chamber and draining the system of the residual material. This mode is only enabled when water based is selected at the start of the process.
Recirculation Wash: This wash cycle is enabled with either water based selected or UV selected. It pulls recycled wash up material from the recirculation container by means of the supply pump, supplies it to the chamber with the chamber drain valve closed to fill the chamber then opens the valve to flush the bottom of the chamber, all of this flowing into the trough and returned to the recirculation container by means of the return pump. The difference between the Water based wash and the UV wash is the UV wash cycle uses only the recirculation container to supply cleaning material, as any fresh water would contaminate the UV material.
Recirculation Drain: This opens the supply pump vent valve stopping the supply of wash materials and allowing residual materials to be drained back into the recirculation tank.
Warm Water Rinse 2: This step pulls warm water from the warm water supply tank up to the chamber with the chamber drain valve closed at first and then opening. This mode is only enabled when water-based is selected at the start of the process.
Water Drain 2: This opens the supply pump vent valve which stops the flow of water to the chamber and drains the residual out of the systems and to waste.
Chamber Unload: At the end of the wash process the chamber is automatically unloaded.
It is significant to note that any residual wash fluid is purged from the system by the introduction of new coating material at the start of the subsequent coating run. The Coating Purge step uses the new coating material to sweep any residual wash fluid from the lines and valves, and this material all goes to waste. Thereafter, the coating fill and run stages are free of any wash fluid that may be solvent-incompatible.
With regard to FIGS. 1, 2 , and 7 , the return lines 133 and 134 are connected to a manifold 61 secured to the return end of the chamber 24 of the doctor blade assembly 21 . The connection of line 133 is used for circulating coating material during a system run cycle, as it provides the smoothest fluid flow through the chamber, and both the connections of lines 133 and 134 are used to drain liquid out of the chamber 24 , due to the fact that the connection of line 133 is at the bottom of the chamber when the system remains engaged with a transfer roller, as shown in FIGS. 1 and 2. On the other hand, the connection of line 134 is lowermost when the doctor blade assembly 21 is rotated about the pivot tube 27 to disengage and move away from the transfer roller 22 , and line 134 is used to drain the chamber in the disengaged disposition. In either case, liquid drained from the chamber first passes through the trough 70 at atmospheric pressure.
Thus the invention provides a system that automatically supplies coating material to a chambered doctor blade assembly, while also loading the doctor blade assembly against a transfer roller with a self-compensating, pressure balanced mounting apparatus. The system further carries out typical printer or industrial job changing tasks, such as draining, cleaning, and rinsing the doctor blade assembly and the transfer roller, and further refilling the system and supplying the system for a further production run, all automatically.
The foregoing description of the preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and many modifications and variations are possible in light of the above teaching without deviating from the spirit and the scope of the invention. The embodiment described is selected to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as suited to the particular purpose contemplated. It is intended that the scope of the invention be defined by the claims appended hereto. | A chambered doctor blade apparatus provides an automatic system for cleanup and replacement of coating substance, as well as operating a hydraulic head loading system that includes hydrostatic compensation, and integrates the head loading mechanism into the automated cleaning, flushing and replacement cycle. A programmable logic controller (PLC) is connected to a touch screen display that presents an interactive graphical user interface for control purposes. The PLC is programmed to carry out sequentially the required steps for cleaning, refilling, and running the chambered doctor blade assembly, and to alternate water-based and non-water-based coatings without necessitating removal of the doctor blade head from the transfer roller. Each coating run begins with a purge step in which a new coating material is pumped through the system to waste to remove any residual material from the previous coating run. | 3 |
[0001] This application claims the benefit of U.S. provisional application No. 60/208,098, filed May 31, 2000.
FIELD OF INVENTION
[0002] The present invention relates to a method and an arrangement in a data communications system according to the preambles of the independent claims. More specifically it relates to a processing unit wirelessly connected to a printer. It further relates to printing a document by means of the printer, the printer being controlled by the processing unit.
DESCRIPTION OF RELATED ART
[0003] Processing units, e.g. PC's requiring to print documents uses typically a printer. A processing unit and a printer are generally communicating with each other through cables. But communication disruption caused by wire breakage or inadequate securing of the cable ends, added cost of providing a reliable cable and reliable associated connectors, tangling of the cables and requirements of flexibility, etc. leads to a requirement of replacing the cables.
[0004] A way of communicating, using a infrared link instead of a cable is shown in the American patent U.S. Pat. No. 6,055,062, which discloses an electronic printer having an attached accessory unit. The accessory unit handles e.g. optional media (e.g. paper) supply units and optional media output. To communicate with the accessory unit, the printer uses a two-ways infrared communications connection to the accessory unit to which it is immediately adjacent.
[0005] However the range of the infrared link is short, so that the distance between processing unit and the printer have to be less than a few meters and there must be a clear line of sight between them.
[0006] The so-called Bluetooth interface is an example of a modern radio interface, which was originally intended as replacement for cables between units. The term Bluetooth is in this disclosure used as an example of usage of short-range radio communication. By replacing the cables, the short-range radio technology provides a universal bridge to existing data networks, a peripheral interface, and a mechanism to form small private ad hoc groupings of connected devices away from fixed network infrastructures or connected to a fixed network infrastructure via a gateway. Designed to operate in a noisy frequency environment, the Bluetooth radio uses a fast acknowledgement and frequency hopping scheme to make the link robust. Bluetooth radio modules avoid interference from other signals by hopping to a new frequency after transmitting or receiving a data packet, as shown in FIG. 1 wherein the X-axis represents the frequency f and the Y-axis represents the time t. Compared with other systems operating in the same frequency band, the Bluetooth radio typically hops faster and uses shorter radio packets. This makes Bluetooth radio more robust than other systems. Use of Forward Error Correction (FEC) limits the impact of random noise on long-distance links.
[0007] Bluetooth radio is a wireless communication technology using a frequency-hopping scheme in the unlicensed Industrial Scientific Medical (ISM) band at 2.4 GHz. A frequency hop transceiver is applied to combat interference and fading. A shaped, binary FM modulation is applied to minimise transceiver complexity. The gross data rate is 1 Mb/s and Time-Division Duplex (TDD) scheme is used for full duplex transmission.
[0008] The Bluetooth protocol is a combination of circuit and packet switching. In FIG. 1, S 1 denotes one time slot, and P 1 denotes a packet covering three time slots. A time slot is 0,625 ms long. Time slots can be reserved for synchronous packets. Each packet is normally transmitted in a different hope frequency. A packet normally covers a single slot, but can be extended to cover up to five slots. Bluetooth can support an asynchronous data channel, up to three simultaneous synchronous voice channels, or a channel with simultaneously supports asynchronous data and synchronous voice. Each voice channel supports 64 kb/s synchronous (voice) link. The asynchronous channel can support an asymmetric link of maximally 721 kb/s in either direction while permitting 57,6 kb/s in the return direction, or a 432,6 kb/s symmetric link.
[0009] In FIG. 2, the different function blocks of a system using short-range radio transceivers such as Bluetooth are shown. A radio unit 201 is connected to a link control unit 202 providing the base band. The link control unit 202 is connected to the Central Processing Unit, called CPU, 203 providing the link management. The CPU is connected to the memory 204 providing software functions and consisting of two memory units: a SRAM 205 and a FLASH 206 . The CPU 203 is connected to a host interface 207 . A SRAM is a fast temporary memory. FLASH is a programmable ROM.
[0010] Two or more, up to eight Bluetooth units sharing the same channel form a piconet, i.e. a piconet is a collection of devices connected via Bluetooth technology in an ad hoc fashion. Within a piconet a Bluetooth unit can have either of two roles: master or slave. Within each piconet there may be one and only one master, and up to seven active slaves, i.e. a piconet starts with two connected devices, such as a portable PC and a cellular telephone, and may grow to eight connected devices. All Bluetooth devices are peer units and have identical implementations. Any Bluetooth unit can become master in a piconet. A master unit is the device in a piconet whose clock and hopping sequence are used to synchronise all other devices within the piconet. A slave unit is every device in a piconet that is not a master.
[0011] The communication within a piconet is organised such that the master polls each slave according to some polling scheme. Master-to-slave transmission always starts in an even-numbered time-slot while slave-to-master transmission always starts in an odd-numbered time slot. With one exception the slave is only allowed to transmit after have been polled by the master. The slave then starts its transmission in a slave-to-master time slot immediately following the packet received from the master. The master may or may not include data in the packets used to poll the slave. The only exception to the above principle is that when a slave has an established Synchronous Connection Oriented (SCO) link, the slave is always allowed to transmit in the pre-allocated slave-to-master slot, even if not explicitly polled by the master in the preceding master-to slave slot. The term SCO-link will be disclosed in more details below. In a Bluetooth communications system there is no direct transmission between slaves in a piconet.
[0012] The Bluetooth protocol stack will be described, according to the specifications of the Bluetooth system. The protocol stack which is depicted in FIG. 3, includes two Bluetooth units 301 and 302 . In the figure the physical layer and the data link layer are shown.
Baseband BB
[0013] The base band describes the digital signal processing part of the hardware, i.e. the Bluetooth link controller, which carries the Bluetooth protocols and other low-level link routines. The Baseband resides in the physical layer 301 and the data link layer 304 . The baseband specification defines two link types: Synchronous Connection-Oriented (SCO) links and Asynchronous Connection-Less (ACL) links. SCO links support real-time voice traffic using reserved bandwidth. ACL links support best effort traffic.
Link Manager Protocol LMP
[0014] LMP handles messages used for link set-up, security and control. LMP is layered over the Baseband protocol and resides in the data link layer 304 .
Logical Link Control and Adaptation layer Protocol, L2CAP
[0015] L2CAP is also layered over the Baseband protocol and resides in the data link layer 304 . L2CAP provides connection oriented and connectionless data services to upper layer protocols with multiplexing capability, segmentation and reassemble operation, and group abstractions. The L2CAP Specification is only defined for ACL links.
Network Layer 305
[0016] The network layer is currently not specified in the Bluetooth standard.
High Level Protocol or Application 306
[0017] Device information, services and the characteristics of the services can be queried using the Service Discovery Protocol SDP. Like SDP, RFCOMM is layered on top of the L2CAP. RFCOMM is the ‘cable replacement’ protocol, which provides transport capabilities for high-level services (e.g. OBEX protocol) that use serial line as the transport mechanism.
[0018] On top of the link and transport protocols, the applications still need some specific protocols to complete the protocol stack. In the Bluetooth architecture, the application-specific protocols are added on top of RFCOMM or directly on the L2CAP. L2CAP can only be accessed via a protocol which is supported by a Bluetooth profile such as RFCOMM.
[0019] The enumerated application-specific protocols offer the basic functionality in the Bluetooth environment and they provide only the cable-replacement capabilities. Features such as broadcasting, point-to-multipoint topologies, and scatternet possibilities are not really utilised by these current high-level protocols and usage models. Thus, there are numerous possibilities for developers to create more applications, the nature of which can be totally different from the existing ones.
[0020] The object of the present invention is to achieve a wireless communication between a processing unit and a printer using a safe transmission and an increased transmission range compared to the infrared transmission used in the above mentioned U.S. patent.
SUMMARY OF THE INVENTION
[0021] The object of the invention is to unravel the above mentioned drawbacks and achieve a way of printing a document in a data communications system using a protocol profiled for printing in the Bluetooth protocol architecture.
[0022] This is achieved according to the method and arrangement set forth in the characterising parts of the independent claims.
[0023] Preferred embodiments are set forth in the independent claims.
[0024] An advantage of the method and arrangement according to the present invention is that it is possible to communicate wirelessly with a printer at a wide range, up to 10 meters and extendable up to 100 meters.
[0025] Another advantage is that it offers a safe transferring of data.
[0026] Yet another advantage is that the present invention makes it possible to wirelessly select a printer among available printers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 is a diagram showing the relationship between timeslots and frequency hops in a system using Bluetooth.
[0028] [0028]FIG. 2 is a diagram illustrating the different function blocks of a Bluetooth system.
[0029] [0029]FIG. 3 is a diagram showing the Bluetooth protocol stack.
[0030] [0030]FIG. 4 is a schematic block diagram showing a communications system according to the present invention.
[0031] [0031]FIG. 5 is a schematic block diagram showing an entity according to the present invention.
[0032] [0032]FIG. 6 is a schematic block diagram showing a printer entity according to the present invention.
[0033] [0033]FIG. 7 shows a flowchart of the method according to the invention.
[0034] [0034]FIG. 8 is a bloc diagram depicting a protocol overview over the Bluetooth protocols according to the invention.
[0035] [0035]FIG. 9 shows a signalling sequence over a typical SDP transaction.
[0036] [0036]FIG. 10 shows a signalling sequence over typical WPP transactions.
[0037] [0037]FIG. 11 shows a signalling sequence over typical WPP transactions.
[0038] [0038]FIG. 12 shows a signalling sequence over typical WPP transactions.
[0039] [0039]FIG. 13 shows a signalling sequence over typical WPP transactions.
[0040] [0040]FIG. 14 shows a signalling sequence over typical WPP transactions.
[0041] [0041]FIG. 15 shows a signalling sequence over typical WPP transactions.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] FIGS. 1 - 3 are related to prior art and described above under “Description of related art”.
[0043] The wording “client” is in this disclosure defined as the entity sending a request, and the wording “server”, is in this disclosure defined as the entity receiving a request.
[0044] [0044]FIG. 4 shows a possible scenario of the present invention. A Bluetooth data communications system 401 includes two nodes whereof one is a processing unit, which in this example is a PC 402 and the other is a printer 403 . A wireless printer protocol according to the invention is implemented in the Bluetooth protocol stack which is included in a entity, e.g. a PC-card 404 , connected to or implemented in the PC 402 , and in a printer entity, e.g. a printer adapter 405 , connected to or implemented in the printer 403 . According to the Bluetooth standard the distance between the processing unit and the printer is up to 10 meters and extendable up to 100 meters The printer adapter 405 might be connected to the printer port on the printer. The PC 402 and the printer 403 are connected to each other via a Bluetooth air interface 406 . Both entities 404 and 405 comprise a respective computer, each computer comprising an internal memory for storing computer program not visible in FIG. 4.
[0045] The entity 404 connected to or implemented in the processing unit 402 , will now be described more in detail. The entity, now referred to as 501 is shown in FIG. 5. The entity 501 includes a Bluetooth protocol stack in which protocol stack a wireless printer protocol is implemented. The printer protocol comprises a printer client which communicates with a printer server by means of the wireless printer protocol, the Bluetooth protocol stack and air interface,. The printer server is included in a printer but is not visible in FIG. 5.
[0046] The entity 501 includes an establishing device 502 arranged for establishing a bi-directional wireless ACL connection between the processing unit and the printer by means of the Bluetooth protocol.
[0047] The entity 501 comprises further a sending device 503 arranged for sending a connection request message to the printer server and a negotiating device 504 arranged for negotiating configuration parameters with the printer server. The negotiating device 504 comprises a sending device 505 arranged for sending, to the printer server, a configuration request message including no new options if the printer client uses default values. The negotiating device 504 comprises also a sending device 506 arranged for sending, to the printer server, a configuration request message including a suggestion of configuration options. The negotiating device 504 comprises further a sending device 507 arranged for sending, to the printer server, a further configuration request message including a suggestion of configuration options which differs from earlier suggestions of configuration options. This latter sending device 507 is to be used if the printer client receives a response message from the printer server that the configuration request was not acceptable due to e.g. unacceptable parameters, unknown option etc.
[0048] The entity 501 comprises a sending device 508 arranged for sending a set attribute request message to the printer server, the message comprising e.g. a coding table concerning a negotiated coding type and is to be loaded by the printer server.
[0049] The entity 501 comprises a sending device 509 arranged for sending keep alive messages frequently to the printer server. A keep alive timer 510 is implemented in the entity 501 and comprises a starting device 511 arranged for starting and restarting the keep alive timer 510 each time a valid message is sent to the printer server and each time a valid message is received from the printer server. The keep alive timer 510 further comprises a closing device 512 arranged for closing the connection between to the printer server, when the keep alive timer 510 expires.
[0050] For starting one or more printjobs the entity 501 comprises a starting device 513 arranged which starting device 513 comprises a sending device 514 arranged for sending a request message to the printer server comprising a request to start a printjob.
[0051] The print data that is to be printed by the printer is sent by means of a sending device 515 arranged for sending the print data to the printer server. Said device 515 includes a sending device 516 arranged for sending a number of request messages to the printer server, the messages comprising print data.
[0052] A printing process might be broken, e.g. because the printer runs out of paper or the ACL connection is broken, etc. This is reported by the printer server in a message received by the printer client. The entity 501 comprises a device 527 arranged for interpret the message and give a note to the user of the processing unit, e.g. by presenting the note on the screen of the PC.
[0053] E.g. a refill of paper or a new creation of a disconnected ACL connection might make, but the entity 501 comprises a continuing device 517 arranged for continuing the printing process by continuing to send print data request messages to the printer server, starting with the print data subsequent to a last received print data acknowledgement message.
[0054] The entity 501 comprises a stopping device 518 arranged for stopping the keep alive timer 510 when an ACL connection is disconnected during a printing process.
[0055] The entity 501 further comprises a requesting device 519 arranged for requesting a reconnection of a session defined by the session identifier in a message sent to the printer server to be used when a new ACL connection is created to the printer, after a break.
[0056] The entity 501 comprises a stopping device 520 arranged for stopping the print job said stopping device 520 comprises a sending device 521 arranged for sending a message to the printer server, the message comprising a request to stop the printjob. The stopping device 520 will be used when all data to be printed in a printjob is sent to the printer.
[0057] The entity 501 further comprises a closing device 522 arranged for closing the connection between the processing unit and the printer, the closing device comprising a sending device 523 arranged for sending a message to the printer server, the message comprising a request to disconnect a session identified by a session identity.
[0058] The entity 501 comprises a stopping device 524 arranged for stopping the sending of keep alive messages after closing a connection between the printer client and the printer server.
[0059] The entity also comprises a receiver 525 for receiving messages sent from a printer and a transmitter 526 for sending messages to the printer.
[0060] The printer entity 405 connected to or implemented in the printer 403 shown in FIG. 4, will now be described more in detail. The printer entity, now referred to as 601 is shown in FIG. 6. The printer entity 601 , including a Bluetooth protocol stack in which a wireless printer protocol is implemented, said protocol comprising a printer server which communicates, by means of the wireless printer protocol, the Bluetooth protocol stack and air interface, with a printer client, e.g. the printer client in the entity 501 described above . The printer client is included in a processing unit 402 and is not visible in FIG. 6.
[0061] The printer entity 601 comprises a receiver 602 for receiving messages sent from a processing unit and a transmitter 603 for sending messages to the processing unit.
[0062] The printer entity 601 further comprises a responding device 604 arranged for responding upon a connection request whether the connection is successful or not, in a response message sent to the printer client.
[0063] The printer entity 601 comprises a negotiating device 605 arranged for negotiating configuration parameters with the printer client within the processing unit.
[0064] The negotiating device 605 comprises a responding device 606 arranged for responding upon a configuration request whether the configuration options in the configuration request are supported by the printer server or not.
[0065] The negotiating device 605 comprises a loading device 607 arranged for loading a coding table or other optional attributes sent from the printer client.
[0066] The negotiating device 605 further comprises a sending device 608 arranged for sending a response, whether the loading of the coding table was successful or not, to the printer client. The printer entity 601 comprises a sending device 609 arranged for sending keep alive messages frequently to the printer client.
[0067] A keep alive timer 610 is implemented in the printer server within the printer entity 601 . The printer entity 601 comprises a starting and restarting device 611 arranged for starting the keep alive timer each time a valid message is received from the printer client and each time a valid message is sent to the printer client.
[0068] The printer entity 601 comprises a starting device 612 arranged for starting a print job. The starting device 612 comprises a confirming device 613 arranged for confirming a start printjob request message sent to the printer client
[0069] The printer entity 601 comprises a receiving device 614 arranged for receiving print data from the printer client. The receiving device 614 including a sending device 615 arranged for sending an acknowledgement message to the printer client after receiving a previous decided number of print data request messages.
[0070] The printer entity 601 comprises an indicating device 616 arranged for indicating, in a message sent to the printer client, that the printer has reported an exemption condition, e.g. that the printer is out of paper, if the printer runs out of paper.
[0071] The printer entity 601 further comprises an indicating device 617 arranged for indicating, in a message sent to the printer client, when the printer clears the exemption, e.g. that the printer is refilled, when the printer is refilled.
[0072] The printer entity 601 comprises a stopping device 618 arranged for stopping the keep alive timer when an ACL connection to the processing unit is disconnected during a printing process.
[0073] The printer entity 601 comprises a sending device 619 arranged for sending a response message to the printer client, according to whether a reconnection request is granted or not.
[0074] The printer entity 601 comprises a stopping device 620 arranged for stopping the print job. The
[0075] stopping device 620 including a sending device 621 arranged for sending a response message, after the printer server has received a request to stop the printjob, the message comprising a confirmation that this is apprehended and is sent to the printer client.
[0076] The printer entity 601 comprises a sending device 622 arranged for sending a response message to the printer client, according to whether a disconnection request is granted or not.
[0077] The printer entity 601 further comprises a stopping device 623 for stopping the sending of keep alive messages after the connection to the printer client is closed.
[0078] [0078]FIG. 7 shows a flowchart of a possible scenario of the printing process according to the present invention.
[0079] The method includes the following steps:
[0080] [0080] 701 . A bi-directional wireless Asynchronous Connection-Less (ACL) connection is established between the processing unit 402 and the printer 403 by means of the printer protocol calling the L2CAP requesting the connection and the L2CAP creating the connection.
[0081] [0081] 702 . A connection is established between the printer client and the printer server for one or more printjobs.
[0082] [0082] 703 . The processing unit 402 and the printer 403 negotiate configuration parameters for said connection.
[0083] [0083] 704 . Keep alive messages are sent frequently during the session from the processing unit 402 to the printer 403 and from the printer 403 to the processing unit 402 .
[0084] [0084] 705 . The processing unit 402 starts the printjob and
[0085] [0085] 706 . sends the printer data to the printer 403 .
[0086] [0086] 707 . The print job is stopped and
[0087] [0087] 708 . the connection is closed between the processing unit 402 and the printer 403 .
[0088] The method is implemented by means of a computer program product comprising the software code portions for performing the steps of the method. The computer program product is run on a computer stored in a digital computer within the process unit 402 and within the printer 403 , e.g. in the printer adapter 405 .
[0089] The computer program is loaded directly or from a computer usable medium, such as floppy-disc, CD, Internet etc.
[0090] [0090]FIG. 8 is a bloc diagram depicting a protocol overview over the Bluetooth protocols including the wireless printer protocol WPP according to the invention. The left side represents the PC 801 and the right side represents the Printer 802 . The Host Control Interface HCI is marked as a horizontal line. The HCI provides a command interface to the baseband controller, link manager, and access to hardware status and control registers. SDP, L2CAP and LMP are described above, under Related Art. WPP will be described more in detail below.
[0091] The interface between two entities on the same layer, a so-called horizontal interface, is defined by it's protocol 803 , 804 , 805 and 812 , e.g. L2CAP on PC communicates with L2CAP on printer using the L2CAP protocol.
[0092] The actual flow of data (Protocol Data Units, PDU:s) is done between entities in different layers 806 , 807 , 808 , 809 , 810 and 811 , a so-called vertical interface.
[0093] On the PC side the protocols is implemented by following applications:
[0094] Client L 2 CA Application implements L2CAP
[0095] Client Printer Application implements WPP
[0096] Client Discovery Application implements SDP
[0097] On the printer side the protocols is implemented by following applications:
[0098] Server L 2 CA Application implements L2CAP.
[0099] Server Printer Application implements WPP.
[0100] Server Discovery Application implements SDP.
[0101] The printing method according to the invention will now be described more in detail.
[0102] A processing unit requires to print a document, i.e. to perform a printjob, by means of a printer.
[0103] The processing unit wishes to know which printers that are available, and select one of them, therefore the printing process starts with the Device Discovery procedure, which is a procedure known from the art. FIG. 9 shows a sequence diagram of a typical SDP transaction between the Client Discovery Application 901 and the Server Discovery Application 902 . It is assumed that inquire has been performed. As a result of inquire the class of device is retrieved. Class of device indicates the type of device and which type of services the device supports. It is also assumed that a point to point connection with the server has been established, using L2CAP. The PrinterServiceClassId is represented as a Universally Unique Identifier (UUID) and is known by client discovery application.
[0104] A message, e.g. a denoted SDP_ServiceSearchReq message 903 is sent, from Client to Server, to ask which services, in this case printers that are available. The server returns service records handles associated with the respective available printers, e.g. in a denoted SDP ServiceSearchRsp message 904 .
[0105] The printer service record database serves as a repository of discovery-related information. All of the information about a service that is maintained by an SDP server is contained in a single service record. The service record consists entirely of a list of attributes. A service record handle uniquely identifies each service record within the SDP server, according to Service Discovery Protocol, Bluetooth Specification version 1.0 B concerning SDP and Appendix VIII, Bluetooth Assigned Numbers, Bluetooth Specification version 1.0 B concerning assigned numbers for predefined attributes and their identity.
[0106] The Client selects one of the available printers and requests for its attributes, e.g. the address of the printer, a in a message, e.g. a denoted SDP_ServiceAttributeReq message 905 using the service record handle. The attributes are returned in one or more messages, e.g. denoted SDP_ServiceAttributeRsp messages 906 .
[0107] The Client stores the received attributes and terminate the L2CAP connection
[0108] A bi-directional wireless asynchronous connection-less (ACL) connection is established ( 701 ) between the processing unit and the printer. This is achieved by means of the printer protocol in the processing unit calling the L2CAP in the within the same unit, requesting the connection to the printer. The printer is connected e.g. by means of the printer address being one of the attributes received. The L2CAP creates the connection and notifies the created connection the printer protocol.
[0109] [0109]FIG. 10 shows sequence diagrams of a typical WPP transactions concerning the connection operations between the WPP Client 1001 and the WPP Server 1002 , according to the invention
[0110] A creation of a session between a client printer application (source) and a server printer application (destination) is to be requested, i.e. for establishing a connection for one or more printjobs. This is performed by sending a message, e.g. a denoted WPP_Connection_Req message 1003 , from the WPP client 1001 to the WPP server 1002 . This is shown in FIG. 10. A status indication to the client printer application whether the connection was successful or not and making the session valid if successful is required. This is be performed in a message by the WPP server 1002 , e.g. in a denoted WPP_Connection_Rsp message 1004 , also shown in FIG. 10. This message also includes a session identity.
[0111] The next step of the printing process is the WPP negotiation procedure according to the invention. FIGS. 11 a - c and 12 shows sequence diagrams of a typical WPP transactions concerning the negotiation operations between the WPP Client 1001 and the WPP Server 1002 , according to the invention.
[0112] After creating the session a configuration of the WPP server 1002 is required. Examples of configuration options are e.g. the number of print data request messages to be received by the printer before return a confirmation message, coding type and table size.
[0113] [0113]FIGS. 11 a, b and c shows three different sub-scenarios of a successful negotiation of a coding type for data compression. A message, e.g. a denoted WPP_Configuration_Req message, is sent from the WPP client 1001 to WPP server 1002 to establish an initial logical link transmission contract between the WPP client 1001 and WPP server 1002 and to negotiate configuration parameters, e.g. the coding type. In this example the WPP server 1002 supports the coding types hamming, table size=80 (default) and huffman table size=80. The three respective sub-scenarios may be a continuation of the connection scenario in FIG. 10.
[0114] In the first sub-scenario, shown in FIG. 11 a, the WPP client 1001 uses default values, i.e. hamming, table size=80 and accordingly the WPP_Configuration_Req message 1101 sent, from the WPP client 1001 to the WPP server 1002 , includes no new options. Since that is a coding type that the WPP server 1002 supports, it responses success in a message, e.g. a denoted WPP_Configuration_Rsp message 1102 .
[0115] [0115]FIG. 11 b shows the second sub-scenario in which the WPP client 1001 requests the WPP server 1002 , in message, e.g. a denoted WPP_Configuration_Req message, if hamming, table size=100 can be used 1103 . This is not a coding type that the WPP server 1002 supports and accordingly it responses in a message, e.g. a denoted WPP_Configuration_Rsp message 1104 , failure and suggests that hamming, table size=80 can be used. The WPP client 1001 supports also hamming, table size=80 and responses this to the WPP server 1002 in a message, e.g. a denoted WPP_Configuration_Req message 1105 . The WPP server responses success in a message, e.g. a denoted WPP_Configuration_Rsp message 1106 .
[0116] In the third scenario, shown in FIG. 11 c, the WPP client 1001 suggests an coding type which is unknown for the printer, i.e. a coding type not supported by the printer, and a size=100, in a message, e.g. a denoted WPP_Configuration_Req message, sent 1107 to the WPP server 1002 . Since this coding type is unknown for the WPP server 1002 , it responses in a message, e.g. a denoted WPP_Configuration_Rsp message 1108 failure and that the coding type is unknown. The WPP client 1001 then tries another coding type that it supports, in this example huffman, size=80, in a subsequent message, e.g. a denoted WPP_Configuration_Req message 1109 sent to the WPP server 1002 . The WPP server 1002 supports huffman, size=80 and accordingly it responses success and confirms huffman, size=80 in a message, e.g. a denoted WPP_Configuration_Rsp message that is sent 1110 to the WPP client 1001 .
[0117] After the configuration negotiation of coding type according to e.g. the scenarios depicted in FIGS. 11 a - c, the WPP client 1001 requests to set an attribute which is illustrated in FIG. 12. The WPP client 1001 sends a coding table concerning the negotiated coding type in a message, e.g. a denoted WPP_Set_Attribute_Reg message sent 1201 to the WPP server 1002 . The WPP server loads the coding table to be used and confirms whether it was successful or failure in a message, e.g. a denoted WPP_Set Attribute_Rsp message 1202 sent to the WPP client 1001 .
[0118] The next step of the printing process is the WPP printing procedure. FIGS. 13 a - d , 14 and 15 shows sequence diagrams of a typical WPP transactions concerning the printing operations, between the WPP client 1001 and the WPP server 1002 , according to the invention.
[0119] [0119]FIGS. 13 a - d shows a first sub-scenario of a successful printing of one print job. FIG. 13 a shows the procedure for sending keep alive messages.
[0120] When the connection has been established and negotiation has been performed, keep alive messages are to be sent, by the WPP client 1001 , 1303 and WPP server 1002 , 1304 , frequently, e.g. once each 5 second, as an indication that the source is up and running. Such a message is a denoted WPP_Keep_Alive message. If a break occurs when printing, the printer will find out that, since it does not receive any more keep alive messages. The printer then terminates the printjob and can let other users in. A break can also occur on the printer side. There is also occasions when the printer or processing unit are hard loaded, sending keep alive messages just to tell the receiver that it still alive but it goes slowly at the moment. When a connection has been disconnected by WPP client, WPP client 1001 and WPP server 1002 shall stop sending denoted WPP_Keep_Alive messages.
[0121] A WPP Keep Alive Timer is restarted each time a valid message is received from the remote endpoint. The timer is implemented on both client and server side. If the Keep Alive timer expires the remote endpoint is considered faulty and the connection is closed and higher level applications is notified. The Keep Alive Timer shall be stopped when a link is disconnected and restarted when a new link is established with the remote endpoint. If a new link is established within a reasonable time, e.g. 10 seconds, the printjob continues where broken. Each WPP message will trigger a restart of a WPP timer.
[0122] In FIG. 13 b a start of a printjob and sending of data to be printed is shown. The WPP client 1001 requests the WPP server 1002 to start a printjob in a denoted WPP_Start_Print_Req message 1305 s, which in turn confirmed by the WPP server ( 1002 ) in a denoted WPP_Start_Print_Cfm message 1306 . The WPP client then requests the WPP server 1002 to print data included in a number of denoted WPP_Print_Data_Req messages 1307 , 1308 . A confirmation is to be sent after the WPP server 1002 has received a number N WPP_Print_Data_Req messages 1307 , 1308 . The value of N is negotiated during configuration e.g. N=4. The acknowledgement is e.g. sent in a denoted WPP_Print_Data_Ack message 1309 . This procedure goes on until all data to be printed is received by the printer server. I.e. until the last WPP_Print_Data_Req message 1310 is received.
[0123] When all data to be printed is sent to the printer server the client requests the printer server to stop the printjob. This is shown in FIG. 13 c wherein the WPP client 1001 sends a denoted WPP_End_Print_Req message 1311 to the WPP server 1002 . That this is apprehended by the printer server is reported e.g. in a denoted WPP End_Print Rsp message 1312 sent to the WPP client 1001 .
[0124] After performing one or more printjobs or if a break of the printjob is requested, the client requests a disconnection of a session defined by the session identifier. Depicted in FIG. 13 d, this request is performed by e.g. sending a denoted WPP_Disconnect_Req message 1313 from the WPP client 1001 to the WPP server 1002 and a response, whether the disconnection is granted or not, is sent in the opposite direction in a denoted WPP_Disconnect_Rsp message 1314 .
[0125] When the session is disconnected the WPP client 1001 and the WPP server 1002 stops sending WPP_Keep_Alive messages.
[0126] [0126]FIG. 14 shows a second sub-scenario of a successful printing of one printjob when the printer is out of paper. Negotiation has been performed, a connection is established and keep alive messages are sent as described above though not visible in FIG. 14. The WPP client 1001 has requested the WPP server 1002 to start the printjob in a message, e.g. a denoted WPP_Start_Print_Req message 1401 , which is responded success to in a message, e.g. a denoted WPP_Start_Print_Rsp message 1402 . When the WPP client 1001 has requested the WPP server 1002 to print data included in a number of messages, e.g. denoted WPP_Print_Data_Req messages 1403 , 1404 , being acknowledged by the WPP server 1002 in a message, e.g. a denoted WPP_Print Data_Ack message 1405 , the printer is out of paper. The printer server then has to report this to the client. This can be performed by the WPP server 1002 sending a message, e.g. a denoted WPP_Status_Ind message 1406 , indicating that the printer is out of paper to the WPP client 1001 . The message is interpreted by the wireless printer protocol and reported to the user of the processing unit, e.g. by presenting a note on the PC screen. The message is obtained by a user of the processing unit including the client, who refills the printer. The printer server then reports that the printer is refilled to the WPP client 1001 by sending a message, e.g. a denoted WPP_Status_Ind message 1407 . The last received denoted WPP_Print_Data_Ack message 1405 defines where to continue the printing by sending messages, e.g. denoted WPP_Print_Data_Req messages 1408 , 1409 from the WPP client 1001 to the WPP server 1002 . The printer will throw data if already printed or if a part of it has been printed. The printing process then continues as described above. FIG. 15 shows a third sub-scenario of a successful printing of one printjob when the ACL connection is disconnected. Negotiation has been performed, a connection is established and keep alive messages are sent as described above though not visible in FIG. 15. The WPP client 1001 has requested the WPP server 1002 to start the printjob in a message, e.g. a denoted WPP_Start_Print_Req message 1501 , which is responded success to in a message, e.g. a denoted WPP_Start_Print_Rsp message 1502 . When the WPP client 1001 has requested the WPP server 1002 to print data included in a number of messages, e.g. WPP_Print_Data_Req messages 1503 , 1504 , the ACL connection is disconnected, indicated by HCI. The Keep Alive Timer is stopped by the WPP client 1001 .
[0127] A reconnection of the session is required because it is possible for another client to start a printjob during ACL-disconnected. A session identity is used to identify the different WPP entities. If another job is ongoing the server will not accept the reconnection. The time the server will wait for the reconnection has to be handled by a reconnection timer. If the timer times out the ongoing job will be flushed. After creating a new ACL-connection a reconnection of the session is requested. This can be performed by the WPP client 1001 by sending a message, e.g. a denoted WPP_Reconnect_Req message 1506 requesting a reconnection of the session defined by the session identifier. A response according to whether the reconnection is granted or not is sent in a message, e.g. a denoted WPP_Reconnect_Rsp message 1507 . In this example it is granted. The WPP Keep Alive timer is started again. The last received denoted WPP_Print_Data_Ack message 1505 defines where to continue the printing by sending messages, e.g. a WPP_Print_Data_Req messages 1507 , 1508 from the WPP client 1001 to the WPP server 1002 . The printer server will throw data if already printed or if the packet is detected to be a retransmission. The printing process then continues as described above.
[0128] The present invention is not limited to the above-described preferred embodiments. Various alternatives, modifications and equivalents may be used. Therefore, the above embodiments should not be taken as limiting the scope of invention, which is defined by the appendant claims. | A method and an arrangement in a data communications system. The object of the invention is to achieve a wireless communication between a processing unit and a printer using a safe transmission and an increased transmission range compared to the infrared transmission. The solution is a way of printing a document in a data communications system using a protocol profiled for printing in the Bluetooth protocol architecture. | 7 |
TECHNICAL FIELD
This invention relates to a connecting apparatus for a powerplant and, more particularly, to an apparatus which provides a clutch and gear reduction between the engine and the propellor or fan and which has a housing for the indicated mechanism providing a dynamically balanced bracket attached integrally thereto for holding the engine and propellor to a frame.
BACKGROUND OF THE INVENTION
In recent years, hang-gliding has captured the imagination of several aviation buffs. In the early years, hang-gliding required a mountain side or a cliff from which to launch. Hence, the sport was geographically limited. It was not long, however, before enthusiasts of the sport added engines so that flatlanders could participate. Powered hang-gliders have become to be known as ultralight aircraft.
In the United States, ultralight aircraft remain unregulated as long as the device is foot-launchable, even though landing gear may be present for convenience.
Early models of ultralight aircraft used a direct drive connection between the engine and the propellor. Often, power was limited with these units, and the rate of climb was slow. More recently, engine power and speed have been increased by correspondingly reducing rotative speed between the engine and the propellor with pulleys and belts.
The sport of power hang-gliding or the flying of ultralight aircraft has been and remains, however, extremely dangerous. Several pilots have crashed to their deaths. Successful flight has been described as an art since weight must be shifted rapidly as wind gusts or drafts affect the wing foils or as propellor thrust varies according to movement of the engine throttle. Present ultralight aircrafts have the further problem that as the throttle is varied, not only does the magnitude of the thrust change, but also the direction of the thrust line changes. The present invention was developed in response to this latter problem. It should be pointed out, however, that, regardless of the reason spawning its development, the present invention has application in areas not related to ultralight aircraft. For example, powerplants comprised of engines driving propellors while attached to a frame are used in conjunction with smoke generators during frost periods in fruit orchards.
SUMMARY OF THE INVENTION
The present invention is directed to a connecting apparatus for an engine mounted to a structural frame. The engine is used for driving a rotary load. The connecting apparatus is comprised of dynamically balanced means for isolating from said frame vibrations from said engine and speed sensitive means for releasibly coupling the engine to the rotary load.
In a preferred embodiment, an engine is connected to a propellor through a gear train which includes a centrifugal clutch device. The clutch and gear mechanisms are enclosed in a housing filled with lubricant. A portion of the housing extends outwardly as a bracket to attach in a dynamically balanced fashion the engine and propellor assembly to a structural frame.
The bracket has a spider-like shape with apertures at the ends of each of the legs. The apertures are filled with vibration dampening mountings comprised of a pair of concentric cylinders having rubber bonded between them. The vibration dampening mountings have greater resistance to shear in the locations required to resist the greater vibratory torque of the engine, and lesser resistance to shear in the locations subjected to lesser vibratory forces. In this fashion, the connecting apparatus dynamically balances the thrust due to the propellor and engine relative to the structural frame to keep the thrust line constant regardless of the throttle setting of the engine.
These advantages and other objects obtained by the use of the present invention may be better understood by reference to the drawings which form a further part hereof, and to the accompanying descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of an ultralight aircraft having apparatus in accordance with the present invention;
FIG. 2 is a side view of the aircraft in FIG. 1;
FIG. 3 is an end view of apparatus in accordance with the present invention attached to a representative framework for connection with the structural frame of an ultralight aircraft;
FIG. 4 is a side view of the apparatus shown in FIG. 3;
FIG. 5 is an end view of connecting apparatus in accordance with the present invention;
FIG. 6 is a side view of the apparatus shown in FIG. 5;
FIG. 7 is a partial sectional view taken approximately along line 7--7 of FIG. 5; and
FIG. 8 is a partial sectional view of clutch apparatus in accordance with the present invention, taken along line 8--8 of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIG. 1, an ultralight aircraft exemplary of the type with which the present invention may be used is designated by numeral 10. In FIG. 2, an engine 12 is shown driving a propellor 14 through connecting apparatus 16 in accordance with the present invention. Connecting apparatus 16 attaches to an intermediate frame 18 which fastens the indicated powerplant to the structural frame 20 of aircraft 10. As indicated previously, although the present invention is described in detail relative to an ultralight aircraft, it is to be understood that a connecting apparatus 16 in accordance with the present invention may as well be used in several other applications not specifically described herein or illustrated in the drawings attached hereto.
Intermediate frame 18 is shown more clearly in FIGS. 3 and 4. Intermediate frame 18 is not a necessary part of the present invention, but does show an adapter frame often needed between the connecting apparatus 16 of the present invention and the structural frame 20 of, in this case, an ultralight aircraft 10. Connecting frame 18 is comprised of a number of tubular members. Connecting apparatus 16 attaches to inverted U-shaped member 22. Four tubular legs 24 extend from U-shaped member 22 on the side opposite apparatus 16. A cylindrical boss 26 is fastened by weld or otherwise to each of the free ends of legs 24. Boss 26 has an aperture therethrough for attachment with a bolt 28 to structural frame 20. A second set of cylindrical bosses 30 are attached to the ends of legs 24 which fasten to U-shaped member 22. Bosses 30 also have apertures therethrough for the passage of bolts 32 for fastening spider bracket 34 with nuts 36. U-shaped member 22 has sufficient spacing between its legs, as well as sufficient contour of the legs, to pass around various parts of engine 12. Legs 24 extend angularly away from U-shaped member 22 as appropriate to provide the necessary connection between spider bracket 34 and the structural frame 20 of aircraft 10. Bosses 30 extend approximately perpendicularly away from U-shaped member 22 in order to provide a proper fastening joint with spider bracket 34. Bosses 26 are oriented as appropriate to provide a proper fastening joint with structural frame 20. Intermediate frame 18 thereby properly orients the powerplant to provide an appropriate thrust line for aircraft 10.
Connecting apparatus 16 is shown in FIGS. 5-7. Connecting apparatus 16 includes a housing 38 and spider bracket 34. The drive train between engine 12 and propellor 14 is enclosed within the enclosure formed by housing 38 and spider bracket 34 as fastened to engine 12. The drive train includes a drive gear 40 slideably mounted about the drive shaft 42 of engine 12. Drive gear 40 is axially spaced from and fixedly attached to a cylindrical shell 44. Shell 44 has a radial wall 46 extending inwardly from the cylindrical portion of shell 44 for attachment by weld or otherwise to a first side of drive gear 40. Wall 46 has a centered aperture axially aligned for passage therethrough of drive shaft 42. A shoulder of drive gear 40 protrudes through the aperture in wall 46 to slideably abut the hub 54 of a clutch device 48. Centrifugal clutch device 48, described hereinafter, is keyed to drive shaft 42 between wall 46 and a shoulder 52 on drive shaft 42 proximate engine 12. Thus, as drive shaft 42 increases in speed, clutch device 48 engages shell 44 to turn drive gear 40. Drive gear 40 is slidingly held in place between nut 50 threaded onto the end of drive shaft 42 and hub 54 of clutch device 48.
As shown in FIG. 8, clutch device 48 is received about drive shaft 42. Hub 54 is fastened to drive shaft 42 with key 56 fitting in keyways 58 and 60 of drive shaft 42 and hub 54, respectively. Hub 54 has a sufficiently thick annular central portion to allow for the groove of keyway 60. A pair of flanges 62 extend outwardly to a greater diameter beyond the annular central portion of hub 54. A pair of guide walls 64 extend radially outwardly from opposite sides of central portion 61. Guide walls 64 extend between flanges 62 and project in a semi-cylindrical fashion beyond the diameter of flanges 62.
A pair of identically shaped weights 66 rest in the region between central portion 61 of hub 54 and the inner surface of shell 44. A weight 66 has width slightly less than the distance between flanges 62. The inner side of weight 66 has a concave, semi-cylindrical shape with diameter approximately the same as the central portion 61 of hub 62. A slot is cut into weight 66 to match and loosely receive guide wall 64. The outer wall of weight 66 is also semi-cylindrical with a diameter the same as the inner diameter of shell 44. Near each end, the outer diameter of weight 66 is contoured along a chord before being squared to extend substantially radially inwardly to the inner diameter. A cavity 70 is bored centrally in each chord surface 68. A pin 72 is pressed into an aperture 74 extending laterally through weight 66 such that pin 72 passes through the portion of aperture 70 nearest the end of weight 66. A pair of coil springs 76 extend between matching ends of the pair of opposing weights 66. The ends of springs 76 pass into apertures 70 to be retained about pins 72. Thus, springs 76 hold weights 66 against the central portion 61 of hub 62 as guided by guide walls 66. When clutch device 48 is rotated rapidly, centrifugal force overcomes the compressive force of springs 76 allowing the outer surface of weights 66 to frictionally contact the inner surface of wall 44. As drive shaft 42 rotates hub 62 because of key 56, hub 62 rotates weights 66 and shell 44 because of the engagement of guide wall 64 with weights 66. Drive gear 40 in turn rotates with shell 44.
Relatively small drive gear 40 drives relatively large driven gear 78. In this way, a gear reduction is accomplished. Driven gear 78 is keyed at 80 to driven shaft 82. Nut 84 further retains driven gear 78 and key 86 in keyway 80. Driven shaft 82 is held within housing 38 and aligned with a pair of spaced-apart bearings 88 pressed in opposite ends of a neck portion 90 of housing 38. Propellor 14 is fastened to a flange 92 welded or otherwise attached to the free end of driven shaft 82 extending outside of housing 38.
As shown in FIGS. 5 and 6, the central portion 102 of housing 38 is comprised generally of a larger cylindrical portion 122 to receive driven gear 78 and a smaller cylindrical portion 124 proximate to portion 122 to receive drive gear 40. Centered on and extending outwardly from cylindrical portion 122 is neck portion 90. Neck portion 90 is generally cylindrical and smaller than larger cylindrical portion 122. A plurality of heat-dissipating veins triangularly extend from one end of neck portion 90 to abut with larger cylindrical portion 122 at the other end of neck portion 90. As shown in FIG. 7, a sealing element 128, commonly known to those skilled in the art, is pressed into the end of neck portion 90 adjacent the outermost bearing 88 to seal the axial opening, through which driven shaft 82 passes, in the space between driven shaft 82 and the surface of the aperture in neck portion 90.
A pressure release valve 130, commonly known, is installed in a wall of central portion 102.
Spider bracket 34 and housing 38 together form an enclosure. In the illustrated embodiment, spider bracket 34 is comprised of a body portion 94, a pair of upper legs 96 and a pair of lower legs 98. Housing 38 is comprised of a flange portion 100, a central portion 102 and a neck portion 90. Spider bracket 34 and housing 38 have correspondingly flat surfaces which mate against opposite sides of gasket 104 to form a seal when compressed by a plurality of nut and bolt combinations 106 and 108. The body portion 94 of spider bracket 34 and housing 38 cooperate to form an enclosing cavity 110 within which are located clutch device 48, drive and driven gears 40 and 78, drive and driven shaft 42 and 82, and bearings 88. Cavity 110 is filled with a commonly known lubricating oil to dissipate heat and reduce friction. The body portion 94 of spider bracket 34 has a wall 112 on the side opposite housing 38. Wall 112 is contoured to include a flat surface for compressing a gasket 114 against a complimentary surface on engine 12. A plurality of screws 116 pass through openings in wall 112 to thread into openings in engine 12, thereby attaching engine 12 to spider bracket 34. Centered within the pattern of screws 116 is a cylindrical aperture 118. Drive shaft 42 is axially aligned with and passes through aperture 118. A sealing element 120 commonly known to those familiar with the art is pressed into aperture 118 to seal the space between the walls of aperture 118 and drive shaft 42.
Since weight is a prime consideration in the design of an ultralight aircraft, weight must also be a prime consideration with regard to spider bracket 34 and housing 38. Thus, the shape of the enclosing walls about cavity 110 is designed to conserve material and hence reduce weight. It is to be understood, of course, that shapes not illustrated are well within the scope of the present invention.
The shape of cavity 110 within the flange portion 100 of housing 38 corresponds with the shape of cavity 110 within the body portion 94 of spider bracket 34. The shape is determined by the relative size and location of shell 44 of clutch device 48 and of driven gear 78. The lower portion generally aligns with the shape of the larger cylindrical portion 122 of central portion 102 of housing 38. The upper portion 134 surrounds and encloses clutch device 48. As shown in FIG. 5, upper portion 134 has a generally square, flanged shape, with the width being approximately the diameter of the rounded lower portion 132. The bolts of combinations 106 and 108 generally pass through ear portions of spider bracket 34 and housing 38. Since the lower portion 132 of spider bracket 34 conforms in shape with the flanged portion 100 and central portion 102 of housing 38, the bolt of combination 108 must be longer than the bolts of combinations 106 so as to extend to the neck portion side of central portion 102 of housing 38.
Upper and lower legs 96 and 98 extend at approximately 45 degrees with respect to the side of the body portion 94 of spider bracket 34 away from the corners of the body portion 94. The length of legs 96 and 98 is dependent on the mating connection with a structural frame, such as intermediate frame 18 in the present embodiment. Each leg 96 and 98 is made as light-weight as possible by forming cavities 136 and 138 between the outer walls and end wall of each of legs 96 and 98. Each of legs 96 and 98 ends in a solid portion having a cylindrical aperture extending therethrough. The apertures in legs 98 are filled appropriately with vibration dampening first mountings 140. Similarly, the apertures and legs 96 are filled with vibration dampening second mountings 142. First mountings 140 are comprised of a pair of concentric cylindrical shells 144 and 146 with rubber 148 bonded between the shells during vulcanization. Similarly, second mountings 142 are comprised of a pair of concentric cylindrical shells 150 and 152 with rubber 154 bonded between them. Rubber 148 and 154 effectively isolate from structural frame 20 of ultralight aircraft 10 the vibrations from engine 12. First and second mountings 140 and 142 are distinguished in that first mountings 140 are approximately twice as long as second mountings 142, as shown in FIG. 6. In this way, first mountings 140 more stiffly resist engine vibration than second mountings 142. First mountings 140 relative to second mountings 142 are rotationally advanced about the vibratory torque axis of engine 12 in the direction of greater vibratory force. In this way, as the throttle of engine 12 is increased, first mountings 140 more stiffly resist the vibrations of engine 12 than do second mountings 142 and, consequently, dynamically balance the powerplant of ultralight aircraft 10. Since the powerplant remains balanced, the thrust line of propellor 14 also maintains a constant direction thereby vastly enhancing the controllability of aircraft 10.
In use, connecting apparatus 16 provides an efficient clutch and gear reduction between engine 12 and propellor 14 and, at the same time, provides a housing with an integral bracket to dynamically balance the engine and propellor assembly with the structural frame 20 of ultralight aircraft 10. When engine 12 is started, propellor 14 is disengaged. As engine 12 increases in speed, clutch 48 functions.
In particular, hub 54 is keyed to and rotates with drive shaft 52. As the rotational speed increases, weights 66 move outwardly as centrifugal force overcomes the compressive force of springs 76. Weights 66 remain engaged with hub 54 because of guide walls 64. Weights 66 eventually move outwardly sufficiently so that the frictional force between the outer surfaces of weights 66 and the inner surface of shell 44 overcomes the forces throughout the remainder of the drive train resisting rotation. When weights 66 engage shell 44, drive gear 40 is caused to rotate. Gear 40 drives driven gear 78 causing driven shaft 82 and propellor 14 to rotate.
As indicated hereinbefore, bolts 32 pass through cylindrical shells 144 and 152 to hold spider bracket 34 to intermediate bracket 18, which in turn is fastened to the structural frame 20 of aircraft 10. The vibrations from engine 12 are damped by rubber 148 and 154 and, thereby isolated from the structural frame 20 of aircraft 10. Even more importantly, as the throttle of engine 12 is increased, the vibratory forces of the engine tend to torque the engine counter-clockwise as viewed in FIG. 2. The vibration dampening first mountings 140 more stiffly resist vibration than the vibration dampening second mountings 142. Hence, as the throttle is increased, even though the engine undergoes a counter-clockwise torque, the first and second vibration dampening mountings 140 and 142 effectively resist the torque at all magnitudes and, consequently, dynamically balance the powerplant relative to the structural frame 20. The vibration isolation or torque-resisting characteristics are particularly advantageous when engine 12 is a two-cycle engine, which is quite usual with ultralight aircraft.
Thus, the present invention as discussed in the foregoing description gives rise to numerous characteristics and advantages. It is to be understood, however, that the disclosure is illustrative only, and any changes made, especially in matters of shape, size and arrangement, to the full extent extended by the generally meaning of the terms in which the appended claims are expressed, are within the principle of the invention. | A connecting apparatus (16) for attaching a propeller or fan (14) to an engine (12) is disclosed. A connecting apparatus (16) includes a centrifugal clutch device (48) and drive and driven gears (40, 78) for reducing the speed of propeller (14) relative to engine (12). These elements are contained within a lubricant-filled housing comprised of housing (38) and spider bracket (34). Spider bracket (34) includes two pairs of vibration-dampening first and second mountings (140). First mountings (140) more stiffly resist engine vibration than second mountings (142), thereby dynamically balancing the powerplant with respect to the structural frame (20). | 8 |
BACKGROUND OF THE INVENTION
[0001] The present application claims priority on Japanese Patent Application No. 2009-207454, filed Sep. 8, 2009; Japanese Patent Application No. 2009-207455, filed Sep. 8, 2009; and Japanese Patent Application No. 2009-207456, filed Sep. 8, 2009, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a slide damper device.
DESCRIPTION OF THE RELATED ART
[0003] According to an air conditioning device for vehicles (HVAC: Heating Ventilation Air Conditioning), a slide damper device is used as an air mixing damper device which adjusts the ratio with which cold air and warm air is mixed, and an internal/external air swiching damper device which switches between a state of introducing external air and a state of circulating internal air. The above-mentioned slide damper device adjusts an opening of a flow path by sliding a slide damper, for example.
[0004] In particular, the slide damper device adjusts the opening of the flow path by moving a slide damper between two openings which are approximately the same size and are positioned in parallel, thereby changing a ratio at which the two openings are opened.
[0005] Conventionally, according to such a slide damper device, a guide groove is provided on an inner wall of a case comprised by an air conditioning device for vehicles, and a connection member protruding from a side end part of a slide damper is slidably fitted to the guide groove. As a result, the slide damper moves along the guide groove. (See Japanese Patent No. 3793309 (hereinafter referred to as Patent Document 1), Japanese Patent No. 2831325 (hereinafter referred to as Patent Document 2), and Japanese Patent No. 3504806 (hereinafter referred to as Patent Document 3).)
[0006] Incidentally, the case comprised by the air conditioning device for vehicles is large and is shaped intricately compared to a simple, planar slide damper. Such a case is more subject to a large amount of displacement due to a deformation compared to a slide damper. Thus, there is a large dimension error during manufacture. Therefore, the width of the guide groove combined with the case should usually be sufficiently large enough so that the slide damper may move in a smooth manner.
[0007] However, an increase in the width of the guide groove leads to an increase in the width of a gap between a side wall comprised by the guide groove and the connection member fitted to the guide groove. This gap may cause a fluid from an upstream of the side damper to a downstream to leak out.
[0008] In other words, regarding conventional slide damper devices, a gap between a side wall and a connection member comprised by the guide groove becomes larger, thereby causing a large amount leakage of a fluid from the upstream of the slide damper to the downstream.
[0009] Japanese Unexamined Patent Application, First Publication No. H9-290618 (hereinafter referred to as Patent Document 4), for instance, discloses a slide damper device preventing a leakage of the fluid by utilizing a configuration in which a connection member is provided at all regions of the side end part of the slide damper. In other words, the side end part of the slide damper itself is used as a connection member.
[0010] However, even when such a configuration is used, the width of the guide groove must be wide enough with respect to the thickness of the connection member. Therefore, the leakage of the fluid cannot be adequately prevented.
[0011] Meanwhile, it may be also possible to reduce the dimension error which occurs when manufacturing the guide groove by manufacturing the guide groove separately from the guide groove and then attaching the guide groove to an inner wall of the case.
[0012] Thus, the dimension error when manufacturing which occurs when manufacturing the guide groove may be reduced, the gap between the side wall and the connection member comprised by the guide groove may be reduced, and the leakage of the fluid can be prevented.
[0013] However, in such a case, the number of components of the air conditioning device for the vehicle increases. As a result, the manufacturing cost also increases.
[0014] On the other hand, a guide groove and a connection member provided on a side end part of a slide damper slide while a surface is always being in contact with the guide groove.
[0015] Therefore, a frictional resistance caused between the guide groove and the connection member increases. Hence, the slide damper may be prevented from sliding smoothly.
[0016] In particular, as in Patent Document 4, when the connection member is provided on all areas of the side end part of the slide damper, the frictional resistance becomes very large. Hence, moving the slide damper may become impossible.
SUMMARY OF THE INVENTION
[0017] The present invention is made considering the problems described above. Accordingly, an object of the present invention is to provide a slide damper device such that a leakage of a fluid from an upstream of a slide damper to a downstream can be prevented without increasing the number of components of an air conditioning device for a vehicle.
[0018] Further, an object of the present invention is to provide a slide damper device such that a slide damper may move smoothly.
[0000] (1) Namely, a slide damper device according to an aspect of the present invention comprises a case of an air conditioning device for a vehicle; a slide damper; a plate-like guide rail provided on an inner wall of the case; and a connection member provided at a side end part of the slide damper. The connection member has a concave shape slidably fitting with the guide rail. The connection member connects the slide damper to the guide rail. Here, an opening of a flow path provided inside the case is adjusted by sliding the slide damper.
[0019] Since the slide damper slides, an opening of a flow path provided in an interior of the case is adjusted.
[0000] (2) In addition, the slide damper device may be configured as follows: the slide damper device further comprises a shield wall shielding a fluid, the shield wall being provided at a side of a moving range of the connection member along the moving range.
(3) In addition, the slide damper device may be configured as follows: the connection member is provided at a side end part of the slide damper along an entire area in a direction in which the slide damper slides.
(4) In addition, the slide damper device may be configured as follows: a plurality of connection members are provided at the side end part of the slide damper in a direction in which the slide damper slides. The plurality of connection members are positioned while being distanced from one another.
(5) In addition, the slide damper device may be configured as follows: a thickness of the connection member is smaller than a thickness of the guide rail.
[0020] According to the above embodiment of the present invention, a plate-like guide rail is provided on an inner wall of a case instead of a guide groove which was provided in a conventional slide damper device. In addition, according to the above embodiment of the present invention, a concave shaped connection member is provided on a side end part of a slide damper.
[0021] First of all, according to an aspect of the present invention, the concave shaped connection member is provided to a slide damper which is smaller and has a simpler shape compared to the case. Therefore, the connection member may be manufactured with a high degree of dimensional precision. Hence, a gap between a guide rail and a connection member may easily be made smaller compared to a gap between a connection member and a guide groove in conventional slide damper devices. As a result, it is possible to prevent a leakage of a fluid from an upstream of a slide damper to a downstream.
[0022] Further, according to an aspect of the present invention, a guide rail and a case may be integrated. In addition, a connection member and a slide damper may be integrated. Therefore, it is possible to prevent the number of components of an air conditioning device for a vehicle from increasing.
[0023] Therefore, according to an aspect of the present invention, a leakage of a fluid from an upstream of a slide damper to a downstream can be prevented without increasing the number of components of an air conditioning device for a vehicle.
[0000] (6) By the way, a slide damper device according to an aspect of the present invention adjusts an opening of a flow path provided inside a case of an air conditioning device for a vehicle by sliding a slide damper. The slide damper comprises a guide provided on an inner wall of the case; a connection member provided at a side end part of the slide damper, the connection member slidably fitting with the guide, the connection member connecting the slide damper to the guide; and a protrusion member provided on either one of a sliding surface of the connection member with respect to the guide and a sliding surface of the guide with respect to the connection member. Here, the connection member and the guide slide against each other.
(7) The above slide damper device may be configured as follows: the protrusion member is provided on the sliding surface of the guide.
(8) The above slide damper device may be configured as follows: a plurality of the protrusion members are aligned while being separated from each other at a distance such that the sliding surface of the connection member is constantly contacting a plurality of the protrusion members.
(9) The above slide damper device may be configured as follows: a set of opposing surfaces comprised by the guide or the connection member are each regarded as the sliding surface. Here, the protrusion member is provided on each of the sliding surface. The protrusion member provided on each of the sliding surface are positioned to be out of alignment in a direction in which the slide damper slides.
(10) The above slide damper device may be configured as follows: a surface of the protrusion member is shaped as an arc warped towards a direction in which the slide damper slides.
(11) The above slide damper device may be configured as follows: the guide is a plate-like guide rail, and the connection member has a concave shape fitting with the guide rail.
[0024] According to the above embodiment of the present invention, a connection member and a guide slide against each other, and a protrusion member is provided on either of a sliding surface of the connection member with respect to the guide or a slide surface of the guide with respect to the connection member. Due to this protrusion member, the sliding surfaces, which slide against each other, are prevented from coming into contact with each other in their entirety. Therefore, the size of the area at which the connection member and the guide come in contact with each other may be reduced.
[0025] Therefore, according to the above embodiment of the present invention, it is possible to reduce the frictional resistance which occurs between the sliding surfaces which slide against each other. Thus, it is possible to allow a slide damper to slide smoothly.
[0000] (12) By the way, a slide damper device according to an aspect of the present invention adjusts an opening of a flow path provided inside a case of an air conditioning device for a vehicle by sliding a slide damper. The slide damper device comprises a guide provided on an inner wall of the case; a connection member provided at a side end part of the slide damper, the connection member slidably fitting with the guide, the connection member connecting the slide damper to the guide; and a plurality of sliding members comprising a first sliding surface of the connection member with respect to the guide and a second sliding surface of the guide with respect to the connection member. Here, the connection member and the guide slide against each other. The first sliding surface of each of the sliding members or the second sliding surface of each of the sliding members are slanted.
(13) The above slide damper device may be configured as follows: the guide is a plate-like guide rail, and the connection member has a concave shape fitting with the guide rail.
(14) The above slide damper device may be configured as follows: the first sliding surface of the connection member with respect to the guide is slanted.
(15) The above slide damper device may be configured as follows: a first separating distance between a first tip of the guide rail at a side of the slide damper and the connection member positioned forward from the first tip is smaller than a second separating distance between a second tip of the connection member at a side of the case and the case positioned forward from the second tip.
[0026] According to the above embodiment of the present invention, a connection member and a guide slide against each other. A sliding member comprises a sliding surface of the connection member with respect to the guide and a sliding surface of the guide with respect to the connection member. Considering the entirety of the sliding member, either one of the sliding surface is slanted. When either one of the sliding surface of the sliding member is slanted, the size of the area at which the sliding surfaces slide against each other decreases. As a result, it is possible to reduce an area of contact between the connection member and the guide.
[0027] Therefore, according to the above embodiment of the present invention, it is possible to reduce the frictional resistance which occurs between the sliding surfaces which slide against each other. Thus, it is possible to allow a slide damper to slide smoothly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view showing a configuration of a slide damper device according to a first embodiment of the present invention.
[0029] FIG. 2 is a cross sectional view along line A-A in FIG. 1 according to a first embodiment of the present invention.
[0030] FIG. 3 is a modeled diagram of a cross section obtained by cutting a slide damper according to a second embodiment of the present invention at the same position as line A-A in FIG. 1 .
[0031] FIG. 4 is a modeled diagram showing a first variation of a connection member comprised by a slide damper device according to a second embodiment of the present invention.
[0032] FIG. 5 is a modeled diagram showing a second variation of a connection member comprised by a slide damper device according to a second embodiment of the present invention.
[0033] FIG. 6 is a perspective view showing a configuration of a slide damper device according to a third embodiment of the present invention.
[0034] FIG. 7 is a perspective view showing a portion of a guide rail comprised by a slide damper device according to a third embodiment of the present invention.
[0035] FIG. 8 is a cross sectional view along line A 100 -A 100 in FIG. 6 according to a third embodiment of the present invention.
[0036] FIG. 9 is a modeled diagram of a cross section obtained by cutting a slide damper according to a fourth embodiment of the present invention at the same position as line A 100 -A 100 in FIG. 6 .
[0037] FIG. 10 is a modeled diagram showing a variation of a slide damper device according to a fourth embodiment of the present invention.
[0038] FIG. 11 is a perspective view showing a configuration of a slide damper device according to a fifth embodiment of the present invention.
[0039] FIG. 12 is a cross sectional diagram along line A 200 -A 200 in FIG. 11 according to a fifth embodiment of the present invention.
[0040] FIG. 13 is an enlarged cross sectional diagram including a connection member comprised by a slide damper device according to a fifth embodiment of the present invention.
[0041] FIG. 14 is a cross sectional view showing a variation of a slide damper device according to a fifth embodiment of the present invention.
[0042] FIG. 15 is a modeled diagram of a cross section obtained by cutting a slide damper according to a sixth embodiment of the present invention at the same position as line A 200 -A 200 in FIG. 11 .
[0043] FIG. 16 is a cross sectional view showing a variation of a slide damper device according to a sixth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] Hereunder, an aspect of a slide damper device according to the present invention is described with reference to FIGS. 1-16 . In the diagrams, the scaling of some of the components are altered if necessary so that the components can be easily viewed.
[0045] The following description aims to provide a detailed explanation to facilitate an understanding of a gist of the present invention. Therefore, the present invention is not limited by the following description unless otherwise specifically noted.
First Embodiment
[0046] Hereunder, a first embodiment of the present invention is described. FIG. 1 is a perspective view showing a configuration of a slide damper device 51 according to the present embodiment. Incidentally, in FIG. 1 , the configuration of the front and back areas of the slide damper S 1 are not diagramed, for purpose of enhancing visibility.
[0047] The slide damper S 1 according to the above embodiment is used as an air mixing damper device which adjusts the ratio with which cold air and warm air is mixed, and an internal/external air swiching damper device which switches between a state of introducing external air and a state of circulating internal air. As shown in FIG. 1 , the slide damper device S 1 according to the present embodiment is placed at an interior part of a case C of an air conditioning device for a vehicle. The slide damper device S 1 adjusts an opening of a flow path provided at an interior of the case.
[0048] Further, as indicated in FIG. 1 , the slide damper device S 1 according to the present embodiment comprises a guide rail 1 , a slide damper 2 , a connection member 3 , a slide mechanism 4 , and a driving device 5 .
[0049] The guide rail 1 guides a movement of the slide damper 2 . This guide rail 1 is shaped to be planar. The guide rail 1 is provided on an inner wall of the case C so as to extend in a direction in which the slide damper 2 slides.
[0050] Further, the guide rail 1 is provided on both sides of the slide damper 2 so as to sandwich the slide damper. Each guide rail 1 is curved according to a moving range of the slide damper 2 in an extending direction. However, two guide rails 1 are similarly curved in an extending direction so that the two guide rails are constantly parallel to each other.
[0051] The slide damper 2 is connected to the guide rail 1 via the connection member 3 . The slide damper 2 may move along the guide rail 1 .
[0052] The slide damper 2 is configured so that the slide damper 2 can slide between a plurality of openings of a flow path provided in parallel at a downstream side of the slide damper 2 . The slide damper 2 adjusts the opening of the flow path by adjusting how much the opening of the flow path is opened in accordance with a sliding position.
[0053] The connection member 3 connects the slide damper 2 to the guide rail 1 .
[0054] FIG. 2 is a diagram showing a cross sectional view along line A-A of FIG. 1 . As shown in this diagram, the connection member 3 is provided on a side end part 2 a of the slide damper 2 . The connection member 3 is concaved shaped, so that the connection member 3 can fit to the guide rail 1 . In particular, the connection member 3 is concaved shaped by comprising a groove part 3 a to which the guide rail 1 can fit.
[0055] Further, both ends of the groove part 3 a are open ends. Thus, the connection member 3 is fitted to the guide rail 1 so that the connection member 3 may slide in a direction in which the guide rail 1 extends.
[0056] Moreover, according to the slide damper device S 1 based on the present embodiment, the connection member 3 is provided on all areas of the side end part 2 a of the slide damper 2 at a guide rail 1 side, as shown in FIG. 1 .
[0057] In addition, as shown in FIG. 2 , the thickness d 1 of the connection member 3 is set to be smaller than the thickness d 2 of the guide rail 1 .
[0058] Returning to FIG. 1 , the slide mechanism 4 provides power to the slide damper 2 for moving the slide damper 2 . This slide mechanism 4 comprises a rack gear 4 a provided on the slide damper 2 , a pinion gear 4 b interlocking with the rack gear 4 a , a cam and a middle gear placed between the pinion gear 4 b and a driving device 5 , and the like.
[0059] The driving device 5 transmits power to the slide damper 2 via the slide mechanism 4 for moving the slide damper 2 . For example, a motor is used as the driving device 5 .
[0060] According to the slide damper device S 1 configured as described above based on the present embodiment, when air (fluid) is supplied from an upstream side, this air is divided and supplied to a plurality of flow paths at a downstream side according to the position of the slide damper 2 .
[0061] According to the slide damper device S 1 based on the present embodiment, a plate-like guide rail 1 is provided on an inner wall of the case C, instead of a guide groove which was provided in conventional devices. Further, according to the slide damper device S 1 based on the present embodiment, a concave shaped connection member 3 is provided on a side end part 2 a of the slide damper 2 .
[0062] First, according to the slide damper device S 1 based on the present embodiment, the concave shaped connection member 3 is provided on a slide damper which is smaller and is shaped more simply compared to the case C. As a result, the connection member 3 may be manufactured with a high degree of dimensional precision by, for example, an injection molding.
[0063] Therefore, according to the slide damper device S 1 based on the present embodiment, it is possible to reduce the width of the gap between the guide rail 1 and the connection member 3 more easily compared reducing the width of a gap between a connection member and a guide groove of conventional devices. Further, according to the slide damper device S 1 based on the present embodiment, the gap s between the guide rail 1 and the connection member 3 is set to be smaller than a gap between a connection member and a guide groove of conventional devices.
[0064] Hence, according to the slide damper device S 1 based on the present embodiment, it is possible to prevent a flowing out of a fluid from an upstream of the slide damper 2 to a downstream.
[0065] Further, according to the slide damper device S 1 based on the present embodiment, the guide rail 1 may be integrated with the case C, and the connection member 3 may be integrated with the slide damper 2 by injection molding. Therefore, it is possible to prevent an increase in the number of components of an air conditioning device for a vehicle.
[0066] As described above, according to the slide damper device S 1 based on the present embodiment, a leakage of a fluid from an upstream of the slide damper 2 to a downstream can be prevented without increasing the number of components of an air conditioning device for a vehicle.
[0067] Further, according to the slide damper device S 1 based on the present embodiment, the connection member 3 is provided along the entire area of the side end part 2 a of the slide damper 2 in a direction in which the slide damper 2 slides.
[0068] Therefore, for the entire length of the slide damper 2 in the sliding direction, leakage of air can be prevented.
[0069] Further, according to the slide damper device S 1 based on the present embodiment, the thickness of the connection member 3 is set to be smaller than the thickness d 2 of the guide rail 1 .
[0070] As a result, it is possible to reduce the amount of resin necessary to form the connection member 3 , thereby reducing the mass of the connection member 3 . Hence, it is possible to easily move the slide damper 2 in a smooth manner. Further, since the amount of resin necessary for forming the connection member 3 decreases, it is possible to reduce the manufacturing cost of the connection member 3 (i.e., the slide damper 2 ).
Second Embodiment
[0071] Next, a second embodiment of the present invention is described. In the present embodiment, components which are similar to that of the first embodiment are not described or are described only briefly.
[0072] FIG. 3 is a modeled diagram of a cross section obtained by cutting a slide damper according to the present embodiment at the same position as line A-A in FIG. 1 .
[0073] As shown in FIG. 3 , the slide damper device according to the present embodiment comprises a shield wall 6 which shield an air flow and is placed at both sides of a moving range of the connection member 3 . The shield wall 6 is placed along the moving range of the connection member 3 . The shield wall 6 , placed at an upstream side of the slide damper 2 , shields air which is about to flow in the gap s between the guide rail 1 and the connection member 3 . Further, the shield wall 6 , placed at a downstream side of the slide damper 2 , shields air leaking from the gap s between the guide rail 1 and the connection member 3 .
[0074] By providing the shield wall 6 as described above, it becomes difficult for air to pass through the gap s between the guide rail 1 and the connection member 3 . As a result, the leakage of the air from the upstream of the slide damper 2 to the downstream may be better restrained.
[0075] Incidentally, when the leakage of the air from the upstream of the slide damper 2 to the downstream may be better restrained by providing the shield wall 6 , a plurality of connection members 3 may be provided on a side end part 2 a of the slide damper 2 in a direction in which the slide damper 2 slides, as indicated in FIG. 4 (a modeled diagram showing a first variation of the connection member 3 ) for instance.
[0076] In such an instance, the amount of air leaking from between the connection members 3 increases. However, because the shield wall 6 restrains the leakage of the air, it is possible to adequately prevent a leakage of the air. Further, by providing a plurality of connection members 3 placed at a distance from one another, the total mass of the connection member 3 decreases. In addition, it becomes possible to provide a smooth movement of the slide damper 2 more easily.
[0077] Further, as indicated in FIG. 5 (a modeled diagram showing a second variation of the connection member 3 ), the connection member 3 may be provided only at an end part of the slide damper 2 in the sliding direction.
[0078] As a result, the total mass of the connection member 3 decreases. Further, it becomes possible to move the slide damper 2 smoothly more easily.
[0079] In addition, when the connection member 3 is provided only at an end part of the slide damper 2 in the sliding direction, a component of the connection member 3 which tucks down the guide rail 1 may be shaped as a cylinder, and an area of contact between the connection member 3 and the guide rail 1 may be reduced. As a result, it is possible to move the slide damper 2 more smoothly.
[0080] Incidentally, a configuration in which a plurality of the connection members 3 , shown in FIG. 4 , are provided at a side end part 2 a of the slide damper 2 in the sliding direction of the slide damper 2 , and a configuration in which a connection member 3 , shown in FIG. 5 , is only provided at an end part of the slide damper 2 in the sliding direction may be used in an instance as in the first embodiment when the shield wall 6 is not provided.
[0081] Further, according to the first embodiment, the slide damper 2 was configured to be curved, as in FIG. 1 .
[0082] However, the present invention is not limited to this configuration. The slide damper may be configured to be planar as well.
Third Embodiment
[0083] Next, a third embodiment of the present invention is described. FIG. 6 is a perspective view showing a configuration of a slide damper device S 101 according to the present embodiment. Incidentally, in FIG. 6 , the areas in the front and back of the slide damper device S 101 are not diagramed in order to enhance visibility.
[0084] Further, because a slide damper device S 101 , a case C 100 , a guide rail 101 , a slide damper 102 , a connection member 103 , a slide mechanism 104 , and a driving device 105 are configured to be similar to those of the first and second embodiments, a detailed description of the components are omitted.
[0085] FIG. 7 is a perspective view showing a part of the guide rail 101 .
[0086] As shown in FIG. 7 , a plurality of protrusion members 110 are provided on both surfaces 101 a of the guide rail 101 . The plurality of protrusion members 110 are aligned in a direction in which the guide rail 101 extends. Here, the surface 101 a of the guide rail 101 is regarded as a sliding surface with respect to the connection member 103 . In other words, according to the slide damper device S 101 based on the present embodiment, the protrusion member 110 is provided on a sliding surface of the guide rail 101 with respect to the connection member 103 .
[0087] Each of the protrusion members 110 is shaped as a semicircular column. A circumferential surface of each of the protrusion members 110 is placed so as to face the side of the moving range of the connection member 103 , described later in detail, so that the shape of the surface becomes an arc in a direction in which the slide damper 102 slides (a direction in which the guide rail 101 extends).
[0088] Incidentally, a gloss is applied on a surface 101 a of the guide rail 101 . Thus, a configuration is made so that the connection member 103 moves smoothly.
[0089] Further, according to the slide damper device S 101 based on the present embodiment, the surface 101 a of the guide rail 101 is configured to be a sliding surface with respect to the connection member 103 . Further, a protrusion member 110 is provided with respect to a surface 101 a of the guide rail 101 . In other words, according to the slide damper device S 101 based on the present embodiment, both sides of the guide rail 101 facing each other are regarded as sliding surfaces, and a protrusion member 110 is provided on both of these sliding surfaces.
[0090] Moreover, as shown in FIG. 7 , according to the slide damper device S 101 based on the present embodiment, a protrusion member 110 provided on a sliding surface of one side of the guide rail 101 and a protrusion member 110 provided on a sliding surface of the other side of the guide rail 101 are placed out of alignment with each other in a sliding direction of the slide damper 102 (i.e., a direction in which the guide rail 101 extends). In other words, the protrusion member 110 is alternatively placed in a sliding direction of the slide damper 102 with respect to the opposing front and back surfaces (i.e., the sliding surfaces) of the guide rail 101 .
[0091] Incidentally, as shown in FIG. 7 , the distance with which the protrusion members 110 are placed from each other at one surface 101 a of the guide rail 101 is set to be a distance such that the sliding surface of the connection member 103 (a surface of the connection member 103 which slides with respect to the surface 101 a of the guide rail 101 ) is constantly in contact with two or more (a plurality of) protrusion members 110 .
[0092] Returning to FIG. 6 , the slide damper 102 is connected to the guide rail 101 via the connection member 103 . The slide damper 102 may move along the guide rail 101 .
[0093] This slide damper 102 is configured so that the slide damper 102 may slide between a plurality of flow path openings which are provided in parallel at a downstream side of the slide damper 102 . Here, a “flow path opening” refers to “an opening of a flow path.” The opening of the flow path is adjusted by adjusting how much each flow path opening is opened in accordance with a sliding position.
[0094] The connection member 103 connects the slide damper 102 to the guide rail 101 .
[0095] FIG. 8 is a diagram showing a cross section along line A 100 -A 100 in FIG. 6 . As shown in FIG. 8 , the connection member 103 is provided on a side end part 102 a of the slide damper 102 , and is concave shaped so that the connection member 103 can fit with the guide rail 101 . In particular, the connection member 103 is concave shaped by comprising a groove portion 103 a which can be fitted to a guide rail 101 .
[0096] Further, both ends of the groove portion 103 in the sliding direction are open ends. Thus, the connection member 103 may freely slide with respect to the guide rail 101 in a direction in which the guide rail 101 extends. As a result, each of an inner wall surface 103 b of the groove portion 103 a of the connection member 103 tucking in the guide rail 101 is regarded as a sliding surface which slides with respect to the guide rail 101 .
[0097] Incidentally, according to the slide damper device 5101 based on the present embodiment, the connection member 103 is provided on an entire area of the side end part 102 a of the slide damper 102 at a side of the guide rail 101 , as shown in FIG. 6 .
[0098] Returning to FIG. 6 , the slide mechanism 104 provides power to the slide damper 102 for moving the slide damper 102 . This slide mechanism 104 comprises a rack gear 104 a provided on the slide damper 102 , a pinion gear 104 b interlocking with the rack gear 104 a , a cam and a middle gear placed between the pinion gear 104 b and a driving device 105 , and the like.
[0099] The driving device 105 transmits power to the slide damper 102 via the slide mechanism 104 for moving the slide damper 102 . For example, a motor is used as the driving device 105 .
[0100] In this way, according to the slide damper device S 101 based on the present embodiment, when one sliding member 120 is regarded to comprise a sliding surface of the guide rail 101 with respect to the connection member 103 (i.e., the surface 101 a of the guide rail 101 ) and a sliding surface of the guide rail 101 with respect to the connection member 103 (i.e., the inner wall surface 103 b of the connection member 103 ), the slide damper device S 101 comprises four sliding members 120 . The sliding surfaces slide against each other. Further, a protrusion member 110 is provided on a surface 101 a of the guide rail 101 , with respect to each of the sliding members 120 .
[0101] Further, according to the slide damper device S 101 based on the present embodiment, when air (fluid) is supplied from an upstream side, this air is divided and supplied to a plurality of flow paths at a downstream side according to the position of the slide damper 102 .
[0102] In this way, according to the slide damper device S 101 based on the present embodiment, a protrusion member 110 is provided on the surface 101 a of the guide rail 101 . As a result, the sliding surfaces (the surface 101 a of the guide rail 101 and the inner wall surface 103 b ) which are sliding against one another are prevented from contacting each other in their entirety. As a result, it is possible to reduce the area of contact between the connection member 103 and the guide rail 101 .
[0103] Therefore, according to the present invention, it is possible to reduce the frictional resistance created between the sliding surfaces which are sliding against each other. Accordingly, the slide damper 102 may be moved smoothly.
[0104] Moreover, a gloss is applied to a surface 101 a of the guide rail 101 as described above. The gloss applied to the surface 101 a of the guide rail 101 is gradually pushed out from the sliding area of the connection member 103 by the sliding of the connection member 103 with respect to the guide rail 101 . When the amount of gloss in the sliding area of the connection member 103 greatly decreases, the slide damper 102 is prevented from moving smoothly.
[0105] Meanwhile, the protrusion member 110 comprised by the slide damper device S 101 based on the present embodiment protrudes with respect to the surface 101 a of the guide rail 101 . Therefore, it is possible to hold the gloss that moves due to the sliding of the connection member 103 . In other words, the protrusion member 110 comprised by the slide damper device S 101 based on the present embodiment operates as a gloss pool. As a result, according to the slide damper device S 101 based on the present embodiment, it is possible to hold the gloss for a long period of time to the sliding area of the connection member 103 . Thus, the slide damper 102 may move smoothly for a long period of time.
[0106] In addition, according to the slide damper device S 101 based on the present embodiment, the protrusion member 110 is provided on a sliding surface (i.e., the surface 101 a ) of the guide rail 101 .
[0107] Therefore, compared to an instance in which the protrusion member 110 is provided at an inner wall surface 103 b of the connection member 103 , a greater number of protrusion members 110 may be placed.
[0108] Hence, it is possible to provide a large number of gloss pools described above. Thus, the slide damper 102 may move smoothly for a longer period of time.
[0109] Further, according to the slide damper device S 101 based on the present embodiment, the protrusion member 110 is aligned so that a sliding surface of the connection member 103 (i.e., a surface of the connection member 103 which slides with respect to the surface 101 a of the guide rail 101 ) always comes in contact with two or more (a plurality of) protrusion members 110 .
[0110] Therefore, the connection member 103 may always be supported stably in a sliding direction of the slide damper 102 . Thus, the slide damper 102 may be moved smoothly.
[0111] Further, according to the slide damper device S 101 based on the present embodiment, a protrusion member 110 provided on a sliding surface of one side of the guide rail 101 and a protrusion member 110 provided on a sliding surface of the other side of the guide rail 101 are placed out of alignment with each other in a sliding direction of the slide damper 102 (i.e., a direction in which the guide rail 101 extends). In other words, the protrusion member 110 is alternatively placed in a sliding direction of the slide damper 102 with respect to the opposing front and back surfaces (i.e., the sliding surfaces) of the guide rail 101 .
[0112] Therefore, when the protrusion member 110 is pressed strongly from the connection member 103 , there is no protrusion member 110 which presses from an opposite side a portion of the guide rail 101 at which the protrusion member 110 is placed. Therefore, the portion of the guide rail 101 may be deformed. Consequently, it is possible to change the position of the protrusion member 110 in a direction of the thickness of the guide rail 101 . Therefore, even in an instance in which the guide rail 101 , the connection member 103 , and the protrusion member 110 includes a dimension error and is pressed strongly from the connection member 103 , the slide damper 102 continues to move smoothly.
Fourth Embodiment
[0113] Next, a fourth embodiment of the present invention is described. Components of the present embodiment which are similar to those of the third embodiment are not described or described only briefly.
[0114] FIG. 9 is a modeled diagram of a cross section obtained by cutting a slide damper according to the present embodiment at the same position as line A 100 -A 100 in FIG. 6 .
[0115] As shown in FIG. 9 , the slide damper device according to the present embodiment comprises a guide groove 130 (hereinafter may be referred to as a “guide”) provided at an inner wall of the case C 100 , instead of the guide rail 101 according to the third embodiment described above.
[0116] Further, according to the slide damper device based on the present embodiment, the connection member 103 is shaped in a protruding manner so as to fit with the guide groove 130 . Incidentally, the connection member 103 may be provided along the entire area of the side end part 102 a of the slide damper 102 in the sliding direction. In addition, the connection member 103 may be provided only at a tip portion in the sliding direction in a pin-like manner.
[0117] Further, according to the slide damper device based on the present embodiment, a plurality of protrusion members 110 are provided on an inner wall surface 130 a (sliding surface) of the guide groove 130 .
[0118] According to a slide damper device based on the present embodiment employing the configuration described above, due to the protrusion member 110 , the sliding surfaces (the inner wall surface 130 a of the guide groove 130 and the surface 103 c of the connection member 103 ) which are sliding against one another are prevented from contacting each other in their entirety. As a result, it is possible to reduce the area of contact between the connection member 103 and the guide groove 130 .
[0119] Therefore, according to the present embodiment, it is also possible to reduce the frictional resistance created between the sliding surfaces which are sliding against each other. Accordingly, the slide damper 102 may be moved smoothly.
[0120] In the present embodiment, a configuration was describe in which a protrusion member 110 is provided at a side of the guide (i.e., the guide rail 101 or the guide groove 130 ) with respect to all of the sliding members.
[0121] However, the present invention is not limited to this configuration. A protrusion member may be provided to a side of the connection member 103 .
[0122] In addition, it is not necessary that a protrusion member be provided on all of the sliding members.
[0123] For example, a protrusion member may be provided only on a sliding member placed at a downstream side of the slide damper 102 . Since the slide damper 102 is pushed towards the downstream side due to an air flow, the slide damper 102 may be moved smoothly in a more efficient manner by placing the protrusion member at a sliding member at a downstream side compared to placing the protrusion member at an upstream side. Therefore, even if the protrusion member is provided only at a sliding member placed at a downstream side of the slide damper 102 , it is possible to make the movement of the slide damper 102 sufficiently smooth. Moreover, since a protrusion member is not provided at a sliding member at an upstream side, it is possible to lower the cost of the sliding damper.
[0124] In addition, the protrusion member may be provided only at a sliding member placed at an upstream side of the slide damper 102 . In this instance, the slide damper 102 is pushed towards the downstream side by an air flow. As a result, the connection member and the guide come in close contact with each other. Therefore, it is possible to prevent leakage of the air from the upstream of the slide damper 102 towards the downstream. Even in this instance, a protrusion member is provided at a sliding member at the upstream side. Therefore, the slide damper 102 may be moved compared to conventional devices.
[0125] Further, according to the third embodiment, a configuration was described in which the slide damper 102 was curved as shown in FIG. 6 .
[0126] However, the present invention is not limited to this configuration. It is possible to employ a configuration in which a planar slide damper is used.
[0127] Further, according to the fourth embodiment, a configuration was described in which the guide groove 130 is provided on an inner wall surface of the case C 100 so as to protrude towards an interior of the case C 100 .
[0128] However, the present invention is not limited to this configuration. As shown in FIG. 10 , a configuration may be employed in which the guide groove 130 is provided on an inner wall surface of the case C 100 so as to protrude towards an exterior of the case C 100 .
Fifth Embodiment
[0129] Hereinafter, a fifth embodiment of the present invention is described. FIG. 11 is a perspective view showing a configuration of a slide damper device 5201 according to the present embodiment. Incidentally, in FIG. 11 , the areas in the front and back of the slide damper device S 201 are not diagramed in order to enhance visibility.
[0130] Further, because a slide damper device 5201 , a case C 200 , a guide rail 201 , a slide damper 202 , a connection member 203 , a slide mechanism 204 , and a driving device 205 are configured to be similar to those of the embodiments described earlier, a detailed description of the components are omitted.
[0131] FIG. 12 is a cross sectional diagram along line A 200 -A 200 in FIG. 11 . As shown in FIG. 12 , the connection member 203 is provided on a side end part 202 a of the slide damper 202 , and is concave shaped so that the connection member 203 can fit with the guide rail 201 . In particular, the connection member 203 is concave shaped by comprising a groove portion 203 a which can be fitted to a guide rail 201 .
[0132] Further, both ends of the groove portion 203 in the sliding direction are open ends. Thus, the connection member 203 may freely slide with respect to the guide rail 201 in a direction in which the guide rail 201 extends. As a result, each of an inner wall surface 203 b of the groove portion 203 a of the connection member 203 tucking in the guide rail 201 is regarded as a sliding surface which slides with respect to the guide rail 201 .
[0133] Incidentally, according to the slide damper device 5201 based on the present embodiment, the connection member 203 is provided on an entire area of the side end part 202 a of the slide damper 202 at a side of the guide rail 201 , as shown in FIG. 11 .
[0134] Returning to FIG. 11 , the slide mechanism 204 provides power to the slide damper 202 for moving the slide damper 202 . This slide mechanism 204 comprises a rack gear 204 a provided on the slide damper 202 , a pinion gear 204 b interlocking with the rack gear 204 a , a cam and a middle gear placed between the pinion gear 204 b and a driving device 205 , and the like.
[0135] The driving device 205 transmits power to the slide damper 202 via the slide mechanism 204 for moving the slide damper 202 . For example, a motor is used as the driving device 205 .
[0136] In this way, according to the slide damper device S 201 based on the present embodiment, when one sliding member 220 is regarded to comprise a sliding surface of the guide rail 201 with respect to the connection member 203 (i.e., the surface 201 a of the guide rail 201 ) and a sliding surface of the guide rail 201 with respect to the connection member 203 (i.e., the inner wall surface 203 b of the connection member 203 ), the slide damper device S 201 comprises four sliding members 220 . The sliding surfaces slide against each other.
[0137] Moreover, according to the slide damper device 5201 based on the present embodiment, a sliding surface of the connection member 203 with respect to the guide rail 201 (the inner wall surface 203 b ) is slanted with respect to a sliding surface of the guide rail 201 with respect to the connection member 203 (surface 201 a ), as shown the enlarged diagram in FIG. 13 .
[0138] In more detail, the inner wall surface 203 b of the connection member 203 is parallel to the surface of the slide damper 202 . Meanwhile, as the surface 201 a of the guide rail 201 extends towards the tip of the guide rail 201 , a slanting is made so as to approach the slide damper 202 . The guide rail 201 is shaped so that the front and back surfaces approach one another towards the tip of the guide rail 201 . In other words, as shown in FIG. 13 , the guide rail 201 is shaped so that the cross sectional area becomes smaller towards the tip of the guide rail 201 .
[0139] Further, according to the slide damper device 5201 based on the present embodiment, the surface 201 a of the guide rail 201 is slanted with respect to all of the sliding members 220 . In other words, according to the slide damper device S 201 based on the present embodiment, the sliding surface of the guide rail 201 with respect to the connection member 203 is slanted with respect to all of the sliding members 220 .
[0140] Further, according to the slide damper device S 201 based on the present embodiment, when the connection member 203 is fitted to the guide rail 201 as shown in FIG. 13 , a separating distance d 201 from the tip 201 b of the slide damper 202 side of the guide rail 201 to the connection member 203 located ahead of the tip 201 b is set to be smaller than a separating distance d 202 from the tip 203 c of the connection member 203 at a case C 200 side to the case C 200 positioned ahead of this tip 203 c.
[0141] Further, according to the slide damper device S 201 based on the present embodiment, when air (fluid) is supplied from an upstream side, this air is divided and supplied to a plurality of flow paths at a downstream side according to the position of the slide damper 202 .
[0142] According to the slide damper device S 201 based on the present embodiment, the surface 201 a , which is a sliding surface of the guide rail 201 , is slanted with respect to the entire sliding member 220 comprising a sliding surface of the connection member 203 with respect to the guide rail 201 (inner wall surface 203 b ) and a sliding surface of the guide rail 201 with respect to the connection member 203 (surface 201 a ) which are sliding against each other.
[0143] According to the sliding member 220 , when the sliding surface of the guide rail 201 (surface 201 a ) is slanted, the inner wall surface 203 b of the connection member 203 partially hits the surface 201 a of the guide rail 201 . As a result, the size of the area at which the sliding surfaces come into contact with each other decreases. As a result, it is possible to reduce the area in contact between the connection member 203 and the guide rail 201 .
[0144] Therefore, according to the slide damper device S 201 based on the present embodiment, it is possible to reduce the frictional resistance which occurs between the sliding surfaces which slide against each other. Thus, it is possible to allow a slide damper to slide smoothly.
[0145] Further, according to the sliding member 220 , because the surface 201 a of the guide rail 201 and the inner wall surface 203 b of the connection member 203 are always sliding against one another, the surface 201 a of the guide rail 201 and the inner wall surface 203 b of the connection member 203 may wear out, thereby changing the condition in which the guide rail 201 and the connection member 203 are fitted against each other.
[0146] Therefore, according to the slide damper device S 201 based on the present embodiment, the separating distance d 201 from the tip 201 b of the slide damper 202 side of the guide rail 201 to the connection member 203 located ahead of the tip 201 b is set to be smaller than the separating distance d 202 from the tip 203 c of the connection member 203 at a case C 200 side to the case C 200 positioned ahead of this tip 203 c.
[0147] Thus, according to the slide damper device S 201 based on the present embodiment, when the connection member 203 and the case C 200 becomes close to each other due to the wearing out described above, the tip 201 b of the guide rail 201 comes in contact with the connection member 203 before the tip 203 c of the connection member 203 contacts the case C 200 .
[0148] The number of the tip 201 b of the guide rail 201 is one. Meanwhile, the number of the tip 203 c of the connection member 203 is two. Therefore, the frictional resistance between the guide rail 201 and the connection member 203 is smaller in an instance in which the tip 201 b of the guide rail 201 contacts the connection member 203 compared to an instance in which the tip 203 c of the connection member 203 contacts the case C 200 . Therefore, according to the slide damper device S 201 based on the present embodiment, even when the guide rail 201 and the connection member 203 are worn out by the passage of time, and even in an instance in which the guide rail 201 and the connection member 203 come in contact with one another at a portion that should not be contacted, it is possible to restrain the frictional resistance from increasing. Thus, it is possible to preserve the sliding motion of the slide damper 202 .
[0149] Further, in order to prevent the surface 201 a of the guide rail 201 and the inner wall surface 203 b of the connection member 203 from wearing out, it is preferable that a surface removing operation be performed on a portion which hits the surface 201 a of the guide rail 201 of the connection member 203 .
[0150] Further, among the sliding surfaces (the surface 201 a of the guide rail 201 and the inner wall surface 203 b of the connection member 203 ) comprised by the sliding member 220 , the present embodiment employs a configuration in which the sliding surface of the guide rail 201 (surface 201 a ) is slanted.
[0151] However, the present invention is not limited to this configuration. As shown in FIG. 14 , it is possible to employ a configuration in which the surface 201 a of the guide rail 201 is parallel to the surface of the slide damper 202 , and the inner wall surface 203 b of the connection member 203 is slanted with respect to the surface 201 a of the guide rail 201 .
[0152] Even if such a configuration is employed, it is possible to reduce the frictional resistance which occurs between the sliding surfaces which slide against each other, and it is possible to allow a slide damper to slide smoothly, as in the slide damper device S 201 based on the present embodiment.
[0153] However, when a configuration shown in FIG. 14 is employed such that the inner wall surface 203 b of the connection member 203 is slanted, the connection member 203 opens outwards towards the tip 203 c.
[0154] When such a shape is employed, a wall unit 3 d comprising the inner wall surface 203 b of the connection member 203 is already facing outwards. Therefore, it is possible to alter the shape of the wall unit 3 d towards the outer side.
[0155] On the other hand, as in the slide damper device S 201 according to the present embodiment, among the sliding surfaces (the surface 201 a of the guide rail 201 and the inner wall surface 203 b of the connection member 203 ) comprised by the sliding member 220 , a configuration is employed such that the sliding surface of the guide rail 201 (surface 201 a ) is slanted. As a result, the wall part 203 d of the connection member 203 may be further deformed towards the outer side. Therefore, according to the slide damper device S 201 based on the present embodiment, even if the sliding slide damper 202 moves towards the case C 200 side due to dimensional errors and the like, this movement is absorbed by the deformation of the wall part 203 d of the connection member 203 . As a result, it is possible to obtain a smooth movement of the slide damper 202 .
Sixth Embodiment
[0156] Next, a sixth embodiment of the present invention is described. In the present embodiment, components which are similar to that of the fifth embodiment are not described or are described only briefly.
[0157] FIG. 15 is a modeled diagram of a cross section obtained by cutting a slide damper according to the present embodiment at the same position as line A 200 -A 200 in FIG. 11 .
[0158] As shown in FIG. 15 , the slide damper device according to the present embodiment comprises a guide groove 230 (hereinafter may be referred to as a “guide”) provided at an inner wall of the case C 200 , instead of the guide rail 201 according to the fifth embodiment described above.
[0159] Further, according to the slide damper device based on the present embodiment, the connection member 203 is shaped in a protruding manner so as to fit with the guide groove 230 . Incidentally, the connection member 203 may be provided along the entire area of the side end part 202 a of the slide damper 202 in the sliding direction. In addition, the connection member 203 may be provided only at a tip portion in the sliding direction in a pin-like manner.
[0160] Further, according to the slide damper device based on the present embodiment, the inner wall surface 230 a (sliding surface) of the guide groove 230 is slanted with respect to the connection member 203 which was parallel with respect to the surface of the slide damper 202 .
[0161] According to the slide damper device based on the present embodiment, it is possible to reduce the area in contact between the connection member 203 and the guide rail 201 , in a way similar to the fifth embodiment.
[0162] Therefore, according to the slide damper device based on the present embodiment, it is possible to reduce the frictional resistance created between the sliding surfaces which are sliding against each other. Accordingly, the slide damper may be moved smoothly.
[0163] Incidentally, according to the fifth embodiment, a configuration was described in which the slide damper 202 was curved as shown in FIG. 11 .
[0164] However, the present invention is not limited to this configuration. It is possible to employ a configuration in which a planar slide damper is used.
[0165] Further, according to the sixth embodiment, a configuration was described in which the guide groove 230 is provided on an inner wall surface of the case C 200 so as to protrude towards an interior of the case C 200 .
[0166] However, the present invention is not limited to this configuration. As shown in FIG. 16 , a configuration may be employed in which the guide groove 230 is provided on an inner wall surface of the case C 200 so as to protrude towards an exterior of the case C 200 .
[0167] While a preferred embodiment of the present invention has been described above, it should be understood that these are exemplary of the invention and are not to be considered as limiting the present invention. Additions, omissions, substitutions, and other modifications can be made without departing from the scope of the present invention. The invention is not to be considered as being limited by the foregoing description, and is only limited by the scope of the appended claims. | A slide damper device comprising: a case of an air conditioning device for a vehicle; a slide damper; a plate-like guide rail provided on an inner wall of the case; a connection member provided at a side end part of the slide damper, the connection member having a concave shape slidably fitting with the guide rail, the connection member connecting the slide damper to the guide rail, wherein an opening of a flow path provided inside the case is adjusted by sliding the slide damper. | 1 |
BENEFIT CLAIM
This application is a continuation-in-part of U.S. patent application Ser. No. 09/296,226, filed Apr. 22, 1999, which claims the benefit of U.S. Provisional Application No. 60/095,612, filed Aug. 6, 1998. The disclosures of both applications are incorporated herein by reference.
RELATED APPLICATIONS
This application is related to U.S. patent application Ser. No. 09/062,128, filed Apr. 17, 1998 and of U.S. patent application Ser. No. 09/252,182, filed Feb. 18, 1999, the disclosures of both of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a process for catalyzing cross coupling reactions (including Suzuki type cross coupling reactions) and aryl amination reactions using either a dicycloalkylphenyl phosphine or dialkylphenyl phosphine ligand, which may be in the form of a metal-ligand complex or metal precursor/ligand composition. In particular, this invention relates to improved processes that use phosphines, which when combined with suitable metals or metal precursor compounds provide useful catalysts for various bond-forming reactions.
BACKGROUND OF THE INVENTION
Ancillary (or spectator) ligand-metal coordination complexes (e.g., organometallic complexes) and compositions are useful as catalysts, additives, stoichiometric reagents, monomers, solid state precursors, therapeutic reagents and drugs. Ancillary ligand-metal coordination complexes of this type can be prepared by combining an ancillary ligand with a suitable metal compound or metal precursor in a suitable solvent under suitable reaction conditions. The ancillary ligand may contain functional groups that bind to the metal center(s), remain associated with the metal center(s), and therefore provide an opportunity to modify the steric, electronic and chemical properties of the active metal center(s) of the complex.
Certain known ancillary ligand-metal complexes and compositions are catalysts for reactions such as oxidation, reduction, hydrogenation, hydrosilylation, hydrocyanation, hydroformylation, polymerization, carbonylation, isomerization, metathesis, carbon-hydrogen activation, carbon-halogen activation, cross-coupling, hetero cross-coupling, Friedel-Crafts acylation and alkylation, hydration, amination, aryl amination, dimerization, trimerization, oligomerization, Diels-Alder reactions and other transformations.
One example of the use of these types of ancillary ligand-metal complexes and compositions is in the field of cross-coupling reactions. The palladium-catalyzed cross-coupling reactions of aryl-bromides, iodides, and triflates with alkyl or aryl-boron compounds provide a general and efficient route to a wide variety of substituted alkylphenyl or biphenyl compounds, and have now been extensively developed. See Suzuki, A. in Metal - Catalyzed Cross - Coupling Reactions ; Diederich, F., Stang, P. J., Eds.; Wiley-VCH: Weinheim, Germany, 1998; Chapter 2, pp. 49-97, which is incorporated herein by reference. See also U.S. Pat. Nos. 5,550,236 and 5,756,804, both of which are incorporated herein by reference.
However, the related palladium-catalyzed reactions of the comparatively inexpensive and readily available aryl chlorides, which represent the most attractive candidates for industrial applications of these reactions, have been underdeveloped. See Old, D. W., Wolfe, J. P., Buchwald, S. L., J Am. Chem. Soc. 1998, 120, 9722-9723; and Littke, A. F., Fu, G. C., Angew. Chem. Int. Ed. Eng. 1998, 37, 3387-3388, which are both incorporated herein by reference. In particular, Buchwald et al. in the above referenced paper note that certain dicycloalkyl phosphine ligands are “not effective” for these palladium-catalyzed reactions. J. Am. Chem. Soc., 1998 at 9723. In the supplemental material to that paper, Buchwald et al. disclose that in a palladium-dicyclohexylphenylphosphine catalyzed Suzuki cross-coupling reaction, the turn over number (TON) was about 9 after 2 days, giving a turn over frequency (TOF) of about 0.19.
This invention thus surprisingly demonstrates that improved catalytic activity can indeed be obtained with the exact ligands and catalyst systems that were previously characterized as “not effective.” Compounds prepared according to the invention are suitable for use as precursors for pharmaceuticals, cosmetics, fungicides, herbicides, dyes, detergents, and polymers, including additives for these. Compounds prepared according to the invention are, in particular, valuable precursors for angiotensin II inhibitors. See Drugs of the Future 1993, 18, 428-432.
SUMMARY OF THE INVENTION
Thus, it is an object of this invention to provide a process for the cross coupling of reactants using ligand/metal compositions and/or metal-ligand complexes. These catalyst assisted chemical transformations obtain a turn over number (TON) of at least 50 and/or a turn over frequency (TOF) of at least 5, possibly with a selectivity in the range of from about 80% to about 100%. The ligand useful in this process can be characterized by the general formula:
wherein each R 1 and R 2 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl and substituted cycloalkyl. Each of R 3 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, alyl, substituted aryl, heteroaryl, substituted heteroaryl, silyl, amino, nitro, ester, acid, alkoxy, aryloxy, hydroxy, transition metals, COOH, SO 3 G (G=Na, K, H, etc.) and combinations thereof; a is 0, 1 or 2 such that R 3 , when present, occupies either the para position or the two meta positions. Each of R 4 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, heteroaryl, substituted heteroaryl, silyl, amino, nitro, ester, acid, alkoxy, aryloxy, hydroxy, transition metals, COOH, SO 3 G (G=Na, K, H, etc.) and combinations thereof; b is 0, 1 or 2, such that when R 4 is present, it occupies either one or two ortho positions.
In a more particular embodiment, the preferred ligands of this invention may be characterized by the general formula:
where R 1 and R 2 are as defined above and R 6 is selected from the same group as R 4 and R 7 is selected from the same group as R 3 or hydrogen.
The ligands are added to a metal precursor to provide a catalytic composition or metal-ligand complex. And, it is an object of this invention to provide improved processes using such compositions (i.e., comprising the ligand and a metal precursor) or metal complexes. The suitable metal or metal precursor compound can be of the form ML n , where the composition has catalytic properties. Also, the ligands can be coordinated with a metal precursor to form metal-ligand complexes, which may be catalysts. Here, M is a transition metal selected from the group consisting of Groups 5, 6, 7, 8, 9 and 10 of the Periodic Table of Elements, preferably Pd, Ni, Ru, Rh, Pt, Co, Ir and Fe; L is independently each occurrence, a neutral and/or charged ligand; and n is a number 0, 1, 2, 3, 4, and 5, depending on M. M is most preferably Pd or Ni.
Another aspect of this invention is the chemical transformations that the new catalytic compositions or metal complexes enhance, and it is an object of this invention to provide catalysts and methods for such transformations. The compositions and metal complexes are useful as catalysts for various chemical transformations, particularly cross coupling reactions and aryl amination reactions. Specifically, the preparation of polycyclic aromatic compounds by a cross-coupling reaction of a first aromatic compound and second aromatic compound, more specifically with aromatic boron compounds and aromatic halogen compounds or perfluoroalkylsulfonates may be performed, and it is an object of this invention to provide catalysts and methods for such cross coupling reactions. The benefit of using these catalysts in such reactions is generally higher conversions (e.g., turnovers) when using less costly starting materials.
Further aspects of this invention will be evident to those of skill in the art upon review of this specification.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the phrase “characterized by the formula” is not intended to be limiting and is used in the same way that “comprising” is commonly used. The term “independently selected” is used herein to indicate that the R groups, e.g., R 1 , R 2 , R 3 or R 4 can be identical or different (e.g. R 1 , R 2 and R 3 may all be substituted alkyls or R 1 and R 4 may be a substituted alkyl and R 3 may be an aryl, etc.). A named R group will generally have the structure that is recognized in the art as corresponding to R groups having that name. For the purposes of illustration, representative R groups as enumerated above are defined herein. These definitions are intended to supplement and illustrate, not preclude, the definitions known to those of skill in the art.
The term “alkyl” is used herein to refer to a branched or unbranched, saturated or unsaturated acyclic hydrocarbon radical. Suitable alkyl radicals include, for example, methyl, ethyl, n-propyl, i-propyl, 2-propenyl (or allyl), vinyl, n-butyl, t-butyl, i-butyl (or 2-methylpropyl), etc. In particular embodiments, alkyls have between 1 and 200 carbon atoms, between 1 and 50 carbon atoms or between 1 and 20 carbon atoms.
“Substituted alkyl” refers to an alkyl as just described in which one or more hydrogen atom to any carbon of the alkyl is replaced by another group such as a halogen, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl, and combinations thereof. Suitable substituted alkyls include, for example, benzyl, trifluoromethyl and the like.
The term “heteroalkyl” refers to an alkyl as described above in which one or more hydrogen atoms to any carbon of the alkyl is replaced by a heteroatom selected from the group consisting of N, O, P, B, S, Si, Se and Ge. The bond between the carbon atom and the heteroatom may be saturated or unsaturated. Thus, an alkyl substituted with a heterocycloalkyl, substituted heterocycloalkyl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, or seleno is within the scope of the term heteroalkyl. Suitable heteroalkyls include cyano, benzoyl, 2-pyridyl, 2-furyl and the like.
The term “cycloalkyl” is used herein to refer to a saturated or unsaturated cyclic non-aromatic hydrocarbon radical having a single ring or multiple condensed rings. Suitable cycloalkyl radicals include, for example, cyclopentyl, cyclohexyl, cyclooctenyl, bicyclooctyl, etc. In particular embodiments, cycloalkyls have between 3 and 200 carbon atoms, between 3 and 50 carbon atoms or between 3 and 20 carbon atoms.
“Substituted cycloalkyl” refers to cycloalkyl as just described including in which one or more hydrogen atom to any carbon of the cycloalkyl is replaced by another group such as a halogen, alkyl, substituted alkyl, aryl, substituted aryl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, seleno and combinations thereof. Suitable substituted cycloalkyl radicals include, for example, 4-dimethylaminocyclohexyl, 4,5-dibromocyclohept-4-enyl, and the like.
The term “heterocycloalkyl” is used herein to refer to a cycloalkyl radical as described, but in which one or more or all carbon atoms of the saturated or unsaturated cyclic radical are replaced by a heteroatom such as nitrogen, phosphorous, oxygen, sulfur, silicon, germanium, selenium, or boron. Suitable heterocycloalkyls include, for example, piperazinyl, morpholinyl, tetrahydropyranyl, tetrahydrofuranyl, piperidinyl, pyrrolidinyl, oxazolinyl, and the like.
“Substituted heterocycloalkyl” refers to heterocycloalkyl as just described including in which one or more hydrogen atom to any atom of the heterocycloalkyl is replaced by another group such as a halogen, alkyl, substituted alkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, boryl, phosphino, amino, silyl, thio, seleno and combinations thereof. Suitable substituted heterocycloalkyl radicals include, for example, N-methylpiperazinyl, 3-dimethylaminomorpholine, and the like.
The term “aryl” is used herein to refer to an aromatic substituent which may be a single aromatic ring or multiple aromatic rings which are fused together, linked covalently, or linked to a common group such as a methylene or ethylene moiety. The common linking group may also be a carbonyl as in benzophenone or oxygen as in diphenylether or nitrogen in diphenylamine. The aromatic ring(s) may include phenyl, naphthyl, biphenyl, diphenylether, diphenylamine and benzophenone among others. In particular embodiments, aryls have between 6 and 200 carbon atoms, between 6 and 50 carbon atoms or between 6 and 20 carbon atoms.
“Substituted aryl” refers to aryl as just described in which one or more hydrogen atom to any carbon is replaced by one or more functional groups such as alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, halogen, alkylhalos (e.g., CF 3 ), hydroxy, phosphino, alkoxy, aryloxy, amino, thio and both saturated and unsaturated cyclic hydrocarbons which are fused to the aromatic ring(s), linked covalently or linked to a common group such as a methylene or ethylene moiety. The linking group may also be a carbonyl such as in cyclohexyl phenyl ketone.
The term “heteroaryl” as used herein refers to aromatic rings in which one or more carbon atoms of the aromatic ring(s) are replaced by a heteroatom(s) such as nitrogen, oxygen, boron, selenium, phosphorus, silicon or sulfur. Heteroaryl refers to structures that may be a single aromatic ring, multiple aromatic ring(s), or one or more aromatic rings coupled to one or more nonaromatic ring(s). In structures having multiple rings, the rings can be fused together, linked covalently, or linked to a common group such as a methylene or ethylene moiety. The common linking group may also be a carbonyl as in phenyl pyridyl ketone. As used herein, rings such as thiophene, pyridine, isoxazole, phthalimide, pyrazole, indole, furan, etc. or benzo-fused analogues of these rings are defined by the term “heteroaryl.”
“Substituted heteroaryl” refers to heteroaryl as just described including in which one or more hydrogen atoms to any atom of the heteroaryl moiety is replaced by another group such as a halogen, alkyl, substituted alkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, phosphino, amino, silyl, thio, seleno and combinations thereof. Suitable substituted heteroaryl radicals include, for example, 4-N,N-dimethylaminopyridine.
The term “alkoxy” is used herein to refer to the —OZ 1 radical, where Z 1 is selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocylcoalkyl, substituted heterocycloalkyl, silyl groups and combinations thereof as described herein. Suitable alkoxy radicals include, for example, methoxy, ethoxy, benzyloxy, t-butoxy, etc. A related term is “aryloxy” where Z 1 is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl, and combinations thereof. Examples of suitable aryloxy radicals include phenoxy, substituted phenoxy, 2-pyridinoxy, 8-quinalinoxy and the like.
As used herein the term “silyl” refers to the —SiZ 1 Z 2 Z 3 radical, where each of Z 1 , Z 2 , and Z 3 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocylcoalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, amino, silyl and combinations thereof.
As used herein the term “boryl” refers to the —BZ 1 Z 2 group, where each of Z 1 and Z 2 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocylcoalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, amino, silyl and combinations thereof.
The term “amino” is used herein to refer to the group —NZ 1 Z 2 , where each of Z 1 and Z 2 is independently selected from the group consisting of hydrogen; alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl and combinations thereof. Additionally, the amino group may be present as N + Z 1 Z 2 Z 3 , with the previous definitions applying and Z 3 being either H or alkyl.
The ligands useful in this invention can be characterized by the general formula:
wherein each R 1 and R 2 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl and substituted cycloalkyl; and
Each of R 3 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, silyl, amino, nitro, ester, acid, alkoxy, aryloxy, hydroxy, transition metals, COOH, SO 3 G (G=Na, K, H, etc.) and combinations thereof; a is 0, 1 or 2 such that R 3 , when present, occupies either the para position or the two meta positions. Each of R 4 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, heteroaryl, substituted heteroaryl, silyl, amino, nitro, ester, acid, alkoxy, aryloxy, hydroxy, transition metals, COOH, SO 3 G (G=Na, K, H, etc.) and combinations thereof; b is 0, 1 or 2, such that when R 4 is present, it occupies either one or two ortho positions. When R 3 or R 4 is absent, a hydrogen atom is present in its place.
In more specific embodiments, each R 1 and R 2 is independently selected from a group consisting of alkyl, substituted, cycloalkyl and substituted cycloalkyl, with specific examples including cyclopentyl, cylcohexyl, cyclooctyl, and the like. Cyclohexyl is preferred.
More specifically, each R 3 may be chosen from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, silyl, amino, alkoxy, aryloxy, phosphino, boryl, transition metals, metallocenes, halogens and combinations thereof. Specific examples of include methyl, ethyl, propyl, t-butyl, phenyl, methoxy, alkoxy, thioalkyl, cyano, acetyl, benzoyl, nitro, dimethylamino, diethylamino, methylphenylamino, benzylmethylamino, trimethylsilyl, dimethylboryl, diphenylboryl, methylphenylboryl, dimethoxyboryl, chromium tricarbonyl, ruthenium tricarbonyl, and cyclopentadienyl iron. R 3 can also be a water-solubilizing group, such as SO 3 G, where G is Na, K, H and the like. R 3 may also be a transition metal that is eta bonded to the benzene ring in the backbone of the ligand.
More specifically, each R 4 may be chosen from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, heteroaryl, substituted heteroaryl, silyl, amino, alkoxy, aryloxy, phosphino, boryl, transition metals, metallocenes, halogens and combinations thereof. Specific examples of include methyl, ethyl, propyl, t-butyl, methoxy, alkoxy, thioalkyl, cyano, acetyl, benzoyl, nitro, dimethylamino, diethylamino, methylphenylamino, benzylmethylamino, trimethylsilyl, chromium tricarbonyl, ruthenium tricarbonyl, and cyclopentadienyl iron. R 4 can also be a water-solubilizing group, such as SO 3 G, where G is Na, K, H and the like. R 4 may also be a transition metal that is eta bonded to the benzene ring in the backbone of the ligand.
In a more particular embodiment, preferred ligands of this invention may be characterized by the general formula:
where R 1 and R 2 are as defined above and R 6 is selected from the same group as R 4 and R 7 is either hydrogen or selected from the same group as R 3 . Specific preferred embodiments of R 6 and R 7 are alkyl and substituted alkyl and cycloalkyl and substituted cycloalkyl, specifically isopropyl, cyclopentyl, cyclohexyl, cyclooctyl, cycloheptyl, isobutyl, and tert-butyl. R 7 can also be hydrogen. Without wishing to be bound by any particular theory or mechanism, it is believed that the R 7 group has substantially less impact on the catalytic performance of the ligand when used as part of the catalyst in cross coupling or aryl amination reactions. Thus, changes in the R 7 group may be useful for specific reactions or reaction conditions, but may not have a substantial impact.
In an alternative embodiment, the phosphine ligands useful in this invention have a cyclopentadienyl ring, and may be characterized by the formula:
where R 1 and R 2 are defined as above and each R 5 is independently selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, silyl, amino, nitro, ester, acid, alkoxy, aryloxy, hydroxy, metallocene, transition metals, COOH, SO 3 G (G=Na, K, H, etc.) and combinations thereof; c is 0, 1, 2, 3 or 4 and R 5 can occupy any available site on the cyclopentadienyl ring, including an eta-bond (such as an η 5 bond). More specific embodiments of R 5 are those where a mono-cyclopentadienyl or bis-cyclopentadienyl metallocene is formed as part of the ligand. Thus, R 5 may be a moiety having a metal atom selected from the group consisting of metals from the Periodic Table of Elements, such as Fe, Rh, Mo, Ru, Cr, Zr, Ti, Hf, Co. Specific examples of R 5 include FeCp, CrCp and ZrCpR 2 , where Cp is a substituted or unsubstituted cyclopentadienyl and R is selected from the same group as R 5 . In this specific embodiment, it is intended that the bond between the Cp ring in the ligand and R 5 is an η 5 bond.
Particularly preferred ligands are:
The ligands useful in this invention may be on a support or not. For example, the support could be any one of the R groups. In that embodiment, the support may be a polymer or functionalized polymer, such as polystyrene. In the case of heterogeneous reactions, the ligands may be supported, with or without the metal coordinated (discussed below), on an organic or inorganic support. Suitable supports include silicas, aluminas, zeolites, polyethyleneglycols, polystyrenes, polyesters, polyamides, peptides and the like.
The ligand is combined with a metal atom, ion, compound or other metal precursor compound. In many applications, the ligands of this invention will be combined with such a metal compound or precursor and the product of such combination is not determined, if a product forms. For example, the ligand may be added to a reaction vessel at the same time as the metal or metal precursor compound along with the reactants. The metal precursor compounds may be characterized by the general formula M(L) n (also referred to as ML n or M—L n ) where M is a metal selected from the group consisting of Groups 5, 6, 7, 8, 9 and 10 of the Periodic Table of Elements. In more specific embodiments, M is selected from the group consisting of Ni, Pd, Fe, Pt, Ru, Rh, Co and Ir. L is a ligand chosen from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, hydrido, thio, seleno, phosphino, amino, and combinations thereof. When L is a charged ligand, L is selected from the group consisting of hydrogen, halogens, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, and combinations thereof. When L is a neutral ligand, L is selected from the group consisting of carbon monoxide, isocyanide, nitrous oxide, PA 3 , NA 3 , OA 2 , SA 2 , SeA 2 , and combinations thereof, wherein each A is independently selected from a group consisting of alkyl, substituted alkyl, heteroalkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, and amino. Specific examples of suitable metal precursor compounds include Pd(dba) 2 (dba=dibenzylydieneacteone), Pd 2 (dba) 3 , Pd(OAc) 2 (Ac=acetate), PdCl 2 , Pd(TFA) 2 , (TFA=trifluoroacetate), (CH 3 CN) 2 PdCl 2 , and the like. In this context, the ligand to metal precursor compound ratio is in the range of about 0.01:1 to about 100:1, more preferably in the range of about 0.5:1 to about 20:1. The metal atom, ion or metal precursor may be supported or not. Supports may be organic or inorganic. Similar to the ligands, the support may be a L. In other embodiments, the support will not form part of the metal precursor and suitable supports include silicas, aluminas, zeolites, polyethyleneglycols, polystyrenes, polyesters, polyamides, peptides and the like. Specific examples of Pd supported metals include Pd/C, Pd/SiO 2 , Pd/CaCO 3 , Pd/BaCO 3 , Pd/aluminate, Pd/aluminum oxide, Pd/polystyrene, although any of the metals listed above could replace Pd in this list, e.g., Ni/C, etc.
In other applications, the ligand will be mixed with a suitable metal precursor compound prior to or simultaneous with allowing the mixture to be contacted to the reactants. When the ligand is mixed with the metal precursor compound, a metal-ligand complex may be formed, which may be a catalyst. By way of example only, the metal complexes may be characterized by the formula:
where R 1 , R 2 , R 3 , R 4 , R 6 , R 7 , M, L, a, b and n have the definitions given above and additionally m is a number that is 1, 2 or 3.
Generally, the ligands useful in this invention may be purchased or prepared methods known to those of skill in the art. Specific synthesis methods are shown in Examples 1 and 2. See, for example, Goetz, H., et al., Liebigs Ann. Chem. (1977), No. 4, pp. 556-564. For synthesis of some preferred embodiments of the ligands of this invention, a metal catalyzed phosphorus-carbon bond may be formed as shown in Scheme 1, below:
where the symbols in Scheme 1 have the same meanings as discussed herein and J is selected from the group consisting of Br, I, Cl, tosylates, triflates and nonaflates. In Scheme 1, the coupling reaction changes depending on J. When J is H or Br, the reaction comprises the addition of a butyl lithium reagent (e.g., n-BuLi or s-BuLi or t-BuLi) followed by addition of ClPR 1 R 2 or BrPR 1 R 2 . When J is F, the reaction comprises addition of a reagent that is characterized by M″PR 1 R 2 where M″ is either Li, Mg, Zn or K. Finally, when J is Br, I, Cl, a tosylate, a triflate or a nonaflate, the reaction in Scheme 1 comprises a metal catalyzed cross-coupling reaction with M′″PR 1 R 2 where M′″ is H, SiR 3 (with R=alkyl, aryl or cycloalkyl) or M″. The catalyst for this reaction is a suitable metal, such as Pd or Ni, optionally with a ligand, such as is generally known to those skilled in the art.
The catalyst compositions and metal complexes of this invention are useful for many metal-catalyzed reactions, particularly for Suzuki cross-coupling reactions with aryl chlorides. In general, this invention may be effectively employed for metal-catalyzed coupling of organometallic reagents with organic electrophiles; metal-catalyzed coupling of organometallic reagents with organic halides; metal-catalyzed coupling of organometallic reagents with aryl halides and vinyl halides; and metal-catalyzed coupling of organometallic reagents with aryl chlorides. In particular, the following reactions can be effectively performed with this invention: aryl-aryl or biaryl coupling reactions, including coupling of aryl boron reagents (aryl boronic acid and esters) with aryl halides including aryl chlorides, aryl triflates, aryl tosylates, aryl mesylates (Suzuki coupling); coupling of aryl zinc reagents with the compounds as above; coupling of aryl magnesium reagents with the compounds as above; coupling of aryl tin reagents with the compounds as above; and coupling of aryl metal reagents with the compounds as above. Those of skill in the art will recognize that this list can be repeated by simply substituting heteroaryl for aryl without departing from the scope of this invention. Additional reactions that can be effectively performed with this invention include vinyl-aryl coupling reactions such as the coupling of vinyl metal reagents with the compounds as above, coupling of vinyl aluminate reagents with the compounds as above, coupling of vinyl cuprate reagents with the compounds as above, coupling of vinyl zirconium reagents with the compounds as above; and the coupling of vinyl boron reagents with the compounds as above. Still further, reactions that can be effectively performed with this invention include reactions which involve oxidative addition, transmetallation and reductive elimination sequence or oxidative addition, insertion or beta-hydride elimnation sequence in the catalytic cycle, including Heck reactions that involve metal-catalyzed olefination of aryl halides including chloride, aryl mesylates, tosylates, aryl triflates. Other reaction examples, include Sonogashira, cyanation, aryl amination, Stille coupling, Castro-Stephens, and hydrogenations.
To carry out the process of this invention for one type of reaction, a first aromatic compound, a second aromatic compound, a base, a catalytic amount of metal precursor and a catalytic amount of the ligand are added to an inert solvent or inert solvent mixture. In a batch methodology, this mixture is stirred at a temperature of from 0° C. to 200° C., preferably at from 30° C. to 170° C., particularly preferably at from 50° C. to 150° C., most particularly preferably at from 60° C. to 120° C., for a period of from 5 minutes to 100 hours, preferably from 15 minutes to 70 hours, particularly preferably from ½ hour to 50 hours, most particularly preferably from 1 hour to 30 hours. After the reaction is complete, the catalyst may be obtained as solid and separated off by filtration. The crude product is freed of the solvent or the solvents and is subsequently purified by methods known to those skilled in the art and matched to the respective product, e.g. by recrystallization, distillation, sublimation, zone melting, melt crystallization or chromatography.
Solvents suitable for the process of the invention are, for example, ethers (e.g., diethyl ether, dimethoxymethane, diethylene glycol, dimethyl ether, tetrahydrofuran, dioxane, diisopropyl ether, tert-butyl methyl ether), hydrocarbons (e.g., hexane, iso-hexane, heptane, cyclohexane, benzene, toluene, xylene), alcohols (e.g., methanol, ethanol, 1-propanol, 2-propanol, ethylene glycol, 1-butanol, 2-butanol, tert-butanol), ketones (e.g., acetone, ethyl methyl ketone, iso-butyl methyl ketone), amides (e.g., dimethylformamide, dimethylacetamide, N-methylpyrrolidone), nitriles (e.g., acetonitrile, propionitrile, butyronitrile), water and mixtures thereof. Particularly preferred solvents are ethers (e.g., dimethoxyethane, tetrahydrofuran), hydrocarbons (e.g., cyclohexane, benzene, toluene, xylene), alcohols (e.g., ethanol, 1-propanol, 2-propanol), water and combinations thereof. Most particularly preferred are dimethoxyethane, benzene, toluene, xylene, dioxane, ethanol, water and combinations thereof.
Bases which are useful in the process of the invention are alkali metal and alkaline earth metal hydroxides, alkali metal and alkaline earth metal carbonates, alkali metal hydrogen carbonates, alkali metal and alkaline earth metal acetates, alkali metal and alkaline earth metal alkoxides, alkali metal and alkaline earth metal phosphates, primary, secondary and tertiary amines, alkali metal and alkaline earth fluorides, and ammonium fluorides. Particularly preferred are alkali metal and alkaline earth metal phosphates, alkali metal and alkaline earth metal carbonates, alkali metal hydrogen carbonates, alkali metal and alkaline earth fluorides, and ammonium fluorides. Most particularly preferred are alkali metal phosphates and alkali metal and alkaline earth metal fluorides (such as potassium phosphate and cesium fluoride). The base is preferably used in the process of the invention in an amount of from about 1 to about 1000 mol %, particularly preferably from about 50 to about 500 mol %, very particularly preferably from about 100 to about 400 mol %, in particular from about 150 to about 300 mol %, based on the aromatic boronic acid.
The metal precursor used is as described above and may be added to the process along with the reactants. The metal portion of the catalyst (metal precursor or metal complex) is used in the process of this invention in a proportion of from about 0.0001 to about 10 mol %, preferably from about 0.1 to about 5 mol %, particularly preferably from about 0.5 to about 3 mol %, most particularly preferably from about 1.0 to about 1.5 mol %, based on the second aromatic compound. The ancillary ligand is used in the process in a proportion of from about 0.0001 to about 20 mol %, preferably from about 0.2 to about 15 mol %, particularly preferably from about 0.5 to about 10 mol %, most particularly preferably from about 1 to about 6 mol %, based on the second aromatic compound. These amounts may be combined to give metal precursor to ligand ratios useful in the process. It is also possible, if desired, to use mixtures of two or more different ligands.
The first aromatic compounds for the process may be characterized by either of the general formulas:
where R 8 is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, and combinations thereof; c is 0, 1, 2, 3, 4 or 5 and optionally two or more R 8 groups are joined together in a ring structure; X′ is selected from the group consisting of BR 10 2 , B(OR 10 ) 2 , MgQ 1 , ZnQ 1 , CuQ 1 , SiR 10 3 SnR 10 3 or Li, wherein each R 10 is independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, silyl, boryl, phosphino, amino, thio, seleno, and combinations thereof; and Q 1 is selected from the group consisting of Cl, Br, I or F. See also U.S. Pat. No. 5,756,804, incorporated herein by reference for other, similar formulas.
The second aromatic compounds for the process of the invention those of the formula:
where X is Br, Cl, F, I, tosylates, triflates, or N 2 + and R 9 is selected from the group consisting of hydrogen, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, substituted heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, and combinations thereof; and c is 0, 1, 2, 3, 4 or 5. Optionally two or more R 9 groups are joined together in a ring structure. Preferable, R 9 is selected from the group consisting of methyl, ethyl, methoxy, —CN and —CF 3 . See also U.S. Pat. No. 5,756,804, incorporated herein by reference for other, similar formulas.
Products of the process of the invention are polycyclic aromatic compounds having an aryl-aryl bond, having the general structure:
The products are also suitable as precursors for pharmaceuticals, cosmetics, fungicides, herbicides, insecticides, dyes, detergents and polymers, including additives for the same. Aryl amination reactions have similar usefulness, e.g., U.S. Pat. No. 5,576,460, incorporated herein by reference.
The processes of this invention are particularly effective in performing the above-disclosed chemical transformations. Turn over numbers (TON), which are calculated as the moles of desired product divided by the moles of metal precursor, are typically at least about 50, preferably at least 100, and more preferably at least 200, but can range to at least 500 or even at least 1000. Turn over frequency (TOF), which is calculated as the TON divided by the reaction time in hours, are typically at least about 5, preferably at least 10, more preferably at least 20, and more preferably at least 50, but can range to at least 100 or even at least 200. Selectivity for the reaction to produce the desired product (as compared to undesired side products) are also in the range of from at least 80% to approaching 100%, with selectivity in the range of from about 90% to about 99% being common. Selectivity is calculated as 100 times units of desired product divided by the sum of the units of desired product plus the units of undesired product. As the TON's, TOF's and selectivity numbers imply, the yield from the processes of this invention are typically greater than 90%.
EXAMPLES
General
All reactions were performed under argon atmosphere in oven-dried glass Schlenk tubes using standard Schlenk techniques. All aryl halides, aryl boronic acids, bases, bis(dibenzylideneacetone)palladium, and solvents were purchased from commercial sources and used as such. All solvents were of the anhydrous, sure-seal grade. Phenyldicyclohexylphosphine (PhPCy 2 ; ligand 1) was also purchased from a commercial source. The detailed procedure described for the synthesis and isolation of 2-Acetyl-4′-methyl-1,1′-biphenyl (example 3) was generally followed for all Pd/Ligand-catalyzed Suzuki reactions of arylboronic acids with aryl halides (examples 4-10). Column chromatography was performed using commercially available Silica Gel 60 (particle size: 0.063-0.100 mm), hexanes and ethyl acetate. GC-MS analyses were conducted on a Hewlett-Packard 6890 instrument. 1 H, 13 C, 31 P NMR spectra were obtained using a Bruker 300 MHz FT-NMR spectrometer. Chemical shifts in 1 H, and 13 C NMR spectra were calibrated with reference to the chemical shift of residual protiated solvent. Chemical shifts in 31 P NMR spectra were calibrated with reference to 85% H 3 PO 4 ; a negative value of chemical shift denotes resonance upfield from H 3 PO 4 . Coupling constants are reported in hertz. TON and TOF were calculated as discussed above.
Example 1
This is an example of synthesis of ligand 2
2-(4′-Dicyclohexylphosphinophenyl)-1,3-dioxolane (Ligand 2)
Part I
A solution of 4-bromobenzaldehyde (5 g, 0.027 mol), ethylene glycol (7.0 g, 0.11 mmol), and p-toluenesulfonic acid (0.1 g, 0.5 mmol) in benzene was heated at reflux for 24 h using a Dean-Stark setup to remove water. The reaction was taken up in diethyl ether (100 mL) and washed with water (5×30 mL) and brine (30 mL). The organic phase was dried over magnesium sulfate and concentrated under vacuum to afford 2-(4′-bromophenyl)-1,3-dioxolane (5.95 g).
Part II
2-(4′-bromophenyl)-1,3-dioxolane (1.0 g, 4.4 mmol) was dissolved in anhydrous diethyl ether (30 mL) and the solution was cooled to −78° C. t-Butyllithium (5.14 mL, 1.7 M solution in pentane, 8.8 mmol) was added dropwise with stirring. The reaction was stirred for 2 h at −78° C. Chlorodicyclohexylphosphine (1.13 g, 4.8 mmol) was added dropwise via a syringe at −78° C. with stirring. The reaction mixture was allowed to warm up to room temperature and stirred for an additional 18 h. To the reaction mixture was added argon purged water (25 mL) slowly. The organic phase was separated under argon and the aqueous phase was washed with diethyl ether (20 mL). The combined organic phase was concentrated under vacuum to afford a colorless oil, which was crystallized from methanol to afford ligand 2 as a white crystalline solid having the structure shown below (yield: 1.4 g, 92%). 31 P{ 1 H} NMR (CDCl 3 ): δ2.4.
Example 2
This is an example of synthesis of ligand 3
4-Dicyclohexylphosphino-benzophenone (Ligand 3)
o-Xylene (4 mL) and dicyclohexylchlorophosphine (0.20 mL, 1.0 mmol) were added to the mixture of 4-bromobenzophenone (261 mg, 1.0 mmol), NaO t Bu (96 mg, 1.0 mmol), Pd(dba) 2 (11 mg, 19 μmol) under Ar. The mixture was heated from 85 to 110° C. in 15 min and remained at 110° C. for an additional 1.5 h. The reaction mixture was filtered through a 2 g silica gel column (Aldrich) and hexanes/ethyl acetate (1:1) was used as elute. The filtrate was concentrated under vacuum, yielding a red oil. The oil was re-crystallized from MeOH (1.0 mL) at −30° C. overnight, yielding ligand 3 as a yellow solid (233 mg, 62%) after filtration and drying under vacuum. 31 P NMR (CDCl 3 ): δ6 3.8.
Example 3
This is an example of Pd/ligand 1-catalyzed Suzuki reaction for biaryl synthesis
2-Acetyl-4′-methyl-1,1′-biphenyl
A solid mixture of 4-methylphenylboronic acid (204 mg, 1.5 mmol), CsF (456 mg, 3.0 mmol), Pd(dba) 2 (3 mg, 5 μmol), and ligand 1 (5 mg, 15 μmol) was thoroughly evacuated and purged with argon. 2′-Chloroacetophenone (0.13 mL, 1.0 mmol) and toluene (4 mL) were added and the reaction was heated at 110° C. for 1 h. GC-MS analysis indicated the reaction to be complete, i.e. starting aryl chloride reagent was completely consumed (quantitative GC yield). The reaction was taken up in ether (100 mL) and washed with H 2 O (30 mL) and brine (30 mL), The organic phase was dried over MgSO 4 , filtered and concentrated under vacuum. The crude product was purified by column chromatography on silica gel using hexanes:ethyl acetate (8:1) as eluant to afford the title compound as a yellow oil (198 mg, 92% isolated yield) after drying under vacuum. TON≈100 and TOF≈100. 1 H NMR (CDCl 3 ): δ7.52 (d, J=8.4, 1H, ArH), 7.47 (d, J=7.2, 1H, ArH), 7.38 (t, J=7.2, 2H, ArH), 7.22 (s, 4H, ArH), 2.39 (s, 3H, C(O)CH 3 ), 2.00 (s, 3H, ArCH 3 ). 13 C{ 1 H} NMR (CDCl 3 ): δ205.1, 140.9, 140.5, 137.8, 137.7, 130.6, 130.2, 129.4, 128.7, 127.8, 127.2, 30.4, 21.2.
Example 4
This is an example of Pd/ligand 1-catalyzed Suzuki reaction for biaryl synthesis.
3,5-Dimethylbiphenyl
The title compound was obtained as a colorless oil (184 mg, 99% isolated yield) from the reaction of phenylboronic acid (190 mg, 1.56 mmol), CsF (473 mg, 3.12 mmol), Pd(dba) 2 (6 mg, 10 μmol), ligand 1 (11 mg, 31 μmol), and 5-chloro-m-xylene (0.14 mL, 1.0 mmol) in toluene at 110° C. for 5 h. TON≈100 and TOF≈20. 1 H NMR (CDCl 3 ): δ7.64 (d,J=8.1, 2H, ArH), 7.47 (t,J=7.7, 2H, ArH), 7.35 (t, J=7.5, 1H, ArH), 7.27 (s, 2H, ArH), 7.05 (s, 1H, ArH), 2.44 (s, 6H, ArCH 3 's). 13 C{ 1 H} NMR (CDCl 3 ): δ141.5, 141.3, 138.2, 128.9, 128.6, 127.2, 127.0, 125.1, 21.4.
Example 5
This is an example of Pd/ligand 1-catalyzed Suzuki reaction for biaryl synthesis
2,2′-Dimethyl-1,1′-biphenyl
The title compound was obtained as a yellowish oil (180 mg, 97% isolated yield) from the reaction of 2-methyl-phenylboronic acid (203 mg, 1.54 mmol), CsF (469 mg, 3.09 mmol), Pd(dba) 2 (11.8 mg, 21 μmol), ligand 1 (22 mg, 61 μmol), and 2-chlorotoluene (0.12 mL, 1.03 mmol) in toluene (4 mL) at 110° C. for 5 h. TON=49 and TOF=9.8. 1 H NMR (CDCl 3 ): δ7.32-7.18 (m, 6H, ArH), 7.13 (d, J=6.2, 2H, ArH), 2.08 (s, 6H, CH 3 's). 13 C{ 1 H} NMR (CDCl 3 ): δ141.6, 135.8, 129.8, 129.3, 127.1, 125.5, 19.8.
Example 6
This is an example of Pd/ligand 1-catalyzed Suzuki reaction for biaryl synthesis. A reaction mixture of CsF (0.764 g, 5.06 mmol), 2-chlorobenzonitrile (0.307 g, 2.24 mmol), and p-tolueneboronic acid (0.329 g, 2.42 mmol), Pd(dba) 2 (1 mg, 1.7 μmol), and ligand 1 (5 mg, 18 μmol) in toluene (4 mL) was heated at reflux and monitored by GC-MS. After 3.5 h, GC-MS analysis showed a >98% GC yield of the desired product 2-cyano-4′-methylbiphenyl. TON=1318 and TOF =377.
Example 7
This is an example of Pd/ligand 1-catalyzed Suzuki reaction for biaryl synthesis. A reaction mixture of CsF (0.764 g, 5.06 mmol), 2-chlorobenzonitrile (0.230 g, 1.68 mmol), and p-tolueneboronic acid (0.329 g, 2.42 mmol), Pd(dba) 2 (2 mg, 3.4 μmol), and ligand 1 (5 mg, 18 μmol) in 1,4-dioxane (4 mL) was heated at reflux and monitored by GC-MS. After 8 h, GC-MS analysis showed a >98% GC yield of the desired product 2-cyano-4′-methylbiphenyl. TON=494 and TOF=62.
Example 8
This is an example of Pd/ligand 3-catalyzed Suzuki reaction for biaryl synthesis. A reaction mixture of CsF (0.750 g, 4.97 mmol), 2-chlorobenzonitrile (0.230 g, 1.68 mmol), and p-tolueneboronic acid (0.329 g, 2.42 mmol), Pd(dba) 2 (1 mg, 1.7 μmol), and ligand 3 (5 mg, 7.6 μmol) in 1,4-dioxane (4 mL) was heated at reflux and monitored by GC-MS. After 19 h, GC-MS analysis showed a >98% GC yield of the desired product 2′-cyano-4-methylbiphenyl. TON =988 and TOF =52.
Example 9
This is an example of Pd/ligand 2-catalyzed Suzuki reaction for biaryl synthesis.
3,5-Dimethylbiphenyl
A reaction mixture of phenylboronic acid (190 mg, 1.56 mmol), CsF (474 mg, 3.12 mmol), Pd(dba) 2 (6 mg, 10 μmol), ligand 2 (10 mg, 29 μmol), and 5-chloro-m-xylene (0.14 mL, 1.0 mmol) in toluene (4 mL) was heated at reflux and monitored by GC-MS. After 5 h, GC-MS analysis showed a >98% GC yield of the desired product 3,5-dimethylbiphenyl. TON=100 and TOF=20.
Comparative Example 10
This is an example of Pd(dba) 2 -catalyzed Suzuki reaction for biaryl synthesis in the absence of a ligand. A reaction mixture of phenylboronic acid (190 mg, 1.56 mmol), CsF (474 mg, 3.12 mmol), Pd(dba) 2 (6 mg, 10 μmol), and 5-chloro-m-xylene (0.14 mL, 1.0 mmol) in toluene (4 mL) was heated at reflux and monitored by GC-MS. After 5 h, GC-MS analysis showed no product formation.
Example 11
This is an example for the synthesis of 2,4,6-(Triisopropylphenyl)dicyclohexylphosphine (Ligand 4), shown below. A solid mixture of NaO t Bu (600 mg, 6.24 mmol) and Pd(dba) 2 (76 mg, 0.13 mmol) was evacuated thoroughly and purged with argon. 2,4,6-Triisopropylbromobenzene (1.13 g, 4.0 mmol), HPCy 2 (0.88 mL, 4.35 mmol) and o-xylene (16 mL) were added. The mixture was heated from 105-140° C. in 15 min and kept at 140° C. for 35 h. The reaction mixture was filtered through a SiO 2 column and the column was washed with toluene (30 mL). The filtrate was concentrated under vacuum and the oily residue was triturated with deoxygenated MeOH, affording ligand 4, after filtration and drying under vacuum, as a white solid (0.55 g, 34%, yield not optimized). 1 H NMR (CDCl 3 ): δ6.96 (d, J=4.2, 1 H, ArH), 6.90 (s, 1H, ArH), 4.43 (sept, J=6.7, 1H, CH), 3.33 (sept, J=6.6, 1H, CH), 2.83 (sept, J=6.9, 1H), 2.17 (m, 2H), 1.98 (br, 2H), 1.77 (d, J=6.3, 4H), 1.61 (m, 4H), 1.4-0.8 (overlapping signals, 30H). 31 P NMR (CDCl3): δ−9.8.
Example 12
This is an example of Pd/ligand 4-catalyzed aryl amination reaction for aryl amine synthesis. A reaction tube containing NaO t Bu (120 mg, 1.25 mmol) was thoroughly evacuated and purged with argon. 5-Chloro-m-xylene (0.14 mL, 1.04 mmol), heptylmethylamine (0.21 mL, 1.25 mmol), a toluene solution of Pd(dba) 2 (1.2 mL, 1.0 mg/mL, 2.1 μmol) and a toluene solution of ligand 4 (2.5 mL, 1.0 mg/mL, 6.2 ,μmol) and toluene (0.3 mL) were added to the reaction tube and the reaction was heated at 105° C. for 21.5 h. The reaction was taken up in ether (100 mL) and washed with H 2 O (30 mL) and brine (30 mL). The organic phase was dried over MgSO 4 , filtered and concentrated under vacuum. The crude product was purified by column chromatography on silica gel using hexanes/ethyl acetate as eluant to afford compound 2 (shown below in Table 1) as a yellowish oil (239 mg, 98%) after drying under vacuum. 1 H NMR (CDCl 3 ): δ6.33 (br, 3H, ArH), 3.25 (t, J=7.6, 2H, —NCH 2 —), 2.89 (s, 3H, —N—CH 3 ), 2.27 (s, 6H, Ar(CH 3 ) 2 ), 1.54 (br, 2H, —NCH 2 CH 2 —), 1.30 (br, 8H, —(CH 2 ) 4 CH 3 ), 0.89 (br t, J=6.6, 3 H, —CH 3 ).
Example 13
This is an example of Pd/ligand 4-catalyzed aryl amination reaction for aryl amine synthesis. The compound 3 (shown below in Table 1) was obtained as a yellowish oil (188 mg, 95%) from the reaction of 5-chloro-m-xylene (0.14 mL, 1.04 mmol), morphorline (0.11 mL, 1.26 mmol), NaO t Bu (120 mg, 1.25 mmol), Pd(dba) 2 (1.2 mg, 2.1 μmol) and ligand 4 (2.5 mg, 6.2 μmol) in toluene at 105° C. for 6 h. 1 H NMR (CDCl 3 ): δ6.60 (s, 3H, ArH), 3.88 (t, J=4.8, 4H, —O—(CH 2 ) 2 —), 3.17 (t, J=4.8, 4H, —O —(CH 2 ) 2 —), 2.34 (s, 6H, CH 3 's).
Example 14
This is an example of Pd/ligand 4-catalyzed aryl amination reaction for aryl amine synthesis. The compound 4 (shown below in Table 1) was obtained as a yellowish oil (239 mg, 79%) from the reaction of 4-chlorobenzophenone (217 mg, 1.0 mmol), N-benzylmethylamine (0.15 mL, 1.16 mmol), NaO t Bu (115 mg, 1.20 mmol), Pd(dba) 2 (0.56 mg, 1.0 μmol) and ligand 4 (1.2 mg, 3.0 μmol) in toluene at 105° C. for 26 h. 1 H NMR (CDCl 3 ): δ7.83 (d, J=9.0, 2H, ArH), 7.75 (d, J=6.8, 2H, ArH), 7.58 -7.22 (m, 8H, ArH), 6.77 (d, J=8.9, 2H, ArH), 4.69 (s, 2H, —N—CH 2 Ph), 3.19 (s, 3H, —NCH 3 ).
Example 15
This is an example of Pd/ligand 4-catalyzed aryl amination reaction for aryl amine synthesis. The compound 5 (shown below in Table 1) was obtained as a yellowish oil (234 mg, 97%) from the reaction of 2-chloroanisole (0.13 mL, 1.02 mmol), octylamine (0.20 mL, 1.21 mmol), NaO t Bu (118 mg, 1.23 mmol), Pd(dba) 2 (6 mg, 10 μmol) and ligand 4 (13 mg, 32 μmol) in toluene at 105° C. for 5 h. 1 H NMR (CDCl 3 ): δ6.92 (t, J=7.6, 1H, ArH), 6.81 (d, J=7.6, 1H, ArH), 6.71 (d, J=7.6, 1H, ArH), 6.67 (t, J=7.6, 1H, ArH), 4.22 (br, 1H,—NH), 3.86 (s, 3H, —OCH 3 ), 3.16 (t, J=7.2, 2H, —NCH 2 —), 1.69 (pentet, 2H, —NCH 2 CH 2 CH 2 —), 1.35 (br, 10H, —CH 2 —'s), 0.95 (br, 3H, CH 3 ).
Example 16
This is an example of Pd/ligand 4-catalyzed Suzuki reaction for biaryl synthesis. A solid mixture of Na 2 CO 3 (369 mg, 3.5 mmol), 2-chlorobenzonitrile (239 mg, 1.7 mmol), and p-tolueneboronic acid (355 mg, 2.6 mmol), Pd(dba) 2 (1 mg, 1.7 μmol), and ligand 4 (7 mg, 17 μmol) was evacuated thoroughly and purged with argon. Toluene (3 mL) and deoxygenated H 2 O (1 mL) were added and the reaction mixture was heated at 95° C. After 3 h, GC-MS analysis showed a conversion of >99% based on the disappearance of 2-chlorobenzonitrile and a selectivity of >99% for the desired product 2-cyano-4′-methylbiphenyl (compound 6, Table 1) over 4,4′-dimethylbiphenyl.
Example 17
This is an example of Pd/ligand 4-catalyzed Suzuki reaction for biaryl synthesis. A solid mixture of Na 2 CO 3 (369 mg, 3.5 mmol), 2-chlorobenzonitrile (239 mg, 1.7 mmol), and p-tolueneboronic acid (355 mg, 2.6 mmol) and ligand 4 (4 mg, 10 μmol) was degassed thoroughly and purged with argon. A toluene solution of Pd(dba) 2 (0.5 mL, 1 mg Pd(dba) 2 /mL, 0.9 μmol), toluene (3 mL) and deoxygenated H 2 O (1 mL) were added and the reaction mixture was heated at 95° C. After 3 h, GC-MS analysis showed a conversion of >99% based on the disappearance of 2-chlorobenzonitrile and a selectivity of >99% for the desired product 2-cyano-4′-methylbiphenyl (compound 6, Table 1) over 4,4′-dimethylbiphenyl.
Example 18
This is an example of Pd/ligand 4-catalyzed Suzuki reaction for biaryl synthesis. A solid mixture of Na 2 CO 3 (369 mg, 3.5 mmol), 2-chlorobenzonitrile (239 mg, 1.7 mmol), and p-tolueneboronic acid (355 mg, 2.6 mmol) and ligand 4 (3 mg, 7 μmol) was evacuated thoroughly and purged with argon. A toluene solution of Pd(dba) 2 (0.2 mL, 1 mg Pd(dba) 2 /mL, 0.3 μmol), toluene (3 mL) and deoxygenated H 2 O (1 mL) were added and the reaction mixture was heated at 95° C. After 3 h, GC-MS analysis showed a conversion of >99% based on the disappearance of 2-chlorobenzonitrile and a selectivity of >99% for the desired product 2-cyano-4′-methylbiphenyl (compound 6, Table 1) over 4,4′-dimethylbiphenyl. The reaction was taken up in diethyl ether (100 mL) and washed with water (30 ml) and brine (30 ml). The organic phase was dried over MgSO 4 and concentrated under vacuum. The crude residue was column chromatographed on silica gel using hexane:EtOAc (4:1) as eluent to afford 323 mg (96% yield) of 2-cyano-4′-methylbiphenyl (6) as an off-white solid.
Example 19
This is an example of Pd/ligand 4-catalyzed Suzuki reaction for biaryl synthesis. A solid mixture of K 3 PO 4 (425 mg, 2.0 mmol) and p-tolueneboronic acid (204 mg, 1.5 mmol) was thoroughly evacuated and purged with argon. A toluene solution of Pd(dba) 2 /ligand 4 (1 mg Pd(dba) 2 /mL, 1.7 μmol, Pd/ligand mole ratio=1:3,), 2′-chloroacetonphenone (0.13 mL, 1.0 mmol) and toluene (3.0 mL) were added. The reaction mixture was heated at 100° C. After 1 h, GC-MS analysis showed a conversion of >99% based on the disappearance of 2′-chloroacetonphenone and a selectivity of >99% for the desired product 2-acetyl-4′-methyl-biphenyl (compound 7, Table 1) over 4,4′-dimethylbiphenyl.
Example 20
This is an example of Pd/ligand 4-catalyzed Suzuki reaction for biaryl synthesis. A solid mixture of CsF (450 mg, 3.0 mmol) and p-tolueneboronic acid (204 mg, 1.5 mmol) was thoroughly evacuated and purged with argon. A toluene solution of Pd(dba) 2 /ligand 1 (1 mL, 1 mg Pd(dba) 2 /mL, 1.7 μmol, Pd/ligand mole ratio=1:3), 2′-chloroacetophenone (0.13 mL, 1.0 mmol) and toluene (3.0 mL) were added. The reaction mixture was heated at 100° C. After 1 h, GC-MS analysis showed a conversion of >99% based on the disappearance of 2′-chloroacetonphenone and a selectivity of >99% for the desired product 2-acetyl-4′-methyl-biphenyl (compound 7, Table 1) over 4,4′-dimethylbiphenyl.
TABLE 1
Pd/Ligand 4-Catalyzed Aryl Amination and Suzuki Reactions
Starting Materials
Product
It is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated herein by reference for all purposes. | The present invention discloses new efficient processes for various bond forming reactions, including Suzuki reactions and aryl aminations. Organic compounds (e.g., ligands), their metal complexes and compositions using those compounds, provide useful catalysts. The invention also relates to performing Suzuki cross coupling reactions with unreactive aryl-chlorides. | 1 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
The present application is a continuation of U.S. application Ser. No. 13/960,640, entitled “Pacing Lead for a Left Cavity of the Heart, Implanted in the Coronary System,” filed Aug. 6, 2013, now U.S. Pat. No. 9,014,822, which is a continuation of U.S. application Ser. No. 13/300,451, entitled “Pacing Lead for a Left Cavity of the Heart, Implanted in the Coronary System,” filed Nov. 18, 2011, now U.S. Pat. No. 8,521,306, which claims the benefit of French Application No. 1059521, entitled “Pacing Lead for a Left Cavity of the Heart, Implanted in the Coronary System,” filed Nov. 19, 2010, each of which is hereby incorporated by reference in their entireties.
BACKGROUND
The present invention relates to “active implantable medical devices” as defined by the 20 Jun. 1990 Directive 90/385/EEC of the Council of the European Communities, more particularly to devices that continuously monitor a patient's heart rhythm and deliver to the heart, if necessary, electrical pulses for stimulation, resynchronization, cardioversion and/or defibrillation, and even more particularly to cardiac pacing leads intended to be implanted in the coronary network of the heart for stimulation of a left ventricular or atrial cavity.
For the right cavities of a patient's heart, it is generally sufficient to implant endocardial leads through the right peripheral venous network. The implantation of permanent leads in a left heart cavity, however, involves significant operational risks, for example, the passage of bubbles to the vascular network of the brain located downstream of the left ventricle. For this reason, when the left cavity has to be stimulated, most often a lead is not introduced to the cavity to be stimulated, but rather into the coronary system, with the lead having an electrode that is guided to the left ventricle or left atrium and applied against the wall of the epicardium, as appropriate.
A lead of this type is, for example, the Situs LV model, marketed by Sorin CRM S.A.S. (Clamart, France) and described in EP 0993840 A1 and its US counterpart U.S. Pat. No. 6,385,492 (both assigned to Sorin CRM S.A.S., previously known as ELA Medical). Such a lead is introduced through the coronary sinus opening into the right atrium, by an endocardial approach. The lead is then guided and pushed along the coronary vein network to the chosen stimulation site. This intervention is very difficult, given the peculiarities of the venous network and its access paths, including the passage through valves and tortuosities, as well as experiencing a gradual reduction in diameter of the vein as the lead is advanced along the selected coronary vein. Once the target vein is reached, the surgeon must then, first of all, ensure the mechanical stability of the lead into the vein.
Another problem is the difficulty of finding a good stimulation site, to obtain good electrical contact between the stimulating electrode and the tissue of the epicardium, and maintain this contact over time.
In addition, the surgeon must ensure that the chosen stimulation point does not generate phrenic nerve stimulation.
To overcome these difficulties, it was proposed to have multiple electrodes along the lead body to increase the chances of an acceptable compromise, by possibly giving the lead body a particular conformation. The surgeon can choose from among the various electrodes present on the lead body to find the one that provides the best efficiency from the electrical and hemodynamic points of view. One such multiple electrode lead is described in EP 1938861 A1 and its US counterpart US Patent Publication No. 2008/0177343 (both assigned to Sorin CRM S.A.S previously known as ELA Medical). These leads allow in particular to implement the concept of “electronic repositioning” to direct or redirect the electrical field between different electrodes arranged along the pacing lead of the left cavity and/or with an electrode of the pacing lead of the right cavity. The technology allows managing the micro-movements or changes in the hemodynamic behavior (reverse modeling) simply by reprogramming the generator via telemetry through the skin, without major surgery.
The counterpart of this solution is an increasing complexity of the structure of the lead, an increase of the number of electrodes causing an increase in the number of components, and therefore of electrical connections, or the use of multiplexing circuits for selecting the various electrodes present on a same lead.
US Patent Publication No. 2009/157136 A1 describes a technique of searching for an optimal pacing site using a temporary mapping catheter to be introduced into the coronary sinus. This catheter is a flexible tube open at both ends, and has, optionally, a guide wire. It is equipped with electrically independent multiple distal electrodes, and at its proximal side, a connector for connection to a data acquisition system for identifying the best stimulation site with an algorithm based on cardiac motion.
A permanent conventional multi-electrode lead, having for example a standard diameter of 4.5 to 6 French, is then placed at the selected location, using either the guide wire and a standard over the wire (“OTW”) technique, or the tube, of the temporary catheter.
Another recent development for a left ventricle pacing lead is to reduce the diameter of the implantable part in the coronary system, to a diameter of 4 French (1.33 mm).
The size of the lead body is indeed a factor directly related to the capacity of controlled guiding of the lead in the coronary venous system, so as to select particular stimulation sites located in some specific collateral veins. These sites are reached by means of a vein sub-selection catheter used to place a guiding stylet at the chosen site. Once the vein is selected and the stylet is placed, the surgeon advances the lead body which slides on the stylet, the latter acting as a guide wire of small diameter axially guiding the lead body to the chosen location (an OTW technique).
The size of the lead body is indeed a factor directly related to the capacity of controlled guiding of the lead in the coronary venous system, so as to select particular stimulation sites located in some specific collateral veins. These sites are reached by means of a vein sub-selection catheter used to place a guiding stylet at the chosen site. Once the vein is selected and the stylet is placed, the surgeon advances the lead body which slides on the stylet, the latter acting as a guide wire of small diameter axially guiding the lead body to the chosen location (an OTW technique).
These solutions however have two notable limitations: (1) The fineness of the lead, whose diameter does not allow to access the deepest collateral veins: for example, the Situs lead referenced above has a diameter of 2.2 mm (6.6 French) and requires a 7 French diameter introducer, and (2) The correct positioning and good maintaining of the electrical contact of the electrode against the tissue to cause stimulation.
The above techniques of multi-electrode leads and electronic repositioning make possible to (more or less appropriately) overcome the second limitation, however they increase the first limitation, to the extent that the multiplication of electrodes and of the internal conductors or components necessarily implies an increase in the diameter of the lead body which reduces its flexibility, making it difficult or even impossible to ensure passage through the tortuous coronary venous system.
The solutions heretofore known are therefore always a compromise between these two constraints.
SUMMARY
It is, therefore, an object of the invention to provide a left heart cavity pacing lead having a very small diameter and an active part for stimulating multiple areas of the epicardium.
It is another object of the invention to propose such a lead having a simple structure that is inexpensive to manufacture, reliable, and avoids problems related to the design and use of multiple electrode leads.
Broadly, the present invention provides a coronary sinus lead that, once the site of stimulation is selected and assessed, ensures optimum and sustainable stability of the stimulating electrode on this site.
The present invention also allows separating the problem of the stability from that of the electro-hemodynamic performance. Indeed, as it will be seen, the stability is ensured by the distal end of the lead (having a predefined shape such as a screw made of silicone), while the stimulation is provided by a telescopic microcable equipped with one or more continuous or disjointed pacing areas.
In particular, if it can be ensured that the electrode remains in place, regardless of at what site or place it was originally implanted, further movements of the lead are prevented, stability is achieved, and it is no longer necessary to overcome the consequences of such a displacement by complex techniques, such as electronic repositioning or the selection among multiple electrodes.
Essentially, one embodiment of the invention is for a pacing lead, intended to be implanted in a coronary network vein for the stimulation of a left cavity of the heart, including the elements known from the US Patent Publication No. 2009/157136 A1 cited above, that is to say comprising a telescopic microcable in a conductive material, comprising at its distal end an active free part comprising a plurality of distinct bare areas, these bare areas being intended to come into contact with the wall of a target vein of the coronary network, so as to form a network of stimulation electrodes. The cable further comprises, on its proximal side, means for coupling the network of stimulation electrodes to a generator of an active implantable medical device, such as a pacemaker or a resynchronizer. Such a coupling means may be, for example, a terminal that can be inserted into a standard connector head of the implantable device, or is otherwise electronically connected, directly or indirectly, to a pulse generator output of an implanted action medical device.
In a preferred embodiment, the cable is a telescopic microcable the diameter of which is between 0.5 and 2 French, made of a plurality of microwires twisted together, in which at least some of the plurality of strands incorporate either a core having a radiopaque material, such as platinum-iridium or tantalum wrapped in a sheath of mechanically durable material such as NiTi or stainless steel, or vice versa. In addition, the distinct bare areas are preferably bare areas of the microcable, and form a network of stimulation electrodes electrically connected together.
The small diameter microcable (more typically from 1 to 2 French) is advantageously used to catheterize veins of very small diameter, which have not before been exploited due to the larger size of the previously known permanent coronary probes.
The dual constraint mentioned above is thus overcome by the microcable structure, which in a preferred embodiment, is a structure without an internal lumen, and with several microwires twisted together, a configuration capable of both ensuring endurance against cardiac movements and resistance to the stresses during implantation.
This microcable is suitable to be introduced into the coronary network via a permanent carrier lead (e.g., with no particular mapping capacity), previously placed into the vein.
The small diameter is the essential characteristic that divides the surface of the monopolar electrode through multiple windows arranged along the body of the microcable. This allows permanent stimulation of a large area of the heart wall via this monopolar microlead. For diameters of between 1 and 2 French, it would not be possible to provide an individual isolation of each strand that can withstand the abrasion constraints between strands.
Various embodiments can be envisaged.
In one embodiment, the present invention provides a pacing lead, intended to be implanted in a coronary network vein for the stimulation of a left cavity of the heart, comprising a telescopic microcable made of a conductive material, having at its distal end an active free part comprising a plurality of distinct bare areas. These distinct bare areas are intended to come into contact with the wall of a target vein of the coronary network, so as to form a network of stimulation electrodes electrically connected together. The microcable further comprises, at its proximal end, means for coupling to a generator of an active implantable medical device, such as a pacemaker or a resynchronizer.
Preferably, the distal end of the microcable comprises a two- or three-dimensional pre-formed shape, having external dimensions in a rest state that are typically included within a cube having dimensions of between 1 to 90 mm per side. The microcable can thus be implanted alone, and held in place by its own particular distal pre-formed shape. In this embodiment, the placement in the vein is carried out by conventional means such as catheter/sub-catheter or brain access catheter.
Another embodiment of the present invention is directed to a system comprising a microcable and a lead body having a hollow sheath made of a deformable material, a central lumen open at both ends and in which the microcable is positioned, ready to slide by extending along the entire length of the lead body and beyond its distal end, such that the part of the microcable emerging beyond the distal end of the lead body is the active free part of the microcable.
To ensure maintaining the position of the microcable in the vein, the distal end of the lead body may be provided with a retaining means, including at least one relief formed on the lead body. Preferably, the at least one relief includes an helical relief with a thread wrapping around the lead body, having a locally increased diameter compared to that of the lead body itself, including a diameter greater than or equal to 7 French.
The lead body preferably includes a main part distally extended by a transition portion having a smaller diameter than that of the main part, including a diameter of the main part lower or equal to 6 French and a diameter of the transition part less than or equal to 5 French.
In yet another embodiment, the lead comprises a common lead body and a plurality of separate telescopic microcables, each of which is housed in the lead body and is slidable therein, the respective active free parts of the different microcables emerging from the lead body in separate locations, longitudinally spaced along the lead body. Preferably, in all cases, the diameter of each microcable is typically between 0.5 and 2 French, with an exposed total surface of the distinct bare region(s) of the active free part of the microcable of at least 1 mm 2 , more preferably between 4 and 6 mm 2 and a length of the active free part being adjustable between 1 and 200 mm.
In one embodiment, the active free part of the microcable comprises a plurality of distinct bare regions that successively extend along the active free part of the microcable. More preferably, these distinct bare areas are separated from each other by portions of tube made of an electrically non-conductive material, wrapping and sheathing the microcable between two consecutive bare areas. The bare areas also may bear tubular rings made of an electrically conductive material, which are crimped on the microcable. The electrically conductive material of the tubular rings inserted on the microcable is preferably made of a radio-opaque material.
In another embodiment, the microcable includes a stranded structure coated with an insulating material, including parylene, in which the distinct bare areas are formed by ablation forming openings in the insulating material along the microcable. Preferably, titanium nitride is then deposited on the distinct bare areas thus formed.
Preferably, the length in the longitudinal direction of each bare area is typically selected to be between 0.5 and 10 mm.
The microcable is advantageously formed of a plurality of strands twisted together, in which at least some strands incorporate either a core made of a radiopaque material, such as platinum-iridium, wrapped in a sheath of a mechanically durable material such as NiTi or stainless steel, or vice versa.
In another embodiment of the invention, the active free part of the microcable has at least an helically bare area extending along the active free part. The microcable can notably include, on at least one portion of the active free part, a strand formed of a plurality of twisted strands having a surface with a corresponding plurality of helical bare regions, isolated from each other in the circumferential direction by helical coatings of an electrically non-conductive material.
Advantageously, a lead in accordance with the present invention has a very small diameter, able to exploit the entire length of the vein and make an optimal use of all the veins present in the basal zone, especially to avoid the risk of phrenic nerve stimulation, which generally increases when the lead is too distal. In addition, the left heart pacing lead ensures an excellent and durable electrical contact with the tissues to be stimulated. A further advantage of the lead is that it increases or expands the areas of stimulation, allowing (as opposed to traditional leads) stimulation of multiple areas of the epicardium, thereby improving the chances of an optimal resynchronization.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features, characteristics, and advantages of the present invention will become apparent to a person of ordinary skill in the art from the following detailed description of preferred embodiments of the present invention, made with reference to the annexed drawings, in which:
FIG. 1 shows the heart and its coronary venous network in which a lead according to the invention is implanted;
FIG. 2 illustrates an active part of a microcable of a first embodiment of the lead of the present invention;
FIG. 3 is an enlarged view of the detail marked III in FIG. 2 ;
FIG. 4 is an enlarged view of an active part of the lead of a second embodiment of the invention;
FIG. 5 is a graph representing a method to adjust the exposed active area by an appropriate selection of the diameter of the insulation coating on the active part of the lead illustrated in FIG. 4 ; and
FIG. 6 illustrates a third embodiment of the invention, wherein the lead carries a plurality of separate microcables.
DETAILED DESCRIPTION
With reference to the drawings, FIGS. 1-6 , preferred embodiments of a device in accordance with the present invention will now be described.
FIG. 1 generally illustrates the myocardium, in which a lead 26 for pacing of the left ventricle according to the present invention has been introduced. Lead 26 is endocardially implanted in the venous coronary network via the superior vena cava 10 , the right atrium 12 and the entry 14 of the venous coronary sinus. The venous coronary system then develops into several branches, including the postero-lateral vein 16 , the lateral vein 18 , the great cardiac vein 20 and the antero-lateral vein 22 .
Reference 24 generally designates the lead of the invention, which includes a lead body having a main part 26 (e.g., a 6 French diameter) entering into the coronary sinus 14 , extended by a transition portion 28 of the same conformation but of smaller diameter (e.g. 4.8 French) to allow better penetration into the coronary venous system.
This lead body is formed of a tubular hollow sheath made of a deformable material, such as silicone or polyurethane, defining a central lumen extending from one end to the other of lead body.
At the distal end, the lead body is provided with retaining means 30 to allow its mechanical support in the vein. This retaining means may be, for example, a screw as described in EP 1374945 A1 and its counterpart U.S. Pat. No. 7,483,753 (both assigned to Sorin CRM S.A.S. previously known as ELA Medical), equipped with a helical thread having a maximum outer diameter of about 7 French. See FIG. 6 . This retaining means is of the same type as that used by the aforementioned Situs LV model lead. The screw thread is molded in a cylindrical element terminating the transition part 28 of the lead body, the whole assembly preferably being molded in one piece in a material such as a silicone rubber, or a similar material that is not traumatic and ensures good biocompatibility. Moreover, the distal end of the lead body, provided with the retaining means 30 is open at lumen end 32 , the outlet including a sealing means (not shown, but of a conventional design), for example, a penetrable silicone plug to prevent any backflow of blood inside the lead body in both the absence and the presence of an element introduced into the central lumen of the lead body.
This lead body is implanted according to a conventional OTW technique by use of a very thin stylet forming a guide wire, provided at its distal end with a flexible end for not being traumatic and for allowing its direct introduction into the vessels of the coronary system without risk of perforation.
Previously, the surgeon has a main catheter allowing him/her to access at the end of the coronary sinus and a sub-selection catheter to choose, under fluoroscopy, the path of the venous system that allows achieving the target vein corresponding to the chosen stimulation site.
The surgeon then introduces the guide wire into the catheter, and pushes it to advance it in the coronary venous system in order to select a particular collateral vein. Once the collateral vein is selected, the surgeon pulls on the guide wire for the lead body (the guide wire passes through the orifice 32 which is normally closed by the penetrable plug). The surgeon then drags and moves the lead body on the guide wire, which axially guides the lead body to the chosen location. Once the lead body is at the final position in the chosen vein, the surgeon gives the lead body an additional motion of rotation, which ensures, by screwing the thread of the retaining means 30 , the further progression of the lead body of a few millimetres with a corresponding reinforcement of the anchoring of the lead body into the vein.
Typically, the lead body as described above (having a well-known and conventional structure) is extended by a telescoping microcable presenting the active part 34 of the lead (possibly in addition to a pre-existing active stimulation electrode, arranged on the lead). Preferably, the microcable has a diameter of about 0.5 to 2 French and extends over a length of 1 to 200 mm beyond the outlet 32 of the distal end of the lead body.
Once the lead body is implanted by the method indicated above and after removal of the guidewire, the microcable is then inserted into the lead body at its proximal end. It is pushed along the length of the lead body to emerge from the outlet 32 , then is deployed beyond the outlet 32 so as to advance, under fluoroscopy in the collateral veins up to the desired position. It is thus possible to reach and stimulate areas of the coronary venous system previously inaccessible with the prior known leads.
The active part 34 of the microcable (i.e., its emerging part) has a plurality of distinct bare parts forming a succession of individual electrodes, together constituting an array of electrodes connected in series forming multiple stimulation points. For example, in FIG. 2 , active part 34 includes, in addition to the distal electrode 36 , a plurality of ring electrodes 38 arranged at regular intervals along the length of the active portion 34 . This allows more opportunities for points 40 to make contact with the wall of the vein and thus to ensure a multi-zone distribution of the stimulation energy at several points of the epicardium and therefore of the left ventricle.
FIGS. 2 and 3 illustrate a first embodiment of an active part (the one linked to the emerging part of microcable) of the lead of the invention. The core of active portion 34 is formed by microcable 42 , on which insulating tubes 44 and short conducting electrodes 38 are successively and alternately threaded. Microcable 42 is terminated by distal electrode 36 . The microcable 42 is advantageously made of a nitinol (NiTi alloy) core, a material whose main advantage is its extreme fatigue endurance. Preferably, the microcable structure has a plurality of strands in which each strand consists of a core of platinum-iridium coated with a thickness of nitinol (or vice versa). The system is then possibly coated either by a thin layer of parylene (e.g., of C type), or by a polyurethane tube. In either case, openings of varying complexity are arranged along the microcable, for example, by plasma ablation, to form the electrically active areas 36 , 38 . To improve the electrical performances, these areas may further be coated, for example by titanium nitride.
These types of microcables are available, for example, from Fort Wayne Metals Company Inc., Fort Wayne, USA, and heretofore have been used in the medical field, notably for defibrillation conductors —but in a different arrangement of material. In these prior known applications, the structure is a multi-wire structure in which each strand includes a core of silver (to improve conductivity) coated with a stainless steel thickness. These microstructures, isolated or not, are then incorporated into a multi-lumen lead body, the construction of which is classic and well known.
The benefits of the microcable structure described above lie in the fact that the less mechanically enduring elements (platinum-iridium or silver) are encapsulated directly in (or are coated around) the nitinol sheath. The consequences of a possible fracture of the strands are thus minimized.
Alternatively, it is possible to have a strand of platinum-iridium in the center of a 1×7-type multi-wire structure, the most fragile strand then being entwined by the most durable external strands.
Finally, platinum-iridium can be replaced by any radio-opaque material such as tantalum, and nitinol can be replaced with materials having a lower, but still sufficient, endurance performance, or a less expensive material such as stainless steel MP35N, commonly used in the manufacture of standard conductors.
Insulating tubes 44 extending between electrodes 36 , 38 are preferably tubes made of polyurethane (PU), glued on the microcable with a PU-type glue. The fluidity of the glue, combined with the crevices formed by the twist of the microcable, ensures an optimum link between the PU tube and the microcable.
Platinum electrodes 36 and 38 are preferably crimped directly onto the microcable. The small thickness of the electrode, combined with the ductility of platinum, enhances the quality of the electrical contact without altering the microcable. On the other hand, the short length of the electrodes (e.g., 0.5 to 10 mm) significantly limits their impact on the overall mechanical behaviour of the system, which is mostly dictated by the microcable.
The individual surface of each electrode is about 0.5 mm 2 , making it possible to distribute a large number (e.g., up to twelve over a length of 1 to 200 mm in the longitudinal direction) without exceeding a combined total surface of 6-8 mm 2 .
Due to the low cumulative active surface area, the advantages of a “high current density” lead in terms of both physiological efficacy of stimulation and lower energy consumption are provided, while at the same time maximizing the chances of a physical, and thus electric, contact of the conductive surface (electrodes 36 and 38 ) of active portion 34 with the excitable tissues, due to an increase in the number of electrodes.
Moreover, the alternation of conductive and insulating zones combined with the telescopic properties of the system allows for an improved managing of the risk of phrenic stimulation. Indeed, if for a given position, the phrenic nerve is included in the electric field, it is possible to slide the microcable in the lead body to position it in a remote area far from the phrenic nerve and thus to escape this parasite stimulation.
The configuration as described above allows separating the two problems of placement of the lead in the coronary venous system and those related to the multiplication of the stimulation points. Indeed, the mechanical fixing and maintaining of the lead is provided upstream by the lead body itself and by the retaining means 30 , while the multiplication of stimulation points is provided by the electrode array disposed along the telescopic microcable, which allows stimulating a large area chosen independently of the usual constraints of accessibility and stability.
In addition, to promote contact with the tissues, multiple types of preformed shapes are possible for the distal end of microcable, including, without limitation:
A sequence of bends with variable radius in a same plane; Sequence of bends with variable radius in a series of separate planes; Three-dimensional strongly curved trajectory, without any base plane, for example, of the pigtail type; The external dimensions of the pre-formed shape in the rest state being included in a cube having a dimension of from 1 to 35 mm per side.
This particular configuration allows considering a particular variant of the implantation of the microcable alone (e.g., without a lead), it being then held in place by its very distal pre-formed shape.
In this embodiment, the placement in the vein is carried out by conventional catheter/sub-catheter means or brain access catheter.
FIG. 4 illustrates a second embodiment of an active part of the lead of the present invention. In this embodiment, the strand formed by the wires 46 , 46 ′, 46 ″ of the microcable has applied on it an insulating coating of isolating PU adhesive 48 , 48 ′, 48 ″, but on a smaller diameter than the overall outside diameter of the strand so as to reveal, in reserve, conductive surfaces 50 , 50 ′, 50 ″ (uncoated surfaces) of helical shape. The active area of the active surface 34 is thus a triple helix shape 50 , 50 ′, 50 ″ on the periphery of the microcable, on all or part of the length of the active region 34 .
This solution makes it possible to “stretch” the surface in the longitudinal direction of stimulation, without increasing the total area of electrode.
With reference to FIG. 5 , the graph shown of the polyurethane coating diameter (mm) against the exposed surface (mm 2 ) illustrates the method for adjusting the total exposed surface (i.e., the active surface) according to the diameter of the coating of adhesive PU. The figures in this chart are for a length of 40 mm for a three strand microcable of overall diameter 0.3 mm.
This variant makes it possible to further optimize the use of the active surface of the electrode of the microcable, promoting its longitudinal extension. Note that the exhibited helical regions 50 , 50 ′, 50 ″ may, if desired, occur only on some parts of the microcable, for example, by alternating active regions where the helical exposed surfaces are apparent and completely isolated regions, e.g. by means of PU tubes such as the tubes 44 described with reference to the first embodiment described above.
Furthermore, the bare conductive areas of the microcable may receive a porous coating, such as NiTi, or be coated with an additional layer formed by a carbon film deposited by sputtering, to improve the biocompatibility properties between the microcable, its insulation and its environment, in order to avoid degradation of the parts in contact with the blood flow. The U.S. Pat. No. 5,370,684 A and U.S. Pat. No. 5,387,247 A, issued to Sorin Biomedica SpA, describe sputtering a submicron thin carbon film, on implantable prostheses such as catheters, heart valves, etc., in polyurethane or in silicone. These documents are to be referred to for more details on the technology to make this carbon film deposit, which are incorporated herein by reference.
FIG. 6 shows a third embodiment of the present invention, which is a variant of the first embodiment, wherein the lead carries a plurality of separate microcables, each of which being similar to that described above and shown in FIGS. 2 and 3 . In this embodiment, a single lead body 24 is equipped with several internal parallel lumens from which a plurality of respective microcables laterally emerges.
Thus, in FIG. 6 , the lead body comprises a plurality of sections 28 a , 28 b , 28 c , each provided with an opening 32 a , 32 b , 32 c communicating with a respective lumen. It also includes at its distal end retaining means 30 and the hole 32 d.
Out of each of the holes 32 a , 32 b , 32 c , 32 d emerges a respective microcable 34 a , 34 b , 34 c , 34 d , made according to either of the embodiments described above, for example, according to the first embodiment in the example shown in FIG. 6 . Each of these microcables includes its own network of electrodes 36 , 38 electrically joined together and separated by insulating parts 44 , on the entire length of the emerging part.
This solution allows covering a large area of the left ventricle, with a multitude of electrodes connected in parallel, each branch corresponding to each active portion 34 a , 34 b , 34 c , 34 d remaining however, electrically independent thanks to its own electrical connection to the proximal end of the lead. This link allows connection to a corresponding terminal of a multi-connector head, for example, of the 18-4 type. Also, a multiplexing system may be included inside the lead to separately handle connecting the different electrode arrays.
In general, whatever embodiment is employed, the technique just described has many advantages, among which include, in particular:
simplified method of implantation, requiring only conventional equipment; stability of the electrical contact with the tissue regardless of the size of the vein; possibility of extending the usable portion of the vein, including the distal area to the venous system, with an excellent adaptation to the thin venous networks, while maintaining an attachment point to the target vein (at the retaining means 30 ); effective distribution of the electrical flow in the deep regions of the epicardium; high reliability as a result of the mechanical performances of the nitinol structure of the microcable; overall mechanical simplicity, therefore having a low manufacturing cost and high reliability; radiopacity, based on the platinum core of each strand forming the microcable as well the platinum rings (in the case of the first embodiment); easy extraction, thanks to (i) the isodiametric profile of the microcable, (ii) its small diameter, and (iii) to its high tensile strength (one-piece robust structure of the microcable at its end); for the lead body, it is sufficient to simply unscrew the distal end of the lead body at the level of retaining means 30 before removing the lead body.
One skilled in the art will appreciate that the present invention can be practiced by other than the embodiments described herein, which are provided for purposes of illustration and not of limitation. | A pacing lead for a left cavity of the heart, implanted in the coronary system. The lead includes a lead body with a hollow sheath of deformable material, having a central lumen open at both ends, and at least one telescopic microcable of conductive material. The microcable slides along the length of the lead body and extends beyond the distal end thereof. The part emerging beyond the distal end is an active free part comprising a plurality of distinct bare areas, intended to come into contact with the wall of a target vein of the coronary system, so as to form a network of stimulation electrodes electrically connected together in parallel. The microcable further comprises, proximally, a connector to a generator of active implantable medical device such as a pacemaker or a resynchronizer. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to certain aminomethyl phenylimidazole derivatives which selectively bind to brain dopamine receptor subtypes. This invention also relates to pharmaceutical compositions comprising such compounds. It further relates to the use of such compounds in treating affective disorders such as schizophrenia and depression as well as certain movement disorders such as Parkinsonism. Furthermore compounds of this invention may be useful in treating the extrapyramidyl side effects associated with the use of conventional neuroleptic agents. The interaction of aminomethyl phenylimidazole derivatives of the invention with dopamine receptor subtypes is described. This interaction results in the pharmacological activities of these compounds.
2. Description of the Related Art
Schizophrenia or psychosis is a term used to describe a group of illnesses of unknown origin which affect approximately 2.5 million people in the United States. These disorders of the brain are characterized by a variety of symptoms which are classified as positive symptoms (disordered thought, hallucinations and delusions) and negative symptoms (social withdrawal and unresponsiveness). These disorders have an age of onset in adolescence or early adulthood and persist for many years. The disorders tend to become more severe during the patients lifetime and can result in prolonged institutionalization. In the US today, approximately 40% of all hospitalized psychiatric patents suffer from schizophrenia.
During the 1950's physicians demonstrated that they could sucessfully treat psychotic patients with medications called neuroleptics; this classification of antipsychotic medication was based largely on the activating (neuroleptic) properties of the nervous system by these drugs. Subsequently, neuroleptic agents were shown to increase the concentrations of dopamine metabolites in the brain suggesting altered neuronal firing of the dopamine system. Additional evidence indicated that dopamine could increase the activity of adenylate cyclase in the corpus striatum, an effect reversed by neuroleptic agents. Thus, cumulative evidence from these and later experiments strongly suggested that the neurotransmitter dopamine was involved in schizophrenia.
One of the major actions of antipsychotic medication is the blockade of dopamine receptors in brain. Several dopamine systems appear to exist in the brain and at least three classes of dopamine receptors appear to mediate the actions of this transmitter. These dopamine receptors differ in their pharmacological specificity and were originally classified upon these differences in the pharmacology of different chemical series. The butyrophenones, containing many potent antipsychotic drugs were quite weak at the dopamine receptor that activated adenylate cyclase (now known as a D1 dopamine receptor). In contrast, they labelled other dopamine receptors (called D2 receptors) in the subnanomolar range and a third type D3 in the nanomolar range. Phenothiazines possess nanomolar affinity for all three types of dopamine receptors. Other drugs have been developed with great specificity for the D1 subtype receptor.
Recently, a new group of drugs (such as sulpiride and clozapine) have been developed with a lesser incidence of extrapyramidal side effects than classical neuroleptics. In addition, there is some indication that they may be more beneficial in treating negative symptoms in some patients. Since all D2 blockers do not possess a similar profile, hypotheses underlying the differences have been investigated. The major differences have been in the anticholinergic actions of the neuroleptics as well as the possibility that the dopamine receptors may differ in motor areas from those in the limbic areas thought to mediate the antipsychotic responses. The existence of the D3 and other as yet undiscovered dopamine receptors may contribute to this profile. Some of the atypical compounds possess similar activity at both D2 and D3 receptors. The examples of this patent fall into this general class of molecules.
Using molecular biological techniques it has been possible to clone cDNAs coding for each of the pharmacologically defined receptors. There are at least two forms of D1, and two forms of D2 dopamine receptors. In addition, there is at least one form of D3 dopamine receptor. Examples from the aminomethyl phenylimidazole series of this patent possess differential affinities for each receptor subtype.
SUMMARY OF THE INVENTION
This invention provides novel compounds of Formula I which interact with dopamine receptor subtypes.
The invention provides pharmaceutical compositions comprising compounds of Formula I. The invention also provides compounds useful in treating affective disorders such as schizophrenia and depression as well as certain movement disorders such as Parkinsonism. Furthermore compounds of this invention may be useful in treating the extrapyramidyl side effects associated with the use of conventional neuroleptic agents. Accordingly, a broad embodiment of the invention is directed to a compound of Formula I: ##STR4## and the pharmaceutically acceptable non-toxic salts thereof wherein R 1 and T are the same or different and represent hydrogen, halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms;
M is ##STR5## R 2 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms, or R 1 and R 2 together may represent --(CH 2 ) n1 -- where n 1 is 1, 2, or 3;
X and Z are the same or different and represent hydrogen, halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, straight or branched chain lower alkoxy having 1-6 carbon atoms or SO 2 R 16 or SO 2 NHR 16 where R 16 is straight or branched chain lower alkyl having 1-6 carbon atoms;
Y is hydrogen, amino, halogen, or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 3 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms, or R 3 and R 4 together may represent --(CH 2 ) n2 -- where n 2 is 2, 3 or 4;
R 6 is hydrogen, halogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 4 and R 5 are the same or different and represent hydrogen, straight or branched chain lower alkyl having 1-6 carbon atoms, aryl straight or branched chain lower alkyl having 1-6 carbon atoms or R 2 and R 5 together may represent --(CH 2 ) n3 -- where n3 is 2 or 3; or
NR 4 R 5 together represent 2-(1,2,3,4-tetrahydroisoquinolinyl), either unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
NR 4 R 5 represents ##STR6## where W is N or CH;
R 7 is hydrogen, phenyl, pyridyl or pyrimidinyl, unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
W--R 7 is oxygen or sulfur; and
n is 1, 2, or 3.
These compounds are highly selective partial agonists or antagonists at brain dopamine receptor subtypes or prodrugs thereof and are useful in the diagnosis and treatment of affective disorders such as schizophrenia and depression as well as certain movement disorders such as Parkinsonism. Furthermore compounds of this invention may be useful in treating the extrapyramidyl side effects associated with the use of conventional neurolepticagents.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1(a-g) show representative aminomethyl phenylimidazoles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The novel compounds encompassed by the instant invention can be described by general formula I: ##STR7## and the pharmaceutically acceptable non-toxic salts thereof wherein R 1 and T are the same or different and represent hydrogen, halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms;
M is ##STR8## R 2 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms, or R 1 and R 2 together may represent --(CH 2 ) n1 -- where n .sbsb.1 is 1, 2, or 3;
X and Z are the same or different and represent hydrogen, halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, straight or branched chain lower alkoxy having 1-6 carbon atoms or SO 2 R 16 or SO 2 NHR 16 where R 16 is straight or branched chain lower alkyl having 1-6 carbon atoms;
Y is hydrogen, amino, halogen, or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 3 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms, or R 3 and R 4 together may represent --(CH 2 ) n .sbsb.2 -- where n 2 is 2, 3 or 4;
R 6 is hydrogen, halogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 4 and R 5 are the same or different and represent hydrogen, straight or branched chain lower alkyl having 1-6 carbon atoms, aryl straight or branched chain lower alkyl having 1-6 carbon atoms or R 2 and R 5 together may represent --(CH 2 ) n .sbsb.3 -- where n 3 is 2 or 3; or
NR 4 R 5 together represent 2-(1,2,3,4-tetrahydroisoquinolinyl), either unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
NR 4 R 5 represents ##STR9## where W is N or CH;
R 7 is hydrogen, phenyl, pyridyl or pyrimidinyl, unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
W--R 7 is oxygen or sulfur; and
n is 1, 2, or 3.
The present invention further encompasses compounds of Formula II: ##STR10## and the pharmaceutically acceptable non-toxic salts thereof wherein M is ##STR11## R 2 is hydrogen or methyl; R 6 is hydrogen, halogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
X and Z are the same or different and represent hydrogen, halogen, straight or branched chain lower alkyl having 1-6 carbon atoms, or SO 2 R 16 or SO 2 NHR 16 where R 16 is straight or branched chain lower alkyl having 1-6 carbon atoms;
Y is hydrogen, amino, or halogen;
T is hydrogen, halogen, hydroxy, or straight or branched chain lower alkoxy having 1-6 carbon atoms;
R 3 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 4 and R 5 are the same or different and represent hydrogen, straight or branched chain lower alkyl having 1-6 carbon atoms, aryl straight or branched chain lower alkyl having 1-6 carbon atoms or R 2 and R 5 together may represent --(CH 2 ) n .sbsb.3 -- where n 3 is 2 or 3; or
NR 4 R 5 represents ##STR12## where W is N or CH;
R 7 is hydrogen, phenyl, pyridyl or pyrimidinyl, unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
W--R 7 is oxygen or sulfur; and
n is 1, 2, or 3.
The present invention also encompasses compounds of Formula III: ##STR13## and the pharmaceutically acceptable non-toxic salts thereof wherein R 1 is hydrogen, halogen,hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms;
M is ##STR14## R 2 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms, or R 1 and R 2 together may represent --(CH 2 ) n .sbsb.1 -- where n 1 is 1,2, or 3;
R 6 is hydrogen, halogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
X and Z are the same or different and represent hydrogen, halogen, straight or branched chain lower alkyl having 1-6 carbon atoms, or SO 2 R 16 or SO 2 NHR 16 where R 16 is straight or branched chain lower alkyl having 1-6 carbon atoms;
T is hydrogen, halogen, hydroxy, or straight or branched chain lower alkoxy having 1-6 carbon atoms;
R 3 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 4 and R 5 are the same or different and represent hydrogen, straight or branched chain lower alkyl having 1-6 carbon atoms, aryl straight or branched chain lower alkyl having 1-6 carbon atoms or R 2 and R 5 together may represent --(CH 2 ) n .sbsb.3 -- where n 3 is 2 or 3; or
NR 4 R 5 represents ##STR15## where W is N or CH;
R 7 is hydrogen, phenyl, pyridyl or pyrimidinyl, unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
W--R 7 is oxygen or sulfur; and
n is 1, 2, or 3.
In addition, the present invention encompasses compounds of Formula IV: ##STR16## and the pharmaceutically acceptable non-toxic salts thereof wherein M is ##STR17## R 2 is hydrogen or methyl; R 6 is hydrogen, halogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
X and Z are the same or different and represent hydrogen, halogen, straight or branched chain lower alkyl having 1-6 carbon atoms, or SO 2 R 16 or SO 2 NHR 16 where R 16 is straight or branched chain lower alkyl having 1-6 carbon atoms;
R 3 is hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 4 and R 5 are the same or different and represent hydrogen, straight or branched chain lower alkyl having 1-6 carbon atoms, aryl straight or branched chain lower alkyl having 1-6 carbon atoms or R 2 and R 5 together may represent --(CH 2 ) n .sbsb.3 -- where n 3 is 2 or 3; or
NR 4 R 5 represents ##STR18## where W is N or CH;
R 7 is hydrogen, phenyl, pyridyl or pyrimidinyl, unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
W--R 7 is oxygen or sulfur; and
n is 1, 2, or 3.
Non-toxic pharmaceutical salts include salts of acids such as hydrochloric, phosphoric, hydrobromic, sulfuric, sulfinic, formic, toluene sulfonic, hydroiodic, acetic and the like. Those skilled in the art will recognize a wide variety of non-toxic pharmaceutically acceptable addition salts.
Representative compounds of the present invention, which are encompassed by Formula I, include, but are not limited to the compounds in FIG. I and their pharmaceutically acceptable salts. The present invention also encompasses the acylated prodrugs of the compounds of Formula I. Those skilled in the art will recognize various synthetic methodologies which may be employed to prepare non-toxic pharmaceutically acceptable addition salts and acylated prodrugs of the compounds encompassed by Formula I.
The pharmaceutical utility of compounds of this invention are indicated by the following assays for dopamine receptor subtype affinity.
Assay for D2 and D3 receptor binding activity
Striatial tissue is dissected from adult male Sprague Dawley rats or BHK 293 cells are harvested containing recombinantly produced D2 or D3 receptors. The sample is homogenized in 100 volumes (w/vol) of 0.05M Tris HCl buffer at 4° C. and pH 7.4. The sample is then centrifuged at 30,000×g and resuspended and rehomogenized. The sample is then centrifuged as described and the final tissue sample is frozen until use. The tissue is resuspended 1:20 (wt/vol) in 0.05M Tris HCl buffer containing 100 mM NaCl.
Incubations are carried out at 48° C. and contain 0.5 ml of tissue sample, 0.5 nM 3H-raclopride and the compound of interest in a total incubation of 1.0 ml. Nonspecific binding is defined as that binding found in the presence of 10-4M dopamine; without further additions, nonspecific binding is less than 20% of total binding. The binding characteristics of examples of this patent are shown in Table 1 for Rat Striatal Homogenates.
TABLE I______________________________________Compound Number.sup.1 IC.sub.50 (uM)______________________________________ 1 0.900 8 0.01116 0.01423 0.10025 0.01828 0.62030 0.200______________________________________ .sup.1 Compound numbers relate to compounds shown in FIG. I.
Compounds 8, 16 and 25 are particularly preferred embodiments of the present invention because of their potency in binding to dopamine receptor subtypes.
The compounds of general formula I may be administered orally, topically, parenterally, by inhalation or spray or rectally in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carriers, adjuvants and vehicles. The term parenteral as used herein includes subcutaneous injections, intravenous, intramuscular, intrasternal injection or infusion techniques. In addition, there is provided a pharmaceutical formulation comprising a compound of general formula I and a pharmaceutically acceptable carrier. One or more compounds of general formula I may be present in association with one or more non-toxic pharmaceutically acceptable carriers and/or diluents and/or adjuvants and if desired other active ingredients. The pharmaceutical compositions containing compounds of general formula I may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsion, hard or soft capsules, or syrups or elixirs.
Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets contain the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for the manufacture of tablets. These excipients may be for example, inert diluents, such as calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate; granulating and disintegrating agents, for example, corn starch, or alginic acid; binding agents, for example starch, gelatin or acacia, and lubricating agents, for example magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monosterate or glyceryl distearate may be employed.
Formulations for oral use may also be presented as hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, for example peanut oil, liquid paraffin or olive oil.
Aqueous suspensions contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients are suspending agents, for example sodium carboxymethylcellulose, methylcellulose, hydropropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents may be a naturally-occuring phosphatide, for example, lecithin, or condensation products of an alkylene oxide with fatty acids, for example polyoxyethylene stearate, or condensation products of ethylene oxide with long chain aliphatic alcohols, for example heptadecaethyleneoxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol such as polyoxyethylene sorbitol monooleate, or condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, for example polyethylene sorbitan monooleate. The aqueous suspensions may also contain one or more preservatives, for example ethyl, or n-propyl p-hydroxybenzoate, one or more coloring agents, one or more flavoring agents, and one or more sweetening agents, such as sucrose or saccharin.
Oily suspensions may be formulated by suspending the active ingredients in a vegetable oil, for example arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oily suspensions may contain a thickening agent, for example beeswax, hard paraffin or cetyl alcohol. Sweetening agents such as those set forth above, and flavoring agents may be added to provide palatable oral preparations. These compositions may be preserved by the addition of an anti-oxidant such as ascorbic acid.
Dispersible powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example sweetening, flavoring and coloring agents, may also be present.
Pharmaceutical compositions of the invention may also be in the form of oil-in-water emulsions. The oily phase may be a vegetable oil, for example olive oil or arachis oil, or a mineral oil, for example liquid paraffin or mixtures of these. Suitable emulsifying agents may be naturally-occurring gums, for example gum acacia or gum tragacanth, naturally-occurring phosphatides, for example soy bean, lecithin, and esters or partial esters derived from fatty acids and hexitol, anhydrides, for example sorbitan monoleate, and condensation products of the said partial esters with ethylene oxide, for example polyoxyethylene sorbitan monoleate. The emulsions may also contain sweetening and flavoring agents.
Syrups and elixirs may be formulated with sweetening agents, for example glycerol, propylene glycol, sorbitor or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents. The pharmaceutical compositions may be in the form of a sterile injectable aqueous or oleaginous suspension. This suspension may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be sterile injectable solution or suspension in a non-toxic parentally acceptable diluent or solvent, for example as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono-or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
The compounds of general formula I may also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug with a suitable nonirritating excipient which is solid at ordinary temperatures but liquid at the rectal temperature and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
Compounds of general formula I may be administered parenterally in a sterile medium. The drug, depending on the vehicle and concentration used, can either be suspended or dissolved in the vehicle. Advantageously, adjuvants such as local anaesthetics, preservatives and buffering agents can be dissolved in the vehicle.
Dosage levels of the order of from about 0.1 mg to about 140 mg per kilogram of body weight per day are useful in the treatment of the above-indicated conditions (about 0.5 mg to about 7 g per patient per day). The amount of active ingredient that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated and the particular mode of administration. Dosage unit forms will generally contain between from about 1 mg to about 500 mg of an active ingredient.
It will be understood, however, that the specific dose level for any particular patient will depend upon a variety of factors including the activity of the specific compound employed, the age, body weight, general health, sex, diet, time of administration, route of administration, and rate of excretion, drug combination and the severity of the particular disease undergoing therapy.
An illustration of the preparation of compounds of the present invention is given in Scheme I. Those having skill in the art will recognize that the starting materials may be varied and additional steps employed to produce compounds encompassed by the present invention. ##STR19## where R 1 and T are the same or different and represent hydrogen, halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms;
X and Z are the same or different and represent hydrogen, halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, straight or branched chain lower alkoxy having 1-6 carbon atoms or SO 2 R 16 or SO 2 NHR 16 where R 16 is straight or branched chain lower alkyl having 1-6 carbon atoms;
Y is hydrogen, amino, halogen, or straight or branched chain lower alkyl having 1-6 carbon atoms;
R 4 and R 5 are the same or different and represent hydrogen, straight or branched chain lower alkyl having 1-6 carbon atoms, aryl straight or branched chain lower alkyl having 1-6 carbon atoms or R 2 and R 5 together may represent --(CH 2 ) n .sbsb.3 -- where n 3 is 2 or 3; or
NR 4 R 5 represents 2-(1,2,3,4-tetrahydroisoquinolinyl), either unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
NR 4 R 5 represents ##STR20## where W is N or CH;
R 7 is hydrogen, phenyl, pyridyl or pyrimidinyl, unsubstituted or mono or disubstituted with halogen, hydroxy, straight or branched chain lower alkyl having 1-6 carbon atoms, or straight or branched chain lower alkoxy having 1-6 carbon atoms; or
W--R 7 is oxygen or sulfur; and
n is 1,2, or 3.
The invention is illustrated further by the following examples which are not to be construed as limiting the invention in scope or spirit to the specific procedures and compounds described in them.
EXAMPLE I ##STR21##
A mixture of 5-Bromo-o-anisaldehyde (6.45 g), hydroxylamine hydrochloride (2.2 g), sodium acetate (4.1 g) and acetic acid (20 mL) was heated at 100° C. with stirring for 1 h. Acetic anhydride was added (20 mL) and the mixture was refluxed for 8 h. The reaction mixture was poured onto ice water and the mixture was made basic by the careful addition of 50% sodium hydroxide. The product was extracted with ether, the ether extracts were dried over magnesium sulfate and the sovent was removed in vacuo. The residue was crystallized from ether/hexane to afford 5-Bromo-2-methoxybenzonitrile.
EXAMPLE II ##STR22##
A mixture of 5-Bromo-2-methoxy-benzonitrile (4.0 g), 3A molecular sieves (5 g) and anhydrous methanol (60 mL) was saturated with HCl gas at room temperature and allowed to stand at room temperature for 24 h. The solvent was removed in vacuo and the residue taken up in 75 mL of anhydrous methanol and saturated with ammonia gas at room temperature. The reaction mixture was then heated at 80° C. for 4 h in a sealed tube. The solvent was removed in vacuo, the reaction mixture was diluted with 3N HCl and washed with ethyl acetate to remove unreacted nitrile. The aqueous layer was made basic with 50% NaOH and the product was extracted three times with 10% methanol in methylene chloride. The combined organic extracts were dried over magnesium sulfate and the solvents removed in vacuo to afford 5-Bromo-2-methoxy-benzamidine as a glassy solid.
EXAMPLE III ##STR23##
To a solution of 1,1,1,3,3,3-hexamethylsisilazane (20 g) in dry ether (150 mL) was added 2.4M n-butyllithium in hexane (5 mL). After 10 min at room temperature, 2,3-Dimethoxybenzonitrile (16.3 g) was added in one portion and the mixture was kept at room temperature for 16 h. The reaction mixture was the poured onto excess 3N HCl. The aqueous layer was separated, basified with 50% NaOH and the product was extracted three times with 10% methanol in methylene chloride. The combined organic extracts were dried over magnesium sulfate and the solvents removed in vacuo to afford 2,3-Dimethoxy-benzamidine as a glassy solid.
EXAMPLE IV ##STR24##
A mixture of 5-Bromo-2-methoxy-benzamidine (1.5 g), 1,3-dihydroxyacetone dimer (1.0 g), ammonium chloride (1.3 g), tetrahydrofuran (3 mL) and con-centrated aqueous ammonium hydroxide (10 mL) was heated at 90° C. for 3 h. The reaction mixture was chilled on ice and the precipitated product was collected and recrystallized from methanol to afford 2-(5-Bromo-2-methoxyphenyl)-5-hydroxymethyl-imidazole as a yellow solid.
EXAMPLE V ##STR25##
A mixture of 2-(5-Bromo-2-methoxyphenyl)-5-hydroxymethylimidazole (500 mg) and thionyl chloride (1.5 mL) was heated at 80° C. for 1 h. Ether (15 mL) was added and the resulting solid was collected and washed with ether. This solid was added in one portion to a mixture of dimethylamine (3 mL), isopropanol (15 mL) and methylene chloride (30 mL) and the mixture was stirred for 20 min. The solvents were removed in vacuo and the residue was dissolved in 2N HCl and washed two times with ethyl acetate. The aqueous layer was made basic with 50% NaOH and the product was extracted with methylene chloride. The organic extracts were dried over magnesium sulfate, the solvents removed in vacuo, and the residue was treated with ethanolic HCl/ether to afford 2-(5-Bromo-2-methoxyphenyl)-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 1) melting at 242°-243° C.
EXAMPLE VI
The following compounds were prepared essentially according to the procedure described in Examples I-V:
(a) 2-Phenyl-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 2) melting at 259°-260° C.
(b) 2-Phenyl-4(5)-(piperidinomethyl)-imidazole dihydrochloride (Compound 3) melting at 245°-247° C.
(c) 2-Phenyl-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 4) melting at 239°-240° C.
(d) 2-(2-Methoxyphenyl)-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 5) melting at 115°-117° C.
(e) 2-(3-Methoxyphenyl)-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 6) melting at 239°-241° C.
(f) 2-(2,3-Dimethoxyphenyl)-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 7) melting at 220°-221° C.
(g) 2-(2,3-Dimethoxyphenyl)-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 8) melting at 200°-202° C.
(h) 2-(3-Methoxyphenyl)-4(5)-[(N,N-diethyl)aminomethyl]-imidazole dihydrochloride (Compound 9) melting at 213°-214° C.
(i) 2-(3-Fluorophenyl)-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 10) melting at 211°-214° C.
(j) 2-(2-Fluorophenyl)-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 11) melting at 241°-244° C.
(k) 2-(3-Methylphenyl)-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 12) melting at 231°-234° C.
(l) 2-(2-Fluorophenyl)-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 13) melting at 246°-247° C.
(m) 2-(4-Fluorophenyl)-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 14) melting at 237°-239° C.
(n) 2-(2-Methoxyphenyl)-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 15) melting at 239°-241° C.
(o) 2-(5-Bromo-2,3-dimethoxyphenyl)-4(5)-[(N,N-dimethyl)aminomethyl]-imidazole dihydrochloride (Compound 16) melting at 194°-196° C.
(p) 2-(5-Bromo-2-methoxyphenyl)-4(5) -[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 17) melting at 169°-172° C.
(q) 2-(5-Bromo-2,3-dimethoxyphenyl)-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole dihydrochloride (Compound 18) melting at 205°-206° C.
(r) 2-(5-Chloro-2-methoxyphenyl)-4(5)-[(N-methyl-N-benzyl)aminomethyl]-imidazole (Compound 19).
(s) 2-(3-Methoxyphenyl)-4(5)-[(N-methyl)aminomethyl]-imidazole dihydrochloride (Compound 20) melting at 208°-209° C.
(t) 4,5-Dihydro-2-(N,N-dimethyl)aminomethyl-imidazo[2,1-a]isoquinoline (Compound 21).
(u) 4,5-Dihydro-2-(N-methyl-N-benzyl)aminomethyl-imidazo[2,1-a]isoquinoline (Compound22).
EXAMPLE VII ##STR26##
A mixture of 2-Phenyl-5-hydroxymethyl-imidazole (350 mg) and thionyl chloride (1 mL) was heated at 80° C. for 1 h. The excess thionyl chloride was removed in vacuo and the residue was dissolved in 20 mL of methylene chloride. This solution was added to a mixture of triethylamine (1 mL) and 1-(2-methoxyphenyl)-piperazine (410 mg) in methylene chloride (20 mL) and the mixture was stirred for 20 min. The solvents were removed in vacuo and the residue was dissolved in 2N HCl and washed two times with ethyl acetate. The aqueous layer was made basic with 50% NaOH and the product was extracted with methylene chloride. The organic extracts were dried over magnesium sulfate, the solvents removed in vacuo, and the residue was crystallized from ethyl acetate to afford 2-Phenyl-4(5)-[(4-(2-methoxyphenyl)-piperazin-1-yl)-methyl]-imidazole (Compound 23) melting at 105°-107° C.
EXAMPLE VIII
The following compounds were prepared essentially according to the procedure described in Example VII:
(a) 2-(4-Fluorophenyl)-4(5)-[(4-(2-methoxyphenyl)-piperazin-1-yl)-methyl]-imidazole (Compound 24) melting at 95°-97° C.
(b) 2-(2,3-Dimethoxyphenyl)-4(5)-[(4-(2-methoxyphenyl)-piperazin-1-yl)-methyl]-imidazole dihydrochloride (Compound 25) melting at 217°-218° C.
(c) 2-(3-Chlorophenyl)-4(5)-[(4-(2-methoxyphenyl)-piperazin-1-yl)-methyl]-imidazole dihydrochloride (Compound 26) melting at 198°-199° C.
(d) 2-Phenyl-4(5)-[(4-(2-pyrimidinyl)-piperazin-1-yl)-methyl]-imidazole dihydrochloride (Compound 27) melting at 246°-248° C.
(e) 2-Phenyl-4(5)-[(4-(2-pyridyl)-piperazin-1-yl)-methyl]-imidazole dihydrochloride (Compound 28) melting at 176°-177° C.
(f) 2-Phenyl-4(5)-[(4-benzyl-piperidin-1-yl)-methyl]-imidazole dihydrochloride (Compound 29) melting at 234°-236° C.
(g) 2-Phenyl-4(5)-[(4-phenyl-piperidin-1-yl)-methyl]-imidazole dihydrochloride (Compound 30) melting at 238°-240° C.
(h) 2-Phenyl-4(5)-[(1,2,3,4-tetrahydroisoquinolin)-2-yl-methyl]-imidazole dihydrochloride (Compound 31) melting at 205°-207° C.
EXAMPLE VIV ##STR27##
A mixture of 2-(3-Methoxyphenyl)-4(5)-[(N-methyl)aminomethyl]-imidazole (86 mg) chloroacetyl chloride (46 mg) and diisopropylethylamine (100 mg) in tetrahydrofuran (1 mL) was kept at room temperature for 30 min. Dimethylformamide (4 mL) and potassium carbonate (200 mg) was added and the mixture was stirred at room temperature for 10 h. The reaction mixture was diluted with water and the product was extracted with methylene chloride. The solvent was dried over magnesium sulfate and the solvent was removed in vacuo to afford 3-(3-Methoxyphenyl)-7-methyl-5,6,7,8-tetrahydro-imidazo[1,5-a]pyrazin-6-one melting at 115°-117° C. after trituration with ether.
EXAMPLE X ##STR28##
A mixture of 3-(3-Methoxyphenyl)-7-methyl-5,6,7,8-tetrahydroimidazo[1,5-a]pyrazin-6-one (65 mg) and 1N lithium aluminum hydride in tetrahydrofuran (2 mL) in tetrahydrofuran (4 mL) was kept at room temperature for 45 min. After quenching the reaction with 2N sodium hydroxide the reaction was filtered through celite and the solvent was removed in vacuo. The residue was subjected to flash chromatography on silica gel with 5% methanol in chloroform as the eluent to afford 3-(3-Methoxyphenyl)-7-methyl-7,8-dihydro-imidazo[1,5-a]pyrazine followed by 3-(3-Methoxyphenyl)-7-methyl-5,6,7,8-tetrahydro-imidazo[1,5-a]pyrazine whose mono fumarate salt (Compound 32) was crystallized from ethanol/ether and melted at 211°-214°.
The invention and the manner and process of making and using it, are now described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains, to make and use the same. It is to be understood that the foregoing describes preferred embodiments of the present invention and that modifications may be made therein without departing from the spirit or scope of the present invention as set forth in the claims. To particularly point out and distinctly claim the subject matter regarded as invention, the following claims conclude this specification. | This invention encompasses compounds of the formula: ##STR1## where X, Y, Z, T, R 1 , R 3 , R 4 , and R 5 are variables representing various organic and inorganic substituents;
M is ##STR2## R 2 and R 6 represent hydrogen or alkyl substituents; or R 1 and R 2 together may represent --(CH 2 ) n1 where n 1 is 1, 2, or 3; or
NR 4 R 5 represents substituted or unsubstituted-tetrahydroisoquinolinyl; or ##STR3## where n is 1, 2, or 3; W is N or CH; and R 7 represents hydrogen or aryl; or W--R 7 is oxygen or sulfur.
These compounds are highly selective partial agonists or antagonists at brain dopamine receptor subtypes or prodrugs thereof and are useful in the diagnosis and treatment of affective disorders such as schizophrenia and depression as well as certain movement disorders such as Parkinsonism. Futhermore compounds of this invention may be useful in treating the extraparamidyl side effects associated with the use of conventional neuroleptic agents. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application is a continuation of copending U.S. patent application Ser. No. 12/598,213, filed on Oct. 30, 2009, entitled “Ion Mobility Spectrometer Including Spaced Electrodes for Filtering,” now U.S. Pat. No. 8,299,423, granted on Oct. 30, 2012, which is assigned to the assignee of the present patent application and which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention—This invention relates to detection apparatus of the kind including spaced electrodes having a source of a substantially symmetric alternating field connected to apply the field between the electrodes.
[0003] Conventional ion mobility spectrometers (IMS) are used to provide an indication of the nature of a gas or vapor by determining the mobility of ions of the analyte substance at relatively low electrical fields, where ion mobility follows a linear relationship with changes in field magnitude. An alternative form of ion mobility spectrometer called a FAIMS (field asymmetric ion mobility spectrometer) or differential mobility spectrometer (DMS) makes use of much higher fields to provide an indication of the nature of analyte ions from the manner in which the mobility of certain ions deviates from the linear relationship with changes in field magnitude at high fields. Both IMS and FAIMS spectrometers have advantages and disadvantages, with an IMS being better suited for detecting certain substances and a FAIMS being better suited for detecting certain other substances. The maximum amount of information about ions, and hence the maximum selectivity, would be obtained by measuring ion mobility at both high and low fields. This could be achieved by connecting a high field detector and a low field detector together in tandem, but this creates various engineering problems. Furthermore, such a combined instrument would be relatively bulky and would have relatively high power requirements.
[0004] It is accordingly desirable to provide an alternative method and apparatus for detection, and an alternative spectrometer.
[0005] The subject matter discussed in this background of the invention section should not be assumed to be prior art merely as a result of its mention in the background of the invention section. Similarly, a problem mentioned in the background of the invention section or associated with the subject matter of the background of the invention section should not be assumed to have been previously recognized in the prior art. The subject matter in the background of the invention section merely represents different approaches, which in and of themselves may also be inventions.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention, there is provided detection apparatus of the above-specified kind, characterized however in that the magnitude of the field varies between a low value and a higher value over a time exceeding the time of the alternating period, wherein the maximum magnitude is less than that required to cause differential ion mobility effects, and wherein the apparatus includes a collector for collecting ions passed through the field to produce an output signal that varies as ions of different low-field mobilities are passed through the electrodes or are captured between them, together with a processor that is responsive to the output signal to provide an indication of the ions detected.
[0007] The electrodes may be arranged laterally with respect to the ion flow path through the apparatus, and they may be of an open construction such that the ions can pass through them. The collector may be arranged to collect those ions passing through the electrodes. Alternatively, the electrodes may be arranged parallel to the ion flow path through the apparatus such that the ions pass along a gap between the electrodes. In the alternative arrangement, the collector is arranged to collect those ions passed along the length of the gap between the electrodes. The apparatus may also be arranged to apply a high field asymmetric alternating field to the electrodes at time different from the time the symmetric alternating field is applied, the high field being sufficient to cause high field differential mobility effects such that the apparatus can be arranged to provide indications of both the high field mobility and the low field mobility of analyte ions.
[0008] According to another aspect of the present invention, a detection apparatus includes spaced electrodes and a voltage source, wherein the voltage source is arranged to apply both low and high alternating fields to the electrodes to produce separate indications of both the low field mobility and the high field mobility of detected ions, wherein the apparatus includes a processor that is arranged and configured to provide an indication of the nature of the detected ions using both of the mobility indications.
[0009] According to a further aspect of the present invention, a method of detecting ions is provided that includes supplying analyte ions for detection between two electrodes and applying two different fields between the electrodes at different times, one field being a relatively low symmetric alternating field that increases in magnitude over a time exceeding the period of the alternating field, the other field being a relatively high asymmetric alternating field sufficient to cause high field differential mobility effects in the ions, and then collecting ions passed through the electrodes during the application of both fields and providing an indication of the nature of the ions collected from signals produced by the collected ions during both the low and high fields.
[0010] According to a fourth aspect of the present invention there is provided a spectrometer having an inlet for an analyte substance and an ionization region arranged to produce ions of the substance and to supply those ions to an electric field region, wherein the electric field region is switchable between two different fields, namely a relatively low magnitude alternating field that varies in magnitude over multiple periods and an asymmetric alternating field of sufficiently high magnitude to cause differential mobility effects.
[0011] The electric field region may be provided between two grid electrodes extending either transversely across the path of flow of the ions or in a gap between two electrodes extending along the path of flow of the ions.
DESCRIPTION OF THE DRAWINGS
[0012] Two different forms of spectrometer and methods of detecting substances constructed and operating according to the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0013] FIG. 1 is a schematic view of a parallel-motion spectrometer;
[0014] FIG. 2 shows movement of high-mobility and low-mobility ions when subject to a relatively low alternating field of increasing magnitude;
[0015] FIG. 3 illustrates the ion current produced by the low magnitude field plotted against time;
[0016] FIG. 4 shows the differentiated ion current output of FIG. 3 ;
[0017] FIG. 5 shows a high magnitude asymmetric field used in the spectrometer instead of the low magnitude field;
[0018] FIG. 6 is a schematic view of a portion of an alternative form of spectrometer; and
[0019] FIG. 7 illustrates the ion current produced by the spectrometer of FIG. 6 when operated in the low field mode plotted against time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring first to FIG. 1 , a detection apparatus is shown in the form of a spectrometer having a housing 1 with an inlet 2 located at its upper end for admitting an analyte substance in the form of a gas or vapor. The inlet 2 opens into an ionization region 3 where the molecules of admitted analyte substance are ionized. The ions that are produced flow down the spectrometer under the influence of an electric field or a gas flow to an electric field region 4 . The electric field region 4 is provided by two or three parallel grid-like electrodes 41 , 42 , and 43 extending laterally across the housing 1 , the open nature of the electrodes 41 , 42 , and 43 being such that neutrally charged ions can pass through the electrodes 41 , 42 , and 43 substantially unhindered. A collector plate 5 that is located below the field region 4 is connected to an amplifier and processing unit 6 , which in turn provides an output to a display or other utilization means 7 . A gas flow system, indicated generally by the numeral 8 , is connected between opposite ends of the housing 1 of the spectrometer to provide a flow of clean dry gas along the housing 1 , as required.
[0021] The electrodes 41 , 42 , and 43 are connected to a voltage source oscillator 10 that is selectively operable to apply two different electrical fields to the electrodes 41 , 42 , and 43 . The first field is of relatively low magnitude. In this description of the present invention, the term “low field” is used to indicate fields where the mobility of ions varies in a linear manner with changes in field magnitude. The field is produced by applying a square wave to the electrodes 41 to 43 that alternates symmetrically between equal positive and negative voltages. The amplitude of the square wave is modulated so that it increases linearly from zero to a maximum value over a time equal to many oscillation periods of the square wave. This causes the ions between the electrodes 41 to 43 to oscillate backwards and forwards between the electrodes 41 to 43 . Those ions with a high mobility have a relatively large amplitude of movement, whereas those ions with a lower mobility have a lower amplitude, as shown by the two traces depicted in FIG. 2 , with the dotted line representing ions of a high mobility and the solid line representing ions of a low mobility. The separation between the electrodes 41 to is represented by the horizontal dashed line “S” positioned against the vertical, displacement scale, which is in arbitrary units.
[0022] The ion current produced is represented in FIG. 3 , which has been smoothed to reduce fluctuations from the high frequency rectangular waveform. In fact, most amplifiers configured for low noise will produce this form of smoothing. It can be seen, therefore, that, at low fields, all the ions will oscillate between the confines of the electrodes 41 to 43 and none will pass through, so there will be a zero ion current. As the field increases further (at point “A” in FIGS. 2 and 3 ), initially, only the higher mobility ions will reach and pass through the lower electrode 43 and, therefore, pass to the collector plate 5 where it is detected. The ion current, therefore, increases steadily as more high mobility ions pass through. Eventually (at point “B” in FIGS. 2 and 3 ), all the high mobility ions pass through the lower electrode 43 , so the current reaches a plateau.
[0023] Further increase in the amplitude of the oscillating field then starts to drive the lower mobility ions through the lower electrode 43 (at point “C” in FIGS. and 3 ), so the ion current again rises to a new plateau (at point “D” in FIGS. 2 and 3 ), where all of the low mobility ions are being driven through the lower electrode 43 . When the field falls to zero again (at point “E” in FIGS. 2 and 3 ), at the end of the cycle, the ion current also drops to zero. It will be appreciated that, in general, there will be a range of ions with ion mobility between the two extremes. The maximum field value is selected according to the separation between the electrodes 41 to 43 . It is set such that the slowest mobility ions likely to be met will be passed through the lower electrode 43 at some point below the maximum field value. The processor 6 is arranged to identify the characteristics of the curve shown in FIG. 3 , which provides information about the nature of the detected ions. The curve shown in FIG. 3 may be used in this form, or it may be differentiated, as shown in FIG. 4 , to make the identification of the characteristics even clearer.
[0024] Variations in the signal caused by the oscillating field can be seen in FIGS. 2 and 4 . To minimize this, it is desirable to have the highest possible ratio between the modulation frequency and the frequency of the oscillating field. The frequency of the modulation sweep might typically be in the range 1 Hz to 10 Hz, giving 1 spectra to 10 spectra per second. The oscillating waveform, which need not be rectangular, would typically have a frequency in the region of kHz.
[0025] Information from the low field mode may, in some cases, be used by itself to identify the nature of the detected ions, such as by correlation with a look-up table of the curve characteristics of known ions. Alternatively, and according to an aspect of the present invention, this information may be combined with information about the high field mobility derived using the same apparatus operated in a high field mode, as described below. To derive the high field information, the oscillator 10 is switched to a high field mode to provide a voltage of the kind shown in FIG. 5 . Instead of using the same oscillator, the high field could be provided by a different oscillator (not shown in the figures). In this application, the term “high field” is used to indicate a field that is high enough to cause differential mobility effects in ions. The voltage shown in FIG. 5 is a conventional FAIMS asymmetric voltage comprising short duration high voltage positive pulses and longer duration lower voltage negative pulses. The duration and magnitude of the positive and negative pulses are selected such that the mean voltage over one cycle is zero. In this example, the voltage switches between +4000 volts and −2000 volts, the duration of the negative part of the cycle thus being twice the duration of the positive part of the cycle. This gives a field between the electrodes 41 to 43 on the order of tens of thousands of volts/cm. When operated in this mode, ions without high field differential mobility have a net zero displacement, so they will remain between the electrodes 41 to 43 . Those ions that do have different mobility at high fields will, however, gradually move towards one or other of the electrodes, according to their charge, and eventually pass through the electrode. The system is arranged such that the ions to be detected move through the lower electrode 43 , and hence pass to the collector plate 5 for detection. Small DC voltages can also be superimposed on electrodes 41 , 42 , and 43 , and ions with various differential mobilities can be selected and identified by adjusting these voltages. Alternatively, the DC voltages on the electrodes can be fixed and the differential mobility of ions can be measured by measuring the time they take to pass through from electrode 41 to electrode 43 . Techniques that combine these two approaches can also be used.
[0026] Thus, by operating the spectrometer in both the low field mode and the high field mode, it is possible to extract two different indications of the nature of the ions, or, alternately, it is possible to identify both ions with a characteristic low field mobility and those with a characteristic high field mobility. The processor 6 uses the information from the two modes to provide an improved indication of the nature of the analyte substance.
[0027] Similar measurements can also be made using spectrometers employing just two grids, such as grids 41 and 42 or 42 and 43 in FIG. 1 .
[0028] It is not essential for the spectrometer to be arranged to produce parallel ion motion by the use of open, grid electrodes arranged transverse to the ion flow direction in the manner shown in FIG. 1 . Instead, it could be arranged in a manner similar to a conventional FAIMS instrument, as shown in FIG. 6 , where components equivalent to those in FIG. 1 have been given the same reference numeral with the addition of 100 . In this arrangement, the electrodes 141 and 142 are arranged parallel to the axis of the instrument and to the direction of gas flow “G” through the instrument. The electrodes 141 and 142 may be provided by two parallel, solid, flat plates, as shown, or they could instead be provided by two coaxial tubular electrodes, as is well known in FAIMS instruments. The same low voltage field is applied between the two electrodes 141 and 142 as in the arrangement of FIG. 1 , and this field produces the same oscillating motion of the low and high mobility ions shown in FIG. 2 . At the low fields, the amplitude of oscillation between the electrodes 141 and 142 is relatively small so the ions do not contact the electrodes, thereby allowing them to flow along the gap between the electrodes and out of the right-hand end of the electrodes (as shown in FIG. 6 ) to the collector plate 105 for detection. The change in ion current with time is represented in FIG. 7 . As the amplitude of oscillation increases with increasing applied field, the higher mobility ions start to impact the electrodes 141 and 142 and be lost, causing a drop in the ion current (at point “A” in FIG. 7 ) detected at the collector plate 105 . Ion current falls as the field strength increases until all of the higher mobility ions impact the electrodes 141 and 142 and there is a plateau (at point “B” in FIG. 7 ). Subsequently (at point “C” in FIG. 7 ), the lower mobility ions start to impact the electrodes 141 and 142 and the ion current again starts to fall until (at point “D” in FIG. 7 ) all of the lower mobility ions impact the electrodes 141 and 142 and there is a plateau in the ion current until the start of the next cycle at point “E” in FIG. 7 .
[0029] When operated in the high field FAIMS mode, a voltage of the kind shown in FIG. 5 is applied to the electrodes 141 and 142 in place of the low field voltage. Ions with a differential high field mobility drift towards one or other of the electrodes 141 or 142 and do not, therefore, pass along the gap between the electrodes for detection by the collector plate 105 . By applying a DC voltage to the alternating voltage, selected ions can be passed through the electrodes 141 and 142 for detection in the manner of a conventional FAIMS instrument. Again, by combining the outputs derived when the instrument is operating in its low field mode and in its high field mode, it is possible to obtain increased information about the ions from the same instrument, thereby giving enhanced selectivity.
[0030] The low field arrangement of the present invention avoids the need for the pulsed operation, which is usual in conventional time-of-flight instrument, and which is relatively inefficient because not all of the ions are analyzed.
[0031] The apparatus may be arranged to switch between the high field mode and the low field mode at regular intervals. Alternatively, it may operate in one mode and be manually switched to the other mode as desired. The apparatus could operate in one mode and automatically switch to the other mode only when the first mode gives an ambiguous output or suggests the presence of a substance that is better suited to detection in the alternative mode.
[0032] Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
[0033] While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be claimed alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above. | An ion mobility spectrometer has an inlet for an analyte substance opening into an ionization region that produces ions of the substance. Parallel grid electrodes extend laterally across the ion flow path and apply an electric field to the ions that is switchable between a relatively low magnitude alternating field that varies in magnitude over multiple periods and an asymmetric alternating field of sufficiently high magnitude to cause differential mobility effects. A collector collects the passed ions, and an indication of the nature of the analyte substance is produced from the collected ions passed during both the low and high field intervals. Also disclosed is the application of a substantially alternating field between the electrodes, which field varies between a low value and a higher value over a time exceeding that of the alternating period. | 7 |
BACKGROUND INFORMATION
In a client-server environment, a client computers can communicate with a server to remotely access information stored at the server. The transfer of information between the server and client computer may be provided using standard protocols and software applications. For example, a hypertext markup language (HTML) browser application at a client computer can communicate over the public Internet using TCP/IP and hypertext transfer protocols (HTTP) to receive web pages from a HTTP server. Web pages may include formatted text as well as multimedia elements, such as embedded graphics and sounds. The multimedia elements may be downloaded by the client and presented to a user by a browser application or a “plug in” browser component. Example browser applications include Netscape Navigator 4.0® and Microsoft Internet Explorer 4.0™.
Browser applications used at client computers can use plug-in software to receive audio and video information using a streaming data transmission protocol. A streaming protocol allows information to be presented by a client computer as it is being received. For example, full-motion video can be sent from a server to a client as a linear stream of frames. As each frame arrives at the client, it can be displayed to create a real-time full-motion video display. Audio and video streaming allows the client to present information without waiting for the entire stream to arrive at the client application. Audio and video streaming are provided by, for example, the RealAudio® and RealVideo™ applications from RealNetworks, Inc.
Browser applications may also make use of executable software applets to enhance the appearance of HTML-based web pages. Applets are software programs that are sent from the server to the client in response to a request from the client. In a typical applet use, HTML-based web pages include HTTP commands that cause a browser application to request an applet from a server and to begin execution of the applet. The applet may thereafter interact with a user to gather and process data, may communicate data across a network, and may display results on a computer output device. Applets may be constructed from a programming language which executes in a run-time environment provided by the browser application at the client computer. For example, the Java® programming language from Sun Microsystems, Inc., allows Java applets to be stored at a web server and attached to web pages for execution by a Java interpreter. Java Applets, may be formed from multiple Java Classes. Java Classes include executable Java code that can be downloaded from a server in response to a dynamically generated request to execute the class (a module execution request). If a Java Class is not available to a Java interpreter when an executing applet attempts to access functionality provided by the Class, the Java interpreter may dynamically retrieve the Class from a server. Other programming languages, such as Microsoft Visual Basic® or Microsoft Visual C++ ®, may also be used to create applet-like software modules, such as Microsoft ActiveX™ controls.
Downloadable applets can also be used to develop large and complex programs. For example, a complex financial program may be constructed from a collection of applets. In such a financial program, separate applets may be used to gather information from a user, compute payments, compute interest, and generate printed reports. As particular program functions are required by a user, the applets associated with the required functions can be retrieved from the server. However, as the size of a software application increases, delays associated with retrieving is modules over a network likewise increase and may be unacceptable to end-users. Consequently, an improvement in the transmission of software modules between computers is desirable.
SUMMARY
The invention includes methods and systems for streaming data modules between a first and a second computer. The modules may be streamed regardless of the existence of a “natural” order among the modules. For example, unlike streaming applications that rely on a natural linear ordering of data to determine the data stream contents, the disclosed streaming mechanism is not constrained to operate according to a linear data ordering. Instead, streamed data modules are selected using predetermined criteria that can be independent of the particular data content.
In an exemplary application, the disclosed streaming mechanism can provide user-dependent streaming of software modules. For example, a home banking application may include modules #1 through #5. A first banking application user may, based on the user's input choices at a menu screen, access the modules in the order 1-3-4-5 while a second user may access the modules in the order 2-4-1. For such a banking application, the predetermined criteria used to determine a streaming sequence may detail each user's module usage pattern. Predetermined criteria associated with the application's users may indicate a preferred streaming sequence 1-3-4-5 when the first user is accessing the banking application but may indicate the preferred sequence 2-4-1 when the second user is accessing the application. The streamed sequence may therefore conform to a historical user-dependent access pattern. Other types of predetermined criteria may also be used. The disclosed streaming mechanism may also be use to stream non-executable data such as hypertext markup language data, binary graphics, and text.
In general, in one aspect, the invention features a computer-implemented method of transmitting modules from a first computer to a second computer. At the first computer, a module set is formed by selecting a sequence of modules from a collection of available modules. Each of the selected modules are associated with an application executing at the second computer. The selected modules may be transparently streamed from the first computer to the second computer. The selection of modules is made in accordance with predetermined selection criteria and is independent of the second computer's execution environment.
Implementations of the invention may include one or more of the following features. A module may include non-executable data, such as hypertext markup language data, and/or program code. The selection criteria may be stored in a streaming control database. The streaming control database may include transition records associating weighted values with transitions between selected modules in the collection. Processing of transition record information, such as by using a path determination algorithm, may be used to determine the sequence of modules. The streaming control database may include list records each of which identifies a predetermined sequences of modules. Selection of modules may be made by selecting a list record. Selecting a sequence of modules may include sending data from the second computer to the first computer to identify each module in the sequence or to identify the status of the executing application. For example, data identifying the status may include a series of user input values.
Implementations may also include one or more of the following features. Streaming of the module set may be interrupted, a second sequence determined, and streaming of the second sequence may occur. The streaming of the module set may be interrupted by a request for a particular module that is sent from the second computer to the first computer. For example, a Java Applet may interrupt a stream of Java Classes by attempting to access a Java Class that has not already been streamed to the second computer. A sequence of modules may be streamed and stored at the second computer independent of the executing application. That is, the executing application need not initiate streaming and need not be aware of the streaming process. Streamed modules may be subsequently integrated with the application at the second computer by interconnecting logic in a streamed module with logic in the application.
Implementations may also include one or more of the following features. The application may include an interrupt statement. Execution of the interrupt statement may transfer control to an executor program. The executor program functions in the manner of a program code debugger by responding to the interrupt statement and preventing the permanent cessation (termination) of the executing application process. The executor program may thereafter integrate logic in a streamed module with the application's logic by replacing the interrupt statement (generally, as part of a block of replacement logic) with replacement logic from the streamed module. The application may thereafter continue executing, generally by executing replacement logic that has been substituted for the interrupt statement. The application may also include a stub procedure that can be replaced by logic in a streamed module. Replacement of the stub procedure may be direct, such as by removing the stub procedure code and replacing it with logic from a streamed module, or replacement may be operative, such as by creating a link to logic in a streamed module.
In general, in another aspect, the invention features a computer program residing on a computer-readable medium. The computer program includes instructions for causing a computer to access a collection of modules associated with an application, to access a database storing module selection criteria, to form a module set by selecting a sequence of modules from the collection in accordance with the module selection criteria, and to transparently stream the module set to a second computer. Implementations of program may also include instructions for causing the computer to retrieve a first module from the collection and to send the first module to the second computer.
In general, in another aspect, the invention features a computer program residing on a computer-readable medium. The program includes instructions for causing a computer to execute an application, to transparently receive a modules associated with the executing application, to store the received module independent of the executing application, and to integrate the received module with the executing application.
In general, in another aspect, the invention features a system for transferring information modules between computers. The system includes a first computer and a second computer. The first computer includes means for executing an application, means for receiving a sequence of modules associated with the application while the application is executing, and means for integrating a first module in the received sequence with the application. The second computer includes means for storing a collection of modules associated with the application, means for selecting a sequence of modules from the collection, and means for transferring the selected sequences from the first computer to the second computer.
Implementations may include one or more of the following advantages. Delays experienced when downloading an applications, a code module, or a data modules can be can be reduced. Software and data modules can be predictively delivered to a client workstation according to a particular end user's requirements. The order in which modules are streamed from a server to a client can be dynamically determined. A collection of module delivery sequences can be associated with a particular application or user and the sequences can be dynamically updated. Module delivery sequences can be determined based on individual software usage patterns or stored statistic associated with module usage. Module streaming can be interrupted and altered during the execution of an application. Implementations may include additional or alternative advantages as will become clear from the description and claims that follow.
DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a computer network.
FIG. 2 illustrates computer software application modules.
FIG. 3 is a directed graph, according to the invention.
FIG. 4 illustrates a server and a client, according to the invention.
FIGS. 5A-5E illustrate application code components, according to the invention.
DETAILED DESCRIPTION
Referring to FIG. 1, a wide area network 100 is shown. In the network 100 , a client computer 101 can communicate with a server computer 102 by sending data over links 103 and 104 to a data network 130 . The data network 130 may include multiple nodes 131 - 134 that can route data between the client 101 and the server 102 . The client computer 101 may transmit and receive data using the TCP/IP, HTTP, and other protocols. For example, the client 101 may use the HTTP protocol to request web pages from the server 102 .
Web pages and multimedia data sent from the server 102 to the client 101 may have a natural linear sequence associated with them. The natural sequence of video data may be the linear order of video frames while the natural sequence of text may be the order in which pages of text are arranged in a document. Data having a natural linear sequence can be streamed from a server to a client to minimize download delays. In a streaming system, while earlier items in a liner sequence are being processed and/or displayed, subsequent items may be downloaded to the client computer. When processing and/or display of an item is complete, processing or display or a fully received “streamed” item may quickly begin. Since receipt of a streamed item is fully or partially complete when the item is requested, a user or client application requesting the streamed item will perceive a reduced downloading delay. For example, if the first page of a document is retrieved by a user, the second page can be downloaded while the first page is being read. If the user continues reading at the second page of the document, that page will then be available at the client, such as in a cache area on a hard disk drive, and can be read without additional downloading delay.
Software execution may not follow a predictable natural linear order. Software may include jump statements, break statements, procedure calls, and other programming constructs that cause abrupt transfers of execution among sections of executing code. The execution path that is traversed during the processing of interrelated code modules (such as code segments, code classes, applets, procedures, and code libraries), will often be non-linear, user dependent, may change with each execution of the application program, and may change depending on the state of various data items. Although a natural order may be lacking, an advantageous order may be determined in which to stream modules. The order may be determined using criteria that is independent of the computer's internal architecture or internal operating system (execution environment) considerations.
Referring to FIG. 2, a software application 200 may include multiple modules “A” through “H.” Modules “A” through “H” may be Java Classes, C++ procedure libraries, or other code modules that can be stored at a server. Some of the modules “A” through “H” may also be stored at the client computer, such as in a hard disk drive cache or as part of a software library stored at the client computer. When a client computer begins execution of the application 200 , a first module, such as module “A,” may be downloaded from the server and its execution at the client 410 may begin. As module “A” is being processed, the programming statements contained therein may branch to, for example, module “E.” If Module “E” is not already resident at the client, the execution of module “A” can be suspended, module “E” can be retrieved from the server, and then the execution of module “E” code may begin. In such a scenario, a user will experience a module download delay associated with retrieving module “E” from the server.
To minimize module download delays experienced by a user, module “E” may be transparently streamed from a server to the client computer. Transparent streaming allows future module use to be predicted and modules to be downloaded while other interrelated modules “A” are executing. Referring to FIG. 4, an exemplary software architecture 400 providing transparent streaming is shown. The software architecture 400 includes a server 401 having a database 403 of stored software modules. The server 401 can transparently transmit a stream of software modules 405 over a communications link to a client computer 410 . The communication link may be an analog modem connection, a digital subscriber line connection, a local area network connection, or any other type of data connection between the server 401 and client 410 . As particular software modules are being executed at the client 410 , additional modules are sent from the server 401 to the client 410 . In a dynamic streaming implementation, the order in which modules are streamed between the server and client may be altered based on the particular client computer 410 being served, based on the user of the client computer, and based on other dynamically determined factors.
Referring to FIG. 3, the execution order of application modules “A” through “H” may resemble a directed graph 300 rather than a linear sequence of modules. For example, as illustrated by the graph 300 , after module “A” is executed, execution can continue at module “B,” “D,” or “E.” After module “B” is executed, execution can continue at module “C” or “G.” The execution path may subsequently flow to additional modules and may return to earlier executed modules.
The server 401 can use streaming control information 402 to determine the order in which to stream modules from the server 401 to the client 410 . The streaming control information 402 can include, for example, a predicted execution flow between software modules such as that represented by the directed graph 300 . As downloaded modules are executed by the client 410 , the client may send control data 415 to the server 401 to dynamically update and alter the order in which modules are streamed from the server 401 to the client 410 . Control data 415 may be used to request particular modules from the server 401 , to send data regarding the current execution state of the application program, to detail the current inventory of modules residing in the client's local storage 411 , and to report user input selections, program execution statistics, and other data derived regarding the client computer 410 and its executing software.
The sequence of modules sent in the stream 405 from the server 401 to the client 410 can be determined using a streaming control file 402 . The streaming control file 402 includes data used by the server to predict modules that will be needed at the client 410 . In a graph-based implementation, the control file 402 may represent modules as nodes of a directed graph. The control file 402 may also represent possible execution transitions between the modules as vertices (“edges”) interconnecting the nodes. Referring to Table 1, in a weighted graph implementation, the streaming control file 402 may include a list of vertices represent possible transitions between modules. For example, Table 1 list vertices representing all possible transitions between the modules “A” through “H” of graph 300 (FIG. 3 ). Each vertex in Table 1 includes a weight value indicating the relative likelihood that the particular transitions between modules will occur. In the example of Table 1, higher weight values indicate less likely transitions. The server 401 may apply a shortest-path graph traversal algorithm (also known as a “least cost” algorithm) to determine a desirable module streaming sequence based on the currently executing module. Example shortest-path algorithms may be found in Telecommunications Networks: Protocols, Modeling and Analysis, Mischa Schwartz, Addison Wesley, 1987, §6.
TABLE 1
Graph Edge Table
Edge
Weight
(A, B)
1
(A, D)
7
(A, E)
3
(B, C)
1
(B, G)
3
(C, E)
2
(C, G)
6
(D, F)
2
(E, H)
2
(F, H)
1
(G, E)
3
(G, H)
4
For example, Table 2 represents the minimum path weight between module “A” and the remaining modules of Table 1.
TABLE 2
Shortest Paths from Application Module “A”
Shortest
Path
From
To
Weight
Path
A
B
1
A-B
C
2
A-B-C
D
7
A-D
E
3
A-E
F
9
A-D-F
G
4
A-B-G
H
5
A-E-H
Based on the weight values shown in Table 2, the server 401 may determine that, during the execution of module “A”, the module streaming sequence “B,” “C,” “E,” “G,” “H,” “D,” “F” is advantageous. If a particular module in a determined sequence is already present at the client 402 , as may have been reported by control data 415 , the server 401 may eliminate that module from the stream of modules 405 . If, during the transmission of the sequence “B,” “C,” “E,” “G,” “H,” “D,” “F,” execution of module “A” completes and execution of another module begins, the server may interrupt the delivery of the sequence “B,” “C,” “E,” “G,” “H,” “D,” “F,” calculate a new sequence based on the now executing module, and resume streaming based on the newly calculated streaming sequence. For example, if execution transitions to module “B” from module “A,” control data 415 may be sent from the client 410 to the server 401 indicating that module “B” is the currently executing module. If module “B” is not already available at the client 410 , the server 401 will complete delivery of module “B” to the client and determine a new module streaming sequence. By applying a shortest-path routing algorithm to the edges of Table 1 based on module “B” as the starting point, the minimum path weights between module “B” and other modules of the graph 300 (FIG. 3) can be determined, as shown in Table 3.
TABLE 3
Shortest Paths from Module “B”
Shortest
Path
From
To
Weight
Path
B
C
1
B-C
E
5
B-C-E
G
3
B-G
H
7
B-C-E-H
Based on the shortest path weights shown in Table 3, the server 401 may determine that module streaming sequence “C,” “G,” “E,” and “H” is advantageous.
Other algorithms may also be used to determine a module streaming sequence. For example, a weighted graph 300 may be used wherein heavier weighted edges indicate a preferred path among modules represented in the graph. In Table 4, higher assigned weight values indicate preferred transitions between modules. For example, edges (A,B), (A,D), and (A,E) are three possible transitions from module A. Since edge (A,B) has a higher weight value then edges (A,D) and (A,E) it is favored and therefore, given module “A” as a starting point, streaming of module “B” before modules “D” or “E” may be preferred. Edge weight values can be, for example, a historical count of the number of times that a particular module was requested by a client, the relative transmission time of the code module, or a value empirically determined by a system administrator and stored in a table 402 at the server 401 . Other edge weight calculation methods may also be used.
TABLE 4
Preferred Path Table
Edge
Weight
(A, B)
100
(A, D)
15
(A, E)
35
(B, C)
100
(B, G)
35
(C, E)
50
(C, G)
20
(D, F)
50
(B, H)
50
(F, H)
100
(G, E)
35
(G, H)
25
In an preferred-path (heavy weighted edge first) implementation, edges in the graph 300 having higher weight values are favored. The following exemplary algorithm may be used to determine a module streaming sequence in a preferred-path implementation:
1: Create two empty ordered sets:
i) A candidate set storing pairs (S,W) wherein “S” is a node identifier and “W” is a weight of an edge that may be traversed to reach node “S.”
ii) A stream set to store a determined stream of code modules.
2: Let S i be the starting node.
3: Append the node S i to the Stream Set and remove any pair (S i , W) from the candidate set.
4: For each node S j that may be reached from node S i by an edge (S i , S j ) having weight W j :
{
If S j is not a member of the stream set then add the pair (S j , W j ) to the candidate set.
If S j appears in more than one pair in the candidate set, remove all but the greatest-weight (S j , W) pair from the candidate set.
}
5: If the Candidate set is not empty
Select the greatest weight pair (S k , W k ) from the candidate set.
Let S i =S k
Repeat at step 3
For example, as shown in Table 5, starting at node “A” and applying the foregoing algorithm to the edges of Table 4 produces the stream set {A, B, C, E, H, G, D, F}:
TABLE 5
Calculation of Stream Set
Iteration
{Stream Set}/{Candidate Set}
1
{A}/{(B,100) (D,15) (E,35) }
2
{A,B}/{(D,15)(E,35)(C,100)(G,35)}
3
{A, B, C}/{(D,15) (E,35) (G,35)}
4
{A, B, C, E}/{(D,15) (G,35) (H,50)}
5
{A, B, C, E, H}/{(D,15) (G,35)}
6
{A,B,C,B,H,G}/{(D,15)}
7
{A,B,C,E,H,G,D}/{(F,50)}
8
{A,B,C,E,H,G,D,F}/{}
Implementations may select alternative algorithms to calculate stream sets.
Application streaming may also be used to stream subsections of an application or module. For example, subsections of compiled applications, such as applications written in C, C++, Fortran, Pascal, or Assembly language may be streamed from a server 401 to a client 410 . Referring to FIG. 5A, an application 500 may include multiple code modules such as a main code module 501 and code libraries 510 and 515 . The module 501 contains program code that is executed when the application is started. The code libraries 510 and 515 may contain header data 511 and 516 as well as executable procedures 512 - 514 and 517 - 519 that are directly or indirectly called from the main module 501 and other library procedures.
In a Microsoft Windows 95/Microsoft Visual C++ implementation, the main code module 501 may contain a compiled C++ “main” procedure and the library modules 510 and 515 may be dynamic link libraries having compiled C++ object code procedures. Header data 511 and 516 may include symbolic names used by operating system link procedures to dynamically link libraries 510 and 515 with the main module 501 . Header data may also indicate the location of each procedure within the library. In a jump table implementation, a calling procedure may access library procedures 512 - 514 , 517 - 519 by jumping to a predetermined location in header 511 or 516 and from there, accessing additional code and/or data resulting in a subsequent jump to the start of the procedure.
Data and procedures within an application's code modules and libraries may be many hundreds or thousands of bytes long. Prior to executing an application, a client may need to retrieve a lengthy set of modules and libraries. By reducing the size of the module and library set, the initial delay experienced prior to application can be reduced. In a streaming implementation of application 500 , code within subsections of the application's code modules can be removed and replaced by shortened streaming “stub” procedures. The replacement of application code with streaming stub procedures may reduce module size and associated transmission delay. For example, referring to FIGS. 5A and 5B, the code library 510 may include a header 511 that is 4 kilobytes (Kbytes) in length and procedures 512 - 514 that are, respectively, 32 Kbytes, 16 Kbytes, and 8 Kbytes. Referring to FIGS. 5B and 5C, to reduce the size of the library 510 , procedures code 512 - 514 may be removed from the library 510 and stored in a streaming code module database 403 at the server 401 (FIG. 4 ). The removed procedure code 512 - 514 may be replaced by “stub” procedures 522 - 524 resulting in reduced-size code library 530 that can be linked with application modules 501 and 515 in place of library 510 . Header data 511 of library 530 can include updated jump or link information allowing stub procedures 522 - 524 to act as link-time substitutes for procedures 512 - 514 .
A server 401 may provide a streaming-enabled version of application 500 to a client 410 by sending main module 501 , library module 515 , “streamed” library 530 , and, in some implementations, a streaming support file 535 to the client 410 in response to a request for the application 500 . The streaming support file 535 may include procedures accessed by the stubs 522 - 524 to facilitate code streaming between the server 401 and client 410 . At the client 410 , modules 501 , 515 , 530 and 535 can be linked and execution of the resulting application can begin. As the main module 501 and various called procedures are executed at the client 410 , code modules stored in the database 403 can be streamed from the server 401 to the client 410 . Data may be included in the stream 403 to identify stub procedures 522 - 524 associated with the streamed code modules. As the streamed modules are received at the client, they are integrated with the executing application.
In an appended module implementation, streamed code modules are integrated with the executing application by appending received modules to their corresponding library or code file. For example, referring to FIGS. 5C and 5D, as modules 512 - 514 are streamed from the server to the client, they are appended to the library file 530 thereby forming an augmented library file 540 . As the modules 512 - 514 are streamed from the server 401 and appended to the file 530 , header data 511 or stub data 522 - 524 is updated so that the now-appended modules are accessible from a calling procedure. For example, referring to FIG. 5D, an additional “jump” may be added between each stub procedure 522 - 524 and its associated appended module 512 - 514 . Alternatively, header data 511 may be updated so that procedures 512 - 514 are accessible in place of stubs 522 - 524 . In a stub-replacement implementation, stubs 515 - 516 are replaced by procedure modules 512 - 514 as the modules are received from the server 401 . Stub replacement may require altering or rearranging the location of the remaining stubs or procedures within a code module or library as replacement code is received. Implementations may employ still other methods of integrating streamed code with executing applications and modules.
In some scenarios, removed code, such as procedure code 512 - 514 which, in the example given, was replaced by stubs 515 - 517 , may be required (called by another procedure) before it is streamed from the server 401 and integrated with the module 530 . In such a case, stub code 522 - 524 may access streaming functions in the streaming support library 535 to obtain the required procedure. To do so, the streaming support library 535 may send control data 415 to the server 401 to request the needed procedure. In response, the server 401 can halt the current module stream 405 and send the requested module. Upon receipt of the requested module, procedures in the streaming support library 535 may be used to integrate the received module with the application and to continue with the execution of the requested module. The server may thereafter determine a new module stream based on the requested module or other control data 415 that was received from the client.
Code modules may be reduced in size without the use of stub procedures. For example, referring again to FIGS. 4, 5 A, 5 B, and 5 E, in a interrupt driven implementation, procedure code 512 - 514 may be removed from a code library 510 and stored in a database 403 . Header information 511 as well as data indicating the size and location of removed procedure code 512 - 514 may then be transmitted to a client 410 . The client 410 may construct a new library 550 by appending a series of interrupt statements in place of the removed procedure code 512 - 514 . When the application 500 is executed, the code library 550 is substituted for the library 510 and execution of the program 500 may begin. As the program 500 executes, the removed procedure code 512 - 514 can be streamed to the client 410 and stored in a local database 411 . If the application 500 attempts to execute procedure code 512 - 514 it may instead execute one of the interrupt statement that have replaced procedure code 512 - 514 . The execution of the interrupt statement halts the execution of the program 500 and transfers control to a streaming executor program 416 .
Executor 416 implements interface technology similar to that of a conventional run-time object code debugger thereby allowing the executor 416 to intercept and process the interrupt generated by the application 500 . When the interrupt is intercepted by the executor 416 , data provided to the executor 416 as part of the client execution platform (operating system) interrupt handling functionality can be used to identify the module 550 in which the interrupt was executed and the address of the interrupt code within the module. The executor 416 then determines whether procedure code 512 - 514 associated with the interrupt location has been received as part of the module stream 415 sent to the client. If the appropriate procedure code has been received, the executor 515 replaces the identified interrupt with the its corresponding code. For example, procedures 512 - 514 may be segmented into 4 Kilobyte code modules that are streamed to the client 410 . When an interrupt statement is executed by the application 500 , the executor 416 intercepts the interrupt, determines an appropriate 4 Kilobyte code block that includes the interrupt statement, and replaces the determined code block with a received code module. If the appropriate code module has not yet been received, an explicit request may be sent from the client 410 to the server 401 to retrieve the code module prior to its insertion in the library 550 . The executor 416 may thereafter cause the application 500 to resume at the address of the encountered interrupt.
Implementations may also stream entire modules or libraries. For example, main code module 501 may be received from the server 401 and begin execution at the client 410 while code libraries 510 and 515 are streamed from the server 401 to the client 410 . Integration of streamed modules with executing modules may be provided by client 410 dynamic module linking facilities. For example, delay import loading provided by Microsoft Visual C++ 6.0 may be used to integrate streamed modules 510 and 515 with executing modules 501 . Dynamic linking of streamed modules may be facilitated by storing the streamed modules on a local hard disk drive or other storage location accessible by client 410 link loading facilities. In an exemplary implementation, streaming is facilitated by altering client 410 operating system link facilities such that the link facility can send control data 415 to the server 401 to request a particular module if the module is has not already been streamed to the client 401 .
In a protected-memory computer system, direct manipulation of executing application code and data may be restricted. In such systems, a “kernel” level processes or procedure may be required to support integration of streamed modules with executing application. In such a case, streaming support 535 may be pre-provisioned by installing support procedures at the client 410 prior to the client's request for the application 500 .
Other methods of determining stream sets may be used. In a list-based implementation, the streaming control file may include predetermined list of module streaming sequences. For example, the streaming control file 402 may include a module streaming sequence list associated with a first user and a second module streaming sequence list associated with a second user. Control data 415 sent from the client 410 to the server 401 may identify the current user at the client 410 . Once the user has been identified to the server, the server may stream software modules in accordance with the user's associated streaming sequence list. User-based streaming data may be advantageous where a user's past behavior can be used to anticipate the order of modules to be accessed by that user.
In graph-based streaming control file implementations, the weight of edges connecting nodes may be determined statically or dynamically and may be determined based on a collection of historical usage data. For example, in a programmer-controlled implementation, a software programmer estimate the likelihood that particular transitions between nodes will occur based on the programmer's knowledge of the software code and the expected application usage patterns. Alternatively, application profiling programs may be used to gather run-time execution data recording transitions between various applets, Classes or code modules and thereby determine the likelihood that particular transitions will occur. In a client-feedback implementation, control data 415 sent from the client 410 to the server 401 during module execution is used to build a statistical database of module usage and, based on that database, determine the module streaming order.
In a client-controlled streaming implementation, streaming control data 402 may be located at the client 410 and control data 415 sent from the client 410 to the server 401 may be used to sequentially request a stream of modules from the server. For example, while the client computer 410 is executing a first module, a background process may send control data 415 to a server to request additional modules that can be buffered on a hard disk 411 at the client computer 410 . A client-controlled streaming implementation may used existing HTTP servers and HTTP protocols to send request from the client 410 to the server 401 and send software modules from the server 401 to the client 410 . Furthermore, although streaming of software modules has been emphasized in the foregoing description, non-executable data, such as hypertext markup language, binary graphic files, and text, may be streamed as a collection of modules.
Implementations may include a “handshaking” procedure whereby, at the start of application execution, control data 415 is sent between the server 401 and the client 410 . The handshaking data may include an inventory of application modules residing at the client and at the server. Such handshaking data allows both the client 410 and server 401 to determine their respective software module inventory and to optimize the stream of software modules based on that inventory information.
In a history-dependent implementation, a server or client can store data about a series of transitions between modules and calculate a new module stream based on a history of transitions. For example, referring to FIG. 3, if the module “G” was reached by the path A-B-G, then a server or client may determine that module “E” followed by “H” is to be streamed. On the other hand, if the module “G” was reached by the path A-B-C-G then the streaming sequence may include only the module “H.”
The invention may be implemented in computer hardware, firmware, software, digital electronic circuitry or in combinations of them. Apparatus of the invention may be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention may be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output.
The invention may advantageously be implemented in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program may be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language may be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory.
Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing may be supplemented by, or incorporated in, specially-designed ASICs (application-specific integrated circuits). | Computer-implemented methods of transmitting modules between a first computer and a second computer are disclosed. At the first computer, a module set is formed by selecting a sequence of modules from a collection of available modules. Each of the selected modules are associated with an application executing at the second computer. The selected modules may then be transparently streamed from the first computer to the second computer. The selection of modules is made in accordance with predetermined selection criteria and is independent of the second computer's execution environment. At the second computer, received modules may be integrated with the executing application.
Systems for transmitting modules between a first computer and a second computer are also featured. The disclosed systems include a first computer and a second computer. The first computer includes means for executing an application, means for receiving a sequence of modules associated with the application while the application is executing, and means for integrating a first module in the received sequence with the application. The second computer includes means for storing a collection of modules associated with the application, means for selecting a sequence of modules from the collection, and means for transferring the selected sequences from the first computer to the second computer. | 7 |
This application claims the benefit of priority to U.S. Provisional Application No. 61/569,929 filed on Dec. 13, 2011.
FIELD OF THE INVENTION
The present invention related generally to firearms and, more particularly, to a device, system, and method for an adjustable gas block with variable gas port dimensions that replaces the conventional gas block to control the amount of gas in the gas block before the gas enters into the gas system of a gas operated firearm.
BACKGROUND AND PRIOR ART
AR-15 rifles and similarly styled firearms have become a best-selling category of sporting firearms. The main mechanism of operation for the rifle utilizes a gas tube which can be seen by prior art patent by Eugene Stoner U.S. Pat. No. 2,951,424. Which is referred to as the Stoner gas system hereinafter. The Stoner gas system routes gas from a port in the barrel directly to a chamber formed in the bolt carrier. The bolt acts as the piston and is sealed with gas rings.
As the bullet is accelerating rapidly down the bore, it passes the gas port and gas begins to flow into the gas block where it is directed toward the bolt carrier via the gas tube. The pressure is high in the barrel, usually 15,000 psi depending on barrel length until the bullet leaves the muzzle. Typically a firearm gas block is a solid piece of metal that goes over the gas port of a barrel to capture the propellant gas to direct that gas to a gas tube or piston. A problem can occur when the gas pressure is too high or too low.
The AR15/M16/AR10 is a gas operated firearm which uses some of the propellant gases in its normal operation and that gas is expelled through a gas port in the barrel and either goes through a gas tube which ultimately dumps the gas in a chamber known as the bolt carrier which is the Stoner gas system; or is used to propel a piston which pushes an op-rod that impacts the bolt carrier known as ‘piston’ operated firearm.
In either case, when a sound suppressor is used, it creates a great amount of backpressure which has the following adverse affects.
1. Increased fouling which in turn decreases the reliability
2. Increased cyclic rate of fire
3. With the increased rate of fire, it makes it difficult for operators to control the firearm since it is different from what they are used to.
4. Increased cyclic rate also increases parts wear
5. The backpressure leaks gas through the back of the receiver which ends up in the operator's eyes making it more difficult to focus on the target
To solve the problems with the prior art, the Govnah gas regulation system addresses the adverse effects. The Govnah regulated gas block is initially comprised of three different variants. The first variant (v 1 ) uses a sliding block that is configurable to allow the operator to choose from two different positions. One position for a suppressor attached to the barrel and the other position when a suppressor is not used. The second variant (v 2 ) also uses a sliding block but has a third, middle position to completely disable the gas system which then requires the user to manually cycle the action. The ‘no gas port’ position can be used to eliminate any fouling from entering the firearm via the gas tube when a 22LR conversion kit is used. The third position can also have a larger than normal port size to allow more gas into the system for adverse conditions. The third variant (v 3 ) uses a circular block for multiple positions of varying port dimensions, including no port, to allow the user to regulate the amount of gas entering the system to compensate for any changing variables that affect the cycling of the gas operated host firearm.
Known prior art patents include U.S. Pat. No. 7,856,917 issued to Noveske and U.S. Pat. No. 7,921,760 issued to Tankersley. Noveske discloses an adjustable gas block designed to interface with an autoloading firearms gas system and has three positions of adjustment that are selected if a silencer is in use, not in use, or if the user desires to stop the autoloading function of the firearm entirely. This design works by restricting the flow of gas from the gas port in the barrel and does not vent excess gas into the atmosphere around the gas block.
The above device uses a rotating drum with two openings in the drum and a gas port to control the amount of gas that enters into the gas tube which are all pre-determined by the factory. The Govnah uses a sliding or rotating block which can be swapped out by the end user to meet the user's requirements. While the Govnah uses standard military specification gas tubes, the Noveske device uses a proprietary straight gas tube and as a result is elevated higher. In result, the Noveske device will not fit under a rail system. While the Noveske device can by adjusted by hand, this is not ideal when it is hot. It requires a special tool or gloves to adjust safely when hot. The Govnah can be adjusted by any device that can push the adjustment plate, ideally a bullet.
There are applications and benefits for each of the two devices which include providing users with two (v 1 ), three (v 2 ) or multiple (v 3 ) positions for gas regulation on the AR15/M16/AR10 platform using unmodified standard gas tubes; they do not require special tools to adjust the position; they reduce logistic issues in regards to parts availability since they work with standard gas tubes; and they work with drop in ‘piston’ operated conversion kits that are on the market such as the Ares Defense GXR-35 and Osprey Defense OPS-416. Neither of which have a built in mechanisms to manually select the gas intake of the respective systems.
The Govnah regulated gas block (v 1 and v 2 ) is low profile which allows it to fit under a rail system and still be accessible for adjustment using the tip of a bullet or other small diameter object to select the gas setting. Since the Govnah regulated gas block fits under a rail system, the design itself is protected by the rail system to prevent any damage or inadvertent changing of the gas setting. The Govnah also uses a symmetrical moving block which controls the gas. Since it is symmetrical, it can be installed two different ways. This allows the user to decide which direction they prefer to have the adjustment plate set.
The Govnah (v 3 ) provides users with a regulated gas block that can quickly adjust to multiple known port diameters to change the amount of gas that is entering the host firearm's gas system without disassembly or special tools. This feature is useful when the user changes any variable that affects the functioning of the gas operated host firearm such as different buffers, sound suppressors, ammunition or springs.
The Govnah also incorporates an alignment hole for installation into the gas block body itself while prior art U.S. Pat. No. 7,921,760 accomplishes this with a separate installation device which requires dimpling the barrel to maintain alignment once the actual gas block is installed. The Govnah doesn't require dimpling since alignment is performed with the actual gas block body not a separate installation device.
What is needed to solve the problem with the prior art gas block is an adjustable gas port assembly that functions as a gas regulator for AR-15 rifles and similarly styled firearms. The present invention uses an adjustable gas block with variable gas port dimensions to control the amount of gas in the gas block before the gas enters into the gas tube or piston.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide methods, systems and devices for an adjustable gas block with variable gas port dimensions that replaces the conventional gas block to control the amount of gas in the gas block before the gas enters into the gas tube of a gas operated firearm.
A secondary objective of the present invention is to provide methods, systems and devices for an adjustable gas block for the AR15/M16/AR10 family of firearms, but is not limited to only that family and can be used for virtually any firearm that is gas operated.
A third objective of the present invention is to provide methods, systems and devices for an adjustable gas block with a sliding adjustment plate with different adjustment plate gas ports to slide one of the different gas ports into alignment with the adjustable gas block gas port and the barrel gas port.
A fourth objective of the present invention is to provide methods, systems and devices for an adjustable gas block with an alignment hole in the gas tube bore can be used to align the adjustable gas block gas port with the barrel gas port.
A fifth objective of the present invention is to provide methods, systems and devices for an adjustable gas block which utilizes a standard un modified gas tube and barrel.
A sixth objective of the present invention is to provide methods, systems and devices for an adjustable gas block which requires no special tools to change the adjustment. Use the tip of a bullet or other small diameter object.
A seventh objective of the present invention is to provide methods, systems and devices for an adjustable gas block which can fit under a rail system and can still be adjusted with no special tools
An eighth objective of the present invention is to provide methods, systems and devices to extend the service life of a barrel when the gas port has been eroded.
A ninth objective of the present invention is to provide methods, systems and devices that gives the operator the option to allow excess gas into the firearm for adverse conditions.
A tenth objective of the present invention is to provide methods, systems and devices that have a modular regulation mechanism in this case the regulator plate. The regulator plate can be swapped out by the end user for varying conditions or for replacement due to wear.
A first preferred embodiment provides adjustable gas block assembly that includes an adjustable gas block having a gas block barrel bore to slide the adjustable gas block over a barrel of a firearm and a gas tube bore to mate with the gas tube of the firearm. The adjustable gas block includes a gas port in the adjustable gas block between the barrel bore and the gas tube bore, a sliding adjustment plate having two or more different adjustment plate gas ports movably positioned between the adjustable gas block barrel bore and the gas tube bore in the gas block to slide one of the two or more different adjustment plate gas ports into alignment with a gas port between the barrel bore and the gas tube bore and the barrel gas port, a spring assembly to hold a selected one of the two or more different adjustment plate gas ports in the sliding adjustment plate in alignment with a barrel gas port, and set screws for attaching the adjustable gas block to the barrel of the firearm.
The adjustable gas block can include an alignment hole in the top of the gas tube bore in alignment with the gas port in the adjustable gas block and the barrel gas port.
The sliding adjustment plate includes a first adjustment plate gas port and a second adjustment plate gas port that is larger in diameter than the first adjustment plate gas port and can alternatively include a third adjustment plate gas port that is larger in diameter (or no port) than the second adjustment plate gas port. The sliding adjustment plate can include one or more adjustment plate baffles in a top side of the sliding adjustment plate to capture a gas escaping from the space between the adjustment gas plate and the gas tube bore. The adjustable gas block can include adjustable gas block baffles parallel to the one or more adjustment plate baffles in the adjustable gas block below the sliding adjustment plate. The spring assembly includes detent dimples in one side of the sliding adjustment plate each aligned with one of the two or more adjustment plate gas ports, a detent pin to mate with the adjustment plate detent dimples and a detent pin spring to releasably secure the detent pin in the adjustment plate detent dimple until a force is applied to move the sliding adjustment plate between two or more positions.
A second preferred embodiment provides a method to control the amount of gas in the gas block before the gas enters into a gas tube or piston that includes removing a prior art gas block from a firearm that uses gas operation, sliding an adjustable gas block with a barrel bore and a gas tube bore onto a barrel of the firearm, securing the adjustable gas block with two or more set screws in the base of the adjustable gas block, and sliding an adjustment plate to align one of two or more different diameter gas ports with a gas tube port.
A third embodiment provides an adjustable gas block that includes a body with a gas block barrel bore to slide the adjustable gas block over a barrel of a firearm and a gas tube bore to mate with the gas tube of the firearm, a gas port in the adjustable gas block between the barrel bore and the gas tube bore, a sliding adjustment plate with two or more different diameter gas ports movably positioned to slide one of the two or more different adjustment plate gas ports into alignment with the adjustable gas block gas port and the barrel gas port, and a spring assembly to hold a selected one of the different adjustment plate gas ports in alignment with a barrel gas port, threaded holes in a bottom of the adjustable gas block to accept set screws to attach the adjustable gas block to the barrel of the firearm.
Further objects and advantages of this invention will be apparent from the following detailed description of preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a top perspective view of rifle with prior art gas block installation.
FIG. 2 shows a section detail of prior art gas block installation of FIG. 1 .
FIG. 3 is a top perspective view of a rifle with new adjustable gas block installation according to the present invention.
FIG. 4 is a section detail of new adjustable gas block installation of FIG. 3 .
FIG. 5 is a side view of a prior art gas block of FIG. 1 .
FIG. 6 is a rear view of the prior art gas block of FIG. 1 .
FIG. 7 is a bottom view of the prior art gas block of FIG. 1 .
FIG. 8 is a right perspective view of the prior art gas block of FIG. 1 .
FIG. 9 is a left perspective view of the prior art gas block of FIG. 1 .
FIG. 10 is a side view of an adjustable gas block shown in FIG. 3 .
FIG. 11 is a front view of the adjustable gas block shown in FIG. 3 .
FIG. 12 is a rear view of the adjustable gas block shown in FIG. 3 .
FIG. 13 is a top view of the adjustable gas block shown in FIG. 3 .
FIG. 14 is a bottom view of the adjustable gas block shown in FIG. 3 .
FIG. 15 is a left perspective view of the adjustable gas block shown in FIG. 3 .
FIG. 16 is a right perspective view with section lines (also see FIGS. 19-22 & 31 - 35 ).
FIG. 17 is a top exploded perspective view of a 2 position embodiment.
FIG. 18 is a bottom exploded perspective view of the 2 position embodiment.
FIG. 19 is a top sectioned perspective showing 2 position adjustment plate lifted to expose the gas port.
FIG. 20 is a sectioned perspective showing small hole in adjustment plate aligning with gas block gas port. Detent pin is shown seated into an adjacent detent dimple.
FIG. 21 is a sectioned perspective showing adjustment plate in transition between its two positions. Detent pin showing sliding on surface between the detent dimples.
FIG. 22 is a left sectioned perspective showing large hole in adjustment plate aligning with gas block gas port. Detent pin is shown seated into adjacent detent dimple.
FIG. 23 is a top view of the 2 position adjustment plate.
FIG. 24 is a front view of the 2 position adjustment plate.
FIG. 25 is a rear view of the 2 position adjustment plate.
FIG. 26 is a side view of the 2 position adjustment plate.
FIG. 27 is a bottom perspective view of the 2 position adjustment plate.
FIG. 28 is a top perspective view of the 2 position adjustment plate.
FIG. 29 is a top exploded perspective view of 3 position embodiment.
FIG. 30 is a bottom exploded perspective view.
FIG. 31 is a top sectioned perspective showing 3 positions adjustable plate lifted to expose gas port.
FIG. 32 is a sectioned perspective showing small-sized hole aligned with gas block gas port. Detent pin is shown seated in adjacent detent dimple.
FIG. 33 is a sectioned perspective showing adjustment plate in transition between positions. Detent pin showing sliding on surface between the detent dimples.
FIG. 34 is a sectioned perspective showing large hole aligned with gas block gas port. Detent pin is shown seated in adjacent detent dimple.
FIG. 35 is a sectioned perspective showing mid hole aligned with gas block gas port. Detent pin is shown seated in adjacent detent dimple.
FIG. 36 is a top view of 3 position adjustment plate.
FIG. 37 is a rear view of 3 position adjustment plate.
FIG. 38 is a front view of 3 position adjustment plate.
FIG. 39 is a side view of 3 position adjustment plate.
FIG. 40 is a bottom perspective of 3 position adjustment plate.
FIG. 41 is a top perspective of 3 position adjustment plate.
FIG. 42 is a section detail of new adjustable gas block installation onto rifle barrel. Block ready to slide onto barrel
FIG. 43 shows the block slid over barrel ready to align block gas port to barrel port. Alignment pin positioned for alignment. Set screws in gas block shown backed off.
FIG. 44 shows the alignment pin shown penetrating block and barrel establishing alignment of gas ports. Set screws in gas block shown tightened.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
The following is a list of reference numerals used in the description and the drawings to identify components:
10 Rifle (Prior Art) 20 Rifle barrel (Prior Art) 30 Gas tube (Prior Art) 40 Bullet (Prior Art) 50 Gas Block (Prior Art) 60 Gas port in barrel (Prior Art) 70 Gas port in block (Prior Art) 80 Gas tube bore in block (Prior Art) 90 Gas port in gas tube (Prior Art) 100 Set screws secure block to barrel 110 New adjustable gas port assembly 120 Sliding adjustment plate (2 position) 130 Detent pin 140 Detent pin spring 150 Adjustment plate gas port 160 Adjustable gas block 170 Gas block barrel bore (Prior Art) 180 Adjustable gas block barrel bore 190 Sliding adjustment plate (3 position) 200 Adjustment block alignment hole 210 Gas trap baffles on adjustment plate 220 Detent dimples 230 Gas trap baffles on gas block 240 Gas port in adjustment gas block 250 New adjustable gas port assembly (3 positions) 270 Rifle bore 280 Alignment pin 290 Bullet fired from rifle pressurizes bore 300 Pressure travels through gas port and gas tube to operate gas actuated rifle mechanisms.
FIG. 1 is a top perspective view of rifle 10 with prior art gas block installation showing the rifle barrel 20 , the gas tube 30 and gas block 50 . FIG. 2 shows a section detail of prior art gas block installation showing the barrel 20 , the rifle bore and a bullet 40 fired from the rifle pressurized bore 290 . Also shown is the prior art gas block 50 and the gas block barrel bore 170 that is secured to the barrel with set screws 100 .
The main mechanism of operation for the rifle is the Stoner gas system. Gas in the barrel 20 is trapped as the bullet 40 moves past a gas port 70 located above the rifle's front sight base. As shown, the gas port includes the gas port in the barrel 60 , the gas port in the block 70 and the gas port in the gas tube. The gas rushes into the gas ports in the barrel and the block 60 and 70 , through the gas port 90 and down the gas tube 30 . Here, the gas tube 30 protrudes into a “gas key” (not shown) which accepts the gas and funnels it into the bolt carrier. The bolt unlocks when enough gas pressure is generated.
FIG. 3 is a top perspective view of a rifle 10 with an adjustable gas block 110 installation according to the present invention. FIG. 4 is a section detail of new adjustable gas block assembly 110 installed on a rifle. The adjustable gas block 160 is installed by sliding the adjustable gas block onto the barrel and attaching the adjustable gas block to the rifle barrel 20 with set screws 100 . As shown, the assembly includes a gas block barrel bore 180 , a gas tube bore 80 in the gas block 160 and a sliding adjustment plate 150 between the barrel bore and gas tube bore. The gas port 70 in the adjustable gas block 160 is aligned with the barrel gas port 60 , both of which are aligned to feed into the gas tube gas port 90 .
Referring back to the prior art gas block installation shown in FIG. 1 , details of the gas block are show in FIG. 5-9 which show a side view, rear view, bottom view, right perspective view and left perspective view, respectively, of the prior art gas block. The right view in FIG. 8 shows gas block barrel bore 170 . Rear view shown in FIG. 6 shows both the gas block barrel bore and the gas tube bore 80 . The bottom view of FIG. 7 shows the set screws 100 that secure the gas block 50 to the rifle barrel 20 . Looking into the gas block barrel bore 170 in FIG. 9 shows the gas tube bore 70 in the gas block.
In contrast, FIGS. 10-14 show details of the adjustable gas block according to the present invention. FIGS. 10 and 13 show adjustable gas block assembly 110 showing the sliding adjustment plate 120 and detent pin spring 140 in the adjustable gas block 160 . The front view of the adjustable gas block shown in FIG. 11 shows the positional sliding adjustment plate 120 and the detent spring in relation to the barrel bore 180 while the back view shown in FIG. 12 shows the relational position with the gas tube bore 80 in the adjustable gas block 160 . Similar to the prior art, the adjustable gas block is attached to the barrel with set screws 100 as shown in FIG. 14 .
FIGS. 15 and 16 are left and right perspective views, respectively, of the adjustable gas port assembly 110 showing the adjustable gas block 160 , the sliding adjustment plate 120 , the adjustment block alignment hole 200 , and the adjustment gas block barrel bore 180 . Unlike the prior art gas blocks, in a preferred embodiment of the present invention the adjustable gas block 160 includes adjustment block alignment hole 200 in the gas tube. With the prior art gas blocks, it is common for the gas block to be mis-aligned with the barrel's gas port. Some users don't realize that you can install a gas tube after installing the gas block.
After the adjustable gas block 160 is mounted on the barrel 20 without the gas tube 30 installed, prior to tightening the set screws 100 , the user inserts a drill rod or gauge pin into the alignment hole 200 to make sure the drill rod or gauge pin goes all the way into the barrel's gas port 60 to ensure that there is no alignment issue. After confirming alignment, the set screws are tightened and the gas tube 30 is installed by inserting the gas tube into the upper receiver upside down, rotating the gas tube 180 degrees then inserting the gas tube into the adjustable gas block 160 and inserting the gas tube roll pin. FIG. 16 also includes section lines relating to FIGS. 19-22 and 31 - 35 .
Another novel feature is the location of the mounting set screws 100 that secure the adjustable gas block 160 to the rifle barrel 20 . The mounting set screws 100 are shifted approximately one-half inch forward toward the muzzle to avoid misalignment of the gas port 60 in the barrel. The placement of the set screw addresses a common problem associated with the prior art replacement gas ports that have the same set screw locations. For example, alignment of the Govnah regulator is critical to proper operation. To prevent mis-alignment, the mounting location of the set screws in the present invention have been moved so the set screws are not inserted into any pre-existing grooves on a barrel, if any are present.
FIGS. 17 and 18 are top and bottom, respectively, exploded perspective views of a 2 position embodiment of the present invention showing the sliding adjustment plate 120 with two different size adjustment plate gas ports 150 and the adjustable gas block alignment hole 200 . The sliding adjustment plate 120 is firmly held in place by the detent pin 130 and detent pin spring 140 . The sliding adjustment plate 120 has two detent dimples configured to mate with the rounded end of the detent pin. The detent spring 140 applies sufficient force to hold the sliding adjustment plate 120 in place when the pin 130 is in the sliding adjustment plate dimple 220 . Since the sliding plate dimples 220 are rounded, when the user applies a force to change the position of the sliding adjustment plate 150 , the detent pin 130 is dislodged to allow the sliding adjustment plate 120 to move. The sliding adjustment plate 120 moves until the detent pin 130 is seated in the other sliding adjustment plate dimple 220 aligning the other adjustment plate gas port 150 with the gas port 240 in the gas block and the barrel gas port.
Details of the sliding adjustment plate 120 are shown in FIGS. 19 and 20 which show a top sectioned perspective showing the 2 position adjustment plate 120 lifted to expose gas port 240 in the gas block 160 and a sectioned perspective showing the small gas port in adjustment plate aligned (dashed line) with the gas block gas port 240 . The detent pin 130 is shown seated in an adjacent detent dimple 220 . The detent pin 130 is located in a trough in the adjustable gas block 160 parallel with the barrel of the firearm and the detent pin is configured to hold the detent pin 130 securely in the trough to prevent the detent pin 130 from moving sideways when the sliding adjustment plate 120 slides between the two different gas port 150 positions. The detent pin 130 has a notch cut into it so that the detent spring 140 can pull the detent pin back so the regulator can be removed without tools. The detent spring 140 can also be used to aid in removing the detent pin 130 from the gas block body.
FIG. 20 shows the sliding adjustment plate 120 in a first position and extending outwardly from the left side of the gas block 160 , FIG. 21 shows the sliding adjustment plate 120 between the two different adjustment plate gas ports 150 , and FIG. 22 shows the sliding adjustment plate 120 in the second position and extending outwardly from the right side of the gas block 160 . As shown, the sliding adjustment plate 120 has right and left sides that extend rearwardly as stops to prevent the sliding adjustment plate 120 from being unintentionally removed from the adjustable gas block 160 .
Another feature of the adjustable gas block of the present invention are the gas trap baffles 230 on the adjustable gas block 160 shown in FIG. 19 and the gas trap baffles 210 shown in FIG. 20 on the sliding adjustment plate 120 . FIGS. 23-28 show 6 different views of the sliding adjustment plate 120 . Due to the nature of the design, there can be some clearance between the regulator and the adjustable gas block 160 . Some gas does leak out of this clearance although amount of leakage is marginal; the design reduces that leakage or delays it as much as possible.
The sliding regulator plate 120 has grooves as gas trap baffles 210 cut along each side of the gas ports 150 and between the two gas ports. As gas passes over the gas trap baffles 210 , turbulence is created which creates a gas trap between the adjustable gas block 50 and the top of the sliding adjustment plate 120 . Likewise, gas trap baffles 230 are cut into the top of the adjustable gas block 160 at the entrance of each side of the regulator openings. This creates a gas trap between the gas block 160 and the bottom of the sliding adjustment plate 120 . In another embodiment, a small hole can be machined at an angle at the bottom of the plate which would serve to jet gas into the gas trap baffles on the adjustable gas block.
FIG. 23 is a top view of the 2 position adjustment plate showing the two different gas ports 150 , three parallel gas trap baffles 210 , the two detent dimples 220 and the extended sides that act as a stop to prevent the adjustment plate 120 from being unintentionally removed. FIG. 23 also shows the alignment of each adjustment gas port 150 with the detent dimples 220 . FIG. 24 is a front view of the 2 position adjustment plate 120 and FIG. 25 is a rear view of the 2 position adjustment plate 120 showing that the adjustment plate gas baffles 210 extending the length of the sliding adjustment plate 120 with the two detent dimples 220 located between the gas trap baffles 210 . FIG. 26 is a side view of the 2 position sliding adjustment plate and FIGS. 27 and 28 are bottom and top perspective views, respectively, of the 2 position sliding adjustment plate 120 .
A second embodiment provides a 3 position sliding adjustment plate 190 . FIGS. 29 and 30 are top and bottom, respectively, exploded perspective views of the three position embodiment. FIG. 31 is a top sectioned perspective view showing the 3 position sliding adjustment plate 190 lifted to expose gas port 240 in the adjustable gas block 160 . FIGS. 36-41 show different views of the 3 position sliding adjustment plate 190 . FIG. 36 is a top view of the 3 position sliding adjustment plate 190 and FIGS. 37 and 38 are rear and front, respectively, views of the 3 position sliding adjustment plate 190 . As shown, the sliding adjustment plate 190 can have three gas ports 150 each of a different diameter, although the sliding adjustment plate can include a different number of gas ports such as the two gas port example previously shown and described or a three position adjustment plate with two gas ports separated by a position without a gas port, effectively blocking the gas in the barrel from escaping into the gas tube.
The 3 position sliding adjustment plate 190 also includes a fourth gas trap baffle 210 to capture any gas escaping from between the sliding adjustment plate 190 and the top of the adjustable gas block 160 . The detent pin 130 and spring 140 are the same configuration and serve the same function as described for the 2 position embodiment.
FIG. 32 is a sectioned perspective view showing a small-sized adjustment plate gas port 150 aligned with gas block gas port 240 with the detent pin 130 shown seated in detent dimple 220 aligned with the small sized adjustment plate gas port 150 . In FIG. 33 the sliding adjustment plate 190 is shown in transition between positions as the detent pin 130 slides on the surface between two adjacent detent dimples 220 . As the user continues to apply pressure to move the sliding adjustment plate 190 , the detent pin 130 is seated in the next adjacent detent dimple 220 with the larger of the three gas ports 150 aligned with the gas port 240 in the adjustable gas block 160 as shown in FIG. 34 . FIG. 35 is a sectioned perspective showing mid hole aligned with gas block gas port. Detent pin 130 is shown seated in adjacent detent dimple 220 .
While the three gas ports are shown and described with a larger one of the gas ports in the center, the configuration is for example only and those skilled in the art will understand that the different diameter gas ports could be configured, for example, with the smallest gas port in the center position. Alternatively, the center position could not include a gas port, effectively blocking the gas discharge from the barrel from escaping into the gas tube via the adjustable gas block.
FIG. 42 is a section detail of new adjustable gas block assembly 110 / 240 installation onto rifle barrel 20 with the adjustable gas block 160 ready to slide onto barrel 20 in the direction shown by the arrows. FIG. 43 shows the adjustable gas block 160 slid over barrel 20 ready to align the block gas port 240 to the gas port 60 in the barrel with an alignment pin 280 positioned for alignment. The set screws in gas block are shown backed off so that the adjustable gas block 160 can be rotated and moved to align the two gas ports. FIG. 44 shows the alignment pin 280 penetrating the adjustable gas block 160 and barrel 20 establishing alignment of gas ports. With the gas ports aligned, the set screws in gas block are tightened as shown in FIG. 44 .
In an alternative embodiment, the sliding adjustment plate is replaced with a dial. The dial uses a rotating adjustment disc in place of the sliding adjustment plate. The rotary adjustment plate is applicable for testing or use when conditions vary in terms of ammunition, springs and buffers and each can require a different diameter gas port. V 1 /V 2 options have fewer settings since increasing the number of settings adds complexity to a law enforcement officer or soldier. Military users typically have standard issue ammunition, springs and buffers so the rotary dial adjustment disc is not the ideal solution. Law enforcement is typically along those lines, but may not be as strict.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Methods, systems and devices for an adjustable gas block with variable gas port dimensions to control the amount of gas in the gas block before the gas enters into the gas tube. The adjustable gas block includes a gas block barrel bore to slide the block over a barrel and a gas tube bore to mate with the firearm gas tube, a gas port between the barrel bore and the gas tube bore, a sliding adjustment plate with different adjustment gas ports to slide one of the gas ports into alignment with the block gas port and the barrel gas port, and a spring to hold the sliding gas port in alignment with the barrel gas port. An alignment hole in the gas tube bore can align the block gas port with the barrel gas port. | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to a vehicle seat, particularly to an upper lid mechanism of the foot massage system for the vehicle seat.
BACKGROUND OF THE INVENTION
[0002] Nowadays, vehicles hare become one of the main tools for travel. But during a long-time travel, it makes the passengers feel muscle tension or soreness, especially on the feet of the passengers. However, the current soft vehicle seat cannot solve this problem. Although there exists portable massagers which can be put inside of a vehicle or a vehicle seat provided with massage function, their mechanism occupies the interior space of the vehicle which is already very small.
[0003] For example, DE 102007041504 describes a footrest behind a backrest and provided with a massage system. However, this document does not describe a mechanism which can provide a function of protection to the message units while provide a space for the foot massage.
SUMMARY OF THE INVENTION
[0004] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art described above. To this end, the present invention provides a vehicle seat comprising a foot massage system, which makes maximum use of the narrow space between the front and rear vehicle seats, wherein the foot massage system is provided with an upper lid mechanism, so as to enable a sufficient space for receiving foot while providing protection to the massage system and providing foot rest surface. Accordingly, it has the advantage of simple structure, good reliability, and it is easy to assembly, manufacture and use.
[0005] Furthermore, the present invention includes the following unique technical features.
[0006] Vehicle seat comprising a seat backrest provided with a foot massage system, and the seat backrest includes a front side and a rear side, the rear side receiving the foot massage system, said foot massage system configured to pivot around an axis that is fixed relative to the seat backrest between an in-use position, wherein the massage system, pivots down to receive passenger's feet, and a folded-away position wherein the massage system is retracted, characterized in that the massage system is provided with an upper lid mechanism configured to move between a closed position, where the upper lid mechanism covers the massages system so as to provide foot rest surface, and an open position where the upper lid mechanism transforms and opens up so as to form a foot accommodation space for foot massage.
[0007] In addition, the present invention further includes a combination of one or more of the following features.
[0008] Alternatively, the upper lid mechanism can further comprise an array of flat sections which are configured to pivot to each, and a set of torsion springs is amounted along the pivotal axis direction between every two flat sections so as to make the latter pivot towards each other; and an actuator connected to the array of flat sections so as to drive the latter to move between the closed position and the open position.
[0009] Alternatively, the upper lid mechanism can further include a foldable flat section, which is configured in the form of accordion when folded; and an actuator connected to the foldable flat section so as to drive the latter to move along the between the closed position and the open position.
[0010] Furthermore, the actuator is a motor and spring system so as to increase the degree of automation of the massage system.
[0011] Preferentially, the actuator can further include a damper cooperating with the spring, so as to make the array of flat sections move at uniform velocity for reducing the impulsion to the massage system and keeping the massage system with high stability.
[0012] Preferentially, the motor and spring system comprises torsion springs.
[0013] Preferentially, the actuator is a motor-driven actuator so as to increase the degree of automation of the massage system.
[0014] In addition, the upper lid mechanism can further comprise a foot sensor which is configured to detect the foot when in the open position so as to make the upper lid mechanism automatically move to the closed position when the foot is no longer in the foot accommodation space, so as to improve the personalised experience for passengers.
[0015] Compared with the prior art, the advantages of the present invention is the use of a sectional construction and torsion springs, which allows a well-controlled transformation (for avoiding interference with seat backrest) when the upper lid mechanism is opening up. When it is closed, the construction also enables to provide a firm support, i.e. foot rest surface.
BRIEF DESCRIPTION OF THE DRAWING
[0016] This invention is now described using an example for illustration only that in no way limits the scope of the invention, on the basis of the following drawings, in which:
[0017] FIG. 1 is the lateral view of the vehicle seat according to the invention;
[0018] FIG. 2 is a perspective view of the vehicle seat according to the invention, wherein the foot massage system of the first embodiment is in the folded-away position;
[0019] FIG. 3 is a perspective view of the vehicle seat according to the invention, wherein the foot massage system of the first embodiment is in the in-use position, and the upper lip mechanism of the foot massage system is in the closed position; and
[0020] FIG. 4 is a perspective view of the vehicle seat according to the invention, wherein the foot massage system of the first embodiment is in the in-use position, and the upper lip mechanism of the foot massage system is in the open position.
DESCRIPTION
[0021] By referring to the figures, the present invention is further described by the description of embodiments. In the figures, the same references are used to denote identical or similar items.
[0022] FIG. 1 shows a vehicle seat which comprises a seat cushion IS fixed on the frame of the vehicle and a seat backrest comprising a foot massage system 4 . The seat backrest rotates around an axis A-A′ relative to the seat cushion 18 .
[0023] As shown in FIGS. 2-4 , in the first embodiment of the invention, the seat backrest of the seat of the vehicle comprises a front side 2 and a rear side 3 , wherein the rear side 3 is configured for receiving a foot massage system 4 . One end of a fixed folding bracket 20 is fixed to the rear side 3 ; the other end of the fixed folding bracket 20 is hinged to the foot massage system 4 . The foot massage system 4 is driven by a hydraulic device or a pneumatic device or a similar device, so as to pivot around axis B-B′ between an in-use position and a folded-away position. When pivoting to the in-use position, the foot message system 4 rotates down from rear side 3 to receive passenger's feet. When pivoting to the folded-away position, the foot massage system 4 turns back to rear side 3 .
[0024] The foot massage system 4 further comprises an upper lip 1 , at least one extendible foot receiving space 7 , a massage assembly 30 comprising massage parts, for example electromagnetic massage elements, massage rollers or pneumatic massage elements, and a sensor assembly comprising at least one sensor for example a pressure sensor or a thermal sensor.
[0025] The upper lip mechanism 1 comprises an array of flat sections, and an actuator 40 connected to the array of flat sections by a support arm 31 and a support arm 32 , wherein the array of flat sections are provided with heatproof surfaces being made of, for example material like dustproof Nano-coating or dustproof coating with high surface density or, dustproof and scratch-proof coating with high surface hardness. The extendible foot receiving space 7 comprises thin plastic or expandable fixed units for holding passenger's feet,
[0026] When the passenger presses the starting button on the rear seat (not shown) the front seat moves a certain distance towards a direction away from the passenger sitting on the rear seat via seat rails controlled by control units, so as to leave more space for the passenger sitting on the rear seat. Then, the foot massage system 4 assembled in rear side 3 of the front seat slowly pivots around axis B-B′ from toe folded-away position to the in-use position via a device, such as a hydraulic device or a pneumatic device or an electric driving device or similar devices. The passenger thus can put his feet wearing with shoes onto the upper lid mechanism 1 provided with dustproof surface in its closed position, so that he can adjust his sitting posture or relax leg muscles.
[0027] When the upper lid mechanism 1 is in the closed position, a large flat section 11 and an array of flat sections 12 , 13 , 14 , 15 (the array of flat sections of the invention are not limited to 4 pieces, the number of pieces can be freely determined according to the vehicle type and customer's needs) are arranged as a plane which substantially covers the whole foot massage portion 30 . The adjacent two flat sections of large flat section 11 and the array of flat sections 12 , 13 , 14 , 15 are rotatablely connected to each other one by one through hinge devices or similar connecting devices. Accordingly, there is a set of torsion springs amounted along the pivotal axis direction between every two flat sections, so as to allow the two flat sections pivot towards each other to close up without any external torsion on the direction of rotation. Further, a small gap is between every two adjacent flat sections, so that their pivot won't lead to interference. Each edge of the flat sections has a thickness and presents a circular arc, wherein the circular arcs of the adjacent flat sections cooperate with each other which provides an arc transition. It is useful to further avoid the interference which may occur when the two adjacent flat sections pivot. Also due to the circular arc, it is easier to clean the dust dropping in the small gap.
[0028] When the passenger uses foot massage, he can take back his feet and then press the massage button, so as to trigger the upper lid mechanism 1 to automatically open up via electric circuits. During the process of the movement of the upper lid mechanism expanding from its closed position to its open position, the actuator 40 fixed in the massage system 4 pushes the support arm 31 (alternatively the support arm 32 ) to pivot around axis c-c′, so as to elevate the large flat section 11 connecting with it, and therefore to drive the support arm 32 (alternatively the support arm 31 ) to pivot around axis d-d′ along a guide path from an original position to a fixed supporting position, so that the support arms 31 and 32 form a stable support for the upper lid mechanism 1 and thus form a foot receiving space 7 . Preferably, the support arms 31 and 32 and the actuator 40 are arranged in a line. Actuator 40 can be a motor or a spring system and may comprise a bumper cooperating to the spring, so as to allow smooth movement and low noise.
[0029] When the upper lid mechanism 1 is expanded, the movement of large flat section 11 drives the array of flat sections connected with it to move towards the seat backrest. After she array of flat sections 12 , 13 , 14 , and 15 cross over the fixed folding bracket 20 , they tilt down by the sets of torsion springs amounted on each hinge axis, and are curled through the space between the foot massage system 4 and the rear side 3 of the seat backrest, and thus keep a distance with the seat backrest. Therefore, the array of flat sections will not interfere with the rear side of the seat, which thus prevents the rear side of the seat from being damaged due to friction, and prevents the possibility of flat sections being stuck. Alternatively, the array of flat sections can tilt according to at least one guide track for guiding them along a fixed track. The fixed track can also ensure that no interference between the arrays of flat sections and the seat backrest will happen during the progress.
[0030] After the upper lid mechanism 1 is completely expanded, at least one extendible foot receiving space 7 is formed, as shown in FIG. 4 . The foot receiving space 7 has an open space with several openings. Thus, it is easy for the passenger to put his feet into the extendible foot receiving space 7 and take his feet out of the receiving space 7 especially in emergency.
[0031] When the upper lid mechanism 1 is completely in the open position, the actuator 40 stops working and correspondingly the support arms 31 and 32 visa stop pivoting. The whole upper lid mechanism 1 is in a static and stable state. Then, the passenger can put his feet into the foot receiving space 7 for massage.
[0032] After the passenger finishes the foot message, he can press the massage button to stop the massage function, then take his feet away from the foot receiving space 7 and leave away from the foot massage system 4 in the working position. Then the actuator 40 starts an inverse operation, drive the support arm 31 (alternatively the support arm 32 ) inversely pivot back to the original position, so as to drive the whole upper lid mechanism 1 back to the closed position and further drive the support arm 32 (alternatively the support arm 31 ) back to the original position. In this case, the upper lid mechanism 1 returns to the original flat position (as shown in FIG. 3 ) i.e. the closed position indirectly by the actuator 40 . In the end, the foot massage system 4 pivots back to rear side 3 .
[0033] In addition, if a passenger forgets to press the button to drive the foot massage system 4 back to the rear side 3 of the seat backrest after finishing massage, as long as the sensor no longer senses any foot on the foot receiving space 7 for a period of time, the actuator 40 will automatically start the inverse operation to drive the support arm 31 (alternatively the support arm 32 ) inversely pivot back to the original position. Accordingly, the whole upper rid mechanism 1 is driven back to the closed position and further the support arm 32 (alternatively support arm 31 ) is driven back to the original position. Then, the foot massage system 4 pivots around axis B-B′ and turns hack to the rear side 3 . In the end, the front seat translates back to the original position, via the seat rails controlled by control units.
[0034] Alternatively, in the second embodiment of the invention, the upper lid mechanism 1 has a foldable flat section. Compared with the first embodiment, the difference is that the foldable flat section is one piece in the closed position rather than the array of flat sections connected by hinges and torsion springs. During the process of the upper lid mechanism 1 expanding from the closed position to the open position, the foldable flat section presents the form of accordion which can fold towards the seat backrest with the large flat section 11 by the actuator 40 .
[0035] Alternatively, in the third embodiment of the invention, the upper lid mechanism 1 has overlapping flat sections of which the construct is similar to a matryoshka shape (a series of section with similar shape but with diminishing size). During the process of the upper lid mechanism 1 expanding from the closed position to the open position, the overlapping flat sections successively overlaps into the largest one with large flat section 11 by the actuator 40 .
[0036] It should be noted that, the embodiments mentioned above are used as examples and cannot be construed as limiting the scope of the invention. On the basic of this, a man skilled in the art could expect other embodiments having the same function within the scope of protection of the application. | The invention, relates to vehicle seat, comprising an upper lid mechanism configured to move between a closed position, where the upper lid mechanism covers the messages system so as to provide foot rest surface, and an open position where the upper lid mechanism transforms and opens up so as to form a foot accommodation space for foot massage. The upper lid mechanism comprises an array of flat sections, and an actuator. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquid transfusion apparatus adapted to forcibly transfusing a transfusion liquid by a pressure generated by a pump or the like.
2. Description of the Related Art
In general, a liquid transfusion apparatus which forcibly feeds a transfusion liquid by a pressure offers advantages over gravity type of liquid transfusion apparatus, such as greater degree of freedom of control of the flow rate of the liquid to be transfused, higher stability of the flow rate, and so forth. When this type of liquid transfusion apparatus is used for transfusion treatment, there is a risk that the pressure at which the transfusion liquid is supplied to the patient's body is dangerously changed due to, for example, inadequate prick of the needle, accidental removal of the needle from the blood vessel as a result of movement of the patient, bending of the transfusion tube, and so forth.
In order to avert from such a danger, the known liquid transfusion apparatus feeding forcibly the transfusion liquid is provided with means for monitoring the pressure of the transfusion liquid during the transfusion treatment. More specifically, the pressure of the transfusion liquid is detected by a pressure sensor disposed at an intermediate portion of the transfusion tube, and the pressure signal from the pressure sensor is converted into a digital signal by an A/D converter, and thus the converted signal is delivered to a display unit which digitally displays the pressure level corresponding to the digital signal. The pressure signal from the pressure sensor also is supplied to a comparator which compares the pressure level with a predetermined reference level When the reference level is exceeded by the pressure level, an alarm is sounded to inform that the pressure of the transfusion liquid is abnormally high.
In this known apparatus, the display unit displays the level of the pressure of the transfusion liquid in, for example, psi (pound square inch) as it is. Thus, there is no means which would show how much the pressure of the transfusion liquid is deviated from a normal pressure level, and how much a margin of pressure is left until the alarm is sounded. Thus, a doctor or a nurse has to determine the margin of pressure which is left until the alarm is sounded, by reading the level displayed on the display unit and comparing the read level with the normal pressure level or a pressure level at which the alarm is to be sounded. Namely, it has been impossible to determine, at a glance of the display unit, the deviation from the normal pressure level and the degree of margin of pressure which is left until the alarm is to be sounded, at a glance of the display unit. In addition, the allowable limit level of the pressure of the transfusion liquid varies according to the nature of the patient. Namely, the maximum allowable pressure for adults is different from that for infants. This means that the pressure level at which the alarm is to be sounded must be changed according to the type of the patient. Once the pressure level at which the alarm is to be sounded is changed, the doctor or the nurse is obliged to reconsider the degree of margin pressure which is left until the alarm is sounded. Thus, the known liquid transfusion apparatus cannot be used conveniently and, hence, an improvement has been required.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a liquid transfusion apparatus which enables a doctor or a nurse to recognize, at a glance, the amount of deviation of the pressure of the transfusion liquid from the normal pressure level or the degree of margin of pressure which is left until the alarm is to be sounded.
According to the present invention, the object of the present, invention is attained by a liquid transfusion apparatus comprising: a transfusion tube for a transfusion liquid to be pricked into human body; a liquid feed unit disposed at the feed tube for feeding to the human body the liquid in the feed tube; a pressure detection unit disposed in the feed tube, in a downstream side of the liquid feed means for detecting a pressure level of the fed liquid; a setting unit adapted to respectively set a normal level of the pressure level of the fed liquid and an upper alarm level of the pressure level of the fed liquid; a calculating unit adapted to calculate a percentage of a difference between the detected level of the pressure level of the liquid and the set normal level to a difference between the set upper alarm level and the set normal level; and a display unit electrically connected to the calculating means for displaying the calculated percentage.
The liquid transfusion apparatus according to the present invention is provided with a setting unit adapted to respectively set a normal level of the pressure level of the fed liquid and an upper alarm level of the pressure level of the fed liquid, a calculating unit adapted to calculate a percentage of a difference between the detected level of the pressure level of the liquid and the set normal level to a difference between the set upper alarm level and the set normal level, and a display unit electrically connected to the calculating means for displaying the calculated percentage.
According to the invention, therefore, a doctor or a nurse can recognize, at a glance, the amount of deviation of the present pressure of the transfusion liquid from the normal pressure level and the degree of margin of pressure which is left until the alarm is to be sounded, when he or she looks at the percentage displayed on the liquid transfusion apparatus.
Therefore, any abnormal pressure rise is easily detected before the alarm is sounded, thereby enabling the nurse or the doctor to take any recovery measure such as re-pricking with the needle or straightening of the bent transfusion tube. In addition, the normal pressure level and the pressure level at which the alarm is to be sounded can easily be changed through an operation of the setting means as required according to the type of the patient and to the existing state of use of the liquid transfusion apparatus.
Thus, the invention provides a liquid transfusion apparatus which is easy to use and which can overcome the above-described problems of the prior art.
Further objects and advantages of the present invention will be apparent from the following description of the preferred embodiment of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an embodiment of a conventional liquid transfusion apparatus.
FIG. 2 is a block diagram of an embodiment of the liquid transfusion apparatus; and
FIGS. 3a and 3b are illustrative view of a display unit used in the embodiment shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram of the conventional liquid transfusion apparatus adapted to forcibly transfusing a transfusion liquid by pressure. This conventional apparatus has a monitoring means which enables the pressure of the transfusion liquid to be monitored. More specifically, the pressure of the transfusion liquid in a transfusion tube 1 is detected by a pressure sensor 2 provided at an intermediate portion of the tube 1, and the pressure signal from the pressure sensor 2 is converted into a digital signal by an A/D converter 3. The digitized signal is displayed as a pressure level in a display unit 4. The pressure signal from the pressure sensor 2 also is supplied to a comparator 5 which compares a pressure level corresponding to the pressure signal with a predetermined reference level. When the reference level is exceeded by the pressure level, an alarm 6 is sounded to inform that the pressure of the transfusion liquid is abnormally high.
FIG. 2 is a block diagram of the liquid transfusion apparatus according to the present invention. The apparatus 101 has a transfusion tube 102 which is connected at its upstream end to a bag (not shown) for receiving a transfusion liquid and at its downstream end to a needle (not shown). Feeding means 104 for feeding the transfusion liquid is provided at an intermediate portion of the tube 102. Also provided at an intermediate portion of the tube 102 is a pressure sensor 106 for sensing the pressure of the transfusion liquid which is being transfused through the tube 102 by the pressure generated by the feeding means 104. The feeding means 104 may be a transfusion pump including eccentric cams provided on the shaft of the pump and fingers provided on the outer circumference of the eccentric cams so as to press the tube 102. The word "transfusion liquid" used in the present specification includes a blood and a medical liquid. In the illustrated embodiment, an electromagnetic induction sensor is used as the pressure sensor 106. This, however, is not exclusive and a strain-gauge-type sensor, capacitance-type sensor and a diaphragm-type sensor capable of directly or indirectly sensing the pressure can be used as the pressure sensor 106.
The pressure sensor 106 senses the pressure of the transfusion liquid transfused through the tube 102 and delivers a pressure signal to an A/D converter 108. The A/D converter 108 converts the pressure signal from the sensor 106 into digital signal and delivers it as an output signal to a CPU (Central Processing Unit) 110 which is adapted to process the digital signal received from the A/D converter 108. An interface section 112, which is electrically connected to the CPU 110, receives a control signal from the CPU 110 and delivers the same to the feeding means 104. A setting device 114 electrically connected to the CPU 110 is adapted to be able to set a normal pressure level for the transfusion liquid and a pressure level at which an alarm is to be sounded.
The CPU 110 has a memory section 116 for storing respectively the normal pressure level and an alarm pressure level at which an alarm is to be sounded, which pressure levels are set by the setting device 114, and a calculation section 118 for calculating the percentage of the difference between the pressure of the transfusion liquid and the normal pressure level to the difference between the normal pressure level and the alarm pressure level on the basis of the normal pressure level and the alarm pressure level, which are stored in the memory section 116, when receiving the pressure signal from the pressure sensor 106 through A/D converter 108. The memory section 116 includes a memory unit 116a for storing the normal pressure level and a memory unit 116b for storing the alarm pressure level. The display unit 120, which is electrically connected to the calculation section 118, is adapted to display a calculation result on the basis of a calculation result signal from the calculation section 118. The alarm 120 is connected to the calculation section 118 and operates in accordance with the calculation result signal from calculation section 118 so as to sound an alarm when the pressure of the liquid detected by the pressure sensor 106 has exceeded the alarm pressure level.
The operation of the described embodiment is as follows.
Before the use of the apparatus 1, the normal pressure level (Pn) for the pressure of the liquid to be transfused and the alarm pressure level (Pa) at which the alarm is to be sounded are set by means of the setting device 114. For instance, the alarm pressure level (Pa) is set at 17 psi for adults and at 7 psi for infants. The normal pressure level (Pn) and the alarm pressure level (Pa) set by the setting device 114, are respectively stored in the memory unit 116a for the normal pressure level and in the memory unit 116b for the alarm pressure level.
An outer diameter of the tube 102 varies according to a change in the internal pressure of the tube 102, with the result that the level of the pressure signal from the pressure sensor 106 also changes. The pressure signal outputted from the pressure sensor 106 is digitized through the converter 108 and the thus digitized pressure signal is supplied from the converter 108 to the calculation section 118 of the CPU 110. The calculation section 118 then calculate a percentage (P%) given by the following formula on the basis of the normal pressure level (Pn) and the alarm pressure level (Pa), which levels are stored in the memory section 116, and the digitized pressure signal which is representative of the pressure level (Px) of transfusion liquid and is supplied from the converter 108.
P%={(Px-Pn)/(Pa-Pn)}×100
The result of the calculation is delivered from the calculation section 118 to the display unit 120 so that the display unit 120 displays the level of the percentage (%) in the form of a numerical representation as shown in FIG. 3a or in the form of a bar graph as shown in FIG. 3b.
The doctor or the nurse can therefore recognize, at a glance of the percentage displayed in the display unit 120, the amount of deviation of the pressure of the transfusion liquid from the normal pressure level or the degree of margin of pressure which is left until the alarm is to be sounded.
When the alarm pressure level at which an alarm is to be sounded is exceeded by the pressure level corresponding to the pressure signal from the pressure sensor 106, the calculation section 118 delivers an alarm signal to the alarm 120 so that the alarm is sounded to inform that the pressure of the transfusion liquid has been raised to an abnormal level. At the same time, the feeding means 104 is stopped by a control signal from the CPU 110 through the interface section 112 to thereby stop the supply of the liquid.
Many widely different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiment described in the specification, except as defined in the appended claims. | The liquid transfusion apparatus according to the present invention includes a setting device adapted to respectively set a normal level of pressure of the fed liquid and an upper alarm level of pressure of the fed liquid, calculating unit for calculating a percentage of a difference between the detected level of pressure of the liquid and the set normal level to a difference between the set upper alarm level and the set normal level, and display unit for displaying the calculated percentage. The liquid transfusion apparatus is very useful for monitoring the pressure of the liquid which is being administered to a patient. | 8 |
TECHNICAL FIELD
This invention relates to false twist texturing of yarns.
BACKGROUND OF THE INVENTION
Conventionally, yarns are textured by the false twisting process in a false twist zone which extends from a twist trap that defines the upstream limit of false twist, and contains a heater that raises the temperature of the false twisted yarn, a cooling zone in which the false twisted yarn is cooled, a false twisting device and an output roller arrangement that hauls the yarn through the false twist zone. The yarn may optionally then be wound up as stretch yarn without further processing, though with some relaxation in an overfeed zone to control the wind-up tension, or, with further heat processing in a relaxation zone, to produce a set textured yarn.
The supply yarn may be fully drawn or oriented yarn, or more usually nowadays, partially oriented yarn produced by high speed extrusion from the spinneret, in which case the false twist texturing may involve sequential drawing, in which the yarn is drawn in an in-line operation before passing into the false twist zone or, more usually, simultaneous drawing in which the partially oriented yarn is drawn in the false twist zone itself.
As false twist devices have been developed which operate at higher and higher twisting speeds, the rate at which yarn can be processed--which is limited by the false twisting speed, since false twist texturing requires high rates of twist per unit length--has increased correspondingly. The threadline of a false twisting machine as described is necessarily straight or substantially so--a gently curved heater track can be tolerated--between twist trap and false twist device--and because the twisted yarn must remain in contact with the heater for a certain time in order to reach an effective temperature, the heater has become very long and much ingenuity has been put into the design of false twist texturing machines to cope with the long heaters--which can be several metres in length. Eventually, limitations on practical heater length have limited processing rates. For example, 167 dtex yarn could be false twisted at a speed corresponding to a throughput speed of 1500 metres/minute, but is rarely processed at speeds in excess of 900 metres/minute because of heater limitations.
SUMMARY OF THE INVENTION
The present invention provides a false twist texturing method that avoids such problems.
The invention comprises false twist texturing comprising supplying a yarn hot to a twist trap upstream of a false twist device instead of supplying heat to the yarn intermediate the twist trap and the false twist device.
The yarn may be cooled between the twist trap and the false twist device.
The yarn may pass through a heating zone as an untwisted yarn prior to the twist trap. The heating zone may comprise a Jet heater, which may be supplied with steam and/or hot air. The yarn may be heated in a plug. Jet heaters can operate on untwisted yarn at speeds in excess of 6000 metres/minute.
A feed back control arrangement may be used to control the texturing. The feed back control may comprise a bulk measurement after the false twisting device and which may be effected in a relaxation zone, as by measuring yarn speed or yarn tension in the relaxation zone.
The feed back control may act on a yarn heater, which may be a supplementary yarn heater--that is to say a readily controllable heater that is additional to a primary, uncontrolled heater. The feed back control may, however, act on a yarn hauling device, which may be the output roller of the false twist zone or a false twisting device.
The yarn may be draw-textured. The supply yarn may be taken from a spinneret over a twist trap into a false twisting zone, the heat remaining in the yarn from the spinning operation being sufficient to avoid the need for a separate heating arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of false twist texturing apparatus and methods according to the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic illustration of a first arrangement;
FIG. 2 is a diagrammatic illustration of a second arrangement; and
FIG. 3 is a diagrammatic illustration of a third arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings illustrate false twist texturing comprising supplying a hot yarn 11 to a twist trap 12 upstream of a false twist device 13 instead of supplying heat to the yarn intermediate the twist trap 12 and the false twist device.
It is, of course, to be understood that heat could still, additionally, be supplied to the yarn 11 downstream of the twist trap 12--the invention does not exclude that, but renders it, rather, unnecessary so to do or a matter of choice as to whether and if so how much heat to supply, but in particular renders it unnecessary to use long heaters as are conventionally used. The process however is simplified both from an operating and a control point of view if the conventional twisted yarn heaters are eliminated altogether, as in the embodiments particularly described and illustrated herein and the false twist texturing machine is considerably reduced in capital and operating costs because of the cost savings on providing the heaters and the framework necessary to accommodate them.
Moreover, without such long contact heaters, the machinery can be started and stopped readily. Conventional heaters cannot be so operated without waste of time or yarn before reaching equilibrium temperature. This facility for ready stop/start operation introduces a large measure of flexibility into the operation of the machinery--no longer is it necessary to keep the machinery running on a continuous basis for economic operation, so that single shift or two shift operation becomes viable.
Between the twist trap 12 and the false twisting device 13 is a cooling zone 14--which may simply be an air gap or which may comprise a forced cooling arrangement such as a cold contact block or forced air cooling.
FIGS. 1 and 2 illustrate the yarn 11 passing through a heating step prior to the twist trap 12. In FIG. 2, the yarn 11 is fed by a hot air and/or steam jet 16 into a plug 17 in a tube or plug constraint 18 with a heater jacket 19. Such arrangements are known from other methods of yarn treatment.
In FIG. 1, yarn is supplied through a jet heater 16 without forming a plug. It is desirable, of course, to heat the yarn to such a temperature as will, allowing for any cooling prior to and at the twist trap 12, leave the yarn still at an appropriate temperature for the false twist process. The use of steam, for some yarns at least, enables a lower temperature to be used than if hot air alone is used. The appropriate temperatures are well known from the literature--what does not appear to have been generally recognised hitherto is that such temperatures produced at the twist trap 11 by feeding to it an already hot yarn can suffice for false twist texturing without the need to add post-twist trap heat. Such a suggestion is made in GB-A-2 026 560, but does not appear to have been adopted in practice.
The hot yarn will, of course, heat up the twist trap, but the thermal capacity of the twist trap which will normally comprise a godet roll or a nip roll arrangement may be arranged to be quite small so that equilibrium is rapidly achieved, and indeed the twist trap itself may be heated--heated godets are of course well known in yarn processing.
It is, of course, known in yarn texturing and in particular in false twist texturing to have a relaxation zone for the yarn prior to wind--up-in producing set-textured yarn, the relaxation zone includes stretch-relaxing heating. In the embodiments of FIGS. 1 to 3, such a zone 21 is provided in which bulk develops and comprises a bulk measuring device 22 comprising a yarn speed measuring wheel or tension measuring device connected to a feed back control 23 acting on the system to maintain a constant wheel speed and hence bulk.
The feed back control 23, in FIGS. 1 and 2, acts on a supplemental heater 24 for the steam and/or hot air input to the jet heater 16. This effects fine tuning on the yarn temperature at false twisting and is able to control the bulk. The relatively short feed back loop resulting from avoiding the need for the conventional metres-long false twisting heater aids the feed back control operation materially.
FIG. 3 illutrates an arrangement in which freshly spun yarn is supplied to an on-line false twist texturing operation utilising the heat remaining in the yarn from the spinning operation. Filaments 31 from the spinneret 32 are gathered together at the twist trap godet 12 and draw-textured as before. The feed back control 23 is shown as controlling the input godet to zone 21 or alternatively the false twist device 13, but the feed back could operate on the extrusion process as by controlling the cooling chimney or the godet 12.
Any kind of false twist device may be used, but really high speeds are attainable with roller twisting devices of the Positorq (RTM) type. | There is disclosed a method for false twist texturing comprising the steps of supplying a yarn hot (11) to a twist trap (12) upstream of a false twist device (13) instead of supplying heat to the yarn intermediate the twist trap and the false twist device. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of and claims priority to PCT Application No. PCT/GB2008/003017 titled Power Split Device and Method, filed Sep. 5, 2008, which claims priority to Great Britain Application No. 0717354.5, filed Sep. 7, 2007.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a power split device and method.
2. Related Art
In multiple-power source devices, such as, for example, hybrid vehicles, arrangements exist to distribute power between elements of the vehicle. For example, it is known in a so-called “parallel” hybrid vehicle to provide a planetary gear power train which links an internal combustion engine, the driven road wheels and any electric machines. The planetary gear hybrid power train provides two power paths between the internal combustion engine and the driven road wheels. The first power path may be a mechanical coupling between the internal combustion engine and the driven wheels, whilst the second power path may be via a motor-generator and battery arrangement.
This approach enables the two power paths to be utilized under different conditions to improve the overall efficiency of the vehicle. However, whilst the planetary gear power train is simple and fairly efficient it suffers from a number of limitations. Accordingly, it is desired to provide an improved power split device.
SUMMARY OF THE INVENTION
According to a first aspect to the present invention there is provided a variable ratio power split device, comprising: radially inner and outer races, each comprising at least two axially spaced parts; a plurality of planetary members arranged for rolling contact between the inner and outer races; a planet follower carrier engaging with the planetary members; a first rotatable power element spindle connected with the planet follower and operable to couple power between the planet follower carrier and a first power element; a second rotatable power element spindle connected with the inner race and operable to couple power between the inner race and a second power element; a third rotatable power element spindle connected with the outer race and operable to couple power between the outer race and a third power element; and means for adjusting an axial separation of the axially spaced parts of at least one of the races to vary a power split ratio between the first, second and third rotatable power element spindles.
The first aspect recognizes that a limitation with the planetary gear hybrid power train mentioned above is that the elements coupled with the planetary gear hybrid power train are often not operating efficiently. For example, the internal combustion engine must always operate when the driven road wheels rotate above certain speeds which limits the potential of the vehicle to reduce emissions. Furthermore, the speed of the motor generators is directly dependent upon the speed of the internal combustion engine and/or the driven road wheels. Hence, it is unlikely that for any particular operating condition, the elements coupled with the power train can be operated efficiently. This is because the planetary gear hybrid power provides is a fixed power split ratio between the elements.
Accordingly, a variable ratio power split device is provided having inner and outer races, planetary members and a planet follower carrier is provided. Rotatable power element spindles are connected to each of the races and the planet follower carrier to couple power with respective power elements. By adjusting the axial separation of one of the races, the ratio of power distributed between the power element spindles is varied which improves the operability of the device.
In one embodiment, each of the first, second and third power elements have predetermined efficiency characteristics under predetermined operating conditions and the variable ratio power split device comprises: at least one sensor operable to determine current operating conditions; and a set-point unit operable to determine, with reference to stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which improves an operating efficiency of at least one of the first, second and third power elements under the current operating conditions.
The sensors enable the current conditions to be established. By using knowledge of the characteristics of the power elements, an appropriate relationship of power distribution between the power elements can be set by adjusting the axial separation of the races. In this way, the differing operating requirements of the power element under the current operating conditions can be better balanced to improve the efficiency of at least one of the power elements.
In one embodiment, the device comprises: a plurality of the sensors and the set-point unit is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which improves an operating efficiency of more than one of the first, second and third power elements under the current operating conditions.
Accordingly, the axial separation may be varied to provide an optimized efficiency of more than one of the power elements for the current operating conditions. It will be appreciated that in doing so the absolute optimum efficiency of one of the power elements may need to be reduced slightly in order to provide a significantly improved efficiency of one of the other power elements and thereby improve the overall efficiency of power elements coupled to the variable ratio power split device.
In one embodiment the set-point unit is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which causes substantially no power to be coupled to one of the first, second and third power elements under the current operating conditions.
Accordingly, the axial separation may be adjusted to enable minimal power to be coupled to any of the first, second or third power elements. Power may then be distributed between the remaining two power elements without any power being provided to the third.
In one embodiment, the first, second and third power elements each comprise one of a prime mover, a vehicle transmission assembly and a power transmission assembly.
It will be appreciated that the vehicle transmission assembly may be a vehicle drive train.
In one embodiment, at least one of the power transmission assembly and the vehicle transmission assembly is operable to store power.
It will be appreciated that these assemblies may store power in a variety of ways such as, for example, mechanically, kinetically, chemically and hydraulically.
In one embodiment, the at least one of the power transmission assembly and the vehicle transmission assembly is operable to reapply the stored power.
Hence, the stored energy may be recovered from these assemblies and reused subsequently.
In one embodiment, the variable ratio power split device comprises a further power coupling and wherein the at least one of the power transmission assembly and the vehicle transmission assembly is operable to reapply the stored power via the further power coupling.
Accordingly, a separate path may exist whereby any power stored by these assemblies may be applied to each other, other than via the variable ratio power split device. For example, the power transmission assembly may store power and apply this directly to the vehicle transmission assembly via a power coupling other than by way of the planetary members to enable the power stored to be directly applied to the vehicle transmission assembly.
In one embodiment, the first power element comprises an internal combustion engine, the second power element comprises a vehicle transmission assembly and the third power element comprises a regenerative power assembly.
In one embodiment, the set-point unit is operable in any one of a number of modes and, when in a regenerative mode, is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which causes minimal power to be coupled to the internal combustion engine and power from the vehicle transmission assembly to be provided to the regenerative power assembly at a speed which improves an operating efficiency of the regenerative power assembly under current operating conditions.
When in a regenerative or power storing mode, energy from the vehicle transmission assembly is diverted to the regenerative power assembly, typically to slow a vehicle, and the kinetic energy of the vehicle is then stored as potential energy in the regenerative power assembly. Typically, in such a mode it is desirable for minimal energy to be provided by the internal combustion engine, which may be inactivated during such braking. Also, it is desirable to operate the regenerative power assembly at a speed which maximizes the efficiency of this power storage. Accordingly, the axial separation of the races is adjusted in order to minimize any power being provided by or to the internal combustion engine and to operate the regenerative power assembly at a near constant efficient speed as the speed of the vehicle and hence the speed of the vehicle transmissions assembly reduces.
In one embodiment, the set-point unit is operable in any one of a number of modes and, when in a moving, high state of charge mode, is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which causes power to be coupled from the internal combustion engine and the regenerative power assembly to the vehicle transmission assembly at a speed which improves an operating efficiency of at least one of the internal combustion engine and the regenerative power assembly under current operating conditions.
When the regenerative power assembly is in a high state of charge, there is little requirement to store any further energy in the regenerative power assembly. Accordingly, power can be utilized from both the internal combustion engine and the regenerative power supply, and applied to the vehicle transmission assembly to propel the vehicle as required. Hence, the axial separation of the races is adjusted to operate either and/or both the internal combustion engine and the regenerative power supply at a speed which improves their operating efficiency as the speed of the vehicle changes.
In one embodiment, the set-point unit is operable in any one of a number of modes and, when in a moving, low state of charge mode, is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which causes power to be coupled from the internal combustion engine to the regenerative power assembly and the vehicle transmission assembly at a speed which improves an operating efficiency of at least one of the internal combustion engine and the regenerative power assembly under current operating conditions.
When the regenerative power assembly is in a low state of charge, any excess energy from the internal combustion energy may be converted to improve the state of charge of the regenerative power assembly. Accordingly, the axial separation of the races is adjusted to enable power to be supplied to the regenerative power supply at a speed which improves the operating efficiency of the regenerative power supply and/or the internal combustion engine.
In one embodiment, the set-point unit is operable in any one of a number of modes and, when in a zero emissions mode, is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which causes minimal power to be coupled to the internal combustion engine and power from the regenerative power assembly to be provided to the vehicle transmission assembly at a speed which improves an operating efficiency of the regenerative power assembly under current operating conditions.
Hence, when it is desired to emit no emissions from the internal combustion engine, the axial separation of the races is set such that minimal power is provided from the internal combustion energy and the power for the vehicle transmission assembly is provided by the regenerative power assembly. Hence, the regenerative power assembly is operated at a speed which maximizes the efficiency of the power provided by the regenerative power assembly based on the speed of the vehicle transmission assembly, whilst minimizing any power from the internal combustion energy, which may be switched off.
In one embodiment, the set-point unit is operable in any one of a number of modes and, when in a stationary, low state of charge mode, is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which causes minimal power to be provided to the vehicle transmission assembly and power from the internal combustion engine to be provided to the regenerative power assembly at a speed which improves an operating efficiency at least one of the internal combustion engine and the regenerative power assembly under current operating conditions.
When the regenerative power assembly is in a low state of charge and the vehicle is not moving, energy from the internal combustion energy may be converted to improve the state of charge of the regenerative power assembly. Accordingly, the axial separation of the races is adjusted to enable power to be supplied to the regenerative power supply at a speed which improves the operating efficiency of the regenerative power supply and/or the internal combustion engine.
In one embodiment, the set-point unit is operable in any one of a number of modes and, when in a moving, low state of charge mode, is operable to determine, with reference to the stored data indicative of the predetermined efficiency characteristics, an axial separation of the axially spaced parts of at least one of the races to provide a power split ratio which causes minimal power to be provided to the regenerative power assembly and power from the internal combustion engine to be provided to the vehicle transmission assembly at a speed which improves an operating efficiency of the internal combustion engine under current operating conditions.
When the regenerative power assembly is in a low state of charge, there is excess energy available in the regenerative power assembly. Accordingly, power can only be utilized from the internal combustion engine and applied to the vehicle transmission assembly to propel the vehicle as required. Hence, the axial separation of the races is adjusted to operate the internal combustion engine at a speed which improves its operating efficiency as the speed of the vehicle changes.
In one embodiment, the variable ratio power split device comprises: a transmission component and wherein at least one of the first, second and third rotatable power element spindles are connected with the transmission component.
Accordingly, a component may be provided between the power element spindles and the power elements.
In one embodiment, the transmission component comprises at least one of a gear train, a clutch and a brake.
In one embodiment, the first and second power element spindles are concentrically rotatable.
Providing concentrically rotatable spindles achieves a simple and compact construction of the variable ratio power split device whilst enabling power to be distributed between each the three power elements.
In one embodiment, the variable ratio power split device comprises: the first power element connected with the first rotatable power element spindle; the second power element connected with the second rotatable power element spindle; and the third power element connected with the first third power element spindle.
According to a second aspect of the present invention, there is provided a method of varying power, comprising the steps of: arranging a plurality of planetary members for rolling contact between radially inner and outer races, each race comprising at least two axially spaced parts; engaging a planet follower carrier with the planetary members; connecting the planet follower carrier, the inner race and the outer race with a respective one of a first power element, a second power element and a third power element; and adjusting an axial separation of the axially spaced parts of at least one of the races to vary a power split ratio between the first, second and third rotatable power element spindles.
In embodiments, there are provided method steps performed by the corresponding features of the first aspect.
Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
FIG. 1 illustrates a hybrid vehicle incorporating a power split device according to one embodiment;
FIG. 2 illustrates the mechanical arrangement of the power split device of FIG. 1 in more detail;
FIG. 3 illustrates a set-point unit of the power split device;
FIGS. 4 a to 4 f illustrate schematically power flows of the power split device when operating in different modes;
FIG. 5 is a graph showing an example relationship between the rotational speed of the components of the power split device when operating at any one of a number of different gearing ratios;
FIG. 6 illustrates an example power flow on each component of the power split device;
FIG. 7 shows an example motor efficiency characteristic a typical permanent magnet motor/generator;
FIG. 8 shows an example generator efficiency characteristics of the typical permanent magnet motor/generator; and
FIG. 9 illustrates an example efficiency characteristic of a typical internal combustion engine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, numerous specific details are set forth in order to provide a more thorough description of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as not to obscure the invention.
FIG. 1 illustrates power elements of a typical hybrid vehicle, generally 10 . The hybrid vehicle 10 is powered by an internal combustion engine 20 and a regenerative power assembly comprising a first motor generator 40 , a battery 50 and a second motor generator 60 . The internal combustion engine 20 is coupled with a power split device 30 . Also coupled with the power split device 30 is the regenerative power assembly and a vehicle drive unit 80 , such as the road wheels. The first motor generator 40 is coupled with the power split device 30 and the battery 50 . The battery 50 is coupled with the second motor generator 60 . The second motor generator 60 is coupled via a further power transfer path with the vehicle drive unit 80 .
The power split device 30 controls the distribution of power between the internal combustion engine 20 , the first motor generator 40 and the vehicle drive unit 80 by varying an axial separation of race components of the power split device 30 , as will be explained in more detail below. The power split device 30 is controlled by a set-point unit 130 which determines the axial separation of the race components and thus the power split ratio between the power elements. The power split device 30 is operated in any one of a number of different operating modes which are selected based upon the current operating condition of the vehicle and the demands of the driver, as will also be explained in more detail below. The set-point unit 130 controls the power distribution of the power split device 30 in order to maximize the overall efficiency of the hybrid vehicle 10 by operating the power elements as near to their optimal efficiency for the current conditions as is possible. Hence, the power split device 30 can be considered to be analogous to an epicyclic transmission that can vary the ratio between each of the three components to allow each of these components to operate nearer to their respective optimal efficiencies. In other words, the power split device 30 operates as a floating three element epicyclic transmission having a variable ratio. Utilizing the power split device 30 as an epicyclic transmission allows the operating envelope to be extended due to the variable ratio capacity of the power split device. Also, the combination of the internal combustion engine 20 , the vehicle drive unit 80 , the regenerative power assembly and the power split device 30 can be considered to be analogous to an infinitely variable transmission.
Although the power elements of the hybrid vehicle 10 have been shown schematically as being coupled with each other, it will be appreciated that transmission components may be provided therebetween in order to provide for further power transmission control.
FIG. 2 schematically illustrates in more detail the mechanical configuration of key components of the power split device 30 . The power split device 30 comprises a radially inner race 100 , a radially outer race 110 and, typically, three planetary members in rolling contact with both the inner race 100 and outer race 110 . The planetary members each engage with a planet follower (not shown). The inner race 100 is comprised of two axially spaced components which are axially moveable relative to each other. Similarly, the outer race 110 is composed of two axially spaced components, also axially moveable relative to each other. Varying the axial separation of the components of the inner race 100 and/or the outer race 110 causes the planetary members to move radially within these races and varies the gear ratio of the power split device. Such an arrangement is shown generally in WO 99/35417. However, in the present arrangement, the planets followers (not shown) are coupled via a engine spindle 125 with the internal combustion engine 20 , the inner race 100 is coupled via a motor generator spindle 105 with the motor generator 40 and the outer race 110 is coupled via a drive spindle 115 with the vehicle drive unit 80 . Hence, each of the inner race, outer race and planets are free to rotate, rather than having at least one fixed component. In this arrangement, the engine spindle 125 and the motor generator spindle 105 are arranged to rotate concentrically. This provides a particularly compact and efficient arrangement. Also, as described in more detail below, the spindles 105 , 11 , 125 may be coupled with its associated power element via a transmission component such as a gear train, a clutch and/or a brake.
The power split device 30 also comprises an actuator 180 operable to vary the axial separation of the components of the outer race 110 . The components of the inner race 100 are resiliently sprung to vary their axial separation in response to pressure from the planetary members 120 , which varies the gear ratio of the power split device 30 . In particular, the inner race 100 comprises two race components 100 A, 100 B which are engaged to the motor generator spindle 105 by means of a coupling comprising a helical interengagement in the form of a screw threaded engagement. The two race components 100 A, 100 B have oppositely handed threads so that a relative rotation of the motor generator spindle 105 and two race components 100 A, 100 B in one directional sense will cause the two components to be displaced towards one another whereas axial separation of the two race components 100 A, 100 B of the inner race 100 occurs where there is relative rotation between them and the motor generator spindle 105 in the opposite directional sense. The actuator 180 controls the axial separation of the components in response to a set-point signal provided by the set-point unit 130 and described in more detail below.
Hence, it can be seen that power can be distributed by the races 100 , 110 and planetary members 120 of the power-split device 30 between the internal combustion engine 20 , the motor generators 40 and the drive unit 80 via their respective spindles. Varying the axial separation of the components varies the ratio of power distribution between these components.
FIG. 3 illustrates the set-point unit 130 in more detail. The set-point unit 130 is typically implemented as a microprocessor having associated memory or as a state machine. The set-point unit 130 receives a number of inputs from sensors within the hybrid vehicle 10 and outputs a set-point signal which controls the axial separation of the components of the outer race 110 , an internal combustion engine control signal which controls the load of the internal combustion engine 20 and a motor generator engine control signal which controls the load of the motor generator 40 to maximize the efficiency of the hybrid vehicle 10 . Among the sensory inputs provided to the set-point unit 30 include the speed of the internal combustion engine 20 , the speed of the motor generator 40 , and the speed of the hybrid vehicle 10 . Also provided to the set-point unit is the current state of charge of the battery 50 , as well as the current engine fuelling arrangements for the internal combustion engine 20 . Additionally, the set-point unit 130 is provided with details of the current demand being made by the driver of the hybrid vehicle 10 , such as whether the driver is requesting more, the same or less power, as well as whether the driver wishes to slow the vehicle by braking, these signals are typically from accelerator pedal position sensors and brake pedal force sensors.
The set-point unit 130 executes an algorithm which determines an optimal axial separation of the components of the outer race 110 , together with an internal combustion engine loading and/or a motor generator engine loading, where appropriate, to improve the efficiency of the hybrid vehicle 10 under the current operating conditions.
FIGS. 4 a to 4 d illustrate different operating modes of the power split device 30 . The operating mode is determined based on the sensor information provided to the set-point unit 130 .
FIG. 4 a illustrates the power flow during a regenerative braking mode. This mode is sensed when the driver demand input to the set-point unit 130 indicates that the driver wishes to slow the vehicle and the engine fuelling demand is at a minimum. When in this mode, the set-point unit 130 determines the current rotation speed of the drive spindle 115 based on the vehicle speed information and utilizes an algorithm to determine an axial separation of the components of the outer race 110 to provide a gear ratio which provides a substantially zero rotation speed for the engine spindle 125 whilst driving the motor generator spindle 105 at a speed which maximizes the generator efficiency based on the efficiency characteristics as shown in, for example, FIG. 8 . The set-point unit 130 outputs a set-point signal to the actuator 180 to achieve this axial separation. As the vehicle slows the algorithm constantly adjusts the axial separation of the race components and in so doing adjusts the gear ratio to best satisfy these demands as closely as possible. In this way, substantially no power is provided to the internal combustion engine 20 during braking and the power from the vehicle drive unit 80 is transferred to the motor generator 40 at a speed which optimizes the efficiency of the motor generator 40 . Hence, during regenerative braking minimal power is provided to the internal combustion engine 20 and instead maximum power is transferred to the motor generator 40 for storage in the battery 50 .
FIG. 4 b illustrates the power flow during a moving, high state of charge mode. This mode is sensed when the driver demand input to the set-point unit 130 indicates that the driver wishes power to be applied to the vehicle drive unit 80 , the vehicle speed information indicates that the vehicle speed is relatively high and the battery state of charge information indicates excess energy is available from the battery 50 . When in this mode both the internal combustion engine 20 and the motor generator 40 are utilized to provide power to the drive unit 80 . Hence, the set-point unit 130 determines the internal combustion engine speed and the motor generator speed as well as the vehicle speed and utilizes an algorithm to optimize the efficiency of the internal combustion engine 20 and the motor generator 40 to achieve the desired vehicle speed. This is achieved by varying the axial separation of the race components of the outer race 110 in order to vary the power provided by both the internal combustion engine 20 and the motor generator 40 , together with varying the load of the internal combustion engine 20 and the load of the motor generator 40 in order to operate these at close to their optimal efficiency. The set-point unit 130 outputs a set-point signal to the actuator 180 to achieve this axial separation, together with an internal combustion engine control signal to achieve the desired load of the internal combustion engine 20 and/or a motor generator engine control signal to achieve the desired load of the motor generator 40 , where appropriate. The internal combustion engine control signal is utilized by an internal combustion engine control unit (not shown) to control the internal combustion engine load using its throttle, fuel injection of other means depending on its type. The motor generator control signal is utilized by a motor generator control unit (not shown) to control the motor generator load, typically by controlling motor current. By varying the axial separation of the components of the outer race 110 the operating speed of the internal combustion engine 20 and the motor generator 40 can be changed such that they operate closer to the most efficient speeds. Clearly, where the demands are such that both cannot possibly be operated at their most efficient then the algorithm may apply weightings to favor operating either the internal combustion engine 20 or the motor generator 40 at their most efficient speeds. In general, where high fuel efficiency is desired, the algorithm will favor operating the internal combustion engine 20 at its most efficient point.
FIG. 4 c illustrates the power flow during a moving, low state of charge mode. This mode is sensed when the driver demand input to the set-point unit 130 indicates that the driver wishes power to be applied to the vehicle drive unit 80 and the battery state of charge information indicates the battery 50 is low on energy. When in this mode the internal combustion engine 20 is utilized to provide power to the drive unit 80 and the motor generator 40 . Accordingly, the set-point unit 130 changes the axial separation of the race components of the outer race 110 to operate the internal combustion engine 20 at its most efficient speed and to divert some of the excess power away from the drive unit 80 and into the motor generator 40 . This is achieved by varying the axial separation of the race components of the outer race 110 in order to vary the power provided by the internal combustion engine 20 to the vehicle drive unit 80 and the motor generator 40 , together with varying the load of the internal combustion engine 20 . The set-point unit 130 outputs a set-point signal to the actuator 180 to achieve this axial separation, together with an internal combustion engine control signal to achieve the desired load of the internal combustion engine 20 . Although the algorithm will seek to drive the motor generator 40 at the most efficient speed possible, once again a weighting will typically be applied to favor operating the internal combustion engine 20 at its most efficient speed. In this way, it can be seen that the axial separation of the race components of the outer race 110 of the power split device 30 can be varied to divert power from the internal combustion engine 20 when operating at its most efficient point and into the regenerative power assembly.
FIG. 4 d illustrates the power flow during a zero emission mode. This mode is sensed when the driver demand input to the set-point unit 130 indicates that the driver wishes power to be applied to the vehicle drive unit 80 , the vehicle speed information indicates that the vehicle speed is relatively low and the battery state of charge information indicates excess energy is available from the battery 50 . When in this mode the motor generator 40 is utilized to provide power to the drive unit 80 . Accordingly, the set-point unit 130 changes the axial separation of the components of the outer race 110 to enable the internal combustion engine 20 to be switched off and power to be supplied from the motor generator 40 instead. The set-point unit 130 outputs a set-point signal to the actuator 180 to achieve this axial separation, together with a motor generator engine control signal to achieve the desired load of the motor generator 40 . The axial separation will be set to attempt to operate the motor generator 40 at the most efficient speed possible for the current conditions. The variable ratio provided by the power split device 30 , enable the motor generator 40 to be utilized to propel the hybrid vehicle 10 for a much wider range of speeds than would otherwise be possible.
FIG. 4 e illustrates the power flow during a stationary, low state of charge mode. This mode is sensed when the driver demand input to the set-point unit 130 indicates that the vehicle 10 is stationary and the battery state of charge information indicates the battery 50 is low on energy. When in this mode the internal combustion engine 20 is utilized to provide power to the motor generator 40 . Accordingly, the set-point unit 130 changes the axial separation of the race components of the outer race 110 to operate the internal combustion engine 20 at its most efficient speed and supply the excess power into the motor generator 40 with substantially no power being supplied to the vehicle drive unit 80 . This is achieved by varying the axial separation of the race components of the outer race 110 in order to vary the power provided by the internal combustion engine 20 to the vehicle drive unit 80 and the motor generator 40 , together with varying the load of the internal combustion engine 20 . The set-point unit 130 outputs a set-point signal to the actuator 180 to achieve this axial separation, together with an internal combustion engine control signal to achieve the desired load of the internal combustion engine 20 . Although the algorithm will seek to drive the motor generator 40 at the most efficient speed possible, once again a weighting will typically be applied to favor operating the internal combustion engine 20 at its most efficient speed. In this way, it can be seen that the axial separation of the race components of the outer race 110 of the power split device 30 can be varied to provide power from the internal combustion engine 20 when operating at its most efficient point into the regenerative power assembly.
FIG. 4 f illustrates the power flow during a moving, low state of charge mode. This mode is sensed when the driver demand input to the set-point unit 130 indicates that the driver wishes power to be applied to the vehicle drive unit 80 , the vehicle speed information indicates that the vehicle speed is relatively high and the battery state of charge information indicates no excess energy is available from the battery 50 . When in this mode only the internal combustion engine 20 is utilized to provide power to the drive unit 80 . Hence, the set-point unit 130 determines the internal combustion engine speed as well as the vehicle speed and utilizes an algorithm to optimize the efficiency of the internal combustion engine 20 to achieve the desired vehicle speed. This is achieved by varying the axial separation of the race components of the outer race 110 in order to vary the power provided by the internal combustion engine 20 , together with varying the load of the internal combustion engine 20 in order to operate this at close to its optimal efficiency. The set-point unit 130 outputs a set-point signal to the actuator 180 to achieve this axial separation, together with an internal combustion engine control signal to achieve the desired load of the internal combustion engine 20 . By varying the axial separation of the components of the outer race 110 , the operating speed of the internal combustion engine 20 can be changed such that it operates closer to its most efficient speed.
FIG. 5 illustrates the speed ratio relationship between elements of a typical power split device 30 . A traditional floating epicyclic gear train has 3 elements that rotate about the principle axis of the transmission, the sun, the carrier and the annulus. The speed of these elements are related to each other by the following relationship:
ω sun =ω carrier (1 +i )− iω annulus,
where the epicyclic ratio is specified as:
i
=
D
a
D
s
.
For a typical existing hybrid vehicle, the epicyclic ratio is around 78/30=2.6. Similarly the torque relationship is as follows:
Tq sun = Ft sun R sun N planets Ft annulus = Ft sun Tq annulus = Ft sun R annulus N planets Tq carrier = - ( 2 Ft sun ) ( R annulus + R sun 2 ) N planets
where N planets is the number of planet elements, Ft is the tooth/traction force and R subscripts are the radii of the specific geometry described by the subscript.
Hence:
Tq
sun
R
sun
=
Tq
annulus
R
annulus
=
-
Tq
carrier
R
annulus
+
R
sun
For the power split device 30 , the equation relating the speed of each element may be derived as:
ω carrier = ( R cont , in ω in + R planet , in R cont , out R planet , out ω outer ) ( R cont , in + R planet , in R cont , out R planet , out ) ,
where the values of radius all vary depending on the specific design geometry and current instantaneous speed ratio of the power split device 30 . The torque relationships on each element of the power split device 30 are as follows:
Tq
in
=
Ft
in
R
cont
,
in
N
planets
Ft
out
=
R
planet
,
out
=
Ft
in
R
planet
,
in
Tq
out
=
Ft
out
R
cont
,
out
N
planets
Tq
carrier
=
-
(
Ft
in
+
Ft
out
)
R
orbit
N
planets
Tq
in
R
cont
,
in
=
Tq
out
R
planet
,
out
R
cont
,
out
R
planet
,
in
=
-
Tq
carrier
R
orbit
(
1
+
R
planet
,
i
n
R
planet
,
out
)
It will be appreciated that utilizing the power split device 30 as an epicyclic transmission allows the operating envelope of the hybrid vehicle to be extended further due to the variable ratio capability of the power split device 30 .
Each of the planes of the graph in FIG. 5 shows the relationship at one particular discrete ratio. The graph shows how the iso-ratio conditions pass through each other when all the components become synchronous. The upper and lower planes of the graph show a complete envelope of relationships possible at different axial separations of the races. The ratio of the power split device 30 dictates the tilt angle of each of the iso-ratio planes. This information is stored by the set-point unit 130 and is utilized by its algorithms. It will be appreciated that a fixed ratio epicyclic gear train would only be able to achieve one of these planes, rather than the operating envelope contained within the upper and lower bounding planes.
FIG. 6 illustrates the power flow on each component of the power split device 30 assuming a unity torque applied to the inner race 100 . Clearly the power split device 30 acts as a summing junction for power transmitted (as would be the case with a fixed ratio epicyclic), although the variable ratio nature of the power split device 30 allows this power split to be varied significantly thus allowing more or less engine power to be delivered to either the electric elements or mechanical elements of the hybrid vehicle 10 . Once again, this information is stored by the set-point unit 130 and utilized by its algorithms.
FIG. 7 illustrates typical motor efficiency characteristics or the motor generator 40 . There is a rapid degradation in electric machine efficiency it is operated away from ideal operating points. Significant overall vehicle efficiency may be achieved by controlling the electric machines to operate at speed and torque conditions that improve their efficiencies. The variable ratio provided by the power split device 30 allows this improved control to be achieved. These characteristics are also stored by the set-point unit 130 and utilized by its algorithms.
FIG. 8 illustrates generator efficiency characteristics of the motor generator 40 . This information is stored by the set-point unit 130 and utilized by its algorithms.
FIG. 9 illustrates typical efficiency characteristics of the internal combustion engine 20 . The efficiency is described by Brake specific fuel consumption contours. As can be seen the internal combustion engine 20 operates near its peak efficiency when at low speed and high load. Again, this information is stored by the set-point unit 130 and utilized by its algorithms.
As can be seen, this arrangement can be utilized to enable a hybrid vehicle 10 to operate at higher road speeds without having to activate the internal combustion engine 20 through the use of the variable gearing provided by the power split device 30 . This reduces the amount of carbon emissions made by the vehicle. Also, the variable ratio nature of the power split device 30 enables the internal combustion engine 20 and machine generator 40 to be operated under conditions which better match each units individual characteristics and improve their efficiency.
Although particular embodiments have been described herein it would be apparent that the invention is not limited thereto and that many modifications and additions may be made within the scope of the invention as defined in the claims. For example, various combinations of features from the following dependent claims could be made with features of the independent claims without departing from the scope of the present invention. | A variable power split device having radially inner and outer races, each comprising at least two axially spaced parts. A plurality of planetary members are arranged for rolling contact between the races and a planet follower carrier engages the planetary members. A first rotatable power element spindle connects with the planet follower to couple power between the planet follower carrier and a first power element. A second rotatable power element spindle connects with the inner race to couple power between the inner race and a second power element. A third rotatable power element spindle connects with the outer race to couple power between the outer race and a third power element. Means for adjusting axial separation adjust separation of the axially spaced parts of at least one of the races to vary a power split ratio between the first, second and third rotatable power element spindles. | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to the field of overhead doors, and, more particularly, to overhead doors used on raised loading docks.
BACKGROUND OF THE INVENTION
[0002] Typically loading docks include a raised dock for the loading and unloading of materials which often come in large quantities and are carried by wooden pallets. Most docks have doorways with overhead doors that provide access to a garage or similar type of building. These overhead doors are similar to garage doors found in most domestic homes and may be operated manually or automatically.
[0003] In many cases, a dock leveler is mounted in a pit in the loading dock in front of the doorway and operation of the dock leveler will serve to bridge the gap between the loading dock and a truck parked in front of the dock so that personnel and material handling equipment, such as a forklift truck, can conveniently move between the loading dock and the truck bed.
[0004] During a loading operation the truck body will enclose the open doorway in the dock. Often when a loading dock operation is not taking place, it is desired to maintain the overhead door in an open position to provide increased ventilation or light in the building or to vent smoke, fumes or odors from the building.
[0005] While there are typically a pair of posts mounted on opposite sides of the doorway to provide a barricade that will protect a forklift truck from damaging the wall or door track at one or both sides of the door, there is a possibility that a forklift truck maneuvering on the dock may accidentally back through the open doorway and fall off the loading dock to the driveway, thus causing possible injury to personnel and/or damage to equipment.
[0006] Attempts to prevent such damage have heretofore included the use of a second door mounted inside of the outer door and constructed of metal mesh to allow the passage of light and air. However, such additional security doors have required use of an additional overhead track system and prohibit passage of materials and people.
[0007] Other attempts have including placing barriers in front of the doorway. However, such barriers must typically be moved by an operator and then must be stored in an non-traffic area.
[0008] Thus, there is a need in the field for a loading dock guard assembly which is readily installed on pre-existing doors and does not require additional tracks, motors or separate operation from the overhead door.
[0009] In addition, there is a need for a loading dock guard assembly which allows passage of people or things, such as packages, while preventing passage of vehicles.
[0010] Also, there is a need for a loading dock guard assembly which may be moved into and out of blocking position by an overhead door, and be disconnected from such door to remain in blocking position while the door is open or closed.
[0011] A guard assembly for use with overhead doors platforms which addresses the problems of known devices would be an important advance in the art.
OBJECTS OF THE INVENTION
[0012] It is an object of the invention to provide a guard assembly for use with an overhead door which can be installed on existing doors.
[0013] Another object of the invention is to provide a guard assembly for use with an overhead door which includes a barrier that can be connected to an overhead door to be raised into an open position and lowered into a blocking position.
[0014] Another object of the invention is to provide a guard assembly for use with an overhead door which includes a barrier that can be disconnected from a door to block the doorway while the door is opened.
[0015] Another object of the invention is to provide a guard assembly for use with an overhead door which includes a barrier that connects to at least one post located adjacent the doorway to block the doorway.
[0016] Another object of the invention is to provide a guard assembly for use with an overhead door which includes a guard rail and, most preferably, an OSHA compliant hand rail.
[0017] Another object of the invention is to provide a guard assembly for use with an overhead door which includes a barrier pivotably connected to the door to allow movement with the door to an open position.
[0018] Another object of the invention is to provide a guard assembly for use with an overhead door to block a vehicle from driving off of a dock when the door is open.
[0019] Yet another object of the invention is to provide a guard assembly for use with an overhead door which includes barrier means adapted to block the doorway when disconnected from the door whether open or closed; block the doorway when connected to the door while the door is closed; and, when connected to the door, move with the door as the door opens so that the barrier means does not block the doorway.
[0020] Still another object of the invention is to provide an efficient and economical way to block an overhead door doorway with a movable barrier.
[0021] How these and other objects are accomplished will become apparent from the following descriptions and drawings herein.
SUMMARY OF THE INVENTION
[0022] This invention is a guard assembly for use near a doorway on a platform. The invention represents a significant advance over the state of the art by providing novel elements to provide broader use, retrofit capability, and safety to loading docks with overhead doors.
[0023] The guard assembly comprises: a barrier adapted to extend across and block the doorway, the barrier having at least one coupling adapted to connect to a respective post and to be preferably supported by the post; and a bracket adapted to facilitate connection and disconnection between the barrier and the overhead door. Such an assembly allows the barrier to block the doorway whether connected to or disconnected from the door. In addition, the barrier, when connected to the door, is adapted to move with the door as the door opens and closes.
[0024] In certain preferred embodiments, the bracket is fixed to the barrier and is adapted for connection with and disconnection from the door. In these embodiments the bracket and door are preferably adapted for connection and disconnection by a pin. In other embodiments, the bracket is fixed to the door and is adapted for connection and disconnection from the barrier. In these embodiments the bracket and barrier are preferably adapted for connection and disconnection by a pin. Therefore, in most preferred embodiments, the bracket is fixed to one of the barrier and the door and is adapted for connection with and disconnection from the other of the barrier and the door, such connection and disconnection preferably being performed by a pin.
[0025] Connection and disconnection are preferably performed in “one motion,” i.e., the door and bracket or barrier and bracket are automatically aligned and the operator simply needs to move the pin along an axis to connect or disconnect the bracket from the other object. “One-motion” connection/disconnection defines such an action in which the operator need only move the pin in the desired direction, no other actions are necessary to complete connection/disconnection since the guard assembly automatically positions the door, bracket and barrier into position for connection/disconnection after installation.
[0026] The platform preferably has two posts mounted on opposite sides of the doorway and the barrier preferably has two couplings which are each adapted to connect to a respective post. Each coupling is preferably a sleeve which is adapted to receive the respective post. In certain embodiments, the couplings are guard couplings and the assembly further comprises upper couplings which are also adapted to connect to respective posts.
[0027] The barrier may also include a guard rail extending between the couplings, a pair of uprights extending from the guard rail to distal ends, and a hand rail extending between the distal ends of the uprights. In certain variations of such embodiments, the bracket preferably includes first and second brackets with each bracket being pivotably connected to the barrier and connected to a respective upright by a tensioning element. In other variations of such embodiments, the bracket includes first and second brackets with each bracket being pivotably connected to the door and further connected to the door by a tensioning element.
[0028] In certain embodiments, the door is movable along a track and the barrier includes a guard rail, a pair of uprights extending from the guard rail to a distal end, and a hand rail extending between the distal ends of the uprights while the bracket includes first and second brackets which provide pivotable connection between the barrier and the door and, optionally, are connected to a respective upright or to the door by a tensioning element. In such embodiments, the distal ends of the uprights are adapted to contact a sloping portion of the track and cause both the barrier to pivot with respect to the door and the tensioning element to extend, thereby allowing the distal ends of the uprights to move substantially horizontally as the guard rail moves substantially vertically when the door and barrier are connected and the door opens. Each bracket preferably provides pivotable connection between the barrier and the door such that the barrier is adapted to pivot with respect to the door as the distal ends of the uprights move substantially horizontally and the guard rail moves substantially vertically.
[0029] In other embodiments, the guard assembly is intended for use with doors which run on tracks that do not include a sloping or substantially horizontal portion, i.e., they extend substantially vertically above the doorway. In such embodiments, the barrier need not be pivotable with respect to the door. Therefore, in such embodiments, the bracket is mounted to one of the door and barrier and is adapted for connection to the other of the door and barrier, with neither the mount nor the connection providing for pivotability.
[0030] In another description of the invention, the guard assembly for use near a doorway on a platform comprises: barrier means adapted to extend across the doorway and having at least one coupling means adapted to connect to a respective post; and connection means adapted to facilitate connection and disconnection between the barrier means and the overhead door. Thus, the barrier means is adapted to block the doorway when disconnected from the door, block the doorway when connected to the door while the door is closed, and move with the door when connected to the door as the door opens so that the barrier means does not block the doorway. When connected to the door, the barrier means is preferably adapted to move with the door as the door closes and to connect to the post to block the doorway.
[0031] The connection means is preferably pivotably mounted to one of the barrier means and the door, a bracket pivotably mounted with respect to one of the door and barrier means, and latching means adapted to connect to and disconnect from the other of the door and barrier means. In certain embodiments, the connection means may include a door plate mounted with respect to the door, a hinge plate pivotably connected to the barrier means and a latching means to connect the door plate and hinge plate. In certain other embodiments, the connection means may include a door plate mounted with respect to the door, a hinge plate pivotably connected to the door plate and a latching means to connect the hinge plate to the barrier means. In such embodiments, the barrier means preferably includes a receiving bracket for connection to the hinge plate.
[0032] In another description of the invention, the guard assembly, in combination with an overhead door in a doorway and a pair of posts mounted on opposite sides of the doorway, comprises: a barrier having two ends with a coupling at each end is adapted to extend across the doorway with each coupling adapted to connect to a respective post; and a bracket adapted to facilitate connection and disconnection between the barrier and the overhead door. In such an embodiment, the barrier is adapted to block the doorway whether connected to or disconnected from the door, and the barrier, when connected to the door, is adapted to move with the door as the door opens and closes.
[0033] In certain embodiments, each post includes a truss which joins the respective post at a shoulder which supports the couplings. It is preferred that the couplings be adapted to contact the respective shoulder when the door is closed and the bracket connects the door and barrier. In certain embodiments, the door preferably includes a plate and the couplings are adapted to contact the respective shoulder when the plate and bracket are aligned to allow a pin to pass therethrough to pivotably connect the door and the barrier.
[0034] In other certain embodiments, the barrier includes a guard rail extending between the couplings, a pair of uprights extending from the guard rail to a distal end, and a hand rail extending between the distal ends of the uprights; the bracket includes first and second brackets which are each pivotably connected to the barrier and connected to a respective upright by a tensioning element; and the overhead door includes pivotably connected panels and moves along a track having substantially vertical and substantially sloping portions. In such embodiments, the distal ends of the uprights are adapted to contact the substantially sloping portion of the track to cause the barrier to pivot with respect to the brackets and to cause the tensioning element to extend to allow the distal ends of the uprights to move substantially horizontally as the guard rail moves substantially vertically when the barrier is connected to the door as the door opens.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The drawings illustrate preferred embodiments which include the above-noted characteristics and features of the invention. The invention will be readily understood from the descriptions and from the drawings, in which:
[0036] [0036]FIG. 1 is a front view of the guard assembly in accordance with the invention.
[0037] [0037]FIG. 2 overhead view of a barrier in connection with the posts and door in accordance with the invention.
[0038] [0038]FIG. 3 is an enlarged view of the connection between the barrier and a post and the door in accordance with the invention.
[0039] [0039]FIGS. 4 a and 4 b are side views of a preferred guard assembly shown disconnected and connected to a door in accordance with the invention.
[0040] [0040]FIG. 5 is a plan view of a pin and preferred bracket components in accordance with the invention.
[0041] [0041]FIG. 6 is a side view of a preferred barrier connected to the door and showing the movement of the barrier as the door is opened and/or closed in accordance with the invention.
[0042] [0042]FIG. 7 is a side view of a preferred guard assembly shown connected to a door in accordance with the invention.
[0043] [0043]FIG. 8 is a side view of a preferred guard assembly shown disconnected from a door in accordance with the invention.
[0044] [0044]FIG. 9 is a side view of a preferred guard assembly shown connected to a door with the door connected to a post in accordance with the invention.
[0045] [0045]FIG. 10 is an enlarged view of a preferred bracket showing the pivoting motion of the bracket in dashed lines in accordance with the invention.
[0046] [0046]FIG. 11 is a side view of a preferred guard assembly connected to a door and showing the barrier pivoting with respect to the door as the door is opened and/or closed in accordance with the invention.
[0047] [0047]FIG. 12 is an enlarged view of a preferred coupling in accordance with the invention.
[0048] [0048]FIG. 13 is perspective view of the preferred coupling of FIG. 12 including connection means for connecting the barrier to the bracket and shown disconnected from the bracket in accordance with the invention.
[0049] [0049]FIG. 14 is perspective view of the preferred coupling of FIG. 13 shown connected to the bracket in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] Referring to FIGS. 1 and 2, details of the guard assembly 10 for use near a doorway 102 on a platform 110 will be set forth. The guard assembly 10 includes a barrier 20 which can be connected to a door 100 and coupled to at least one post 120 near the doorway 102 . The posts 120 are preferably mounted to the platform 110 near doorway 102 and equidistant from wall 106 and may be supported by at least one truss 122 . Trusses 122 preferably join the posts to form shoulders 124 which can support barrier 20 when barrier 20 and posts 120 are coupled.
[0051] Barrier 20 includes a guard rail 23 and preferably has couplings 30 at each end 21 , 22 to couple with posts 120 . Couplings 30 are preferably sleeves which are formed to slide around posts 120 such that each post 120 is received within a coupling 30 . In certain embodiments, uprights 24 extend substantially vertically from barrier 20 and a hand rail 26 preferably extends between the distal ends 25 of uprights 24 . Also connected with respect to uprights 24 are upper couplings 32 which, like guard coupling 31 , are sleeves which are dimensioned to receive posts 120 therein.
[0052] Hand rail 26 preferably includes a roller 27 at each end to contact track 130 to which door 100 is mounted. Hand rail 26 is preferably compliant with work environment requirements pertaining to railings such as OSHA 1910.23 which requires that certain types, sizes and arrangements of railing construction have a smooth-surfaced top rail at a height above floor, platform, runway or ramp level of 42 inches nominal, have a strength to withstand at least the minimum requirement of 200 pounds top rail pressure, and include protection between the top rail and the floor, platform, runway, ramp or stair treads equivalent to at least that afforded by a standard intermediate rail.
[0053] Barrier 20 can be connected to door 100 through use of bracket 40 . Preferably first and second brackets 41 , 42 interconnect door 100 and each end 21 , 22 of barrier 20 . In order to facilitate connection and disconnection between barrier 20 and door 100 , at least one door plate 44 is mounted on door 100 . Each plate 44 includes a channel 55 which receives a pin 45 . Channel 55 is preferably designed to align with a hole 56 in bracket 40 when door 100 is closed and barrier 20 is coupled to posts 120 and rests on shoulders 124 . Pin 45 can then slide through hole 56 to connect barrier 20 and door 100 . FIG. 3 offers an enlarged view of the right side of FIG. 2. As shown, pin 45 is in the locked position and passes through bracket 40 and raised walls 52 .
[0054] [0054]FIG. 5 shows door plate 44 in more detail. Plate 44 includes two raised walls 52 which form a groove 54 which is formed to snugly receive bracket 40 . When hole 56 in bracket 40 is aligned with channel 55 , pin 45 can be moved along channel 55 through hole 56 in bracket 40 . Pin 45 is then engaged by raised walls 52 and bracket 40 and interconnects door 100 and barrier 20 . This locked position is shown in FIG. 5. To facilitate movement of pin 45 into and out of the hole in bracket 40 there is provided handle 51 which is connected to pin 45 within housing 53 . As is understood, handle 51 can be moved in a pivoting motion to cause pin 45 to slide along channel 55 into and out of groove 54 .
[0055] [0055]FIGS. 4 a and 4 b are side views of the barrier 20 , bracket, 40 and door 100 and show the preferred version of door 100 as having pivotably connected door panels 104 . As can be seen, door plate 44 includes channel 55 which is defined by raised walls 52 . When door is closed, channel 55 is aligned with hole 56 in hinge plate 46 which is a component of bracket 40 .
[0056] Hinge plate 46 includes an arm 47 which extends away from door 100 . Arm 47 is pivotably connected to bracket mount 48 at pivot 49 , which may of a pin and channel construction. Bracket mount 48 is fixed to barrier 20 such that barrier 20 may pivot about pivot 49 in relation to hinge plate 46 . Hinge plate 46 also includes an upper aperture 57 to receive a tensioning element 43 which may be a spring or any other device which provides tension between hinge plate 46 and barrier 20 . Tensioning element 43 is connected to barrier 20 by catch 58 . Tensioning element 43 , arm 47 and mount 48 keep hinge plate 46 in proper orientation with respect to barrier 20 and door 100 when door is not positioned adjacent barrier 20 (as seen in FIG. 4 a ).
[0057] [0057]FIG. 6 shows barrier 20 at two positions during upward movement with door 100 . In the lower position door panel 104 is traveling along a substantially vertical portion 132 of track 130 . As door panel moves upward, tensioning elements 43 , arms 47 and mounts 48 keep uprights 24 substantially vertical until rollers 27 contact sloping portion 134 of track 130 . Then rollers 27 roll along track 130 and tensioning element 43 allows barrier 20 to pivot about pivot 49 . When door panel 104 moves downward, tensioning element 43 pulls uprights 24 such that they keep contact with track 130 and barrier 20 pivots back to its original position. In this way, barrier 20 can be moved into and out of the blocking position in which it extends across doorway 102 .
[0058] During the initial installation of guard assembly 10 on a door 100 , barrier 20 is positioned across doorway 102 and coupled to pre-existing posts 120 or posts 120 installed along with the assembly 10 . When barrier 20 is properly positioned, door plates may be mounted to the door 100 along a door panel 104 which is at the same height as barrier 20 such that each channel 55 is aligned with each hole 56 . Barrier 20 may remain in this blocking position while door 100 is opened or closed. To remove barrier 20 from doorway 104 , channels 55 and holes 56 are aligned and pins 45 are passed through each pair of channels and holes to connect barrier 20 to door 100 . Then door 100 is opened so that barrier 20 is moved upward solely by the power of the door opening mechanism.
[0059] [0059]FIGS. 7-14 show a preferred embodiment of guard assembly 10 in which bracket 60 is mounted to door 100 rather than to barrier 20 as in FIGS. 1-6. As shown in FIG. 7, bracket 60 includes a door plate 61 which is mounted to door 100 by bolts 68 (shown in FIG. 10) and a hinge plate 63 which is pivotably connected to door plate 61 at pivot 62 such that hinge plate 63 may pivot with respect to door 100 and door plate 61 . Hinge plate 63 includes a hole 64 which provides for connection to and disconnection from barrier 20 as shown in FIGS. 13 and 14. Hinge plate 63 also includes hinge-plate aperture 67 at which tensioning element 65 , preferably a gas spring, is connected. Tensioning element 65 is further connected to door-plate aperture 66 on door plate 61 . Tensioning element 65 resists movement of hinge-plate aperture 67 toward door-plate aperture 66 when hinge plate 63 pivots about pivot 62 .
[0060] [0060]FIG. 8 shows bracket 60 mounted to door panel 104 while disconnected from barrier 20 . As shown, tensioning element 65 keeps hinge plate 63 at a position substantially perpendicular to door plate 61 . FIG. 9 shows bracket 60 mounted to door panel 104 and connected to barrier 30 at hole 64 . As shown, guard coupling 31 rests on the shoulder 124 formed by trusses 122 when guard coupling 31 receives post 120 and barrier 20 is connected to door 100 by bracket 60 . Upper coupling 32 is also shown receiving post 120 . FIG. 10 shows bracket 60 after pivoting of hinge plate 63 with respect to door plate 61 . As can be seen, tensioning element 65 is compressed by the pivoting of hinge plate 63 toward door plate 61 .
[0061] [0061]FIG. 11 depicts the opening of a door on a track 130 which includes a sloping portion 134 leading to a substantially horizontal portion. As can be seen, barrier 20 has pivoted with respect to door panel 104 to allow uprights 24 to extend substantially horizontally. As door panel 104 moves upward, tensioning elements 65 and hinge plates 63 keep uprights 24 substantially vertical until rollers 27 contact sloping portion 134 of track 130 . Then rollers 27 roll along track 130 and tensioning element 65 allows barrier 20 and hinge plate 63 to pivot about pivot 62 . When door panel 104 moves downward, tensioning element 65 pushes hinge plate 63 such that uprights 24 keep contact with track 130 and barrier 20 pivots back to its original position. In this way, barrier 20 can be moved into and out of the blocking position in which it extends across doorway 102 .
[0062] [0062]FIG. 12 depicts a preferred barrier 20 which includes a coupling 30 having a cable fitting 34 around which a cable 33 extends. Cable 33 preferably runs along barrier 20 to the opposite coupling 30 and opposite cable fitting 33 . Cable 33 provides sufficient tension to prevent anything from breaking through barrier 20 and damaging door 100 or falling off of the dock. In addition, cable 33 is sufficiently light-weight to optimize use of door 100 to remove barrier 20 from the doorway. Cable 33 may include two or more cables to provide increased tension. Cable fitting 33 is preferably aluminum or other similar lightweight metal and includes coupling 31 which receives post 120 and rests on shoulder 124 formed by trusses 122 when barrier 120 is in its blocking position.
[0063] [0063]FIGS. 13 and 14 depict the connection between bracket 60 and barrier 20 . FIG. 13 shows bracket 60 when disconnected from barrier 20 . As can be seen hole 64 of hinge plate 63 is positioned above bores 74 of receiving brackets 73 which are mounted to cable fitting 34 and upright 24 . Pin 71 is held in pin brace 72 which mounted to cable fitting 73 . When the door moves downward, hinge plate 63 is received within the space between brackets 73 until hole 64 is aligned with bores 74 , which preferably occurs when the door is closed. Pin 71 is then passed through bores 74 and hole 64 , thereby connecting barrier 20 to bracket 60 , and thus to the door.
[0064] During the initial installation of guard assembly 10 on a door 100 , barrier 20 is positioned across doorway 102 and coupled to pre-existing posts 120 or posts 120 installed along with the assembly 10 . When barrier 20 is properly positioned, door plates 61 may be mounted to the door 100 along a door panel 104 which is at the same height as barrier 20 . Preferably hinge plate 63 is pivotably mounted to door plate 61 before door plate is mounted to door 100 . Door plate 61 is preferably positioned such that hole 64 in hinge plate aligns with bore 74 in brackets 73 when door 100 is closed and barrier 20 rests on shoulders 124 . Barrier 20 may remain in this blocking position while door 100 is opened or closed. To remove barrier 20 from doorway 104 , holes 64 and bores 74 are aligned and pins 71 are passed through brackets 73 and hinge plate 63 to connect barrier 20 to door 100 . Then door 100 is opened so that barrier 20 is moved upward solely by the power of the door opening mechanism.
[0065] While the invention has been described with respect to specific embodiments by way of illustration, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true scope and spirit of the invention. | A guard assembly for use near a doorway with an overhead door on a platform having at least one post mounted adjacent the doorway is disclosed. The assembly preferably comprises a barrier adapted to extend across the doorway and having at least one coupling which is adapted to connect to a respective post to allow the barrier to block the doorway; and a bracket adapted to facilitate connection and disconnection between the barrier and the overhead door. Such an assembly allows the barrier to block the doorway whether connected to or disconnected from the door and to move with the door as the door opens and closes. | 4 |
CROSS-REFERENCE TO RELATED CASE
This application is related to the commonly assigned United States application Ser. No. 107,331, filed Dec. 26, 1979, and entitled "Control Apparatus for Controlling a Feed Movement In a Gear Cutting Machine". This application is also related to my commonly assigned United States application Ser. No. 06/170,759, filed July 21, 1980, entitled "Method For Fabricating Bevel and Axially Offset Gear Pairs".
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved method of fabricating gears with rolled or generated tooth flanks by cutting-out tooth slots or spaces by means of at least one face-mill cutter head which performs a rotational movement about a cutter head axis, and furthermore, relates to a new and improved gear cutting machine for the performance of the aforesaid method.
There is already known to the art a method of fabricating gears according to the foregoing. With this prior art method the face-mill cutter head, in order to cut-out tooth slots or spaces, carries out in relation to the workpieces, apart from the rotational movement along a cutter head axis, only a generating or rolling motion, but no plunge-cut motion. The feed, and therefore the depth of penetration of the cutters into the workpiece thus occurs in the direction of the rolling or generating movement. As a result, rolled or generated toothed slots are formed during one machining operation.
With this method the individual cutting edges of the cutters or cutter blades of the face-mill cutter head are non-uniformly loaded. The cutting edge which first reaches the workpiece during the generating or rolling motion must perform the greatest cutting work, and therefore, also must again be first reground. Experience has shown that the highly loaded cutting edge must in fact be reground a number of times, whereas the remaining cutting edges need only be reground once. The grinding of the cutter or cutter blade is associated with an interruption in production, the duration of which is not only dependent upon the number of cutting edges which must be reground, but also upon the therewith associated work, such as dismantling of the cutters, adjusting the cutters and so forth.
Furthermore, there is known from U.S. Pat. No. 3,583,278 a method of manufacturing bevel gears, wherein the tooth slots or spaces constrict in the lengthwise direction of the teeth. With this method during a first step the tooth slots are roughed only by plunge cutting. The plunge-cut begins at the region of an end surface of the bevel gear or at an end region of the tooth slot which is to be fabricated, and with increasing tooth slot depth there also increases the length of the tooth slot. After the tooth slot or space has reached a depth which is still appreciably less than the desired final depth of the finish rough cut tooth slot, then there is initiated a rolling or generating operation. Now the tooth slot also is further cut in the lengthwise direction, so that it extends up to the other end surface of the bevel gear. Hence, there has been cut-out a tooth slot or space, the depth of which must be increased and the flank profile of which must be further improved upon.
This is accomplished during a further working step, in that the tooth slot is further machined at the tooth root or base as well as at the tooth flanks, so that after the second working step the tooth slots have a shape which comes closer to that of the finished machined tooth slots.
During the fabrication of rough cut tooth slots according to the above-described method there are used different cutter heads. To cut the tooth slots to a first limited depth there are provided wide cutters, by means of which it is not possible to cut to the complete tooth slot depth. During the subsequent further rough cutting to a greater tooth slot depth it is then necessary to employ narrower, less efficient cutters.
However, this method only has an apparent similarity with the method of the present invention, since it is concerned with only part of the method for rough cutting the tooth slots. Further operating steps of the prior art method under consideration for the finish machining of such tooth slots are very cumbersome and entail a number of operating steps which must be carried out at different machines.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind it is a primary object of the present invention to provide a new and improved method of fabricating gears with generated or rolled tooth flanks and an apparatus for use with a gear cutting machine for the performance of the method, which is not afflicted with the aforementioned drawbacks and limitations of the prior art proposals.
Another and more specific object of the present invention aims at providing a new and improved method of, and apparatus for, fabricating gears which enables increasing the production capacity of the equipment during the fabrication of gears having rolled or generated tooth flanks.
The advantages of the invention reside in the fact that the individual cutting edges tend to essentially uniformly wear, since the inner and outer cutting edges are equally markedly loaded right from the start, which in turn means that the machine need only be shutdown at relatively large time intervals in order to exchange all of the cutters or for regrinding all of the cutting edges and thus the service life of the cutters is increased and the machining time shortened.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method of manufacturing gears with rolled or generated tooth flanks during the cutting-out of tooth slots as contemplated by the present development is manifested by the features that for the rough cutting of the tooth slots, during a first working step, the face-mill cutter head and the workpiece carry out a plunge-cut motion in relation to one another and thus the cutter of the face-mill cutter head initially contacts the workpiece at a predeterminable plunge-cut position between end regions of a tooth slot which is to be fabricated. For the finish cutting of the tooth slots, during a second working step, there is performed a generating or rolling motion between the face-mill cutter and the workpiece.
As already mentioned heretofore, the invention is also concerned with a new and improved construction of apparatus for a gear cutting machine for the performance of the aforementioned method aspects, wherein there are provided means for setting a generating or roll drum at predeterminable plunge cut positions.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 schematically illustrates part of a gear cutting machine according to the invention;
FIG. 2 illustrates the geometric relationships prevailing during the procedure of a bevel gear;
FIGS. 3 and 4 schematically illustrate in front view a bevel gear having a tooth slot or gap during the fabrication of such bevel gear; and
FIG. 5 schematically illustrates in fragmentary view a bevel gear having a tooth slot.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, in FIG. 1 there will be recognized a bevel gear blank constituting a workpiece 1 which, in a not here further illustrated but conventional and well known manner, is mounted to be rotatable at a gear cutting machine 3 about a workpiece axis 2. As a further well known component of the conventional gear cutting machine 3 there will be recognized a generating or roll cradle 4 which is displaceably mounted in the direction of a generating or roll axis 5 upon a partially shown socket or pedestal 6 or equivalent structure. A generating or roll drum 7 is rotatably mounted in the generating or roll cradle 4 about the generating or roll axis 5. This generating or roll drum 7 carries an end or face-mill cutter head 9 which is rotatable about a cutter head axis 8. Protruding out of the face-mill cutter head 9, in the direction of the workpiece 1, are the cutters or cutter blades 10, wherein as a matter of convenience in illustration only one such cutter 10 has been shown. Reference character 12 designates a circumferential surface of the workpiece 1.
Dogs or cams 14, 15, 16 and 17 or equivalent structure are provided at the generating or roll drum 7, and at the generating or roll cradle 4 there are provided switches 18 and 19. The cam or dog 15 is shown in a position where it is just covered by the switch 19, and it is for this reason that it has been illustrated in broken lines. The cams or dogs 14 and 16 are displaceable and individually fixable along a track 20, and the cams or dogs 15 and 17 are displaceable and individually fixable along a track 21 or equivalent structure.
Now in FIG. 2 there will be recognized as the workpiece a bevel gear 22 in partially sectional and fragmentary illustration, this bevel gear 22 having an axis 23. At the bevel gear 22 there is to be cut-out a tooth slot or space 24. Reference character 25 designates a generatrix of the partial or incremental surface of the bevel gear 22.
The left-hand portion of the showing of FIG. 2 illustrates in top plan view the pitch plane 26 of a crown gear and thus is disposed perpendicular to the side view illustrated at the right-hand half of the illustration of FIG. 2. The crown gear is limited by the arcuate sections 27 and 28 and meshes with the bevel gear 24. The generatrix 25 of the partial surface of the bevel gear 22 therefore also appears in the pitch plane 26. The intersection point 29 between the axis 23 of the bevel gear 22 and the generatrix 25 is therefore identical with the center 30 of the crown gear 27, 28. Reference character 31 designates a computation point of a tooth lengthwise line 32. The cutter head axis 8 of the face-mill cutter head 9, according to the showing of FIG. 1, intersects the pitch plane 26 of the crown gear 27, 28 (FIG. 2) at a point 33 and the cutters 10 rotate along an arc 35 having the radius 34. Since in the embodiment under discussion one is concerned for instance with a continuous cutting method, the tooth lengthwise line 32 has a different curvature and a different center than the arc 35.
By determining the elevational difference between the partial surface of the bevel gear 22 and the pitch plane 26 of the crown gear 27, 28 at the points 36 and 37 there can be derived the cut depth deviations 38, 39 in relation to the cut depth 40 at the computation point 31. Such cut or cutting depth deviations 38, 39 are that much greater the greater that there is selected the spiral angle β.
FIG. 3 schematically illustrates in front view a workpiece 1' having an axis 2'. Reference character 41 designates the slightly elliptical-shaped path through which rotatably passes a cutter 10' about a cutter head axis 8' which is slightly inclined with respect to the plane of the drawing. The cutter 10' thus cuts-out tooth slot or space 42, which is this case is represented by both of the boundary lines 43 and 44 at the circumferential surface 12'. Both ends of the tooth slot 42 and their immediate surroundings are designated as end regions 59 and 60. The selected spiral angle β" is relatively small. As the cutter 10' there also can be used and therefore there should be understood a group of cutters composed of a number of individual cutters or cutter blades.
According to the showing of FIG. 4, and analogous to the illustration of FIG. 3, there is cut-out at the workpiece 1" a tooth slot or space 45 having a larger spiral angle β", the tooth slot 45 being illustrated by boundary lines 47 and 48 at the circumferential surface 12". Such tooth slot 45 is cut-out with a face-mill cutter head which rotates about a cutter head axis 8". A further broken illustrated tooth slot or space 46 containing the boundary lines 49 and 50 is rotatably cut-out with the same face-mill cutter head, but the rotation being about the cutter head axis 8"'.
FIG. 5 illustrates a combination of the tooth slots 45 and 46 of the arrangement of FIG. 4, wherein there is formed a tooth slot 53 containing the boundary lines 54 and 55.
Having now had the benefit of the foregoing discussion the mode of operation of the apparatus of the invention and the novel method of fabricating gears with rolled or generated tooth flanks will be described and is as follows:
In order to cut a tooth slot in a workpiece 1 the following procedures are undertaken. After the workpiece 1 is chucked in conventional manner upon the gear cutting machine 3, it is necessary to initially determine a plunge-cut position. This is accomplished in that for instance, the cam 15 is fixed along the track 21 in a predetermined position. This means that at the start of the machining operation the generating drum 7 is rotated until the cam or dog 15 activates the switch 19. Consequently, the rotation of the generating drum 7 is interrupted and the generating or roll cradle 4 begins to move towards the workpiece 1. Hence, the face-mill cutter head 9 begins to rotate about the cutter head axis 8. Depending upon the position of the cam or dog 15, and thus, the position of the generating or roll drum 7, the cutters 10 of the face-mill cutter head 9 begin to carry out a plunge-cut at a predetermined plunge-cut position 56, 57 in the direction of the arrow 61 at the workpiece 1 between the end regions 59, 60 of a tooth slot or space 42' which is to be fabricated. In this respect a plunge-cut position 56 approximately at the center between the end or terminal regions 59, 60 is particularly advantageous for small spiral angles β' (see FIG. 3), since such produces boundary lines 43 and 44 whose course results in only a slightly reduced tooth slot depth at the region of the tooth slot ends.
Now in FIG. 2 there have been shown cutting depth deviations 38 and 39 for a comparable spiral angle β. The fact that the spiral angle β of FIG. 2 appears to be greater than the spiral angle β' of FIG. 3 is attributable to the fact that the spiral angle β is valid for a tooth slot or gap 24 which is fabricated according to a continuous method, whereas the spiral angle β' is valid for a tooth slot 42 which is fabricated according to an individual indexing method. The difference resides in the fact that with a continuous method the workpiece rotates during the cutting operation. Therefore the continuous method allows larger spiral angles β for the same cutting depth deviations 38 and 39.
Now if the cutters of the end or face-mill cutter head 9 have plunge-cut the workpiece 1 up to the desired tooth slot depth, then the tooth slots 24 and 42 are thus finish rough cut and there is initiated the return stroke for the generating or roll cradle 4 in conventional manner. With a continuous cutting method the entire circumference or periphery of the workpiece 1 is provided with tooth slots or spaces 24. During the individual indexing method the face-mill cutter head, after completing the first tooth slot 42, is again retracted therefrom and the workpiece 1 is indexed or further rotated through one tooth division or pitch, and the plunge-cut operation again is repeated until also in this case the entire workpiece 1 is provided with tooth slots or spaces 42.
The thus rough cut tooth slots 24 and 42 now must be finish cut. To this end the generating drum 7, after completion of the return stroke, continues to rotate until the cams 16 and 17 simultaneously activate the switches 18 and 19, respectively. Then there is again begun a plunge-cut stroke, which is thereafter replaced by a generating motion, which is completed when the cam or dog 14 activates the switch 18. Thereafter the generating or roll cradle 4 again carries out a return stroke and the gear is finished. The gear is completely fabricated at that time if the gear is produced according to a continuous generating method. With an individual indexing method these operations are repeated in analogous fashion a number of times. Due to such generating motion the tooth flanks now have imparted thereto their final profile or shape.
In the case of larger spiral angle β" (FIG. 4) or smaller gear diameter, a one-time plunge-cut at the plunge-cut position 56 but along the tooth slot 45 results in greater differences in the tooth slot depth. The course of the boundary lines 47 and 48 supports the conclusion that at one end of the tooth slot 45 the tooth slots depth is equal to null. A plunge-cut in the plunge-cut position 57 produces a tooth slot or space 46 with uniform tooth slot depth, as indicated by the course of the boundary lines 49 and 50. But also in this case there are perceivable greater tooth slot width differences, and thus, greater tooth slot depth differences.
In such case it is advantageous both in the plunge-cut position 56 and also in the plunge-cut position 57 to carry out a plunge-cut operation, producing an appreciably more uniform tooth slot 53 (FIG. 5), as indicated by the course of the boundary lines 54 and 55. To this end a further cam or dog 15' must be arranged at the generating drum 7, in order to trigger a further plunge-cut motion. Of course, the workpiece 1" must be rotated in relation to the face-mill cutter head between both of the plunge-cut positions 56 and 57, so that during a double plunge-cut there is formed a single tooth slot or space 53. The arc 58 in FIG. 4 determines the geometric location of possible positions of the cutter head axis 8", 8"', and the cutter head axes 8", 8"' are correlated to the plunge-cut positions 56 and 57.
Depending upon the nature of the workpiece, whether such is a spur gear, bevel gear and so forth, and the nature of the desired teeth, it is particularly advantageous to provide a multiplicity of plunge-cut positions along a tooth slot. This however does not produce any appreciable prolongation of the machining time, since the plunge-cut operations can be accomplished extremely rapidly.
As already indicated, the method of the invention can be beneficially employed both for continuous fabrication techniques as well as for individual indexing techniques. Equally, the method is capable of being effectively used for fabricating gears produced according to the generating crown gear method or the generating mating gear method. The use of this method upon machines having a number of stations and cutter heads, or upon a number of machines which are specialized for performing one or another method step, likewise falls within and is intended to be encompassed by the scope of the appended claims.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly, | In a method of manufacturing gears with rolled or generated tooth flanks by cutting-out tooth slots or spaces with at least one face-mill cutter head performing a rotational movement about a cutter head axis, wherein the production capacity or efficiency is increased in that for rough cutting the tooth slots, during a first working step, the face-mill cutter head and the workpiece perform a plunge-cut movement with respect to one another. Hence, the cutters of the face-mill cutter head initially contact the workpiece at a predeterminable plunge-cut position between end regions of a tooth slot or space which is to be fabricated. For finish cutting the tooth slots, during a further working step, there is performed a generating movement between the face-mill cutter head and the workpiece. | 8 |
FIELD OF THE INVENTION
The present invention relates to a process for the preparation of molecular sieve adsorbent for selective adsorption of oxygen from air. The present invention also relates to the use of rare earth exchanged zeolites as selective adsorbents for separation of gases having closely related physical properties. More particularly, the present invention relates to the preparation and use of adsorbent, which is selective towards oxygen, from a gaseous mixture of oxygen with argon.
BACKGROUND OF THE INVENTION
The use of adsorption techniques to separate a gaseous component from a gaseous stream was initially developed for the removal of carbon dioxide and water from air. Gas adsorption techniques are now employed in processes for the recovery of hydrogen from its mixture with hydrocarbons, and enrichment of oxygen from air.
The four types of adsorbents widely used include activated carbon, zeolite molecular sieves, silica gel and activated alumina. Carbon molecular sieves (CMS), which exhibit very narrow pore size distribution, facilitates separation of air to recover nitrogen has provided a secure and growing market for carbon molecular sieve.
Adsorption processes for the separation of oxygen and argon from air are being increasingly used for commercial purposes for the last three decades. Oxygen requirements in sewage treatment, fermentation, cutting and welding, fish breeding, electric furnaces, pulp bleaching, glass blowing, medical purposes and in the steel industries particularly where the required oxygen purity is between 90 to 95% are being largely met by adsorption based pressure swing or vacuum swing processes. It is estimated that at present, around 20% of the world's oxygen demand is met by adsorptive separation of air. However, the maximum attainable purity by adsorption processes is around 95% with separation of 0.934 mole percent argon present in the air being a limiting factor to achieve 100% oxygen purity. Furthermore, adsorption based production of oxygen from air is economically not competitive to cryogenic fractionation of air for production levels of more than 200 tons per day.
Argon gas is mainly used in industries as an inert gas for creating inert atmosphere. An argon or argon-hydrogen mixture is employed in the production of high-purity iron. Argon is also used in welding, cutting, and spraying of metals, depending on the welding process, the noble gas is used pure, as a mixture, or in combination with oxygen, hydrogen, or carbon dioxide. Argon/argon-hydrogen mixtures (>5% H 2 ) are used as protective gases for plasma welding. There are many potential applications of argon and it is expected that this work will lead to increased consumption of argon in the future.
For the adsorbents used in adsorption separation processes, there are two key; characteristics namely adsorption capacity and adsorption selectivity which need to be considered to assess their potential. Adsorption capacity of the adsorbent is defined as the amount in terms of volume or weight of the adsorbent. The higher the adsorbent's capacity for the desired components the better is the adsorbent as the increased adsorption required to separate a specific amount of a component from a mixture of particular concentration. Such a reduction in adsorbent quantity in a specific adsorption process brings down the cost of a separation process.
The adsorption selectivity of a component over the other is calculated as the ratio of the volumes of gas adsorbed at any given pressure and temperature. The adsorption selectivity of a component results from steric effect, i.e., when the adsorption isotherms of components of a gas mixture differ appreciably; kinetic effect, when the components have substantially different adsorption rates.
Adsorption for oxygen and nitrogen production is being widely used and tremendous research effort is being directed to improve the adsorption processes for higher adsorption capacity and selectivity. Adsorbents affect separations by adsorbing one or more components of the mixture strongly than the others components present in the mixture. The various interactive forces involved in adsorption process are van der Waals interactions, acid-base interactions, hydrogen bond, electrostatic, chelation, and clathration. Therefore, adsorbents are appropriately modified to enhance the interactions between adsorbent and adsorbate molecules to improve adsorption capacity and selectivity. Zeolites which are crystalline inorganic porous materials having pores with molecular dimensions have largely been used for adsorption separation. As the extra framework cations of the zeolites are reasonably mobile, cations exchange in zeolites is one the most common used techniques for surface modifications with cations of suitable size and charge to enhance zeolite adsorbate interactions. Literature on adsorbent development work carried out on zeolites shows that most of the reported work is confined to alkali and alkaline earth cations as extra framework cations. Adsorption of nitrogen, oxygen and argon in zeolites with cations having higher than bivalent is sparsely reported. As trivalent cations have higher charge density, they will have higher electrostatic interactions with nitrogen molecules if these cations are present at sites accessible to nitrogen molecules.
The principal characteristic of the separation, removal or concentration of oxygen, nitrogen and argon from the air is that usually there is no cost for the starting material, which is air. The cost of the desired gas produced or removed, depends essentially upon the following other factors.
(a) Costs of equipment necessary for separating, or concentrating the gas, (b) Costs of energy necessary for operating the equipment, (c) When gas with high purity is needed, the cost of the additional purification step which has to be taken into account.
Taking the above factors into consideration, various economically advantageous processes have, heretofore, been proposed. These include, for example; a process wherein air is liquefied al low temperatures to separate oxygen or nitrogen making use of difference in the boiling point between liquid oxygen (−182.9° C.) and liquid nitrogen (−195.8° C.). The apparatus employed is suited for producing large amounts of oxygen and nitrogen in the world is based on this procedure. Disadvantages of the process is that it requires large amounts of power, large-scale equipment is necessary site specific and portability is very less, it takes hours for switching on and switching off the plant. Last two decades, adsorption and membrane based processes for the separation of oxygen, nitrogen from air has emerged as potential alternatives.
A membrane system has been employed for the separation of oxygen and nitrogen from air. U.S. Pat. No. 5,091,216 (1992) to Hayes et al; U.S. Pat. No. 5,004,482 (1991) to Haas et al. and U.S. patent application 2,038,62 (2002), to Katz et al disclose the separation of oxygen and nitrogen from air using polymeric type membranes. The membrane based systems works at very high pressure. The main drawbacks of this method is the thin polymeric films are too weak to withstand the high differential gas pressures required for the separation and purity of the product gas is only around 50%.
In the prior art, adsorbent which are selective for nitrogen from its mixture with oxygen and argon have been reported [U.S. Pat. No. 5,114,440 (1992) to Reiss], [U.S. Pat. No. 4,481,018 (1984) to Coe et al., U.S. Pat. No. 4,557,736 (1985) to Sircar et al., U.S. Pat. No. 4,859,217 (1989) to Chao; Chien-Chung, U.S. Pat. No. 5,152,813 (1992) to Coe et al., U.S. Pat. No. 5,174,979 (1992) to Chao; Chien-Chung et al., U.S. Pat. No. 5,454,857 (1995) to Chao; Chien-Chung., U.S. Pat. No. 5,464,467 (1995) to Fitch et al., U.S. Pat. No. 5,698,013 (1997) to Chao; Chien-Chung., U.S. Pat. No. 5,868,818 (1999) to Ogawa et al., U.S. Pat. No. 6,030,916 (2000) to Choudary et al.,], [U.S. Pat. No. 4,964,889 (1990) to Chao; Chien-Chung, Gerhard,], [U.S. Pat. No. 4,943,304 (1990) to Coe et al.,] and [U.S. Pat. No. 6,231,644 (2001) to Jain et al.] wherein the zeolites of type A, faujasite, clinoptilolite, chabazite and monolith respectively have been used. The efforts to enhance the adsorption capacity and selectivity have been reported by exchanging the extra framework cations with alkali and/or alkaline earth metal cations and increasing the number of extra framework cations of the zeolite. The adsorption selectivity for nitrogen has also been substantially enhanced by exchanging the zeolite with cations like lithium and/or calcium in faujasite type zeolite. These adsorbents have been employed in processes for the separation or concentration of oxygen by removing nitrogen selectively from the air. The drawback of these adsorbents are the maximum attainable oxygen purity by adsorption processes is around 95%, with separation of 0.934-mole percent argon present in the air being a limiting factor t achieve 100% oxygen purity. These adsorbents are also highly moisture sensitive and the adsorption capacity and selectivity will decay in the presence of moisture.
U.S. Pat. No. 4,453,952 (1984) to Izumi et al. discloses the manufacture of an oxygen selective adsorbent by substituting the Na cations of zeolite A with K and Fe(II). The adsorbent shows oxygen selectivity only at low temperature and its preparation requires iron exchange carried out at around 80° C. using aqueous salt solutions of metal ions followed by exchange with potassium. The drawback of this invention is that the potassium exchange in zeolite leads to lower thermal and hydrothermal stability of the adsorbent.
U.S. Pat. No. 3,979,330 to Munzner et al. discloses the preparation of carbon containing molecular sieves in which coke containing up to 5% volatile components is treated at 600-900° C. in order to split off carbon from a hydrocarbon. The split-off carbon is deposited in the carbon framework of the coke to narrow the existing pores. The drawback of this process is deposition on carbon framework is not uniform and very energy intensive process.
U.S. Pat. No. 4,742,040 to Ohsaki et al. discloses a process for making a carbon molecular sieve having increased adsorption capacity and selectivity by palletising powder of charcoal containing small amounts of coal tar as a binder, carbonising, washing in mineral acid solution to remove soluble ingredients, adding specified amounts of creosote or other aromatic compounds, heating at 950-1000° C., and then cooling in an inert gas. The drawback of this process is energy intensive and tedious and organic compounds are expensive.
U.S. Pat. No. 4,880,765 to Knoblauch et al., discloses a process for producing carbon molecular sieves with uniform quality and good separating properties by treating a carbonaceous product with inert gas and steam in a vibrating oven with multi step and further treating it with benzene at high temperatures thereby narrow existing pores. Preparation of carbon molecular sieve is a multi-step process with utmost care at each state to get totally reproducible carbon molecular sieve. Additionally, the process is very high temperature process, which results into higher cost of the products.
U.S. Pat. No. 5,081,097 (1992) to Sharma et al., discloses copper modified carbon molecular sieves for selective removal of oxygen from air. The sieve is prepared by pyrolysis of a mixture of a copper-containing material and polyfunctional alcohol to form a sorbent precursor. The sorbent precursor is then heated and reduced to produce a copper modified carbon molecular sieve. Pyrolysis is high temperature process making the whole process of preparation of the adsorbent an energy intensive process.
U.S. Pat. No. 6,087,289 (2000) to Choudary et al. discloses a process for the preparation of a zeolite-based adsorbent containing cerium cations for the selective adsorption of oxygen from the gas mixture. Cerium exchange into zeolite is carried out under reflux conditions using aqueous solution of cerium salt at around 80° C. for 4-8 hours and repeating the ion exchange process several times and separation of gases was studied by gas chromatography in very low-pressure range. The main drawbacks of this adsorbent are oxygen selectivity being obtained only in the low-pressure region. Additionally, adsorption was studied only by gas chromatography in limited pressure range. Thus higher pressure range adsorption data was not obtained.
In another approach, chemical vapour deposition technique was used for controlling the pore opening size of the zeolites by the deposition of silicon alkoxide [M. Niwa et al., JCS Farady Trans. I, 1984, 80, 3135-3145; M. Niwa et al., M. Niwa et al., J. Phys. Chem., 1986, 90, 6233-6237; Chemistry Letters, 1989, 441-442; M. Niwa et al., Ind. Eng. Chem. Res., 1991, 30, 38-42; D. Ohayon et al., Applied Catalysis A-General, 2001, 217, 241-251]. Chemcal vapour deposition is carried out by taking a requisite quantity of zeolite in a glass reactor, which is thermally activated at 450° C. in situ under inert gas like nitrogen flow. The vapours of silicon alkoxide are continuously injected into inert gas stream, which carries the vapours to zeolite surface where alkoxide chemically reacts with silanol groups of the zeolite. Once the desired quantity of alkoxide is deposited on the zeolite, sample is heated to 550° C. in air for 4-6 hours after which it is brought down to ambient temperature and used for adsorption. The major disadvantages of this technique are (i) Chemical vapour deposition, which leads to non-uniform coating of alkoxide results in non-uniform pore mouth closure, (ii) The process has to be carried out at elevated temperature where the alkoxide is likely to be vaporised.
U.S. Pat. No. 4,239,509 (1980) to Bligh et al. discloses a method for purifying crude argon containing argon, oxygen and nitrogen which comprises the steps of reducing the amount of nitrogen in the crude argon to between a trace and 0.15% (by volume) and passing the remaining oxygen and argon, together with residual nitrogen, through 4A molecular sieve to separate the oxygen and argon. All the remaining oxygen and nitrogen has to pass through a volume of 4A molecular sieve, which is wholly at or below −250 F. The disadvantages of this process are adsorption process was carried out at −157° C. (−250° F.) temperature, and the arrangement of equipment is complicated for very low temperature separation, which is not economically acceptable.
U.S. Pat. No. 4,447,265 (1984) to Kumar et al. discloses that argon is recovered from a gas stream comprising the same in admixture with oxygen and nitrogen, by a vacuum swing adsorption (VSA) process wherein the mixed gas is passed through an adsorbent bed having thermodynamic selectivity for adsorption of nitrogen and unabsorbed portion is then passed through a second adsorbent bed having kinetic selectivity for retaining oxygen. Both adsorbent beds are regenerated by vacuum desorption, applied to the first bed for a longer time period than that of the second bed. The mixed gas stream fed to the VSA unit may be that obtained from the crude argon column associated with a cryogenic air separation plant and waste gas from the VSA unit may be recycled to the main column of the cryogenic air separation plant, thus enhancing argon recovery. The disadvantages of this possess are regeneration of the adsorbent is time consuming process and also for more recovery; of argon required cryogenic unit otherwise recovery is low.
U.S. Pat. No. 4,529,412 (1985) to Hayashi et al. discloses a process for obtaining high purity argon from air by means of pressure-swing-adsorption. The air is initially passed through a zeolite molecular sieve-packed adsorption apparatus and then again passed through carbon molecular sieve-packed adsorption apparatus, and then subjected to pressure-swing-adsorption operation, obtaining concentrated argon and high purity oxygen simultaneously. The drawback of this process is, to adsorption beds are required and process takes longer time. Moreover, in the process two beds are required for production thereby increasing the production cost.
U.S. Pat. No. 4,817,392 (1989) to Agrawal et al. discloses a process for the production and recovery of an O 2 -lean argon stream from a gas mixture containing argon and oxygen. The argon-containing gas mixture is initially treated in a cryogenic separation unit to produce a crude argon stream having an argon concentration between 80-98%. The crude argon stream is then passed to a membrane based separation unit where it is separated to produce an O 2 -lean argon stream and an O 2 -rich stream. The O 2 -rich stream is recycled to the cryogenic separation unit and the Ar-lean oxygen stream is recovered as product or further purified. The disadvantage of this process is that it requires membrane based separation, thereby increasing the production cost.
U.S. Pat. No. 5,557,951 (1996) to Prasad et al. discloses an apparatus for producing high purity product grade argon from an argon-containing stream using a cryogenic argon column in combination with a solid electrolyte ionic or mixed conductor membrane. The disadvantage of this process is recovery of argon can be achieved by two processes—one is cryogenic and the other is membrane separation, thereby increasing the production cost.
US Patent RE 34, 595 (1994) to Chen et al. discloses a process for purifying argon gas, specially an argon gas stream obtained by cryogenically separating air, wherein the argon gas is heated and compressed, and then permeated through a solid electrolyte membrane selective to the permeation of oxygen over other components of the gas, and removing oxygen from the argon by selective permeation of oxygen through the membrane. The purified argon can then be distilled to remove other components such as nitrogen. A process is provided for producing a purified argon stream wherein oxygen and nitrogen are removed from crude bulk argon streams, particularly those produced by cryogenic, adsorptive or membrane separation of air. The process comprises separating a heated, compressed crude argon stream containing nitrogen and oxygen into an oxygen permeate stream and an oxygen-depleted argon stream by passing the compressed heated argon stream through a solid electrolyte membrane selective to the permeation of oxygen. The oxygen-depleted argon stream is then fed to a distillation column to separate nitrogen from the oxygen-depleted argon stream to form the purified argon stream and a nitrogen waste system.
OBJECTS OF THE INVENTION
The main object of the present invention is to provide a process for the preparation of molecular sieve adsorbent for selective adsorption of oxygen from air, which obviates, the drawbacks as detailed above.
Still another object of the present invention is to provide an oxygen selective zeolite based adsorbent.
Still another object of the present invention is to provide an adsorbent, which can be prepared by the exchanging rare earth cations especially cerium, europium and gadolinium in ziolite X.
Yet another object of the present invention is to provide oxygen selective adsorbent by a simple post-systhesis modification of zeolite X.
Yet another object of the present invention is to provide an adsorbent, which can be regenerated by desorption of oxygen by controlling equillibrium adsorption pressure.
Yet another object of the present invention is to provide an adsorbent, which is selective towards oxygen over argon with high selectivity and can be commercially for the separation and purification of argon.
SUMMARY OF THE INVENTION
The present invention provides a process for the preparation of molecular sieve adsorbent for selective adsorption of oxygen from air, by exchanging powder and pellet form of sodium zeolite X, with an aqueous solution of rare earth cations such as cerium, europium and gadolinium, at elevated temperature. The dry zeolite X, containing 20 to 95% rare earth cations of the total exchangeable sodium cations, after activation at high temperature and vacuum were subjected to adsorption studies for oxygen, nitrogen and argon using a static volumetric system of an adsorption equipment supplied by Micromeritics Corporation USA (Model ASAP 2010). Adsorption capacities and selectivity for rare earth exchanged zeolite for oxygen, nitrogen and argon was measured at 15° C. and in the pressure range of 0.5 to 760 mmHg. From these data adsorption isotherm were plotted and pure component selectivity of gases were calculated. This invention provides a process to prepare zeolite adsorbent having selectivity for oxygen over nitrogen and argon.
Accordingly, the present invention provides a process for preparing a molecular sieve adsorbent for selective adsorption of oxygen from air, the process comprising
(i) exchanging zeolite X in powder or pellet form with water-soluble salt of a rare earth metal selected from the group consisting of cerium, europium, gadolinium and any mixture thereof, (ii) filtering the mixture, washing the powder or pellet with hot distilled water till it is free from anions to obtain an exchanged zeolite; (iii) drying the exchanged zeolite; (iv) and activating the exchanged zeolite.
In an embodiment of the present invention, zeolite X in powder form having 100% crystallinity and spherical pellet forms can be used for the preparation of the surface modified molecular sieve adsorbent.
In another embodiment of the present invention, Na cations of zeolite were exchanged with salts or rare earth ions 10 to 100 equivalent percentage (Cerium Europium and Gadolinium) are loaded using any water-soluble salts of chloride nitrate and acetate.
In still another embodiment of the present invention, the cation exchange can be carried at a temperature in the range of 30° C. to 90° C. for a period in the range of 4 to 8 hours.
In still another embodiment of the present invention, the cation exchange can be carried out at a cation concentration in the range of 0.01 to 0.1 M solution.
In still another embodiment of the present invention, the exchanged zeolite may be dried in a temperature range of 20° C. to 80° C. in air or under vacuum conditions.
In still another embodiment of the present invention, the exchanged zeolite may be activated in the temperature range of 350 to 450° C. for a period in the range of 3-6 hours followed by cooling under inert or vacuum condition.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
In the drawings accompanying this specification.
FIG. 1 represents the adsorption isotherms of nitrogen, argon and oxygen at 15° C. on the zeolite X pellets at pressures up to 850 mm Hg.
FIG. 2 represents the adsorption isotherms of nitrogen, argon and oxygen at 15° C. on the cerium exchanged zeolite X pellets at pressures up to 850 mm Hg.
FIG. 3 represents the adsorption isotherms of nitrogen, argon and oxygen at 15° C. on the europium exchanged zeolite Z pellets at pressures up to 850 mm Hg.
FIG. 4 represents the adsorption isotherms of nitrogen, argon and oxygen at 15° C. on the gadolunium exchanged zeolite X pellets at pressures up to 850 mm Hg.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a process for the preparation of an oxygen selective adsorbent, which has oxygen adsorption selectivity over nitrogen and argon. Furthermore, this adsorbent displays higher interaction with oxygen compared to nitrogen and argon as observed from heats adsorption values determined I the in Henry region.
Zeolites, which are microporous crystalline aluminosilicates, are finding increased applications as adsorbents for separating mixtures of compounds having closely related molecular properties.
The attributes which makes the zeolites attractive for separation include, an unusually high thermal and hydrothermal stability, uniform pore structure, easy pore aperture modification and substantial adsorption capacity even at low adsorbate pressures. Furthermore, zeolites can be produced synthetically under relatively moderate hydrothermal conditions.
The zeolite NaX powder and pellet [Na 86 (AIO 2 ) 86 (SiO 2 ) 106 wH 2 O] was used as the starting material. X-ray diffraction data showed that the starting material was highly crystalline. A known amount of the zeolite NaX powder and pellet [Na 86 (AIO 2 ) 86 (SiO 2 ) 106 wH 2 O] was refluxed with 0.01 M rare earth (Ce, Eu and Gd) acetate and chloride solution taken in 2 litre round bottomed flask with zeolite X (powder or pellet) to rare earth solution ratio 1:80 at 80-120° C. for 4 h. Zeolite samples having different amount of rare earth were prepared by subjecting repeated rare earth cation exchange into the zeolite. Zeolite sample were filtered after reflux and washed with distilled water until free from chloride as tested by AgNO 3 solution. In case of acetate, excess wash with not (60° C.) water was done. Extent of rare earth exchange into zeolite X was determined from the concentration of rare earth cations in original solution and the filtrate. Rare earth cations were analysed by using 0.01 M EDTA solution with xylenol orange tetra sodium salt indicator at pH=6 employing sodium acetate buffer.
Oxygen, nitrogen and argon adsorption at 15° C. was measured using a static volumentric system (Micromeritics, USA. ASAP 2010), after activating the sample at 350° C. to 450° C. under vacuum for 4-8 hours as described in the examples. Addition of the adsorbate gas was made at volumes required to achieve a targeted set of pressures ranging from 100 to 760 mmHg. A minimum equilibrium interval of 5 seconds was used to determine equilibrium for each measurement point.
The pure component selectivity of one gas over other (A and B) was determined by the equation,
α A/B =[V A /V B ] P,T
where V A and V B are the volumes of gas A and B adsorbed at equilibrium pressure P and temperature T.
Structural analysis of the zeolite samples was done by X-ray diffraction wherein the crystallinity of the zeolites are measured from the intensity of the well-defined peaks at 2 theta values of 6, 10, 11, 8, 15.5, 20, 23.4, 26.8, 30.5, 31, 32 and 33.8 X-ray powder diffraction was measured using PHILIPS X'pert MPD system equipped with XRK 900 reaction chamber.
The important inventive steps involved in the present invention are that the molecular sieve adsorbent, formation of oxygen selective species inside the zeolite cavities (i) by exchanging with lanthanide aqueous solution and in addition to cation exchange by forming non-stoichiometric oxide of cerium/europium/gadolinium which can selectively; interact with oxygen molecules (ii) the process lies in providing a new technique, in addition to conventional cation exchange, of introducing sorbate specific metal oxide in the micropores of the zeolites for developing new adsorbents. The non-stochiometric oxides of these rare earths like cerium and europium can react with oxygen in a reversible manner and reversibly changes the oxidation state thus acting as chemisorption-assisted adsorption. High heats of adsorption values observed also are indicative chemisorption type interactions with oxygen molecule.
The adsorbtive capacity of the catalyst was verified evaluated by adsorbing nitrogen, oxygen and argon gases on exchanged zeolites having 99.9% purity at 15° C. and in the pressure range of 0.5 to 800 mmHg and then calculating the adsorption selectivity of gases at 15° C. and 100 and 760-mmHg pressures.
The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention.
EXAMPLE-1
1.0 gm of zeolite NaX pellet, [Na 2 O) 86 (AI 2 O 3 ) 86 .(SiO 2 ) 106 .wH 2 O], was activated at 350° C. temperature under vacuum at 10 −3 mmHg and adsorption measurements were carried out for N 2 , O 2 , Ar having 99.9% purity at 15° C. using volumetric system (Micromeritics ASAP 2010C) operating at 760 mmHg pressure with equilibrium interval of 5 seconds. Adsorption capacity for N 2 ,O 2 and Ar is 9.74 cc/g, 3.31 cc/g and 3.29 cc/g respectively at 15° C. temperature and 760-mmHg pressures. Selectivity for nitrogen over oxygen is 2.9; selectivity for nitrogen over argon is 2.96, and selectivity for oxygen over argon is 1.0 at 15° C. at 760-mmHg pressures.
EXAMPLE-2
25.0 g of the molecular sieve NaX pellet was exchanged with 0.301M Cerium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The Cerium content in dry zeolite amount is 25% of the total replaceable sodium cations. This ziolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.17 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 2.4 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 1.0, selectivity for nitrogen over oxygen is 3.3 and nitrogen over argon is 3.3 at the 100-mmHg pressure.
EXAMPLE-3
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Cerium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The cerium content in dry zeolite amount is 84% of the total replaceable sodium cations. This zeolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 1.4 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 3.7 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 8.0, selectivity for nitrogen over oxygen is 0.4 and nitrogen over argon is 3.5 at the 100-mmHg pressure.
EXAMPLE-4
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Cerium chloride solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from chloride ions and then dried in air at room temperature (28° C.). The cerium content in dry zeolite amount is 28% of the total replaceable sodium cations. This zeolite was activated at 3500C temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.58 gm. The adsorption measurement was carried out at 15° C. temperature 760-mmHg pressures. The adsorption measurement was carried out at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 3.0, selectivity for nitrogen over oxygen is 1.3 and nitrogen over argon is 4.0 at the 100-mmHg pressure.
EXAMPLE-5
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Cerium chloride solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from chloride ions and then dried in air at room temperature (28° C.). The cerium content in dry zeolite amount is 93% of the total replaceable sodium cations. This zeolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.53 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 3.1 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 3.5, selectivity for nitrogen over oxygen is 1.4 and nitrogen over argon is 5.0 at the 100-mmHg pressure.
EXAMPLE-6
25.0 g of the molecular sieve NaX powder was exchanged with 0.014M Cerium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The cerium content in dry zeolite amount is 74% of the total replaceable sodium cations. This zeolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.13 gm. The adsorption capacity for oxygen is 4.6 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 4.0, selectivity for nitrogen over oxygen is 1.1 and nitrogen over argon is 4.2 at the 100-mmHg pressure.
EXAMPLE-7
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Cerium acetate solutions in the ratio 1:80 and refluxed at 50° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The cerium content in dry zeolite amount is 20% of the total replaceable sodium cations. This zeolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.22 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 2.2 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 1.5, selectivity for nitrogen over oxygen is 2.2 and nitrogen over argon is 3.2 at the 100-mmHg pressure.
EXAMPLE-8
25.0 g of the molecular sieve NaX pellet was exchanged with 0.1M Cerium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The cerium content in dry zeolite amount is 30% of the total replaceable sodium cations. This zeolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.15 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 3.2 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 2.0, selectivity for nitrogen over oxygen is 2.4 and nitrogen over argon is 3.8 at the 100-mmHg pressure.
EXAMPLE-9
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Europium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The europium content in dry zeolite amount is 52% of the total replaceable sodium cations. This zeolite was activated at 3500C temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.59 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 2.3 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 1.7, selectivity for nitrogen over oxygen is 1.1 and nitrogen over argon is 2.7 at the 100-mmHg pressure.
EXAMPLE-10
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Europium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The europium content in dry zeolite amount is 67% of the total replaceable sodium cations. This zeolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.52 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 2.6 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 2.3, selectivity for nitrogen over oxygen is 1.3 and nitrogen over argon is 3.1 at the 100-mmHg pressure.
EXAMPLE-11
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Gadolinium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The gadolinium content in dry zeolite amount is 82% of the total replaceable sodium cations. This zeolite was activated at 35° C. temperature under vacuum (10 −3 mmHg) and the weight of sample after activation was 0.59 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 3.2 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 4.0, selectivity for nitrogen over oxygen is 1.3 and nitrogen over argon is 5.0 at the 100-mmHg pressure.
EXAMPLE-12
25.0 g of the molecular sieve NaX pellet was exchanged with 0.01M Gadolinium acetate solutions in the ratio 1:80 and refluxed at 80° C. for 4 hours. The hot solution was filtered, washed with hot distilled water, until the washings are free from acetate ions and then dried in air at room temperature (28° C.). The gadolinium content in dry zeolite amount is 88% of the total replaceable sodium cations. This zeolite was activated at 350° C. temperature under vacuum (10 −3 mmHg) and weight of sample after activation was 0.66 gm. The adsorption measurement was carried out at 15° C. temperature and 760-mmHg pressures. The adsorption capacity for oxygen is 2.8 cc/g at 15° C. temperature and 760 mmHg and selectivity for oxygen over argon is 2.0, selectivity for nitrogen over oxygen is 3.0 and nitrogen over argon is 6.0 at the 100-mmHg pressure.
The main advantages of the invention are:
1. The adsorbent, prepared by the modification of zeolite X shows oxygen selectivity over nitrogen argon.
2. A simple exchange with aqueous solution of rare earth cations is used for the preparation of the adsorbent.
3. The exchange is carried out at 80° C. and atmospheric pressure.
4. The adsorbent is very easy to handle.
5. The adsorbent shows oxygen/argon selectivity of nearly 8 in the low-pressure range studied.
6. The adsorbent is useful in the commercial separation and purification of oxygen and argon from its mixture with nitrogen.
7. The adsorbent is useful for the chromatographic separation of oxygen nitrogen and argon. | The invention relates to the manufacture of molecular sieve adsorbents, which are selective towards oxygen from its gaseous mixture with argon and/or nitrogen. More particularly, this invention relates to the manufacture of molecular sieve adsorbents useful for the separation of oxygen-argon gaseous mixture. More specifically, the invention relates to the manufacture and use of a molecular sieve adsorbent by cation exchange in zeolites by rare earth cations to obtain oxygen selective adsorbent from its gaseous mixture with nitrogen and argon at ambient conditions of temperature and pressure. Thus prepared adsorbent is useful for the separation and purification of nitrogen and argon from its mixture with oxygen. | 1 |
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates to a multiple-compartment insulated food tray for storage and service, and more particularly an insulated food tray and method of manufacture using a durable polymer matrix wherein each main compartment is insulated.
BACKGROUND
[0002] Meals served to humans generally include multiple courses served at different temperatures. Normally, each courses is served on a different plate, often at different temperatures, and at different time intervals. In some circumstances, large groups of people must be fed where special requirements are imposed. In some environments, such as school cafeterias, incarceration facilities, hospitals, military bases, summer camps, airplanes, nursing homes, etc., food service must be provided to large groups without generating excessive dirty dishes or utensils, and those dishes and utensils must limit manipulation problems at service, provide ease in storage, be easily cleaned, protect the user from sharp objects, and even respect strict logistical restraints.
[0003] The use of food serving systems based on trays is known in the art. The first generation of trays was made of disposable structures with removable inserts. More robust trays include a light-weight frame with vertical separators designed to segregate the courses, but these trays offered little or no thermal insulation between the courses. A common example of these trays include the familiar TV dinner tray, which is able to hold frozen food for long periods of time and later be placed in a conventional oven. Trays may include compartments to separate cold foods from hot foods, wet courses from dry courses, and prevent mixing of the courses. Trays may also include compartments in which small items such as condiments can be served.
[0004] Thin-walled metallic trays are light and disposable but offer little temperature control of the food. If heated courses are placed in these trays, the trays themselves can become hot, the hands of users can be burned, and food courses can reach thermal equilibrium within minutes. Newer versions of trays include insulation placed within a shell made by the tray, but these shells are often bulky, require numerous and expensive manufacturing steps, result in very small compartment sizes, and are still vulnerable to thermal equilibrium unless they are covered by a second tray or a lid. For this reason, a thin-walled robust food tray capable of insulating the food is needed.
[0005] Another problem with existing trays is the incapacity to provide for an efficient and safe way to supply of utensils without resulting to a dedicated compartment in the tray, or an independent and external supply of utensils. Placing utensils within a compartment often results in the utensil being in contact with the food. What is needed is a food tray able to provide for utensil delivery system without negatively affecting the other functions of the food tray, such as the capacity.
[0006] Yet another problem of existing food tray technology is partial insulation resulting from stacking trays. Food place within a recessed portion of a first insulated food tray is insulated from the environment, but if the courses include hot and cold portions located in different compartments, both courses reach an intermediate thermal equilibrium quickly within the food tray. What is needed is a compartment-specific insulated food tray. The use of compartment-specific insulation may also offer odor control in order to better preserve the aroma of each course.
SUMMARY
[0007] It is an object of the present disclosure to provide an insulated, multiple-compartment food tray and lid for storage and service. The insulated food tray and lid is equipped with a circumferential, weight-activated lip and a series of female U-shaped lips located on the tops of the internal and external walls of the insulated food tray. If a lid or a second insulated food tray acting as a lid is placed on top of the first insulated food tray, an L-shaped circumferential lip and male U-shaped lip located on the bottom portion of the second tray seals the compartments from each other resulting in thermal and aromatic segregation among the compartments. The use of a long, L-shaped lip on the circumference of the insulated food trays allows for two stacked strays to be mechanically unified using the weight of the top tray on the bottom tray in any orientation where the weight of the second tray remains on the first tray.
[0008] In another embodiment of the present disclosure, a polymer with foam and blowing agents is used during the molding process to create in a first phase a hard shell in contact with the mold. In a second phase, insulation is created in the hard shell by thermal treatment and expansion of the residual polymer inserted in the mold. This two-step formation process allows for a light, robust insulated food tray with better capacity and improved properties over existing food tray technologies. In a third embodiment of the present disclosure, the insulated food trays can be stacked in a nondiscriminatory arrangement by rotating one tray in relationship with the next by a fixed angle depending on the geometry of the insulated trays.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an exploded view of a stack of two insulated food trays and a top lid in accordance with an embodiment of this disclosure.
[0010] FIG. 2 is a side view along cut-line 2 - 2 of the exploded view of the stack of two insulated food trays and the top lid of FIG. 1 .
[0011] FIG. 3 is a top view of an insulated food tray in accordance with an embodiment of this disclosure.
[0012] FIG. 4 is a bottom view of the insulated food tray of FIG. 4 .
[0013] FIG. 5 is a detail cut view of the L-shaped lip of an assembled stack of insulated food trays and a top lid in accordance with an embodiment of the present disclosure.
[0014] FIG. 6 is a detail cut view of the U-shaped lip in the assembled stack of insulated food trays and top lid in accordance with the embodiment of FIG. 5 .
[0015] FIG. 7 is a functional diagram in accordance with a method of manufacturing an insulated food tray in accordance with an embodiment of this disclosure.
DETAILED DESCRIPTION
[0016] Referring to FIG. 1 , a stack 16 of insulated food trays 1 and lid 2 is shown. In this possible embodiment, two insulated food trays 1 are shown stacked vertically, and a lid 2 is placed on top of the upper insulated food tray 1 . It is understood by one of ordinary skill in the art that while only two insulated food trays 1 are illustrated, a stack can include a greater plurality of insulated food trays 1 .
[0017] The bottom insulated food tray 1 as shown on FIG. 1 is arranged nondiscriminatorily in relation to the top insulated food tray 1 and can be rotated in the horizontal plane by 180 degrees. While a single nondiscriminatorily arranged configuration is illustrated in FIG. 1 , it is understood by one of ordinary skill in the art that many different configurations and nondiscriminatory arrangements are possible based on a plurality of factors, including the geometry of the insulated food tray 1 and the arrangement of the different inner compartments. An illustrative but nonlimiting example includes an octagonal insulated food tray with eight compartments located circumferentially around a single center compartment. In this example, a top insulated food tray 1 could be placed nondiscriminatorily in eight orientations in relation to a bottom insulated food tray 1 by rotating the top or bottom tray by any factor of 45 degrees.
[0018] FIG. 2 shows an insulated food tray 1 of FIG. 1 comprising an upper surface member 3 of a first height 51 and a lower surface member 4 of a second height 53 connected to the upper surface member 3 to form an outer shell 21 with an inner volume 20 . An insulated material is released in the inner volume 20 in a phase of the formation process of the insulated food tray 1 .
[0019] The inner volume 20 is filled with an insulating medium as a result of the formation process of the outer shell 21 . An injection molding method for manufacturing an insulated food tray is shown in FIG. 7 . In a first step 101 , a series of agents are blended into a polymer in order to create a durable polymer matrix. A quantity of blowing agent is added to the mix. In a preferred embodiment, a range of 1% to 5% of weight is added. It is understood by one of ordinary skill in the art that while a preferred range is disclosed, the determination of the quantity and proportion of blowing agent to be added to a mix is a function of the chemical nature of the blowing agent and the chemical stability of the base polymer as processed during molding by the injection mold and associated molding apparatus. A quantity of structural foam is also added to the polymer mix. In a preferred embodiment, the range is 5% to 20%. It is also understood by one of ordinary skill in the art that as for any other agent added to the polymer mix, the determination of the quantity and proportion of structural foam needed are a function of the chemical nature of the foaming agent and the chemical stability of the base polymer in combination with any other agent as used during the process of molding by injection. In a second step 102 , the durable polymer matrix is injected into the mold using conventional injection molding techniques. It is understood by one of ordinary skill in the art that the precise amount of durable polymer to be injected is a function of the actual geometry of the insulated food tray and the expansion volume of the insulation 20 within the inner shell 21 and must be calibrated upon injection based on the parameters of the injection molding device.
[0020] In a third step 103 also shown in FIG. 7 , the polymer matrix is solidified on the outer surface of the insulated food tray in order to form an outer shell 21 in contact with the cold, inside surface of the injection mold. It is understood by one of ordinary skill in the art of injection molding that the thickness of the shell and the injection locations in the mold needed to form the plurality of ribs and structures of the insulated food tray 1 are calibrated using classical injection molding techniques. In a fourth step 104 , a fraction of the polymer matrix remaining inside the shell is heated to allow the endothermic or exothermic durable polymer matrix to generate gas to form a solid insulation material with small gas bubbles. In a preferred embodiment, nitrogen gas is released during an endothermic reaction, but it is understood by one of ordinary skill in the art that any type of release gas chemically activated during the heating phase may be used, as well as any other neutral gas or expansion solid. It is understood that activation of the foam agent and the blowing agent by heat or other activation source is a very broad technology. What is contemplated is any activation means including but not limited to heat, cold, friction, time, chemical by-products, electrical current, magnetic excitation, irradiation, vibration, and any other potential energy source able to activate an agent found within a polymer matrix and create an insulation phase. In a preferred embodiment, the heating phase is conducted during approximately six minutes and at a temperature of approximately 140 degrees F. It is understood by one of ordinary skill in the art of heating injection molded pieces that the temperature and duration of the heating phase are a function of a plurality of parameters needed to activate agents within the polymer matrix and correspond to the current best mode.
[0021] The next step of the method of manufacturing relates to cooling the insulated food tray within the injection mold 105 . In a preferred embodiment, water is used to cool the mold to facilitate stabilization of the agents and the insulation 20 within the outer shell 21 . It is understood by one of ordinary skill in the art that the insulated food tray 1 within the injection mold can be cooled using a plurality of conventional means including but not limited to air cooling, mold cooling, time cooling, and compressed gas cooling. In a next step, the insulated tray 1 is stabilized 106 before removal from the injection mold using classical techniques including but not limited to hand removal or mechanical removal.
[0022] Returning to the embodiment shown as FIGS. 1 and 2 , the upper surface 3 of a first height 51 and the lower surface 4 of a second height 53 are shown to be the same height corresponding to roughly half of the total height of the insulated food tray 1 . It is understood by one of ordinary skill in the art that while first and second heights 51 , 53 are shown in this proportion in a preferred embodiment, the respective heights can correspond to any proportion of the total height of the insulated food tray 1 as long as the functional limitations associated with stacking the insulated food trays 1 is made possible.
[0023] The upper surface member 3 is relieved to define a plurality of inner compartments 5 of at least a third height 50 of a first top lip 57 and an outer rim 7 [not shown] with a second top lip 55 of the first height 51 . The lower surface member 4 is relieved to define inner ribs 58 of a fourth height 52 with a first bottom lip 56 and a second outer rim 14 [not shown] with a second bottom lip 54 of the second height 53 . While the surface member 3 is described with the help of elements of two heights called a first height 51 and a third height 50 , respectively, it is understood by one of ordinary skill in the art that both heights may be of the same height or that any of the two heights may be higher from the bottom surface of the compartments 5 without any influence on this disclosure. The same may be said for the second height 53 and the fourth height 52 on the bottom member 4 . The use of the terms “second” and “fourth” are not indicative of the necessity of a difference in height or any indication that the second height 53 is more important than the fourth height 52 .
[0024] The contents of an inner compartment 5 in a first insulated food tray 1 , as shown in FIG. 3 , is insulated by another inner compartment 5 in the first insulated food tray 1 by placing a second insulated food tray 1 on the top of the first insulated food tray 1 so the first bottom lip 56 and the second bottom lip 54 of the second insulated food tray 1 connects with the first top lip 57 and the second top lip 55 of the first insulated food tray 1 , respectively. FIGS. 5 and 6 show two detail of the embodiment of FIGS. 1 and 2 where both bottom lips 56 , 54 of the second insulated food tray 1 connect with both top lips 57 , 55 of the first insulated food tray 1 . It is understood that while the present disclosure relates to an embodiment where the combined height of the first and second heights 51 , 53 must be approximately the same as the combined height of the third and fourth heights 50 , 52 in order to seal the compartments 5 , other heights may be contemplated that are sufficient to seal the compartments 5 . It is be understood by one of ordinary skill in the art that while the best mode of a preferred embodiment disclosed is made of a single molded element, the art of injection molding allows contemplation of the use of the merger of more than a single molded element in order to create the preferred embodiment. A nonlimiting example includes the use of a first upper surface member 3 of a first height 51 wherein a series of smaller containers would be connected to the inside portion of the relieved portion of the upper surface member in order to recreate containers 5 . The present disclosure contemplates the use of any combination of elements in order to create the essential properties of the insulated food tray disclosed herein.
[0025] In another embodiment, the seal between the first top lip 57 is made of a female U-shaped lip, and the first bottom lip 56 is made of a male U-shaped lip in order to allow for the compartment 5 to be sealed when the upper surface member 3 of a first insulating food tray 1 is placed under the lower surface member 4 of a second insulated food tray 1 . In another preferred embodiment, the second top lip 55 is made of a male U-shaped and the second bottom lip 54 is a recessed L-shaped lip. In the preferred embodiment shown as FIGS. 1-6 , the L-shaped lip is inverted and the top portion of the L-shaped lip is located inside of the volume formed by the second top lip 55 of the first insulated food tray 1 . It is understood by one of ordinary skill in the art that while U-shaped and L-shaped lips are disclosed and shown, these shapes may be made of a series of flat or curved sections assembled to recreate these shapes. It is understood that the maximum angular radius of any connecting angle is determined by the manufacturing process and molding tolerances associated with the molding process. In a preferred embodiment, the lips 56 , 54 are approximately ⅛th inch in lateral thickness and the U-shaped lip and L-shaped lip have a quasicircular head radius and a very thick wall.
[0026] As shown on FIG. 4 , support corner tabs 11 are placed on the bottom section of the L-shaped lip 54 . These tabs serve a plurality of functions including but not limited to improving locally the coverage section between both insulated food trays in a stack 16 , and protecting the first bottom lip 56 from friction and wear when the insulated food tray 1 is placed on a table or other surface. In a preferred embodiment, the support corner tabs are about 1/16th inch in height. It is understood by one of ordinary skill in the art that a plurality of support mechanisms can be used to protect the first bottom lip 56 from wear.
[0027] One of the compartments 5 includes a notch holder 12 able to receive a utensil 60 as shown using phantom lines in FIG. 1 . The notch holder is designed to hold a utensil 60 specifically designed to be used in conjunction with food courses served within one or more of the compartments 5 . In a preferred embodiment, the handle of the utensil is inserted in the notch 12 in order to protect the apprehension section of the utensil 60 from coming in substantial contact with food placed in the compartment 5 where the utensil 60 is situated.
[0028] In yet another embodiment as shown in FIGS. 1-2 , the upper surface 3 of the insulated food tray 1 is further relieved to create two side-by-side volume separators 13 . In a preferred embodiment, the volume separators 13 define condiment holders to be used in association with one of the courses placed in the containers 5 . It is understood by one of ordinary skill in the art what while two volumes are shown, different quantities or types of volumes may be contemplated. In addition, in the preferred embodiment shown, the third height 50 of the condiment sections 13 does not include a first top lip 57 to be associated with a first bottom lip 56 of an associated fourth height 52 of a second insulated food tray 1 . This configuration contemplates use where the condiment compartments 13 are not completely insulated from the surrounding immediate compartment 5 . It is understood by one of ordinary skill that any combination of sealed or unsealed first bottom lip 56 may be used in association with this disclosure depending on the desired level of insulation to be obtained.
[0029] FIG. 1-2 illustrates a situation where a first insulated food tray 1 is insulated by placing a second insulated food tray 1 on top. The figures also show the situation where the second insulated food tray 1 is insulated by placing a lid 2 on top. The lid comprises a second upper surface member 17 and a second lower surface member 18 . The lower surface member 18 is relieved to create a series of ribs 22 to mimic the lower surface 4 of the insulated food tray 1 . In the preferred embodiment, the second upper surface member 17 is flat, but it is understood by one of ordinary skill in the art that the lid may be made of a wide variety of geometries and include numerous functional features to serve any additional purpose.
[0030] FIGS. 1-2 show an exploded view of the tray stack shown in FIGS. 5-6 . When trays and/or a lid are stacked, the weight of the top trays, along with the weight of the food courses placed in the compartments 5 , serve to seal the bottom insulated food tray 1 with the top insulated food tray 1 or lid 2 . It is understood that if an insulated food tray is insulated and sealed by gravitational force, the seal may be broken if the stack 16 is rotated to a significantly vertical configuration. The disclosure provides for a stack of trays able to remain sealed as long as the weight of the top insulated food tray 1 or lid 2 pushes on the bottom insulated food trays 1 .
[0031] FIG. 3 is a top view of an insulated food tray in accordance with an embodiment of this disclosure. FIG. 4 is a bottom view of the insulated food tray of FIG. 4 . FIG. 5 is a detail cut view of the L-shaped lip of an assembled stack and top lid of insulated food trays in accordance with an embodiment of the present disclosure. FIG. 6 is a detail cut view of the U-shaped lip in the assembled stack and top lid of insulated food trays in accordance with the embodiment of FIG. 5 .
[0032] Persons of ordinary skill in the art appreciate that although the teachings of the disclosure have been illustrated in connection with certain embodiments, there is no intent to limit the invention to such embodiments. On the contrary, the intention of this disclosure is to cover all modifications and embodiments falling fairly within the scope of the teachings of the disclosure. | The present disclosure provides a multiple-compartment insulated food tray and lid for storage and service. The insulated food trays allow for two or more stacked strays to be mechanically unified using the weight of the top tray on the bottom tray in any orientation where the weight of the second tray remains on the first tray. In another embodiment of the present disclosure, a polymer with foam and blowing agents are used during the molding process to create in a first phase a hard shell in contact with the mold. In a second phase, insulation is created in the hard shell by thermal treatment and expansion of the residual polymer inserted in the mold. In a third embodiment of the present disclosure, the insulated food trays, when stacked, can be placed in a nondiscriminatory arrangement. | 0 |
1. FIELD OF INVENTION
[0001] This application generally relates to the field of drilling. In particular, this application discusses a drilling system for drilling core samples that can increase drilling productivity by reducing the amount of time needed to place and retrieve a core sample tube (or sample tube) in a drill string.
2. BACKGROUND AND RELATED ART
[0002] Drilling core samples (or core sampling) allows observation of subterranean formations within the earth at various depths for many different purposes. For example, by drilling a core sample and testing the retrieved core, scientists can determine what materials, such as petroleum, precious metals, and other desirable materials, are present or are likely to be present at a desired depth. In some cases, core sampling can be used to give a geological timeline of materials and events. As such, core sampling may be used to determine the desirability of further exploration in a particular area.
[0003] In order to properly explore an area or even a single site, many core samples may be needed at varying depths. In some cases, core samples may be retrieved from thousands of feet below ground level. In such cases, retrieving a core sample may require the time consuming and costly process of removing the entire drill string (or tripping the drill string out) from the borehole. In other cases, a faster wireline core drilling system may include a core retrieval assembly that travels (or trips in and out of) the drill string by using a wireline cable and hoist.
[0004] While wireline systems may be more efficient than retracting and extending the entire drill string, the time to trip the core sample tube in and out of the drill string still often remains a time-consuming portion of the drilling process. The slow tripping rate of the core retrieval assembly of some conventional wireline systems may be cause by several factors. For example, the core retrieval assembly of some wireline systems may include a spring-loaded latching mechanism. Often the latches of such a mechanism may drag against the interior surface of the drill string and, thereby, slow the tripping of the core sample tube in the drill string. Additionally, because drilling fluid and/or ground fluid may be present inside the drill string, the movement of many conventional core retrieval assemblies within the drill string may create a hydraulic pressure that limits the rate at which the core sample tube may be tripped in and out of the borehole.
BRIEF SUMMARY OF THE INVENTION
[0005] This application describes a high productivity core drilling system. The system includes a drill string, an inner core barrel assembly, an outer core barrel assembly, and a retrieval tool that connects the inner core barrel assembly to a wireline cable and hoist. The drill string comprises multiple variable geometry drill rods. The inner core barrel assembly comprises a latching mechanism that can be configured to not drag against the interior surface of the drill string during tripping. In some instances, the latching mechanism may be fluid-driven and contain a detent mechanism that retains the latches in either an engaged or a retracted position. The inner core barrel assembly also comprises high efficiency fluid porting. Accordingly, the drilling system significantly increases productivity and efficiency in core drilling operations by reducing the time required for the inner core barrel assembly to travel through the drill string.
BRIEF DESCRIPTION OF THE FIGURES
[0006] To further clarify the advantages and features of the drilling systems described herein, a particular description of the systems will be rendered by reference to specific embodiments illustrated in the drawings. These drawings depict only some illustrative embodiments of the drilling systems and are, therefore, not to be considered as limiting in scope. The same reference numerals in different drawings represent the same element, and thus their descriptions will be omitted. The systems will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0007] FIG. 1 is a depiction of some embodiments of a core sample drilling system;
[0008] FIGS. 2A and 2B contain different views of some embodiments of an inner core barrel assembly;
[0009] FIGS. 3A and 3B depict cross-sectional views of some embodiments of one portion of a core sample drilling system;
[0010] FIG. 4 is a cross-sectional view of some embodiments of a portion of a core sample drilling system;
[0011] FIGS. 5A-5C are cross-sectional views of some embodiments of a portion of a core sample drilling system in different modes of performance; and
[0012] FIGS. 6A-6C are cross-sectional views of some embodiments of a portion of a core sample drilling system in different modes of performance.
DETAILED DESCRIPTION
[0013] The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the drilling systems and associated methods can be implemented and used without employing these specific details. Indeed, the systems and associated methods can be placed into practice by modifying the systems and associated components and methods and can be used in conjunction with any existing apparatus, system, component, and/or technique conventionally used in the industry. For instance, while the drilling systems are described as being used in a downhole drilling operation, they can be modified to be used in an uphole drilling operation. Additionally, while the description below focuses on a drilling system used to trip a core barrel assembly into and out of a drill string, portions of the described system can be used with any suitable downhole or uphole tool, such as a core sample orientation measuring device, a hole direction measuring device, a drill hole deviation device, or any other suitable downhole or uphole object.
[0014] FIG. 1 illustrates some embodiments of a drilling system. Although the system may comprise any suitable component, FIG. 1 shows the drilling system 100 may comprise a drill string 110 , an inner core barrel assembly comprising an inner core barrel 200 , an outer core barrel assembly comprising an outer core barrel 205 , and a retrieval tool 300 that is connected to a cable 310 .
[0015] The drill string may include several sections of tubular drill rod that are connected together to create an elongated, tubular drill string. The drill string may have any suitable characteristic known in the art. For example, FIG. 1 shows a section of drill rod 120 where the drill rod 120 may be of any suitable length, depending on the drilling application.
[0016] The drill rod sections may also have any suitable cross-sectional wall thickness. In some embodiments, at least one section of the drill rod in the drill string may have a varying cross-sectional wall thickness. For example, FIG. 1 shows a drill string 110 in which the inner diameter of the drill rod sections 120 varies along the length of the drill rod, while the outer diameter of the sections remains constant. FIG. 1 also shows that the wall thickness at the first end 122 of a section of the drill rod 120 can be thicker than the wall thickness near the middle 124 of that section of the drill rod 120 .
[0017] The cross-sectional wall thickness of the drill rod may vary any suitable amount. For instance, the cross-sectional wall thickness of the drill rod may be varied to the extent that the drill rod maintains sufficient structural integrity and remains compatible with standard drill rods, wirelines, and/or drilling tools. By way of example, a drill rod with an outer diameter (OD) of about 2.75 inches may have a cross-sectional wall thickness that varies about 15% from its thickest to its thinnest section. In another example, a drill rod with an OD of about 3.5 inches may have a cross-sectional wall thickness that varies about 22% from its thickest to its thinnest section. In yet another example, a drill rod with an OD of about 4.5 inches may have a cross-sectional wall thickness that varies about 30% from its thickest to its thinnest section. Nevertheless, the cross-sectional wall thickness of the drill rods may vary to a greater or lesser extent than in these examples.
[0018] The varying cross-sectional wall thickness of the drill rod may serve many purposes. One purpose is that the varying wall thickness may allow the inner core barrel to move through the drill string with less resistance. Often, the drilling fluid and/or ground fluid within the drill string may cause fluid drag and hydraulic resistance to the movement of the inner core barrel. However, the varying inner diameter of drill string 110 may allow drilling fluid or other materials (e.g., drilling gases, drilling muds, debris, air, etc.) contained in the drill string 110 to flow past the inner core barrel in greater volume, and therefore to flow more quickly. For example, fluid may flow past the inner core barrel 200 as the inner barrel passes through the wider sections (e.g., near the middle 124 of a section 120 ) of the drill string 110 during tripping.
[0019] In some embodiments, the drilling system comprises a mechanism for retaining the inner core barrel at a desired distance from the drilling end of the outer core barrel. Although any mechanism suitable for achieving the intended purpose may be used, FIG. 1 shows some embodiments where the retaining mechanism comprises a landing shoulder 140 and a landing ring 219 . Specifically, FIG. 1 shows that the landing shoulder 140 comprises an enlarged shoulder portion on the inner core barrel 200 . Further, FIG. 1 shows the outer core barrel 205 can comprise a landing ring 219 that mates with the landing shoulder 140 .
[0020] The landing ring and landing shoulder may have any feature that allows the inner core barrel to “seat” at a desired distance from the drilling end of drill string 110 . For example, the landing shoulder may be slightly larger than the outer diameter of the inner core barrel and the core sample tube. In another example, the landing ring may have a smaller inner diameter than the smallest inner diameter of any section of drill rod. Thus, the reduced diameter of the landing ring may be wide enough to allow passage of the sample tube, while being narrow enough to stop and seat the landing shoulder of the inner core barrel in a desired drilling position.
[0021] The annular space between the outer perimeter of the landing shoulder and the interior surface of the drill string may be any suitable width. In some instances, the annular space may be thin because a thin annular space may allow the sample tube to have a larger diameter. In other instances, though, because a thin annular space may prevent substantial passage of fluid as the inner core barrel trips through the drill string, the landing shoulder may comprise any suitable feature that allows for increased fluid flow past the landing shoulder. In these other instances, FIG. 2B shows that the landing shoulder 140 may have a plurality of flat surfaces or flats 145 incorporated into its outer perimeter, giving the outer perimeter of the landing shoulder 140 a polygonal appearance. Such flats can increase the average width of the annular space so as to reduce fluid resistance—and thereby increase fluid flow—in both tripping directions.
[0022] The drill string 110 may be oriented at any angle, including between about 30 and about 90 degrees from a horizontal surface, whether for an up-hole or a down-hole drilling process. Indeed, when the system 100 used with a drilling fluid in a downhole drilling process, a downward angle may help retain some of the drilling fluid at the bottom of a borehole. Additionally, the downward angle may allow the use of a retrieval tool and cable to trip the inner core barrel from the drill string.
[0023] The inner core barrel may have any characteristic or component that allows it to connect a downhole object (e.g., a sample tube) with a retrieval tool so that the downhole object can be tripped in or out of the drill string. For example, FIG. 2A shows the inner core barrel 200 may include a retrieval point 280 , an upper core barrel assembly comprising an upper core barrel 210 , and a lower core barrel assembly comprising a lower core barrel 240 .
[0024] The retrieval point 280 of the inner core barrel 200 may have any characteristic that allows it to be selectively attached to any retrieval tool, such as an overshot assembly and a wireline hoist. For example, FIG. 2A shows the retrieval point 280 may be shaped like a spear point so as to aid the retrieval tool to correctly align and couple with the retrieval tool. In another example, the retrieval point 280 may be pivotally attached to the upper core barrel so as to pivot in one plane with a plurality of detent positions. By way of illustration, FIG. 2B shows the retrieval point 280 may be pivotally attached to a spearhead base 285 of a retrieval tool via a pin 290 so a spring-loaded detent plunger 292 can interact with a corresponding part on the spearhead base 285 .
[0025] The upper core barrel 210 may have any suitable component or characteristic that allows the core sample tube to be positioned for core sample collection and to be tripped out of the drill string. For example, FIGS. 3A and 3B show the upper core barrel 210 may include an inner sub-assembly 230 , an outer sub-assembly 270 , a fluid control valve 212 , a latching mechanism 220 , and a connection member 213 for connecting to the lower core barrel.
[0026] The inner sub-assembly 230 and the outer sub-assembly 270 may have any component or characteristic suitable for use in an inner core barrel. For instance, FIG. 2B shows some embodiments where the inner and the outer sub-assembly may be configured to allow the inner sub-assembly 230 to be coupled to and move axially (or move back and/or forth in the drilling direction) with respect to the outer sub-assembly 270 . FIG. 2B also shows that the inner sub-assembly 230 can be connected to the outer sub-assembly 270 via a pin 227 that passes through a slot 232 in the inner sub-assembly 230 in a manner that allows the inner sub-assembly 230 to move axially with respect to the outer sub-assembly 270 for a distance corresponding to the length of the slot 232 .
[0027] In some embodiments, the upper core barrel comprises a fluid control valve. Such a valve may serve many functions, including providing control over the amount of drilling fluid that passes through the inner core barrel during tripping and/or drilling. Another function can include partially controlling the latching mechanism, as described herein.
[0028] The fluid control valve may have any characteristic or component consistent with these functions. For example, FIGS. 2B and 3A show that the fluid control value 212 can comprise a fluid control valve member 215 and a valve ring 211 . The valve member 215 may be coupled to the outer sub-assembly 270 by any known connector, such as pin 216 . The pin 216 may travel in a slot 214 of the valve member 215 so that the valve member 215 can move axially with respect to both the inner sub-assembly 230 and the outer sub-assembly 270 . The movement of the valve member 215 relative to the inner sub-assembly 230 allows the fluid control valve 212 to be selectively opened or closed by interacting with the valve ring 211 . For example, FIG. 3A shows the fluid control valve 212 in an open position where the valve member 215 has traveled past the valve ring 211 , to one extent of the slot 214 . Conversely, FIG. 3B shows the fluid control valve 212 in an open position where the valve member 215 is retracted to another extent of the slot 214 . The fluid control valve in FIG. 3B is in a position ready to be inserted into the drill string where it can allow fluid to flow from the lower core barrel to the upper core barrel.
[0029] In some embodiments, the upper core barrel 210 can contain an inner channel 242 that allows a portion of the drilling fluid to pass through the upper core barrel 210 . While fluid ports may be provided along the length of the inner core barrel 200 as desired, FIGS. 2A and 3B show fluid ports 217 and 217 B that provide fluid communication between the inner channel 242 and the exterior of inner core barrel 200 . The fluid ports 217 and 217 B may be designed to be efficient and to allow fluid to flow through and past portions of inner core barrel 200 where fluid flow may be limited by geometry or by features and aspects of inner core barrel 200 . Similarly, any additional fluid flow features may be incorporated as desired, i.e., flats machined into portions of inner core barrel.
[0030] FIG. 3A shows some embodiments where the fluid control valve 212 is located within the inner channel 242 . In such embodiments, a drilling fluid supply pump (not shown) may be engaged to deliver fluid flow and pressure to generate fluid drag across the valve member 215 so as to push the valve member 215 to engage and/or move past the valve ring 211 .
[0031] In some embodiments, the upper core barrel also comprises a latching mechanism that can retain the core sample tube in a desired position with respect to the outer core barrel while the core sample tube is filled. In order to not hinder the movement of the inner core barrel within the drill string, the latching mechanism can be configured so that the latches do not drag against the drill string's interior surface. Accordingly, this non-dragging latching mechanism can be any latching mechanism that allows it to perform this retaining function without dragging against the interior surface of the drill string during tripping. For instance, the latching mechanism can comprise a fluid-driven latching mechanism, a gravity-actuated latching mechanism, a pressure-activated latching mechanism, a contact-actuated mechanism, or a magnetic-actuated latching mechanism. Consequently, in some embodiments, the latching mechanism can be actuated by electronic or magnetic sub-systems, by valve works driven by hydraulic differences above and/or below the latching mechanism, or by another suitable actuating mechanism.
[0032] The latching mechanism may also comprise any component or characteristic that allows it to perform its intended purposes. For example, the latching mechanism may comprise any number of latch arms, latch rollers, latch balls, multi-component linkages, or any mechanism configured to move the latching mechanism into the engaged position when the landing shoulder of the inner core barrel is seated against the landing ring.
[0033] By way of non-limiting example, FIGS. 2B and 3A show some embodiments of the latching mechanism 220 comprising at least one pivot member 225 that is pivotally coupled to the outer sub-assembly 270 by a connector, such as pin 227 . FIGS. 2B and 3A also show the latching mechanism 220 can include at least one latch arm 226 that is coupled to the inner sub-assembly 230 by a connector (such as pin 228 ) so that the latch arm or arms 226 may be retracted or extended from the outer sub-assembly 270 . FIG. 2B shows the latch arm 226 can comprise an engagement flange 229 , or a surface configured to frictionally engage the interior surface of the drill string when the latching mechanism is in an engaged position. For example, FIG. 3A shows that when in an engaged position, the latch arms 226 may extend out of and/or away from the outer sub-assembly 270 . Conversely, when in a retracted position (as shown in FIG. 5C ), the latch arms 226 may not extend outside the outer diameter of the outer sub-assembly 270 .
[0034] In some embodiments, the latching mechanism may also comprise a detent mechanism that helps maintain the latching mechanism in an engaged or retracted position. The detent mechanism may help hold the latch arms in contact with the interior surface of the drill string during drilling. The detent mechanism may also help the latch arms to stay retracted so as to not contact and drag against the interior surface of the drill string during any tripping action.
[0035] The detent mechanism may contain any feature that allows the mechanism to have a plurality of detent positions. FIG. 3B shows some embodiments where the detent mechanism 234 comprises a spring 237 with a ball 238 at each end. The detent mechanism 234 is located in the inner sub-assembly 230 and cooperates with detent positions 235 and 236 in the outer sub-assembly 270 to hold the latching mechanism in either an engaged position, as when the detent mechanism 234 is in an engaged detent position 235 , or a retracted position, as when the detent mechanism 234 is in a retracted detent position 236 .
[0036] In some preferred embodiments, the latching mechanism may cooperate with the fluid control valve so as to be a fluid-driven latching mechanism. Accordingly, the fluid control valve 212 can operate in conjunction with the latching mechanism 220 so as to allow the inner core barrel 200 to be quickly and efficiently tripped in and out of the drill string 110 . The latching mechanism and the fluid control valve may be operatively connected in any suitable manner that allows the fluid control valve to move the latching mechanism to the engaged position as shown in FIGS. 5A-6C , as described in detail below.
[0037] FIG. 4 illustrates some embodiments of the lower core barrel 240 . The lower core barrel 240 may include any component or characteristic suitable for use with an inner core barrel. In some embodiments, as shown in FIG. 4 , the lower core barrel may comprise at least one inner channel 242 , check valve 256 , core breaking apparatus 252 , bearing assembly 255 , compression washer 254 , core sample tube connection 258 , and/or upper core barrel assembly connection 245 .
[0038] FIG. 4 shows that the inner channel 242 can extend from the upper core barrel through the lower core barrel 240 . Among other things, the inner channel can increase productivity by allowing fluid to flow directly through the lower core barrel. The inner channel may have any feature that allows fluid to flow through it. For example, FIG. 2B shows the inner channel 242 may comprise a hollow spindle 251 that runs from the upper core barrel 210 to the lower core barrel 240 .
[0039] According to some embodiments, the lower core barrel comprises a check valve 256 that allows fluid to flow from the core sample tube to the inner channel, but does not allow fluid to flow from the inner channel to the core sample tube. Accordingly, the check valve may allow fluid to pass into the inner channel and then through the inner core barrel when the inner core barrel is being tripped into the drill string and when core sample tube is empty. In this manner, fluid resistance can be lessened so the inner core barrel can be tripped into the drill string faster and more easily. On the other hand, when the inner core barrel is tripped out of the drill string, the check valve can prevent fluid from pressing down on a core sample contained in core sample tube. Accordingly, the check valve may prevent the sample from being dislodged or lost. And when the check valve prevents fluid from passing through the lower core barrel and into the core sample tube, the fluid may be forced to flow around the outside of the core sample tube and the lower core barrel. Although any unidirectional valve may serve as the check valve, FIG. 4 shows some embodiments where the check valve 256 comprises a ball valve 259 .
[0040] In some embodiments, the lower core barrel 240 may comprise a bearing assembly that allows the core sample tube to remain stationary while the upper core barrel and drill string rotate. The lower core barrel may comprise any bearing assembly that operates in this manner. In the embodiments shown in FIG. 4 , the bearing assembly 255 comprises ball bearings that allow an outer portion 257 of the lower core barrel 240 to rotate with the drill string during drilling operations, while maintaining the core sample tube in a fixed rotational position with respect to the core sample.
[0041] The lower core barrel may be connected to the core sample tube in any suitable manner. FIG. 4 shows some embodiments where the lower core barrel 240 is configured to be threadingly connected to the inner tube cap 270 (shown in FIG. 2B ) and/or the core sample tube by a core sample tube connection 258 , which is coupled to the bearing assembly 255 .
[0042] FIG. 4 also shows some embodiments where the lower core barrel 240 contains a core breaking apparatus. The core breaking apparatus may be used to apply a moment to the core sample and, thereby, cause the core sample to break at or near the drill head (not shown) so the core sample can be retrieved in the core sample tube. While the lower core barrel 240 may comprise any core breaking apparatus, FIG. 4 shows some embodiments where the core breaking apparatus 252 comprises a spring 261 and a bushing 263 that can allow relative movement of the core sample tube and the lower core barrel 240 .
[0043] In some embodiments, the lower core barrel may also comprise one or more compression washers that restrict the flow of drilling fluid once the core sample tube is full, or once a core sample is jammed in the core sample tube. The compression washers ( 254 shown in FIG. 4 ) can be axially compressed when the drill string and the upper core barrel press in the drilling direction, but the core sample tube does not move axially because the sample tube is full or otherwise prevented from moving downwardly with the drill string. This axial compression causes the washers to increase in diameter so as to reduce, and eventually eliminate, any space between the interior surface of the drill string and the outer perimeter of the washers. As the washers reduce this space, they can cause an increase in drilling fluid pressure. This increase in drilling fluid pressure may function to notify an operator of the need to retrieve the core sample and/or the inner core barrel.
[0044] FIGS. 5A-6C illustrate some examples of the function of the inner core barrel 200 during tripping and drilling and the function of some embodiments of both the detent mechanism 234 and the fluid-driven latching mechanism 220 . FIG. 5A depicts the detent mechanism 234 in an intermediary position, as may be the case when the latching mechanism 220 is manually placed in a retracted position in preparation for insertion into the drill string. FIG. 5B shows that when the latch arms 226 are in an engaged position, the pivot member 225 is extended to force the latch arms 226 to remain outward (as also shown in FIG. 3A ). On the contrary, when the latch arms 226 are in a retracted position, as shown in FIG. 5C , the pivot member 225 can be rotated such that the latch arms 226 may be retracted into the upper core barrel 210 .
[0045] As described above, the inner sub-assembly 230 can move axially with respect to the outer sub-assembly 270 . In some embodiments, this movement can cause the latching mechanism to move between the retracted and the engaged positions as illustrated in FIGS. 5A-5C , where the movement of the inner sub-assembly 230 with respect to the outer sub-assembly 270 may change the position of the latch arms 226 . The pin 228 holding the latch arms 226 can be connected only to the inner sub-assembly 230 and the pin 227 holding the pivot member 225 can be connected to the outer sub-assembly 270 . Thus, when the outer sub-assembly 270 moves axially with respect to the inner sub-assembly 230 so as to cover less of the of the inner sub-assembly 230 , the distance between the two pins (pin 228 and pin 227 ) can increase and the pivot member 225 can rotate. As a result, the latch arms 226 may partially or completely move into the outer sub-assembly 270 and the detent mechanism 234 can move from the engaged detent position 235 to the retracted detent position 236 (as shown in FIG. 5C ). On the contrary, when the outer sub-assembly 270 moves axially so as to cover more of the inner sub-assembly 230 , the distance between the two pins (pins 228 and 227 ) can decrease and the latch arms 226 may be forced out of the outer sub-assembly 270 into an engaged position (as shown in FIG. 5B ).
[0046] FIGS. 6A-6C show some examples of how the fluid control valve 212 can function. FIG. 6A shows the fluid control valve 212 in an open position so that fluid can flow from the lower core barrel 240 , through the inner channel 242 , past the fluid ring 211 , past the fluid control valve 212 , and through the fluid ports 217 B to the exterior of the inner core barrel 200 . With the fluid control valve 212 in an open position, the latching mechanism 220 can be in a retracted position and ready for insertion into the drill string. In this open position shown in FIG. 6A , the fluid can flow from the lower core barrel 240 to the upper core barrel 210 , but fluid pressure forces the valve member 215 towards the fluid ring 211 and causes the fluid control valve to press against the fluid ring 211 and prevent fluid flow.
[0047] When the landing shoulder of the inner core barrel reaches the landing ring in the drill string, the inner core barrel can be prevented from moving closer to the drilling end of the outer core barrel. Because the landing shoulder can be in close tolerance with the interior surface of the drill string, drilling fluid may be substantially prevented from flowing around the landing shoulder 140 . Instead, the drilling fluid can travel through the inner core barrel 200 (e.g., via fluid ports 217 B and the inner channel 242 ). Thus, the fluid can flow and press against the valve member 215 . The slot 214 may then allow the valve member 215 to move axially so as to press into and past the fluid ring 211 until the slot 214 engages pin 216 . FIGS. 6B and 3A show that at this point, the fluid control valve 212 may again be in an open position below the fluid ring 211 . Where the detent mechanism 234 is in an intermediary position (as shown in FIG. 5A ), the inner sub-assembly 230 may be moved when the valve member 215 pulls on the pin 216 that is attached to the inner sub-assembly 230 . Thus, fluid pressure can cause the valve member 215 to move past the fluid ring 211 and, thereby, move the inner sub-assembly 230 and the detent mechanism 234 so that the latching mechanism 220 moves into and is retained in the engaged position.
[0048] FIGS. 5B and 6B illustrate some embodiments of the inner core barrel 200 with the latching mechanism 220 in the engaged position (i.e., ready for drilling). As shown in FIG. 5B , the detent mechanism 234 can be held in the engaged detent position 235 . And as shown in FIG. 6B , during drilling the fluid control valve 212 can be held in an open position with the valve member 215 pushed below the fluid ring 211 by the fluid pressure.
[0049] Once the core sample tube is filled as desired, the drilling process may be stopped and the core sample can be tripped out of the drill string. To retrieve the core sample, the retrieval point 280 is pulled towards earth's surface by a retrieval tool 300 connected to a wireline cable 310 and hoist (not shown). The pulling force on the retrieval point 280 (and hence the pulling force on the outer sub-assembly 270 ) may be resisted by the engaged latching mechanism (e.g., mechanism 220 ) and the weight of the core sample in the core sample tube. These resisting forces may cause the inner sub-assembly 230 to move with respect to the outer sub-assembly 270 so that the detent mechanism 234 moves from the engaged detent position 235 (as shown in FIG. 5B ) to the retracted detent position 236 (as shown in FIG. 5C ). The movement of the inner sub-assembly 230 forces the pin 216 to move away from the fluid ring 211 . As the slot 214 in the valve member 215 is caught by the pin 216 , the fluid control valve 212 moves into a closed position where the valve member 215 is seated in the fluid ring 211 (as shown in FIG. 6C ). And as the inner core barrel is tripped out of the drill string, downward fluid pressure may prevent the fluid control valve 212 from opening upwardly.
[0050] As mentioned above, the movement of the inner sub-assembly 230 may force the latching mechanism 220 into a retracted position, as shown in FIG. 6C . In the retracted position, the latching mechanism 220 does not drag or otherwise resist extraction of the inner core barrel 200 from the drill string. Thus, the fluid-driven latching mechanism greatly reduces the time required to retrieve a core sample. Once the inner core barrel 200 is tripped out of the drill string and the core sample is removed, the inner core barrel can be reset, as illustrated by FIGS. 5A and 6A , to be placed into drill string to retrieve another core sample.
[0051] In some variations of the described system, one or more of the various components of the inner core barrel may be incorporated with a variety of other downhole or uphole tools and/or objects. For instance, some form of the non-dragging latching mechanism, such as the fluid-driven latching mechanism with the detent mechanism, may be incorporated with a ground or hole measuring instrument or a hole conditioning mechanism. By way of example, any in-hole measuring instrument assembly may comprise a fluid-driven latching mechanism, such as that previously described. In this example, the assembly may be tripped into the drill string and stopped at a desired position (e.g., at the landing ring). Then, as fluid applies pressure to the fluid control valve in the assembly, the latching mechanism can be moved to the engaged position in a manner similar to that described above.
[0052] The embodiments described in connection with this disclosure are intended to be illustrative only and non-limiting. The skilled artisan will recognize many diverse and varied embodiments and implementations consistent with this disclosure. Accordingly, the appended claims are not to be limited by particular details set forth in the above description, as many apparent variations thereof are possible without departing from the spirit or scope thereof. | High productivity core drilling systems are described. The system includes a drill string, an inner core barrel assembly, an outer core barrel assembly, and a retrieval tool that connects the inner core barrel assembly to a wireline cable and hoist. The drill string comprises multiple variable geometry drill rods. The inner core barrel assembly comprises a non-dragging latching mechanism, such as a fluid-driven latching mechanism that contains a detent mechanism that retains the latches in either an engaged or a retracted position. The inner core barrel assembly also comprised high efficiency fluid porting. Accordingly, the drilling system significantly increases productivity and efficiency in core drilling operations by reducing the time required for the inner core barrel assembly to travel through the drill string. Other embodiments are also described. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for collecting/transporting a medical capsule and an endoscopic apparatus for the method, in particular, a method for holding a medical capsule in lower gastrointestinal tract such as small intestine or colon to collect or transport it and an endoscopic apparatus for the method.
[0003] 2. Description of the Related Art
[0004] In recent years, as endoscopes for medical use, various types of capsule endoscopes containing miniature cameras have been developed. Because such capsule endoscopes are wireless, patient discomfort can be decreased compared to the case with an endoscope in which an inserting section of the endoscope is also inserted in his/her body cavity.
[0005] A medical capsule such as a capsule endoscope is generally expected to be naturally extruded out of a body cavity, but there is a need to collect the medical capsule at a predetermined position in a body cavity. Also, a medical capsule often gets stuck at a narrow portion of a body cavity, which requires a procedure to find the medical capsule to hold it in order to collect it or to bring it beyond the narrow portion. Moreover, in recent years, there has been a need to transport a medical capsule to a predetermined position in body cavity so that an observation can be started from the position. In these various applications, it is necessary to hold a medical capsule in a body cavity.
[0006] Then, various endoscopic apparatuses having a function to hold a medical capsule in a body cavity have been developed. For example, an endoscopic apparatus disclosed in Japanese Patent Application Laid-Open No. 2004-194976 has an inserting section with a distal end formed with a suction opening to suck and hold a medical capsule therein.
[0007] The endoscopic apparatus disclosed in Japanese Patent Application Laid-Open No. 2004-194976, however, attracts and holds a medical capsule having an outer diameter of usually on the order of 10 mm in a suction opening thereof having a small inner diameter of 2 to 4 mm, which means the endoscopic apparatus does not have a enough power to hold a capsule, and the medical capsule can be fallen.
[0008] The endoscopic apparatus disclosed in Japanese Patent Application Laid-Open No. 2004-194976 has another problem that even if a held medical capsule is fallen, the falling is not recognizable because the endoscopic apparatus holds the capsule at a position which is unlikely to be within a range for observation and it is difficult to check the capsule visually, and the fallen medical capsule has to be located again.
[0009] In addition, as the endoscopic apparatus disclosed in Japanese Patent Application Laid-Open No. 2004-194976 is generally in the form of string of scope, it cannot easily reach the inside of lower gastrointestinal tract such as small intestine to collect or transport a medical capsule.
[0010] The present invention is made in view of the above problems, and one object of the present invention is to provide a method for collecting/transporting a medical capsule which reliably holds a medical capsule in body cavity to collect or transport, and an endoscopic apparatus for the method.
SUMMARY OF THE INVENTION
[0011] To achieve the above object, a first aspect of the present invention provides a method for collecting/transporting a medical capsule by holding the medical capsule using an endoscopic apparatus comprising: an endoscope having an inserting section to be inserted in a body cavity with a distal end including an observation section to observe a subject and a suction opening; a sucking device in communicated with the suction opening; and a generally cylindrical hood member which is attached to the distal end of the inserting section, the method comprising: a sucking step of making an inside of the hood member vacuum by actuating the sucking device to suck the inside of the hood member through the suction opening; and a holding step of attracting and holding the medical capsule to the hood member sucked by the sucking step.
[0012] According to the first aspect of the present invention, the inside of a hood member is sucked through a suction opening to make the inside of the hood member vacuum so that a medical capsule can be attracted to and held by the hood member, thereby the medical capsule can be held by the hood member having a larger opening than the suction opening. Thus, a larger holding power for a medical capsule is obtained, and a medical capsule can be reliably held with it.
[0013] According to the first aspect of the present invention, as a medical capsule is held by a hood member, the held medical capsule can be observed by an observation section of an endoscope.
[0014] To achieve the above object, a second aspect of the present invention provides an endoscopic apparatus, comprising: an endoscope having an inserting section to be inserted in body cavity with a distal end including an observation section to observe a subject and an suction opening; a sucking device in communicated with the suction opening; and a generally cylindrical hood member which is attached to the distal end of the inserting section, wherein the hood member has a holding section to attract and hold a medical capsule when the sucking device is actuated to suck the inside of the hood member through the suction opening to make the inside of the hood member vacuum.
[0015] According to the second aspect of the present invention, the hood member can hold a medical capsule at the holding section thereof. Thus, a medical capsule is reliably held, which prevents the medical capsule from falling.
[0016] According to the second aspect of the present invention, as a medical capsule is held by a hood member, the held medical capsule can be observed by an observation section of an endoscope.
[0017] A third aspect of the present invention according to the second aspect provides an endoscopic apparatus, wherein the hood member is configured to hold a medical capsule with at least a part of the medical capsule being pulled into the inside of the hood member. The configuration to hold a medical capsule with at least a part of the medical capsule being pulled into the inside of the hood member increases a holding power, which can reliably prevent the medical capsule from falling.
[0018] A fourth aspect of the present invention according to the second aspect or the third aspect provides an endoscopic apparatus, wherein at least a part of the hood member is transparent or semitransparent. According to the fourth aspect of the present invention, because at least a part of the hood member is transparent or semitransparent, view is not restricted while the endoscopic apparatus is inserted to find a medical capsule, and even when the hood member holds a medical capsule, the outside of the hood member can be observed by the observation section.
[0019] A fifth aspect of the present invention according to any one of the second aspect to the fourth aspect provides an endoscopic apparatus, further comprising: a first expandable and contractible balloon which is mounted to an outer circumferential surface of the distal end of the inserting section, an insertion assisting tool into which the inserting section is inserted to be guided in a body cavity; and a second expandable and contractible balloon which is mounted to an outer circumferential surface of the insertion assisting tool.
[0020] The fifth aspect of the present invention provides a double balloon endoscopic apparatus, and this type of endoscopic apparatus makes it possible to hold a medical capsule at an inside of lower gastrointestinal tract such as small intestine.
[0021] A sixth aspect of the present invention according to any one of the second aspect to the fifth aspect provides an endoscopic apparatus, wherein the holding section is configured to include a distal end of the hood member having an inner circumferential surface which has a curved portion corresponding to a curved shape of the medical capsule.
[0022] According to the sixth aspect of the present invention, as the curved portion corresponding to a curved shape of the medical capsule is formed at an inner circumferential surface of a distal end of the hood member, the vacuum hood member has an increased airtightness so that the hood member and the medical capsule are attracted more closely to each other, which in turn increased the power to hold the medical capsule. This allows a medical capsule to be reliably held at the holding section of the hood member.
[0023] A seventh aspect of the present invention according to any one of the second aspect to the fifth aspect provides an endoscopic apparatus, wherein the holding section is configured to include a distal end of the hood member which is formed thinner than any other parts of the hood member.
[0024] According to the seventh aspect of the present invention, as the thinner distal end of the hood member is flexible, the hood member and a medical capsule are attracted closely to each other even when the hood member approaches the medical capsule at an angle. In this way, the increased airtightness of the vacuum hood member improves the power to hold the medical capsule, which allows a medical capsule to be reliably held at the holding section of the hood member.
[0025] A eighth aspect of the present invention according to any one of the second aspect to the fifth aspect provides an endoscopic apparatus, wherein he holding section is configured to include a distal end of the hood member having an inner circumferential surface in which a groove is formed in the circumferential direction.
[0026] According to the eighth aspect of the present invention, as the groove in the inner circumferential surface of the distal end of the hood member makes the distal of the hood member flexible, the closeness between the hood member and a medical capsule is not reduced even when the hood member approaches the medical capsule at an angle. In this way, the increased airtightness of the vacuum hood member improves the power to hold the medical capsule, which allows a medical capsule to be reliably held at the holding section of the hood member.
[0027] A ninth aspect of the present invention according to any one of the second aspect to the fifth aspect provides an endoscopic apparatus, wherein the holding section is configured to include a distal end of the hood member having an outer circumferential surface in which a groove is formed.
[0028] According to the ninth aspect of the present invention, as the groove in the outer circumferential surface of the distal end of the hood member makes the distal of the hood member flexible, the closeness between the hood member and a medical capsule is not reduced even when the hood member approaches the medical capsule at an angle. In this way, the increased airtightness of the vacuum hood member improves the power to hold the medical capsule, which allows a medical capsule to be reliably held at the holding section of the hood member.
[0029] A tenth aspect of the present invention according to the ninth aspect provides an endoscopic apparatus, wherein there are a plurality of the grooves in a direction along a central axis of the hood member with ribs being formed between the grooves.
[0030] According to the tenth aspect of the present invention, the grooves in a direction along the central axis of the hood member makes the distal end flexible, and the rib makes the distal end appropriately rigid.
[0031] According to the present invention, the inside of a hood member is sucked through a suction opening to make the inside of the hood member vacuum so that a medical capsule can be attracted to and held by the hood member, thereby the medical capsule can be reliably held by the hood member without falling. Also according to the present invention, as a medical capsule is held by a hood member, the held medical capsule can be observed by an observation section of an endoscope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a system configuration diagram of an endoscopic apparatus according to the present invention;
[0033] FIG. 2 is a perspective diagram to show a distal end of an inserting section of an endoscope and a hood member;
[0034] FIG. 3 is a cross sectional diagram to show a distal end of an inserting section of an endoscope and a hood member;
[0035] FIG. 4 is a cross sectional diagram to show a distal end of an inserting section of an endoscope with a hood member being mounted to;
[0036] FIG. 5 is a cross sectional diagram to show a hood member which is approaching a medical capsule at an angle;
[0037] FIG. 6A to 6 J are diagrams to illustrate a method to operate an endoscopic apparatus according to the present invention;
[0038] FIG. 7 is a cross sectional diagram to show a hood member having a different configuration from that of FIG. 4 ;
[0039] FIG. 8 is a cross sectional diagram to show the hood member of FIG. 7 which is approaching a medical capsule at an angle;
[0040] FIG. 9 is a cross sectional diagram to show a hood member having a different configuration from that of FIG. 7 ;
[0041] FIG. 10 is a cross sectional diagram to show the hood member of FIG. 9 which is approaching a medical capsule at an angle;
[0042] FIG. 11 is a perspective diagram to show a hood member having a different configuration from that of FIG. 2 ;
[0043] FIG. 12 is a cross sectional diagram to show a hood member having a different configuration from that of FIG. 4 ;
[0044] FIG. 13 is a cross sectional diagram to show a hood member having a different configuration from that of FIG. 12 ;
[0045] FIG. 14 is a perspective diagram to show a hood member having a different configuration from that of FIG. 2 ; and
[0046] FIG. 15 is a side view of the hood member of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Now, a preferred embodiment of a method for collecting/transporting a medical capsule and an endoscopic apparatus for the method according to the present invention will be described in detail with reference to the accompanying drawings.
[0048] FIG. 1 is a system configuration diagram to show an embodiment of an endoscopic apparatus according to the present invention. As shown in FIG. 1 , an endoscopic apparatus generally comprises an endoscope 10 , an insertion assisting tool 70 , and a balloon controlling device 100 .
[0049] The endoscope 10 comprises a hand-held control section 14 and an inserting section 12 connected to the hand-held control section 14 to be inserted into a body cavity. The hand-held control section 14 is connected to a universal cable 16 having an end which is provided with a LG connector 18 . The LG connector 18 is removably coupled to a light source device 20 which sends an illumination light to an illumination optical system 54 which will be explained below (see FIG. 2 ). The LG connector 18 is connected to an electric connector 24 via a cable 22 , the electric connector 24 being removably coupled to a processor 26 .
[0050] To the hand-held control section 14 , an air and water supply button 28 , a suction button 30 , a shutter button 32 , and a function switch button 34 are arranged in a line, and a pair of angle adjustment knobs 36 are also provided therewith. The hand-held control section 14 has a rear end in which an air inlet for balloon 38 is formed with a pipe which is bent into an L shape. A supply or suction of fluids such as air through the air inlet for balloon 38 makes a first balloon 60 expanded or contracted, which will be explained below.
[0051] The inserting section 12 consists of a soft portion 40 , a curved portion 42 , and a distal end portion 44 , starting from the hand-held control section 14 , and the curved portion 42 is remotely controlled by turning the angle adjustment knobs 36 at the hand-held control section 14 . This control allows the distal end portion 44 to be directed to a desired direction.
[0052] As shown in FIG. 2 , the distal end portion 44 has a front surface 45 where an observation optical system 52 , an illumination optical system 54 , an air and water supply nozzle 56 , and a forceps port (corresponds to a suction opening) 58 are provided.
[0053] A prism 53 is mounted to the back of the observation optical system 52 as shown in FIG. 3 , so that a light path of a light from a subject obtained through the observation optical system 52 is bent downward by the prism 53 . Below the prism 53 is disposed a CCD 55 which is supported by a substrate 57 , and the light from a subject which was bent by the prism 53 is focused on a light sensitive surface of the CCD 55 . Then the light from a subject is converted into an electrical signal by the CCD 55 to be transmitted through a signal cable 59 . The signal cable 59 is inserted through into the inserting section 12 , the hand held control section 14 , the universal cable 16 and the like of FIG. 1 to be extended to the electric connector 24 which is connected to the processor 26 . Thus, an observation image which is obtained by the observation optical system 52 is focused on a light sensitive surface of the CCD 55 to be converted into an electrical signal, which is output through a signal cable 59 to the processor 26 where the electrical signal is converted into an image signal. In this way, a picture image from observation is displayed on a monitor 50 which is in connection with the processor 26 .
[0054] Behind the illumination optical systems 54 of FIG. 2 , light guides (not shown) are disposed with the outputting ends thereof. The light guides are inserted through into the inserting section 12 , the hand held control section 14 , the universal cable 16 and the like of FIG. 1 to dispose the inputting ends thereof in the LG connector 18 . Thus, when the LG connector 18 is coupled to the light source device 20 , an illumination light irradiated from the light source device 20 is transmitted through the light guides to the illumination optical systems 54 to be irradiated forward from the illumination optical systems 54 .
[0055] The air and water supply nozzle 56 of FIG. 2 is in communicated with a valve (not shown) which is controlled by the air and water supply button 28 of FIG. 1 , and the valve is in turn in communicated with an air and water supply connector 48 which is provided in the LG connector 18 . The air and water supply connector 48 is connected with an air and water supply device (not shown) to supply air or water. Thus, an actuation of the air and water supply button 28 causes air or water to be ejected from the air and water supply nozzle 56 toward the observation optical system 52 .
[0056] The forceps port 58 of FIG. 2 is in communicated with a pipe 61 which is supported by a distal end portion body 65 of FIG. 3 , and the pipe 61 is in turn coupled with a tube 63 . The tube 63 is inserted through into the inserting section 12 of FIG. 1 to be in communicated with a forceps inserting section 46 . When a procedure tool such as a forceps is inserted into from the forceps inserting section 46 , the procedure tool can be pulled out from the forceps port 58 . The tube 63 of FIG. 3 is diverged along its way to be in communicated with a valve (not shown) which is controlled by the suction button 30 of FIG. 1 , and the valve is in turn connected with a suction connector 49 of the LG connector 18 . The suction connector 49 is connected with a suction pump (corresponds to a suction device) 51 . Thus, an actuation of the suction pump 51 and an operation of the valve by the suction button 30 causes body fluid, air, and the like to be sucked through the forceps port 58 .
[0057] Reference numeral 67 in FIG. 3 designates a cap mounted on the distal end surface of the distal end portion body 65 , and reference numeral 69 designates a covering member which covers an outer circumferential surface of the inserting section 12 .
[0058] As shown in FIG. 2 , to the outer circumferential surface of the inserting section 12 , a first balloon 60 is attached which is made of a resilient material such as rubber. The first balloon 60 is formed into a generally tubular shape having two deflated ends, and after the inserting section 12 is inserted through into the first balloon 60 and the first balloon 60 is disposed at a desired position, fixing rubber rings 62 are fit onto the both ends of the first balloon 60 so that the first balloon 60 is fixed around the inserting section 12 .
[0059] An air vent 64 is formed in the outer circumferential surface of the inserting section 12 where the first balloon 60 is attached. The air vent 64 is in communicated with the air inlet for balloon 38 which is provided in the hand held control section 14 of FIG. 1 . The air inlet for balloon 38 is connected to the balloon controlling device 100 via a tube 110 . Thus, a supply or sucking air by the balloon controlling device 100 allows the first balloon 60 to be expanded or contracted. The first balloon 60 is expanded into a generally spherical shape by air supply, and is contracted to stick around the outer circumferential surface of the inserting section 12 by air suction.
[0060] Meanwhile, the insertion assisting tool 70 shown in FIG. 1 comprises a tubular and rigid holding section 72 which is provided at the rear end of the insertion assisting tool 70 and a tube body 73 which is attached to the distal end of the holding section 72 , and the inserting section 12 of the endoscope 10 above described is inserted from the holding section 72 into the tube body 73 .
[0061] The tube body 73 comprises a flexible resin tube substrate which is formed of urethane for example, and the substrate has an outer circumferential surface and an inner circumferential surface which are coated by a hydrophilic coating material (a lubricant coating material). The hydrophilic coating material may be, for example, polyvinyl pyrrolidone.
[0062] A second balloon 80 is attached near the distal end of the tube body 73 . The second balloon 80 is formed into a tubular shape having two deflated ends, and is attached to the tube body 73 with the insertion assisting tool 70 being therethrough, and is fixed there by winding a thread (not shown) around the ends. The second balloon 80 is in communicated with a tube 74 which is adhered to the outer circumferential surface of the insertion assisting tool 70 , and the tube 74 has a rear end to which a connector 76 is provided. The connector 76 is connected to a tube 120 , and to the balloon controlling device 100 via the tube 120 . Thus, a supply or sucking air by the balloon controlling device 100 allows the second balloon 80 to be expanded or contracted. The second balloon 80 is expanded into a generally spherical shape by air supply, and is contracted to stick around the outer circumferential surface of the insertion assisting tool 70 by air suction.
[0063] The insertion assisting tool 70 has a rear end in which an inlet 78 is formed. The inlet 78 is in communicated with an opening (not shown) which is formed in the inner circumferential surface of the insertion assisting tool 70 . Thus, a lubricant (e.g. water) can be supplied into the insertion assisting tool 70 by injecting the lubricant with a syringe or the like from the inlet 78 . This reduces the friction between the inner circumferential surface of the insertion assisting tool 70 and the outer circumferential surface of the inserting section 12 in inserting of the inserting section 12 into the insertion assisting tool 70 , and enables a smooth relative movement between the inserting section 12 and the insertion assisting tool 70 .
[0064] The balloon controlling device 100 supplies and sucks in fluids such as air through the first balloon 60 , and also supplies and sucks in fluids such as air to and from the second balloon 80 . The balloon controlling device 100 generally comprises a device body 102 and a hand held switch 104 for remotely controlling.
[0065] The device body 102 has a front side where a power switch SW 1 , a stop switch SW 2 , a first pressure indicator 106 , a second pressure indicator 108 , a first function stop switch SW 3 , and a second function stop switch SW 4 are provided. Each of the first pressure indicator 106 and the second pressure indicator 108 is a panel to indicate a pressure value of the first balloon 60 and the second balloon 80 respectively, and the pressure indicators 106 and 108 indicate an error code in the event of failure such as a balloon burst.
[0066] The first function stop switch SW 3 and the second function stop switch SW 4 turn on and off the functions of the control system for endoscope A and the control system for insertion assisting tool B which will be described below, respectively, and when only one of the first balloon 60 and the second balloon 80 is used, one of the function stop switches SW 3 and SW 4 , not in use, is controlled to be turned off. In the turned off control system A or B, any supply and suction of air is completely stopped, and the pressure indicator 106 or 108 for the system is also turned off. The initial conditions of the systems may be set by turning off both of the function stop switches SW 3 and SW 4 . For example, a calibration for an atmosphere pressure is performed by holding down all of the switches SW 5 to SW 9 simultaneously on the hand held switch 104 while both of the function stop switches SW 3 and SW 4 are turned off.
[0067] To the front of the device body 102 are connected an air supply and suction tube 110 and an air supply and suction tube 120 , for the first balloon 60 and the second balloon 80 respectively. Backflow prevention units 112 and 122 are provided at the points where each of the tubes 110 and 120 is connected to the device body 102 , which prevent any backflow of body fluid when the first balloon 60 or the second balloon 80 is burst. The backflow prevention units 112 and 122 are respectively structured by fitting a filter for gas and liquid separation into the inside a hollow disk-like case (not shown) which is removably attached to the device body 102 , so that the filter prevents any liquid flowing into the device body 102 .
[0068] The pressure indicators 106 and 108 , the function stop switches SW 3 and SW 4 , and the backflow prevention units 112 and 122 are fixedly arranged for the endoscope 10 and for the insertion assisting tool 70 . That is, the pressure indicator 106 , the function stop switch SW 3 , and the backflow prevention unit 112 are arranged for the endoscope 10 on the right side relative to the pressure indicator 108 , the function stop switch SW 4 , and the backflow prevention units 122 for the insertion assisting tool 70 , respectively.
[0069] Meanwhile, to the hand held switch 104 , a stop switch SW 5 which is similar to the stop switch SW 2 on the device body 102 , an ON/OFF switch SW 6 to give a command to pressurize/depressurize the first balloon 60 , a pose switch SW 7 to maintain a pressure of the first balloon 60 , an ON/OFF switch SW 8 to give a command to pressurize/depressurize the second balloon 80 , and a pose switch SW 9 to maintain a pressure of the second balloon 80 are provided, and the hand held switch 104 is electrically connected to the device body 102 via a code 130 . Also, display sections to display a condition of air supply or exhaust of the first balloon 60 and second balloon 80 , which are not shown in FIG. 1 , are provided to the hand held switch 104 .
[0070] The balloon controlling device 100 configured as described above expands each balloon 60 and 80 by supplying air, and maintains the expanded balloons 60 and 80 by controlling the air pressure in the balloons at a constant value. The balloon controlling device 100 also contracts each balloon 60 and 80 by sucking air, and maintains the contracted balloons 60 and 80 by controlling the air pressure in the balloons at a constant value.
[0071] The balloon controlling device 100 is connected to a balloon exclusive monitor 82 which displays a pressure value and an expanded or contracted condition of each balloon 60 and 80 . A pressure value and an expanded or contracted condition of each balloon 60 and 80 may be displayed on the monitor 50 by superimposing on an observation image obtained by the endoscope 10 .
[0072] As shown in FIG. 2 , a hood member 200 is applied to the distal end portion 44 of the inserting section 12 of the endoscope 10 . The hood member 200 is formed of a resin or rubber into a cylindrical shape. As shown in FIG. 3 , the hood member 200 has an inner diameter d which is generally the same with or slightly smaller than the outer diameter of the distal end portion 44 , thereby the hood member 200 is applied to the distal end portion 44 by elastically deforming a rear end of the hood member 200 C to fit the hood member 200 onto the distal end portion 44 .
[0073] The hood member 200 has an opening at its distal end having an area larger than the opening area of the forceps port 58 in the distal end portion 44 . The shape of the hood member 200 is not limited to a cylinder, and the hood member 200 may be formed into any shape such as a tapered shape. However, the opening at the distal end of the hood member 200 is preferably larger than the opening area of the forceps port 58 .
[0074] The hood member 200 has an inner circumferential surface having a position defining project 202 is formed to define a minimum projecting length of the hood, and the position defining project 202 contacts with the front surface of the inserting section 12 when the hood member 200 is attached to the distal end portion 44 . This maintains the hood member 200 in a position projected from the distal end portion 44 when the hood member 200 is attached to the distal end portion 44 . The position defining project 202 defines a minimum projecting length of the hood, the length may be increased as needed by an operator.
[0075] The hood member 200 has a distal end portion 200 A and a middle portion 200 B, and the distal end portion 200 A is formed of a material which is more flexible than that for the middle portion 200 B. Thus, the distal end portion 200 A of the hood member 200 elastically deforms when a medical capsule 220 is attracted by the vacuum inside of the hood member 200 to the distal end portion 200 A of the hood member 200 , which allows the medical capsule 220 to be reliably held. That is, as shown in FIG. 4 , when the medical capsule 220 is attracted to the hood member 200 with the longitudinal sides of the medical capsule 220 being generally parallel to the central axis of the hood member 200 , the inner circumferential part of the distal end portion 200 A of the hood member 200 elastically deforms to reliably hold the medical capsule 220 . As shown in FIG. 5 , when the medical capsule 220 is attracted to the hood member 200 at an angle, the distal end portion 200 A of the hood member 200 elastically deforms along the medical capsule 220 , which can increase an airtightness to reliably hold the medical capsule 220 . In this way, the hood member 200 of this embodiment is configured to have the distal end portion 200 A as a holding section to hold the medical capsule 220 .
[0076] The middle portion 200 B is formed of a material which is less flexible than that of the distal end portion 200 A, thereby the middle portion 200 B of the hood member 200 keeps its original cylindrical shape when the inside of the hood member 200 is vacuum (or in a depressurized state). This prevents any crash of the middle portion 200 B of the hood member 200 , which in turn prevents the medical capsule 220 from falling.
[0077] At least the middle portion 200 B of the hood member 200 is formed of a transparent or semitransparent material. Thus, view is not restricted while the hood member 200 is inserted in a body cavity to find the medical capsule 220 , and when the medical capsule 220 is held at the distal end portion 200 A of the hood member 200 , the outside of the hood member 200 can be observed through the transparent or semitransparent middle portion 200 B. The entire of the hood member 200 may be formed of a transparent or semitransparent material.
[0078] Now, a method to insert the inserting section 12 of the endoscopic apparatus which is configured as described above into a body cavity will be explained with reference to FIGS. 6A to 6 J. FIGS. 6A to 6 J show an example to insert an endoscopic apparatus by oral route, but the endoscopic apparatus may be inserted by anal route.
[0079] First, the first balloon 60 and the second balloon 80 are contracted and the inserting section 12 is inserted into the insertion assisting tool 70 to start the insertion of the inserting section 12 . As shown in FIG. 6A , when the distal end of the inserting section 12 reaches the inside of stomach 90 A, the insertion assisting tool 70 is inserted along the inserting section 12 , so that, as shown in FIG. 6B , the distal end of the insertion assisting tool 70 reaches the inside of the stomach 90 A.
[0080] Next, while holding the insertion assisting tool 70 so as not to be pulled out of the body cavity, the inserting section 12 is inserted into the insertion assisting tool 70 until the distal end of the inserting section 12 reaches the second portion of duodenum 90 B as shown in FIG. 6C (an inserting operation). Then the first balloon 60 is expanded to fix the distal end of the inserting section 12 to the second portion of duodenum (a fixing operation).
[0081] Then the insertion assisting tool 70 is pushed down to be inserted along the inserting section 12 (a pushing operation). As shown in FIG. 6D , after the distal end of the insertion assisting tool 70 comes close to the first balloon 60 , the second balloon 80 is expanded by supplying air. This fixes the second balloon 80 to the second portion of duodenum 90 B, which holds the second portion of duodenum 90 B around the insertion assisting tool 70 via the second balloon 80 (a holding operation).
[0082] In this holding state, both of the insertion assisting tool 70 and the inserting section 12 are drawn back (a drawing back operation). This removes any excess deflection or bending between the entrance and the second portion of duodenum 90 B of the gastrointestinal tract 90 .
[0083] Next, after the air in the first balloon 60 is sucked to contract the first balloon 60 as shown in FIG. 6E , the inserting section 12 is inserted into the small intestine 90 C (an inserting operation). Because any excess deflection or bending between the entrance and the second portion of duodenum 90 B of the gastrointestinal tract 90 is already removed by the insertion assisting tool 70 , the inserting section 12 can be readily inserted.
[0084] Next, as shown in FIG. 6F , the first balloon 60 is expanded to fix the distal end of the inserting section 12 to the gastrointestinal tract 90 (a fixing operation). After the second balloon 80 is contracted, as shown in FIG. 6G , the insertion assisting tool 70 is pushed down to be inserted along the inserting section 12 (a pushing operation), so that the distal end of the insertion assisting tool 70 comes close to the first balloon 60 to expand the second balloon 80 (a holding operation).
[0085] Then, as shown in FIG. 6H , while the first balloon 60 and the second balloon 80 are expanded, both of the insertion assisting tool 70 and the inserting section 12 are drawn back (a drawing back operation). This removes any excess deflection or bending of the gastrointestinal tract 90 .
[0086] This series of operations described above (an inserting operation, a fixing operation, a pushing operation, a holding operation, and a drawing back operation) is repeatedly performed, and as a result, the gastrointestinal tract 90 which has been complicatedly bent or deflected is made simplified as shown in FIG. 6I . This allows the inserting section 12 to be inserted further into the gastrointestinal tract 90 as shown in FIG. 6J .
[0087] Now, operations of the endoscopic apparatus according to the present invention will be explained. An example is shown below in which a medical capsule 220 in a body cavity is held to be collected at outside of the body cavity.
[0088] First, the inserting section 12 is inserted into a body cavity with a hood member 200 being attached to the distal end portion 44 of the inserting section 12 . For example, operations such as those described with FIGS. 6A to 6 J are performed to insert the distal end portion 44 of the inserting section 12 into a lower gastrointestinal tract such as small intestine.
[0089] Then, the distal end portion 44 of the inserting section 12 is inserted to a position where a medical capsule 220 is located, the distal end portion 200 A of the hood member 200 is brought close to the medical capsule 220 in the body cavity while observing image obtained by the observation optical system 52 . 5 The suction button 30 is controlled to start a sucking through the forceps port 58 . This causes the gas (or liquid) in the hood member 200 to be sucked through the forceps port 58 , and the inside of the hood member 200 is made vacuum.
[0090] Due to the vacuum inside of the hood member 200 , the medical capsule 220 is attracted to the distal end portion 200 A of the hood member 200 . As the distal end portion 200 A of the hood member 200 is formed of a flexible material, the medical capsule 220 is reliably attracted to and held by the distal end portion 200 A of the hood member 200 , in spite of a posture of the medical capsule 220 . Also, as the medical capsule 220 is attracted to and held by the distal opening of the hood member 200 the area of which is larger than that of the forceps port 58 , the medical capsule 220 is reliably held with a larger holding power. In addition, the medical capsule 220 is held with a part of the medical capsule 220 being pulled into the inside of the hood member 200 , which increases closeness due to increased airtightness between the medical capsule 220 and the hood member 200 , so that the holding power for the medical capsule 220 is increased. Thus, the medical capsule 220 can be more reliably held.
[0091] After the medical capsule 220 is held, the inserting section 12 of the endoscope 10 is withdrawn out of the body cavity to bring the medical capsule 220 to the outside of the body cavity and collect it. During this operation, as the medical capsule 220 is held in a region where can be observed by the observation optical system 52 , the holding of the medical capsule 220 can be continuously checked visually from an observation image. Thus, in case of the medical capsule 220 being fallen, the situation would be immediately known.
[0092] During the withdrawing of the inserting section 12 of the endoscope 10 out of the body cavity, as the middle portion 200 B of the hood member 200 is transparent or semitransparent, the outside of the hood member 200 can be observed. This prevents the held medical capsule 220 from being stuck to a wall surface and the like of the body cavity.
[0093] As described above, according to the endoscopic apparatus of this embodiment, the inside of the hood member 200 is sucked through the forceps port 58 to be vacuum, so that a medical capsule 220 is attracted to and held by the distal end portion 200 A of the hood member 200 . Because the distal end portion 200 A of the hood member 200 has an opening the area of which is larger than that of the forceps port 58 , the distal end portion 200 A has a larger power to hold the medical capsule 220 . So, according to this embodiment, the medical capsule 220 can be reliably held and collected without falling.
[0094] According to this embodiment, because the medical capsule 220 is held by the hood member 200 , the held medical capsule 220 can be continuously checked visually from an observation image obtained by the observation optical system 52 .
[0095] The configuration of the holding section in the hood member 200 is not limited to the above embodiment, but the holding section in the hood member 200 may be configured in any way which is appropriate to hold a medical capsule 220 . For example, a hood member 206 shown in FIG. 7 includes a distal end portion 206 A and a middle portion 206 B, the distal end portion 206 A having a thickness smaller than that of the middle portion 206 B so that the distal end portion 206 A is easily deflected. So, as shown in FIG. 8 , even when the hood member 206 approached the medical capsule 220 at an angle, the distal end portion 206 A of the hood member 206 is deflected to closely contact with the medical capsule 220 . This increases closeness due to increased airtightness between the medical capsule 220 and the hood member 206 , so that the holding power for the medical capsule 220 is increased. Thus, the medical capsule 220 can be reliably held. The middle portion 206 B of the hood member 206 of FIG. 7 and FIG. 8 is formed thicker than the distal end portion 206 A with an inner circumferential surface of the middle portion 206 B being projecting inward, and the middle portion 206 B also functions as a positioning element when it contacts with the front surface 45 of the inserting section 12 . The thick middle portion 206 B keeps its original cylindrical shape even when the inside of the hood member 206 is sucked vacuum. This prevents the attracting power from being decreased due to a crash of the middle portion 206 B, which in turn prevents the medical capsule 220 from falling.
[0096] A hood member 208 shown in FIG. 9 has a distal end portion 208 A and a middle portion 208 B, and a groove 208 D is formed between the distal end portion 208 A and the middle portion 208 B. The groove 208 D is annularly formed in an inner circumferential surface of the hood member 208 in a circumferential direction thereof. The groove 208 D of this configuration reduces the rigidity of the distal end portion 208 A of the hood member 208 , which allows the distal end portion 208 A to be easily deflected. This increases closeness due to increased airtightness between the medical capsule 220 and the distal end portion 208 A of the hood member 208 , so that the holding power for the medical capsule 220 is increased. Thus, the medical capsule 220 can be reliably held. Especially, as shown in FIG. 10 , even when the hood member 208 approaches the medical capsule 220 at an angle, the distal end portion 208 A of the hood member 208 is deflected to closely contact with the medical capsule 220 , thereby the medical capsule 220 can be reliably held.
[0097] A hood member 210 shown in FIG. 11 includes a distal end portion 210 A having an outer circumferential surface provided with a plurality of grooves 210 E. Each of the grooves 210 E is formed in an axis direction of the hood member 210 , and has a circular cross section which is perpendicular to the axis direction. The grooves 210 E are separated by a uniform distance from each other in the circumferential direction, and ribs 210 F are formed between the grooves 210 E. The grooves 210 E allow the distal end portion 210 A of the hood member 210 to be easily deflected, and the ribs 210 F allow the distal end portion 210 A of the hood member 210 to maintain its appropriate rigidity. In addition, the grooves 210 E formed in the outer circumferential surface make the inner -circumferential surface smooth which readily contacts closely with a medical capsule 220 . This increases closeness between the medical capsule 220 and the hood member 210 , so that the medical capsule 220 can be more reliably held.
[0098] A hood member 212 shown in FIG. 12 includes a distal end portion 212 A having an inner circumferential surface which is formed to correspond to the curved shape of a medical capsule 220 . That is, the distal end portion 212 A of the hood member 212 has on its inner circumferential surface a curved surface portion 212 G which corresponds to a part of the sphere of a medical capsule 220 . Thus, when a medical capsule 220 is attracted to and held by the distal end portion 212 A, the closeness between the medical capsule 220 and the distal end portion 212 A of the hood member 212 is increased, so that the medical capsule 220 can be more reliably held.
[0099] A hood member 214 shown in FIG. 13 includes a distal end portion 214 A having an inner circumferential surface which has a taper 214 H to provide a holding section. Thus, when a medical capsule 220 is attracted to and held by the distal end portion 214 A, the taper 214 H contacts with the curved portion of the medical capsule 220 , which increases closeness between the hood member 214 and the medical capsule 220 , so that the medical capsule 220 can be more reliably held.
[0100] A hood member 216 shown in FIGS. 14 and 15 includes a distal end portion 216 A which is provided with a circular groove 216 I. The side of a medical capsule 220 is pulled into the groove 216 I to be held, so that the medical capsule 220 can be reliably held.
[0101] The above embodiment has been explained by an example in which a medical capsule 220 in a body cavity is held to be collected at outside of the body cavity, but the embodiment may be used in an application to transport a held medical capsule 220 through a body cavity. For example, when a medical capsule 220 is stuck at a narrowed portion of a body cavity, the held medical capsule 220 is transported beyond the narrowed portion, and is released. A release of a medical capsule 220 is performed by controlling the suction button 30 of FIG. 1 to stop a sucking operation through the forceps port 58 .
[0102] The embodiment may be also used in an application to transport a medical capsule 220 into a body cavity by inserting the inserting section 12 into the body cavity after a medical capsule 220 is held by the inserting section 12 at the outside of the body cavity.
[0103] The above embodiment has been explained as an example in which the present invention is applied to a double balloon endoscopic apparatus having a first balloon 60 and a second balloon 80 , but a configuration of an endoscopic apparatus according to the present invention is not limited to this, and the present invention may be applied to an endoscopic apparatus without a first balloon 60 and a second balloon 80 , or an endoscopic apparatus without an insertion assisting tool 70 . That is, a hood member 200 is attached to a distal end portion 44 of an inserting section 12 of an endoscope 10 , and the inside of the hood member 200 is made vacuum through a forceps port 58 to attract a medical capsule 220 to the distal end of the hood member 200 so that the medical capsule 220 can be reliably held for its collection or transportation. | The present invention provides a method for collecting/transporting a medical capsule by holding the medical capsule using an endoscopic apparatus comprising: an endoscope having an inserting section to be inserted in a body cavity with a distal end including an observation section to observe a subject and an suction opening; a sucking device in communicated with the suction opening; and a generally cylindrical hood member which is attached to the distal end of the inserting section, the method comprising: a sucking step of making an inside of the hood member vacuum by actuating the sucking device to suck the inside of the hood member through the suction opening; and a holding step of attracting and holding the medical capsule to the hood member sucked by the sucking step. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to non-volatile, electrically erasable programmable memories (EEPROMs), and more particularly but not exclusively to EEPROMS designed to be incorporated into chip cards.
2. Discussion of the Related Art
In many applications of electronic circuits using non-volatile memories, it is desirable to prevent access to certain memory zones without preventing access to other memory zones.
One typical example of an application that shall be referred to throughout the following description is the that of a chip card circuit. The chip card circuit, manufactured by the manufacturer, is purchased by a customer for use in a given application in which the chip card circuit is incorporated into a chip card or circuit board. The customer stores operation programs and certain data elements on the chip card, and then places this chip card at the disposal of a user for applications such as the supply of goods or services, control of access, etc. The operation programs and data elements are defined by the customer and recorded or modified solely under control of the customer. Deliberate or accidental modification of the operation programs or the data elements defined by the customer should be prevented. However, other data elements of the memory should remain accessible and modifiable by the user.
It is therefore planned that the EEPROMs will be capable of working in a protected mode, wherein a part of the memory is protected while another part is freely accessible.
Write protection of a zone of the memory prevents modification of data in the zone by the user or an accidental modification caused by parasitic signals in the circuitry (e.g., undesired noise created during a sequence of powering up the circuit) or by errors or instability in operating programs when a microprocessor, whether internal or external to the card, controls the memory.
The manufacturer of the memory circuit often does not have any prior knowledge of the size of memory that has to be protected and of the size of memory that must be left free for the user. Indeed, the respective sizes depend on the application. It is the customer of the memory circuit and not the manufacturer or the final user that defines the sizes. It is desirable to manufacture only one type of memory circuit which is independent of the application envisaged by the customer. If this were not to be the case, the manufacturer would have to produce different types of memories for different customers or different applications, even if the memory circuits were identical in all respects except for the size of the protected zone.
Therefore, conventional memory circuits typically enable a customer to define a part of the memory that has to be protected. The customer then, after having recorded the information to be protected in the part of the memory to be protected, puts the protection system into operation.
For this purpose a special encoded instruction designed for the microprocessor that controls the memory circuit has been used. This instruction enables the storing, in a non-volatile register external to the memory proper, of an information element specifying the memory zone that is protected and the memory zone that is not protected. Sometimes, this information is stored partly in a non-volatile register and partly in the form of hard wiring. For example, the least significant values of a starting address of a protected zone are stored in the non-volatile register and the most significant values of the starting address are stored by connecting one or two external pins of the integrated circuit to either Vcc or to the ground depending on the values of the address bits to be memorized. These approaches are inconvenient for the customer.
In an alternative solution for use in applications wherein no specific microprocessor instruction is available, the protected zone is defined by a sequence of instructions whose combination is normally impossible or very improbable. Thus, it is unlikely for the sequence defining the protected zone to occur accidentally or even intentionally. However, such unlikely occurrences are not impossible and the implementation of this method is inconvenient for the customer wishing to define the protected zone.
It is an object of the present invention to provide an improved method and apparatus for achieving a desired partition of the memory between protected zones and unprotected zones.
SUMMARY OF THE INVENTION
According to an embodiment of the invention, there is proposed a method to achieve a partition of a memory between a protected zone and a non-protected zone, in an integrated memory circuit including means to prevent or permit access to memory addresses depending on whether they are located in the protected zone or in the non-protected zone, respectively, the protected zone being defined by two zone end addresses, one of which is predetermined while the other is to be chosen. The method includes the steps of:
a) writing in the memory at successive addresses in the desired protected zone;
b) automatically writing the first address of the successive addresses in a volatile register;
c) performing a last writing operation at the predetermined address representing an end of the protected zone;
d) making an automatic transfer, to a non-volatile register, of the address contained in the volatile register, during the operation of writing in the predetermined register, the protected zone being thereupon included between the first address written in the non-volatile register and the predetermined address.
In a first embodiment, the address written in the volatile register, as shall be explained further below, is stable throughout the procedure or, alternatively in another embodiment, the volatile register undergoes changes between steps b) and c).
In the first embodiment the customer is not required to set up a special procedure to define a protected zone, either before or after writing the sensitive information elements in the zone to be protected. Rather, the customer simply writes the sensitive information elements to be protected in the memory, and it is quite simply the order of succession of the write addresses that defines the zone which was written to as the protected zone. There are no special zone protection instructions. Only the normal instructions for writing in the memory are performed. This is especially convenient for the customer.
Another embodiment of the invention is directed to a method for partitioning a memory between a protected zone that contains sensitive information elements, and a non-protected zone, in an integrated circuit including means to limit access to the protected zone of the memory, wherein one end of the protected zone is predetermined before partitioning the memory, the other end being initially undetermined. The method includes the step of writing of the sensitive information elements in the addresses of the desired protected zone, the last write operation being done at the address of the predetermined end, and wherein this last write operation automatically activates the storage, in a non-volatile register, of a specific address defined on the basis of the addresses in which the sensitive information elements are written, this specific address defining the other end of the protected zone.
Several variants of implementation are possible according to the invention.
According to another embodiment of the invention, the final predetermined address is the last address ADF of the memory. The customer requires a protected zone between a starting address ADP and the final address ADF. For this purpose, the customer writes the information to be protected in this zone by starting with the address ADP and ending with the address ADF. It is the fact of writing by starting with the address ADP that temporarily stores the address ADP in the circuit. And it is the fact of writing in the address ADF that activates an automatic procedure, which is invisible to the customer, for the permanent storage of the address ADP in a non-volatile register that defines the partition of the memory.
Another embodiment of the invention includes more complicated circuitry. The protected zone is the zone between, firstly, the smallest address used by the customer during the programming in a protected zone and, secondly, the final address of the memory. In this embodiment, between the steps b) and c) defined here above, there is inserted the recurrent step b1. This step b1 includes modifying, at each write operation, of the volatile register in order to place therein the smallest of the address being written and the address contained in the register. When the writing is done in the last address ADF of the memory, or alternatively another predetermined address, the contents of the volatile register are transferred automatically into the non-volatile register. The contents represent the smallest of the addresses at which writing has been done during this operation. The protected zone is defined solely by the operations of writing in this zone.
In another embodiment, the core of the invention is an automatic procedure for the definition of a partition between a protected zone and a non-protected zone, wherein the sole fact of writing the information to be protected defines one end of the protected zone, the other end being predefined and imposed.
This procedure entails the assumption only that one of the ends of the protected zone is predetermined, i.e. that the configuration of the circuit at the time of the operation of partition makes it possible to recognize the reception of a write command at this address to activate the automatic partition.
Another embodiment of the invention is directed to a memory circuit having means adapted to perform the above-described methods.
Another embodiment is directed to an integrated memory circuit including means for limiting access to a protected zone of the memory, the means for limiting having a non-volatile register that stores an end address of the protected zone. The memory circuit further includes means for defining a desired partition of the memory between this protected zone and a non-protected zone, the means for defining having a sequencer, activated automatically by an operation of writing in a predetermined address of the memory, after operations for the writing of information in a series of other addresses of the desired protected zone, in order to carry out the storage, in the non-volatile register, of a specific address defined automatically in the circuit on the basis of the addresses of the series.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention shall appear from the following detailed description, made with reference to the drawings.
FIG. 1 illustrates a configuration of the memory zones;
FIG. 2 illustrates an integrated circuit according to an embodiment of the invention; and
FIG. 3 illustrates a circuit according to an alternative embodiment of the invention.
DETAILED DESCRIPTION
An embodiment of the invention is described hereinbelow with reference to a particular example of a 16-kilobit EEPROM in which at least a first half of the memory is freely accessible and in which a part of a second half of the memory is protected when a protected mode is activated. The size of the protected part of the memory can be defined by the customer when the customer records sensitive information elements in the protected part. By way of example, the protection is a standard write protection.
Reference is made solely to write protection wherein any modification of the contents of a protected zone of the memory is prohibited. However, the invention is transposable to read protection wherein the reading of the protected zone is prohibited, or alternatively to both read and write protection.
According to an embodiment of the invention, the memory is organized in pages of sixteen words of eight bits each, and the protected zone is defined with a resolution of one page and not one word as illustrated in FIG. 1. However, other resolutions may be provided such as a resolution of one word, if desired. The value of using one-page resolution is that the number of address bits that have to be stored to define the ends of the protected zone is limited. Here, the page address is defined by seven bits. The word address is defined by four additional least significant bits.
In the exemplary embodiment shown in FIG. 1, the protected zone is in the second half of the memory. Consequently, the most significant bit of a protected zone end address is predetermined to indicate the second half of the memory and does not need to be memorized. Six bits remain necessary to define a protected zone end address. Therefore, the address considered as a protected zone end address is a page address formed solely by the six bits used to define this address with the resolution of a page. However, other forms of organization are possible.
According to an embodiment of the invention, one of the protected zone end addresses is predetermined. The other protected zone end address is defined directly and automatically by the process of writing sensitive information elements into the memory.
All that the customer needs to do is to record the sensitive information elements in the protected zone. The zone is protected after the operation of writing sensitive information elements into the memory has completed, as shall be explained.
First mode of implementation
According to one embodiment of the invention, one end of the protected zone is predetermined to be the end of the memory itself. The predetermined end address is that of the last page ADF of the memory if the memory is programmable by page, or alternatively that of the last word address ADFM of the memory if the memory is programmable by word.
In connection with choosing the other protected zone end address, the customer chooses the page address ADP on the basis of the sensitive information elements to be protected. The protected zone is then the zone between the page address ADP and the end of the memory, i.e., the page address ADF.
One illustrative implementation of a circuit that implements this protection scheme is shown in FIG. 2. The customer writes the sensitive information elements in the memory MM, starting with a word at the address ADP corresponding to the start of the protected zone, for it is the first address written that automatically dictates the start of a protected zone. The customer then writes all the sensitive information elements. The customer ends with the writing of a word at the address ADF, which activates the storage of the address ADP in a non-volatile register used as a permanent reference indicating the boundaries of the protected zone to control the access to this zone and allow free access to the rest of the memory.
The circuit for partitioning zones of the memory into a protected zone and a non-protected zone includes a volatile register RV in which the first page address ADP written by the customer is recorded. In the example described, the page address ADP includes six page-address bits (wherein a word address includes 11 address bits). The address ADP remains in the register RV as the customer continues to write sensitive information elements.
The WRITE command received by the memory is used to record the address ADP in the register RV. The register RV is connected to an address line of the memory at a node 9, and receives the page address bits of the current address AD applied to the memory MM. However, so that the contents of the register RV are not modified during the following writing operations, the write control signal for writing in the register RV, which is the WRITE signal itself, is inhibited after the first writing operation. This inhibition is performed by means of a monostable flip-flop circuit FW that provides a non-inhibiting signal at the outset (output at zero) and immediately flips over to provide an inhibiting signal (output at one) after the first write command. An AND gate 8 receives the output (i.e., the inhibiting or non-inhibiting signal) of the flip-flop circuit FW and inhibits any subsequent modification of the contents of the register RV after the first writing operation.
The address recorded in the register RV is therefore the address ADP if the customer follows the normal procedure.
The customer then continues the writing of the sensitive information elements in the addresses of the desired protected zone, between the address ADP and the page address ADF (e.g., the first word of the page at address ADP and the last word of the page at address ADF). The references to word addresses hereinafter are applicable if the memory is programmable by words.
The customer ends with a writing operation at the address ADF, or alternatively ADFM. The partition circuit includes a detector for detecting the writing of sensitive information elements at the address ADF, or alternatively ADFM. This detection activates a sequencer SEQ1 which stores, in a non-volatile register RNV, the address ADP that is temporarily stored in the register RV. This may be done, as shown schematically in FIG. 2, by means of an AND gate 10 that receives the address ADF, or alternatively ADFM, the current address AD (page or word) received by the memory, and the signal WRITE. If there is a writing operation at the address ADF (or ADFM), the gate 10 opens and activates the sequencer SEQ1. However, this activation takes place only if the memory partition operation has not yet taken place. A non-volatile register RNVA which may be formed by an additional compartment of the register RNV contains a non-volatile flag FL, which is initially at zero, indicating that the partition procedure has not yet taken place. If the flag is activated, the sequencer SEQ1 is inhibited. This has been shown by means of an AND gate 12 receiving the inverted output of the register RNVA from inverter 11, and the output of the gate 10.
The sequencer SEQ1 activates the non-volatile flag FL of the register RNVA and transfers the contents of the volatile register RV into the non-volatile register RNV (e.g., six page address bits of the second half of the memory). The partition is then set up.
If the customer has made a mistake, is in the course of performing a test, or for some other reason desires to stop setting up the partition, the customer may prevent the activation of the sequencer SEQ1 by not writing at the address ADF (or ADFM), and by cutting off the supply to the circuit. This returns the circuit to its initial state as if no attempt had been made to set up the partition of the memory zone. The operation then may be started at the beginning.
However, if the customer writes at the address ADF (or ADFM), the partition is set up, and the flag FL is set at 1.
According to another embodiment of the invention, a microprocessor-based partitioning circuit is provided. The circuit includes a microprocessor that receives a series of instructions for writing the first address in the register RV, detecting the writing at the address ADF or ADFM, reading the contents of the volatile register RV, writing these contents in the register RNV, and setting up the flag FL at 1 in the compartment RNVA. Alternatively, this series of instructions can be performed, without any microprocessor, by a wired control circuit of the state machine type.
When the partition is achieved using either of the circuits described above, the circuit works in a protected mode. That is, any address AD received is compared with the stored address ADP in a comparator COMP. If the address is at a lower value (referencing the non-protected zone), a write enable signal WE is transmitted to the memory MM (by the gates 14 and 16) for the performance of a write cycle. However, if the address has a value greater than ADP, i.e., a value between that of the page addresses ADP and ADF, a logic gate 18 enables the inhibition of the signal WE. This inhibition however takes place only if the partition has been previously created. This is checked by the flag RNVA for the activation of the partition. The gate 18 receives the contents FL of the register RNVA. So long as these contents remain at zero, the write enable signal persists for all the addresses of the memory.
It should be understood that the address ADF (or ADFM), which represents the second end of the protected zone and is predetermined, could quite easily be different from the final address of the memory. In particular, the second end of the protected zone could be any predetermined address ADQ (page address for programming by page) or ADQM (word address for programming by word). In this case, however, the programmer who writes the sensitive information elements in the protected zone must know that, as soon as the customer has written in this particular address, the partition is considered to have been formed, the sequencer SEQ1 is active and the protective zone is located between the address ADQ (or ADQM) and the address contained in the volatile register RV at the time of the activation. The customer (or programmer) must therefore take into account when writing the sensitive information elements, the main rule being that the customer (or programmer) should write last in the predetermined address which activates the partition. To implement this, the partitioning circuit can be modified so that the comparator COMP makes an examination to find out whether the current address is between ADP and ADQ to inhibit the write signal WE.
It should be understood that the protected zone can be located not only after the first written address ADP and up to the predetermined address ADQ, but alternatively can be located before the address ADP from a predetermined address identified as ADQ'. In this instance, the customer carries out a programming operation on the basis of the address ADP, and the partitioning process begins when the customer programs the address ADQ' (or ADQ'M). The comparator COMP then inhibits access to the memory when the current address is included between ADQ' and ADP.
Second mode of implementation
Definition of the location of the protected zone may be obtained in ways that are different form the ones discussed above. In particular, the customer does not need to start the writing of the sensitive information elements at a particular address defining one end of the protected zone. A circuit for implementing this alternate embodiment of the present invention is shown in FIG. 3.
In accordance with this embodiment of the invention, the customer writes the sensitive information elements in the protected zone that he chooses by starting anywhere and simply avoiding the programming of the particular address ADQ (or ADQM) that will activate the partition. Here again, the address ADQ or ADQM may be an address pertaining to the end of the memory or the start of the memory or any other predetermined address. According to the embodiment of the invention shown in FIG. 3, rewriting in the volatile register is enabled at each operation of writing in the memory.
The page address that is rewritten at each time in the volatile register RV is the smallest of either the current page address or the page address already contained in the register RV. In other words, if a write operation is performed at an address with a value greater than the address contained in the register, this value is left in the register RV. However, if the writing is done at an address with a lower value, the value of the new page address is written in the register RV. After the customer has written the sensitive information elements, the register RV contains the smallest page address value ADmin used by the customer (or the programmer) to store the sensitive information elements. According to this embodiment, the customer is not bound by having to start programming at the smallest address that the customer will need.
In the embodiment of the invention shown in FIG. 3, an additional comparator COMP1 receives the current page address (e.g., six AD bits) and the contents of the register RV during the writing of the sensitive information elements, and defines whether the contents of the register must be modified in order to be replaced by a smaller address. A monostable trigger circuit inhibits this comparator during the first comparison if the register is initially at zero, so that a first address is stored in the register before starting the comparisons. Alternatively, the register can be set at an initial maximum value (e.g., a sequence of ones) when the circuit is powered up, and hence before the first write operation. This is represented by a command SET of the register RV, made when the circuit is powered up.
In other respects, the circuit of FIG. 3 works as described with reference to the embodiment of FIG. 2. The variants mentioned with respect to FIG. 2 can be transposed to the embodiment of FIG. 3. The predetermined address that is programmed last to trigger the activation of the partition can be any address ADQ or ADQM other than the last address ADF or ADFM of the memory. Furthermore, the register RV can be filled each time with the greatest, rather than the smallest of the two values between the value already contained in the register and the current address value. In this embodiment, the register RV is set at zero rather than at one by the command SET. The predetermined address ADQ' or ADQ'M is the starting address of the protected zone and not the end address. The last write operation at the predetermined address activates the partition.
The circuits of FIGS. 2 and 3 are provided as schematic examples of circuits for implementing the present invention. These circuits can be modified while still performing the same functions. For example, the registers RNV and RNVA may be words of an extension of the memory MM, i.e., words that may be written and read through addresses that are different from those defining the memory array accessible to the user. In this case, it should be understood that the functions represented by simple connections and elements shown in FIGS. 2 and 3 are obtained, in practice, by more complicated sequencers. Thus, any operation of writing in the memory MM uses a prior reading of the flag FL of the register RNVA, and a reading of the contents of the register RNV. These contents are then used to determine whether write access is permitted. This has been shown schematically in FIGS. 2 and 3 by means of simple logic gates and comparators connected to the registers RNV and RNVA.
Throughout the above description, it has been assumed that there is only one possible value of a predetermined address ADF or ADQ (ADFM or ADQM) in a given circuit. However, it is also possible for a user to define the value ADQ or ADQM himself prior to the above-defined operation of partition. An embodiment of the invention enables this definition to be made by programming, or by any other means. This however places an additional constraint on the customer. It is also possible, for example, to provide for a case where the first operation of writing in any address of the memory defines the predetermined address ADQ, and wherein it is the second writing operation that is considered to be the first writing operation as understood in the entire description given here above. The circuits of FIGS. 2 and 3 are easily be adapted to this additional constraint.
Having thus described at least one illustrative embodiment of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto. | The disclosure relates to integrated circuits and methods in which it is desired to implement a partition of a memory between a protected zone and a non-protected zone, the dimensions of the protected zone being defined by a customer of the memory. A disclosed method avoids the use of special instructions to define these dimensions. The method includes writing sensitive information elements by starting at an address ADP, and ending at an address ADFM dictated by the circuit. The writing in the address ADFM automatically triggers a sequence for storing, in a non-volatile register RV, the first written address, and a sequence for the activation of a system for the protection of the zone between the addresses ADP and ADFM. | 6 |
REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application No. 61/049,075 filed Apr. 30, 2008.
BACKGROUND OF THE INVENTION
This invention relates generally to a method and system for remotely acquiring data relating to a refrigerated vehicle.
A refrigerated vehicle is used to transport refrigerated cargo, such as frozen or refrigerated food, from one location to another. The refrigerated vehicle includes a refrigerated container having a space for goods. The container also includes a refrigeration unit that functions to cool the space.
The refrigeration unit includes a refrigeration system, and an evaporator of the refrigeration system cools the refrigerated box and the goods.
SUMMARY OF THE INVENTION
Exemplary embodiments of the invention include an apparatus and method of accessing data including detecting at least one parameter of a component of a refrigerated container and providing data relating to the at least one parameter to a transmitting computer located on the refrigerated container. The invention can further include transferring the data from the transmitting computer to a first remote computer located at an off-site location and transferring the data from the first remote computer to a second remote computer located at another off-site location.
Other exemplary embodiments of the invention include a system for accessing data including at least one sensor to detect at least one parameter of a component of a refrigerated container and a transmitting computer located on the refrigerated container. Data relating to the at least one parameter is provided to the transmitting computer, the transmitting computer including a transmitter. The system includes a first remote computer located at an off-site location, the first remote computer including a transmitter and a receiver. The first remote computer receives the data from the transmitting computer. The system includes a second remote computer located at another off-site location, the second remote computer including a receiver. The second remote computer receives the data from the first remote computer.
These and other features of the present invention will be best understood from the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
FIG. 1 illustrates a refrigerated vehicle;
FIG. 2 illustrates a system including the refrigerated vehicle, a refrigeration system and a plurality of computers;
FIG. 3 illustrates a side view of components of a compressor; and
FIG. 4 illustrates a cross-sectional view of a crankshaft showing the orientation of sensors in a stationary compressor shaft seal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a refrigerated vehicle 10 that cools or refrigerates cargo or goods 12 , such as frozen or refrigerated goods, during transport from one location to another. The refrigerated vehicle 10 includes a cab portion 14 . The cab portion 14 pulls a refrigerated box 16 or trailer or container that contains the goods 12 . A refrigeration unit 17 is located in the refrigerated box 16 . In one example, the refrigeration unit 17 is attached to the front of the refrigerated box 16 . A refrigeration system 20 cools the refrigerated box 16 . The refrigeration unit 17 includes a first computer 18 that monitors and controls the refrigeration system 20 and obtains data relating to operating conditions of components of the refrigeration system 20 and the refrigerated vehicle 10 , such as temperature or pressure, as described blow. The data is collected by sensors (described below). The refrigeration unit 17 also includes a second computer 44 that is in communication with the first computer 18 and transmits data obtained by the first computer 18 to a remote location, as discussed below. The second computer 44 can be provided by PAR Technology Corporation. In one example, the second computer 44 provided by PAR Technology Corporation has Model No. CHDG LMS-WO-08-0110C. The second computer 44 includes the features described below.
The first computer 18 includes a first microprocessor 38 , storage 40 and memory 42 . The first microprocessor 38 can be a hardware device for executing software (particularly software stored in the memory 42 ), to communicate data to and from the memory 42 , and to generally control operations of the first computer 18 pursuant to the software. Software in the memory 42 is read by the first microprocessor 38 and then executed. The memory 42 can include volatile memory elements, such as random access memory or RAM. The storage 40 can include non-volatile memory elements.
The second computer 44 includes a second microprocessor 46 , storage 48 and memory 50 . The second microprocessor 46 can be a hardware device for executing software (particularly software stored in the memory 50 ), to communicate data to and from the memory 50 , and to generally control operations of the second computer 44 pursuant to the software. Software in the memory 50 is read by the second microprocessor 46 and then executed. The memory 50 can include volatile memory elements, such as random access memory or RAM. The storage 48 can include non-volatile memory elements. The second computer 44 also includes a transmitter 52 that transmits data provided to the second microprocessor 46 to a first remote computer 118 , as described below. In one example, the first remote computer 118 is a central server.
FIG. 2 illustrates a system 23 including the refrigeration system 20 of the refrigeration unit 17 . The refrigeration system 20 includes a compressor 22 , a first heat exchanger 24 , an expansion device 26 , and a second heat exchanger 28 that provides cool air to the refrigerated box 16 to cool the goods 12 . Refrigerant circulates through the closed circuit refrigeration system 20 .
The compressor 22 compresses the refrigerant to a high pressure and a high enthalpy, and the refrigerant exits the compressor 22 and flows through the first heat exchanger 24 . When the refrigeration system 20 is operating in a cooling mode, the first heat exchanger 24 acts a condenser. In the first heat exchanger 24 , the refrigerant rejects heat to air 30 and is condensed into a liquid that exits the first heat exchanger 24 at a low enthalpy and a high pressure. A fan 32 directs the air through the first heat exchanger 24 , and the heated air is exhausted from the refrigerated vehicle 10 . The cooled refrigerant then passes through the expansion device 26 , which expands the refrigerant to a low pressure. After expansion, the refrigerant flows through the second heat exchanger 28 , which acts as an evaporator. In the second heat exchanger 28 , the refrigerant accepts heat from air 34 drawn from the refrigerated box 16 by a fan 36 , cooling the air. The refrigerant exits the second heat exchanger 28 at a high enthalpy and a low pressure. The cooled air 34 is supplied to the refrigerated box 16 . After cooling the refrigerated box 16 , the air 34 returns to the second heat exchanger 28 for additional cooling. The refrigerant then flows to the compressor 22 , completing the cycle.
When the refrigeration system 20 is operating in a heating mode, the flow of the refrigerant is reversed by opening and/or closing a plurality of valves (not shown). The first heat exchanger 24 accepts heat from the air 30 and functions as an evaporator, and the second heat exchanger 28 rejects heat to the air 34 and functions as a condenser.
Information and data about the refrigeration unit 17 and the refrigeration system 20 is provided to the first microprocessor 38 . The serial number of the refrigeration unit 17 , the identification number of the refrigeration unit 17 , the software version running on the first computer 18 , a time stamp of the refrigeration unit 17 , the overall status of the refrigeration unit 17 (on, off, PC mode, configuration mode, etc.), a mode of operation of the refrigeration unit 17 (cool, heat, etc.), and information about the status of active or inactive alarms (such as shut down or non-shut down alarms) are provided to the first microprocessor 38 . The temperature set point of the refrigerated box 16 can be inputted by an individual with an input device 25 and provided to the first microprocessor 38 . For example, the temperature set point can be inputted with a keyboard, mouse, or other input device 25 . Sensors detect information about the refrigeration system 20 , and data about this information is provided to the first microprocessor 38 .
As an illustration, a sensor 54 located near the middle of a coil of the first heat exchanger 24 (the condenser) detects the ambient air temperature. A sensor 56 detects the return air temperature of the airflow between the refrigerated box 16 and the refrigeration unit 17 , a sensor 58 detects the supply air temperature of the airflow between the refrigeration unit 17 and the refrigerated box 16 , and a sensor 60 located on a coil of the second heat exchanger 28 (the evaporator) detects the defrost termination temperature.
In other illustrations, a sensor 62 detects the discharge pressure of the compressor 22 , a sensor 64 detects the discharge temperature of the compressor 22 , a sensor 66 detects the suction pressure of the compressor 22 , and a sensor 68 detects the suction temperature of the compressor 22 . A sensor 70 detects the percentage opening of a suction modulation valve 72 . Sensors 74 and 76 located at a compressor head (not shown) determine the mode of compressor unloader valves 78 and 80 , respectively that unload pressure in the compressor heads.
As an example of the present invention, FIG. 3 illustrates a portion of the compressor 22 . The compressor 22 includes a housing 82 , a crankshaft 84 and a gland plate 86 . A body portion 88 with a surrounding spring 90 surrounds the crankshaft 84 . The compressor 22 includes a stationary compressor shaft seal 92 located between the crankshaft 84 and the gland plate 86 and a rotary seal 94 located between the crankshaft 84 and the body portion 88 . The stationary compressor shaft seal 92 is spaced from the crankshaft 84 by a space 116 . The spring 90 provides axial loading between the stationary compressor shaft seal 92 and the rotary seal 94 to provide a refrigerant seal. An o-ring 96 is received in a groove 98 of the stationary compressor shaft seal 92 and positioned between the stationary compressor shaft seal 92 and the gland plate 86 . A lip seal 100 can be positioned in a groove 102 in the gland plate 86 and positioned between the crankshaft 84 and the gland plate 86 to prevent the ingress of dirt.
As shown in FIG. 4 , in one example, the stationary compressor shaft seal 92 includes three holes 104 , 106 and 108 that each receive a sensor 110 , 112 and 114 , such as a thermistor. The sensors 110 , 112 and 114 detect the temperature at the stationary compressor shaft seal 92 . In this example, the sensors 110 , 112 and 114 are employed to provide multiple temperature readings and to determine if there is any variation in temperature around the profile of the crankshaft 84 . The temperature detected by the sensors 110 , 112 and 114 should be equal, and any variation in the temperature readings detected by the sensors 110 , 112 and 114 could indicate a failure at the stationary compressor shaft seal 92 that requires service.
In one example, the sensors 110 , 112 and 114 are positioned approximately 120° relative to each other. As there are three sensors 110 , 112 and 114 , the 120° orientation provides equal spacing of the sensors 110 , 112 and 114 about the crankshaft 84 .
In one example, the temperature detected by the sensors 110 , 112 and 114 should be at or below a threshold temperature, which is determined by previous testing. If the sensors 110 , 112 or 114 detect a temperature greater than the threshold temperature, this could indicate that there could be a failure at the stationary compressor shaft seal 92 that requires service. The threshold temperature depends on the type of system and is determined by previous testing. In one example, the threshold temperature around the stationary compressor shaft seal 92 of the compressor 22 employed in the refrigerated vehicle 10 is approximately 225° F., which is determined by previous testing. However, the threshold temperature depends on specifics of the refrigeration system 20 , and one skilled in the art would understand how to determine the threshold temperature for the specific system. The temperatures detected by the sensors 110 , 112 and 114 are provided to the first microprocessor 38 .
The sensors 110 , 112 and 114 should detect the same temperature. If there is any variation between the temperature readings of the sensors 110 , 112 and 114 , this could indicate a failure at the stationary compressor shaft seal 92 that requires service.
Returning to FIG. 1 , the refrigeration unit 17 includes an engine 19 . In one example, the engine 19 is a diesel engine. A sensor 119 detects the engine coolant temperature. The engine coolant temperature indicates the horsepower load on the engine 19 , which directly correlates to the power required by the compressor 22 . A sensor 121 detects the RPM of the engine 19 . The RPM of the engine 19 indicates if and how the compressor 22 is running. The compressor 22 can run at a high speed or a low speed. For example, if the RPM of the engine 19 is zero, then the engine 19 , and therefore the compressor 22 , is not operating. If the RPM of the engine 19 is at a first value, then the compressor 22 is operating at the low speed. If the PRM of the engine 19 is at a second value, then the compressor 22 is operating at the high speed. Data about this information is provided to the first microprocessor 38 .
The refrigeration unit 17 can include other sensors that can detect parameters of other components of the refrigeration system 20 . Data about this information can be stored on the memory 42 and accessed at a later time.
Returning to FIG. 2 , the information and data provided to the first microprocessor 38 from the various sensors is provided to the second microprocessor 46 . In one example, the second microprocessor 46 receives data every 5 seconds from the first microprocessor 38 .
In addition to receiving data from the first microprocessor 38 , the second computer 44 determines the location of the refrigerated vehicle 10 . The second microprocessor 46 directly obtains information and data regarding the latitude of a GPS location of the refrigeration unit 17 and the longitude of a GPS location of the refrigeration unit 17 . For example, GPS technology is incorporated into the second computer 44 provided by PAR Technology Corporation. In one example, this information is provided to the second microprocessor 46 at least once a day. This allows the location of the refrigerated vehicle 10 to be monitored. For example, if other sensors determine that the engine 19 is delivering less power (which decreases the performance of the refrigeration unit 17 ) and the GPS technology indicates that the refrigerated vehicle 10 is located at a location that is at a high altitude, this could indicate why the engine 19 is delivering less power, as opposed to there being a failure. The second microprocessor 46 also receives information and data about a datagate timestamp.
The transmitter 52 of the second computer 44 transmits the information and data obtained by the second microprocessor 46 (both the information and data provided by the first microprocessor 38 to the second microprocessor 46 and the information and data provided directly to the second microprocessor 46 ) to a first remote computer 118 .
If the refrigeration unit 17 is inactive and the engine 19 is not running, the GPS information does not need to be provided to the first remote computer 118 . However, if these conditions are not achieved and no GPS data has been collected within the previous 23 hours, the GPS data will be transmitted to the first remote computer 118 after the next regular data transmission session.
The first remote computer 118 is located at an off-site location. The data and information can be transmitted from the second microprocessor 46 to the first remote computer 118 over a wireless network 140 , such as, but not limited to, a cellular, RF, satellite, etc. network.
The first remote computer 118 includes a receiver 120 that receives the data and information transmitted from the second computer 44 by the transmitter 52 through the wireless network 140 . The first remote computer 118 includes a third microprocessor 122 , memory 124 and storage 126 . The third microprocessor 122 can be a hardware device for executing software (particularly software stored in the memory 124 ), to communicate data to and from the memory 124 , and to generally control operations of the first remote computer 118 pursuant to the software. Software in the memory 124 is read by the third microprocessor 122 and then executed. The memory 124 can include volatile memory elements, such as random access memory or RAM. The storage 126 can include non-volatile memory elements. The first remote computer 118 also includes a transmitter 128 that can transmit the data and information from the first remote computer 118 to a second remote computer 132 . The first remote computer 118 also formats the data and information for analysis. For example, the first remote computer 118 converts the information and data from hexidecimal to base 10 , which is readable by a technician who accesses the data at the second remote computer 132 . Once the information and data is stored on the first remote computer 118 , the first remote computer 118 erases the memory 50 of the second computer 44 . Therefore, there are no data storage constraints.
The information and data about the refrigerated vehicle 10 and the refrigeration system 20 is stored on the first remote computer 118 . The data can be accessed remotely from a second remote computer 132 at another off-site location through a computer network 137 , such as WAN (i.e., Internet) or LAN, by a user.
The second remote computer 132 includes a receiver 130 that receives the data and information transmitted from the first remote computer 118 by the transmitter 128 over the computer network 137 . The second remote computer 132 includes a fourth microprocessor 136 , memory 138 and storage 134 . The fourth microprocessor 136 can be a hardware device for executing software (particularly software stored in the memory 138 ), to communicate data to and from the memory 138 , and to generally control operations of the second remote computer 132 pursuant to the software. Software in the memory 138 is read by the fourth microprocessor 136 and then executed. The memory 138 can include volatile memory elements, such as random access memory or RAM. The storage 134 can include non-volatile memory elements.
The information and data about the refrigerated vehicle 10 and the refrigeration system 20 can be accessed in real time over the Internet 137 by accessing a website. A keyboard 144 and/or a mouse 146 can be employed to access the information and data. The operator accesses the website through the second remote computer 132 and then inputs a username and password. Once authorized, the operator can access the data about the refrigerated vehicle 10 and the refrigeration system 20 that is stored on the first remote computer 118 . The data can be downloaded on the second remote computer 132 .
The data can be displayed in any manner, such as a real time reading of each of the parameters mentioned above or an average of each of the parameters mentioned above. The data can be displayed on a monitor 141 or printed by a printer 142 .
By employing telematics, the user can remotely obtain real time data about the refrigerated vehicle 10 and the refrigeration system 20 to determine how the refrigerated vehicle 10 and the refrigeration system 20 are performing. Therefore, a user does not have to travel to the refrigerated vehicle 10 to obtain the information. The remote access to data can have a polling rate as high as 1 second per data point.
The user can use the remotely accessed information and data to assist in the design and manufacture of future systems. In another example, through the second remote computer 132 , the user can control the settings of the refrigeration unit 17 to obtain the desired performance of the refrigeration system 20 . The location of the refrigeration unit 17 can also be monitored.
In one example, the user can monitor the operation of the refrigeration device or component, such as the compressor 22 , by monitoring the temperature detected by each of the sensors 110 , 112 and 114 . If any of the sensors 110 , 112 and 114 detect a temperature that is above or below a threshold value (such as 225° F.), this may indicate that the compressor 22 is not operating properly or most efficiently. The user can use this information to help in the design of future refrigeration units 17 to achieve optimal results. The information provided by the sensor 68 that detects the suction temperature of the compressor 22 can also be used in determining how the compressor 22 is operating.
The foregoing description is only exemplary of the principles of the invention. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, so that one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention. | A method or apparatus of accessing data includes detecting at least one parameter of a component of a refrigerated container and providing data relating to the at least one parameter to a transmitting computer located on the refrigerated container. The method or apparatus can further include transferring the data from the transmitting computer to a first remote computer located at an off-site location and transferring the data from the first remote computer to a second remote computer located at another off-site location. | 5 |
FIELD
The subject matter herein generally relates to a motherboard.
BACKGROUND
Traditional universal serial bus (USB) 3.0 interfaces are compatible with USB2.0 interfaces. That is to say USB3.0 interfaces are capable of transmitting USB3.0 signals and USB2.0 signals. When a motherboard is testing USB3.0 signals, the USB2.0 signals should be failed.
BRIEF DESCRIPTION OF THE DRAWINGS
Implementations of the present technology will now be described, by way of example only, with reference to the attached figures.
FIG. 1 is a block diagram of an embodiment of a motherboard.
FIG. 2 is a diagrammatic view of the motherboard in FIG. 1 .
DETAILED DESCRIPTION
It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features of the present disclosure.
Several definitions that apply throughout this disclosure will now be presented.
The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The connection can be such that the objects are permanently connected or releasably connected. The term “comprising” when utilized, means “including, but not necessarily limited to”; it specifically indicates open-ended inclusion or membership in the so-described combination, group, series and the like.
The present disclosure is described in relation to a motherboard.
FIG. 1 illustrates an embodiment of a motherboard 100 . The motherboard 100 comprises a south bridge 10 , a universal serial bus (USB) 3.0 connector 20 , and a ground module 30 . The south bridge 10 is coupled to the USB3.0 connector 20 and the ground module 30 . The USB3.0 connector 20 is coupled to the ground module 30 . The south bridge 10 is capable of transmitting USB3.0 signals and USB2.0 signals to the USB3.0 connector 20 , and controlling the ground module 30 to operate. The ground module 30 is capable of transmitting the USB2.0 signals between the south bridge 10 and the USB3.0 connector 20 to the ground.
FIG. 2 illustrates the schematic of the motherboard 100 . The south bridge 10 comprises a first sending pin TX 1 and a second sending pin TX 2 for sending USB3.0 signals, a first receiving pin RX 1 and a second receiving pin RX 2 for receiving USB3.0 signals, a first transmitting pin TR 1 and a second transmitting pin TR 2 for transmitting USB2.0 signals, and an output pin DP for outputting a control signal.
The USB3.0 connector 20 comprises a third sending pin TX 3 and a forth sending pin TX 4 for sending USB3.0 signals, a third receiving pin RX 3 and a forth receiving pin RX 4 for receiving USB3.0 signals, and a third transmitting pin TR 3 and a forth transmitting pin TR 4 for transmitting USB2.0 signals.
The first sending pin TX 1 is coupled to the third receiving pin RX 3 and the second sending pin TX 2 is coupled to the forth receiving pin RX 4 . The first receiving pin RX 1 is coupled to the third sending pin TX 3 and the second receiving pin RX 2 is coupled to the forth sending pin TX 4 . The first transmitting pin TR 1 is coupled to the third transmitting pin TR 3 and the second transmitting pin TR 2 is coupled to the forth transmitting pin TR 4 .
The ground module 30 comprises a first electronic switch Q 1 and a second electronic switch Q 2 . First ends of the first electronic switch Q 1 and the second electronic switch Q 2 are coupled to the output pin DP for receiving the control signal. Second ends of the first electronic switch Q 1 and the second electronic switch Q 2 are grounded. A third end of the first electronic switch Q 1 is coupled to the third transmitting pin TR 3 and a third end of the second electronic switch Q 2 is coupled to the forth transmitting pin TR 4 . In at least one embodiment, the first electronic switch Q 1 and the second electronic switch Q 2 can be n-channel field-effect transistors (FETs). The first ends of the first electronic switch Q 1 and the second electronic switch Q 2 are corresponding to gates of the FETs. The second ends of the first electronic switch Q 1 and the second electronic switch Q 2 are corresponding to sources of the FETs. The third ends of the first electronic switch Q 1 and the second electronic switch Q 2 are corresponding to drains of the FETs. In other embodiments, the first electronic switch Q 1 and the second electronic switch Q 2 can be npn bipolar junction transistors or any switches having a same function.
When the motherboard 100 is testing the USB3.0 signal, the output pin DP outputs a first control signal. The electronic switch Q 1 and the second electronic switch Q 2 are switched on after the first ends receive the first control signal. The third transmitting pin TR 3 is grounded through the first electronic switch Q 1 and the forth transmitting pin TR 4 is grounded through the second electronic switch Q 2 , so that the USB2.0 signals transmitted between the south bridge 10 and the USB3.0 connector 20 are grounded. Then, the motherboard 100 can be further tested.
When the motherboard 100 is not testing the USB3.0 signal, the output pin DP outputs a second control signal. The electronic switch Q 1 and the second electronic switch Q 2 are switched off after the first ends receive the second control signal. The south bridge 10 and the USB3.0 connector 20 can send and receive USB2.0 signals through the first transmitting pin TR 1 , the second transmitting pin TR 2 , the third transmitting pin TR 3 , and the forth transmitting pin TR 4 . Then, USB2.0 signals and USB3.0 signals can be transmitted between the south bridge 10 and the USB3.0 connector 20 . In at least one embodiment, the first control signal can be a high level signal, and the second control signal can be a low level signal.
As detailed above, the motherboard 100 has the south bridge 10 controlling the ground module 30 to operate, so that the USB2.0 signals transmitted between the south bridge 10 and the USB3.0 connector 20 are grounded. Then, the motherboard 100 can test the USB3.0 signal.
The embodiments shown and described above are only examples. Many details are well known by those in the art therefore, many such details are neither shown nor described. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the details, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure up to, and including the full extent established by the broad general meaning of the terms used in the claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the claims. | An electronic device includes a motherboard that includes a south bridge, a universal serial bus (USB) 3.0 connector, and a ground module. The south bridge is connected to the USB3.0 connector for transporting USB3.0 signals and USB2.0 signals. The grounded module is connected to the south bridge and the USB3.0 connector. The south bridge is used for controlling the ground module to work. The USB2.0 signals transmit between the south bridge and the USB3.0 connector flow into the ground, while the ground module is working. | 6 |
FIELD OF THE INVENTION
[0001] The present invention concerns improvements in and relating to paving and particularly to a method and apparatus for applying a settable material such as, for example, cement or concrete to a surface to form paving.
BACKGROUND TO THE INVENTION
[0002] There have, in recent years, been a number of important developments in the field of paving extending the range of options available for materials and finishes and the way in which the paving is laid. One of the most important developments was the introduction of pattern-imprinted concrete to enable an area of paving to be given the appearance of block paving when, in fact, it is formed in situ as a layer of concrete is subsequently coloured and imprinted using a set of moulds for the pattern design, pressed down from above. An example of this system is described in GB 2,193,989A. Among benefits that can be obtained from this process is the ability to obtain a block paved appearance with a substantially monolithic formation that stops through-growth of weeds. Furthermore, the paving can be laid comparatively rapidly and less labour intensively than conventional block paving. However, the level of skill required to lay the pattern imprinted concrete paving is substantially higher than for block paving and there are tight constraints in when and how the pattern-imprinted concrete can be laid.
[0003] Laying pattern-imprinted concrete during hot periods should be avoided to prevent accelerated concrete curing which can lead to crack formation. The quality of the installation during hot spells can also be undermined as the installers are under greater pressure to rush the process before the concrete is too hard to work with, i.e. loss of pattern definition.
[0004] Given constraints such as the finite curing time window, the need to pattern imprint substantially the full area to be paved in one session in order to avoid unsightly discontinuities in the pattern, to ensure the colour is consist nt throughout and the difficulty in rectifying any errors once the pattern has been applied, speed, care and skill are all needed. Luck with the weather also helps. As with any process based on curing of cement/concrete, and especially with coloured pattern-imprinted concrete, if not sheltered a sudden downpour could be disastrous, affecting the colour and imprint if the concrete had not hardened sufficiently or the job was still in progress at any stage.
[0005] Therefore climatic conditions have a great bearing on the outcome of pattern imprinted concrete quality, which deters many block paving and paving companies from getting involved as this could lead to jobs being excavated and relaid.
[0006] Furthermore, although the monolithic construction gives one of the key benefits of pattern-imprinted concrete, some provision still has to be made for concrete expansion and contraction during varying weather conditions and possible slight ground movement, by including expansion and contraction joints or crack control joints (gap) in the formation. These are generally placed at certain intervals at the discretion of the installer and can in some patterns appear unsightly. Placing of these joints is no guarantee that cracks are prevented, as has happened on many occasions.
[0007] It is a general objective of the present invention to provide an improved paving system which exploits benefits of the existing pattern-imprinted concrete systems, while increasing the ease with which they can be laid, reducing the skill levels necessary.
[0008] It is an objective to mitigate against the need for visible expansion lines and enable the paving to be built up in manageable modular regions without undermining the integrity or the appearance of the paving. It is a further objective to enable good access to be had to remote areas of the paving being laid before the concrete has cured.
[0009] It is a further general object to make the system economical to implement, and in combination with the reduction in skill required, to enable a pattern-imprinted concrete type of approach to be used far more widely as an alternative to the conventional cobble-laying, block paving, slabs or tarmacing of driveways, patios and other paved areas in domestic and commercial premises.
[0010] It is an objective to be able to lay paving imitating the look of pattern imprinted concrete in hot or inclement weather conditions reducing downtime, whilst maintaining quality.
[0011] It is an objective to prevent cracking throughout the installation by providing a system that facilitates movement, expansion and contraction.
[0012] It is an objective to facilitate better access to the client into their home by boards placed over the area being paved, a difficulty with normal pattern imprinted concrete paving during the setting period.
SUMMARY OF THE INVENTION
[0013] According to a first aspect of the present invention there is provided an apparatus for forming paving from a settable material and which comprises a base frame which, alone or together with an adjacent positioned said base frame, defines a plurality of compartments within which the settable material may be placed to be moulded by the compartments of the base frame(s) into a plurality of blocks, wherein the base frame is adapted to be left in situ.
[0014] The base frame is particularly preferably a matrix frame defining several compartments and adapted to be used with other such base frames and provided with one or more apertures in a perimeter wall of the base frame whereby settable material may flow from a first base frame to an adjacent base frame so that an expansive area to be paved may be covered by multiple matrix frames and each matrix frame interlinked by the settable material. A particular benefit of this is that expansive areas may be covered rapidly and efficiently using the matrix frames as modules and with the resulting whole expanse of paving being cohesive. The cohesive interlinked expanse allows for expansion of the concrete by shear of the interlinking concrete and even where shear of the interlinking concrete occurs the sheared interlinking concrete stubs will persist in maintaining the spacing apart of the matrix frames.
[0015] During hot spells the compartment structure will allow shrinkage due to accelerated curing, without cracking, with improved control as installers can lay at will without rushing the process. During wet weather the concrete can be covered in plastic sheeting at any stage so that the paving can be formed and covered in sections without loss of colour and pattern. The walls of the base frame(s) between adjacent compartments preferably have one or more apertures therethrough to enable a settable material to flow from one compartment to the next to interlink the paving blocks formed as the settable material sets. The base frame is preferably of matrix form defining said plurality of compartments within which the settable material may be placed. Suitably there are a plurality of the apertures and these are formed as crenellation recesses in the upper, in use, edges of the walls between the compartments of the base frame(s).
[0016] Preferably further apertures are formed in the walls between compartments lower down the walls than the crenellation recesses.
[0017] Suitably the crenellation recesses in the walls between compartments are at least partly staggered as they run through the walls, and if fully staggered and thereby occluded are provided only in combination with said further apertures. One or more recesses may be formed in the walls between compartments lower down the walls than the upper edges of the walls.
[0018] In accordance with a major aspect of the present invention the apparatus suitably further has a grout frame which is of a substantially corresponding shape in plan to the base frame in order to be positioned atop the walls of the base frame in use extending the walls upwardly. The grout frame is preferably a pre-assembled frame but could be assembled on site by the paving contractor of a set of individual elongate frame members. Thus the grout frame is a frame that is either wholely preformed as an assembled frame or is at least formed of elongate pre-formed frame members that are assembled together relative to each other on site. This contrasts to the prior art where any grouting is not formed as a frame/of frame members but instead always applied as a fluid paste/putty or mortar that is inserted between blocks of solid paving.
[0019] The grout frame preferably is an assembly comprising a grout carrier/cover component carrying on its face that is to be placed atop the base frame a component to serve as th grouting, which latter is releasably held to the grout carrier/cover component so that it may be left in place between th paving blocks when the grout carrier/cover component is removed. It is to be understood that the expression “to serve as the grouting” is intended to mean that th item in question need not be a conventional grouting mortar, putty or paste composition but rather is serving as grouting by fitting in the interstitial space where grouting paste is normally applied, simulating the appearance of grouted interstices between the blocks. Indeed, in the preferred embodiment the grouting component of the grout frame is not a soft putty or paste but a frame-shaped moulding of plastics or other suitable material.
[0020] Alternatively the frame that mounts atop the base frame is a grout channel-forming frame and the frame is formed of grouting material or at least serves in use as th grouting. In this or the preceding aspect/embodiment the part that serves as the grouting being pre-configured to a frame shape in plan greatly facilitates the grouting stage of the paving process. Furthermore, the use of a grouting part that is embedded in the setting concrete of the blocks as a “pre-grout” and therefore firmly held in place overcomes/mitigates against the problem of grout dislodgement that occurs with the conventional application of grouting mortar, putty or paste after setting of the concrete. Such dislodgement of conventional grout occurs frequently when high pressure jet washes are used on conventional block paving.
[0021] The grouting component suitably extends beyond the top edge of the grout carrier cover component into the compartments to be embedded in the settable material.
[0022] In any of the embodiments the base frame is particularly preferably of cardboard or other degradable material that will degrade in situ over time and preferably is a flat pack frame formed of one or more sheets that are assembled/folded to form the frame. Suitably the base frame has one or more transverse walls bridging between a plane parallel opposed pair of walls, the or each of which transverse walls is configured with a tab at each end defining a slit to be slotted in place down onto a corresponding one of the opposing walls to lock the walls relative to each other. Each tab with slit may be further used to hold one base frame to an adjacent positioned base frame.
[0023] Preferably the base frame is provided with a floor and particularly preferably the floor is apertured so that the settable material is substantially held within the compartments but nevertheless in contact with the underlying ground. A particularly preferred arrangement is the provision of a large central aperture through the floor of each compartment.
[0024] According to a further aspect of the present invention there is provided a method of forming a paving from a settable material and which comprises the steps of providing an apparatus as defined in one of the above statements, laying it on the surface to be paved, positioning the settable material into the compartments of the apparatus and allowing the settable material to set, embedding the base frame(s) of the apparatus in situ in the paving. This particularly suitably further comprises, prior to or after placing the settable material into the compartments, placing a said grout frame atop the base frame.
[0025] In an adaptation of the method and apparatus of the invention for use in a ‘hybrid’ manner, the apparatus suitably further comprises a set of paving tiles, one to cap each block and which are each configured to sit atop the walls of a respective compartment and be held in place by the setting of the settable material. This is particularly useful in areas of unpredictable/high rainfall where use of preformed capping further simplifies laying of the paving while ensuring a quality finish.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Preferred embodiments of the present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, wherein:
[0027] FIG. 1 is a schematic perspective view from above of a base matrix frame and a grout-holding/channel-forming frame that, in use, is superimposed on the base matrix frame;
[0028] FIG. 2 is a perspective view from above of a base matrix frame and grout-holding frame such as shown in FIG. 1 but showing the grout-holding or “Channel-forming” frame operatively positioned on the base matrix frame;
[0029] FIG. 3 is a close-up perspective view of abutting walls of adjacent base matrix frames clipped one to another;
[0030] FIG. 4 is a view similar to FIG. 2 of a curved base matrix frame and grout-holding frame suitable for providing edging to the paving;
[0031] FIG. 5 is a schematic transverse sectional view of paving formed using the system of the invention;
[0032] FIG. 6 is a transverse sectional view of a pavement formed using an alternative embodiment of the invention;
[0033] FIG. 7 is a side elevation view of the FIG. 6 pavement;
[0034] FIG. 8 is a schematic perspective detail view of a staggered arrangement of castellation of adjacent base matrix frames;
[0035] FIG. 9A is a plan view from above of a blank of corrugated cardboard or other suitable material that may be folded to assemble into a base frame that is one row of compartments wide and, when transverse/divider walls are inserted in place, comprises five compartments in a series with the walls of the base frame being two ply thick:
[0036] FIG. 9B is an elevation view of a transverse/divider wall;
[0037] FIG. 9C is an elevation view of a longitudinal side wall of a base frame assembled from the blank of FIG. 9A ; and
[0038] FIG. 10 is a perspective view from above of a particularly preferred variant of the grout frame of the FIG. 1 embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring firstly to FIG. 1 , the primary component of the new paving system is a base matrix frame 1 that is partitioned into a series of compartments by dividing walls 2 , 3 extending longitudinally and transversely of th frame 1 . This base matrix frame 1 is effectively a mould into which fresh concrete is poured with the individual compartments 5 defining the individual blocks/cobbles of the paving.
[0040] As can be seen, the partitioning walls 2 , 3 are of substantially the same height as the outer boundary walls 4 of the matrix frame 1 . In a preferred construction th base matrix frame 1 is pre-formed from card or compressed paper that is sealed in a wax or PVA coating for added strength and water resistance. Indeed, the use of card or compressed paper or similar environmentally degradable or biodegradable material serves two roles. Not only does it keep the costs of the system very low, but importantly it also serves a technical function in that when the card or paper begins to degrade over time the degradation of the walls 2 , 3 and 4 of the base matrix frame 1 gives rise to voids that serve as expansion zones or shear lines.
[0041] Whereas the partition walls 2 , 3 divide the concrete that is poured into the matrix base frame 1 into discrete blocks, the whole will have a monolithic nature, each block being linked to neighbouring blocks, since apertures 10 are provided through the partition walls 2 , 3 and also through the outer walls 4 that abut, in use, adjacent base matrix frames. As illustrated, these apertures 10 are in the form of a series of recesses spaced at regular intervals along the upper, in use, edge of each partition wall 2 , 3 or boundary wall 4 of the base matrix frame 1 , giving the walls 2 , 3 , 4 a crenellated appearance, with a raised portion 11 between each crenel recess/aperture 10 .
[0042] Although each of FIGS. 1 to 3 shows crenellations only along the upper edge of some but not all of the partition walls 2 , 3 it is intended that these extend along all partition walls 2 , 3 substantially for their full length and also substantially along the full length of at least each of those boundary walls 4 that are intended to abut adjacent base matrix frames 1 .
[0043] Furthermore, although not illustrated as such, the partition walls 2 , 3 are suitably of a thickness that is approximately double that of the boundary walls 4 . The purpose of this is to ensure that the thickness of the walls is uniform throughout the ultimately assembled arrangement of base matrix frames I both between base matrix frames 1 and between the compartments 5 of each frame 1 . This is important in order for the arrangement of base frames 1 to give uniform robust support over the full area to be paved so that later on during the concrete laying process the area may be walked over and, indeed, a wheelbarrow or other receptacle carrying concrete may be advanced over the ar a (suitably having first laid boards over the tops of the base matrix frames 1 ).
[0044] With reference to FIG. 3 , during the initial stage of installation of the system a plurality of base matrix frames 1 are placed side-by-side in an arrangement to enable the paving to cover the full extent of the area to be paved. The abutting border walls 4 of the adjacent base matrix frames 1 can be readily held together by simple securing clips 12 that are suitably resilient and press-fit over the upper edges of the abutting border walls 4 . As shown, these securing clips 12 suitably locate over the walls 4 within the apertures/recesses 10 . Only a relatively small number of them need be used to hold the assembly of the base matrix frames 1 in the desired configuration on the ground.
[0045] With the assembly of base matrix frames I in place, the next major component f the system, a grout channel-forming, or grout-holding, frame 20 , is lowered into place on top of each base matrix frame 1 .
[0046] As can be seen in FIG. 1 , the grout-holding frame 20 is a grid/matrix frame of longitudinal and transverse members 21 , 22 configured directly to correspond to the longitudinal and transverse border walls 4 and partitioning walls 2 , 3 of the base matrix frame 1 so as to overlie/cap their upper edges.
[0047] The grout-holding frame 20 is suitably substantially rigid at least in so far as the mutual spacing of the longitudinal and transverse members is defined, but may have the nature of a sheet that can be stored in a rolled up state and then rolled out over the base matrix frame 1 .
[0048] The skeleton of the grout-holding frame 20 may, like the base matrix frame 1 , also be formed of PVA coated card/compressed paper. It carries beneath it strips of grout 23 extending the length of the longitudinal and transverse members 21 , 22 and glued to the underside of the grout-holding frame 20 by a peelable adhesive that will enable th frame 20 to subsequently be peeled away from the grout strips 23 , leaving them in place along th top edges of the bas matrix frame 1 walls 2 , 3 , 4 .
[0049] Referring to FIG. 2 , the illustrated grout-holding frame 20 is shown as not having any member 21 , 22 extending along its near side or right hand end as viewed and the transverse members 22 that terminate at the nearside edge and longitudinal members 21 that terminate at the right hand edge when positioned on the base matrix frame 1 are foreshortened so that they only partially overlap or reach but do not overlap the corresponding border walls 4 of the base matrix frame 1 . This is to allow for dose adjacent placement of the next adjoining base matrix frame 1 and associated next adjacent grout-holding frame 20 . For the same reason, at the outer borders 4 of the illustrated base matrix frame I (rear edge and left-hand edge as viewed), the grout-holding frame 20 and associated grout strip 23 overhang.
[0050] Accordingly, when a first base matrix frame 1 is butted to a second base matrix frame 1 , the grout-holding frame 20 of one overlaps the top edges of the front and right border walls 4 of the other. The grout strips 23 although only shown on part of the grout-holding frame 20 in FIG. 2 do extend throughout the grout-holding frame 20 . Furthermore, the grout strips 23 are shown as spreading beyond the sides of each grout-holding frame member 21 , 22 to which they are mounted thereby defining an overhang portion 24 of the grout strip 23 on each side of each member 21 , 22 of the grout-holding frame 20 . This overhang portion 24 is important to serve as an anchor that beds the grout strip 23 into the concrete during the next stage of the procedure in which the wet concrete is poured into the base matrix frame 1 compartments 5 (see FIG. 5 ). The grout strip 23 can be of an upstanding/vertical nature straddling the base matrix frame 1 walls 2 , 3 , 4 .
[0051] Although the overhang 24 of the grout strips 23 is illustrated in FIG. 5 as extending substantially perpendicularly from the strips 23 , i.e. perpendicularly to the partitioning 2 . 3 and border 4 walls of the base matrix frame 1 , an alternative preferred arrangement is to have them extending inclined at least somewhat downwardly into the respective compartments 5 . A downward angling of the overhangs 24 of the grout strips 23 will minimise disruption to concrete flow being poured into the compartments 5 and may ensure more uniform spread of the concrete.
[0052] FIG. 4 illustrates a bas matrix frame 1 and associated grout-holding frame 20 that are particularly suited for use as edging to a paved ar a. As can be seen, the base matrix frame 1 and grout-holding frame 20 are not only with distinctive curved form of a single row of compartments 5 but it would also be noted that the grout-holding frame 20 fits neatly flush with the bas matrix frame 1 throughout, i.e. the grout-holding frame 20 does not extend beyond the base matrix frame on one side and fall short of it on the other, unlike the previously described embodiment. The edging do s not need to be seen to be integral with the main area of paving and, accordingly, there is no need for overlap of the grout strips 23 between one base matrix frame and associated grout-holding frame and the next.
[0053] Although not shown in FIG. 4 , the outer boundary wall 4 of the edging base matrix frame 1 is suitably provided with a blanking strip extending the length of the outer boundary wall 4 to close off the apertures/crenel recess 10 to prevent leakage of concrete beyond the edging border.
[0054] In a first preferred procedure for laying concrete paving using the apparatus of the invention, the preparative stages are, as conventional, to firstly build up a bed of hardcore on the ground to be paved and to level the hardcore before then spreading across the top of the hardcore a sand screed. Once this is done the base matrix frames 1 are then placed on top of the screeded surface in the desired arrangement to cover the area to be paved. Adjacent base matrix frames 1 are clipped together with the clips and a corresponding grout-holding frame 20 is fitted on top of each base matrix frame 1 . As discussed previously, the grout-holding frames 20 will generally overlap the base matrix frames 1 along two edges, integrating the whole assembly.
[0055] The cement mix freshly prepared is suitably deposited in each of the compartments 5 , suitably by advancing a wheelbarrow of fresh concrete out over the area to be paved riding on boards laid across the top of the frame assembly 1 , 20 , and filling the compartments up to a level that is dose to being flush with the tops of the grout-holding frames 20 . A coloured powder is suitably then applied to the exposed upper concrete layer then smoothed, suitably by trowel, to give the paving the desired colour finish.
[0056] Once the colour mix has been added to the concrete and before the concrete sets, a desired surface pattern is generally then imprinted in the concrete using a contoured roller or other suitable imprinting tool of which there are many currently available and used in conventional pattern-imprinted concrete laying.
[0057] Once the concrete has substantially set the grout-holding frame 20 is then detached from the grout strips 23 leaving them behind and embedded in the concrete in exactly the configuration dictated by the frames 1 , 20 , between each of the concrete blocks defined by the frame compartments.
[0058] Following removal of the grout-holding frames 20 , the concrete will, on average, set within a couple of days enabling the paving to be walked upon or driven upon. An acrylic sealant is suitably applied to the top of the concrete when it has substantially set in order to protect the concrete surface and grout from weathering and enhance the finished appearance, and to enable oil and dirt to be removed easily.
[0059] As can further be seen from FIG. 5 , the skeleton of the grout-holding frame 20 , suitably formed of compacted card, has a clearly defined profile/transverse sectional shape which is responsible for giving the exposed upper edges of the concrete blocks a desired shape, in this case, a rounded shape. In particular it will be seen that the profile/section of each grout-holding frame member 21 , 22 is of a fluted form, giving rise to the round-edged form of the top of the blocks 25 . It will also be appreciated that the size and shape of the grout-holding frame 20 skeleton determines the size shape and depth of the channel between each block when the grout-holding frame 20 is removed, leaving the grout strips 23 behind. On average the preferred depth of channel to be formed is between 3 mm and 5 mm and the preferred thickness of grout 23 may be of the order of 3 mm. However this can vary depending on the pattern and style of pattern which can include varying shapes and sizes such as cobble, slate, stone, tile, brick etc.
[0060] The concrete is linked throughout as a substantially monolithic structure by virtue of the concrete bridges formed by the concrete flow between compartments through the apertures of the crenellation recesses 10 or other apertures that extend through the partitioning or boundary walls 2 , 3 , 4 of the base matrix frames 1 .
[0061] As time passes, the degradable base matrix frames 1 will disintegrate leaving the interlinked blocks with substantial voids between them that function as shear and expansion lines. All blocks will be connected or touching on shearing maintaining stability, preventing spreading or sideways movement.
[0062] Significantly, the bridging concrete between the blocks not only gives the paving structural integrity, it also provides support to the overlying grout strips. Indeed, the bridging concrete would generally be sufficient to prevent even a woman's stiletto heel from penetrating between the blocks. However, as a further safeguard against this, the bridging concrete between blocks can be strategically configured by further refinements to the base matrix frame 1 construction as illustrated in FIG. 8 .
[0063] Referring to FIG. 8 , this shows the boundary wall 4 of one base matrix frame 1 in position butting up against the corresponding adjacent boundary wall 4 of an adjoining base matrix frame 1 and where the crenellations 10 along the top edge of each border wall 4 are staggered relative to each other. In consequence, a raised portion 11 of the crenellation of one base matrix frame 1 lies directly next to and therefore obstructs the crenel/recess 10 of the next base matrix frame 1 preventing through-flow of concrete but providing the basis for staggered concrete projections to be formed in the recesses 10 to give support to the overlying grout strip for the full length of the border wall. Accordingly, once the border wall has disintegrated the concrete support immediately underlying the grout strip remains.
[0064] To compensate for loss of through-flow of bridging concrete through the crenel recesses 10 , separate throughflow apertures 10 ′ are provided through the border walls 4 lower down, as illustrated.
[0065] Whereas the FIG. 8 arrangement is described and illustrated with respect to the border walls 4 , this arrangement applies equally to the partitioning walls 2 , 3 and can most readily be used with them when the partitioning walls 2 , 3 are formed as two-ply or double thickness walls whereby one half of their thickness is crenellated in a first sequence, and the other half of their thickness is crenellated in a second sequence that is staggered relative to the first sequence. By this means all upper edges of all walls, both border 4 and partitioning 2 , 3 of each base matrix frame 1 have the desired staggered configuration of crenellations to provide uniform support throughout to the corresponding overlying grout strips 23 .
[0066] In the above described procedure, while laying th cement, w have suggested that the cement mix be poured into the compartments 5 of the base matrix frame 1 once th grout-holding frame 20 is in place and is then topped off with coloured powder. In a refinement to this process to minimise any risk of uncoloured areas two different alternative procedures may be adopted. In the first alternative the assembly of base matrix frames 1 is installed and plain concrete poured into the compartments 5 prior to mounting the grout-holding frames 20 and then filling these with coloured concrete mix. Indeed, it is this embodiment that is illustrated in FIG. 5 where one can clearly see the top layer 26 of colour mix concrete above the base matrix frame 1 , within the grout-holding frame 20 .
[0067] In a second alternative procedure, instead of using plain concrete with a coloured powder or colour mix, a fully coloured concrete mix may be used alone and be poured into the fully assembled base matrix frame 1 and grout holding frame 20 assembly to be level with the top of the grout-holding frame 20 . This option is the simplest to implement but is subject to the somewhat higher costs of having enough pigment to colour the concrete throughout rather than simply the topmost layer.
[0068] In the above described embodiments the grout-holding or channel forming frame 20 is described as holding grout to be left in situ overlying the walls 2 , 3 , 4 of the corresponding base matrix frame 1 . Alternatively, however, the grout channel forming frame 20 need not hold a grout material itself but may be a frame that still has the corresponding plan shape to the plan shape of the base matrix frame 1 but serves solely to form the grout channels between the compartments 5 , i.e. between the paving blocks as they are formed, and which is removed once the concrete has substantially set. Separate grouting material, e.g. a wet or powder grout, may th n be placed into the grout channels between the blocks left behind following removal of the grout channel forming frame 20 .
[0069] Turning now to FIG. 6 , this illustrates an alternative embodiment of the invention in which the base matrix frame 1 is substantially as in the previously described embodiment but which differs significantly in that the topmost surface of the paving comprises preformed paving tiles, suitably preformed of concrete and/or resin, and the grout-holding frame 20 being replaced by a grout frame 30 that functions as the grout itself and which is left in situ during the laying process. Grout frame 30 is similar in plan to the grout-holding frame 20 of th first embodiment and is suitably simply formed of grout medium and has, as illustrated, a cross-section that is suitably rectangular, being of a width equivalent to the width of the partition walls 2 , 3 or border walls 4 of the base matrix frame 1 to directly overlie those walls 2 , 3 , 4 . As with the grout-holding frame 20 , the frame 30 is, however, suitably configured to provide overlap from on base matrix frame 1 to the next. Here, the concrete tiles 31 are formed of a profile having an overhang lip 34 on all sides to seat on top of the correspondingly positioned member of the grout frame 30 .
[0070] The concrete tiles 31 are suitably each formed with studs 32 on their undersurface to bed into the freshly poured concrete that is first poured into the compartments of the base matrix frame 1 . The level of the poured concrete suitably comes to th level of the bottom edge of the grout frame 30 , as illustrated, and anchoring of the grout frame 30 is suitably achieved by similar studs 33 provided on the underside of the grout frame 30 that project into the concrete where the concrete has flowed int the crenel recesses 10 of the base matrix frame 1 .
[0071] The pre-manufactured paving tiles 31 are suitably delivered in pack form. The studs on the undersides of the tiles 31 may be moulded of the concrete from which the tiles are moulded or may be plastics or other suitable material that is compatible with concrete and thereby provides a good long term secure anchoring of the tiles 31 into the poured concrete in the base matrix frame 1 .
[0072] The procedure for laying this embodiment of paving is suitably to begin by setting out the base matrix frames 1 in the desired configuration of assembly. The concrete is then poured and smoothed off and the grout frames then placed onto the base matrix frames 1 (overlapping as per the earlier embodiment grout frame 20 ). Then the overlapping tiles 31 are placed onto the grout frames 30 and secured into the wet/soft concrete in the compartments 5 .
[0073] Turning now to FIGS. 9A to 9 C, these show details of the preferred construction of the base matrix frame 1 using a corrugated cardboard blank, outer panels of which are folded up and over to form two ply upstanding sidewalls and end walls to the frame. The base frame 1 here has a floor 35 that is, for each compartment, perforated by a respective large generally square central aperture 36 . The compartments in the assembled base frame 1 are defined by transverse dividing walls 37 such as shown in FIG. 9B . The dividing wall 37 has tabs 38 a on its opposing side edges that overhang and define slits 38 b which co-operatively engage with the opposing parallel sidewalls such as shown in FIG. 9C suitably slottingly engaging with complementary slits 38 C on those sidewalls.
[0074] Location each of the dividing walls 37 within th bas frame suitably also entails location of a bottom protrusion 39 a of ach dividing wall into a respective slit 39 b in th floor 35 .
[0075] In the FIG. 9 illustrations the base frame is seen to have arcuate crenellations 10 . These are easier to punch from card using conventional punching equipment with less risk of jamming of the punch mechanism than is the case with polygonal/straight sided crenellations.
[0076] Referring finally to FIG. 10 , this shows a variant of the grout frame that has th structural integrity of the frame provided not by the over-lying grout holding frame/cover component 41 but by the rigid frame-shaped grouting component 40 which is suitably moulded of a plastics material such as nylon, polypropylene or reconstituted plastics and which has each member of its grid/lattice-work with an arched profile.
[0077] The cover component 41 is here shown as a much thinner component than the corresponding cover component 41 grout holding frame 20 shown in FIG. 1 but may be thicker if required to provide a greater depth of inset of the grouting below the paving top surface. It is still frame-shaped in plan but is of a relativelty soft, flexible and preferably elastomeric resilient material that is readily peelable away from the top of the frame-shaped grouting component 40 when the grouting component 40 is securely anchored in the set/setting concrete. The resilient nature of the cover component 41 may also facilitate trowelling and smoothing of the cement including any to player colouring cement or screed.
[0078] The arched profile of the members of the lattice-work of the grouting component 40 provides the downwardly inclined lateral extensions/flanges 42 of the grouting component 40 that bed into the concrete and anchor the grouting component 40 in place.
[0079] Apertures 43 in the lateral extensions 42 of the grouting component 40 may, if required, be large enough to allow the cement to ooze though to better even out th distribution of the cement, but most importantly help to prevent air pockets from forming under the extensions 42 . | In one aspect the present invention provides an apparatus for forming paving from a settable material and which comprises: a base frame having a plurality of upstanding walls which, alone or together with an adjacent positioned said base frame, defines a plurality of compartments within which the settable material may be placed to be moulded by the compartments of the base frame(s) into a plurality of blocks, the base frame being adapted to be left in situ; and a grout frame which is of a substantially corresponding shape in plan to the base frame and which is positioned atop the walls of the base frame in use, extending the walls upwardly. Amongst further aspects are: provision for modular interlinking of matrix type base frames to facilitate paving substantial areas in a cohesive manner; ease of storage and distribution through use of a flat pack construction; yet further improved ease of use in areas of high rainfall by providing a hybrid tiling system; and improved integrity through use of an apertured floor | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an air conditioning device or air heating device for power vehicles. More particularly, it relates to an air conditioning device which has a control member formed advantageously as an air-regulating flap, an electric servomotor or adjusting motor arranged to drive the control member, and a temperature regulator having a temperature sensor and acting upon the electric motor.
Devices of the above mentioned general type are known in the art. One such device is disclosed, for example, in the U.S. Pat. No. 2,284,764. This device has a warm air supply passage and a cold air supply passage which both merge into an air passage in the interior of the vehicle. In the region of transition, the above mentioned control member, formed as an air-regulating flap, is turnably mounted, and thereby blocks one or the other supply passage relative to the air passage. The air-regulating flap is adjustable by the electric adjusting motor via a reduction transmission. The adjusting motor is connected with a control device having at least one temperature sensor. It cannot be excluded that the control device has a defect, and that the adjusting motor forces the air-regulating flap to one of its two possible positions and, particularly when the reduction transmission is formed as a worm transmission, fixedly holds the flap in its position. When, in the event of freezing temperatures, the warm air supply passage is blocked because of such defect, it is not possible to defrost the windshield. In modern air conditioning or air heating devices, the control device is provided with transistors. When a defect occurs in the transistors, an expert, particularly in electronics, must be found. Such experts are not available as often as mechanics.
In the air conditioning device disclosed in U.S. Pat. No. 4,216,822, a vaporizer is arranged in a passage behind a blower which aspirates air and completely fills the cross section of the passage. A heater through which motor-cooling water flows is arranged behind the vaporizer at a distance therefrom and only partially fills the cross section of the passage, so that a bypass cross section remains free. A regulating flap is arranged in the passage such that the bypass cross section can be selectively closed or opened to any width. The regulating flap can be turned, as described in U.S. Pat. No. 2,284,764, with the aid of an electric adjusting motor and a reduction transmission. It is not guaranteed there that, in the event of defective control device or adjusting motor, the temperature of the air, at least for defrosting of windshields and heating the interior of the vehicle, can be adjusted.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an air conditioning device which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide an air conditioning device for a power vehicle which, in event of a defect in the control device or in the adjusting motor, permits adjustment of the air temperature by hand.
In keeping with these objects, and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in an air conditioning device in which, in addition to motor means for driving a control member, means are provided for interrupting the connection between the electric motor and the control member, and further means for manually adjusting the control member upon interruption of the connection between the electric motor and the control member.
When the air conditioning device is designed in accordance with these features, it guarantees that, in the event of a defective control device or adjusting motor, the air temperature can still be adjusted, manually.
In accordance with another advantageous feature of the present invention, a planetary transmission is arranged between the electric motor and the control member and connects the former with the latter. The control member is connected with one planetary transmission element, such as a hollow shaft or a planetary wheel carrier, and the interrupting means includes the other of the planetary transmission elements, which is arranged rotatable for interrupting purposes, and a self-engaging arresting mechanism preventing rotation of the other planetary transmission element during driving of the control member by the electric motor, and a releasing element is arranged to release the arresting mechanism.
In accordance with still another advantageous feature of the present invention, the manual adjusting means includes a turnable adjusting lever provided with a disk which mounts the adjusting lever coaxially with the planetary wheel carrier, and the disk is provided with a cam and arranged so that, after releasing of the arresting mechanism, the disk is coupled with the one planetary transmission element which is fixedly connected with the control member. When the air conditioning device is designed in accordance with these features, it has a very compact construction and also guarantees that the manual adjusting means is immovable during the driving of the air-regulating flap by the motor, so as to exclude the danger of injury to vehicle passengers.
A further feature of the present invention is that the arresting mechanism include an arresting pin extending substantially radially to the turning axis of the adjusting lever and loaded with a spring, and a recess provided in the other planetary transmission element and associated with the arresting pin, wherein a cam is arranged to act radially on the arresting pin.
Still a further feature of the present invention is that the adjusting lever is provided with an abutment arranged so that, after releasing of the arresting mechanism, the abutment, during turning of the adjusting lever in its turning direction, engages a follower provided on the one planetary transmission element and formed as a pin. The recess and the cam can be arranged adjacent to one another, so that one portion of the arresting pin extends toward the cam, whereas another portion of the arresting pin extends into the recess.
When the air conditioning device is provided with the latter mentioned features, this contributes to compact construction of the device.
The novel features which are considered characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a view showing a longitudinal section of an air conditioning device during its automatic operation, in accordance with the present invention;
FIG. 2 is a plan view of the air conditioning device shown in FIG. 1;
FIG. 3 is a longitudinal section of the air conditioning device of FIG. 1 during its manual operation;
FIG. 4 is a view showing individual parts of the air conditioning device of FIG. 3, in a plan view; and
FIG. 5 is a view showing a longitudinal section of the air conditioning device in accordance with a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An air conditioning device for a power vehicle in accordance with the present invention is identified in toto by reference numeral 2. The air conditioning device 2 has a warm air supply passage 3, a cold air supply passage 4, and an air passage 5 which leads into the interior of the power vehicle and/or to defrosting nozzles. It further has a control member 6 which is formed as a turnable air-regulating flap, a planetary transmission 7, a reducing transmission 8, an electrical adjusting or servo motor 9, a temperature regulator 10 with a temperature sensor 11, and a manual adjusting device 12.
The warm air supply passage 3 and the cold air supply passage 4 lead to the air-regulating flap 6 and to the air passage 5. A not shown heating element, such as a heating coil, is arranged in the warm air supply passage 3. The cold air supply passage 4 has a not shown vaporizer for the case when the device is formed as an air conditioning device. Depending upon the position of the air-regulating flap, cold or unheated air, warm air, or a mixture of both of these is supplied into the air passage. The first option is provided when the air-regulating flap is in its position shown in FIG. 2.
The planetary transmission 7 has an input shaft 13 with a sun gear 14, several planetary gears 15, a planetary gear carrier 16 which is coaxial with the input shaft, and a hollow gear 17 surrounding the planetary gears 15 and provided with an output shaft 18. The output shaft 18 transits into a portion with two flat faces 19 on which a hub 20 of the air-regulating flap 6 is fitted.
The planetary gear carrier 16 has at least one recess 21 on its periphery. A disk 22 is supported on the input shaft 13 and arranged adjacent to recess 21 and directly on the planetary gear carrier 16. An adjusting lever 23 extending radially outwardly is formed on the disk 22 and can be actuated by hand. A part of the periphery of the disk 22 forms a cam 24.
An arresting mechanism 25 includes an arresting pin 26 and a spring 27. The arresting pin 26 is guided radially toward the input shaft 13 in a housing 28 of the planetary transmission 7 and arranged so that a part of its cross section engages under the pressure of the spring 27 into the recess 21, whereas the other part (half) of its cross section can be engaged by the cam 24. The planetary gear carrier 16, the recess 21, the arresting mechanism 25 and the cam 24, as well as the disk 22 and the adjusting lever 23, together form means for interrupting the driving connection between the input shaft 13 and the output shaft 18.
A ray-like abutment 29 is formed on the disk 22. The hollow gear 17 has on its periphery a follower which is formed as a pin 30 and located in a movement plane of the abutment 29 determined by the input shaft 13. When, as shown in FIG. 2, the disk 22 is turned with the aid of the adjusting lever 23 in clockwise direction, the abutment 29 displaces against the pin 30. Thereby, when the arresting pin 26 is not in the recess 21, it is possible by turning the adjusting lever 23 to turn the hollow gear 17 in clockwise direction.
During turning of the adjustment lever 23, before the abutment 29 hits the pin 30, the cam 24 presses the arresting pin 26 from the recess 21. The adjusting lever 23, the abutment 29, the pin 30 and the hollow gear 17 together form manual adjusting means for the air-regulating flap 6. The manual adjusting means 12 acts on the air-regulating flap 6 first when a force-transmitting driving connection between the input shaft 13 and the hollow gear 17 is interrupted. As long as the adjusting lever 23 is located in its position shown in FIG. 2, the adjusting motor 9, which is switched in a known manner by the temperature sensor via the temperature regulator 10, turns via the reduction transmission 8 the input shaft 13, the sun gear 14, the planetary gears 15, and the hollow gear 17 with its output shaft 18, and thereby turns the air-regulating flap 6. During motor-driven turning of the air-regulating flap 6, the manual adjusting means 12 does not work.
If for some reason, for example because of a defect in the temperature regulator 10, the adjusting motor 9, or the reduction transmission 8, the air-regulating flap turns in the clockwise direction, then by turning the adjusting lever 23 first the hollow gear 17 is disengaged so that it can rotate freely, and then it acts upon the air-regulating flap 6. Thereby, any danger of injury to the operator is excluded, when the adjusting motor 9 must rotate the sun gear continuously in any suitable direction.
When the air-regulating flap 6 must be turned in counterclockwise direction, for example when cold air must be supplied into the air passage 5, a spring 31 provided on the abutment 29 and carrying with its free end an arresting projection 32 extending radially to the driving axis 13 comes into effect. As soon as the abutment 29 is turned sufficiently against the pin 30, the arresting projection 32 meets the pin 30, elastically deflects it, and finally engages it over, as can be seen from FIGS. 3 and 4. Thereby the air-regulating flap 6 can be turned by hand from its position shown in broken lines in FIG. 2 in counterclockwise direction, until finally by abutment of the air-regulating flap 6 against a wall 33 of the air passage 5 the arresting projection 32 is separated from the pin 30 by arbitrary further turning of the abutment 29.
The possible turning angle of the abutment 29 is so dimensioned that, in the shown zero position of the adjusting lever 23 and motor-driven adjustment of the air-regulating flap 6, the pin 30 does not get under the arresting projection 32. Thereby the adjusting lever 23 remains so long in its initial position until an adjustment by hand is performed.
In the air conditioning device in accordance with the embodiment shown in FIG. 5, the output shaft 18 of a planetary transmission 7' is formed on a planetary gear carrier 16'. A hollow gear 17' is arranged rotatable about the planetary gear carrier 16' and has on its periphery recesses 21'. The input shaft 13, the sun gear 14, the planetary gears 15, the disk 22 with the cam 24, the arresting pin 26 and the spring 27 are formed in this embodiment similarly to the previously described embodiment. For separating the force transmission between the input shaft 13 and the output shaft 18, the hollow gear 17' is released by the cam 24. The manual adjustment is performed then in the above described manner via the pin 30 mounted on the planetary gear carrier 16'.
The air conditioning device in accordance with a further embodiment can be designed so that the input shaft is connected with the hollow gear, the air-regulating flap 6 is fixedly coupled with the planetary gear carrier, and the sun gear for forced transmission is prevented from rotation or for manual adjustment is released. In this case, however, smaller reductions to the low speed must be taken into consideration. It is also possible to provide different planetary transmissions, as compared with the transmission described above, in that such transmission can be provided for transmission to higher speeds and require more reducing reduction transmissions, for example a worm transmission.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in an air conditioning device, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | An air conditioning device has a control member, an electric motor arranged to be operatively connected with the control member and drive the latter, an actuating element arranged to sense air temperature and to actuate the electric motor, an interrupting element for interrupting the connection between the electric motor and the control member, and a manual adjustment member arranged for manually adjusting the control member upon interruption of the connection between the electric motor and the control member. | 1 |
RELATED CASES
This application is a continuation in part application of U.S. provisional patent application 60/878,303, filed Jan. 2, 2007, by Patrick J. Vanderheiden and Michael A. Herman. The benefit of provisional patent application 60/878,303 is claimed.
BACKGROUND OF THE INVENTION
This invention relates to wrapping machines and methods of using them.
It is known to mount rolls of wrapping material such as for example stretch wrapping plastic on movable carts such as push carts and to use the movable carts to wrap materials and apparatuses in place. A typical movable wrapping cart is easily maneuverable by hand to permit circling of the object or objects to be wrapped. One end of a roll of wrapping material is fastened to the objects at a starting point and the roll is moved around the objects to wrap them together. Commonly, the objects are positioned together on a pallet and stretch wrap material is wound around them to hold them together in a process referred to at times as palletizing. Three wheeled push carts with a low horizontal support bed with three wheels mounted below the horizontal support bed and a vertical mast extending from the top of the support bed are one form of maneuverable push/pull cart that may be used. Two front wheels provide support for one end of the mast and one or two turnable rear wheels permit easy maneuverability. A roll of wrapping material is mounted to the mast by a movable carriage. Some prior art wrapping push/pull carts are disclosed in U.S. Pat. Nos. 6,526,734 and 7,051,492.
The prior art wrapping carts utilize one roll of wrapping material that is applied to materials or apparatuses that are being wrapped. These prior art wrapping carts have a disadvantage of being slow and at times difficult to use. Moreover, the positioning and adjustment as to tension of the rolls of wrapping material are clumsy and difficult.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a novel wrapping cart.
It is a further object of the invention to provide a novel method of wrapping materials or apparatuses to form palletized materials and apparatuses.
It is a still further object of the invention to provide a fast and economical method of wrapping apparatuses and materials.
It is a still further object of the invention to provide a novel wrapping cart capable of wrapping materials with exceptional speed.
It is a still further object of the invention to provide a novel wrapping method that applies wrapping material from multiple rolls of wrapping material at the same time.
It is a still further object of the invention to provide a novel wrapping apparatus that applies wrapping material from multiple rolls of wrapping material at the same time.
It is a still further object of the invention to provide a novel method and apparatus for controlling the tension applied to stretchable wrapping materials as they are being used.
It is a still further object of the invention to provide a novel method for inserting and removing rolls of wrapping material.
It is a still further object of the invention to provide a multiple roll wrapping apparatus in which individual rolls may be independently removed and have the tension on the wrapping material adjusted.
It is a still further object of the invention to provide wrapping apparatus and a method in which the user may bring the wrapping material to the desired elevation easily and conveniently.
In accordance with the above and further objects of the invention, an electrically controlled drive mechanism on a vehicle such as a push/pull cart positions rolls of wrapping material (wrapping paper or wrapping film) in elevation under the control of a switch on the handle of the vehicle. In the preferred embodiment, the drive mechanism is an electric actuator which can be actuated by the user from his location when using the vehicle. In the preferred embodiment, the vehicle is a push/pull cart with four wheels, two forward wheels being at the front of the push/pull cart and two rear wheels being at the rear of the cart with the two rear wheels being steerable by a handle mounted at the rear of the cart. However, the push/pull cart may also include three wheels, two forward wheels being at the front of the push/pull cart and one rear wheel being at the rear of the cart with the rear wheel being steerable by a handle mounted at the rear of the cart. Multiple rolls of wrapping material are mounted at vertically spaced positions and simultaneously wrapped around objects or apparatuses to be wrapped. This reduces the time in which the wrapping is performed. For example, with two rolls, two wraps may be applied simultaneously to reduce the time of wrapping by as much as twofold. Similarly, three rolls vertically spaced may reduce the time as much as by threefold and reduce the number of times that a particular item must be encircled by the operator.
Individual rolls of wrapping material may be connected to the apparatus at vertically spaced-apart positions with respect to each other and the resistance to rotation of each roll and thus the tension on the wrapping material may be individually adjusted for that particular roll. If one roll runs out before the other, it may be replaced without having to move the other rolls of wrapping material. Tension is easily manually adjusted by mounting the rolls between an upper adjustable member and a lower adjustable member. The distances between the rolls of wrapping material are wrapping effective distances. In this specification, the words “wrapping effective distances” means distances selected to permit rolls of wrapping material having a weight that can be supported by cantilevers that extend from ball nuts, with widths and a spacing provided to accommodate uneven objects to be securely wrapped without the rolls interfering with one another. The width of the wrapping material is the length of the roll.
The wrapping vehicle or machine of this invention has several advantages, such as for example: (1) it is labor saving; (2) it is fast because of the ability to wrap more than one turn of wrapping material in one revolution about the objects being wrapped; (3) it permits easy positioning of the wrapping material in elevation; and (4) it permits effective adjustment of tension on the rolls of wrapping material.
BRIEF DESCRIPTION OF THE DRAWINGS
The above noted and other features of the invention will be better understood from the following detailed description when considered in the light of the accompanied drawings, in which:
FIG. 1 is a perspective view of a wrapping machine mounted to a push/pull cart in accordance with one embodiment of the invention;
FIG. 2 is a fragmentary perspective view of a lower portion of the wrapping machine of FIG. 1 ;
FIG. 3 is a perspective view showing another portion of the lower part of the wrapping machine of FIG. 1 ;
FIG. 4 is a fragmentary simplified perspective view showing the upper portion of the wrapping machine of FIG. 1 ;
FIG. 5 is a detailed perspective fragmentary view of a movable support member which is part of the embodiment of FIG. 1 ;
FIG. 6 is a schematic diagram of a drive mechanism in the embodiment of FIG. 1 ;
FIG. 7 is a schematic circuit diagram of a circuit used to operate the drive mechanism of FIG. 6 ;
FIG. 8 is a fragmentary perspective view of a portion of another embodiment of the push/pull cart showing the rear wheels and handle of a four wheel push/pull cart;
FIG. 9 is a perspective view showing the use of the wrapping machine of FIG. 1 ; and
FIG. 10 is a perspective view of the use of the wrapping machine of FIG. 1 in another position.
DETAILED DESCRIPTION
In FIG. 1 , there is shown a perspective view of a wrapping vehicle 10 having a vehicle bed 12 , a wrapping material assembly 14 and a handle assembly 16 . In the embodiment of FIG. 1 , the vehicle 10 is a push/pull cart and the handle assembly 16 includes an actuator switch assembly 18 that controls the vertical location of wrapping material mounted to the vehicle. The vehicle bed 12 in FIG. 1 includes three wheels 20 A- 20 C (wheels 20 A and 20 C being shown in FIG. 1 ) and a horizontal support 22 . Two wheels, 20 A and 20 B are mounted forward on the bed 12 (only 20 A being shown in FIG. 1 ) and a third wheel 20 C is mounted in the back. The third wheel 20 C is pivotable to steer the vehicle. While a three-wheeled push/pull cart is shown in FIG. 1 , a four-wheeled push/pull cart could be used having two forward wheels at the front of the push/pull cart and two rear wheels ( FIG. 8 ) at the rear of the cart with the two rear wheels being pivotable by the handle mounted at the rear of the cart. Obviously, a pulling cart, a stationary wrapping machine that cooperates with a movable pallet, or a motorized vehicle such as a scooter with rolls of wrapping material attached or any other suitable configuration may also be used.
The wrapping material assembly 14 includes adjustable wrapping material, which in the preferred embodiment is three rolls of wrapping material 24 A, 24 B and 24 C positioned one above the other, a plurality of corresponding tension adjustment mechanisms 26 A, 26 B and 26 C, one for each roll of wrapping material, a mast 28 and a battery 30 . The rolls of wrapping material 26 A- 26 C are vertically adjustable as a group and the number of rolls and vertical spacing between the rolls can be changed. The width of the wrapping material is changed by changing the rolls of wrapping paper. The mast 28 includes a drive mechanism that lifts the entire assembly of wrapping material upwardly or lowers it downwardly as called for during the wrapping operation.
The handle assembly 16 controls the angle of the rear wheel 20 C in the preferred embodiment but the wrapping vehicle 10 may be steered by other mechanisms that alter the angle of the front wheels or the angle of an intermediate joint between the rear wheels and the front wheels. The actuator switch assembly 18 on top of the handle assembly 16 is connected by an electrical connector 32 to the battery 30 that supplies power through an electrical connector 34 to the drive mechanism. In this specification, the word, “front” means the side of the vehicle that is at the front of the direction in which the vehicle is intended to move and the word “rear” means the side of the vehicle having a handle for pushing the vehicle.
While a movable vehicle is described in connection with FIG. 1 , the objects to be wrapped may instead be mounted on a movable member and the wrapping material on a stationery member or both may be movable to create movement between the two and thus a wrapping operation of the wrapping material on the object to be wrapped. Thus, a turntable may mount an object or objects that are to be wrapped and a stationary wrapping assembly may be connected to the objects and the objects turn so that the wrapping material is wrapped around the objects. The elevation of the wrapping material may be controlled by an operator to wrap the entire desired vertical length of an object or objects. Moreover, the wrapping vehicle or wrapping machine 10 may contain a plurality of parallel wrapping material assembles and the rolls of the wrapping material may be at overlapping positions on the different wrapping material assemblies to apply overlapping wraps in a single loop around a pallet.
In FIG. 2 , there is shown a fragmentary perspective view of the vehicle bed 12 , the wrapping material assembly 14 and the handle assembly 16 . The wheels 20 A- 20 C are shown supporting the horizontal support 22 of the vehicle bed 12 with the battery 30 mounted on a rearward section of the horizontal support 22 and the handle assembly 16 supported by the turnable wheel 20 C and connected to the rearmost end of the horizontal support 22 . The wrapping material assembly 14 is shown without rolls of wrapping material to make visible a lower vertically-moveable ball-nut driven cantilever 38 , a lower wrapping material roll bottom support 42 , a lower wrapping material roll tension adjustment mechanism 26 C, a middle vertically-moveable ball-nut driven cantilever 40 and a middle wrapping material roll bottom support 44 . As shown in this view, a vertical central support post 48 extends through and connects the vertically-moveable ball-nut driven cantilevers 38 , 40 and 58 ( 38 and 40 being shown in FIG. 2 ) and corresponding wrapping material roll tension adjustment mechanisms 26 A- 26 C ( 26 C for the lower roll 24 C ( FIG. 1 ) being shown in FIG. 2 ) so that each roll fits between a bottom support such as 42 shown in FIG. 2 and a tension adjustment mechanism such as 26 C shown in FIG. 2 . The tension adjustment mechanisms 26 A- 26 C ( FIG. 1 ) may be tightened toward the bottom supports 42 , 44 and 46 ( FIG. 1 ) to adjust the tension in the rolls with the vertical post 48 permitting rotation of the rolls as the wrapping material is removed for application to an object.
The vertical support post 48 is formed in sections with each section extending between a bottom roll support such as lower vertically-moveable ball-nut driven cantilever 38 and lower wrapping material roll support 42 and a tension adjustment mechanism such as tension adjustment mechanisms 26 C so that the sections can be disconnected for replacement of a roll if desired. Each of the vertically-moveable ball-nut driven cantilevers such as the lower vertically-movable ball-nut driven cantilever 38 and the middle vertically-movable ball-nut driven cantilever 40 is separately mounted by a roller nut to a drive screw within a mast enclosure 36 to be separately supported and thus permit removal of a roll at any position for replacement with a full roll. The mast 28 is supported by a central section 50 of the support bed 22 by two parallel struts 52 A and 52 B that connect a forward edge of the central section 50 to two parallel sides of the mast enclosure 36 .
In FIG. 3 , there is shown a fragmentary view of the mast 28 of the wrapping machine 10 supported by the parallel struts 52 A and 52 B and a mast support plate 54 which are mounted to two extending legs of the horizontal support 22 . As shown in this view, the vertical axial central support post 48 extends upwardly forwardly of the mast 28 and includes a plurality of vertically-moveable ball-nut driven cantilevers 38 , 40 and 58 ( 38 being shown in FIG. 3 ), bottom supports 42 , 44 and 46 ( 42 being shown in FIG. 3 ) and movable ball-nut driven cantilevers 38 , 40 and 58 ( 38 being shown in FIG. 3 ).
In FIG. 4 , there is shown a fragmentary view showing a switch 18 at the top of the handle assembly 16 , a motor compartment 56 at the top of the mast enclosure 36 for moving the top vertically-movable ball-nut driven cantilever 58 for the bottom of the wrapping roll 24 A ( FIG. 1 ) and the middle movable support 44 for the bottom of the middle wrapping material roll 24 B ( FIG. 1 ). The motor 56 rotates a screw lift to move the middle roll bottom support 44 and the upper roll bottom support 46 to adjust the wrapping material to the location on the object being wrapped.
In FIG. 5 , there is shown a fragmentary perspective view of the mast 28 with a vertically movable ball-nut driven cantilever 40 mounted to a support guide plate 62 . The support guide plate 62 fits slideably within a channel of the vertical mast 28 to be movable upwardly and downwardly in response to the drive screw 66 ( FIG. 6 ). As it moves upwardly or downwardly, it carries the wrapping roll vertically-movable ball-nut-driven cantilever 40 with it.
In FIG. 6 , there is shown a schematic diagram of the mast 28 which is shaped as a channel to provide side members to support guide plates 62 and having a motor 64 mounted within the motor compartment 56 and adapted to drive the drive screw 66 . The drive screw 66 is mounted within a ball nut 68 to move the ball nut 68 upwardly or downwardly depending on the direction of rotation of the motor 64 . The ball nut 68 is connected to the support guide plate 62 to move the support guide plate 62 upwardly or downwardly and thus move the wrapping material rolls 24 A- 24 C ( FIG. 1 ) upwardly or downwardly in response to the actuation of the switch 18 ( FIG. 4 ). The motor 64 is a 12 volt DC motor attached to the drive screw 66 through a worm gear case 70 . The ball nut 68 is a ⅜ inch diameter standard housing nut held in place to the support guide plate 62 by a bolt 72 to move the support guide plate 62 upwardly and downwardly under the control of the switch 18 ( FIG. 4 ). This unit is an actuator unit model 85152 within an 18 inch stroke and a 20 to 1 reduction. The motor is a 6,000 revolutions per minute motor with an H-D break type B. In the preferred embodiment, the drive screw 66 has three ball nuts mounted to it to drive the three cantilevers 38 , 40 and 58 ( FIGS. 1 , 2 and 4 ).
In FIG. 7 , there is shown a schematic circuit diagram showing the switch assembly 18 , the DC battery 30 and the motor 64 interconnected so that the switch assembly 18 may raise or lower the rolls of wrapping material 24 A- 24 C ( FIG. 1 ). The switch assembly 18 includes first and second normally open, single throw, double pole push button switches 74 A and 74 B each having a first contact 76 A and 76 B respectively electrically connected to the positive terminal of the DC battery 30 and a contact 78 A and 78 B respectively electrically connected to ground. One terminal of the DC motor 64 is electrically connected through a conductor 80 A to a contact 82 A of the double pole push button switch 74 A and to a contact 82 B of the double pole push button switch 74 B. With this arrangement, when the double pole, single throw, push button switch 74 A is depressed, the contact 82 A is connected to the contact 76 A to apply positive voltage through the conductor 80 A to the motor 64 . At the same time, a conductor 80 B is electrically connected through a contact 84 A to ground through the contact 78 A so that the motor 64 rotates in a first direction with a positive potential being applied through one terminal through the conductor 80 A with the conductor 80 B being grounded.
Similarly, when the push button switch 74 B is depressed, the contact 82 B is connected to the contact 78 B to ground so as to connect the conductor 80 A to ground and a contact 84 B is connected to the contact 76 B to connect the conductor 80 B to the source of positive potential from the battery 30 and thus rotate the motor 64 in the opposite direction. With this arrangement, the rolls of wrapping material can be raised or lowered by depressing the appropriate push button switches 74 A or 74 B of the switch assembly 18 on the handle assembly 16 ( FIGS. 1 , 2 and 4 ). The operator by using the handle assembly 16 can in this manner raise or lift the rolls of paper and the vertical location at which the wrapping material is being as the operator moves the vehicle around the object or group of objects being wrapped. Similarly, when the object or group of objects is mounted on a turntable, the operator can easily raise or lower the rolls of wrapping material to adjust the elevation at which the wrapping material is being applied to the object or groups of objects.
In FIG. 8 , there is shown a perspective view of a rear portion of another embodiment of wrapping vehicle 10 A having four wheels two of which are rear steerable wheels 20 D and 20 E (the two front wheels not being shown in FIG. 8 ). In FIG. 8 , the parts of the wrapping machine 10 A that are the same as the corresponding parts in the wrapping machine 10 of FIG. 1 have the same reference numerals as in FIG. 1 . In the embodiment 10 A, the two rear wheels 20 D and 20 E, are mounted to an elongated support 94 and are each turnable to permit steering of the vehicle from the handle.
In FIG. 9 , there is shown an operator 92 holding the handle of a push/pull cart vehicle 10 with two rolls of wrapping material on it and moving the wrapping material around objects 88 on a pallet 90 to palletize them. With his hand on the handle 16 (handle 16 not shown in FIG. 9 ) the operator 92 may actuate the switch assembly 18 ( FIGS. 1 and 7 ) to raise or lower the rolls of wrapping material to position them correctly on the objects 88 as the operator 92 pushes the cart around the objects 88 to palletize them.
In FIG. 10 , the operator 92 is shown cutting the wrapping material between the push/pull cart vehicle 10 and the palletized objects 88 so that it may be separated from the rolls of wrapping material on the push/pull cart vehicle 10 .
As can be understood from the above description, the wrapping vehicle or machine of this invention has several advantages, such as for example: (1) it is labor saving; (2) it is fast because of the ability to wrap more than one turn of wrapping material in one revolution about the objects being wrapped; (3) it permits easy positioning of the wrapping material in elevation; and (4) it permits effective adjustment of tension on the rolls of wrapping material.
While a preferred embodiment of the invention has been described with some particularity, many modifications and variations of the invention are possible within the light of the above teachings, and therefore, it is to be understood that the invention may be practiced other than as specifically described but within the scope of the appended claims. | To palletize packages, a wrapping vehicle includes a vertically mounted drive screw having a plurality of ball nuts mounted at wrapping-effective distances from each other on the vertically mounted drive screw. Each ball-nut has a corresponding cantilever mounted to the ball nut to support a roll of wrapping material. A tension adjustment mechanism is mounted to adjust the resistance to motion of each roll of wrapping material and thus the tension on the wrapping material. The ball nuts are each connected to side support guide plates positioned to slide against the sides of mast housing the drive screw wherein said ball nuts are supported against tilting movement. | 1 |
FIELD OF THE INVENTION
This invention relates to water treatment and purification and, more particularly, to methods and apparatus for treating water containing hydrocarbon waste.
BACKGROUND OF THE INVENTION
Unsaturated hydrocarbons are a significant contaminant in ground water and a variety of industrial waste solutions. A large number of systems and methods have been proposed for reacting or otherwise eliminating various types of contaminants.
For example, in recent years UV-peroxide and ozone systems have become a treatment of preference for removal of toxic organics in waste water because such systems chemically convert contaminant species to benign components. Published PCT application PCT/US94/07983, in which applicant is an inventor and which is hereby incorporated by reference, discloses systems in which hydrogen peroxide is added to the waste solution and is subjected to ultraviolet irradiation either before or after it is so added, and in which the waste is treated in a reactor coated with a photocatalyst such as titanium oxide.
However, hydrogen peroxide is relatively expensive, the cost becomes a significant consideration particularly as contaminant concentrations increase. Further, the rate of contaminant oxidation depends on the ability of peroxide to absorb UV light and to dissociate into hydroxyl radicals. UV light intensity diminishes with distance from the light source, and reactor size thus has been limited since reactors with radii larger than a critical dimension to not achieve their decontamination goals.
There remains a need for less expensive systems that can treat greater volumes of waste water containing higher concentrations of hydrocarbon waste.
SUMMARY OF THE INVENTION
The invention provides a water treatment system that features both a reactor vessel providing for flow of water to be treated through an annular treatment region that surrounds a longitudinally-extending source of ultraviolet radiation, porous wall surrounding the annular treatment region, and an annular air/oxygen chamber between the porous wall and the exterior of the vessel. Preferably, tangential flow inlets and outlets are provided adjacent opposite ends of the annular treatment region, and an air/oxygen inlet is provided adjacent an end of the air/oxygen chamber.
In one preferred aspect of the invention, the ultraviolet source produces radiation having a wavelength in the range of about 185 nanometers. Oxygen permeates through the porous wall as a fine bubble mist. The tangential aqueous stream shears the mist from the wall, the oxygen bubbles encounter UV light, and the oxygen is converted to ozone which in turn reacts with water to produce hydrogen peroxide in the water.
In another preferred aspect, a layer of particulate anatase titanium dioxide is deposited on the interior surface of the porous wall, oxygen from the air/oxygen chamber is bubbled through the titanium dioxide layer into the circumstantially outer portion of the annular treatment region, and UV light activates the titanium dioxide to provide ionized dissolved oxygen in the outer portion of the annular treatment region.
In most preferred aspects, the system includes at least two of such reactors connected in series so that hydrogen peroxide produced by one reactor is introduced into the waste water stream that flows into the second reactor.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic of a waste treatment system embodying the present invention.
FIG. 2 is a sectional view of the oxygen production reactor of the system of FIG. 1.
FIG. 3 is a sectional view of the toxic reduction reactor of the system of FIG. 1.
FIG. 4 is a schematic of a second waste treatment system embodying the present invention.
FIG. 5 is a schematic of a third waste treatment system embodying the invention.
DETAILED DESCRIPTION
Referring now to FIGS. 1 through 3, a water treatment system includes an oxidant production reactor 10 having its outlet 12 connected to the inlet 34 of a toxic reduction reactor 30. As described in more detail below, each of the reactors includes a cylindrical outer wall, designated 16, 36, respectively, a cylindrical housing, designated 18, 38, made of suprasil quartz or any suitable material capable of transmitting the emitted light surrounding a central axially extending UV lamp, designated 20, 40 respectively, and a porous stainless steel cylindrical wall, designated 22, 42 having a radius slightly less than that of the respective housing 18, 38. A tangential flow inlet 14, 34 is provided at one end of each housing for introducing a liquid flow tangentially into the annular flow chamber 24, 44 between the respective porous wall 22, 42 and lamp housing 18, 38. At the other end of each housing is a tangential outlet 12, 32 from the respective flow chamber 24, 44. A second annular chamber 26, 46 having a respective inlet 28, 48 is provided between the respective porous wall 22, 42 and the outer wall 16, 36 of the reactor.
With particular reference to FIG. 2, the lamp 20 of oxidant production reactor 10 is a low intensity (120 watt, about 4 watts per inch), low pressure mercury UV lamp, having an overall efficiency of 30% to 40%. It is desirable that one major wavelength of light emitted by lamp 20 be neither less than about 175 nanometers (to avoid water absorption) nor more than about 200 nanometers (to provide the desired photochemical reactions. By reducing the mercury vapor pressure in the lamp, an about 185 nanometer (e.g., a 184.9 nm) output may be generated at 10% conversion efficiency, with the remaining 20% to 30% of the output emitted at 254 nm. The outer envelope of the lamp itself, and also lamp housing 18, are made of supracil quartz which will transmit the about 185 nm component. The gap 21 between the lamp 20 and lamp housing 18 is flushed with argon. The use of argon rather than air in the gap prevents absorption of the about 185 nm component of the UV light.
Porous wall 22 is sintered stainless steel or other suitable non-reactive sintered material with approximately 0.5 to 3 micron pores extending generally radially therethrough. Optionally, and as discussed in more detail with respect to the toxic reduction reactor 30, the interior surface of the porous wall may be coated with a layer of lightly sintered anatase phase titanium dioxide.
Referring now to FIG. 3, the lamp 30 of reactor 30 is a high pressure, high intensity mercury lamp, producing up to 400 watts per inch of lamp length. The wavelength of UV light emitted by lamp 30 is primarily about 254 nm, with some further emission in the range of 300-400 nm. As discussed hereinafter, it has been found that the fraction above 300 nanometers excites titania, while the about 254 nanometer fraction is effective in dissociating hydrogen peroxide in the bulk fluid phase. The use of mercury at high pressure in the lamp results in very little 185 nm light being generated. The envelope of lamp 30 and lamp housing 28 are both quartz, but need not be suprasil quartz. As in reactor 10, the gap 41 between the lamp 40 and lamp housing 38 is flushed with argon.
The inner cylindrical surface of porous wall 42 is covered with a thin layer of anatase titania particles (mean particle size 0.3 to about 1.0 microns) that are lightly sintered to hold the particles in place while maintaining a large surface area per unit mass.
Referring again to FIG. 1, water (from either a fresh water source 42 or from reactor 30) flows into reactor 10 through tangential inlet 14, and exits from the reactor through tangential outlet 12. The inlet flow rate is established to maintain turbulent flow in both reactor 30 and also reactor 10, and the tangential flow produces a swirling flow in the confined annular flow chamber 24. Oxygen from oxygen source 45 flows under modest pressure (p<6 atm) through a pressure valve 46, motor-controlled valve 48 and flow meter 50 into the annular chamber 26 between the reactor outer wall 16 and porous wall 22. The pressurized gas passes through the porous wall 20 and exits into flow chamber 24 in the form of small bubbles, e.g., 20 to 120 microns in diameter with a mean diameter of about 80 microns. At the inner surface of porous wall 22, the swirling flow shears the bubbles from the wall, producing micron-sized bubbles in suspension. The bubble size is controlled by the shear rate, the higher the shear rate the smaller the bubble size. The centrifugal action of the swirling flow drives the denser liquid phase in flow chamber 24 towards the outer porous wall 22, while the lighter bubble phase passes inwardly towards lamp 20, i.e., towards a region of high intensity UV light.
The oxygen within the bubbles diffuses towards the bubble-water interface, where the oxygen is irradiated and converted to ozone according to the following reaction: ##EQU1## The ozone (O 3 ) in turn reacts with the water in chamber 64 to form hydrogen peroxide (H 2 O 2 ):
O.sub.3 +H.sub.2 O=O.sub.2 +H.sub.2 O.sub.2.
The hydrogen peroxide dissolves in the water in chamber 64, and the oxygen is further irradiated to form more ozone.
Because oxygen's light absorption coefficient increases with decreasing wavelength, it is desirable to use ultraviolet light having a wavelength less than 200 nm to convert the oxygen to ozone. However, and as previously indicated, the wavelength should not be less than about 170 nanometers because the water absorbs such shorter wavelengths. It has been found that the reactions at the bubble interface are rapid, and that the oxygen diffusion rate in the air bubble is the limiting factor. Thus, small bubble size is also a key to rapid reaction rates.
The water-hydrogen peroxide solution thus-produced exits from reactor 10 through tangential outlet 12 and passes through a check valve 29 to a recycle pump 31 which in turn causes the stream to pass through an in-line mixer 33 and then into reactor 30 through tangential inlet 34. It is the flow rate set by recycle pump 31 that establishes the total flow rate, shear rate, and turbulence in the reactor. In circumstances in which the output from reactor 10 is not itself a waste stream with a high concentration of hydrocarbon contaminants, the flow from reactor 10 is mixed (at in-line mixer 33) with a contaminated aqueous waste stream 52, and the combined stream is forced into the tangential inlet 34 of reactor 30. A motor operated valve 54 in a return line 56 in parallel with feed pump 57 is connected to a controller 58 to assist in adjusting the make-up of the stream introduced into the reactor from mixer 33.
If the level of hydrogen peroxide in the stream from reactor 10 is too low, additional make-up hydrogen peroxide from a storage tank 60 is provided by a peroxide pump 62. Parallel, return flow line 64, motor valve 66 and controller 68 permit the amount of flow of hydrogen peroxide tank 60 to be metered as desired.
In annular flow chamber of reactor 30, ultraviolet light from lamp 40 is absorbed by the hydrogen peroxide in the waste stream, causing the hydrogen peroxide to dissociate into two OH radicals: ##EQU2## The OH* radicals in turn react with and oxidize the hydrocarbon contaminant R in the waste stream:
R+20H*==RO+H.sub.2 O.
The rate of contaminant oxidation depends on the ability of peroxide to absorb UV light and dissociate into hydroxyl radicals, which are the principal oxidant in the system. The intensity of UV light decreases rapidly with distance (radially outwardly in reactor 30) from lamp 40, both because of radial spreading of the light and because of light absorption by competitive species. Thus, there is a first critical radius beyond which the rate of contaminant oxidation becomes less than that required to achieve a target level of overall decontamination by the time the aqueous fluid in annular flow chamber 44 reaches outlet 32. Since the level of decontamination is greatest near the lamp, the radius of the annular flow chamber 44 may be extended somewhat beyond this first critical radius without the integrated decontamination of all the fluid in the flow chamber 44 falling below the target level. Beyond a second critical radius, however, reactors do not achieve their decontamination goals.
In reactor 30, the reaction rate, particularly at distances beyond the first critical radius, is enhanced, and the second critical radius is thus increased to a radius not less than that of porous wall 42. A significant portion of the UV spectrum emitted by lamp 40 is emitted at wavelengths longer than 250 nm. At these wavelengths, the emitted light activates the titania on the inner surface of wall 42, causing electrons to transfer from the valence band to the conducting band, leaving the conducting band with a slight positive hole. Organics absorbed on the titania in the vicinity of such a hole serve as electron donors; and oxidants absorbed in the vicinity of the conduction band electrons become electron acceptors. As a result, the oxidants are reduced and the organics oxidized, at a rate which depends on (a) the rate at which photons transfer electrons from the valence band to the conduction band, and (b) the rate at which reactants will absorb on the photocatalyst surface. It has been found that sufficient UV light having a wavelength greater than 255 nm is not absorbed in the path between lamp 40 and the titania inner surface of porous wall 42. Although the intensity of the UV radiation diminishes significantly with distance from the lamp 40, the photon energy remains essentially unchanged and in sufficient to transfer valence band electrons to the conduction band. It has also been found that small, lightly-sintered titania particles provide a desirably large surface area per unit mass (e.g., at least 50 m 2 /gram of sintered titania, or 0.002 m 2 /cm2 of the inner cylindrical surface of wall 42).
The oxidation rate of the contaminant in the region near wall 22 is further increased by oxygen permeation through the microporous sintered titania structure. Oxygen from oxygen source 44 flows under pressure through pressure control valve 46, motor-operated flow control valve 76 and flow meter 78 into the annular chamber 46 between the outer wall 36 of reactor 10 and porous wall 22. The oxygen permeates the titania structure, absorbs on the lighted (i.e., inner) side of the titania, and provides an additional oxidant in the vicinity of the porous wall 42.
The treated (i.e., oxidized) contaminant stream exiting from reactor 30 through outlet 34 may flow directly to a treated waste tank if the total TOC has been reduced to desired levels. More typically, and as shown in FIG. 1, it is recycled to the inlet of reactor 10 and upon exiting reactor 10 is (depending on the level of remaining contaminants) either directed to a treated waste tank or recycled through toxic reduction reactor 30.
It will be recognized that both reactor 10 (with or without a sintered titania layer on the inner surface of its porous wall 22) and reactor 30 may be useful alone, in addition to being used together in a system as previously described.
In situations in which the cost of hydrogen peroxide is relatively unimportant, a toxic reduction reactor such as reactor 30 may be part of a stand-alone system, such as that illustrated in FIG. 4. In FIG. 4, components essentially identical to those of the system of FIG. 1 are identified by the same reference numbers, with a differentiating prime (') added. Thus, in the system of FIG. 4, hydrogen peroxide from source 60' is mixed with a contaminated waste stream 52' from tank 100 at inline mixer 33', and the mixed stream is introduced into inlet 34' of reactor 30'. The treated stream exiting from outlet 32' is either recycled by recycle pump 80, or is discharged to a treated waste tank (not shown). Power for lamp 40' is provided by power source 102.
Similarly, FIG. 5 shows a system based on a reactor such as reactor 10 and including several components essentially identical to those of the system of FIG. 1 and identified by the same reference numbers, with a differentiating prime (') added. In the system of FIG. 5, an argon feed 110 from argon source 112 passes between lamp 20' and the supracil lamp housing 18'; and an air/oxygen mix from air source 114 and oxygen source 45' is provided under pressure to the annular chamber 26' between porous wall 22' and the exterior wall of the reactor 10'. As in the system of FIG. 1, the approximately 185 nm ultraviolet light from lamp converts oxygen bubbles permeating inwardly from porous wall 22' into ozone; the ozone reacts with water in the flow chamber 24' of reactor 10' to form hydrogen peroxide; and the longer wavelength ultraviolet energy from the lamp causes the hydrogen peroxide to dissociate into OH radicals which in turn reacts with and oxidizes hydrocarbon contaminants in the flow chamber 24'.
Contaminated water from waste stream 52' is recycled through the reactor 10' until, as a result of reactions between the hydrocarbon contaminants and the OH radicals, the concentration of hydrocarbon contaminants in the waste stream has been reduced to the desirable level, at which point the treated stream is discharged into treated water tank 130. | A water treatment system that a pair of series connected reactor vessels, each of which provides for flow of water to be treated through an annular treatment region that surrounds a longitudinally-extending source of ultraviolet radiation, has porous wall surrounding the annular treatment region, and an annular air/oxygen chamber between the porous wall and the exterior of the vessel. In one reactor, the ultraviolet source produces radiation having a wavelength in the range of about 185 nanometers, oxygen permeates through the porous wall as a fine bubble mist, the tangential aqueous stream shears the mist from the wall, the oxygen bubbles encounter UV light, and the oxygen is converted to ozone which in turn reacts with water in the water to produce hydrogen peroxide. In the other reactor, a layer of particulate anatase titanium dioxide is deposited on the interior surface of the porous wall, oxygen from the air/oxygen chamber is bubbled through the titanium dioxide layer into the circumstantially outer portion of the annular treatment region, and UV light activates the titanium dioxide to provide ionized dissolved oxygen in the outer portion of the annular treatment region. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 10/776,721, filed Feb. 11, 2004, entitled “REMOVABLE VENA CAVA FILTER”, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/446,711, filed Feb. 11, 2003, entitled, “REMOVABLE VENA CAVA CLOT FILTER,” each of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates to medical devices. More particularly, the invention relates to a removable vena cava clot filter that can be percutaneously placed in and removed from the vena cava of a patient.
Filtering devices that are percutaneously placed in the vena cava have been available for over thirty years. A need for filtering devices arises in trauma patients, orthopedic surgery patients, neurosurgery patients, or in patients having medical conditions requiring bed rest or non-movement. During such medical conditions, the need for filtering devices arises due to the likelihood of thrombosis in the peripheral vasculature of patients wherein thrombi break away from the vessel wall, risking downstream embolism or embolization. For example, depending on the size, such thrombi pose a serious risk of pulmonary embolism wherein blood clots migrate from the peripheral vasculature through the heart and into the lungs.
A filtering device can be deployed in the vena cava of a patient when, for example, anticoagulant therapy is contraindicated or has failed. Typically, filtering devices are permanent implants, each of which remains implanted in the patient for life, even though the condition or medical problem that required the device has passed. In more recent years, filters have been used or considered in preoperative patients and in patients predisposed to thrombosis which places the patient at risk for pulmonary embolism.
The benefits of a vena cava filter have been well established, but improvements may be made. For example, filters generally have not been considered removable from a patient due to the likelihood of endotheliosis of the filter during treatment. After deployment of a filter in a patient, proliferating intimal cells begin to accumulate around the filter struts which contact the wall of the vessel. After a length of time, such ingrowth prevents removal of the filter without risk of trauma, requiring the filter to remain in the patient. As a result, there has been a need for an effective filter that can be removed after the underlying medical condition has passed.
Moreover, conventional filters commonly become off-centered or tilted with respect to the hub of the filter and the longitudinal axis of the vessel in which it has been inserted. As a result, the filter including the hub and the retrieval hook engage the vessel wall along their lengths and potentially become endothelialized therein. This condition is illustrated in prior art FIG. 1 in which a prior art filter 13 has been delivered through a delivery sheath 25 into a blood vessel 51 . In the event of this occurrence, there is a greater likelihood of endotheliosis of the filter to the blood vessel along a substantial length of the filter wire. As a result, the filter becomes a permanent implant in a shorter time period than otherwise.
Some filters have been designed so that the filter has minimal contact with the vessel wall. Ideally, some filters can be removed after several weeks with minimal difficulty and little injury to the vessel wall. One such filter is described in U.S. Pat. No. 5,836,968. The filter is designed so that the filter wires or struts are not positioned parallel to the vessel walls or not in contact with the vessel walls for a substantial portion of the length of the filters. The ends of the struts contact the vessel walls and provide anchoring to reduce the likelihood of filter migration. When the filter is removed, a wire is docked to one end of the device while a sheath or sleeve is passed over the wire. Using counter traction by pulling the wire while pushing the sheath, the sheath is passed over the filter and the filter struts are retracted from the vessel wall. In this way, only small point lesions are created where the filter was attached to the vessel wall.
The filter of U.S. Pat. No. 5,836,968 teaches two levels of oppositely expanding filter wires or struts to insure that the filter is properly aligned in the lumen of the vessel. If the filter tilts or becomes misaligned with the central axis of the vessel, the filter wires will contact the wall of the vessel along a greater area, and become endothelialized. As a result of the two levels, removal of the filter from the blood vessel becomes impossible or at least difficult.
Additionally, the configuration of the second level of filter wires in the device of U.S. Pat. No. 5,836,968 provides a filter which may be too long for the segment of the vessel that the filter would normally be placed. The normal placement segment of a vena cava filter is between the femoral veins and the renal veins. If the lower part of the filter extends into the femoral veins, filtering effectiveness will be compromised. Moreover, it is not desirable to have filter wires crossing the origin of the renal veins, since the filter wires may interfere with the flow of blood from the kidneys. In the device disclosed in U.S. Pat. No. 5,836,968, both levels of filter wires are attached at one point as a bundle at the central axis of the filter. The resulting diameter of this bundle of filter wires results in a filter that may be too large for easy placement and becomes an obstacle to blood flow in the vena cava.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a vena cava filter comprising struts configured to align the filter about the center axis of a blood vessel and minimize engagement with the blood vessel. The filter comprises a plurality of primary struts, each of which having a first end. A hub axially connects the first ends of the struts to define a central axis of the filter. Each primary strut has a curved member extending from the central axis. Each curved member terminates at an anchoring hook to engage the blood vessel at a first axial plane and secure the filter in the blood vessel. Each anchoring hook includes a barb formed at an angle relative to the strut to allow a removal sheath to be advanced over the filter and allow the hooks to be removed straight away from the vessel wall, resulting in minimal vessel damage. The filter further comprises a plurality of secondary struts. Each secondary strut is connected to one of the curved members and extends therefrom to a free end for engaging the blood vessel at a second axial plane, aligning the filter in the blood vessel.
In one embodiment, a set of at least two secondary struts are connected to the curved member of one primary strut. The set of secondary struts extend radially from each side of the primary strut, forming a netting configuration of the filter. In another embodiment, one secondary strut is connected to the curved member of one primary strut. The secondary strut extends from the primary strut and is in radial alignment with the primary strut, avoiding interference with blood flow.
In a collapsed configuration, the vena cava filter occupies a reduced diameter, since the hub is the origin to only primary struts. In an expanded configuration, the hub occupies a reduced cross-sectional area. As a result, interference with blood flow is lessened in the vena cava.
In an expanded configuration, the vena cava filter occupies a reduced length, since the secondary struts merely extend within the axial length of the primary struts. As a result, the filter can more easily be placed in the vena cava of a patient, lessening the risk of interference in the femoral and renal veins.
Further aspects, features, and advantages of the invention will become apparent from consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a prior art filter deployed in a blood vessel;
FIG. 2 is an illustration of the anatomy of the renal veins, the femoral veins, and the vena cava in which one embodiment of a vena cava filter of the present invention is deployed;
FIG. 3 is a side perspective view of one embodiment of the vena cava filter of the present invention;
FIG. 4 is a cross-sectional view of a blood vessel showing the filter of the present invention partially deployed;
FIG. 5 is a cross-sectional view of a blood vessel showing the filter of the present invention fully deployed;
FIG. 6 is a cross-sectional view of a blood vessel in which the filter of FIG. 3 has been deployed;
FIG. 7 is a cross-sectional view of the blood vessel of FIG. 6 taken along line 7 - 7 ;
FIG. 8 is a cross-sectional view of a blood vessel showing a portion of a retrieval device for the filter in FIG. 3 ;
FIG. 9 is a side perspective view of a vena cava filter in accordance with another embodiment of the present invention; and
FIG. 10 is a cross-sectional view of a blood vessel in which the filter in FIG. 9 is disposed.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with a first embodiment of the present invention, FIG. 2 illustrates a vena cava filter 20 implanted in the vena cava 50 for the purpose of lysing or capturing thrombi carried by the blood flowing through the femoral veins 54 , 56 toward the heart and into the pulmonary arteries. As shown, the femoral veins from the legs merge at juncture 58 into the vena cava 50 . The renal veins 60 from the kidneys 62 join the vena cava 50 downstream of juncture 58 . The portion of the vena cava 50 , between the juncture 58 and the renal veins 60 , defines the inferior vena cava 52 in which the vena cava filter 20 has been percutaneously deployed through one of the femoral veins 54 . Preferably, the vena cava filter 20 has a length smaller than the length of the inferior vena cava 52 . If the lower part of the filter extends into the femoral veins, filtering effectiveness will be compromised and if the filter wires cross over the origin of the renal veins the filter wires might interfere with the flow of blood from the kidneys.
The first embodiment of the present invention will be discussed with reference to FIGS. 3-8 in which filter 20 is shown. FIG. 3 illustrates filter 20 comprising four primary struts 12 each having first ends that emanate from a hub 10 . Hub 10 secures the first ends of primary struts 12 together in a compact bundle to define a central or longitudinal axis of the filter. The hub 10 has a minimal diameter for the size of wire used to form the struts. Preferably, the primary struts 12 are formed from stainless steel wire, MP35N, Nitinol, or any other suitable superelastic material that will result in a self-opening or self-expanding filter. In this embodiment, the primary struts 12 are formed from wire having a round cross-section with a diameter of about 0.015 inches. Of course, it is not necessary that the primary struts have a round cross-section. For example, the primary struts could have a square shaped or other suitable shaped cross section without falling beyond the scope or spirit of the present invention.
Each primary strut 12 is formed with a first curved portion 13 that is configured to bend away from the longitudinal or central axis of the filter 20 and a second curved portion 15 that is configured to bend toward the longitudinal axis of the filter 20 . Each primary strut 12 maintains a non-parallel relationship with the longitudinal axis of the filter 20 . The primary struts 12 terminate at anchoring hooks 18 that will anchor in the vessel wall when the filter 20 is deployed at a delivery location in the blood vessel. When the filter is deployed, the anchoring hooks define a first axial plane to secure the filter in the blood vessel. The anchoring hooks 18 prevent the filter 20 from migrating from the delivery location in the blood vessel where it has been deposited. The primary struts 12 are shaped and dimensioned such that, when the filter 20 is deployed and expanded, the filter 20 has a diameter of about 35 mm and a length of about 5 cm. For example, when expanded, the filter 20 may have a diameter of between about 30 mm and 40 mm, and a length of between about 3 cm and 7 cm. The primary struts 12 have sufficient spring strength that when the filter is deployed the anchoring hooks 18 will anchor into the vessel wall.
In this embodiment, each primary strut 12 has two secondary struts 14 secured thereto by laser welding, brazing, crimping or any suitable process that will avoid damaging the material or adding to the thickness of the filter and thus the size of the delivery system. The secondary struts 14 may be made from the same type of material as the primary struts. However, the secondary struts may have a smaller diameter, e.g., about 0.012 inches, than the primary struts. Each of the secondary struts 14 is formed of a single curve and is secured to one of the primary struts 12 on its first curved portion 13 such that the secondary strut 14 becomes a continuation or an extension of the first curved portion 13 of the primary strut 12 . In this embodiment, two secondary struts 14 flare away from each side of one primary strut 12 to form a part of a netting configuration of the filter 20 .
When opened, free ends 17 of the secondary struts 14 will expand radially outwardly to a diameter of about 35 mm to engage the vessel wall. For example, the secondary struts 14 may expand radially outwardly to a diameter of between about 30 mm and 40 mm. The free ends 17 define a second axial plane where the vessel wall is engaged. The secondary struts 14 function to stabilize the position of the filter 10 about the center of the blood vessel in which it is deployed. As a result, the filter 20 has two layers or planes of struts longitudinally engaging the vessel wall of the filter. The length of the filter is preferably defined by the length of a single set of primary struts. Furthermore, the diameter of the hub 10 is defined by the size of a bundle containing the primary struts 12 . In this embodiment, the eight secondary struts, although maintaining the filter in a centered attitude relative to the vessel wall and formed as a part of the netting configuration of the filter, minimally add to the diameter of the hub or the overall length of the filter.
FIG. 4 illustrates the filter 20 partially deployed in inferior vena cava 52 . For deployment of the filter 20 , a delivery tube 24 is percutaneously inserted through the patient's vessels such that the distal end of the delivery tube is at the location of deployment. In this embodiment, a wire guide is preferably used to guide the delivery tube to the location of deployment. The filter is preferably inserted through the proximal end of the delivery tube 24 with the removal hook 16 leading and free ends of the primary struts 12 held by a filter retainer member. The filter retainer member may be connected to a pusher wire (not shown) that is fed through the proximal end of the delivery tube 24 until the filter reaches the distal end of the delivery tube 24 . For a more complete disclosure of a filter delivery system that may be used to deliver the filter 20 to a desired location, reference may be made to U.S. Pat. No. 5,324,304 which is incorporated herein by reference.
As shown in FIG. 4 , filter 20 is deployed leading with removal hook 16 from the delivery tube 24 . The secondary struts expand first. When the free ends of the secondary struts emerge from the distal end of delivery tube 24 , the secondary struts expand to an expanded position shown in FIG. 4 . The free ends engage the inner wall of the vessel in which the filter is being deployed. The free ends of the secondary struts function to stabilize the attitude of filter 20 about the center of the blood vessel. The filter is then pushed further by the pusher wire (not shown) until it is fully deployed as shown in FIG. 5 .
As shown in FIG. 5 , the ends of the primary struts 12 and the secondary struts 14 are in engagement with the vessel wall. The anchoring hooks of the primary struts have anchored the filter at the location of deployment in the vessel, preventing the filter 20 from moving with the blood flow through the vessel. As a result, the filter 20 is supported by two sets of struts that are spaced axially along the length of the filter. The struts avoid engaging the vessel wall along their lengths and thus avoid becoming endothelialized in the vessel wall.
FIGS. 6 and 7 show the filter 20 fully expanded after being deployed in inferior vena cava 52 . In FIG. 6 , the inferior vena cava 52 has been broken away so that the filter 20 can be seen. The direction of the blood flow BF is indicated in FIG. 6 by the arrow that is labeled BF. The anchoring hooks 18 at the ends of the primary struts 12 are shown as being anchored in the inner lining of the inferior vena cava 52 . The anchoring hooks 18 include barbs 19 that, in one embodiment, project toward the hub 10 of the filter. The barbs 19 function to retain the filter 20 in the location of deployment.
In this embodiment, the filter 20 is pushed in a direction BF of the blood flow by the pusher wire (not shown) during deployment. The pusher wire pushes the filter 20 from the delivery tube, causing the barbs 19 to move in the direction BF of the blood flow and secure anchoring hooks 18 in the inferior vena cava 52 . The spring biased configuration of the primary struts 12 causes the anchoring hooks 18 to puncture the vessel wall and anchor the filter at the location of deployment. After initial deployment, the pressure of the blood flow on the filter 20 contributes in maintaining the barbs 19 anchored in the inner lining of the inferior vena cava 52 . As seen in FIG. 6 , the free ends 17 of secondary struts 14 also have a spring biased configuration to engage with the vessel wall. In this embodiment, the free ends 17 of secondary struts 14 are not provided with anchoring hooks, minimizing the trauma of retrieving the filter 20 .
FIG. 7 illustrates a netting configuration formed by the primary struts 12 , secondary struts 14 , and the hub 10 . The netting configuration shown in FIG. 7 functions to catch thrombi carried in the blood stream prior to reaching the heart and lungs to prevent the possibility of a pulmonary embolism. The netting configuration is sized to catch and stop thrombi that are of a size that are undesirable to be carried in the vasculature of the patient. As shown, the hub 10 houses a bundle of first ends of the four primary struts 14 . Due to its compacted size, the hub minimally resists blood flow.
As seen in FIG. 6 , the hub 10 and removal hook 16 are positioned downstream from the location at which the anchoring hooks 18 are anchored in the vessel. When captured by the struts, thrombi remains lodged in the filter. The filter along with the thrombi may then be percutaneously removed from the vena cava. When the filter 20 is to be removed, the removal hook 16 is preferably grasped by a retrieval instrument that is percutaneously introduced in the vena cava in the direction opposite to the direction in which the filter was deployed.
FIG. 8 illustrates part of a retrieval device 65 being used in a procedure for removing the filter 20 from the inferior vena cava 52 . The retrieval device 65 is percutaneously introduced into the superior vena cava via the jugular vein. In this procedure, a removal catheter or sheath 68 of the retrieval device 65 is inserted into the superior vena cava. A wire 70 having a loop snare 72 at its distal end is threaded through the removal sheath 68 and is exited through the distal end of the sheath 68 . The wire is then manipulated by any suitable means from the proximal end of the retrieval device such that the loop snare 72 captures the removal hook 16 of the filter 20 . Using counter traction by pulling the wire 70 while pushing the sheath 68 , the sheath 68 is passed over the filter. As the sheath 68 passes over the filter 20 , the secondary struts 14 and then the primary struts 12 engage the edge of the sheath 68 and are caused to pivot at the hub 10 toward the longitudinal axis of the filter. The pivoting toward the longitudinal axis causes the ends of the struts 14 and 12 to be retracted from the vessel wall. In this way, only surface lesions 74 and small point lesions 76 on the vessel wall are created in the removal procedure. As shown, the surface lesions 74 are created by the ends of the secondary struts 14 and the small point legions 76 are created by the anchoring hooks 18 of the primary struts 12 . However, it is to be noted that any other suitable procedure may be implemented to remove the filter from the patient.
A second embodiment of the present invention will be discussed with reference to FIGS. 9 and 10 in which a filter 28 is shown. FIG. 9 illustrates filter 28 comprising six primary struts 32 each having first ends that emanate from a hub 30 . Hub 30 secures the first ends of primary struts 32 together in a compact bundle to define a central axis of the filter. Similar to the hub 10 in the first embodiment discussed above, the hub 30 in this embodiment has a minimal diameter for the size of wire used to form the struts.
The primary struts 32 in this embodiment are similar in structure to the primary struts 12 in the first embodiment above. For example, in the second embodiment, each primary strut 32 of the filter 28 includes first and second curved portions 33 and 35 , removal hook 36 , free ends 37 , an anchoring hook 38 , and a barb 39 which are respectively similar to the first and second curved portions 13 and 15 , removal hook 16 , free ends 17 , the anchoring hook 18 , and the barb 19 of the filter 28 in the first embodiment. Preferably, the primary struts 32 are shaped and dimensioned such that, when the filter 28 is deployed and expanded, the filter 28 has a diameter of about 35 mm and a length of about 5 cm. For example, when expanded, the filter 28 may have a diameter of between about 30 mm and 40 mm, and a length of between about 3 cm and 7 cm. The primary struts 32 have sufficient spring strength such that when the filter is deployed the anchoring hooks 38 will anchor into the vessel wall.
Preferably, the primary struts 32 are formed of the same material as the primary struts 12 mentioned above, e.g., stainless steel wire, MP35N, Nitinol, or any other suitable material. In this embodiment, the primary struts 32 are formed from wire having a round cross-section with a diameter of about 0.015 inches. As stated above, it is not necessary that the primary struts have a round cross-section.
In this embodiment, each primary strut 32 has one secondary strut 34 secured thereto by laser welding, brazing, crimping or any suitable process that will not damage the material or add to the thickness of the filter and thus the size of the delivery system. The secondary struts 34 may be made from the same type of material as the primary struts. Preferably, the secondary struts may have a smaller diameter, e.g., about 0.012 inches, than the primary struts. As in the first embodiment, each of the secondary struts 34 in this embodiment is formed of a single curve and is secured to one of the primary struts 32 on the first curved portion such that the secondary strut 34 becomes a continuation or extension of the first curved portion of the primary strut 32 . As shown, each of the secondary struts 34 flares away from one primary strut 32 and is in radial alignment therewith.
When opened, the free ends of the secondary struts 34 will expand outwardly to a diameter of about 35 mm to engage the vessel wall. For example, the secondary struts 34 may expand outwardly to a diameter of between about 30 mm and 40 mm. Similar to the secondary struts 14 in the first embodiment, the secondary struts 34 in this embodiment function to stabilize the position of the filter 28 about the center of the blood vessel in which it is deployed. As a result, the filter 28 has two layers or planes of struts longitudinally engaging the vessel wall of the filter. The length of the filter is preferably defined by the length of a single set of primary struts. Furthermore, the diameter of the hub 30 is defined by the size of a bundle containing the primary struts 32 . As in the first embodiment, the secondary struts in this embodiment, although maintaining the filter in a centered attitude relative to the vessel wall and formed as a part of a netting configuration of the filter, minimally add to the diameter of the hub or the overall length of the filter.
FIG. 10 illustrates the netting configuration of the filter 28 formed by the primary struts 32 and the hub 30 . As shown, the secondary struts 34 are positioned behind and in alignment with the primary struts 32 and, thus, avoid substantially affecting blood flow. The netting configuration functions to catch thrombi carried in the blood stream prior to reaching the heart and lungs to prevent the possibility of a pulmonary embolism. The netting configuration is sized to catch and stop thrombi that are of a size that are undesirable to be carried in the vasculature of a patient. As shown, the hub 30 houses a bundle of ends of the six primary struts 34 . Due to its compacted size, the hub minimally resists blood flow.
It is to be noted that the filter 28 may be deployed in the vena cava in the same manner previously discussed for filter 20 with reference to FIGS. 2 , 4 , and 5 . Additionally, the filter 28 may be removed from the vena cava with the removal procedure previously discussed for filter 20 with reference to FIG. 8 .
Although the embodiments of this device have been disclosed as being constructed from wire having a round cross section, it could also be cut from a tube of suitable material by laser cutting, electrical discharge machining or any other suitable process.
While the present invention has been described in terms of preferred embodiments, it will be understood, of course, that the invention is not limited thereto since modifications may be made to those skilled in the art, particularly in light of the foregoing teachings. | A removable filter for capturing thrombi in a blood vessel. The filter comprises a plurality of primary struts having first ends connected to each other to define a central axis of the filter. Each primary strut has a curved member extending from the central axis and terminates at an anchoring hook to engage the blood vessel at a first axial plane. The filter further comprises a plurality of secondary struts connected to the curved members of the primary struts and extending therefrom to a free end at a second axial plane to centralize the filter in the blood vessel. | 0 |
The invention relates to attaching a master cylinder to a booster and more particularly an adapter for attaching a standardized master cylinder to various style boosters.
BACKGROUND OF THE INVENTION
Vehicle brake systems for motor vehicles include a master cylinder which is attached to a brake booster. The brake booster is actuated by a brake pedal and has a plunger which extends into the master cylinder to actuate the master cylinder.
The master cylinder conventionally has a cast housing with a flanged end having holes for receiving studs which project from the front surface of the brake booster shell. Thus, in order to attach a master cylinder to a brake booster, the holes of the master cylinder casting must be of the same number, spacing and diameter as the studs projecting from the brake booster shell.
It would be desirable to be able to attach a master cylinder to a brake booster regardless of the number, spacing and diameter of the studs projecting from the brake booster so that vehicle manufactures and service garages would not have to inventory a large number of different master cylinders having different hole numbers, spacings and sizes.
SUMMARY OF THE INVENTION
The invention provides an apparatus for connecting a master cylinder to a brake booster of the type which has a shell with a planar front surface and a plurality of threaded studs displayed about the bore and projecting from the planar front surface. The master cylinder has a necked down end portion defining a shoulder facing the booster. The master cylinder has a circumferential extending groove provided in the necked down end portion and spaced longitudinally from the shoulder. An adapter has a central aperture to receive the necked down end portion of the master cylinder and a plurality of apertures which register with the plurality of threaded studs. A lock ring or other locking device is received in the groove of the master cylinder and is effective to lock the adapter to the master cylinder and in engagement with the shoulder. A plurality of threaded nuts are installed on the threaded studs to retain the adapter in engagement with the planar surface of the booster shell.
Alternatively the master cylinder body has a connection end with a flange providing a plurality of tabs. There is a plurality of braces with each brace adapted to fit in overlying engagement with one of the tabs and having a hole for receiving one of the threaded studs. A plurality of threaded nuts are installed on the threaded studs so that the braces retain the tabs in engagement with the planar surface of the booster shell.
One object, feature and advantage of the invention is to provide an improved means for attaching the master cylinder to the booster.
It is an object of the present invention to standardize the connection means of master cylinder.
It is an object of the present invention to eliminate the requirement of different setups and machinings of master cylinder.
It is an object of the present invention to reduce the need for inventory of multiple style master cylinders.
Further objects, features and advantages of the present invention will become more apparent to those skilled in the art as the nature of the invention is better understood from the accompanying drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a prior art brake booster and master cylinder.
FIG. 2 is an exploded perspective view of a first embodiment of the invention.
FIG. 3 is a fragmentary view in section of the interface of the master cylinder and the booster of FIG. 2.
FIG. 4 is an exploded fragmentary view in perspective of another embodiment of the invention.
FIG. 5 is an exploded fragmentary view in perspective of another embodiment of the invention.
FIG. 6 is an exploded fragmentary view in perspective of another embodiment of the invention.
FIG. 7 is an exploded fragmentary view in perspective of another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The prior art master cylinder and servo booster assembly 10 has a servo booster 12 which has a front shell 14 as shown in FIG. 1. The front shell 14 has a planar front surface 16 and a bore 18 with a pushrod 20 projecting from the bore 18. The front shell 14 has threaded studs 22 and 24 projecting from the planar front surface 16 for connecting the servo booster 12 to a master cylinder 30. The master cylinder 30 has a cast flange 32 with a pair of holes 34 and 36. The holes 34 and 36 are spaced and aligned to accept the threaded studs 22 and 24. The master cylinder 30 had to be designed to specifically fit a certain servo booster 12 so that the holes 34 and 36 align with the threaded studs 22 and 24.
The master cylinder and servo booster assembly 28 of the present invention as shown in FIG. 2, contains an adapter flange 38 which allows a master cylinder 40 to have a standardized end portion 42 but connects to a variety of servo booster 52. The end portion 42 of the master cylinder 40 has a necked down segment 44 which defines a shoulder 46 facing the booster 52. The necked down segment 44 has a flat surface or portion 43 giving the end portion 42 a "D" shaped cross section. A circumferential extending groove 48 is located on the necked down segment 44 a defined distance from the shoulder 46. The end portion has a bore 50 which receives a pushrod, not shown, from the servo booster 52.
The servo booster 52 has a front shell 54 with a planar front surface 56 and a bore 58. The bore 58 has a pushrod, not shown, projecting from it. The front shell 54 has two threaded studs 60 and 62 for connecting the servo booster 52 to the flange 38. The flange 38 has two holes 64 and 66 that are aligned and spaced to register with the threaded studs 60 and 62.
The flange 38 has an aperture 68 for fitting the necked down segment 44 of the master cylinder 40. A lock ring 70 is received in the groove 48 on the master cylinder 40. The lock ring 70 holds the flange 38 against the shoulder 46 of the master cylinder 40. The aperture 68 is a "D" shape which engages with flat surface 43 of the necked down segment 44 to prevent rotation between the master cylinder 40 and the flange 38.
Two threaded nuts 72 and 74 are installed on the threaded studs 60 and 62 to hold the flange 38 against the planar front surface 56 of the servo booster 52.
FIG. 3 shows the master cylinder 40 and the servo booster 52 connected together. The bore 58 of the servo booster 52 receives the neck down segment 44 of the master cylinder 40. The flange 38 is held against the planar front surface 56 by the threaded nuts 72 and 74 in connection with the threaded studs 60 and 62. The lock ring 70 holds the flange 38 against the shoulder 46 of the master cylinder 40.
A second embodiment of the invention, shown in FIG. 4, has a master cylinder identical to the master cylinder of FIGS. 2 and 3 and has like parts designated by like reference numbers. A first adapter flange 76 has a slot 78 for straddling the necked down portion 44 of the master cylinder. A second adapter flange 80 has a slot 82 to be received in the groove 48 in the necked down segment 44 of the master cylinder 40.
A servo booster 84 has a front shell 86 with a planar front surface 88 and a bore 90. The bore 90 has a pushrod, not shown, projecting from it. The front shell 86 has two threaded studs 92 and 94 for connecting the servo booster 84 to the first flange 76 and the second flange 80. The first flange 76 has as two holes 96 and 98 that are aligned and spaced to register with the threaded studs 92 and 94. The second flange 80 also has two holes 100 and 102 that are aligned and spaced to register with the threaded studs 92 and 94.
The slot 82 of second flange 80 acts as a lock ring that slips into the groove 48 of the necked down segment 44 and holds the first flange 76 against the shoulder 46 of the master cylinder 40. The first flange 76 has a flat region 79 provided in the slot 78 to engage with the flat portion 43 of the "D" shaped necked down segment 44 to prevent rotation between the master cylinder 40 and the flanges 76 and 80.
Two threaded nuts 104 and 106 are installed on the threaded studs 92 and 94 to hold the second flange 80 against the planar front surface 88 of the servo booster.
FIG. 5 shows that the standard master cylinder 40 may be attached to a different servo booster 108 by an adapter flange 110. The servo booster 108 has a front shell 112 with a planar front surface 114 and a bore 116. The bore has a pushrod, not shown, projecting from it. The front shell 112 has three threaded studs 118, 120 and 122 for connecting the servo booster 108 to the flange 110. The flange 110 has three holes 124, 126 and 128 that are aligned and spaced to register with the threaded studs 118, 120, and 122.
The flange 110 has an aperture 130 for fitting the necked down segment 44 of the master cylinder 40. A lock ring 70 is received in the groove 48 on the master cylinder 40. The lock ring 70 holds the flange 110 against the shoulder 46 of the master cylinder 40. The aperture 130 has a flat portion 131 which engages with the flat portion 43 to prevent rotation between the master cylinder 40 and the flange 110.
Three threaded nuts 132, 134 and 136 are installed on the threaded studs 118, 120, and 122 to hold the flange 110 against the planar front surface 114 of the servo booster 108. The servo booster bore 116 receives the end portion 42 and the lock ring 70 that extends beyond the flange 110.
Another embodiment is shown in FIG. 6, where a master cylinder 138 has a connection end 140. The connection end 140 has a flange 142 with two tabs 144 and 146.
The servo booster 148 has a front shell 150 with a planar front surface 152 and a bore 154. The bore has a pushrod, not shown, projecting from it. The front shell 150 has two threaded studs 156 and 158 for connecting the servo booster 148 to the master cylinder 138. The tabs 144 and 146 on the flange 142 are sized so that the they fit between the threaded studs 156 and 158.
A pair of braces 160 and 162 hold the flange 142 of the master cylinder 138 to the planar front surface 152 of the servo booster 148. The brace 160 has a channel shape with a base 164 and a pair of legs 166 and 168. The legs 166 and 168 are spaced to straddle and overlay the tab 144. The length of the legs 166 and 168 does not exceed the thickness of the tab 144 so that the base 164 will engage the tab 144. The brace 160 has a hole 170 to receive the threaded stud 156. The second brace 162 is similarly shaped and has a base 172 and a pair of legs 174 and 176. The base 172 has a hole 178 to receive the threaded stud 158. A pair of threaded nuts 180 and 182 are installed on the threaded studs 156 and 158 so that braces 160 and 162 hold the flange 142 against the planar surface 152. The tabs 144 and 146 can be part of the casting of the master cylinder 138 or welded on to the master cylinder. The legs of the braces 160 and 162 prevent the rotation between the tabs 144 and 146 of the master cylinder 138 and the servo booster 148.
Another embodiment of the invention shown in FIG. 7 has a master cylinder identical to the master cylinder 40 of FIG. 2 and 3 and has like parts designated by like reference numbers. A wire form 184 connects the master cylinder 40 to a servo booster 186. The wire form is constructed of spring wire bent substantially in one plane to define an enclosed central portion 198 and two enclosed offset portions 200 and 202 that border the central portion 198. The central portion 198 of the wire form 184 defines a lock ring portion which is received in the groove 48 of the master cylinder to attach the wire form to the master cylinder 40. The central portion 198 has a straight segment 199 which fits the flat portion 43 of the "D" shaped necked down segment 44 to prevent rotation between the master cylinder 40 and the wire form 184.
The servo booster 186 has a front shell 188 with a planar front surface 190 and a bore 192. The bore 192 has a pushrod, not shown, projecting from it. The front shell 188 has a plurality of threaded studs 194 and 196 for connecting the servo booster 186 to the wire form 184. The two offset portions 200 and 202 are aligned and spaced to register with the threaded studs 194 and 196.
Two threaded nuts 204 and 206 are installed on the threaded studs 194 and 196 to hold the wire form 184 against the planar front surface 190 of the servo booster 186.
The use of the adapter comprised of a flange or a wire form allows the use of a standard master cylinder with a variety of different servo boosters with two or more threaded studs. The threaded studs can be various sizes and located in various places on the servo booster. All that is required is to use the appropriate size flange or wire form so that the holes in the flange or wire form will register with the studs. This will eliminate the need to inventory various master cylinders or machine various fittings.
The use of the braces of FIG. 6 will allow a standardized master cylinder having the same number and spacing of tabs as threaded studs on the servo booster to be used even when the offset distance and diameter of the threaded stud varies from servo booster to servo booster. It is realized with this embodiment that different master cylinder will be required if the servo booster has a different number of threaded studs.
Thus it is seen that the objective of eliminating the requirement to keep in inventory various styles of master cylinder has been achieved.
While embodiments of the present invention have been explained, it will be readily apparent to those skilled in the art of the various modifications which can be made to the present invention without departing from the spirit and scope of this application as it is encompassed by the following claims. | An apparatus is provided for connecting a master cylinder to a brake booster of the type which has a shell with a planar front surface and a plurality of threaded studs displayed about the bore and projecting from the planar front surface. The master cyliner has a necked down end portion defining a shoulder facing the booster. The master cylinder has a circumferential extending groove provided in the necked down end portion and spaced longitudinally from the shoulder. An adapter has a central aperture to receive the necked down end portion of the master cylinder and a plurality of apertures which register with the plurality of threaded studs. A lock ring or other locking device is received in the groove of the master cylinder and effective to lock the adapter to the master cylinder and in engagement with the shoulder. A plurality of threaded nuts are installed on the threaded studs to retain the adapter in engagement with the planar surface of the booster shell. | 1 |
This application is a continuation-in-part of Ser. No. 090,360 filed Aug. 29, 1987, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hypodermic needles and more specifically to a hypodermic needle which retracts into the syringe after use, thereby preventing reuse and the spread of diseases normally associated therewith.
2. Description of the Prior Art
It is well known that diseases can be spready by re-using a needle and that a person can come in contact with a disease by being accidently scratched by the needle. Hypodermic needles and syringes on the market today have fixed needles attached to a cylinder. After the needle has been used, it should be disabled and destroyed to prevent transmission of diseases.
But, even thrown away needles can expose one to disease as the needle and syringe can quite often be re-used by an unsuspecting person. The contaminated needle can also accidently cut or prick a person, exposing that individual to a transmittable disease. Efforts have been made to educate people not to re-use needles, but the spread of disease through needles is still widespread and hospital personnel have been accidently cut by contaminated needles even though they are extremely careful and well aware of the dangers. Some medical facilities have equipment to break the needle from the syringe or cylinder rendering the syringe harmless, but, these devices are not available to the general public. Some syringes have a protective cap covering the needle which can be placed over the needle after use, allowing the needle to be broken from the syringe, but here again an accidental scratch from the needle could be devastating.
SUMMARY OF THE INVENTION
The present invention effectively overcomes the problems of the prior art and provides for an efficient way of disposing of a spent needle without subjecting one to the potential hazzards of handling it after use while simultaneously removing the needle from circulation, whereby reuse becomes impossible.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b and 1c show various techniques for applying force to the instant retractable needle for securing it within the body of a syringe after use;
FIGS. 2a and 2b show clamp mechanisms for securely holding the needle in place until released for storage within the syringe;
FIG. 3 shows one embodiment of this invention using a spring under tension to retract the spent needle into the syringe; and
FIG. 4 shows a top cross-sectional view of the hypodermic syringe at Section A--A of FIG. 3;
FIG. 5 shows another embodiment of the invention with a spring under compression for forcing the needle into the hollow of the syringe upon release of the hold-down tabs;
FIG. 6 is a cross-sectional view of FIG. 5 at Section B--B; and
FIG. 7 shows a pair of semi-circular stops placed between the lips of the thumb actuated plunger and the finger hold of the syringe cylinder.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention may perhaps be best understood by making reference to several drawings and specifically describing one of the preferred embodiments.
In the needle's initial state, in FIG. 3, the handle cannot be pushed down. The needle is inserted into a container of fluid and when the handle (7) is pulled back, stop (8) falls off, and the slide or plunger moves away from the needle, thus creating a vacuum to draw fluid from the container into the syringe. When a desired fluid level is reached, the operator stops the pulling process and adjusts the dose. The needle is inserted into a patient or area. Then, the handle (7) is pushed in to force the fluid through the needle. When the slide extensions (9) reach the clamps (10), a push on handle (7) provides a force to release or break the clamps, thus releasing the hold on the needle. The needle is automatically drawing through the gasket (11) and pulled into the inside cylinder (6) where is becomes inaccessible and non-reusable.
FIG. 3 shows a syringe and needle in its initial state with needle (12) protruding through gasket (11) which serves as a leak-proof seal for the syringe (14) and stabilizes the shaft of the needle (12). In this case the head of the needle (13) is attached to a tensioned spring (16) by an attachment means (15), which can employ any of the means shown in FIGS. 1a, 1b or 1c. The needle is held in place by clamps or tabs (10) fabricated of breakable material or at least a material malleable enough to allow the needle head to be released upon the exertion of force by projections (9) on the end of plunger 18. The tabs (10) can be moulded into the syringe end plate through which the needle protrudes or they could be moulded as part of a washer plate (not shown) which is appropriately seated within syringe body (14). Spring (16) is shown extended and under tension with one end connected to the needle head (13) and the other end connected to the end surface of the inside cylinder (17). In this mechanical state, the needle (12) and head are in mechanical equilibrium wherein the spring force tends to pull the needle through the gasket (11) and the clamp (10) prevents it from being retracted into the body of the syringe. It should be noted here that the syringe is shown in its simplest form with simple finger tabs on the upper and outer portion of the syringe cylinder for holding the syringe, but it should be fully understood that finger tabs are well known in the art and that the handle or plunger cap (7) is thumb actuated and may also contain a lip to extract the plunger from the top of the cylinder during the filling of the syringe.
A slide or plunger mechanism (18) has projections (9) on its bottom surface. These projections will release the clamps or tabs (10) when the handle (7) is pushed down. In the initial state, the handle is prevented from being pushed down by a mechanical stop (8). The mechanical stops (8) can be any type of temporary bushing, such as slip rings, or two semi-circlar inserts, as shown in FIG. 7, placed between handle (7) and the top end of syringe housing (14) to assure that the protrusions (9) on the plunger (18) do not release the tabs (10) until the syringe has been used and the needle is ready to be retracted into the inside cylinder (6). The stops (8) are released and fall from their places upon filling the syringe, thus readying the syringe for retraction of the needle upon demand. When the handle is pushed down, the projections (9) release the clamps (10) and attachments (15) pull the needle through gasket (11) and pull the head through the diaphragm (19). Diagraphm (19) prevents liquid from entering the spring cylinder until the diaphragm is broken. The needle and head are then pulled deep into the inside cylinder (12). Once inside the cylinder (6), the needle (12) cannot be again pushed through the gasket by any means, thus rendering the needle inaccessible and non-reuseable.
FIG. 5 shows another arrangement of the invention. In this arrangement, a spring mechanism is under compression in its initial state. Spring force is applied to the needle head (20) tending to drive the head and needle through diaphragm (21) and into chamber (22). In the initial state, clamps (23) hold the needle head from moving up or down. When slide (24) is moved in the direction of the clamps, the projections (25) on the bottom of the slide release the clamps (23) by a release mechanism or by breaking the clamps, thus releasing the needle and needle head. The force of the spring mechanism (26) drives the needle into chamber (22) thereby rendering inaccessible and non-reuseable.
FIG. 6 shows a top view of the circular projection (25) and the diaphragm (21). FIG. 7 shows a top view of the circular mechanical stop (8) which prevents the handle (7) of FIGS. 3 and 5 from accidently moving forward and triggering the retraction of the needle. The stop (8) falls from the syringe as the plunger is activated to fill the syringe. | A retractable hypodermic needle configured for one-time use wherein the needle is spring loaded and automatically irretrievably retracted into the hypodermic syringe when the syringe plunger is fully depressed, whereby protrusions on the end of the plunger engage tabs holding the spring loaded needle to release the needle for retraction. | 0 |
CLAIM OF PRIORITY
[0001] This application is a continuation application of U.S. Ser. No. 14/463,724 filed on Aug. 20, 2014 which claims priority to U.S. Ser. No. 61/867,737 filed on Aug. 20, 2013, the contents of both of which are herein fully incorporated by reference in their entirety.
FIELD OF THE EMBODIMENTS
[0002] The field of invention and its embodiments relates to printing presses, namely foil printing presses employing a cold foil methodology. In particular, using a specific methodology to reduce foil waste, thus implementing substantive cost saving measures to the manufacturer and consumer alike.
BACKGROUND OF THE EMBODIMENTS
[0003] Historically, foil has been used for centuries as a means of adornment and decoration. A malleable metal, such as gold, was typically pounded into very thin sheets (i.e. foil) and then applied to armor, letters, and various types of furniture or artwork. What used to be reserved for the rich now has become a staple of the masses thanks to substantive improvements in technology.
[0004] Foil is still expensive; however, it is now more common to find various types of foil with a base of aluminum in present mechanical processes. These foil works are ubiquitous and most often seen in commercial packaging, books, wedding announcements, cards, and the like. Notwithstanding the progression of foiling technology, the current foiling processes are not without their drawbacks. Most often, vast amounts of foil are wasted in the printing or stamping process. This is due to the high speed at which the presses run, which is typically referred to as “press speed.” This continuous foiling process is fast and simple, but as mentioned results in a substantial waste of foil and thus a waste of money.
[0005] Even still, the cold foiling process has remained fairly unchanged for some time. Typically, a substrate is fed through a pair of rollers which apply an adhesive to the substrate. A separate foil web is then merged with the adhesive laden substrate and the two are pressed together through another set of rollers. The adhesive then cures on its own, or is cured by another means such as ultraviolet light. The excess foil is then stripped away from the substrate and the substrate continues down a conveyor for further treatment or packaging. The excess foil is collected by a collection core. Once the foil has run its course through the press, it cannot be reused.
[0006] Thus, there is a need for a more efficient process in order to reduce said foil waste and manufacturing costs. The current invention meets and exceeds these needs and objectives.
[0007] Review of Related Technology:
[0008] U.S. Patent Application 2013/0075040 pertains to systems, machines and products for producing foil relief. The system includes apparatuses for placing a foil on a curable adhesive deposited on a substrate when the curable adhesive is substantially non-tacky, and applying energy to the adhesive deposited on the substrate while pressing the foil to the adhesive to cause the adhesive to become tacky and to adhere to the foil. The adhesive becomes substantially fully cured prior to completion of the pressing of the foil to the adhesive deposited on the substrate. In some embodiments, the system may further include one or more energy sources for pre-curing the curable adhesive prior to placing the foil on the adhesive to initiate the curing process of the adhesive and manipulate a viscosity level of the adhesive, with the pre-cured adhesive remaining substantially non-tacky. The curable adhesive includes one or more of, for example, a radical type adhesive and/or a cationic adhesive.
[0009] U.S. Patent Application 2012/0193024 pertains to a material deposition technique for transferring material to a substrate. The material may be a foil on a carrier and the substrate may be printable paper. A computer-controlled, material application subsystem is provided having a material roller assembly including one or more material pressing rollers. The entire assembly is configured for controlled rotation such that the material pressing rollers alternately engage and disengage an impression cylinder. In a first rotatable position, the material roller assembly is rotated so that one of the material deposition rollers over which the material carrier is fed engages the impression cylinder and deposits the material onto the substrate as it passes beneath the roller. In a second rotatable position, the material roller assembly is rotated so as to disengage the material roller from the impression cylinder thereby precluding deposition of material onto the substrate as it passes beneath the roller.
[0010] Various devices are known in the art. However, their structure and means of operation are substantially different from the present disclosure. The other inventions fail to solve all the problems taught by the present disclosure. The present invention and its embodiments enable a foil web to be used repeatedly on a single pass through a press. The foil web is positioned to minimize waste while not comprising the speed and effectiveness of the press. At least one embodiment of this invention is presented in the drawings below and will be described in more detail herein.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0011] The current invention and its embodiments disclose a material deposition method having the steps of unwinding a foil web from an unwind core; feeding the foil web through a press, wherein the press has a sync cartridge having a plurality of roller trays, the plurality of roller trays having at least two angular guide assemblies and being operably connected to a plurality of motors wherein, the plurality of motors provide differing angles to the at least two angular guide assemblies to manipulate the circumference of the foil web in relation to adherence to the substrate; using the sync cartridge to create at least two connected, substantially circular foil raceways for the foil web; applying a layer of adhesive to the substrate; bringing at least two sections of the foil web into contact with the substrate more than once; and separating the foil web from the layer of adhesive for a final time, wherein the foil web is collected upon a rewind core and the substrate continues through the press.
[0012] The material deposition method uses a continuous foil web in the foiling process. The process itself is also continual, unlike other start/stop methodologies. This is done by looping the foil at least twice, and as many as 6 times or more, through the press and cold foiling attachment. The number of loops, typically referred to as “raceways,” is determined by the width of the foil web layout in relation to the maximum allowed width of the machine. The press can change the angle of the angular guide assemblies thereby changing the circumference of the foil web. If one desires to increase the circumference of the foil raceways, then the angle of the angular guide assemblies and distance between them is increased, and to decrease the circumference of the foil web the angle of the angular guide assemblies and the distance between them is decreased. The method may further comprise repeating the aforementioned steps using a second foil web. In this instance, the above described methodology can be combined with multiple foils of varying widths and types of foils to accommodate the various foiled areas needed for a particular project.
[0013] In another embodiment, a material deposition method is described having the steps of unwinding a foil web from an unwind core; feeding the foil web through a press wherein the press has a sync cartridge wherein, the sync cartridge has a plurality of roller trays, the roller trays having at least two angular guide assemblies, the at least two angular guide assemblies having the capability to be manually manipulated to a particular angle and distance in order to change the circumference of the foil web in relation to the adherence to the substrate; using the sync cartridge to create at least two connected, substantially circular foil raceways for the foil web; applying a layer of adhesive to the substrate; bringing at least two sections of the foil web into contact with the substrate more than once; and separating the foil web from the layer of adhesive for a final time, wherein the foil web is collected upon a rewind core and the substrate continues through the press. This embodiment comprises generally the same principles as the previous embodiment described above; however, here one must manually change the angles and distances of the angular guide assemblies to achieve the varying circumferences for the foil web.
[0014] In general, the present invention succeeds in conferring the following, and others not mentioned, benefits and objectives:
[0015] It is an object of the present invention to provide a material deposition method for reducing waste in cold foil printing.
[0016] It is an object of the present invention to provide a material deposition method that enables multiple foil webs of varying widths to be run through a press simultaneously.
[0017] It is an object of the present invention to provide a material deposition method that provides a cost effective solution for reducing waste and its associated costs.
[0018] It is an object of the present invention to provide a material deposition method that reduces manufacturer and consumer cost.
[0019] It is an object of the present invention to provide a material deposition method that enables one to manually manipulate the length of the foil raceway.
[0020] It is another object of the present invention to provide a material deposition method that enables one to automatically change the length of the foil raceway.
[0021] It is another object of the present invention to provide a material deposition method for a cold foil press that permits multiple, continuous raceways for a foil web.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 is a diagram demonstrating a prior art method of depositing a material using a cold foil press.
[0023] FIG. 2 is a flow chart illustrating a method of depositing a material as described by the present invention and its embodiments.
[0024] FIG. 3 is perspective back view of an example of a press employing at least the methodology as described in FIG. 2 .
[0025] FIG. 4 is a perspective view of a sync cartridge assembly in accordance with the methodology of the present invention.
[0026] FIG. 5 is a perspective view of a roller tray of a sync cartridge assembly.
[0027] FIG. 6 is a perspective view of an angular guide assembly of a sync cartridge assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified, as far as possible, with the same reference numerals.
[0029] Reference will now be made in detail to embodiments of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto without deviating from the innovative concepts of the invention.
[0030] As defined herein, “circumference” refers to the distance traveled by the foil web by way of a number of looped passes, or raceways, through the complete press. The overall distance is calculated and can be changed to suit the job at hand based on the number and size of images that must be printed.
[0031] In FIG. 1 , there is a typical prior art apparatus/method for depositing a material, such as a foil web 16 , onto a substrate 25 . The foil web 16 is unwound from a foil unwind core 18 . It moves along through the press and meets an alignment roller 20 . The foil web 16 passes through the alignment roller 20 and alignment nip 31 meeting the substrate 25 laden with an adhesive 26 . The foil web 16 and substrate 25 combination pass through a roller assembly 28 and 32 .
[0032] Here, the foil web 16 is pressed into the adhesive laden substrate 25 fusing the foil web 16 to the adhesive 26 . The unadhered foil web 16 and substrate 25 are separated by a separation nip 34 and the leftover foil web 16 goes to a foil rewind core 24 . The substrate 25 , typically in an individual sheet form, goes to the next transfer cylinder (not shown) and continues through the press to have various transparent colors printed on top of foiled and non foiled areas of the sheet This method creates a large amount of wasted foil web 16 , as the operational press speed is such that it allows for small percentages of the foil web 16 to be adhered to the substrate 25 . The process is typically driven by a number of servo motors 40 . The current method, as described, greatly reduces the waste experienced with the aforementioned prior art methodology.
[0033] FIG. 2 generally illustrates the preferred material deposition method 200 as described by the current invention and its embodiments.
[0034] In step 201 , a foil web is unwound from the foil unwind core. This is a continuous foil web which is used from start to finish for the job.
[0035] In step 205 , the foil web is fed through the press fitted with a sync cartridge. The sync cartridge permits the foil web to form multiple raceways through the press thereby increasing the amount of foil web used and decreasing the amount of foil web waste. The sync cartridge and its components are further described in FIGS. 3-6 .
[0036] In step 210 , the angle of the angular guide assemblies are set to a particular angle. The exact angle setting of the angular guide assemblies will be dependent on the specifications of the particular print job. Further, the angle settings of the angular guide assemblies can be manipulated independent of one another. In some instances, this step may be performed before the foil web is fed through the press in step 205 .
[0037] In step 250 , the angle adjustments of the angular guide assemblies may be performed manually. Alternatively, the angle adjustments of the angular guide assemblies may be performed automatically by servo motors or the like in step 255 .
[0038] In step 215 , there are at least two continuous raceways that have been created using the press and the sync cartridge. The press used in this methodology is preferably fitted with a cold foil attachment such as the one manufactured by KBA of Germany. Such a press enables one to retrofit a sync cartridge (see FIG. 4 ) into the existing cold foil attachment.
[0039] In step 220 , the substrate is then transported with at least one roller to the press.
[0040] In step 225 , a layer of adhesive is applied to the surface of the substrate. The adhesive used is dependent on the specifications of the job but is nonetheless known in the art.
[0041] In step 230 , the foil web and the substrate are advanced to a material roller assembly.
[0042] In step 235 , the two materials are brought together and the foil contacts the adhesive and the two components are pressed together via rollers to ensure a proper adhesion.
[0043] In step 240 , the remaining unadhered foil is separated from the substrate and rewound on a rewind drum and then disposed.
[0044] Referring now to FIG. 3 , there is an example of a complete press 50 comprising of a cold foil attachment 55 and a press unit 60 . The press unit 60 can be a number of different styles or brands that are receptive to any type of cold foil attachment 55 . The cold foil attachment 55 primarily dictates the alignment of the foil web, while the press unit 60 primarily dictates on the impression and adhesion properties of the process. Area A-A′ is the area that is receptive to the sync cartridge further described in FIGS. 4-6 .
[0045] In making determinations of cost/cost savings and the number of raceways to be run, a number of calculations can be completed. For example, the complete press 50 may accommodate up to about a 1.00 m (40 inch) foil web. Thus, if one desired to run four (4) lanes, or raceways, the maximum foil web width is about 25.4 cm (10 inches).
[0046] In general, the cost for a 2.54 cm (1 inch) web is USD$60 for 8000 sheets. Thus, the cost for an about 1.00 m (40 inch) web is USD$2400 for 8000 sheets. By permitting a second raceway, or pass through the complete press 50 , the cost for the about 1.00 m (40 inch) foil web is reduced by half or USD$1200. There are multiple iterations where this holds true and the number of passes and widths of the foil web can vary. The one constant in this methodology is the increased foil usage and increased monetary savings.
[0047] The complete press 50 typically ranges from about 0.4 m (15 inches) to about 2.3 m (90 inches) and the number of raceways is determined by the amount of space by dividing into the printing press width down to about 5 cm (2 inches) wide of the maximum size. For example, a 0.4 m (15 inch) machine could theoretically have seven (7) raceways that are about 5 cm (2 inches) wide and an about 2.3 m (90 inch) machine could have as much as forty-five (45) raceways if the layouts of the actual foiling job(s) allowed.
[0048] FIG. 4 is perspective view of a sync cartridge 50 that is received in area A-A′ of FIG. 3 . The sync cartridge 150 has a frame 100 generally defined by a number, typically four, lateral perimeters. The frame 100 may have a number of locking mechanisms that interact with the press thereby securing the sync cartridge 150 to the press.
[0049] There is also a locking track 135 for the roller trays 110 . The locking track 135 permits the movement of the roller trays 110 . The locking track 135 is positioned to generally run laterally to the width of the frame. The locking tray 135 has a groove which receives the roller trays 110 . In some embodiments, the locking tray 135 only permits lateral movement of the roller trays 110 . However, in some instances, one can lift a roller tray 110 out of the locking tray 135 thereby allowing one to change the number of roller trays 110 present in the sync cartridge 150 .
[0050] In order to move a roller tray 110 , one must first loosen the fasteners holding the roller trays 110 in place. The roller trays 110 then can be moved and positioned at specific points along the locking track 135 . The points at which the roller trays 110 may be secured to the locking track 135 may be fixed (i.e. set points along the track) or the locking tray 135 may enable the roller trays 110 to be positioned at any point along the locking tray 135 . Each of the roller trays 110 is further described in FIG. 5 in more detail.
[0051] The sync cartridge 150 generally interacts with at least one foil web as described by FIGS. 3 & 4 . First, a foil web passes over one of the roller assemblies 115 . It passes underneath one of the angular guide assemblies 125 and around over the top of the same angular guide assembly 125 . The particular angle of the angular guide assembly 125 dictates the direction the foil web takes thereon. Usually, the foil web will then pass underneath another angular guide assembly 125 and then pass over the top of the same angular guide assembly 125 . The foil web will then pass over a roller assembly 115 and travel down into the press unit 60 . The general process and orientation of passing the foil web through the angular guide assemblies 125 and roller assemblies 115 is repeated based on the number of raceways being run at a particular time.
[0052] FIG. 5 is a perspective view of an example of an individual roller tray 110 from the sync cartridge 150 described in FIG. 4 . The roller tray 110 has a base 175 on which the individual components of the tray 110 are disposed. On one end of the base 175 is a roller assembly 115 with a lock block 165 . The lock block 165 permits attachment of the roller assembly 115 while still permitting movement of the roller tray 110 .
[0053] The roller assembly 115 helps with the alignment and tension in the foil web. As shown, there is a roller assembly 115 on the top side of the roller tray 110 and a roller assembly 115 attached to the lower side of the roller tray 110 . This provides proper tensioning for the foil web as it travels up and over the roller tray 110 and down the roller tray 110 . In some instances, there may be only one roller assembly 115 whereas in other instances the layout may require more than two roller assemblies 115 .
[0054] The base 175 may also have a slidable track 140 . The slidable track 140 permits the angular guide assembly 125 to change angles and distance in relation to the roller assembly 115 . The slidable track 140 is a series of channels or grooves in an upper surface of the roller tray 110 . Each of the two ends of the angular guide assembly 125 can be adjusted independent the other side via the slidable channel 140 . This allows for virtually innumerable angular differences to be created.
[0055] The angular guide assembly is held in place by the angle roller pivot lock 160 , which further enables the pivoting motion necessary to independently adjust the ends of the angular guide assembly 125 . Further, the angle roller pivot lock 160 prevents movement of the angular guide assembly 125 by way of at least one securement mechanism.
[0056] FIG. 6 is an example of an angular guide assembly 125 as described above. The angular guide assembly 125 changes angles and positions relative to the sync cartridge 150 in order to change the circumference of the foil web. The circumference of the foil web can be decreased by decreasing the angle and distance between at least two of the angular guide assemblies 125 . The circumference of the foil web can be increased by increasing the angle and distance between at least two of the angular guide assemblies 125 . A base 190 of the angular guide assembly 125 supports a bar and locking mechanism 180 .
[0057] As the circumference of the foil web is manipulated by the angular guide assemblies 125 , the foil web impacts the substrate at different points on each pass. Thus, the position of the foil web can be such that multiple areas of the foil web can be used in close proximity to one another rather than the wide gaps and wasted foil that is seen with the current cold foiling methodologies. | A method for material deposition employs a printing press, such as those used in cold foil transfers, that permits a greater usage of the foil web than traditional methods. This is achieved by increasing the number of times the foil web is passed through the press, while simultaneously taking into account the area that has not been used and adjusting the impacted area of the foil web accordingly. The foil web is adjusted by using a series of adjustable rollers and angular bars to change the length of the circumferential path the foil takes through the press. By modifying the angle of these rollers and the distance between them, the path can be lengthened or shortened to correspond to the particular needs for a particular print job. This allows the press to use the foil in such a way that reduces foil waste and manufacturer and consumer costs. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from Provisional U.S. Patent Application Ser. No. 60/140,075 filed Jun. 24, 1999 and Provisional U.S. Patent Application Serial No. (UNASSIGNED, DOCKET NO CRUS-0156) filed on June 26, 1999, both of which are incorporated herein by reference.
[0002] The subject matter of the present invention is related to that in the following co-pending U.S. patent applications:
[0003] Attorney Docket No. 0931 entitled “Digital Impairment Learning Sequence” filed on Jun. 12, 2000, which is incorporated herein by reference;
[0004] Attorney Docket No. 0933 entitled “Inter-Modulation Distortion Detection”, filed Jun. 21, 2000, which is incorporated herein by reference;
[0005] Attorney Docket No. 0934 entitled “Constellation Generation and Re-evaluation” filed May 18, 2000, which is incorporated herein by reference; and
[0006] Attorney Docket No. 0935 entitled “Receiver Codec Super Set Constellation Generator” filed May 26, 2000, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0007] The present invention relates generally to an improved technique for generating and using a learning sequence for a modem. In particular, the present invention is directed towards an improved digital impairment learning sequence which accommodates detection of Robbed-Bit Signaling (RBS), Digital Pad and Line CODEC type particularly for use with V.90 modems or the like.
BACKGROUND OF THE INVENTION
[0008] The necessity of digital communication over existing communications networks, such as telephone companies, has necessitated the use of increasingly complex and efficient modulators/demodulators (modems). Because most communication systems were originally designed as analog systems, conventional modems have always been limited by the necessity of analog capabilities. Consequently, such modems operate as if the entire communications network, such as a public switch telephone network (PSTN), is an analog system, even though much of the communication throughout the PSTN is digital in nature.
[0009] [0009]FIG. 3 is a block diagram of a communications system, which includes a digital public switch telephone network (PSTN) 40 . Remote or client modem 10 communicates with a server modem installation 20 through digital PSTN 40 . In order to communicate with the digital portion 40 of the PSTN, it may be necessary to communicate over an analog link 50 . Accordingly, digital information at client modem 10 is converted to analog signals, transmitted over analog link. 50 (generally designated as a local loop), and transmitted to PSTN circuitry 33 , which is a hybrid that converts the 2 wire bi-directional local loop signal to 4 wire transmit and receive pair of signals and 30 , which is a network interface that does the conversion from the analog loop signals to digital trunk signals using ADC 31 , and also does the PCM encoding in case a mu-law or A-law CODEC interface is used and transmitted into digital portion 40 of PSTN 40 .
[0010] Such systems are characterized by the use of an analog-to-digital converter (ADC) 31 , which is used to digitize analog signals for transmission to a digital portion of the PSTN 40 . Two types of quantization systems may be used in such systems, mu-law and A-law. Both systems encompass signal compression algorithms to maximize the dynamic range of an analog signal that could be represented by 8 bits. Both of these systems are used to optimize the PSTN for traditional voice communications.
[0011] Unfortunately, the wide dynamic range of normal speech does not lend itself well to efficient linear digital encoding. Digitizing is done in both systems by limiting the Signal to Quantization noise of the signals thus reducing the bandwidth required for each call. These encoding systems impose significant limitations on data communications.
[0012] Client modem 10 may typically transmit data using a digital-to-analog converter (DAC) 15 to convert digital signals into analog signals. Eventually, the analog signal is received and converted back to digital form by an analog-to-digital converter (ADC) 31 somewhere in the PSTN 40 . When the analog signal levels transmitted by DAC 15 in client modem 10 do not accurately correspond to the quantization intervals used by receiving ADC 31 , the data transmitted may not be properly converted back into the exact digital form originally sent. If receiving ADC 31 incorrectly converts an analog signal transmitted, receiving modem (e.g., server modem 20 ) may not receive the same data which was transmitted. The same is true in the downstream direction of server digital modem 20 to client analog modem 10 .
[0013] In order to avoid such communications errors, certain error-checking protocols may be used. However, such protocols may require retransmission of corrected data, thereby reducing the rate at which data can be transmitted. The result is greatly reduced digital efficiency for the PSTN constituting the digital communications system.
[0014] Under the V.90 standard, a modem at a client computer may request that a server modem transmit a learning sequence in order to characterize the data channel. The V.90 specification does not specify a particular learning sequence and thus each manufacturer or communications system operator may use an unique learning sequence to characterize the data channel.
[0015] In some T1 lines, a telephone company (Telco) may use one of a number of time-division multiplexed channels for transmission of control data. However, in other instances, a technique of “robbed bits” (RBS) may be used to transmit control data for use by the Telco. In the robbed bit signaling technique, a least significant bit of one or more slots is used during initial connection to transmit control data from one portion of the Telco to another indicating numbered dialed, hang up, and the like. During data transmission, this same least significant bit may be set to a predetermined value (e.g., 0 or 1), or may be toggled.
[0016] In traditional voice communications signalling, Robbed Bit techniques produced few problems, as arbitrarily changing the least significant bit of a digitized audio signal does not produce any noticeable audio artifacts in the resultant analog audio signal. However, in a digital signalling environment, such legacy techniques as Robbed Bit Signalling create problems for digital data transmission. Arbitrarily changing the least significant bit in a data stream may produce a digital data transmission error.
[0017] The wide variety of digital system characteristics means digital impairments such as RBS and pad variations, as well as CODEC types which would modify the digital information the server outputs before it is converted to analog information that the client receives. Apart from these there could be analog impairments such as line distortion, noise and Inter-Modulation Distortion (IMD) which could create conditions for greater communications errors. Consequently, additional techniques are necessary to properly measure the pad and accommodate any RBS such that received signals can be properly adjusted to reflect the reality of those signals as sent, rather than theoretical values, which may prove to be incorrect.
SUMMARY OF THE INVENTION
[0018] In the present invention, a novel learning sequence is used which compensates for different types of digital data channels used by telephone companies, as well as digital impairments.
[0019] A unique Digital Impairment Learning (DIL) sequence may be transmitted during the digital hand shake procedure, or in other predetermined time slots, based upon certain signaling protocols requested by a client or user modem. The DIL sequence is designed such that the net sum of all the elements in the pattern over a specific period comes to zero. A net sum of zero is required since a telephone system may not readily transmit a signal with a DC offset. In the DIL sequence of the present invention, this zero sum occurs every twenty frames and the pattern is generated in such a way that the zero sum will be achieved regardless of whether RBS is used or which type of RBS is used.
[0020] The objects and goals of the present invention are achieved by a communication system with digital and analog sections. The communication system includes at least one client modem and at least one server modem separated by at least one of the digital sections. The client and server modem are arranged to exchange a Digital Impairment Learning (DIL) sequence between them. The client modem includes an apparatus for sending first parameter signals to the server modem. The server modem includes an apparatus for sending training symbols to the client modem based upon the first parameter signals.
[0021] The second aspect of the present invention is directed to a method of operating a client modem in a communication system. The client modem is configured to receive training signals provided in a DIL sequence from a server modem. The method includes the steps of sending first parameter signals from the client modem to the server modem, and receiving training symbols in a DIL sequence at the client modem. The server modem sends the training symbols configured in accordance to the first parameter signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1A is a graphic illustration depicting one example of a DIL sequence of the present invention.
[0023] [0023]FIG. 1B is an enlarged portion of the DIL sequence of FIG. 1A., emphasizing training and reference levels.
[0024] [0024]FIG. 2 is a table depicting sign and training patterns for twenty frames of a DIL sequence of one embodiment of the present invention.
[0025] [0025]FIG. 3 is a block diagram depicting the overall communication system in which the present invention operates.
[0026] [0026]FIG. 4 is a schematic diagram of a modem configured in accordance with the present invention.
[0027] [0027]FIG. 5 is a diagram depicting the averaging operation carried out on the slots of the same received training symbol values.
[0028] [0028]FIG. 6 is a graph plotting differences in Ucode values.
[0029] [0029]FIG. 7 is a graph depicting third order modulation distortion using the smooth differences between different Ucodes.
[0030] [0030]FIG. 8 is a block diagram depicting functions carried out in a communications system, which may create digital impairments.
[0031] [0031]FIG. 9 is a partial representation of the block diagram of FIG. 8, emphasizing functional relationships between parts of the communications systems.
[0032] [0032]FIG. 10 is a representation of one of the algorithms used to facilitate the method of the present invention.
[0033] [0033]FIG. 11 is a table illustrating an example of two different test fractions used in the same set of data, illustrating the accuracy of the present invention.
[0034] [0034]FIG. 12 is a graph depicting the plot of some absolute errors against test fractions used in determining the correct pad.
[0035] [0035]FIG. 13 is a flowchart illustrating the basic steps in generating and receiving the DIL pattern to characterize the data channel.
DETAILED DESCRIPTION OF THE INVENTION
[0036] [0036]FIG. 13 is a simplified flowchart illustrating the basic steps in generating and receiving the DIL pattern in order to characterize the data channel. In step 1301 , a client modem transmits sign an amplitude information for the DIL pattern to the server modem. Sign and amplitude data may include training level, reference level, sign pattern, training pattern and DIL segment length.
[0037] Training level may represent a G.711 symbol amplitude that the client modem will use for learning about the data channel. Reference level may represent a G.711 symbol amplitude which is known by the client modem, and used to maintain stability during the DIL sequence. Sign Pattern may represent a series of bits representing the sign of the symbol to be transmitted, for example, 0 being negative and 1 being positive. Training Pattern may represent a series of bits representing the level to be transmitted, for example, 0 being reference, 1 being training. DIL Segment Length may represent the number of frames (6 symbols per frame) in which the current training level and pattern should be transmitted.
[0038] From these parameters, a server modem may generate a DIL sequence as illustrated in step 1302 , for transmission to a client modem. In step 1303 , the client modem received the DIL sequence from the server modem. Since the client modem has defined the parameters of the learning sequence, the client modem can compare the received sequence with an expected sequence (based upon its transmitted parameters) and characterize the data channel based upon the difference between the two signals.
[0039] Note that since the client modem defines the parameters for the DIL sequence, different brands or models of client modems may use different DIL sequences. Since the server modem (in the V.90 specification) will generate a DIL sequence based upon client DIL parameters, the server modem need not be modified to interface with a number of modems of different brand or type. Moreover, DIL sequences may be updated or improved without necessarily changing hardware within the server modem.
[0040] [0040]FIG. 3 depicts a portion of a communications system, which includes a digital public switch telephone network (PSTN) 40 . All of the elements depicted in FIG. 3 represent standard components within a typical communications system. As such, the system depicted in FIG. 3 merely depicts the environment in which the present invention operates. Components such as modem 10 , are part of the present invention and may be altered in terms of the programming provided to DSP 13 and the data found in symbol table 11 .
[0041] DSP 13 may receive stored instructions from RAM/ROM 13 A which may contain software embodying the present invention. Such a “software modem” as the term as known in the art, may be programmed to operate in order to perform different functions. Thus, various means encompassed by the present invention may be realized in a combination of software and hardware as exemplified by DSP 13 and RAM/ROM 13 A.
[0042] The present invention may likewise be found in the data exchanged between client modem 10 and server modem 20 . Otherwise, the components may be typical of those found in conventional systems.
[0043] [0043]FIG. 4 depicts functional circuitry of a client modem 10 which may be used to carry out the operation of the present invention. It is to be understood that the present invention is not limited to a specific communication device or type of communication device. Rather, the devices depicted in FIGS. 3 and 4 are merely exemplary in nature.
[0044] As depicted in FIG. 4, the client modem 10 includes a telephone interface 141 coupled to training circuitry 132 which determines the signal conversion guide values of DAC 32 in the PSTN analog interface 30 , 33 .
[0045] A symbol table 11 is used for storing a constellation of symbols for the upstream and downstream channels. A logic circuit 131 is used for selecting optimal constellations in accordance with conventional functionality as well as carrying out the calculations of the present invention which compensate for variations in pad, IMD and RBS. Such information is transmitted from the client modem 10 to the server modem 20 via interface circuitry 33 , 30 and the digital PSTN 40 . This is accomplished using transmission circuit 121 , operating through the telephone interface 141 .
[0046] Although client modem 10 is depicted as including a number of discrete circuits for each function, it should be recognized that the modem employing the principals of the present invention may be integrated into one or more semiconductor devices without is limitation. Examples of such devices are digital signal processors (DSP) such as device 13 in FIG. 3, microprocessors, Applications Specific Integrated Circuits (ASIC) and programmable read-only memories (PROM).
[0047] In the present invention, training circuitry 132 , or it's functional equivalent, is responsible for sending signaling parameters (such as the designation of the sign and amplitude of the training signals) to the server modem 20 . In the conventional art, the training circuit 132 also operates to determine signal conversion values for ADC 31 and DAC 32 at the server modem 20 . A base constellation stored in symbol table 11 is accessible for the functionality of training circuit 132 , as is the capability of adjusting equalizers (not shown) used in the DAC 15 and ADC 16 of the client modem 10 . This functionality is necessary for carrying out the present invention since coefficients have to be developed to operate on received signals to obtain actual readings as opposed to theoretical or idealized values.
[0048] The structure of the digital portion of the telephone network significantly affects the performance of V.90 type modems. Digital data is transmitted as 8-bit bytes, or symbols, as defined by the G.711 standard. There are six symbols in a frame. The V.90 standard uses U-codes 0 to 127 to represent symbols from both mu-law and A-law, standard G.711 tables. Digital pad, robbed-bit signaling (RBS), CODEC type are the primary digital impairments which must be discovered during each connection to optimize the data rate for that connection. IMD is calculated and removed before the digital impairment estimation. Noise is minimized using averaging, echo is cancelled and Other analog impairments are compensated by the adaptive loops in the modem receiver during training.
[0049] In the present invention, optimization is carried out by calculating the effects on the symbols received from the server modem 20 as caused by such system characteristics as RBS, pad, CODEC, Inter-Modulation Distortion (IMD) and noise. The calculations are performed to determine the effects of each of these factors, as well as other system characteristics, both in the effects on actual signals received and the effects in the correction calculations.
[0050] Through a series of calculations, the effects of each digital impairment is quantized until an error level between received signals and the idealized values in symbol table 11 of the client modem are accurately determined. Once errors can be determined, an optimized co-efficient can be selected from a number of candidate values (described in the present disclose as test fractions). Error levels and test fractions may be used in one embodiment of the present invention to detect the presence of digital pads in the connection.
[0051] Digital pad is a loss measured in dB which reduces the power of the signal being transmitted. Typical pad's are 0 dB, 3 dB, and 6 dB although other pads are possible. A 3 dB pad causes the analog signal at the output of the digital network to be approximately half the power of the digital signal when it is transmitted from the server.
[0052] Robbed-bit Signaling (RBS) is a signaling method used by digital networks to send control data between digital equipment on the telephone network. RBS uses the least-significant bit of the same slot in each frame to send this data. During the connection, this bit may be set to always one, always zero, or toggling one and zero. Therefore, the digital network may change one of every six symbols to a different value than was originally sent.
[0053] RBS may be applied before the pad occurs or after the pad occurs. Depending upon the number of digital links in the phone connection, multiple slots can be used for RBS. For example, the least-significant bit of the second slot in a frame may always be set to one before the pad and the least-significant bit of the third slot in a frame may be toggling one and zero after the pad.
[0054] The structure of the Digital Impairment. Learning (DIL) Sequence is part of the V.90 standard. There are a number of parameters which are set by the client modem 10 and sent to the server modem 20 to define the transmission during the DIL sequence. The purpose of the sequence is for the client modem 10 to learn how the digital channel is structured so optimum constellations can be formed for data transfer.
[0055] A DIL sequence consists of a series of training symbols transmitted by the server modem, whose sign and amplitude are defined by the client modem. Parameters defined by the client modem for a DIL sequence are:
[0056] Training Level—a G.711 symbol amplitude which the client modem will use for learning about the channel;
[0057] Reference Level—a G.711 symbol amplitude which is known by the client modem, and used to maintain stability during the DIL sequence;
[0058] Sign Pattern—a series of bits representing the sign of the symbol to be transmitted, for example, 0 being negative and 1 being positive;
[0059] Training Pattern—a series of bits representing the level to be transmitted, for example, 0 being reference, 1 being training; and,
[0060] DIL-Segment Length—the number of frames (6 symbols per frame) in which the current training level and pattern should be transmitted.
[0061] The training sign pattern is repeated until the end of the DIL-segment at which point they are restarted from the beginning. The magnitudes of the repeated training symbols are averaged together for each data or symbol slot in a frame during each DIL-segment. At the end of a DIL-segment, the six numbers representing the average magnitude of the training symbols for the slots in that segment are stored in a table. These numbers are used for detecting the use of RBS and the pad and IMD in the digital network.
[0062] [0062]FIG. 1 depicts an example of a DIL sequence. The top graph is an entire DIL sequence. The bottom graph is an enlarged portion used to emphasize the training and reference levels.
[0063] An example of a DIL sequence could be
[0064] sign pattern: 1 0 0 1=+−−+;
[0065] training pattern: 0 1 0 1=reference training reference training;
[0066] training levels: 2 3;
[0067] reference levels: 4 4;
[0068] DIL-segment length: 6; and,
[0069] Server transmits: +4 −2 −4 +2 +4 −2 +4 −3 −4 +3 +4 −3.
[0070] The DIL sequence of the present invention uses Ucode 62 as a reference level. This corresponds to G.711 mu-law code 193 which is preferred because it has a least-significant bit of one which is not changed when the digital network has a 0 dB, 3 dB, or 6 dB pad. This allows for an RBS of one, the most common designation, before or after the pad without changing the signal level of the reference symbol.
[0071] There are other Ucodes with this property which may be used with the present invention. Ucode 62 was chosen as one example because it has enough power such that line noise would not have a significant affect on it. The next more powerful Ucode with this pad and RBS invariance property is Ucode 98 which could be affected by other distortions because of its high power. It should be noted that the Ucode 62 and user Ucode 98 were chosen as examples for use with the present invention because of the aforementioned characteristics of these two codes. However, other codes can be used while still maintaining the basic concepts of the present invention.
[0072] In one embodiment the equalizer taps (not shown) in the modem 10 are trained during the initial portion of the DIL using Ucode 62 as both the training and reference signal.
[0073] Signals transmitted through the telephone system are forced to have a zero DC component. Here the DIL sequence sign and training patterns are optimized so that the received levels, both training and reference, will sum to zero for each slot in the received is frames every twenty frames independent of any RBS pattern received.
[0074] This is done while maintaining a pseudo-random pattern during the DIL sequence.
[0075] A pseudo-random pattern is used so the equalizer (not shown) in the client modem 10 can be updated during the DIL sequence. If the equalizer updates are not required, a tonal pattern may be used. The training pattern has seventy percent training symbols and thirty percent reference symbols. This maximizes the number of training symbols while maintaining enough reference symbols to keep the system stable. The sign and training patterns are depicted in the table of FIG. 2. The values in this table are exemplary only, and are not necessarily the proper values for any particular communication system or modems within that system.
[0076] Training levels are used from Ucode 12 to Ucode 119 with lower powered symbols being transmitted for longer periods of time so that more symbols can be averaged together. This reduces the significance of signal variance caused by line noise in lower power symbols. In modems where noise is detected before the DIL, the duration of the DIL-segments can be adjusted to allow for sufficient averaging to remove noise. The higher power training symbols are interleaved with lower power symbols to reduce any distortions caused by excessive power in the signal path.
[0077] The DIL sequence can be provided at any time before the message data is exchanged between the client modem 10 and server modem 20 . For example, both the initial transmission of parameters defining sign and amplitude from the client modem 10 and the resulting DIL can be carried out during the initial hand shake that is conventionally carried out between modems before message data is sent. Conventionally, only predefined sequences are exchanged when two modems initially make contact. However, the DIL sequence can be inserted instead of fixed sequences. In any case, the DIL sequence is sent before any message data (as opposed to the control data which is the subject of this disclosure) is exchanged between the two modems.
[0078] Another impairment, Inter-Modulation Distortion (IMD) is a non-linear distortion that deteriorates the performance of the V.90 modem. IMD creates second and third order components of the signal. Measurement and correction of the third order distortion is necessary for accurate pad detection and constellation limitation. The highest power transmitted symbols are most influenced by this impairment. Once the IMD level is quantified, a decision can be made on which high power points must be excluded from use during a data transfer. IMD levels are measured based on the data received during the Digital Impairment Learning (DIL) sequence. Equation 1 below models the affect of third-order IMD on the symbols received during the DIL sequence.
x′=x+ax 3 Equation 1
[0079] where: x—transmitted symbol
[0080] x′—received symbol
[0081] a—constant
[0082] The IMD measurement algorithm uses a series of averaged received symbols from the DIL sequence. The goal of the algorithm is to measure how much the difference between the symbols is expanding or contracting beyond what is normal. The data from the non-RBS slots in a frame is initially averaged as shown in FIG. 5. If one slot in the frame is used for RBS, then the other five would be averaged.
[0083] The RBS and non-RBS slots are detected by inspecting the differences between adjacent received symbols. Although pads can cause some symbol pairing, resulting in differences equal to zero, RBS causes ever other symbol to pair with an adjacent symbol. Therefore, if a slot in a frame has approximately half its received values paired, then it is an RBS slot. Thirty-four consecutive high level PCM codes corresponding to Ucode 72 to 105 may be used for this as these levels are highly noise immune.
[0084] Once the symbol values have been averaged, the differences between adjacent symbol averages are calculated. One example is provided as follows
[0085] Difference 1=(Average of Ucode 73)−(Average of Ucode72)
[0086] Difference 2=(Average of Ucode 74)−(Average of Ucode 73)
[0087] Difference 3=(Average of Ucode 75)−(Average of Ucode 74)
[0088] [0088]FIG. 6 is a graph depicting a plot of these differences (in adjacent symbol values) for a line with 6.02 dB pad and −45 dB third-order IMD.
[0089] Although the differences between adjacent symbols values will not be the same, most will be multiples (usually by a factor of two) of each other. In FIG. 6, the dominant values are approximately 128, 256, and 512. By doubling the non-zero lower values until they are approximately equal to the maximum value,it is possible to roughly normalize the differences in value. Zeros and other anomalies are replaced by averages of the values of adjacent symbols. Since different pads will produce varying values for the subject differences in adjacent symbol values, the normalized differences are multiplied by a constant that brings the average of the normalized differences to 2048. This removes any variation in the differences caused by pad.
[0090] Third-order IMD can be seen in FIG. 7 as a slope in the data points. IMD is can be quantified by measuring the slope of the sum-of-at-least squares line though the data. This value, designated as the IMD Constant, can be used in the Equation 2 below to remove IMD distortion from the received DIL data so that accurate pad measurements can be made. Instead of subtracting the received symbol value cubed, it is preferable to use the corresponding G.711 linear value for the same Ucode as the received value. This substitution permits an accurate calculation of (by) 3 .
x″=x′−I (by 3 ) Equation 2
[0091] where: x″—received symbol with IMD removed
[0092] x′—received symbol
[0093] I—IMD constant
[0094] b—constant
[0095] y—G.711 symbol for the same Ucode as x′
[0096] The result is stored in a table (such as the symbol table in FIG. 11) before processing Equation 3 is used to limit the maximum constellation point selected to one that is not significantly distorted by IMD. If the magnitude of the IMD Constant is less than 180 h, no constellation limitation is attempted. The minimum point that the constellation will be limited to is Ucode 80.
Last Ucode=110−0.0241I Equation 3
[0097] where: Last Ucode—last allowable Ucode in the constellation
[0098] I—IMD constant
[0099] Digital pad is defined as programmed attenuation that is built into the digital portion of many communication system, such as telephone networks. Accurate measurement of the pad for a communication system is necessary for a V.90 modem to operate at maximum speeds. FIG. 8 is a block diagram depicting various digital impairments and the functions that may cause such impairments in a typical V.90 connection.
[0100] Among the examples are the conversion of PCM to a linear format where PCM is an eight-bit mu-law or A-law digital symbol transmitted over the network. The subject digital symbol represents a signal amplitude. A linear value corresponds to the digital symbol in accordance with the G.711 standard The analog link generally refers to the local twisted-wire pair running from the central office (CO) of the telephone company to the client modem 10 . All of the depicted transformations can bring about variations that might effect the accuracy of digital communications. However, the most profound factors impacting on digital communication accuracy are RBS and pad.
[0101] Robbed-bit signaling is a major impairment which complicates pad measurement by forcing the least-significant bit of the digital byte to be between, one, zero, or alternating one and zero. However, both pad and IMD create the variable effects in the transmitted data stream so that predicting the effects of both of these factors becomes far more problematical than dealing with the known effects of RBS.
[0102] During the Digital Impairment Learning Sequence (DIL) the server 20 transmits a specified symbol amplitude that varies in sign. The digital pad and analog local-loop attenuate this symbol. The client modem 10 compensates for this attenuation by inserting a gain (as depicted in FIG. 9) that will restore the received symbol to its transmitted value. This gain is then fixed for the rest of the connection and applied to all symbols that are received. Once the gain is fixed, a broad range of symbol amplitudes are respectively transmitted by the server, averaged in the client modem, and stored in a table. Due to the Linear to PCM conversion after the pad, not all symbols require exactly the same gain to restore them to their original transmitted level.
[0103] The goal of the pad measurement algorithm (depicted in FIG. 10) is to measure the gain that the modem has applied to the signal resulting from the digital pad while ignoring the portion of the gain that compensates for any analog loss. The algorithm relies on the fact that all symbol levels at the output of the codec 81 are linear values based upon the G.711 standard table. The core logic of the algorithm is that all received symbols can be divided by a constant value equal to the gain applied by the modem due to the digital pad loss and the resulting value will be a corresponding value taken from the G.711 table. FIG. 9 illustrates that the attenuation of the pad, P 1 , is compensated for in the modem by the gain P 2 that is approximately equal to 1/P 1 . It is assumed that the analog loss is exactly compensated for by the gain A 2 . The product P 2 A 2 is the modem system gain.
[0104] The pad measurement algorithm (FIG. 10) is an iterative method that multiplies a range of received symbols from the DIL by various test fractions estimating 1/P 2 between 1.0 and 0.25. Using this range of fractions, pads from 0 to 12.0 dB can be detected. In this equation the function of sliced(x) results in the G.711 value closest to the received sample. The Ucode number refers to PCM symbols sent by the server modem 20 in accordance with V.90 specifications corresponding to the specified Ucode number. The test fraction is a value between 1.0 and 0.25, which is adjusted to result in a minimum error. The purpose of the operation using this equation is to obtain the lowest possible error and a test fraction which corresponds to that error.
[0105] The results of multiplication of the received symbol level and test fraction are subtracted from the nearest G.711 linear values and the absolute differences are summed. This result is then divided by the test fraction to normalize the error sum which makes it independent of the test fraction being used. The test fraction resulting in the minimum error sum is the test fraction that approximates the digital pad. The Ucodes 72 to 105 were chosen for pad measurement because using symbols with larger amplitudes would result in a sensitivity to non-linear distortions and including smaller symbol amplitudes would not affect the error measurement significantly.
[0106] Even though the difference in the test fraction is small, the error generated by the 0.5 test fraction is very large in comparison to the 0.5077 test fraction (See FIG. 11). Since minor deviations in the test fraction result in large deviations in the error sum, the pad measurement algorithm can be accurately determine the system gain due to the digital pad. FIG. 12 is a graph of the plot of the summed absolute errors using the equation of FIG. 10 on a connection with a 6.02 dB pad for all test fractions between 0.25 and 1.0. Minor variations in the error plot will be seen when the algorithm is run on RBS slots, but the pad measurement algorithm is valid for both RBS and non-RBS slots without any modification.
[0107] Equation number 4 below uses the current error at each step of the iterative process determined by the equation of FIG. 10 to result in the next test fraction. The test fraction is initially sent to 1.0 and is iteratively decremented using equation number 4.
TestFraction n + 1 = TestFraction n - Error n × TestFraction n 16 × 32768 - 1 32768 Equation 4
[0108] This method adjusts the test fraction by smaller values as the error becomes smaller. This makes the pad measurement more precise. By adding {fraction (1/32768)}, the step size will never become zero, which would halt the iteration.
[0109] The algorithm (of FIG. 10 and equation number 4) is run twice for DIL data sampled from each slot in the frame. Once for the mu-law G.711 codec values and once for A-law G.711 codec values. This results in the algorithm being run twelve times. A minimum error value and the corresponding test fraction are stored in memory for each run. The six minimum error value for the mu-law test are summed and the six minimum error values for the A-law test are summed. The system, mu-law or A-law, with the lowest summed error is the system to which the client modem is connected. If the summed slot errors are not below 2400 h, then the client modem assumes the same system as the server modem and a 0 dB pad.
[0110] If the summed slot errors are not below 2400 h, then the client modem assumes that the noise in the received DIL data is too high for accurate pad detection. In this case, a flag is established to signify a pad failure, the client modem assumes the same coding system as the server modem (mu-law or A-Law), and the pad value is set to 0 dB to prevent a constellation from being generated that would cause the server modem to exceed the federal limit for transmit power.
[0111] For error sums less than 2400 h, the estimate is refined further by grouping the six test fractions corresponding to the frame slots in the selected PCM coding system into two bins of those with most similar values. The test fractions in the bin with the most pad estimates are averaged together to form the final pad decision. This decision is converted in to a coefficient used to create an accurate symbol table at the client modem 10 to correct for the aforementioned digital impairments.
[0112] Some mu-law codecs violate the G.711 spec in the RBS slot by sending the transmit encode level instead of the receive decode level for a PCM code at its decoder output. These are the D4 channel bank CODECs specified in AT&T Technical Reference, PUB 43801, November 1982. These RBS slots are sometimes referred to as ½ RBS slots. Detecting this further refines the codec decision. This is accomplished by measuring the slot errors using the equation of FIG. 10 at the test fraction equivalent to the final pad decision. The slot with this anomaly will have a maxima at the correct pad decision instead of a minima like all other slots. The error surface of this slot will look like FIG. 12, only upside down.
[0113] It should be noted, for example, that the present invention has been described in terms of “client” and “server” modems in conjunction with the V.90 standard. However, the present invention may be embodied in other types of configurations such as the V.91 or V.92 standard or beyond without departing from the spirit and scope of the present invention. In particular, the present invention may be used in any PCM encode/decode technique.
[0114] Although a number of embodiments of the present invention have been presented by way of example, the present invention should not be construed to be limited thereby. Rather, the present invention should be interpreted to encompass any and all variations, permutations, modifications, adaptations, embodiments and derivations that would occur to one skilled in this art, having been taught the present invention by the instant application. Accordingly, the present invention should be construed as being limited only by the following claims. | A Digital Impairment detection scheme which is designed for providing reliable estimate of digital impairments such as PAD, and CODEC type in the presence of digital impairments such as Robbed Bit Signalling and non G.711 complaint network CODECs and analog impairments such as IMD, noise and changing line conditions. This estimate is used to derive optimum transmit symbol constellations for a modem connected digitally to a trunk so as to maximize its data transmission rate. | 7 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a Divisional of U.S. patent application Ser. No. 10/539,760, filed Feb. 8, 2006, which is the national stage entry of PCT/NZ2003/000282, filed Dec. 22, 2003, which claims priority to New Zealand Application No. 523321, filed Dec. 20, 2002, the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND
The invention comprises an improved form of bath.
A standard bath is filled with generally warm water, from taps or a mixer and spout, and is used for bathing.
A spa bath typically incorporates an intake and a number of spa jets positioned in the bath side walls, and piping around the exterior of the bath, through which water is circulated from an intake to the jets in the side walls of the bath by one or more pumps. A spa bath provides the bathes) with a more luxuriant bathing experience.
SUMMARY
It is an object of the invention to provide an improved or at least alternative form of bath, which further adds to the bathing experience.
In broad terms in one aspect the invention comprises a bath including a water outlet or outlets arranged to in use direct a flow of water onto the upper body of a person or persons sitting in the bad and lea back against a wall or walls of the bath, and a pump and water recirculation system arranged to recirculate a flow of water from the bath through said upper body water outlets onto the shoulders of a bather or bathers in the bath.
In broad terms in another aspect the invention comprises a bath including an end wall section which is approximately convexly curved over at least a part of the height of the wall section and which includes a water outlet on one side of the wall section and another water outlet on another side of the wall section, both of which water outlets are arranged to in use direct a flow of water onto the shoulders and/or neck of a person sitting in the bath leaning against the curved wall section of the bath.
In broad terms in another aspect the invention comprises a bath including an end wall section and upper body water outlets arranged to direct a flow of water from behind onto the shoulders and/or neck of a bather sitting in the bath leaning against the curved wall section of the bath, said upper body water outlet(s) comprising two spaced upper body water outlets one positioned to direct a water flow onto the left-side of a bather and the other positioned to direct a water flow at the same temperature onto the right-side upper body of the bather, said left and right side upper body water outlet fittings being pivotally mounted enabling a bather sitting in the bath to adjust the direction of the water flow from the fittings onto the bathe upper body, each fitting having a hollow interior and a hollow mounting neck by which the fitting is pivotally mounted in an aperture. In the top of the bath wall or in a rim around the top of the bath wall.
In the bath of the invention, water outlets are provided which are positioned to direct a flow of water, typically warm bath water recirculated by a pump, onto the shoulders of a bather or bathers in the bath. It is generally envisaged that two spaced water outlets will be provided in some form, one positioned so that in use it will direct a water flow onto the left-side upper body of the bather and the other positioned so that it will direct a water flow onto the right-side upper body of the bather. However in an alternative form a single water outlet may for example be arranged to direct a wide flow of water across the neck and shoulders region of a bather, from behind. Instead of being recirculated warm bath water, the water flow may be fresh ie non-recirculated water, which is preferably warmed by a water heater.
A standard (single person) bath may include upper body water outlets at one end of the bath only. A bath designed to accommodate two persons sitting in the bath against opposite ends of the bath may incorporate upper body water outlets at both ends of the bath. A bath designed to accommodate two persons sitting side by side may incorporate side by side upper body water outlets arranged to direct water onto the upper body of both bathers. A spa bath or pool designed to accommodate up to three or more persons may incorporate upper body water outlets in accordance with the invention at a number of seating positions around the bath or pool. In this specification the term “bath” is intended to also include spa baths and spa pools, including and also known as spas, whirlpools, and jacuzzis.
Typically the upper body water outlets will be positioned in a junction portion of the bath which joins a wall section of the bath which defines the bath cavity, with a surrounding rim section around the bath cavity. Where two spaced upper body water outlets are provided to direct water flows on to the left and right-sides of a bather or bathers, typically the junction portion between the bath wall section and surrounding rim section will between the upper body water outlets be a smooth joining portion shaped so that it is comfortable for the neck or head of a bather to rest against. Alternatively or additionally the bath may incorporate a pillow formed of a compressible material such as synthetic foam which is positioned between the upper body water outlets to give added comfort to a bather. In a further form of the invention the upper body water outlets may be integral with such a pillow as will be further described. In another form of the invention the upper body water outlets may be positioned on the generally horizontal rim section around the bath cavity or in recesses in such a rim section. The outlets maybe arranged to direct an arching and preferably laminar flow of water onto the upper body or bodies of a bather or bathers.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is fiber illustrated by the following description of embodiments of baths of the invention, which are described by way of example and without intending to be limiting. In the drawings:
FIG. 1 is a view from above showing one form bath of the invention, with a user therein,
FIG. 2 is a view from above one end of the bath of FIG. 1 when empty,
FIGS. 3A and 3B are close up views of the upper body water outlets of the bath of FIG. 1 positioned on either side of a neck pillow,
FIG. 4 is a view from above of one of the pivotable upper body water outlets of the bath of FIGS. 1 to 3 ,
FIG. 5 is a view of the upper body water outlet of FIG. 4 from one end,
FIG. 6 is a cross-section view of the upper body water outlet of FIG. 4 along line A-A of FIG. 34 ,
FIG. 7 shows another form of bath of the invention in which upper body water outlets are integral with a neck-pillow,
FIG. 8 shows a bath of the invention with upper body water outlets mounted in a surrounding rim section of the bath,
FIG. 9 shows a bath in which a single fitting around a curved end wall of a bath provides upper body water outlets which direct a wide flow of water onto the shoulders and neck of a bather, and
FIG. 10 shows a bath of the invention similar to that of FIG. 9 in which a single fitting around a curved end wall of a bath provides upper body water outlets and also supports a neck pillow
DETAILED DESCRIPTION
Referring to FIGS. 1 to 3 , the bath shown therein is a spa bath and incorporates a suction inlet from which water is drawn and a number of spa outlets or jets from which water is pumped back into the bath. The bath has one or more wall sections 1 which are shaped so as to be comfortable for bathers sitting in the bath and leaning back against the wall of the bath. The bath may include water outlets 2 in the curved wall sections 1 as shown in FIG. 2 which direct water against the back of the bather.
At the top of wall sections 1 is optionally provided a pillow 3 which is moulded from a synthetic foam material, and on either side of the pillow are mounted left and right upper body water fittings 4 including outlets 5 , which are also connected to the spa pump or pumps so that they will in use direct a flow of water onto the upper body of a bather sitting in the bath, on both the left and right sides as shown in FIG. 1 . Preferably the fittings 4 provide water outlets 5 which are elongate in shape as shown so that the flow of water from each outlet 5 is wider than it is deep, or laminar, so that when the water flows impact the shoulder and/or neck regions of a bather they will cover and warm as much of the bathers upper body exposed above the water in the bath, as possible. Alternatively however the outlets 5 may comprise a number of smaller elongate or circular outlets for example.
In the bath shown in FIGS. 1 to 3 the upper body water fittings 4 can pivot in the direction of arrows P and/or Q (if both, then through an approximate quadrant arc) as shown in FIGS. 3A and 3B , which enables a bather sitting in the bath to perfect the aim of the water flow onto the bathers upper body.
FIGS. 4 to 6 show a single fitting 4 . The fitting which is elongate in shape between two ends and has a hollow interior and also has a hollow mounting neck 6 extending from closer to one end of the fitting than an opposite end which is in turn carried in a tubular collar 7 fixed in an aperture 18 in the bath wall 1 (shown in phantom in FIG. 4 ), so that a user can pivot the fitting 4 by pushing or pulling the top of the fitting, causing the fitting to rotate in the tubular collar 7 about a generally upright axis V along the fitting 4 . A pipe (not shown) from the water pump of the bath or alternatively a separate pump, connects to the lower end 8 of the tubular collar 7 and O-rings at 9 and 10 seal between the mounting neck 6 and the tubular collar 7 .
In an alternative form upper body water outlet fittings similar to those shown in FIGS. 1-6 may be fixed rater than having the ability to be pivoted by a bather as described. Such fixed fittings may be formed separately from the bath wall or alternatively may be formed as integral shaped moulded portions of the bath wall and/or rim section around the top of the bath wall.
FIG. 7 shows another form of bath of the invention in which neck-shoulder water outlets 5 are integral with a neck-pillow 3 . The neck pillow may be of any desired shape. Apertures through a removable moulded foam pillow may align with water outlets through the wall or horizontal rim of the bath. Optionally the neck pillow including the water outlet apertures 5 may be covered with an open weave material such as a LYCRA™ material which will at least partially conceal the water outlets 5 without significantly interrupting the water flow in use. In another form pivotable neck-shoulder water outlets 5 as in the bath of FIGS. 1 to 3 may comprise flexible wings or ears of a pillow by being over-moulded with moulded foam material from which the pillow 3 is formed. Alternatively the pivotable neck-shoulder water outlets 5 as in FIGS. 1 to 3 may be non-integral with the pillow 3 i.e. separate components, but still be over-moulded or covered with a softer synthetic material.
FIG. 8 shows a bath of the invention with neck-shoulder water outlets 5 in fittings 4 mounted in an upper rim section of the bath. The outlets 5 are again positioned so that they will in use direct a flow of water on to the upper body of person sitting in a bath leaning against the curved wall section 1 of the bath.
FIG. 9 shows a bath of the invention in which a single tubular fitting 7 around curved end wall 1 of the bath provides neck-water outlets 5 as shown. The tubular fitting may be a chromed fitting for example. It may be mounted to the upper rim section of the bath by short upright tubes 8 through which water is supplied to the interior of the tube 7 . The outlets 5 in the tube 7 may comprise a series of slot outlets around approximately the full length of the tube 7 , or slot outlets on either side only, or the outlets may be formed as a series of non-slot shaped apertures.
FIG. 10 shows a bath similar to that of FIG. 9 in which a similar curved fitting 7 around the upper rim section of the bath also supports a moulded foam pillow 3 , and provides neck-shoulder water outlets 5 which direct a laminar flow of water onto the shoulder regions and also neck of a bather.
The foregoing describes the invention including a preferred forms thereof Alterations and modifications as will be obvious to those skilled in the art are intended to be incorporated in the scope hereof. | A bath includes a water outlet or outlets arranged to in use direct a flow of water from behind onto the upper body of a bather or bathers sitting in the bath and leaning back against the wall of the bath. The upper body water outlet(s) may comprise two spaced water outlets one positioned to direct a water flow onto the left-side upper body of a bather and the other positioned to direct a water flow at the same temperature onto the right-side upper body of the bather. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a method of treating disorders of the Central Nervous System (CNS) and other disorders in a mammal, including a human, by administering to the mammal a CNS-penetrant α7 nicotinic receptor agonist. It also relates to pharmaceutical compositions containing a pharmaceutically acceptable carrier and a CNS-penetrant α7 nicotinic receptor agonist.
Schizophrenia is characterized by some or all of the following symptoms: delusions (i.e., thoughts of grandeur, persecution, or control by an outside force), auditory hallucinations, incoherence of thought, loss of association between ideas, marked poverty of speech, and loss of emotional responsiveness. Schizophrenia has long been recognized as a complex disease, which to date has eluded biochemical or genetic characterization. However, recent data in the literature suggest that α7 nicotinic receptor agonists may be therapeutic for this, and other CNS disorders, see: Alder, L. E.; Hoffer, L. D.; Wiser, A.; Freedman, R. Am. J. Psychiatry 1993, 150, 1856; Bickford, P. C.; Luntz-Leybman, V.; Freedman, R. Brain Research, 1993, 607, 33; Stevens, K. E.; Meltzer, J.; Rose, G. M. Psychopharmacology 1995, 119, 163; Freedman, R.; Coon, H.; Myles-Worsley, M.; Orr-Urtreger, A.; Olincy, A.; Davis, A.; Polymeropoulos, M.; Holik, J.; Hopkins, J.; Hoff, M.; Rosenthal, J.; Waldo, M. C.; Reimherr, F.; Wender, P.; Yaw, J.; Young, D. A.; Breese, C. R.; Adams, C.; Patterson, D.; Alder, L. E.; Kruglyak, L.; Leonard, S.; Byerley, W. Proc. Nat. Acad. Sci. USA 1997, 94, 587.
The compositions of the present invention that contain an α7 nicotinic receptor agonist are useful for the treatment of depression. As used herein, the term “depression” includes depressive disorders, for example, single episodic or recurrent major depressive disorders, and dysthymic disorders, depressive neurosis, and neurotic depression; melancholic depression including anorexia, weight loss, insomnia and early morning waking, and psychomotor retardation; atypical depression (or reactive depression) including increased appetite, hypersomnia, psychomotor agitation or irritability, anxiety and phobias, seasonal affective disorder, or bipolar disorders or manic depression, for example, bipolar I disorder, bipolar II disorder and cyclothymic disorder.
Other mood disorders encompassed within the term “depression” include dysthymic disorder with early or late onset and with or without atypical features; dementia of the Alzheimer's type, with early or late onset, with depressed mood; vascular dementia with depressed mood, mood disorders induced by alcohol, amphetamines, cocaine, hallucinogens, inhalants, opioids, phencyclidine, sedatives, hypnotics, anxiolytics and other substances; schizoaffective disorder of the depressed type; and adjustment disorder with depressed mood.
The compositions of the present invention that contain an α7 nicotinic receptor agonist are useful for the treatment of anxiety. As used herein, the term “anxiety” includes anxiety disorders, such as panic disorder with or without agoraphobia, agoraphobia without history of panic disorder, specific phobias, for example, specific animal phobias, social phobias, obsessive-compulsive disorder, stress disorders including post-traumatic stress disorder and acute stress disorder, and generalized anxiety disorders.
“Generalized anxiety” is typically defined as an extended period (e.g. at least six months) of excessive anxiety or worry with symptoms on most days of that period. The anxiety and worry is difficult to control and may be accompanied by restlessness, being easily fatigued, difficulty concentrating, irritability, muscle tension, and disturbed sleep.
“Panic disorder” is defined as the presence of recurrent panic attacks followed by at least one month of persistent concern about having another panic attack. A “panic attack” is a discrete period in which there is a sudden onset of intense apprehension, fearfulness or terror. During a panic attack, the individual may experience a variety of symptoms including palpitations, sweating, trembling, shortness of breath, chest pain, nausea and dizziness. Panic disorder may occur with or without agoraphobia.
“Phobias” includes agoraphobia, specific phobias and social phobias. “Agoraphobia” is characterized by an anxiety about being in places or situations from which escape might be difficult or embarrassing or in which help may not be available in the event of a panic attack. Agoraphobia may occur without history of a panic attack. A “specific phobia” is characterized by clinically significant anxiety provoked by feared object or situation. Specific phobias include the following subtypes: animal type, cued by animals or insects; natural environment type, cued by objects in the natural environment, for example storms, heights or water; blood-injection-injury type, cued by the sight of blood or an injury or by seeing or receiving an injection or other invasive medical procedure; situational type, cued by a specific situation such as public transportation, tunnels, bridges, elevators, flying, driving or enclosed spaces; and other type where fear is cued by other stimuli. Specific phobias may also be referred to as simple phobias. A “social phobia” is characterized by clinically significant anxiety provoked by exposure to certain types of social or performance circumstances. Social phobia may also be referred to as social anxiety disorder.
Other anxiety disorders encompassed within the term “anxiety” include anxiety disorders induced by alcohol, amphetamines, caffeine, cannabis, cocaine, hallucinogens, inhalants, phencychdine, sedatives, hypnotics, anxiolytics and other substances, and adjustment disorders with anxiety or with mixed anxiety and depression.
Anxiety may be present with or without other disorders such as depression in mixed anxiety and depressive disorders. The compositions of the present invention are therefore useful in the treatment of anxiety with or without accompanying depression.
By the use of a CNS-penetrant α7 nicotinic receptor agonist in accordance with the present invention, it is possible to treat depression and/or anxiety in patients for whom conventional antidepressant or antianxiety therapy might not be wholly successful or where dependence upon the antidepressant or antianxiety therapy is prevalent.
SUMMARY OF THE INVENTION
This invention relates to compounds of the formula I
wherein n =1-2;
m=1-2;
o=1-2;
A=O, S or NR 1 ;
B═N or CR 2 ;
Q=N or CR 3 ;
D=N or CR 4 ;
E=N or CR 5 ;
R 1 is H, a straight chain or branched (C 1 -C 8 )alkyl, C(═O)OR 6 , CH 2 R 6 , C(═O)NR 6 R 7 , C(═O)R 6 , or SO 2 R 6 ;
each R 2 , R 3 , R 4 and R 5 is independently selected from F, Cl, Br, I, nitro, cyano, CF 3 , —NR 6 R 7 , —NR 6 C(═O)R 7 , —NR 6 C(═O)NR 7 R 8 , —NR 6 C(═O)OR 7 , —NR 6 S(═O) 2 R 7 , —NR 6 S(═O) 2 NR 7 R 8 , —OR, —OC(═O)R 6 , —OC(═O)OR 6 , —OC(═O)NR 6 R 7 , —OC(═O)SR 6 , —C(═O)OR 6 , —C(═O)R 6 , —C(═O)NR 6 R 7 , —SR 6 , —S(═O)R 6 , —S(═O) 2 R 6 , —S(═O) 2 NR 6 R 7 , and R 6 ;
each R 6 , R 7 , and R 8 is independently selected from H, straight chain or branched (C 1 -C 8 )alkyl, straight chain or branched (C 2 -C 8 )alkenyl, straight chain or branched (C 2 -C 8 )alkynyl, (C 3 -C 8 )cycloalkyl, (C 4 -C 8 )cycloalkenyl, 3-8 membered heterocycloalkyl, (C 5 -C 11 )bicycloalkyl, (C 7 -C 11 )bicycloalkenyl, 5-11 membered heterobicycloalkyl, 5-11 membered heterobicycloalkenyl, (C 6 -C 11 ) aryl, and 5-12 membered heteroaryl; wherein each R 6 , R 7 , and R 8 is optionally substituted with from one to six substituents, independently selected from F, Cl, Br, I, nitro, cyano, CF 3 , —NR 9 R 10 , —NR 9 C(═O)R 10 , —NR 9 C(═O)NR 10 R 11 , —NR 9 C(═O)OR 10 , —NR 9 S(═O) 2 R 10 , —NR 9 S(═O) 2 NR 10 R 11 , —OR 9 , —OC(═O)R 9 , —OC(═O)OR 9 , —OC(═O)NR 9 R 10 , —OC(═O)SR 9 , —C(═O)OR 9 , —C(═O)R 9 , —C(═O)NR 9 R 10 , —SR 9 , —S(═O)R 9 , —S(═O) 2 R 9 , —S(═O) 2 NR 9 R 10 and R 9 ;
each R 9 , R 10 and R 11 is independently selected from H, straight chain or branched (C 1 -C 8 )alkyl, straight chain or branched (C 2 -C 8 )alkenyl, straight chain or branched (C 2 -C 8 )alkynyl, (C 3 -C 8 )cycloalkyl, (C 4 -C 8 )cycloalkenyl, 3-8 membered heterocycloalkyl, (C 5 -C 11 )bicycloalkyl, (C 7 -C 11 )bicycloalkenyl, 5-11 membered heterobicycloalkyl, (5-11 membered) heterobicycloalkenyl, (C 6 -C 11 )aryl or 5-12 membered heteroaryl; wherein each R 9 , R 10 and R 11 is optionally substituted with from one to six substituents independently selected from F, Cl, Br, I, nitro, cyano, CF 3 , —NR 12 R 13 , —NR 12 C(═O)R 13 , —NR 12 C(═O)NR 13 R 14 , —NR 12 C(═O)OR 13 , —NR 12 S(═O) 2 R 13 , —NR 12 S(═O) 2 NR 13 R 14 , —OR 12 , —OC(═O)R 12 , —OC(═O)OR 12 , —OC(═O)NR 12 R 13 , —OC(═O)SR 12 , —C(═O)OR 12 , —C(═O)R 12 , —C(═O)NR 12 R 13 , —SR 12 , —S(═O)R 12 , —S(═O) 2 R 12 , —S(═O) 2 NR 12 R 13 and R 12 ;
each R 12 , R 13 , and R 14 is independently selected from H, straight chain or branched (C 1 -C 8 )alkyl, straight chain or branched (C 2 -C 8 )alkenyl, straight chain or branched (C 2 -C 8 )alkynyl, (C 3 -C 8 )cycloalkyl, (C 4 -C 8 )cycloalkenyl, 3-8 membered heterocycloalkyl, (C 5 -C 11 )bicycloalkyl, (C 7 -C 11 )bicycloalkenyl, 5-11 membered heterobicycloalkyl, 5-11 membered heterobicycloalkenyl, (C 6 -C 11 ) aryl and (5-12 membered) heteroaryl;
or R 2 and R 3 , or R 3 and R 4 , or R 4 and R 5 , may form another 6-membered aromatic or heteroaromatic ring sharing B and Q, or Q and D, or D and E, respectively, and may be optionally substituted with from one to four substitutuents independently selected from the group of radicals set forth in the definition of R 6 , R 7 and R 8 above;
and all enantiomeric, diastereomeric, and tautomeric isomers and pharmaceutically acceptable salts thereof.
More specific embodiments of this invention relate to compounds of the formula I wherein n=1, m=2, and o=1.
More specific embodiments of this invention relate to compounds of the formula I wherein A=S.
More specific embodiments of this invention relate to compounds of the formula I wherein A=NR 1 .
More specific embodiments of this invention relate to compounds of the formula I wherein A=O.
More specific embodiments of this invention relate to compounds of the formula I wherein A=O, B═CR 2 , Q=CR 3 , D=CR 4 , E=CR 5 .
More specific embodiments of this invention relate to compounds of the formula I wherein A=O, B=N, Q=CR 3 , D=CR 4 , E=CR 5 .
More specific embodiments of this invention relate to compounds of the formula I wherein A=O, B=CR 2 , Q=N, D=CR 4 , E=CR 5 .
More specific embodiments of this invention relate to compounds of the formula I wherein A=O, B=CR 2 , Q=CR 3 , D=N, E=CR 5 .
More specific embodiments of this invention relate to compounds of the formula I wherein A=O, B=CR 2 , Q=CR 3 , D=CR 4 , E=N.
The term “alkyl”, as used herein, unless otherwise indicated, includes saturated monovalent hydrocarbon radicals having straight or branched moieties. Examples of alkyl groups include, but are not limited to, methyl, ethyl, propyl, isopropyl, and t-butyl.
The term “alkenyl”, as used herein, unless otherwise indicated, includes alkyl moieties having at least one carbon-carbon double bond wherein alkyl is as defined above. Examples of alkenyl include, but are not limited to, ethenyl and propenyl.
The term “alkynyl”, as used herein, unless otherwise indicated, includes alkyl moieties having at least one carbon-carbon triple bond wherein alkyl is as defined above. Examples of alkynyl groups include, but are not limited to, ethynyl and 2-propynyl.
The term “cycloalkyl”, as used herein, unless otherwise indicated, includes non-aromatic saturated cyclic alkyl moieties wherein alkyl is as defined above. Examples of cycloalkyl include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl. “Bicycloalkyl” groups are non-aromatic saturated carbocyclic groups consisting of two rings. Examples of bicycloalkyl groups include, but are not limited to, bicyclo-[2.2.2]-octyl and norbornyl. The term “cycloalkenyl” and “bicycloalkenyl” refer to non-aromatic carbocyclic cycloalkyl and bicycloalkyl moieties as defined above, except comprising of one or more carbon-carbon double bonds connecting carbon ring members (an “endocyclic” double bond) and/or one or more carbon-carbon double bonds connecting a carbon ring member and an adjacent non-ring carbon (an “exocyclic” double bond). Examples of cycloalkenyl groups include, but are not limited to, cyclopentenyl and cyclohexenyl. A non-limiting example of a bicycloalkenyl group is norborenyl. Cycloalkyl, cycloalkenyl, bicycloalkyl, and bicycloalkenyl groups also include groups similar to those described above for each of these respective categories, but which are substituted with one or more oxo moieties. Examples of such groups with oxo moieties include, but are not limited to oxocyclopentyl, oxocyclobutyl, oxocyclopentenyl, and norcamphoryl.
The term “aryl”, as used herein, unless otherwise indicated, includes an organic radical derived from an aromatic hydrocarbon by removal of one hydrogen atom. Examples of aryl groups include, but are not limited to phenyl and naphthyl.
The terms “heterocyclic” and “heterocycloalkyl”, as used herein, refer to non-aromatic cyclic groups containing one or more heteroatoms, preferably from one to four heteroatoms, each selected from O, S and N. “Heterobicycloalkyl” groups are non-aromatic two-ringed cyclic groups, wherein at least one of the rings contains a heteroatom (O, S, or N). The heterocyclic groups of this invention can also include ring systems substituted with one or more oxo moieties. Examples of non-aromatic heterocyclic groups include, but are not limited to, aziridinyl, azetidinyl, pyrrolidinyl, piperidinyl, azepinyl, piperazinyl, 1,2,3,6-tetrahydropyridinyl, oxiranyl, oxetanyl, tetrahydrofuranyl, tetrahydropyranyl, tetrahydrothienyl, tetrahydrothiopyranyl, piperidino, morpholino, thiomorpholino, thioxanyl, pyrrolinyl, indolinyl, 2H-pyranyl, 4H-pyranyl, dioxanyl, 1,3-dioxolanyl, pyrazolinyl, dihydropyranyl, dihydrothienyl, dihydrofuranyl, pyrazolidinyl, imidazolinyl, imidazolidinyl, 3-azabicyclo[3.1.0]hexanyl, 3-azabicyclo[4.1.0]heptanyl, 3H-indolyl, quinuclidinyl and quinolizinyl.
The term “heteroaryl”, as used herein, refers to aromatic groups containing one or more heteroatoms (O, S, or N). A multicyclic group containing one or more heteroatoms wherein at least one ring of the group is aromatic is a “heteroaryl” group. The heteroaryl groups of this invention can also include ring systems substituted with one or more oxo moieties. Examples of heteroaryl groups include, but are not limited to, pyridinyl, pyridazinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, quinolyl, isoquinolyl, tetrazolyl, furyl, thienyl, isoxazolyl, thiazolyl, oxazolyl, isothiazolyl, pyrrolyl, quinolinyl, isoquinolinyl, indolyl, benzimidazolyl, benzofuranyl, cinnolinyl, indazolyl, indolizinyl, phthalazinyl, pyridazinyl, triazinyl, isoindolyl, purinyl, oxadiazolyl, thiazolyl, thiadiazolyl, furazanyl, benzofurazanyl, benzothiophenyl, benzotriazolyl, benzothiazolyl, benzoxazolyl, quinazolinyl, quinoxalinyl, naphthyridinyl, dihydroquinolyl, tetrahydroquinolyl, dihydroisoquinolyl, tetrahydroisoquinolyl, benzofuryl, furopyridinyl, pyrolopyrimidinyl, and azaindolyl.
The foregoing heteroaryl, heterocyclic and heterocycloalkyl groups may be C-attached or N-attached (where such is possible). For instance, a group derived from pyrrole may be pyrrol-1-yl (N-attached) or pyrrol-3-yl (C-attached).
Examples of specific compounds of this invention are the following compounds of the formula I and their pharmaceutically acceptable salts, hydrates, solvates and optical and other stereoisomers:
4-Benzooxazol-2-yl-1,4-diaza-bicyclo[3.2.2]nonane;
2-(1,4-Diaza-bicyclo[3.2.2]non-4-yl)-1-oxa-3-aza-cyclopenta[b]-naphthalene;
4-Benzothiazol-2-yl-1,4-diaza-bicyclo[3.2.2]nonane;
4-(5-Phenyl-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(1H-Benzoimidazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Phenyl-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
2-(1,4-Diaza-bicyclo[3.2.2]non-4-yl)-3-oxa-1-aza-cyclopenta[a]-naphthalene;
4-(5-Chloro-benzooxazol-2-yl )-1,4-diaza-bicyclo[3.2.2]nonane;
4-(5-Fluoro-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Nitro-benzooxazol-2-yl )-1,4-diaza-bicyclo[3.2.2]nonane;
4-Oxazolo[5,4-b]pyridin-2-yl-1,4-diaza-bicyclo[3.2.2]nonane;
4-Oxazolo[5,4-c]pyridin-2-yl-1,4-diaza-bicyclo[3.2.2]nonane;
4-Oxazolo[4,5-c]pyridin-2-yl-1,4-diaza-bicyclo[3.2.2]nonane;
4-Oxazolo[4,5-b]pyridin-2-yl-1,4-diaza-bicyclo[3.2.2]nonane;
4-(5-Pyridin-3-yl-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]-nonane;
4-(5-Bromo-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Bromo-oxazolo[5,4-b]pyridin-2-yl)-1,4-diaza-bicyclo[3.2.2]-nonane;
4-(5-Iodo-benzooxazol-2-yl )-1,4-diaza-bicyclo[3.2.2]nonane;
4-(4-Nitro-benzooxazol-2-yl )-1,4-diaza-bicyclo[3.2.2]nonane;
4-(5-Nitro-benzooxazol-2-yl )-1,4-diaza-bicyclo[3.2.2]nonane;
4-(5-Methyl-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Methyl-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(5-Methyl-oxazolo[4,5-b]pyridin-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Chloro-5-nitro-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(5-Chloro-6-nitro-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
Benzyl-[2-(1,4-diaza-bicyclo[3.2.2]non-4-yl)-benzooxazol-5-yl]-amine;
[2-(1,4-Diaza-bicyclo[3.2.2]non-4-yl)-benzooxazol-5-yl]-(3-phenyl-allyl)-amine; [2-(1,4-Diaza-bicyclo[3.2.2]non-4-yl)-benzooxazol-5-yl]-pyridin-3-ylmethyl-amine;
Dibenzyl-[2-(1,4-diaza-bicyclo[3.2.2]non4-yl)-benzooxazol-5-yl]-amine;
4-(5-m-Tolyl-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Phenyl-oxazolo[5,4-b]pyridin-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-[5-(4-Trifluoromethyl-phenyl)-benzooxazol-2-yl]-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Bromo-oxazolo[4,5-b]pyridin-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane;
4-(6-Phenyl-oxazolo[4,5-b]pyridin-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane; and
4-(5,7-Dichloro-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane.
Unless otherwise indicated, the term “one or more substituents”, as used herein, refers to from one to the maximum number of substituents possible based on the number of available bonding sites.
The term “treatment”, as used herein, refers to reversing, alleviating, inhibiting the progress of, or preventing the disorder or condition to which such term applies, or one or more symptoms of such condition or disorder. The term “treatment”, as used herein, refers to the act of treating, as “treating” is defined immediately above.
Compounds of formula I may contain chiral centers and therefore may exist in different enantiomeric and diastereomeric forms. Individual isomers can be obtained by known methods, such as optical resolution, optically selective reaction, or chromatographic separation in the preparation of the final product or its intermediate. This invention relates to all optical isomers and all stereoisomers of compounds of the formula I, both as racemic mixtures and as individual enantiomers and diastereoismers of such compounds, and mixtures thereof, and to all pharmaceutical compositions and methods of treatment defined above that contain or employ them, respectively.
In so far as the compounds of formula I of this invention are basic compounds, they are all capable of forming a wide variety of different salts with various inorganic and organic acids. Although such salts must be pharmaceutically acceptable for administration to animals, it is often desirable in practice to initially isolate the base compound from the reaction mixture as a pharmaceutically unacceptable salt and then simply convert to the free base compound by treatment with an alkaline reagent and thereafter convert the free base to a pharmaceutically acceptable acid addition salt. The acid addition salts of the base compounds of this invention are readily prepared by treating the base compound with a substantially equivalent amount of the chosen mineral or organic acid in an aqueous solvent or in a suitable organic solvent, such as methanol or ethanol. Upon careful evaporation of the solvent, the desired solid salt is readily obtained. The acids which are used to prepare the pharmaceutically acceptable acid addition salts of the aforementioned base compounds of this invention are those which form non-toxic acid addition salts, i.e., salts containing pharmaceutically acceptable anions, such as the hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate or bisulfate, phosphate or acid phosphate, acetate, lactate, citrate or acid citrate, tartrate or bi-tartrate, succinate, maleate, fumarate, gluconate, saccharate, benzoate, methanesulfonate, ethanesulfonate, benzenesulfonate, p-toluenesulfonate and pamoate (i.e., 1,1′-methylene-bis-(2-hydroxy-3-naphthoate))salts.
The present invention also includes isotopically labelled compounds, which are identical to those recited in formula I, but for the fact that one or more atoms are replaced by an atom having an atomic mass or mass number different from the atomic mass or mass number usually found in nature. Examples of isotopes that can be incorporated into compounds of the present invention include isotopes of hydrogen, carbon, nitrogen, oxygen, phosphorous, sulfur, fluorine and chlorine, such as 2 H, 3 H, 13 C, 11 C, 14 C, 15 N, 18 O, 17 O, 31 P, 32 P, 35 S, 18 F, and 36 Cl, respectively. Compounds of the present invention, prodrugs thereof, and pharmaceutically acceptable salts of said compounds or of said prodrugs which contain the aforementioned isotopes and/or other isotopes of other atoms are within the scope of this invention. Certain isotopically labelled compounds of the present invention, for example those into which radioactive isotopes such as 3 H and 14 C are incorporated, are useful in drug and/or substrate tissue distribution assays. Tritiated, i.e., 3 H, and carbon-14, i.e., 14 C, isotopes are particularly preferred for their ease of preparation and detectability. Further, substitution with heavier isotopes such as deuterium, i.e., 2 H, can afford certain therapeutic advantages resulting from greater metabolic stability, for example increased in vivo half-life or reduced dosage requirements and, hence, may be preferred in some circumstances. Isotopically labelled compounds of formula I of this invention and prodrugs thereof can generally be prepared by carrying out the procedures disclosed in the Schemes and/or in the Examples and Preparations below, by substituting a readily available isotopically labelled reagent for a non-isotopically labelled reagent.
The present invention also relates to a pharmaceutical composition for the treatment of schizophrenia in a mammal, including a human, comprising an amount of a compound of the formula I, or a pharmaceutically acceptable salt thereof, that is effective in treating schizophrenia and a pharmaceutically acceptable carrier.
The present invention also relates to a method of treating schizophrenia in a mammal, including a human, comprising administering to said mammal an amount of a compound of the formula I, or a pharmaceutically acceptable salt thereof, that is effective in treating schizophrenia.
The present invention also relates to a pharmaceutical composition for the treatment of schizophrenia in a mammal, including a human, comprising an α7 nicotinic receptor agonist compound of the formula I, or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier.
The present invention also relates to a method of treating schizophrenia in a mammal, including a human, comprising administering to said mammal an α7 nicotinic receptor agonizing amount of a compound of the formula I, or a pharmaceutically acceptable salt thereof.
The present invention also relates to a pharmaceutical composition for treating a disorder or condition selected from inflammatory bowel disease (including but not limited to ulcerative colitis, pyoderma gangrenosum and Crohn's disease), irritable bowel syndrome, spastic dystonia, chronic pain, acute pain, celiac sprue, pouchitis, vasoconstriction, anxiety, panic disorder, depression, bipolar disorder, autism, sleep disorders, jet lag, amylotropic lateral sclerosis (ALS), cognitive dysfunction, tinnitus, hypertension, bulimia, anorexia, obesity, cardiac arrythmias, gastric acid hypersecretion, ulcers, pheochromocytoma, progressive supramuscular palsy, chemical dependencies and addictions (e.g., dependencies on, or addictions to nicotine (and/or tobacco products), alcohol, benzodiazepines, barbituates, opioids or cocaine), headache, stroke, traumatic brain injury (TBI), psychosis, Huntington's Chorea, tardive dyskinesia, hyperkinesia, dyslexia, multi-infarct dementia, age related cognitive decline, epilepsy, including petit mal absence epilepsy, senile dementia of the Alzheimer's type (AD), Parkinson's disease (PD), attention deficit hyperactivity disorder (ADHD) and Tourette's Syndrome in a mammal, comprising an amount of a compound of the formula I, or a pharmaceutically acceptable salt thereof, that is effective in treating such disorder or condition and a pharmaceutically acceptable carrier.
The present invention also relates to a method of treating a disorder or condition selected from inflammatory bowel disease (including but not limited to ulcerative colitis, pyoderma gangrenosum and Crohn's disease), irritable bowel syndrome, spastic dystonia, chronic pain, acute pain, celiac sprue, pouchitis, vasoconstriction, anxiety, panic disorder, depression, bipolar disorder, autism, sleep disorders, jet lag, amyotropic lateral sclerosis (ALS), cognitive dysfunction, tinnitus, hypertension, bulimia, anorexia, obesity, cardiac arrythmias, gastric acid hypersecretion, ulcers, pheochromocytoma, progressive supramuscular palsy, chemical dependencies and addictions (e.g., dependencies on, or addictions to nicotine (and/or tobacco products), alcohol, benzodiazepines, barbituates, opioids or cocaine), headache, stroke, traumatic brain injury (TBI), psychosis, Huntington's Chorea, tardive dyskinesia, hyperkinesia, dyslexia, multi-infarct dementia, age related cognitive decline, epilepsy, including petit mal absence epilepsy, senile dementia of the Alzheimer's type (AD), Parkinson's disease (PD), attention deficit hyperactivity disorder (ADHD) and Tourette's Syndrome in a mammal, comprising administering to a mammal in need of such treatment an amount of a compound of the formula I, or a pharmaceutically acceptable salt thereof, that is effective in treating such disorder or condition.
The present invention also relates to a pharmaceutical composition for treating a disorder or condition selected from inflammatory bowel disease (including but not limited to ulcerative colitis, pyoderma gangrenosum and Crohn's disease), irritable bowel syndrome, spastic dystonia, chronic pain, acute pain, celiac sprue, pouchitis, vasoconstriction, anxiety, panic disorder, depression, bipolar disorder, autism, sleep disorders, jet lag, amyotropic lateral sclerosis (ALS), cognitive dysfunction, tinnitus, hypertension, bulimia, anorexia, obesity, cardiac arrythmias, gastric acid hypersecretion, ulcers, pheochromocytoma, progressive supramuscular palsy, chemical dependencies and addictions (e.g., dependencies on, or addictions to nicotine (and/or tobacco products), alcohol, benzodiazepines, barbituates, opioids or cocaine), headache, stroke, traumatic brain injury (TBI), psychosis, Huntington's Chorea, tardive dyskinesia, hyperkinesia, dyslexia, multi-infarct dementia, age related cognitive decline, epilepsy, including petit mal absence epilepsy, senile dementia of the Alzheimer's type (AD), Parkinson's disease (PD), attention deficit hyperactivity disorder (ADHD) and Tourefte's Syndrome in a mammal, comprising an α7 nicotinic receptor agonizing amount of a compound of the formula I, or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier.
The present invention also relates to a method of treating a disorder or condition selected from inflammatory bowel disease (including but not limited to ulcerative colitis, pyoderma gangrenosum and Crohn's disease), irritable bowel syndrome, spastic dystonia, chronic pain, acute pain, celiac sprue, pouchitis, vasoconstriction, anxiety, panic disorder, depression, bipolar disorder, autism, sleep disorders, jet lag, amyotropic lateral sclerosis (ALS), cognitive dysfunction, tinnitus, hypertension, bulimia, anorexia, obesity, cardiac arrythmias, gastric acid hypersecretion, ulcers, pheochromocytoma, progressive supramuscular palsy, chemical dependencies and addictions (, dependencies on, or addictions to nicotine (and/or tobacco products), alcohol, benzodiazepines, barbituates, opioids or cocaine), headache, stroke, traumatic brain injury (TBI), psychosis, Huntington's Chorea, tardive dyskinesia, hyperkinesia, dyslexia, multi-infarct dementia, age related cognitive decline, epilepsy, including petit mal absence epilepsy, senile dementia of the Alzheimer's type (AD), Parkinson's disease (PD), attention deficit hyperactivity disorder (ADHD) and Tourette's Syndrome in a mammal, comprising administering to a mammal in need of such treatment an α7 nicotinic receptor agonizing amount of a compound of the formula I, or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
Compounds of the formula I can be readily prepared according to the methods described below. In the reaction schemes and discussion that follow, m, n, o, A, B, Q, D, and E, unless otherwise indicated, are defined as they are above in the definition of compounds of the formula I.
As used herein, the expression “inert reaction solvent” refers to a solvent system in which the components do not interact with starting materials, reagents, or intermediates of products in a manner which adversely affects the yield of the desired product.
During any of the following synthetic sequences it may be necessary and/or desirable to protect sensitive or reactive groups on any of the molecules concerned. This may be achieved by means of conventional protecting groups, such as those described in T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis , John Wiley & Sons, 1999.
Compounds of the formula I wherein A is an oxygen or sulfur atom can be prepared as illustrated in Scheme 1. Referring to Scheme 1, a compound of the formula II is reacted with a compound of the formula III wherein A is oxygen or sulfur and L is a leaving group (e.g., choride, bromide, methyl sulfide, alkyl sulfide, aryl sulfide, alkyl sulfoxide, or aryl sulfoxide) in the presence or absence of base (e.g., triethylamine, diisopropylamine, pyridine, 2,6-lutidine, sodium or potassium hydroxide, sodium or potassium or cesium carbonate, sodium or potassium tert-butoxide, diisopropylethylamine, or 1,8-diazabicyclo[5.4.0]undec-7-ene) in the presence or absence of an inert reaction solvent such as water, methanol, ethanol, isopropanol, acetonitrile, methylene chloride, chloroform, 1,2-dichloroethane, tetrahydrofuran, diethylether, dioxane, 1,2-dimethoxyethane, benzene, toluene, dimethylformamide, or dimethylsulfoxide. This reaction is typically carried out at a temperature from about −10° C. to about 150° C. In one set of preferred conditions, when A is oxygen, L is methylsulfide and the reaction is carried out in the absence of solvent at a temperature from about 70° C. to about 120° C. In a second set of preferred conditions, when A is oxygen, L is chloride and the reaction is carried out in the presence of triethylamine, diisopropylethylamine, or sodium tert-butoxide in a solvent selected from chloroform, methylene chloride and toluene at a temperature from about 0° C. to about 50° C.
Compounds of the formula I wherein A is NR 1 can be prepared as illustrated in Scheme 2. Referring to Scheme 2, treatment of a compound of the formula II with a compound of the formula IV wherein X is equal to chlorine, bromine, iodine or trimethylmethanesulfonate, preferably chlorine or bromine, affords the desired compound of formula I. This reaction is generally carried out using a palladium catalyst such as palladium (0) tetrakis(triphenylphosphine), palladium (II) acetate, allyl palladium chloride dimer, tris(dibenzylideneacetone)dipalladium (0), tris(dibenzylideneacetone)dipalladium (0) chloroform adduct, palladium (II) chloride or dichloro[1,1′-bis(diphenylphosphino)ferrocene]palladium (II) dichloromethane adduct, preferably tris(dibenzylideneacetone)dipalladium (0), in the presence or absence of a phosphine ligand such as 1,1′-bis(diphenylphosphino)ferrocene, triphenylphosphine, tri-o-tolylphosphine, tri-tert-butylphosphine, 1,2-bis(diphenylphosphino)ethane, 1,3-bis(diphenylphosphino)propane, 2,2′-bis(diphenylphosphino)-1,1′-binaphthyl, 2-biphenyl dicyclohexylphosphine, 2-biphenyl-di-tert-butylphosphine, 2-(N,N-dimethylamino)-2′-di-tert-butylphosphinobiphenyl or 2-(N,N-dimethylamino)-2′-dicyclohexylphosphinobiphenyl, preferably 2,2′-bis(diphenylphosphino)-1,1′-binaphthyl, in the presence of a base such as potassium acetate, sodium acetate, cesium acetate, sodium tert-butoxide, potassium tert-butoxide, sodium carbonate, lithium carbonate, potassium carbonate, cesium carbonate or cesium fluoride, preferably sodium tert-butoxide. Suitable reaction inert solvents for this reaction include, but are not limited to, 1,4-dioxane, acetonitrile, methyl sulfoxide, tetrahydrofuran, ethanol, methanol, 2-propanol and toluene. The preferred solvent is toluene. Suitable reaction temperatures can range from about 0° C. to about 200° C., and are preferably from about 80° C. to about 120° C.
Compounds of the formula II can be prepared using methods analogous to those reported in the literature, see: Rubstov, M. V.; Mikhlina, E. E.; Vorob'eva, V. Ya.; Yanina, A. Zh. Obshch. Khim . (1964), V34, 2222-2226. Compounds of formula III and formula IV can also be prepared by methods analogous to those reported in the literature, see: Lok, R.; Leone, R. E.; Williams, A. J. J. Org. Chem . (1996), 61, 3289-3297; Yamato, M.; Takeuchi, Y.; Hashigaki, K.; Hirota, T. Chem. Pharm. Bull . (1983), 31, 733-736; Chu-Moyer, M. Y.; Berger, R. J. Org. Chem . (1995), 60, 5721-5725; Sato, Y.; Yamada, M.; Yoshida, S.; Soneda, T.; Ishikawa, M.; Nizato, T.; Suzuki, K.; Konno, F. J. Med. Chem . (1998), 41, 3015-3021 and Van Allan, J. A.; Deacon, B. D. Organic Syntheses ; Wiley: New York (1963); Collect. Vol. IV, pp 569-70.
Compounds of the formula I wherein one of the substituents on B, Q, D or E is equal to NR 6 R 7 can be prepared as illustrated in Scheme 3. Referring to Scheme 3, treatment of a compound of formula V wherein one of the substituents on B, Q, D or E is substituted with a nitro group with reducing conditions such as but not limited to zinc, tin or iron and acid, catalytic hydrogenation, tranfer hydrogenolysis or sodium hydrosulfite in an inert reaction solvent such as water, methanol, ethanol, isopropanol, with the preferred conditions being catalytic hydrogenation using palladium on carbon as a catalyst in ethanol at ambient temperature and 50 psi of hyrdogen affords a compound of formula VI wherin the nitro group has been converted to a primary amine. The compound of formula VI can then be treated with a compound of formula VII wherein F and G are defined as R 6 and R 7 above and a reducing agent such as but not limited to sodium triacetoxyborohydride, sodium borohydride, sodium cyanoborohydride, lithium aluminum hydride, catalytic hydrogenation or transfer hydrogenolysis in the presence or absence of an acid such as but not limited to acetic acid, hydrochloric acid, trifluoroacetic acid, sulfuric acid, phosphoric acid or nitric acid in an inert reaction solvent such as chloroform, dichloromethane, 1,2-dichloroethane, acetonitrile, toluene, benzene, ethanol, methanol or water at 0° C. to 100° C. with the preferred conditions being sodium triacetoxyborohydride in 1,2-dichloroethane at 25° C. to 90° C. to afford a compound of formula VIII.
Also referring to Scheme 3, a compound of formula VI and be reacted with a compound of formula IX in which R 6 is as defined above and L is a leaving group (e.g., Cl, Br, I, OSO 2 alkyl, OSO 2 aryl) in the presence or absence of base (e.g., sodium or potassium hydroxide, sodium or potassium or cesium carbonate, sodium or potassium tert-butoxide, sodium or potassium hydrogen carbonate, sodium or potassium acetate) in the presence or absence of an inert reaction solvent such as water, methanol, ethanol, isopropanol, acetonitrile, methylene chloride, chloroform, 1,2-dichloroethane, tetrahydrofuran, diethylether, dioxane, 1,2-dimethoxyethane, benzene, toluene, dimethylformamide, or dimethylsulfoxide at a temperature from about −10° C. to about 150° C. to produce a compound of formula X. The preferred condition are L=Br, in ethanol at 25° C. to 78° C.
Scheme 4 illustrates an alternative preparation of compounds of the formula I wherein B, Q, D, or E is Cl, Br, I or wherein B, Q, D, or E is optionally substituted with a (C 6 -C 11 )aryl or 5-12 membered heteroaryl (R 6 ) group. Referring to Scheme 4, treatment of a compound of the formula XI with a halogenating reagent such as but not limited to Cl 2 , Br 2 , I 2 , N-bromosuccinimide, N-chlorosuccinimide, or N-iodosuccinimide in an inert reaction solvent such as water, acetic acid, methanol, ethanol, tetrhydrofuran, carbon tetrachloride, chloroform, acetonitrile or mixtures thereof in the presence or absence of a base such as potassium acetate, sodium acetate, cesium acetate, sodium carbonate, lithium carbonate, potassium carbonate, cesium carbonate, cesium fluoride n-butyllithium, lithium diisopropyl amide at −78° C. to 100° C.; preferable Br 2 in water and acetic acid with sodium acetate at 25° C. to 100° C. produces a compound of formula XIII where Z is Br. Alternatively, a compound of formula XIII where Z=OTf can be prepared by reaction of a compound of formula XII wherein one of the substituents on B, Q, D, or E is a hydroxy group with trifluoroacetic anyhydride, N-phenyltrifluoromethanesulfonimide, or 2-[N,N-bis(trifluoromethylsulfonyl)amino]-5-chloropyridine in the presence of a base such as but not limited to triethylamine, diethylisopropylamine, lithium diisopropyl amide, potassium diisopropyl amide, lithium hexamethyldisilazide, potassium hexamethyldisilazide, pyridine, lutidine, collidine, sodium or potassium hydroxide, sodium or potassium or cesium carbonate, sodium or potassium tert-butoxide, sodium or potassium hydrogen carbonate, sodium or potassium acetate in an inert reaction solvent such as ether, tetrahydrofuran, 1,2-dimethoxyethane, dioxanes, methylene chloride, chloroform, benzene, toluene at −78° C. to 100° C.; preferable N-phenyltrifluoromethanesulfonimide, lithium diisopropyl amide in THF at −78° C. to 25° C.
Referring to Scheme 4, a compound of the formula I wherein B, Q, D, or E is optionally substituted with a (C 6 -C 11 )aryl or 5-12 membered heteroaryl (R 6 ) group can be prepared from a compound of formula XIII wherein Z is chloro, bromo, iodo or triflate (OTf) by first reacting it with bis(pinacolato)diboron and a palladium catalyst such as palladium (0) tetrakis(triphenylphosphine), palladium (II) acetate, allyl palladium chloride dimer, tris(dibenzylideneacetone)dipalladium (0), tris(dibenzylidene-acetone)dipalladium (0) chloroform adduct, palladium (II) chloride or dichloro[1,1′-bis(diphenylphosphino)ferrocene]palladium (II) dichloromethane adduct, preferably dichloro[1,1′-bis(diphenylphosphino)-ferrocene]palladium (II) dichloromethane adduct, in the presence or absence of a phosphine ligand such as 1,1′-bis(diphenylphosphino)ferrocene, triphenylphosphine, tri-o-tolylphosphine, tri-tert-butylphosphine, 1,2-bis(diphenylphosphino)ethane, 1,3-bis(diphenylphosphino)-propane, BINAP, 2-biphenyl dicyclohexylphosphine, 2-biphenyl-di-tert-butylphosphine, 2-(N,N-dimethylamino)-2′-di-tert-butylphosphino-biphenyl or 2-(N,N-dimethylamino)-2′-dicyclohexylphosphinobiphenyl, preferably 1,1′-bis(diphenylphosphino)ferrocene, and in the presence or absence of a base such as potassium acetate, sodium acetate, cesium acetate, sodium carbonate, lithium carbonate, potassium carbonate, cesium carbonate or cesium fluoride, preferably potassium acetate, to yield a compound of the formula XIV wherein the Z group has been replaced with M, wherein M=borane pinacol ester. Generally, this reaction is carried out in a reaction inert solvent such as 1,4-dioxane, acetonitrile, methyl sulfoxide, tetrahydrofuran, ethanol, methanol, 2-propanol, toluene, preferably methyl sulfoxide, at a temperature from about from 0° C. to about 200° C., preferably from about 80° C. to about 120° C.
Other methods of converting a compound of the formula XIII with the Z group mentioned above into a compound of the formula XIV wherein the Z group is replaced with M, wherein M is boronic acid, boronic acid ester or trialkylstannane, are known in the art. For instance, treatment of a compound of the formula XIII, wherein Z is Br or I, with an alkyl lithium reagent such as, but not limited to n-butyl lithium, sec butyl lithium or tert-butyl lithium, in a solvent such as diethyl ether, tetrahydrofuran, 1,2-dimethoxyethane, hexane, toluene, dioxane or a similar reaction inert solvent, at a temperature from about −100° C. to about 25° C. affords the corresponding compound of the formula XIV wherein Z is Li. Treatment of a solution of this material with a suitable boronic ester such as trimethoxyborane, triethoxyborane or triisopropylborane, followed by a standard aqueous work-up with acid will afford the corresponding compound of the formula XIV wherein M is boronic acid.
Alternatively, treating a mixture of a compound of the formula XIII wherein Z is Br or I and a boronic ester with an alkyl lithium reagent, as described above, followed by a standard aqueous work-up with acid will afford the corresponding compound of formula XIV wherein M is boronic acid. Alternatively, treating a compound of the formula XIII wherein Z is Br or I with an alkyl lithium reagent such as, but not limited to n-butyl lithium, sec butyl lithium or tert-butyl lithium, in a solvent such as dieathyl ether, tetrahydrofuran, dimethoxyethane, hexane, toluene, dioxane or a similar reaction inert solvent, at a temperature from about −100° C. to about 25° C. will afford the corresponding compound of the formula XIV wherein M is Li. Treatment of a solution of this material with a suitable trialkylstannyl halide such as, but not limited to trimethylstannyl chloride or bromide or tributylstannyl chloride or bromide, followed by a standard aqueous work-up will afford the corresponding compound of the formula XIV wherein M is trimethyl or tributylstannane.
Referring to Scheme 4, treatment of a compound of the formula XIV wherein M is a boronic acid, boronic ester, or trialkylstannane group, with an aryl or heteroaryl chloride, aryl or heteroaryl bromide, aryl or heteroaryl iodide, or aryl or heteroaryl triflate of the formula XV, preferably an aryl or heteroaryl bromide, with a palladium catalyst such as palladium (0) tetrakis(triphenylphosphine), palladium (II) acetate, allyl palladium chloride dimer, tris(dibenzylideneacetone)dipalladium (0), tris(dibenzylideneacetone)dipalladium (0) chloroform adduct, palladium (II) chloride or dichloro[1,1 ′-bis(diphenylphosphino)ferrocene]palladium (II) dichloromethane adduct, preferably dichloro[1,1′-bis(diphenylphosphino)-ferrocene]palladium (II) dichloromethane adduct, in the presence or absence of a phosphine ligand such as 1,1′-bis(diphenylphosphino)ferrocene, triphenylphosphine, tri-o-tolylphosphine, tri-tert-butylphosphine, 1,2-bis(diphenylphosphino)ethane, 1,3-bis(diphenylphosphino)-propane, BINAP, 2-biphenyl dicyclohexylphosphine, 2-biphenyl-di-tert-butylphosphine, 2-(N,N-dimethylamino)-2′-di-tert-butylphosphino-biphenyl or 2-(N,N-dimethylamino)-2′-dicyclohexylphosphinobiphenyl, preferably 1,1′-bis(diphenylphosphino)ferrocene, and in the presence or absence of a base such as potassium phosphate, potassium acetate, sodium acetate, cesium acetate, sodium carbonate, lithium carbonate, potassium carbonate, cesium fluoride or cesium carbonate, preferably potassium phosphate, affords a compound of formula XVII. This reaction is typically carried out in a reaction inert solvent such as 1,4-dioxane, acetonitrile, methyl sulfoxide, tetrahydrofuran, ethanol, methanol, 2-propanol, or toluene, preferably 1,4-dioxane, in the presence or absence of from about 1%-about 10% water, preferably about 5% water, at a temperature from about 0° C. to about 200° C., preferably from about 60° C. to about 100° C.
Referring to Scheme 4, alternatively, a compound of the formula Xil can be reacted with a compound of the formula XVI, wherein M is a boronic acid, boronic acid ester, borane pinacol ester or trialkylstannane group, in the presence of a palladium catalyst such as palladium (0) tetrakis(triphenylphosphine), palladium (II) acetate, allyl palladium chloride dimer, tris(dibenzylideneacetone)dipalladium (0), tris(dibenzylideneacetone)dipalladium (0) chloroform adduct, palladium (II) chloride or dichloro[1,1′-bis(diphenylphosphino)ferrocene]palladium (II) dichloromethane adduct, preferably palladium (II) acetate, in the presence or absence of a phosphine ligand such as 1,1′-bis(diphenylphosphino)ferrocene, triphenylphosphine, tri-o-tolylphosphine, tri-tert-butylphosphine, 1,2-bis(diphenylphosphino)ethane, 1,3-bis(diphenylphosphino)-propane, BINAP, 2-biphenyl dicyclohexylphosphine, 2-biphenyl-di-tert-butylphosphine, 2-(N,N-dimethylamino)-2′-di-tert-butylphosphino-biphenyl or 2-(N,N-dimethylamino)-2′-dicyclohexylphosphinobiphenyl, preferably 2-(N,N-dimethylamino)-2′-dicyclohexylphosphinobiphenyl, and in the presence or absence of a base such as potassium phosphate, potassium acetate, sodium acetate, cesium acetate, sodium carbonate, lithium carbonate, potassium carbonate, cesium fluoride or cesium carbonate, preferably cesium fluoride, affords a compound of formula XVII. This reaction is typically carried out in a reaction inert solvent such as 1,4-dioxane, 1,2-dimethoxyethane, acetonitrile, methyl sulfoxide, tetrahydrofuran, ethanol, methanol, 2-propanol, or toluene, preferably 1,2-dimethoxyethane, in the presence or absence of from about 1% to about 10% triethylamine, preferably about 1% triethylamine, at a temperature from about 0° C. to about 200° C., preferably from about 60° C. to about 100° C.
Isolation and purification of the products can be accomplished by standard procedures that are known to a chemist of ordinary skill.
In each of the reactions discussed above, or illustrated in Schemes 1-4, above, pressure is not critical unless otherwise indicated. Pressures from about 0.5 atmospheres to about 5 atmospheres are generally acceptable, with ambient pressure, i.e., about 1 atmosphere, being preferred as a matter of convenience.
The compounds of the formula I and their pharmaceutically acceptable salts (hereafter “the active compounds”) can be administered via either the oral, transdermal (e.g., through the use of a patch), intranasal, sublingual, rectal, parenteral or topical routes. Transdermal and oral administration are preferred. These compounds are, most desirably, administered in dosages ranging from about 0.25 mg up to about 1500 mg per day, preferably from about 0.25 to about 300 mg per day in single or divided doses, although variations will necessarily occur depending upon the weight and condition of the subject being treated and the particular route of administration chosen. However, a dosage level that is in the range of about 0.01 mg to about 10 mg per kg of body weight per day is most desirably employed. Variations may nevertheless occur depending upon the weight and condition of the persons being treated and their individual responses to said medicament, as well as on the type of pharmaceutical formulation chosen and the time period and interval during which such administration is carried out. In some instances, dosage levels below the lower limit of the aforesaid range may be more than adequate, while in other cases still larger doses may be employed without causing any harmful side effects, provided that such larger doses are first divided into several small doses for administration throughout the day.
The active compounds can be administered alone or in combination with pharmaceutically acceptable carriers or diluents by any of the several routes previously indicated. More particularly, the active compounds can be administered in a wide variety of different dosage forms, e.g., they may be combined with various pharmaceutically acceptable inert carriers in the form of tablets, capsules, transdermal patches, lozenges, troches, hard candies, powders, sprays, creams, salves, suppositories, jellies, gels, pastes, lotions, ointments, aqueous suspensions, injectable solutions, elixirs, syrups, and the like. Such carriers include solid diluents or fillers, sterile aqueous media and various non-toxic organic solvents. In addition, oral pharmaceutical compositions can be suitably sweetened and/or flavored. In general, the active compounds are present in such dosage forms at concentration levels ranging from about 5.0% to about 70% by weight.
For oral administration, tablets containing various excipients such as microcrystalline cellulose, sodium citrate, calcium carbonate, dicalcium phosphate and glycine may be employed along with various disintegrants such as starch (preferably corn, potato or tapioca starch), alginic acid and certain complex silicates, together with granulation binders like polyvinylpyrrolidone, sucrose, gelatin and acacia. Additionally, lubricating agents such as magnesium stearate, sodium lauryl sulfate and talc can be used for tabletting purposes. Solid compositions of a similar type may also be employed as fillers in gelatin capsules; preferred materials in this connection also include lactose or milk sugar, as well as high molecular weight polyethylene glycols. When aqueous suspensions and/or elixirs are desired for oral administration the active ingredient may be combined with various sweetening or flavoring agents, coloring matter and, if so desired, emulsifying and/or suspending agents, together with such diluents as water, ethanol, propylene glycol, glycerin and various combinations thereof.
For parenteral administration, a solution of an active compound in either sesame or peanut oil or in aqueous propylene glycol can be employed. The aqueous solutions should be suitably buffered (preferably pH greater than 8), if necessary, and the liquid diluent first rendered isotonic. These aqueous solutions are suitable for intravenous injection purposes. The oily solutions are suitable for intraarticular, intramuscular and subcutaneous injection purposes. The preparation of all these solutions under sterile conditions is readily accomplished by standard pharmaceutical techniques well known to those skilled in the art.
It is also possible to administer the active compounds topically and this can be done by way of creams, a patch, jellies, gels, pastes, ointments and the like, in accordance with standard pharmaceutical practice.
The effectiveness of the active compounds in suppressing nicotine binding to specific receptor sites can be determined by the following procedure, which is a modification of the methods of Lippiello, P. M. and Fernandes, K. G. (in “The Binding of L-[ 3 H]Nicotine To A Single Class of High-Affinity Sites in Rat Brain Membranes”, Molecular Pharm., 29, 448-54, (1986)) and Anderson, D. J. and Arneric, S. P. (in “Nicotinic Receptor Binding of 3 H-Cystisine, 3 H-Nicotine and 3 H-Methylcarmbamylcholine In Rat Brain”, European J. Pharm., 253, 261-67 (1994)). Male Sprague-Dawley rats (200-300 g) from Charles River were housed in groups in hanging stainless steel wire cages and were maintained on a 12 hour light/dark cycle (7 a.m.-7 p.m. light period). They received standard Purina Rat Chow and water ad libitum. The rats were killed by decapitation. Brains were removed immediately following decapitation. Membranes were prepared from brain tissue according to the methods of Lippiello and Fernandez ( Molec. Pharmacol., 29, 448-454, (1986)) with some modifications. Whole brains were removed, rinsed with ice-cold buffer, and homogenized at 0° in 10 volumes of buffer (w/v) using a Brinkmann Polytron™ (Brinkmann Instruments Inc., Westbury, N.Y.), setting 6, for 30 seconds. The buffer consisted of 50 mM Tris HCl at a pH of 7.5 at room temperature. The homogenate was sedimented by centrifugation (10 minutes; 50,000×g; 0° to 4° C.). The supernatant was poured off and the membranes were gently resuspended with the Polytron and centrifuged again (10 minutes; 50,000×g; 0° C. to 4° C.). After the second centrifugation, the membranes were resuspended in assay buffer at a concentration of 1.0 g/100 mL. The composition of the standard assay buffer was 50 mM Tris HCl, 120 mM NaCl, 5 mM KCl, 2 mM MgCl 2 , 2 mM CaCl 2 and had a pH of 7.4 at room temperature.
Routine assays were performed in borosilicate glass test tubes. The assay mixture typically consisted of 0.9 mg of membrane protein in a final incubation volume of 1.0 mL. Three sets of tubes were prepared wherein the tubes in each set contained 50 μL of vehicle, blank, or test compound solution, respectively. To each tube was added 200 μL of [ 3 H]-nicotine in assay buffer followed by 750 μL of the membrane suspension. The final concentration of nicotine in each tube was 0.9 nM. The final concentration of cytisine in the blank was 1 μM. The vehicle consisted of deionized water containing 30 μL of 1 N acetic acid per 50 mL of water. The test compounds and cytisine were dissolved in vehicle. Assays were initiated by vortexing after addition of the membrane suspension to the tube. The samples were incubated at 0° to 4° C. in an iced shaking water bath. Incubations were terminated by rapid filtration under vacuum through Whatman GF/B™ glass fiber filters (Brandel Biomedical Research & Development Laboratories, Inc., Gaithersburg, Md.) using a Brandel™ multi-manifold tissue harvester (Brandel Biomedical Research & Development Laboratories, Inc., Gaithersburg, Md.). Following the initial filtration of the assay mixture, filters were washed two times with ice-cold assay buffer (5 ml each). The filters were then placed in counting vials and mixed vigorously with 20 ml of Ready Safe™ (Beckman, Fullerton, Calif.) before quantification of radioactivity. Samples were counted in a LKB Wallac Rackbeta™ liquid scintillation counter (Wallac Inc., Gaithersburg, Md.) at 40-50% efficiency. All determinations were in triplicate.
Calculations: Specific binding (C) to the membrane is the difference between total binding in the samples containing vehicle only and membrane (A) and non-specific binding in the samples containing the membrane and cytisine (B), i.e.,
Specific binding=( C )=( A )−( B ).
Specific binding in the presence of the test compound (E) is the difference between the total binding in the presence of the test compound (D) and non-specific binding (B), i.e., (E)=(D)−(B).
% Inhibition=(1−(( E )/( C )) times 100.
The compounds of the invention that were tested in the above assay exhibited IC 50 values of less than 100 μM.
[ 125 I]-Bungarotoxin binding to nicotinic receptors in GH 4 Cl cells: Membrane preparations were made for nicotinic receptors expressed in GH 4 Cl cell line. Briefly, one gram of cells by wet weight were homogenized with a polytron in 25 mls of buffer containing 20 mM Hepes, 118 mM NaCl, 4.5 mM KCl, 2.5 mM CaCl 2 , 1.2 mM MgSO 4 , pH 7.5. The homogenate was centrifuged at 40,000×g for 10 min at 4° C., the resulting pellet was homogenized and centrifuged again as described above. The final pellet was resuspended in 20 mls of the same buffer. Radioligand binding was carried out with [ 125 I] alpha-bungarotoxin from New England Nuclear, specific activity about 16 uCi/ug, used at 0.4 nM final concentration in a 96 well microtiter plate. The plates were incubated at 37° C. for 2 hours with 25 μl drugs or vehicle for total binding, 100 μl [ 125 I] Bungarotoxin and 125 μl tissue preparation. Nonspecific binding was determined in the presence of methyllycaconitine at 1 μM final concentration. The reaction was terminated by filtration using 0.5% Polyethylene imine treated Whatman GF/B™ glass fiberfilters (Brandel Biomedical Research & Development Laboratories, Inc., Gaithersburg, Md.) on a Skatron cell harvester (Molecular Devices Corporation, Sunnyvale, Calif.) with ice-cold buffer, filters were dried overnight, and counted on a Beta plate counter using Betaplate Scint. (Wallac Inc., Gaithersburg, Md.). Data are expressed as IC50's (concentration that inhibits 50% of the specific binding) or as an apparent Ki, IC50/1+[L]/KD. [L]=ligand concentration, KD=affinity constant for [ 125 I] ligand determined in separate experiment.
The compounds of the invention that were tested in the above assay exhibited IC 50 values of less than 10 μM.
[ 125 I]-Bungarotoxin binding to alpha1 nicotinic receptors in Torpedo electroplax membranes: Frozen Torpedo electroplax membranes (100 μl) were resuspended in 213 mls of buffer containing 20 mM Hepes, 118 mM NaCl, 4.5 mM KCl, 2.5 mM CaCl 2 , 1.2 mM MgSO 4 , pH 7.5 with 2 mg/ml BSA. Radioligand binding was carried out with [ 125 I] alpha-bungarotoxin from New England Nuclear, specific activity about 16 uCi/ug, used at 0.4 nM final concentration in a 96 well microtiter plate. The plates were incubated at 37° C. for 3 hours with 25 μl drugs or vehicle for total binding, 100 μl [ 125 I] Bungarotoxin and 125 μl tissue preparation. Nonspecific binding was determined in the presence of alpha-bungarotoxin at 1 μM final concentration. The reaction was terminated by filtration using 0.5% Polyethylene imine treated GF/B filters on a Brandel cell harvester with ice-cold buffer, filters were dried overnight, and counted on a Beta plate counter using Betaplate Scint. Data are expressed as IC50's (concentration that inhibits 50% of the specific binding) or as an apparent Ki, IC50/1 +[L]/KD. [L]=ligand concentration, KD=affinity constant for [ 125 I] ligand determined in separate experiment.
The compounds of the invention that were tested in the above assay exhibited IC 50 values of less than 100 μM.
5-HT 3 Receptor Binding in NG-108 Cells Using 3H-LY278584: NG-108 cells endogenously express 5-HT 3 receptors. Cells are grown in DMEM containing 10% fetal bovine serum supplemented with L-glutamine (1:100). Cells are grown to confluence and harvested by removing the media, rinsing the flasks with phosphate buffered saline (PBS) and then allowed to sit for a 2-3 minutes with PBS containing 5 mM EDTA. Cells are dislodged and poured into a centrifuge tube. Flasks are rinsed with PBS and added to centrifuge tube. The cells are centrifuged for ten minutes at 40,000×g (20,000 rpm in Sorvall SS34 rotor(Kendro Laboratory Products, Newtown, Conn.)). The supernatant is discarded (into chlorox) and at this point the remaining pellet is weighed and can be stored frozen (−80 degrees C.) until used in the binding assay. Pellets (fresh or frozen −250 mgs per 96 well plate) are homogenized in 50 mM Tris HCl buffer containing 2 mM MgCl 2 (pH 7.4) using a Polytron homogenizer (setting 15,000 rpm) for ten seconds. The homogenate is centrifuged for ten minutes at 40,000×g. The supernatant is discarded and the pellet resuspended with the Polytron in fresh ice-cold 50 mM Tris HCl containing 2 mM MgCl 2 (pH 7.4) buffer and centrifuged again. The final pellet is resuspended in assay buffer (50 mM Tris HCl buffer (pH 7.4 at 37° C. degrees) containing 154 mM NaCl,) for a final tissue concentration of 12.5 mg per mL buffer (1.25× final concentration). Incubations were initiated by the addition of tissue homogenate to 96 well polypropylene plates containing test compounds that have been diluted in 10% DMSO/50 mM Tris buffer and radioligand (1 nM final concentration of 3H-LY278584). Nonspecific binding was determined using a saturating concentration of a known potent 5-HT 3 antagonist (10 μM ICS-205930). After an hour incubation at 37° C. in a water bath, the incubation is ended by rapid filtration under vacuum through a fire-treated Whatman. GF/B glass fiber filter (presoaked in 0.5% Polyethylene imine for two hours and dried) using a 96 well Skatron Harvester (3 sec pre-wet; 20 seconds wash; 15 seconds dry). Filters are dried overnight and then placed into Wallac sample bags with 10 mLs BetaScint. Radioactivity is quantified by liquid scintillation counting using a BetaPlate counter (Wallac, Gaithersburg, Md.). The percent inhibition of specific binding is calculated for each concentration of test compound. An IC50 value (the concentration which inhibits 50% of the specific binding) is determined by linear regression of the concentration-response data (log concentration vs. logit percent values). Ki values are calculated according to Cheng & Prusoff−Ki=IC50/(1+(L/Kd)), where L is the concentration of the radioligand used in the experiment and the Kd value is the dissociation constant for the radioligand determined in separate saturation experiments.
The compounds of the invention that were tested in the above assay exhibited IC 50 values of less than 100 μM.
The following experimental examples illustrate but do not limit the present invention. In the examples, commercial reagents were used without further purification. Purification by chromatography was done on prepacked silica columns from Biotage (Dyax Corp, Biotage Division, Charlottesville, Va.). Melting points (mp) were obtained using a Mettler Toledo FP62 melting point apparatus (Mettler-Toledo, Inc., Worthington, Ohio) with a temperature ramp rate of 10° C./min and are uncorrected. Proton nuclear magnetic resonance ( 1 H NMR) spectra were recorded in deuterated solvents on a Varian INOVA400 (400 MHz) spectrometer (Varian NMR Systems, Palo Alto, Calif.). Chemical shifts are reported in parts per million (ppm, δ) relative to Me 4 Si (δ 0.00). Proton NMR splitting patterns are designated as singlet (s), doublet (d),-triplet (t), quartet (q), quintet (quin), sextet (sex), septet (sep), multiplet (m) apparent (ap) and broad (br). Coupling constants are reported in hertz (Hz). Carbon-13 nuclear magnetic resonance ( 13 C NMR) spectra were recorded on a Varian INOVA400 (100 MHz). Chemical shifts are reported in ppm (δ) relative to the central line of the 1:1:1 triplet of deuterochloroform (δ 77.00), the center line of deuteromethanol (δ 49.0) or deuterodimethylsulfoxide (δ 39.7). The number of carbon resonance's reported may not match the actual number of carbons in some molecules due to magnetically and chemically equivalent carbons and may exceed the number of actual carbons due to conformational isomers. Mass spectra (MS) were obtained using a Waters ZMD mass spectrometer using flow injection atmospheric pressure chemical ionization (APCI) (Waters Corporation, Milford, Mass.). Gas chromatography with mass detection (GCMS) were obtained using a Hewlett Packard HP 6890 series GC system with a HP 5973 mass selective detector and a HP-1 (crosslinked methyl siloxane) column (Agilent Technologies, Wilmington, Del.). HPLC spectra were recorded on a Hewlett Packard 1100 series HPLC system with a Zorbax SB-C8, 5 μm, 4.6×150 mm column (Agilent Technologies, Wilmington, Del.) at 25° C. using gradient elution. Solvent A is water, Solvent B is acetonitrile, Solvent C is 1% trifluoroacetic acid in water. A linear gradient over four minutes was used starting at 80% A, 10% B, 10% C and ending at 0% A, 90% B, 10% C. The eluent remained at 0% A, 90% B, 10% C for three minutes. A linear gradient over one minute was used to return the eluent to 80% A, 10% B, 10% C and it was held at this until the run time equaled ten minutes. Room temperature (RT) refers to 20-25° C. The abbreviations “h” and “hrs” refer to “hours”. 1,4-Diaza-bicyclo[3.2.2]nonane was prepared via slight modifications of the published procedure: see, Rubstov, M. V.; Mikhlina, E. E.; Vorob'eva, V. Ya.; Yanina, A. Zh. Obshch. Khim. 1964, V34, 2222-2226.
EXAMPLE 1
4-BENZOOXAZOL-2-YL-1,4-DIAZA-BICYCLO[3.2.2]NONANE
2-Chlorobenzoxazole (Aldrich, 99 μL, 0.87 mmol) was added to a solution of 1,4-diazabicyclo[3.2.2]nonane (100 mg, 0.79 mmol) in methanol (2.65 mL) at 0° C. The reaction mixture was allowed to slowly warm to RT. After a period of 16 h iPr 2 NEt (138 μL, 0.79 mmol) was added and the mixture was stirred at RT for 4.5 h at which time it was diluted with CHCl 3 and NaHCO 3 . The layers were partitioned and the aqueous layer was extracted with CHCl 3 (×3). The combined organic layers were washed with H 2 O and brine, dried (Na 2 SO 4 ), filtered and concentrated. The crude residue was purified by chromatography (Biotage, 12L) eluting with 4% MeOH in CHCl 3 containing 20 drops of NH 4 OH per liter of eluent to afford 67 mg (35%) of the title compound as a yellow oil: 1 H NMR (CDCl 3 , 400 MHz) δ 7.30 (d, 1H, J=7.5 Hz), 7.19 (d, 1H, J=7.9 Hz), 7.10 (t, 1H, J=7.5 Hz), 6.94 (t, 1H, J=7.9 Hz), 4.46 (s, 1H), 3.87, (t, 2H, J=5.8 Hz), 3.12-2.92 (m, 6H), 2.15-2.05 (m, 2H), 1.79-1.70 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 161.8, 148.9, 143.7, 124.1, 120.3, 116.1, 108.7, 57.3, 50.3, 46.5, 44.4, 27.1; MS (Cl) m/z 244.3 (M+1). The hydrochloride salt was prepared by dissolving the title compound in iPrOH and adding 0.1 mL of 6 M hydrochloric acid.
EXAMPLE 2
4-BENZOTHIAZOL-2-YL-1,4-DIAZA-BICYCLO[3.2.2]NONANE
2-Chlorobenzothiazole (Aldrich, 109 μL, 0.841 mmol) was added to a solution of 1,4-diazabicyclo[3.2.2]nonane (57%, 169 mg, 0.765 mmol), Et 3 N (213 μL, 1.53 mmol) in DMF (2.5 mL). The reaction mixture was heated at 100° C. for 2 h. The mixture was allowed to cool to RT, diluted with EtOAc and H 2 O and the layers were partitioned. The aqueous layer was extracted with EtOAc (3×) and the combined organic extracts were washed successively with H 2 O and brine and then dried (Na 2 SO 4 ), filtered and concentrated. The crude residue was purified by chromatography (Biotage, 12L) eluting with 5% MeOH in CHCl 3 to afford 68 mg (34%) of the title compound as a yellow oil: 1 H NMR (CDCl 3 , 400 MHz) δ 7.58 (d, 1H, J=7.9 Hz), 7.57 (d, 1H, J=7.9 Hz), 7.27 (t, 1H, J=8.3 Hz), 7.04 (td, 1H, J=7.9, 1.2 Hz), 4.31 (s, 1H), 3.92 (t, 2H, J=5.8 Hz), 3.19-2.98 (m, 6H), 2.25-2.16 (m, 2H), 1.84-1.77 (m, 2H), MS (Cl) m/z 260.2 (M+1). The hydrochloride salt was prepared by dissolving the title compound in iPrOH and adding 0.1 mL of 6 M hydrochloric acid.
The 2-mercaptobenzoxazoles were prepared by two different methods and the general procedures are described in the literature, see: Sato, Y.; Yamada, M.; Yoshida, S.; Soneda, T.; Ishikawa, M.; Nizato, T.; Suzuki, K.; Konno, F. J. Med. Chem. 1998, 41, 3015-3021 and Van Allan, J. A.; Deacon, B. D. Organic Syntheses ; Wiley: New York, 1963; Collect. Vol. IV, pp 569-70.
EXAMPLE 3
5-PHENYL-3H-BENZOOXAZOLE-2-THIONE
Carbon disulfide (7.7 mL) was added to a mixture of 2-amino-4-phenylphenol (1.0 g, 5.4 mmol), potassium hydroxide (0.36 g, 6.5 mmol) and ethanol (11.7 mL). The flask was fitted with a reflux condenser and the resulting mixture was placed in an oil bath at 60° C. for 16 h. After cooling to RT, the mixture was concentrated and ethyl acetate (20 mL) and 1 M hydrochloric acid (10 mL) were added to the residue. The layers were partitioned and the organic layer was washed successively with 1 M HCl, water and brine. The organic layer was dried (Na 2 SO 4 ), filtered and concentrated to afford 1.20 g (98%) which was used without further purification: 1 H NMR (d6-DMSO, 400 MHz) δ 13.98 (s, 1H), 7.64-7.62 (m, 2H), 7.58-7.49 (m, 2H), 7.46-7.42 (m, 2H), 7.39-7.33 (m, 2H); 13 C (d6-DMSO, 400 MHz) δ 181.2, 148.2, 140.1, 138.5, 132.7, 129.7, 128.3, 127.7, 123.4, 111.0, 109.1; MS (Cl) m/z 228.1 (M+1); HPLC retention time=3.09 min.
EXAMPLE 4
2-AMINO-4-BROMOPHENOL
A solution of KOH (5.14 g, 91.7 mmol) in water (33 mL) was added to 4-bromo-2-nitrophenol (Aldrich, 1.00 g, 4.59 mmol). Sodium hydrosulfite (7.98 g, 45.9 mmol) was added in one portion. The mixture was stirred at RT for 30 min. and poured into ethyl acetate (25 mL). The layers were partitioned and the aqueous layer was extracted with ethyl acetate (4×25 mL). The combined organic layers were dried (Na 2 SO 4 ), filtered and concentrated to give 488 mg (56%) of the title compound which was used without further purification: 1 H NMR (CDCl 3 , 400 MHz) δ 6.77 (d, 1H, J=2.1 Hz), 6.65 (dd, 1H, J=8.3, 2.5 Hz), 6.52 (d, 1H, J=8.3 Hz); 13 C NMR (CDCl 3 , 100 MHz) δ 144.0, 136.6, 121.7, 118.7, 116.2, 112.1; MS (Cl) m/z 188.0 (M+1); HPLC retention time=1.10 min.
EXAMPLE 5
5-BROMO-3H-BENZOOXAZOLE-2-THIONE
Potassium ethyl xanthate (416 mg, 2.60 mmol) was added to a solution of 2-amino-4-bromophenol (244 mg, 1.30 mmol) in EtOH (3.24 mL). The reaction mixture was heated at reflux for 4 h. Upon cooling to RT the mixture was concentrated and the resulting residue was dissolved in water. Acetic acid was added until pH=5 and a white solid precipitated from the solution. The solid was filtered, washed with water and dried to afford 270 mg (90%) of a tan powder which was used without further purification: 1 H NMR (d6-DMSO, 400 MHz) δ 14.02 (s, 1H), 7.47-7.38 (m, 3H); 13 C (d6-DMSO, 400 MHz) δ 181.4, 148.1, 133.7, 127.1, 117.8,118.8, 112.2; MS (Cl) m/z 229.8 (M−1); HPLC retention time=4.34 min.
The 2-chlorobenzoxazole compounds were prepared by the general procedures described in the literature, see: Lok, R.; Leone, R. E.; Williams, A. J. J. Org. Chem. 1996, 61, 3289-3297.
EXAMPLE 6
2-CHLORO-5-PHENYLBENZOXAZOLE
5-Phenyl-3H-benzooxazole-2-thione (227 mg, 1.0 mmol) was dissolved in phosphorus oxychloride (1.6 mL). Phosphorus pentachloride (208 mg, 1.0 mmol) was added and the mixture was placed in an oil bath at 100° C. for 3 h. The mixture was allowed to cool to RT and concentrated. The crude residue was concentrated from CH 2 Cl 2 (3×). The crude reaction product was triturated with hexanes (40 mL), and the resulting solids were collected by filtration. The solids were washed with hexanes (20 mL×3) and dried to afford 1.47 g (73%) of the title compound: 1 H NMR (CDCl 3 , 400 MHz) δ 7.86 (d, 1H, J=1.3 Hz), 7.60-7.56 (m, 3H), 7.55-7.52 (m, 1H), 7.49-7.44 (m, 2H), 7.40-7.36 (m, 1H); 13 C NMR (CDCl 3 , 100 MHz) δ 151.6, 151.4, 141.9, 140.7, 139.3, 129.2, 127.8, 127.7, 125.2, 118.4, 110.7; MS (Cl) m/z 230.1 (M+1); HPLC retention time=5.41 min.
The 2-methylthiobenzoxazole compounds were prepared by the general procedures described in the literature, see: Yamato, M.; Takeuchi, Y.; Hashigaki, K.; Hirota, T. Chem. Pharm. Bull. 1983, 31, 733-736.
EXAMPLE 7
5-BROMO-2-METHYLSULFANYL-BENZOOXAZOLE
5-Bromo-3H-benzooxazole-2-thione (530 mg, 2.30 mmol) was dissolved in DMF (5.75 mL). Potassium carbonate (318 mg, 2.30 mmol) and iodomethane (172 μL, 2.76 mmol) were added and the reaction mixture was allowed to stir at RT for 3.5 h. The mixture was diluted with water (10 mL) and extracted with ethyl acetate (4×10 mL): The combined organic extracts were washed with water (3×10 mL), brine (10 mL) and dried (Na 2 SO 4 ), filtered and concentrated to afford 538 mg (96%) of the title compound as a dark brown solid:
1 H NMR (CDCl 3 , 400 MHz) δ 7.72 (d, 1H, J=2.1 Hz), 7.36-7.26 (m, 2H), 2.75 (s, 3H); 13 C NMR (CDCl 3 , 100 MHz) δ 167.6, 151.2, 143.8, 126.9, 121.6, 117.3, 111.2, 14.8; MS (Cl) m/z 244.0 (M+1); HPLC retention time=5.10 min.
EXAMPLE 8
4-(5-PHENYL-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.21NONANE
1,4-Diazabicyclo[3.2.2]nonane (504 mg, 4.0 mmol) was added to a mixture of 2-chloro-5-phenylbenzoxazole (919 mg, 4.0 mmol), sodium tert-butoxide (423 mg, 4.4 mmol) and toluene (4 mL) at RT. The mixture was stirred at RT for 16 h and water (10 mL) and ethyl acetate (10 mL) were added. The layers were partitioned and the aqueous layer was extracted with ethyl acetate (3×10 mL). The combined organic layers were dried (Na 2 SO 4 ), filtered and concentrated and the residue was purified by chromatography (Biotage, 40S) eluting with 4% MeOH in CHCl 3 with 20 drops of NH 4 OH per liter of eluent to afford 540 mg (42%) of the title compound as an oil: 1 H NMR (CDCl 3 , 400 MHz) δ 7.60-7.56 (m, 3H), 7.42 (t, 2H, J=7.7 Hz), 7.33-7.20 (m, 3H), 4.51 (s, 1H), 3.92 (t, 2H, J=5.8 Hz), 3.17-2.97 (m, 6H), 2.20-2.07 (m, 2H), 1.84-1.75 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 162.2, 148.6, 144.3, 141.9, 137.9, 129.0, 127.5, 127.1, 119.8, 114.8, 108.8, 57.3, 50.4, 46.5, 44.4, 27.0; MS (Cl) m/z 320.1 (M+1). The hydrochloride salt was prepared by diluting the title compound in ethyl acetate and adding a 2.5 N HCl in ethyl acetate solution: mp>300° C.
EXAMPLE 9
4-(5-BROMO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
1,4-Diazabicyclo[3.2.2]nonane (57%, 731 mg, 3.31 mmol) was added to a solution of 5-bromo-2-methylsulfanyl-benzooxazole (538 mg, 2.20 mmol) in iPrOH (4.4 mL). The mixture was placed in an oil bath at 90° C. and the solvent was evaporated. The mixture was allowed to stir neat at 90° C. for 18 h. Upon cooling to RT the mixture was purified by chromatography (Biotage, 25M) eluting with 4% MeOH in CHCl 3 with 20 drops of NH 4 OH per liter of eluent to afford 392 mg (55%) of the title compound as an oil: 1 H NMR (CDCl 3 , 400 MHz) δ 7.40 (t, 1H, J=1.2 Hz), 7.05 (d, 2H, J=1.2 Hz), 4.46-4.43 (m, 1H), 3.87 (t, 2H, J=5.8 Hz), 3.14-2.93 (m, 6H), 2.13-2.06 (m, 2H), 1.81-1.73 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 162.3, 148.0, 145.6, 122.9, 119.0, 116.8, 109.8, 57.2, 50.5, 46.5, 44.4, 27.0; MS (Cl) m/z 322.0 (M+1); HPLC retention time=3.36 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a solution of 2.5 N HCl in ethyl acetate: mp>300° C.
EXAMPLE 10
3H-1-OXA-3-AZA-CYCLOPENTA[B]NAPHTHALENE-2-THIONE
The title compound was prepared from 3-amino-2-napthol (Aldrich) by the procedure described in Example 3 in 93% yield: 1 H NMR (d6-DMSO, 400 MHz) δ 7.99-7.92 (m, 3H), 7.64 (s, 1H), 7.48-7.42 (m, 2H); 13 C (d6-DMSO, 100 MHz) δ 182.3, 148.1, 131.7, 131.6, 130.6, 128.7, 128.4, 126.2, 125.9, 106.9, 106.4; MS (Cl) m/z 202.1 (M+1); HPLC retention time=4.46 min.
EXAMPLE 11
2-CHLORO-1-OXA-3-AZA-CYCLOPENTA[B]NAPHTHALENE
The title compound was prepared from 3H-1-oxa-3-aza-cyclopenta[b]naphthalene-2-thione by the procedure described in Example 6 in 22% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 8.08 (s, 1H), 7.97-7.95 (m, 1H), 7.92-7.90 (m, 1H), 7.84 (s, 1H), 7.54-7.47 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 153.7, 150.4, 140.7, 131.6, 131.5, 128.8, 128.2, 126.3, 125.5, 117.5, 106.7; MS (Cl) m/z 204.1 (M+1); HPLC retention time=5.17 min.
EXAMPLE 12
2-(1,4-DIAZA-BICYCLO[3.2.2]NON-4-YL)-1-OXA-3-AZA-CYCLOPENTA[B]NAPHTHALENE
The title compound was prepared from 2-chloro-1-oxa-3-aza-cyclopenta[b]naphthalene by the procedure described in Example 8 in 48% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.85-7.80 (m, 2H), 7.65 (s, 1H), 7.57 (s, 1H), 7.40-7.32 (m, 2H), 4.59-4.58 (m, 1H), 3.97 (t, 2H, J=5.8 Hz), 3.20-3.12 (m, 4H), 3.10-3.00 (m, 2H), 2.21-2.14 (m, 2H), 1.88-1.79 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 162.8, 149.2, 144.1, 132.1, 129.5, 127.8, 127.7, 124.5, 123.8, 111.7, 104.6, 57.2, 50.6, 46.5, 44.4, 27.0; MS (Cl) m/z 294.2 (M+1); HPLC retention time=3.33 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a solution of 2.5 N HCl in ethyl acetate: mp>300° C.
EXAMPLE 13
1H-3-OXA-1-AZA-CYCLOPENTA[A]NAPHTHALENE-2-THIONE
The title compound was prepared from 1-amino-2-naphthol by the procedure described in Example 3 in 98% yield: 1 H NMR (d4-MeOH, 400 MHz) δ 7.93 (d, 1H, J=8.3 Hz), 7.87 (d, 1H, J=7.9 Hz), 7.65 (d, 1H, J=8.7 Hz), 7.56 (t, 1H, J=8.3 Hz), 7.49-7.43 (m, 2H); MS (Cl) m/z 202.1 (M+1).
EXAMPLE 14
2-CHLORO-3-OXA-1-AZA-CYCLOPENTA[A]NAPHTHALENE
The title compound was prepared from 3H-1-oxa-3-aza-cyclopenta[b]naphthalene-2-thione by the procedure described in Example 6 in 77% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 8.41 (dd, 1H, J=8.3, 0.8 Hz), 7.94 (d, 1H, J=7.9 Hz), 7.79 (d, 1H, J=9.1 Hz), 7.68-7.53 (m, 3H); 13 C NMR (CDCl 3 , 100 MHz) δ 149.3, 149.2, 136.9, 131.3, 128.8, 127.7, 126.7, 126.1, 126.0, 122.2, 110.4; MS (Cl) m/z 204.1 (M+1).
EXAMPLE 15
2-(1,4-DIAZA-BICYCLO[3.2.2]NON-4-YL)-3-OXA-1-AZA-CYCLOPENTA[A]NAPHTHALENE
The title compound was prepared from 2-chloro-3-oxa-1-aza-cyclopenta[a]naphthalene by the procedure described in Example 8 in 33% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 8.33 (d, 1H, J=8.3 Hz), 7.87 (d, 1H, J=8.3 Hz), 7.53-7.40 (m, 4H), 4.60 (s, 1H), 4.01 (t, 2H, J=5.4 Hz), 3.19-3.00 (m, 6H), 2.25-2.15 (m, 2H), 1.88-1.80 (m, 2H), 13 C NMR (CDCl 3 , 100 MHz) δ 161.9, 145.0, 138.8, 131.3, 128.6, 125.8, 125.0, 124.7, 122.4, 120.5, 109.9, 57.3, 50.2, 46.6, 44.4, 27.1; MS (Cl) m/z 294.2 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a solution of 2.5 N HCl in ethyl acetate: mp=167.2° C.
EXAMPLE 16
6-PHENYL-3H-BENZOOXAZOLE-2-THIONE
The title compound was prepared from 2-amino-5-phenylphenol ( J. Am. Chem. Soc. 1993, 115, 9453) by the procedure described in Example 3 in 72% yield: 1 H NMR (d6-DMSO, 400 MHz) δ 7.79 (s, 1H), 7.64 (d, 2H, J=7.9 Hz), 7.55 (d, 1H, J=8.3 Hz), 7.43 (t, 2H, J=7.5 Hz), 7.34 (d, 1H, J=7.1 Hz), 7.27 (d, 1H, J=8.3 Hz); 13 C (d6-DMSO, 100 MHz) δ 181.0, 149.6, 139.9, 137.1, 131.3, 129.7, 128.3, 127.5, 124.5, 111.3, 108.9; MS (Cl) m/z 226.0 (M−1); HPLC retention time=4.60 min.
EXAMPLE 17
2-CHLORO-4-PHENYLBENZOXAZOLE
The title compound was prepared from 6-phenyl-3H-benzooxazole-2-thione by the procedure described in Example 6 in 94% yield: mp=85.8° C.; 1 H NMR (CDCl 3 , 400 MHz) δ 7.72-7.68 (m, 2H), 7.61-7.58 (m, 3H), 7.49-7.45 (m, 2H), 7.41-7.37 (m, 1H); 13 C NMR (CDCl 3 , 100 MHz) δ 152.5, 151.3, 140.6, 140.5, 139.7, 129.2, 128.0, 127.7, 124.8, 119.9, 109.1; MS (Cl) m/z 230.1 (M+1); HPLC retention time=5.41 min.
EXAMPLE 18
4-(6-PHENYL-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-chloro-4-phenylbenzoxazole by the procedure described in Example 8 in 33% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.58 (d, 2H, J=7.0 Hz), 7.48 (d, 1H, J=1.2 Hz), 7.44-7.36 (m, 3H), 7.30 (t, 2H, J=7.5 Hz), 4.54-4.52 (m, 1H), 3.94 (t, 2H, J=5.8 Hz), 3.19-3.11 (m, 4H), 3.05-2.98 (m, 2H), 2.20-2.12 (m, 2H), 1.86-1.77 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 162.1, 149.6, 143.3, 141.6, 134.2, 129.0, 127.2, 126.9, 123.5, 116.0, 107.5, 57.3, 50.5, 46.6, 44.4, 27.1; MS (Cl) m/z 320.1 (M+1); HPLC retention time=3.55 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=281.3° C.
EXAMPLE 19
4-(5-CHLORO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 5-chloro-2-methylsulfanyl-benzooxazole ( Chem. Pharm. Bull. 1983, 31, 733) by the procedure described in Example 9 in 40% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.25 (d, 1H, J=2.1 Hz), 7.09 (d, 1H, J=8.3 Hz), 6.91 (dd, 1H), J=8.3, 2.1 Hz), 4.49-4.47 (m, 1H), 3.90 (t, 2H, J=5.8 Hz), 3.20-3.12 (m, 4H), 3.07-2.99 (m, 2H), 2.17-2.09 (m, 2H), 1.85-1.77 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 162.4, 147.5, 145.0, 129.4, 120.2, 116.2, 109.3, 57.0, 50.4, 46.3, 44.0, 26.7; MS (Cl) m/z 278.1 (M+1); HPLC retention time=3.23 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 20
4-(5-FLUORO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 5-fluoro-2-methylsulfanyl-benzooxazole (prepared from 2-amino-4-fluorophenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 15% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.12 (dd, 1H, J=8.7, 4.6 Hz), 7.01 (dd, 1H, J=9.1, 2.5 Hz), 6.70-6.65 (m, 1H), 4.54-4.51 (m, 1H), 3.94 (t, 2H, J=5.8 Hz), 3.24-3.17 (m, 4H), 3.11-3.03 (m, 2H), 2.21-2.14 (m, 2H), 1.90-1.82 (m, 2H); MS (Cl) m/z 262.1 (M+1); HPLC retention time=3.08 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 21
4-(6-NITRO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-methylsulfanyl-6-nitro-benzooxazole (prepared from 2-amino-5-nitrophenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 89% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 8.11 (dd, 1H, J=8.7, 2.1 Hz), 8.05 (d, 1H, J=2.1 Hz), 7.24 (d, 1H, J=8.7 Hz), 4.51 (s, 1H), 3.94 (t, 2H, J=5.8 Hz), 3.18-3.10 (m, 4H), 3.04-2.96 (m, 2H), 2.15-2.09 (m, 2H), 1.87-1.78 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 164.3, 150.6, 148.0, 141.2, 121.7, 114.7, 105.1, 57.0, 51.1, 46.4, 44.7, 26.9; MS (Cl) m/z 289.2 (M+1); HPLC retention time=3.10 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=296.4° C.
EXAMPLE 22
4-(5-IODO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 5-iodo-2-methylsulfanyl-benzooxazole (prepared from 4-iodo-2-nitrophenol by the methods described in Examples 4, 5 and 7) by the procedure described in Example 9 in 38% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.58 (d, 1H, J=1.2 Hz), 7.23 (dd, 1H, J=8.3, 1.7 Hz), 6.94 (d, 1H, J=8.3 Hz), 4.44-4.42 (m, 1H), 3.85 (t, 2H, J=5.8 Hz), 3.13-3.06 (m, 4H), 2.99-2.92 (m, 2H), 2.12-2.05 (m, 2H), 1.80-1.72 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 162.0, 148.7, 146.0, 128.9, 124.9, 110.5, 87.2, 57.2, 50.5, 46.5, 44.4, 27.0; MS (Cl) m/z 370.0 (M+1); HPLC retention time=3.44 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 23
4-(6-BROMO-OXAZOLO[5,4-b]PYRIDIN-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 6-bromo-2-methylsulfanyl-oxazolo[5,4-b]pyridine (prepared from 5-bromo-2-hydroxy-3-nitropyridine by the methods described in Examples 4, 5 and 7) by the procedure described in Example 9 in 64% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.90 (d, 1H, J=2.1 Hz), 7.59 (d, 1H, J=2.1 Hz), 4.50-4.49 (m, 1H), 3.91 (t, 2H, J=5.8 Hz), 3.18-3.11 (m, 4H), 3.03-2.96 (m, 2H), 2.16-2.08 (m, 2H), 1.85-1.76 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 161.4, 138.8, 125.3, 121.4, 116.7, 116.2, 57.0, 50.6, 46.4, 44.3, 26.8; MS (Cl) m/z 323.0 (M+1); HPLC retention time=3.08 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 24
4-OXAZOLO[5,4-b]PYRIDIN-2-YL-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-(methylthio)oxazolo[5.4-b]pyridine ( J. Org. Chem. 1995, 60, 5721) by the procedure described in Example 9 in 72% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.83 (dd, 1H, J=5.0, 1.2 Hz), 7.47 (dd, 1H, J=7.5, 1.2 Hz), 7.04 (dd, J=7.5, 5.0 Hz), 4.49-4.47 (m, 1H), 3.89 (t, 2H, J=5.8 Hz), 3.13-3.05 (m, 4H), 3.00-2.92 (m, 2H), 2.13-2.06 (m, 2H), 1.81-1.72 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 160.7, 158.4, 138.6, 136.3, 122.7, 120.7, 57.1, 50.4, 46.4, 44.2, 26.9; MS (Cl) m/z 245.2 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 25
4-OXAZOLO[5,4-C]PYRIDIN-2-YL-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-(methylthio)oxazolo[5,4-C]pyridine ( J. Org. Chem. 1995, 60, 5721) by the procedure described in Example 9 in 67% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 8.44 (s, 1H), 8.27 (d, 1H, J=5.0 Hz), 7.19 (d, 1H, J=5.3 Hz), 4.48 (s, 1H), 3.90 (t, 2H, J=5.8 Hz), 3.14-3.07 (m, 4H), 3.00-2.93 (m, 2H), 2.12-2.07 (m, 2H), 1.82-1.74 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 163.4, 150.9, 147.5, 145.5, 129.8, 111.6, 62.3, 50.9, 46.4, 44.7, 30.3, 26.9; MS (Cl) m/z 245.2 (M+1); HPLC retention time=1.28 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 26
4-OXAZOLO[4,5-C]PYRIDIN-2-YL-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-(methylthio)oxazolo[4.5-C]pyridine ( J. Org. Chem. 1995, 60, 5721) by the procedure described in Example 9 in 32% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 8.57 (s, 1H), 8.21 (d, 1H, J=5.4 Hz), 7.16 (d, 1H, J=5.4 Hz), 4.46-4.45 (m, 1H), 3.88 (t, 2H, J=5.8 Hz), 3.14-3.03 (m, 4H), 3.00-2.93 (m, 2H), 2.13-2.06 (m, 2H), 1.82-1.74 (m, 2H); 13 C NMR (CDCl 3 , 100 MHz) δ 161.6, 154.3, 142.0, 141.4, 138.0, 104.9, 62.3, 57.1, 50.8, 46.3, 44.6, 30.3, 26.9; MS (Cl) m/z 245.2 (M+1); HPLC retention time=1.28 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=288.5° C.
EXAMPLE 27
4-OXAZOLO[4,5-b]PYRIDIN-2-YL-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-(methylthio)oxazolo[4,5-b]pyridine ( J. Org. Chem. 1995, 60, 5721) by the procedure described in Example 9 in 98% yield: 1 H NMR CDCl 3 , 400 MHz) δ 8.14 (dd, 1H, J=5.0, 1.2 Hz), 7.34 (dd, 1H, J=7.5, 1.2 Hz), 6.81 (dd, 1H, J=7.8, 5.0 Hz), 4.50 (s, 1H), 3.90 (t, 2H, J=5.8 Hz), 3.13-3.05 (m, 4H), 2.98-2.91 (m, 2H), 2.13-2.05 (m, 2H), 1.79-1.71 (m, 2H); 13 C NMR CDCl 3 , 100 MHz) δ 163.1, 158.7, 144.7, 141.4, 115.4, 114.8, 57.1, 50.6, 46.4, 46.3, 44.4, 30.3, 26.9; MS (Cl) m/z 245.2 (M+1); HPLC retention time=1.38 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 28
2-AMINO-4-PYRIDIN-3-YL-PHENOL
Tetrakis(triphenylphosphine)palladium (139 mg, 0.12 mmol) was added to a flask containing 4-bromophenol (519 mg, 3.0 mmol), 3-pyridyl boronic acid (553 mg, 4.5 mmol) and sodium carbonate (1.27 g, 12.0 mmol). The flask was flushed with nitrogen and ethanol (6 mL) and water (0.6 mL) were added. The mixture was placed in an oil bath at 80° C. for 16 h. Upon cooling to RT the mixture was partitioned between water and chloroform. The aqueous layer was extracted with chloroform (3×) and the combined organic layers were dried (Na 2 SO 4 ), filtered and concentrated. The crude residue was purified by chromatography (Biotage, 40S) eluting with 50% ethyl acetate in hexanes to afford 165 mg (32%) of 4-pyridin-3-yl-phenol as a white solid: mp=194.6° C., MS (Cl) m/z 172.1 (M+1).
Nitric acid (60 μL, 1.0 mmol) was added to a solution of 4-pyridin-3-yl-phenol (164 mg, 0.96 mmol) in acetic acid (2.8 mL). The mixture was heated at 60° C. for 30 min and the solution turned orange/brown in color. Upon cooling, water was added (3 mL) and 6 N NaOH (aq) was added until the solution was basic. The solution was extracted with ethyl acetate (3×) and then the aqueous phase was concentrated. The crude residue was washed with boiling methanol to afford 90 mg (43%) of 2-nitro-4-pyridin-3-yl-phenol as an orange solid: mp>300° C., MS (Cl) m/z 217.1 (M+1).
A mixture of 2-nitro-4-pyridin-3-yl-phenol (80 mg, 0.37 mmol), 10% Pd—C (8.0 mg), acetic acid (21 μL, 0.37 mmol) in MeOH (3.7 mL) was hydrogenated at 45 PSI at RT for 16 h. The mixture was filtered through a pad of celite and concentrate to afford 70 mg (100%) of the title compound as a brown oil: 1 H NMR CDCl 3 , 400 MHz) δ 8.57 (d, 1H, J=1.7 Hz), 8.30 (d, 1H, J=5.0 Hz), 7.75 (dt, 1H, J=7.9, 2.1 Hz), 7.25 (dd, 1H, J=7.9, 5.0 Hz), 6.77-6.69 (m, 2H), 3.94 (br s, 3H); 13 C NMR CDCl 3 , 100 MHz) δ 147.0, 146.5, 145.7, 137.6, 135.5, 134.8, 129.3, 124.0, 118.1, 115.4, 114.6; MS (Cl) m/z 187.1 (M+1); HPLC retention time=1.29 min.
EXAMPLE 29
4-(5-PYRIDIN-3-YL-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared 2-methylsulfanyl-5-pyridin-3-yl-benzooxazole (prepared from 2-amino-4-pyridin-3-yl-phenol by the methods described in Examples 5 and 7) by the procedure described in Example 9 in 13% yield: 1 H NMR CDCl 3 , 400 MHz) δ 8.83 (d, 1H, J=2.1 Hz), 8.55 (dd, 1H, J=5.0, 1.6 Hz), 7.86-7.83 (m, 1H), 7.52 (d, 1H, J=1.6 Hz), 7.35-7.33 (m, 1H), 7.31 (d, 1H, J=8.3 Hz), 7.18 (dd, 1H, J=8.3, 1.6 Hz), 4.54-4.52 (m, 1H), 3.95 (t, 2H, J=5.8 Hz), 3.20-3.12 (m, 4H), 3.07-2.99 (m, 2H), 2.20-2.12 (m, 2H), 1.87-1.79 (m, 2H); 13 C NMR CDCl 3 , 100 MHz) δ 162.3, 149.1, 148.7, 148.3, 144.7, 137.3, 134.7, 134.4, 123.8, 119.7, 114.7, 109.1, 62.3, 57.2, 50.5, 46.5, 46.4, 44.4, 30.3, 27.0; MS (Cl) m/z 321.1 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 30
4-(1H-BENZOIMIDAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
Di-tert-butyl dicarbonate (600 mg, 2.75 mmol) was added to a solution of 2-chloroimidazole (381 mg, 2.50 mmol), and sodium hydroxide (120 mg, 3.0 mmol) in tetrahydrofuran (2.5 mL) and water (2.5 mL). After 3 h at RT an additional portion of di-tert-butyl dicarbonate (100 mg, 0.46 mmol) was added and the mixture was stirred at RT for 16 h. The mixture was extracted with ethyl acetate (3×) and the combined organic layers were dried (Na 2 SO 4 ), filtered and concentrated to afford 627 mg (99%) of 2-chloro-benzoimidazole-1-carboxylic acid tert-butyl ester which was used without further purification: MS (Cl) m/z 253.1 (M+1).
2-Chloro-benzoimidazole-1-carboxylic acid tert-butyl ester (333 mg, 1.32 mmol), 1,4-diazabicyclo[3.2.2]nonane (57%, 195 mg, 0.88 mmol), tris(dibenzylideneacetone)dipalladium (28 mg, 0.031 mmol), racemic-2,2′-bis(diphenylphosphino)-1,1′-binaphthyl (58 mg, 0.093 mmol), sodium tert-butoxide (208 mg, 2.17 mmol) and toluene (1.55 mL) were added to a flame dried round bottom flask purged with nitrogen. The mixture was placed in an oil bath at 80° C. for 18 h and then cooled to RT. The mixture was filtered through a pad of celite and washed with chloroform and methanol. The filtrate was concentrated and the residue was purified by chromatography (Biotage, 12M) eluting with 8% methanol in chloroform with 20 drops of NH 4 OH per liter of eluent to afford 104 mg (34%) of 2-(1,4-diaza-bicyclo[3.2.2]non-4-yl)-benzoimidazole-1-carboxylic acid tert-butyl ester: MS (Cl) m/z 343.1 (M+1).
1 N Hydrochloric acid (3 mL, in methanol) was added to of 2-(1,4-diaza-bicyclo[3.2.2]non-4-yl)-benzoimidazole-1-carboxylic acid tert-butyl ester (104 mg, 0.304 mmol). The mixture was stirred at RT for 18 h and concentrated. The residue was diluted with 1 N hydrochloric acid (3 mL, aq.) and extracted with ethyl acetate (3×). The aqueous layer was treated with 6 N sodium hydroxide (3 mL, aq.) and extracted with chloroform (6×). The combined organic layers were dried (Na 2 SO 4 ), filtered and concentrated to afford 50 mg (68%) of the title compound: 1 H NMR (CD 3 OD, 400 MHz) δ 7.19 (dd, 2H, J=5.8 Hz, 3.3 Hz), 6.95 (dd, 2H, J=5.8, 2.9 Hz), 4.98 (br s, 1H), 4.27-4.24 (m, 1H), 3.83 (t, 2H, J=5.8 Hz), 3.09-2.91 (m, 6H), 2.16-2.08 (m, 2H), 1.87-1.78 (m, 2H); MS (Cl) m/z 243.3 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 31
4-(4-NITRO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-methylsulfanyl-4-nitro-benzooxazole (prepared from 2-amino-3-nitrophenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 79% yield: 1 H NMR CDCl 3 , 400 MHz) δ 7.84 (dd, 1H, J=8.7, 0.8 Hz), 7.36 (dd, 1H, J=7.5, 0.8 Hz), 6.92 (t, 1H, J=8.3 Hz), 4.51 (s, 1H), 3.93-3.91 (m, 2H), 3.06-2.99 (m, 4H), 2.94-2.87 (m, 2H), 2.07-2.01 (m, 2H), 1.83-1.74 (m, 2H); 13 C NMR CDCl 3 , 100 MHz) δ 163.9, 151.0, 140.3, 133.5, 120.2, 119.2, 113.9, 56.3, 50.6, 45.9, 44.1, 26.3; MS (Cl) m/z 289.2 (M+1); HPLC retention time=3.02 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=232.1 ° C.
EXAMPLE 32
4-(5-NITRO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 2-methylsulfanyl-5-nitro-benzooxazole (prepared from 2-amino-4-nitrophenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 36% yield: 1 H NMR CDCl 3 , 400 MHz) δ 7.84 (d, 1H, J=2.1 Hz), 7.97 (dd, 1H, J=8.7, 2.1 Hz), 7.28 (d, 1H, J=8.7 Hz), 4.56-4.55 (m, 1H), 3.97 (t, 2H, J=5.8 Hz), 3.23-3.16 (m, 4H), 3.08-3.01 (m, 2H), 2.23-2.15 (m, 2H), 1.94-1.85 (m, 2H); 13 C NMR CDCl 3 , 100 MHz) δ 163.1, 152.8, 145.2, 144.3, 117.2, 111.7, 108.5, 56.4, 50.5, 45.9, 43.8, 26.3; MS (Cl) m/z 289.2 (M+1); HPLC retention time=3.11 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=240.2° C.
EXAMPLE 33
4-(5-METHYL-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 5-methyl-2-methylsulfanyl-benzooxazole (prepared from 2-amino-4-methylphenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 4% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 7.14 (s, 1H), 7.10 (d, 1H, J=7.9 Hz), 6.80 (dd, 1H, J=7.9, 0.8Hz), 4.55-4.53 (m, 1H), 3.95 (t, 2H, J=5.8 Hz), 3.24-3.17 (m, 4H), 3.10-3.03 (m, 2H), 2.38 (s, 3H), 2.22-2.15 (m, 2H), 1.89-1.81 (m, 2H); MS (Cl) m/z 258.2 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=220.2° C.
EXAMPLE 34
4-(6-METHYL-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 6-methyl-2-methylsulfanyl-benzooxazole (prepared from 2-amino-5-methylphenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 2% yield: 1 H NMR CDCl 3 , 400 MHz) δ 7.21 (d, 1H, J=7.9 Hz), 7.06 (s, 1H), 6.96 (d, 1H, J=8.3 Hz), 4.55-4.52 (m, 1H), 3.94 (t, 2H, J=5.8 Hz), 3.23-3.15 (m, 4H), 3.09-3.01 (m, 2H), 2.39 (s, 3H), 2.22-2.14 (m, 2H), 1.89-1.80 (m, 2H); MS (Cl) m/z 258.2 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate.
EXAMPLE 35
4-(5-METHYL-OXAZOLO[4,5-b]PYRIDIN-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 5-methyl-2-methylsulfanyl-oxazolo[4,5-b]pyridine (prepared from 6-methyl-2-nitro-pyridin-3-ol by the methods described in Examples 4, 5 and 7) by the procedure described in Example 9 in 67% yield: 1 H NMR CDCl 3 , 400 MHz) δ 7.22 (d, 1H, J=7.9 Hz), 6.65 (d, 1H, J=7.9 Hz), 4.49 (s, 1H), 3.89 (t, 2H, J=5.8 Hz), 3.13-3.05 (m, 4H), 2.99-2.90 (m, 2H), 2.47 (s, 3H), 2.13-2.06 (m, 2H), 1.78-1.70 (m, 2H), 13 C NMR CDCl 3 , 100 MHz) δ 163.3, 158.2, 153.5, 139.8, 114.9, 114.3, 57.1, 50.5, 46.4, 44.3, 26.9, 24.1; MS (Cl) m/z 259.2 (M+1); HPLC retention time=2.08 min. The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=287.5° C.
EXAMPLE 36
4-(6-CHLORO-5-NITRO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 6-chloro-2-methylsulfanyl-5-nitro-benzooxazole (prepared from 2-amino-5-chloro-4-nitrophenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 74% yield: 1 H NMR (CDCl 3 , 400 MHz) δ 8.02 (d, 1H, J=2.1 Hz), 7.95 (d, 1H, J=2.1 Hz), 4.56-4.54 (m, 1H), 3.97 (t, 2H, J=5.8 Hz), 3.23-3.12 (m, 4H), 3.08-3.01 (m, 2H), 2.20-2.14 (m, 2H), 1.91-1.83 (m, 2H); MS (Cl) m/z 323.1 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=242.3° C.
EXAMPLE 37
4-(5,7-DICHLORO-BENXOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared from 5,7-dichloro-2-methylsulfanyl-benzooxazole (prepared from 2-amino-4,6-dichlorophenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 71% yield: 1 H NMR CDCl 3 , 400 MHz) δ 7.17 (d, 1H, J=1.3 Hz), 6.98 (d, 1H, J=1.3 Hz), 4.57 (s, 1H), 3.99 (t, 2H, J=5.8 Hz), 3.30-3.23 (m, 4H), 3.15-3.08 (m, 2H), 2.24-2.17 (m, 2H), 1.95-1.86 (m, 2H); MS (Cl) m/z 312.1 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp=251.2° C.
EXAMPLE 38
4-(5-CHLORO-6-NITRO-BENZOOXAZOL-2-YL)-1,4-DIAZABICYCLO[3.2.2]NONANE
The title compound was prepared 5-chloro-2-methylsulfanyl-6-nitro-benzooxazole (prepared from 2-amino-4-chloro-5-nitrophenol by the methods described in Example 5 and Example 7) by the procedure described in Example 9 in 30% yield: MS (Cl) m/z 323.1 (M+1). The hydrochloride salt was prepared by diluting in ethyl acetate and adding a 2.5 N HCl solution in ethyl acetate: mp>300° C.
EXAMPLE 39
4-(5-AMINO-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
10% Palladium on carbon (300 mg) was added to a solution of 4-(5-nitro-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane (288 mg, 1 mmol, prepared as in Example 21) in ethanol (5 mL) and subjected to hydrogen gas at 50 PSI at RT for a period of 16 h. The reation mixture was diluted with ethanol (20 mL) and filtered through a pad of celite. Concentration in vacuo gave 209 mg of the title compound as a brown oil: 1 H NMR (CD 3 OD, 400 MHz) δ 7.06 (d, 1H, J=8.3 Hz), 6.75 (d, 1H, J=1.3 Hz), 6.50 (dd, 1H, J=8.3, 1.3 Hz), 4.56 (br s, 1H), 4.08 (br s, 2H), 3.62-3.47 (m, 6H), 2.34-2.31 (m, 2H), 2.20-2.16 (m, 2H); MS (Cl) m/z 259.2 (M+1).
EXAMPLE 40
BENZYL-[2-(1,4-DIAZA-BICYCLO[3.2.2]NON-4-YL)-BENZOOXAZOL-5-YL]-AMINE
Sodium triacetoxyborohydride (118 mg, 0.56 mmol) was added to a solution of 4-(5-amino-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane (52 mg, 0.20 mmol, prepared as in Example 39) and benzaldehyde (21 μL, 0.204 mmol) in 1,2-dichloroethane. The resulting mixture was allowed to stir at RT for a period of 3 h. at which time 2 mL of 1 N NaOH solution was added. The aqueous layer was extracted with CDCl 3 (3×) and the combined organic layers were washed with water and brine and then dried (Na 2 SO 4 ), filtered and concentrated. The crude residue was purified by chromatography (Biotage, 25M) eluting with 6% MeOH in CDCl 3 containing 1 mL of NH 4 OH per L of eluent to give 37 mg of the title compound as an oil: 1 H NMR CDCl 3 , 400 MHz) δ 7.37-7.29 (m, 3H), 7.25-7.22 (m, 2H), 7.00 (d, 1H, J=8.7 Hz), 6.64 (d, 1H, J=2.1 Hz), 6.27 (dd, 1H, J=8.7, 2.1 Hz), 4.47-4.45 (m, 1H), 4.30 (s, 2H), 3.87 (t, 2H, J=5.8 Hz), 3.16-3.09 (m, 4H), 3.01-2.96 (m, 2H), 2.15-2.08 (m, 2H), 1.81-1.73 (m, 2H): 13 C NMR (CDCl 3 , 100 MHz) δ 146.0, 145.1, 142.0, 139.8, 128.8, 127.7, 127.3, 108.8, 106.0, 100.6, 57.3, 50.1, 49.4, 46.5, 44.1, 27.0; MS (Cl) m/z 349.2 (M+1).
EXAMPLE 41
[2-(1,4-DIAZA-BICYCLO[3.2.2]NON-4-YL)-BENZOOXAZOL-5-YL]-(3-PHENYL-ALLYL)-AMINE
The title compound was prepared according to the procedure in Example 40 using trans-cinnamaldehyde in 42% yield: MS (Cl) m/z 375.2 (M+1).
EXAMPLE 42
[2-(1,4-DIAZA-BICYCLO[3.2.2]NON-4-YL)-BENZOOXAZOL-5-YL]-PYRIDIN-3-YLMETHYL-AMINE
The title compound was prepared according to the procedure in Example 40 using 3-pyridinecarboxaldehyde in 52% yield: MS (Cl) m/z 350.2 (M+1).
EXAMPLE 43
DIBENZYL-[2-(1,4-DIAZA-BICYCLO[3.2.2]NON-4-YL)-BENZOOXAZOL-5-YL]-AMINE
The title compound was prepared according to the procedure in Example 40 using 2.2 equivalents of benzaldehyde in 10% yield: 1 H NMR CDCl 3 , 400 MHz) δ 7.37-7.20 (m, 10H), 7.01 (d, 1H, J=8.7 Hz), 6.76 (d, 1H, J=2.1 Hz), 6.39 (dd, 1H, J=8.7, 2.5 Hz), 4.63 (s, 4H), 4.50 (br s, 1H), 3.91-3.89 (m, 2H), 3.20-3.10 (m, 4H), 3.05-2.95 (m, 2H), 2.20-2.10 (m, 2H), 1.90-1.80 (m, 2H); MS (Cl) m/z 439.2 (M+1).
EXAMPLE 44
4-(5-m-TOLYL-BENZOOXAZOL-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
Et 3 N (5 μL) was added to a solution of palladium (II) acetate (0.7 mg, 3.1 μmol) and 2-(N,N-dimethylamino)-2′-dicyclohexylphosphinobiphenyl (1.8 mg, 4.65 μmol) in 1,2-dimethoxyethane (0.5 mL) under a nitrogen atmosphere at RT. 4-(5-Bromo-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane (50 mg, 0.155 mmol, prepared in example 9), m-tolylboronic acid (32 mg, 0.233 mmol) and CsF (70 mg, 0.465 mmol) were added to the solution and the mixture was heated in an oil bath (temp=80° C.) for a period of 16 h. The reaction mixture was cooled to RT, filtered through a pad of celite and concentrated in vacuo. The crude residue was purified by chromatography (Biotage, 12L) eluting with 4% MeOH in CDCl 3 with 1 mL of NH 4 OH per L to give 39 mg (75%) of the title compound as a film: 1 H NMR CDCl 3 , 400 MHz) δ 7.55 (d, 1H, J=1.7 Hz), 7.40-7.38 (m, 2H), 7.33-7.26 (m, 2H), 7.22-7.19 (m, 1H), 7.14 (d, 1H, J=7.4 Hz), 4.54-4.52 (m, 1H), 3.94 (t, 2H, J=5.8 Hz), 3.19-3.12 (m, 4H), 3.06-2.99 (m, 2H), 2.41 (s, 3H), 2.20-2.13 (m, 2H), 1.86-1.78 (m, 2H); 13 C NMR CDCl 3 , 100 MHz) δ 162.2, 148.6, 144.3, 141.9, 138.5, 138.0, 128.9, 128.4, 127.8, 124.6, 119.8, 114.8,108.7, 57.3, 50.4, 46.5, 44.4, 27.0, 21.8; MS (Cl) m/z 334,1 (M+1).
EXAMPLE 45
4-(6-PHENYL-OXAZOLO[5,4-b]PYRIDIN-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared according to the procedure in Example 44 using phenylboronic acid and 4-(6-bromo-oxazolo[5,4-b]pyridin-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane (prepared in Example 23) in 50% yield as a colorless oil: 1 H NMR (CDCl 3 , 400 MHz) δ 8.10 (d, 1H, J=2.1 Hz), 7.72 (d, 1H, J=2.1 Hz), 7.57-7.55 (m, 2H), 7.47-7.44 (m, 2H), 7.39-7.36 (m, 1H), 4.58 (br s, 1H), 3.98 (t, 2H, J=5.8 Hz), 3.22-3.14 (m, 4H), 3.11-3.01 (m, 2H), 2.22-2.15 (m, 2H), 1.89-1.82 (m, 2H); MS (Cl) m/z 321.2 (M+1).
EXAMPLE 46
4-[5-(4-TRIFLUOROMETHYL-PHENYL)-BENZOOXAZOL-2-YL]-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared according to the procedure in Example 44 using 4-trifluoromethyl-phenylboronic acid and 4-(5-bromo-benzooxazol-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane in 54% yield: MS (Cl) m/z 388.4 (M+1).
EXAMPLE 47
4-(6-BROMO-OXAZOLO[4,5-b]PYRIDIN-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
Bromine (0.12 mL, 2.29 mmol) was added to a solution of 4-oxazolo[4,5-b]pyridin-2-yl-1,4-diaza-bicyclo[3.2.2]nonane (560 mg, 2.29 mmol, prepared in Example 27) and sodium acetate (2.26 g, 27.5 mmol) in water (12 mL) and acetic acid (12 mL). The resulting mixture was heated to reflux for 2 h. The mixture was cooled and extracted with ethyl acetate (3×). The combined organic layers were washed with water (2×) and brine (1×) and dried over sodium sulfate, filtered and concentrated. The crude residue was purified by chromatography (Biotage, 25M) using a gradient elution from 4% MeOH/CDCl 3 containing 0.1% NH 4 OH to 8% MeOH/CDCl 3 containing 0.1% NH 4 OH giving 578 mg (78%) of the title compound as an oil: 1 H NMR CDCl 3 , 400 MHz) δ 8.23 (d, 1H, J=1.7 Hz), 7.50 (d, 1H, J=1.7 Hz), 4.51 (br s, 1H), 3.92 (br s, 2H), 3.16-3.04 (m, 4H), 3.02-2.94 (m, 2H), 2.17-2.01 (m, 2H), 1.83-1.74 (m, 2); MS (Cl) m/z 325.0/323.0 (M+1).
EXAMPLE 48
4-(6-PHENYL-OXAZOLO[4,5-b]PYRIDIN-2-YL)-1,4-DIAZA-BICYCLO[3.2.2]NONANE
The title compound was prepared according to the procedure detailed in Example 44 using phenyl boronic acid and 4-(6-bromo-oxazolo[4,5-b]pyridin-2-yl)-1,4-diaza-bicyclo[3.2.2]nonane (prepared in Example 47) in 27% yield: 1 H NMR CDCl 3 , 400 MHz) δ 8.48 (d, 1H, J=2.1 Hz), 7.62 (d, 1H, J=2.1 Hz), 7.57-7.55 (m, 2H), 7.47-7.43 (m, 2H), 7.40-7.34 (m, 1H), 4.62 (br s, 1H), 4.00 (t, 2H, J=5.8 Hz), 3.20-3.15 (m, 4H), 3.08-3.01 (m, 2H), 2.19-2.08 (m, 2H), 1.90-1.81 (m, 2H); MS (Cl) m/z 321.2 (M+1). | The present invention relates to a method of treating disorders of the Central Nervous System (CNS) and other disorders in a mammal, including a human, by administering to the mammal a CNS-penetrant α7 nicotinic receptor agonist. It also relates to pharmaceutical compositions containing a pharmaceutically acceptable carrier and a CNS-penetrant α7 nicotinic receptor agonist. | 2 |
RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. JP2008-020011 filed Jan. 31, 2008, the entire content of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a management system having a management system connected to a plurality of analysis devices via a network, a computer system, and a method of providing information.
BACKGROUND
A remote support system is known in which a plurality of analysis devices is connected to a management device via a network. For example, US Patent Application Publication No. 2002-128801 discloses a remote support system in which a management device collects quality control data obtained by measuring a quality control substance from a plurality of analysis devices and calculates an aggregate result for each analysis device and for each quality control substance. According to the remote support system disclosed in US Patent Application Publication No. 2002-128801, the management device analyzes the quality control data, and when a quality control result is outside a predetermined range or when worsening of the quality control data is expected, a notification thereof is sent to a user thereof.
As described above, the remote support system of US Patent Application Publication No. 2002-128801 is extremely useful because the management device is capable of detecting a trouble in the analysis device based on a predetermined setting to send a notification thereof to a user thereof, so that the trouble occurring in the analysis device can be promptly treated. However, US Patent Application Publication No. 2002-128801 does not provide any suggestion as to how the settings for detecting the trouble in the analysis device can be determined. For this reason, there is a desire to obtain useful information for determining the settings. For example, when the settings are too loose, information on a trouble which is not required to be notified to a user may be notified to the user, imposing an unnecessary burden to the user. On the other hand, when the settings are too strict, information on a trouble which must have been notified to the user might not be notified to the users.
SUMMARY OF THE INVENTION
The scope of the present invention is defined solely by the appended claims, and is not affected to any degree by the statements within this summary.
A first aspect of the present invention is a management system, comprising: a plurality of analyzers; and a computer system connected to the analyzers via a network, wherein each of the analyzers comprises: a data transmitter for transmitting data produced by the analyzer to the computer system via the network, and wherein the computer system includes a memory under control of a processor, the memory storing instructions enabling the processor to carry out operations, comprising: (a) receiving a plurality of data transmitted from the data transmitters of the plurality of analyzers; (b) generating an aggregate result used for determining a determination condition for making a determination as to whether or not a notification to a user of the analyzer is required based on the plurality of received data; and (c) outputting the aggregate result.
A second aspect of the present invention is a computer system connected to a plurality of analyzers via a network, comprising: a memory under control of a processor, the memory storing instructions enabling the processor to carry out operations, wherein the instructions comprise, (a) receiving a plurality of data transmitted from the plurality of analyzers; (b) generating an aggregate result used for determining a determination condition for making a determination as to whether or not a notification to a user of the analyzer is required based on the plurality of received data; and (c) outputting the generated aggregate result.
A third aspect of the present invention is a method of providing information for determining whether or not a notification to a user is required based on data received from a plurality of analyzers, comprising: (a) receiving data transmitted from the plurality of analyzers; (b) generating an aggregate result used for determining a determination condition for making a determination as to whether or not a notification to a user of the analyzer is required based on the received data; and (c) outputting the generated aggregate result.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating an example of an overall configuration of a management system for managing a plurality of analysis devices according to a first embodiment.
FIG. 2 is a perspective view of an analysis device illustrated in FIG. 1 .
FIG. 3 is a block diagram illustrating a configuration of a main body of the analysis device illustrated in FIG. 1 .
FIG. 4 is a hardware configuration diagram of a control device illustrated in FIG. 1 .
FIG. 5 is a hardware configuration diagram of a management device illustrated in FIG. 1 .
FIG. 6 is a hardware configuration diagram of a terminal equipment of a call center illustrated in FIG. 1 .
FIG. 7 is a flow chart illustrating an exemplary procedure of a main process performed by the management system illustrated in FIG. 1 .
FIG. 8 is a diagram illustrating an example of quality control data which are transmitted from the analysis device illustrated in FIG. 1 to the management device.
FIG. 9 is a diagram illustrating an example of a quality control error determination condition database provided to the management device illustrated in FIG. 1 .
FIG. 10 is a diagram illustrating an example of a dialog screen for updating the quality control error determination condition.
FIG. 11 is a diagram illustrating an example of quality control error determination result data which are transmitted from the management device illustrated in FIG. 1 to a terminal equipment of the call center.
FIG. 12 is a flow chart illustrating an exemplary procedure of a graph creating process of the management device illustrated in FIG. 1 .
FIG. 13 is a diagram illustrating an example of a graph that is output in step S 277 and displayed on the terminal equipment 300 of the call center 203 .
FIG. 14 is a diagram illustrating an example of a graph that is output in step S 285 and displayed on the terminal equipment 300 of the call center 203 .
FIG. 15 is a diagram illustrating an example of error information that is transmitted from the analysis device illustrated in FIG. 1 to the management device.
FIG. 16 is a diagram illustrating an example of error information determination condition database provided to the management device illustrated in FIG. 1 .
FIG. 17 is a diagram illustrating an example of a device error determination result that is transmitted from the management device illustrated in FIG. 1 to the terminal equipment of the call center.
FIG. 18 is a diagram illustrating an example of a graph that is output in step S 285 and displayed on the terminal equipment 300 of the call center 203 .
FIG. 19 is a diagram illustrating an example of a dialog screen for updating a quality control error determination condition on an analysis device side.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described hereinafter with reference to the drawings.
First, a description of a management system according to an embodiment of the present invention will be provided in detail with reference to the drawings.
FIG. 1 is a diagram illustrating a configuration of a management system according to the embodiment. As illustrated in FIG. 1 , the management system according to the present embodiment includes an analysis device 100 a installed in a facility A, an analysis device 100 b installed in a facility B, an analysis device 100 c installed in a facility C, a network 103 such as the Internet, a management device 200 installed in a customer support center 202 , a network 201 such as a LAN, and a plurality of terminal equipments 300 installed in a call center 203 . It is to be noted that a plurality of analysis devices 100 a , 100 b , and 100 c may be installed in one facility. A description of the processing to the analysis device 100 a will be provided hereinbelow by way of an example.
The customer support center 202 is a facility of a vendor who provides maintenance services for the analysis device 100 a and has an engineer 205 capable of operating the management device 200 .
The call center 203 is a facility which is provided in the customer support center 202 to enable the engineer 204 of the call center 203 to make calls to a user 107 of the analysis device 100 a to cope with failures or inquiries. The user 107 of the analysis device 100 a takes a measurement of a quality control substance 106 by means of the analysis device 100 a prior to a measurement of a sample of a human subject. The quality control substance 106 is a sample prepared using a human blood, as a raw material, so as to include a predetermined component in a predetermined concentration, and the e-CHECK (available from Sysmex Corporation) may be used, for example. When the quality control substance 106 is measured by the analysis device 100 a , an analysis result thereof is transmitted to the management device 200 via the networks 103 and 201 . When the analysis result (quality control data) of the quality control substance 106 transmitted from the analysis device 100 a has exceeded a predetermined range, the management device 200 sends a notification thereof to the terminal equipment 300 . When the notification from the management device 200 is received by the terminal equipment 300 , the engineer 204 makes a call to the user 107 of the facility A being a sender of the analysis result and resolves a trouble occurring in the analysis device 100 a.
Moreover, upon occurrence of an error during the measurement, the analysis device 100 a transmits error information thereof to the management device 200 via the networks 103 and 201 . When the error information satisfies a predetermined condition, the management device 200 sends a notification thereof to the terminal equipment 300 . When the notification has been received by the terminal equipment 300 from the management device 200 , the engineer 204 makes a call to the user 107 of the analysis device 100 a being the sender of the analysis result to resolve a trouble occurring in the analysis device 100 a . As the analysis device 100 a , a variety of sample analysis devices are used, e.g., a biochemical analysis device, a blood cell counter, a blood coagulation measurement device, an immunological measurement device, and a urinary analysis device. The analysis device 100 a to be connected to the management device 200 is not limited to one type, but a plurality of types of devices such as a combination of a biochemical analysis device and a blood cell counter may be connected to the management device. In this embodiment, a description of an example where only a blood cell counter is connected will be provided for the sake of simple description.
FIG. 2 is a perspective view illustrating an overall configuration of the analysis device 100 a . The analysis device 100 a is a blood cell counter used for a blood examination, and is configured by an analysis device main body 101 and a control device 102 . The analysis device main body 101 is provided with a transfer section 111 capable of transferring a subject to an aspiratory position of the analysis device main body. For example, when the quality control substance 106 has been measured in the analysis device 100 a , the analysis device main body 101 transmits measurement data to the control device 102 , the measurement data being obtained by aspirating and measuring the quality control substance 106 transferred to the subject aspiratory position of the analysis device main body 101 by the transfer section 111 .
The control device 102 performs an analysis on the received measurement data within a main body thereof 102 b and displays the quality control data 240 (see FIG. 8 ) obtained through the analysis on a display 102 a.
FIG. 3 is a block diagram of the analysis device main body 101 .
The analysis device main body 101 is provided with the transfer section 111 , a subject ID reading section 112 , a subject arrival confirmation section 113 , a subject aspiration section 114 , a sample preparation section 115 , a detection section 116 , a control section 117 , and a communication interface 118 .
The subject ID reading section 112 is provided with a bar code reader 112 a . Moreover, the subject arrival confirmation section 113 and the subject aspiration section 114 are provided with sensors 113 a and 114 a , respectively. Furthermore, the detection section 116 is provided with a white blood cell detection section 116 a , a red blood cell detection section 116 b , and an HGB detection section 116 c.
The transfer section 111 is configured to be capable of transferring the subject to the subject ID reading section 112 and the subject aspiration section 114 . The subject ID reading section 112 is configured such that a bar code attached on the subject transferred by the transfer section 111 is read by the bar code reader 112 a , and the transfer section 111 transfers the subject to the subject aspiration section 114 after the bar code of the subject has been read by the bar code reader 112 a . When the arrival of the subject on the subject aspiration section 114 has been confirmed by the sensor 113 a of the subject arrival confirmation section 113 , the subject aspiration section 114 performs an aspiration of the subject.
The subject aspiration section 114 is configured to monitor whether or not a predetermined amount of the subject has been aspirated by means of the sensor 114 a . The subject aspirated in the subject aspiration section 114 is mixed with a measurement reagent in the sample preparation section 115 , and measurement data are obtained by the respective detection sections of the detection section 116 . The measurement data include measurement data of a white blood cell count obtained by the white blood cell detection section 116 a , measurement data of a red blood cell count obtained by the red blood cell detection section 116 b , and measurement data of a hemoglobin amount in blood obtained by the HGB detection section 116 c . The control section 117 is configured to transmit the obtained measurement data to the control device 102 via the communication interface 118 .
FIG. 4 is a block diagram of the control device 102 . As illustrated in FIG. 4 , the control device 102 is a computer which is mainly configured by the display 102 a , the main body 102 b , and an input device 102 c.
The main body 102 b is mainly configured by a CPU 120 , a ROM 121 , a RAM 122 , a hard disk 123 , an I/O interface 124 , a reading device 125 , a communication interface 126 , and an image output interface 127 . The CPU 120 , the ROM 121 , the RAM 122 , the hard disk 123 , the I/O interface 124 , the reading device 125 , the communication interface 126 , and the image output interface 127 are connected with each other via a bus 128 so as to be capable of performing data communication between them.
The CPU 120 is capable of executing a computer program stored in the ROM 121 and a computer program loaded to the RAM 122 . When an application program is executed by the CPU 120 , later-described functional blocks are realized, and thus a computer functions as the control device 102 .
The ROM 121 is configured by a mask ROM, a PROM, an EPROM, an EEPROM, or the like, and stores therein a computer program executed by the CPU 120 and data used by the computer program.
The RAM 122 is configured by an SRAM, a DRAM, or the like. The RAM 122 is used for reading the computer program recorded on the ROM 121 and the hard disk 123 . Moreover, the RAM 122 is used as a work area of the CPU 120 when the computer program is executed.
The hard disk 123 has installed therein a variety of computer programs to be executed by the CPU 120 , such as an operating system or an application program, and data for use in execution of the computer programs.
The reading device 125 is configured by a flexible disk drive, a CD-ROM drive, a DVD-ROM drive, or the like. The reading device 125 is capable of reading the computer program or the data recorded on a portable recording medium 130 .
The I/O interface 124 is configured by a serial interface such as a USB, an IEEE 1394, or an RS-232C, a parallel interface such as an SCSI, an IDE, or an IEEE 1284, an analog interface such as a D/A converter or an A/D converter, or the like. The I/O interface 124 has connected thereto the input device 102 c that includes a keyboard and a mouse, so that data can be input to the main body 102 b by an operator using the input device 102 c.
The communication interface 126 is an Ethernet (the registered trademark) interface, for example, and the control device 102 is capable of transmitting or receiving data to or from the analysis device main body 101 connected thereto via the network 104 using a predetermined communication protocol by means of the communication interface 126 .
The image output interface 127 is connected to the display 102 a configured by an LCD, a CRT, or the like, and is configured to output an image signal corresponding to image data sent from the CPU 120 to the display 102 a . The display 102 a displays an image (screen) in accordance with the input image signal.
FIG. 5 is a block diagram of the management device 200 . The management device 200 is configured by a computer which is mainly configured by a main body 200 a , a display 200 b , and an input device 200 c.
The main body 200 a is mainly configured by a CPU 220 , a ROM 221 , a RAM 222 , a hard disk 223 , an I/O interface 224 , a reading device 225 , a communication interface 226 , and an image output interface 227 . The CPU 220 , the ROM 221 , the RAM 222 , the hard disk 223 , the I/O interface 224 , the reading device 225 , the communication interface 226 , and the image output interface 227 are connected with each other via a bus 228 so as to be capable of performing data communication between them.
The CPU 220 is capable of executing a computer program stored in the ROM 221 and a computer program loaded to the RAM 222 . When an application program is executed by the CPU 220 , later-described functional blocks are realized, and thus a computer functions as the management device 201 .
The ROM 221 is configured by a mask ROM, a PROM, an EPROM, an EEPROM, or the like, and stores therein a computer program executed by the CPU 220 and data used by the computer program.
The RAM 222 is configured by an SRAM, a DRAM, or the like. The RAM 222 is used for reading the computer program recorded on the ROM 221 and the hard disk 223 . Moreover, the RAM 222 is used as a work area of the CPU 220 when the computer program is executed.
The hard disk 223 has installed therein a variety of computer programs to be executed by the CPU 220 , such as an operating system or an application program, and data for use in execution of the computer programs.
The reading device 225 is configured by a flexible disk drive, a CD-ROM drive, a DVD-ROM drive, or the like. The reading device 225 is capable of reading the computer program or the data 230 a recorded on a portable recording medium 230 .
The application program does not only need to be provided by the portable recording medium 230 but also may be provided over an electronic telecommunication line (wired or wireless) from an external device communicably connected to a computer via the electronic telecommunication line. For example, the application program may be installed in a hard disk of a server computer on the Internet, so that the management device 200 makes an access to the server computer, downloads the computer program, and then installs the computer program in the hard disk 223 .
Furthermore, an operating system capable of providing a graphical user interface, e.g., the Windows (the registered trademark) manufactured and sold by Microsoft Corporation (US), is installed in the hard disk 223 . In the following description, the application program according to the present embodiment is assumed as running on the operating system.
In addition, the hard disk 223 stores, in a predetermined area thereof, a quality control result data database 223 a , a quality control error determination condition database 223 b , a quality control aggregate result database 223 c , an error information database 223 d , an error information determination condition database 223 e , an error information aggregate result database 223 f , and an application program 223 g.
The application program 223 g includes a notification determination processing program 223 h , a graph creation processing program 223 i , and a determination condition update program 223 j . The quality control result data database 223 a stores therein the quality control data received from the analysis device 100 a and a determination result which has been determined as requiring a notification to a user based on a quality control error determination condition. The quality control error determination condition database 223 b stores therein a determination condition for making a determination on the quality control data received from the analysis device 100 a as to whether or not a notification to the user is required. The quality control aggregate result database 223 c stores therein an output result of the graph creation processing program 223 i with respect to the determination result stored in the quality control result database 223 a . The error information database 223 d stores therein the error information received from the management device 100 and a determination result which has been determined as requiring a notification to a user based on the error information determination condition. The error information determination condition database 223 e stores therein a determination condition for making a determination on the error information received from the analysis device 100 a as to whether or not a notification to the user is required.
The error information aggregate result 223 f stores therein an output result of the graph creation processing program 223 i with respect to the determination result stored in the error information database 223 d . The notification determination processing program 223 h is configured to make a determination on the quality control data and the error information received from the analysis device 100 a as to whether a notification to a user is required. The graph creation processing program 223 i is configured to create and output a graph of the determination results stored in the quality control result database 223 a and the error information database 223 d . The determination condition update program 223 j is configured to update the error determination conditions stored in the quality control error determination condition database 223 b and the error information determination condition database 223 e.
The I/O interface 224 is configured by a serial interface such as a USB, an IEEE 1394, or an RS-232C, a parallel interface such as an SCSI, an IDE, or an IEEE 1284, an analog interface such as a D/A converter or an A/D converter, or the like. The I/O interface 224 has connected thereto the input device 200 c that includes a keyboard and a mouse, so that data can be input to the main body 200 a by an operator using the input device 200 c.
The communication interface 226 is an Ethernet (the registered trademark) interface, for example, and the management device 200 is capable of transmitting or receiving data to or from the analysis device 100 a connected thereto via the network 103 using a predetermined communication protocol and the terminal equipment of the call center connected thereto via the network 201 , by means of the communication interface 226 .
The image output interface 227 is connected to the display 200 b configured by an LCD, a CRT, or the like, and is configured to output an image signal corresponding to image data sent from the CPU 220 to the display 200 b . The display 200 b displays an image (screen) in accordance with the input image signal.
FIG. 6 is a block diagram of the terminal equipment 300 of the call center 203 . The terminal equipment 300 of the call center 203 is a computer which is mainly configured by a main body 300 a , a display 300 b , and an input device 300 c.
The main body 300 a is provided with a CPU 320 , a ROM 321 , a RAM 322 , a hard disk 323 , an I/O interface 324 , a reading device 325 , a communication interface 326 , and an image output interface 327 . The CPU 320 , the ROM 321 , the RAM 322 , the hard disk 323 , the I/O interface 324 , the reading device 325 , the communication interface 326 , and the image output interface 327 are connected with each other via a bus 328 so as to be capable of performing data communication between them.
The CPU 320 is capable of executing a computer program stored in the ROM 321 and a computer program loaded to the RAM 322 . When an application program is executed by the CPU 320 , later-described functional blocks are realized, and thus a computer functions as the terminal equipment 300 of the call center 203 .
The ROM 321 is configured by a mask ROM, a PROM, an EPROM, an EEPROM, or the like, and stores therein a computer program executed by the CPU 320 and data used by the computer program.
The RAM 322 is configured by an SRAM, a DRAM, or the like. The RAM 322 is used for reading the computer program recorded on the ROM 321 and the hard disk 323 . Moreover, the RAM 322 is used as a work area of the CPU 320 when the computer program is executed.
The hard disk 323 has installed therein a variety of computer programs to be executed by the CPU 320 , such as an operating system or an application program, and data for use in execution of the computer programs.
The reading device 325 is configured by a flexible disk drive, a CD-ROM drive, a DVD-ROM drive, or the like. The reading device 325 is capable of reading the computer program or the data 330 a recorded on a portable recording medium 330 .
The I/O interface 324 is configured by a serial interface such as a USB, an IEEE 1394, or an RS-232C, a parallel interface such as an SCSI, an IDE, or an IEEE 1284, an analog interface such as a D/A converter or an A/D converter, or the like. The I/O interface 324 has connected thereto the input device 300 c that includes a keyboard and a mouse, so that data can be input to the main body 300 a by an operator using the input device 300 c.
The communication interface 326 is an Ethernet (the registered trademark) interface, for example, and the terminal equipment 300 of the call center 203 is capable of transmitting or receiving data to or from the management device 200 connected thereto via the network 201 using a predetermined communication protocol by means of the communication interface 326 .
The image output interface 327 is connected to the display 300 b configured by an LCD, a CRT, or the like, and is configured to output an image signal corresponding to image data sent from the CPU 320 to the display 300 b . The display 300 b displays an image (screen) in accordance with the input image signal.
FIG. 7 is a flow chart illustrating the processing executed by the CPUs 120 , 220 and 320 of the control device, the management device, and the terminal equipment. As illustrated in FIG. 7 , the CPU 120 executes processing of making a determination in step S 100 as to whether or not an error has occurred in the analysis device main body 101 , i.e., whether or not the error information has been received from the analysis device main body 101 .
In the analysis device main body 101 , when the control section 117 has determined that it was impossible to read the bar code by means of the bar code reader 112 a , the control section 117 transmits information representing a bar code read error to the control device 102 . Moreover, when the control section 117 has determined that it was impossible to detect the arrival of the subject by means of the sensor 113 a , in spite of a fact that the subject has actually been arrived, the control section 117 transmits error information representing a subject arrival confirmation error to the control device 102 . Furthermore, when the control section 117 has determined that it was impossible to detect the aspiration of the subject by means of the sensor 114 a , in spite of a fact that the subject has actually been aspirated, the control section 117 transmits error information representing a subject aspiration error to the control device 102 .
When an error is determined to have occurred in step S 100 (No in step S 100 ), the CPU 120 stores therein the received error information (step S 105 ). On the other hand, when the error is determined not to have occurred in step S 1100 (Yes in step S 100 ), the CPU 120 makes a determination in step S 101 as to whether or not the measurement data of the quality control substance 106 have been received from the analysis device main body 101 .
The analysis device main body 101 is configured such that upon measurement of the quality control substance 106 , the measurement data are transmitted from the detection section 117 to the control section 117 and the control section 117 transmits the measurement data to the control device 102 .
When the measurement data are determined to have been received in step S 101 (Yes in step S 101 ), the CPU 120 analyzes the measurement data to acquire the quality control data 240 in step S 102 . Then, the CPU 120 stores in step S 103 the quality control data 240 acquired in step S 102 in the hard disk 123 and transmits in step S 104 the quality control data 240 to the management device 200 .
FIG. 8 illustrates the quality control data 240 transmitted in step S 104 from the control device 102 to the management device 200 . The quality control data 240 include device information 241 , information 242 on the quality control substance 106 , a quality control measurement date 243 , and a quality control measurement result 244 .
The device information 241 includes a facility name 241 a being the name of a facility in which the analysis device is installed, a device name 241 b , a PS Code 241 c appended to each analysis device main body 101 at the time of factory shipment, and a serial number 241 d.
The information 242 on the quality control substance 106 includes a quality control substance name 242 a , a level 242 b and a lot number 242 c of the quality control substance 106 , which are read from the bar code appended to the quality control substance 106 by means of a handy bar code reader or input by the input device 102 c of the control device 102 .
The quality control substance name 242 a is information representing a name of the quality control substance 106 . The level 242 b is information representing a concentration, e.g., LOW, NORMAL, and the like, of the quality control substance 106 . The lot number 242 c is information representing a lot at the time of manufacture of the quality control substance 106 .
The quality control measurement date 243 is information representing a date 243 a and a time 243 b of the receipt of the measurement data in step S 101 .
The quality control measurement result 244 is information representing the number of quality control measurement items 244 a and a measurement result of each item. For example, in FIG. 8 , the number of quality control measurement items 244 a shows that there are three measurement items including an RBC 244 b , an HGB 244 c , and a WBC 244 d . Moreover, the measurement result of each item shows that 4,470,000 cells/μL is for RBC, 13.5 g/L is for HGB, and 384 cells/μL is for WBC.
When the data received from the analysis device 100 a via the networks 103 and 201 are determined to be the quality control data 240 in step S 200 (Yes in step S 200 ), the CPU 220 of the management device 200 stores the received quality control data 240 in an area of the quality control result database 223 a of the hard disk 223 in step S 201 . Then, the CPU 220 activates the notification determination processing program 223 h to make a determination on the quality control data 240 received from the analysis device 100 a as to whether or not a notification is to be sent to a user of the analysis device 100 a by referring to a user determination availability 255 of the quality control error determination condition 250 , stored in the quality control error determination condition database 223 b in step S 202 .
FIG. 9 is a schematic view illustrating the quality control error determination condition 250 stored in the quality control error determination condition database 223 b . The quality control error determination condition 250 includes a material name 251 for identifying the quality control substance 106 , a level 252 , a measurement item 253 , an abnormality determination rule 254 , a user determination availability 255 , and an external cooperative error determination availability 256 .
The material name 251 is information representing a name of the quality control substance 106 . The level 251 is information representing a concentration, e.g., LOW, NORMAL, and the like, of the quality control substance 106 . The measurement item 253 is information representing a quality control measurement item. The abnormality determination rule 254 is information representing a determination item that makes a determination as to whether or not a notification to a user is required. For example, an action limit over 254 a determines that a notification to the user is required when the quality control data 240 obtained from a plurality of analysis devices 100 a have exceeded a value corresponding to an average thereof±an allowable percentage. A trend 254 b determines that a notification to the user is required when the quality control data 240 have exceeded an allowable range and showed four consecutive ascending or descending tendencies in the same direction. The user determination availability 255 is a setting that is set by the user of the analysis device 100 a , and is information representing whether or not a determination is to be made based on each abnormality determination rule 254 upon receipt of the quality control data 240 .
The external cooperative error determination availability 256 is a setting that is set by the engineer 205 of the customer support center 202 , and is information representing whether or not a determination is made based on each abnormality determination rule 254 upon receipt of the quality control data 240 .
Thereafter, in step S 203 , the CPU 220 makes a determination on the quality control data 240 as to whether the notification to the user is to be sent by referring to the external cooperative error determination availability 256 of the quality control error determination condition 250 .
In the present embodiment, a description has been made for a configuration in which a determination is made in step S 202 as to whether or not a notification is to be sent to the user of the analysis device 100 a by referring to the user determination availability 255 , and thereafter, a determination is made in step S 203 as to whether a notification is to be sent to the user of the analysis device 100 a by referring to the external cooperative error determination availability 256 . However, a configuration may be employed in which either one of the determination conditions may be selected so that a determination is made as to whether the notification is to be sent to the user of the analysis device 100 a by referring to the selected determination condition.
When the CPU 220 has determined in step S 220 that the notification to the user is required in the determination process of steps S 202 or S 203 (Yes in step S 220 ), the CPU 220 stores the quality control result 260 (see FIG. 11 ) in the quality control result database 223 a of the hard disk 223 in step S 221 , determines the terminal equipment 300 to be a destination of the notification from a plurality of terminal equipments 300 of the call center 203 , and sends a notification, in step S 223 , that it is necessary to send a notification to the user of the terminal equipment 300 of the call center 203 via the network 201 by referring to the notification destination determined in step S 222 . On the other hand, when the CPU 220 has determined in step S 220 that the notification to the user is not required (No in step S 220 ), the processes of steps S 221 to S 223 are not performed and the flow proceeds to the step S 230 .
FIG. 11 is a schematic view illustrating the quality control result 260 sent from the CPU 220 of the management device 200 to the terminal equipment 300 of the call center 203 in step S 223 . The quality control result 260 includes device information 261 , quality control substance information 262 , a measurement item 263 , a user determination condition 264 , an engineer determination condition 265 , a quality control measurement date 266 , a quality control result 267 , and an error name 268 .
The device information 261 includes a device name 261 b , a PS Code 261 c appended to each analysis device main body 101 at the time of factory shipment, and a serial number 261 d.
The quality control substance information 262 includes a quality control substance name 262 a , a level 262 b and a lot number 262 c of the quality control substance 106 .
The quality control substance name 262 a is information representing a name of the quality control substance 106 . The level 262 b is information representing a concentration, e.g., LOW, NORMAL, and the like, of the quality control substance 106 . The lot number 262 c is information representing a lot at the time of manufacture. The measurement item 263 is information representing a quality control measurement item for the quality control data 240 received by the CPU 220 , which have been determined by the notification determination processing program 223 h as requiring the notification to the user. The user determination condition 264 and the engineer determination condition 265 are information representing the availability of each determination condition. The quality control measurement date 266 is information representing the date and time of completion of the quality control measurement. The quality control result 267 and the error name 268 are information representing the measurement result of the measurement item 263 , which has been determined to be abnormal, and the abnormality determination rule 254 , which has been determined as requiring the notification to the user, in the notification determination process of step S 202 or S 203 .
Next, when the CPU 320 of the terminal equipment 300 of the call center 203 has determined in step S 300 that the data received from the management device 200 via the network 201 are the quality control result 260 as illustrated in FIG. 11 (Yes in step S 300 ), the CPU 320 displays the quality control result 260 as illustrated in FIG. 11 on the display 300 b via the image output interface 327 in step S 301 , thereby informing that a notification to a user is required.
Thereafter, a determination is made in step S 320 by the CPU 320 as to whether it has been instructed to shut down the operating system (OS) by the selection of shutdown from a start menu of the Windows (the registered trademark) being the OS of the terminal equipment 300 of the call center 203 . When it has been determined in step S 320 that the OS shutdown instruction has not been received (No in step S 320 ), the flow returns to step S 300 . On the other hand, when it has been determined in step S 320 that the OS shutdown instruction has been received (Yes in step S 320 ), the flow proceeds to step S 321 , where the process is terminated by the CPU 320 shutting down the Windows (the registered trademark) being the OS of the terminal equipment 300 of the call center 203 .
On the other hand, when the data have been determined in step S 300 not to be the quality control result 260 as illustrated in FIG. 11 (No in step S 300 ), the process of step S 310 is performed.
Next, a description of the processes which are performed when the error information 280 has been transmitted from the analysis device 100 a to the management device 200 via the networks 103 and 201 , and thereafter, a notification is sent from the management device 200 to the terminal equipment 300 of the call center 203 via the network 201 will be provided with reference to FIG. 7 .
When it has been determined in step S 106 that a shutdown instruction has been sent to the analysis device main body 101 from a user thereof (Yes in step S 106 ), the CPU 120 transmits the error information 280 as illustrated in FIG. 15 to the management device 200 via the networks 103 and 201 in step S 107 .
On the other hand, when it has been determined in step S 106 that the shutdown instruction has not been sent to the analysis device main body 101 (No in step S 106 ), the CPU 120 returns its flow to step S 100 and the processes of steps S 100 to S 105 are repeated.
FIG. 15 is a schematic view illustrating the error information 280 transmitted from the analysis device 100 a to the management device 200 . The error information 280 sent from the analysis device 100 a includes a serial number 281 , device information 282 , an error occurrence date and time 283 , and an error code 284 . The device information 282 is provided in order to identify the analysis device 100 a and includes a facility name 282 a being the name of a facility in which the analysis device 100 a is installed, a name 282 b of the analysis device 100 a , a PS Code 282 c appended to each analysis device main body at the time of factory shipment, and a serial number 282 d . The error occurrence date and time 283 includes an error occurrence date 283 a and an error occurrence time 283 b . The error code 284 represents identification information of an error occurred, so that a type of the error received from the analysis device 100 a can be uniquely identified.
When the CPU 220 of the management device 200 has determined in step S 211 that the data received from the analysis device 100 a via the networks 103 and 201 are the error information 280 as illustrated in FIG. 15 (Yes in step S 211 ), the CPU 220 stores the received error information 280 in the error information database 223 d of the hard disk 223 in step S 212 . Then, the CPU 220 executes the notification determination processing program 223 h in step S 213 to make a determination as to whether or not a notification is to be sent to the user of the analysis device 100 a by referring to the error information determination condition 290 of the error information determination condition database 223 e as illustrated in FIG. 16 .
FIG. 16 is a schematic view of the error information determination condition 290 stored in the error information determination condition database 223 e . The error information determination condition 290 includes a device name 291 , an error name 292 , an error code 293 , and an action limit 294 . The device name 291 is information representing a name of the analysis device 100 a . The error name 292 is information representing a name of the error. The error code 293 is information representing identification information uniquely corresponding to the error name 292 . The action limit 294 is information representing the limit of the number of times the error as specified in the error code 293 is allowed to occur per one day, the information being used in such a way that the notification to the user is determined to be necessary when the error information 280 received from the analysis device 100 a showed the number of occurrences of the error has exceeded the number as specified in the action limit 294 .
A description will be provided by way of example in which the error name 292 of the error information determination condition 290 illustrated in FIG. 16 is a short sample error. The short sample error represents an error occurring when it is determined that the sensor 114 a was impossible to sufficiently aspirate a subject, in spite of a fact that the control section 117 is aspirating the subject. When the error has occurred 10 times or more per one day, it is determined that the notification to the user is required.
When the notification determination processing program 223 h executed in step S 213 has determined in step S 220 that the notification to the user is required (Yes in step S 220 ), the error information determination result 295 as illustrated in FIG. 17 is stored in the error information database 223 d of the hard disk 223 in step S 221 . Then, the terminal equipment 300 of the call center 203 , which will be a notification destination, is determined in step S 222 , and a notification that the notification to the user is to be required is sent in step S 223 to the terminal equipment 300 of the call center 203 via the network 201 by referring to the notification destination determined in step S 222 .
On the other hand, when the notification to the user has been determined not to be necessary in step S 220 (No in step S 220 ), the CPU 220 determines whether or not a predetermined period has been elapsed in step S 230 , while the processes of steps S 221 to S 223 are not executed.
FIG. 17 is a schematic view illustrating the error information determination result 295 sent from the management device 200 to the terminal equipment 300 of the call center 203 .
The error information determination result 295 sent from the management device 200 to the terminal equipment 300 of the call center 203 includes device information 296 , an error occurrence date and time 297 , error information 298 , and an action limit 299 . The device information 296 includes a facility name 296 a being the name of a facility in which the analysis device 100 a is installed, a name 296 b of the analysis device 100 a , a PS Code 296 c appended to each analysis device main body at the time of factory shipment, and a serial number 296 d , for identification of the analysis device 100 a . The error occurrence date and time 297 includes information representing the date and time of occurrence of an error. The error information 298 includes an error name 298 a and an error code 298 b . The error name 298 a is information representing a name of an error occurring in the analysis device 100 a . The error code 298 b is information representing identification information of an error corresponding to the error name.
The action limit 299 is information representing the limit of the number of times the error as specified by the error information 298 is allowed to occur per one day, the information being used in such a way that the notification to the user is determined to be necessary when the error information 298 showed the number of occurrences of the error has exceeded the number as specified in the action limit 299 .
Next, when the CPU 320 of the terminal equipment 300 of the call center 203 has determined in step S 310 that the data received from the management device 200 via the network 201 are the error information determination result 295 as illustrated in FIG. 17 (Yes in step S 310 ), the CPU 320 displays the error information determination result 295 as illustrated in FIG. 17 on the display 300 b via the image output interface 327 in step S 311 .
On the other hand, when the data have been determined not to be the error information determination result 295 as illustrated in FIG. 17 (No in step S 310 ), the CPU 320 executes the process of step S 320 .
Thereafter, a determination is made in step S 320 by the CPU 320 as to whether it has been instructed to shut down the operating system (OS) by the selection of shutdown from a start menu of the Windows (the registered trademark) being the OS of the terminal equipment 300 of the call center 203 . When it has been determined in step S 320 that the OS shutdown instruction has not been received (No in step S 320 ), the flow returns to step S 300 . On the other hand, when it has been determined in step S 320 that the OS shutdown instruction has been received (Yes in step S 320 ), the flow proceeds to step S 321 , where the process is terminated by the CPU 320 shutting down the Windows (the registered trademark) being the OS of the terminal equipment 300 of the call center 203 .
Moreover, when the CPU 220 has determined in step S 230 that a predetermined period (e.g., one month) has been elapsed after previous graph creation processing (Yes in step S 230 ), the CPU 220 executes the graph creation processing program 223 i illustrated in FIG. 5 in step S 231 to collect the quality control result 260 stored in the quality control result database 223 a and the error information determination result 295 stored in the error information database 223 d to be output to a predetermined area of the hard disk 223 . After execution of the graph creation processing (step S 231 ), the flow returns to step S 200 .
On the other hand, when the CPU 220 has determined in step S 230 that the predetermined period has not been elapsed (No in step S 230 ), the flow proceeds to step S 232 .
Next, when there is an update request to update any one of the user determination availability 255 , the external cooperative error determination availability 256 of the quality control error determination condition 250 illustrated in FIG. 9 and the action limit 294 of the error information determination condition 290 from the engineer 205 of the customer support center 202 in step S 232 (Yes in step S 232 ), the CPU 220 executes the determination condition update program 223 j in step S 233 to update the determination condition stored in the quality control error determination condition database 223 b or the error information determination condition database 223 e of the hard disk 223 as illustrated in FIG. 5 based on the received determination condition.
FIG. 10 is a schematic view of a screen on which the engineer 205 of the customer support center 202 performs the update of the quality control error determination condition database 223 b illustrated in FIG. 5 .
A quality control error determination condition setting dialog 310 mainly includes a material name 311 , a level 312 , a measurement item 313 , an abnormality determination rule 314 , user determination availability 315 , external cooperative error determination availability 316 , an OK button 317 , and a Cancel button 318 .
The material name 311 is information representing a name of the quality control substance 106 . The level 312 is information representing a concentration, e.g., LOW, NORMAL, and the like, of the quality control substance 106 . The measurement item 313 is information representing a quality control measurement item. The abnormality determination rule 314 is information representing a determination item that makes a determination as to whether or not a notification to a user is required. The user determination availability 315 is a setting that is set by the user of the analysis device 100 a , and includes a user determination availability check box 315 a . The user determination availability check box 315 a is information representing that a determination as to the necessity of sending the notification to the user is to be performed when the box is checked (selected) while the determination as to the necessity of sending the notification to the user is not to be performed when the box is not checked. The external cooperative error determination availability 316 is a setting that is set by the engineer 205 of the customer support center 202 , and includes an external cooperative error determination availability check box 316 a . The external cooperative error determination availability check box 316 a is information representing that a determination as to the necessity of sending the notification to the user is to be performed when the box is checked (selected) while the determination as to the necessity of sending the notification to the user is not to be performed when the box is not checked.
When the OK button 317 is pressed, the contents of the quality control error determination condition database 223 b are updated to the setting contents being displayed on the quality control error determination condition setting dialog 310 , and the quality control error determination condition setting dialog 310 is closed. When the Cancel button 318 is pressed, the contents of the quality control error determination condition database 223 b are not updated, and the quality control error determination condition setting dialog 310 is closed.
For example, the quality control error determination condition setting dialog 310 illustrated in FIG. 10 shows that for a material having settings wherein the material name 311 is quality control substance A, the level 312 is LOW, the measurement item 313 is RBC, and the abnormality determination rule 314 is action limit over, when the quality control data 240 have been received from the analysis device 100 a , the determination as to the necessity of the notification to the user is performed in step S 202 , while the determination as to the necessity of the notification to the user is not performed in step S 203 .
On the other hand, when the CPU 220 has determined in step S 232 that there is no update request for any of the user determination availability 255 and the external cooperative error determination availability 256 of the quality control error determination condition 250 illustrated in FIG. 9 and the action limit 294 of the error information determination condition 290 illustrated in FIG. 16 (No in step S 232 ), the flow returns to step S 200 .
FIG. 12 is a flow chart illustrating a procedure of the graph creation processing in step S 231 . The CPU 220 acquires the quality control result 260 for a predetermined period from the quality control result database 223 a in step S 271 and then classifies the quality control result 260 for each device name 261 b from the acquired result in step S 272 .
Next, in step S 273 , the quality control result 260 is classified for each quality control substance name 262 a from the quality control result 260 classified in step S 272 , and the quality control result 260 is further classified for each level 262 b representing the concentration of the quality control substance 106 . Furthermore, the classified quality control result 260 is classified for each measurement item 263 in step S 274 , and the classified quality control result 260 is further classified for each error name 268 in step S 275 .
In this way, a plurality of groups is generated: e.g., a group (Group 1) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device A, the quality control substance name is quality control substance A, the level is LOW, the measurement item is RBC, and the error name is action limit over; a group (Group 2) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device A, the quality control substance name is quality control substance A, the level is LOW, the measurement item is RBC, and the error name is trend; a group (Group 3) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device A, the quality control substance name is quality control substance B, the level is NORMAL, the measurement item is HGB, and the error name is action limit over; and the like.
Thereafter, in step S 276 , a notification determination rate is calculated for each of the groups generated in step S 275 by using the following formula (1).
Notification Determination Rate=(Number of Notifications to User)/(Total Number of Quality Control Data) (1)
Herein, the number of notifications to user corresponds to the number of quality control results 260 contained in each of the groups. Moreover, the total number of quality control data corresponds to the number of quality control data 240 for each level of the quality control substance received from the plurality of analysis devices 100 a during the target period.
For example, when the notification determination rate for each of the groups is calculated, in calculation of the notification determination rate of Groups 1 and 2, the total number of quality control data represents the number of quality control data 240 contained in a group wherein the target period is from the previous graph creation date to the present graph creation date, the analysis device name is device A, the quality control substance name is quality control substance A, and the level is LOW. Moreover, in calculation of the notification determination rate of Group 3, the total number of quality control data represents the number of quality control data 240 contained in a group wherein the target period is from the previous graph creation date to the present graph creation date, the analysis device name is device A, the quality control substance name is quality control substance B, and the level is NORMAL.
In step S 277 , the notification determination rate calculated in step S 276 is output as an accumulated bar graph for each measurement item 263 . Furthermore, in step S 278 , the graph output in step S 277 is stored in a predetermined area of the quality control aggregate result database 223 c.
FIG. 13 is an example of a graph output in step S 277 and displayed to the terminal equipment 300 of the call center 203 . On an upper portion of the graph, an aggregate period 401 , an analysis device name 402 , a quality control substance name 403 , and a quality control substance level 404 are displayed.
In a graph portion 400 , an accumulated bar graph showing the notification determination rate for each item of the abnormality determination rule 254 of the quality control data 240 is displayed. Herein, RBC 405 is information representing a quality control measurement item. Reference numeral 406 is information representing the notification determination rate of the action limit of the RBC 405 . Reference numeral 407 is information representing the notification determination rate of the trend of the RBC 405 . Moreover, HGB 408 is information representing a quality control measurement item. Reference numeral 409 is information representing the notification determination rate of the action limit of the HGB 408 . Reference numeral 410 is information representing the notification determination rate of the trend of the HGB 408 .
As will be understood from the quality control measurement aggregate result for device A on April illustrated in FIG. 13 , for the quality control substance A having a concentration level of 1, the quality control item RBC shows a high notification determination rate based on the trend compared with the HGB. For example, when the high notification determination rate results from poor storage stability of the RBC of the quality control substance A, the quality control substance 106 itself has a problem but the analysis device 100 a does not have any problem. Therefore, it can be determined that the determination condition on the trend of the RBC is to be loosened to decrease the number of notifications to the user.
Next, the CPU 220 acquires the error information determination result 295 for a predetermined period from the error information database 223 d of the hard disk 223 in step S 281 and then classifies the error information determination result 295 for each name 296 b of the analysis device 100 a from the acquired error information determination result 295 in step S 282 . Subsequently, in step S 283 , the error information determination result 295 is classified for each error information 298 from the error information determination result 295 classified in step S 282 .
In this way, a plurality of groups is generated: e.g., a group (Group 4) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device A, and the error name is short sample; a group (Group 5) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device A, and the error name is whole blood aspiration motor stoppage abnormality; a group (Group 6) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device B, and the error name is short sample; and the like.
Thereafter, in step S 284 , a notification determination rate is calculated for each of the groups generated in step S 283 by using the following formula (2).
Notification Determination Rate=(Number of Determinations as Requiring Notification)/(Total Number of Device Names 296 b being Connected to Management Device 200) (2)
Herein, the number of determinations as requiring notification corresponds to the number of error information determination results 295 contained in each of the groups. Moreover, the total number of device names 296 b being connected to the management device 200 corresponds to the number of analysis devices 100 a having the same device name, being connected to the management device 200 .
For example, when the notification determination rate for each of the groups is calculated, in calculation of the notification determination rate of Groups 4 and 5, the total number of device names 296 b being connected to the management device 200 represents the number of analysis devices 100 a having the analysis device name of device A among the analysis devices 100 a being connected to the management device 200 . Moreover, in calculation of the notification determination rate of Group 6, the total number of device names 296 b being connected to the management device 200 represents the number of analysis devices 100 a having the analysis device name of device B among the analysis devices 100 a being connected to the management device 200 .
In step S 285 , the notification determination rate calculated in step S 284 is output as an accumulated bar graph for each device name 296 b . Furthermore, in step S 286 , the graph output in step S 285 is stored in a predetermined area of the error information aggregate result database 223 f.
FIG. 14 is an example of a graph output in step S 285 and displayed to the terminal equipment 300 of the call center 203 . On an upper portion of the graph, an aggregate period 451 and an analysis device name 452 are displayed.
Reference numeral 453 is information representing the notification determination rate of a short sample error. The short sample error represents an error occurring when the subject aspiration section 114 has detected that the sensor 114 a was impossible to sufficiently aspirate a subject at the time of the subject aspiration.
Reference numeral 454 is information representing the notification determination rate of a blank error. The blank error represents an error occurring when the detection section 116 has detected that the sample of a previous subject is left in the detection section 116 by a predetermined concentration or more.
Reference numeral 455 is information representing the notification determination rate of a rack operation abnormality error. The rack operation abnormality error is an error occurring when the transfer section 111 was unable to normally transfer a subject to the subject ID reading section 112 or the subject aspiration section 114 .
Moreover, reference numeral 456 is information representing the notification determination rate of a subject ID reading error. The subject ID reading error is an error occurring when it was impossible to read a bar code appended to the subject by means of the bar code reader 112 a.
It can, therefore, be expected from FIG. 14 , showing the notification determination rate of an error (rack operation abnormality) related to the transfer section 111 being 0.1 percent, that for example, when the notification determination rate is increasing compared with a previous month, the frequency of occurrence of the error related to the transfer section 111 will increase with time. Therefore, in order to reduce a shutdown time of the analysis device 100 a on next months, it is necessary to decrease the setting value of the action limit 294 for the rack operation abnormality of the error information determination condition 290 for the error related to the transfer section 111 and dispatch the engineer 204 to a facility being determined as requiring a notification, thereby preventing serious failures.
Moreover, when it is determined that notifications have been frequently sent to the user of the analysis device 100 a in which the short sample error has occurred due to a reason other than a failure of the device, such as a reason that the amount of a subject filled in a test tube is smaller than a prescribed amount, it may be determined that it is necessary to increase the setting value of the action limit 294 for the short sample of the error information determination condition 290 , thereby decreasing the number of notifications to the user.
Furthermore, since it is possible to obtain information on which unit showed a high error occurrence frequency, it is possible to know which unit preferentially requires an improvement design in future device development, which becomes useful information in development of an efficient device capable of reducing a shutdown time of the analysis device 100 a.
In the embodiment described above, a description has been made for a configuration in which when the quality control data 240 and the error information 280 received from the analysis device 100 a have been determined as requiring a notification to a user, the management device 200 of the customer support center 202 sends a notification thereof to the terminal equipment 300 of the call center 203 . However, the present invention is not limited to this and the terminal equipment 300 of the call center 203 may not be provided, for example. In such a case, a configuration may be employed in which when the notification to the user is determined to be necessary, the management device 200 sends a notification thereof to the control device 102 . This notification may be sent in such a way that a method of coping with the occurred error is sent via an email. Owing to such a configuration, it is possible to send a notification of occurrence of a trouble to a user even in the absence of the engineer 204 of the call center 203 to thereby eliminate further processing in the call center 203 , and thus, the trouble can be promptly notified to the user of the analysis device 100 a.
Moreover, in the present embodiment, a description has been made for a configuration in which when the management device 200 of the customer support center 202 has received the error information 280 , the received error information 280 is stored in the error information database 223 d of the hard disk 223 in step S 212 of the flow chart illustrated in FIG. 7 , and the notification determination processing program 223 h is executed in step S 213 to make a determination as to whether or not the notification to the user is required. However, a configuration may be employed in which the CPU 220 does not execute the determination processing of step S 213 .
That is, when the CPU 220 of the management device 200 has determined in step S 211 that the data received from the analysis device 100 a via the networks 103 and 201 are the error information 280 as illustrated in FIG. 15 (Yes in step S 211 ), the CPU 220 stores the received error information 280 in the error information database 223 d of the hard disk 223 in step S 212 .
Next, when the CPU 220 has determined in step S 230 that a predetermined period (e.g., one month) has been elapsed after previous graph creation processing (Yes in step S 230 ), the CPU 220 executes the graph creation processing program 223 i illustrated in FIG. 5 in step S 231 .
Then, the CPU 220 acquires the error information 280 for a predetermined period from the error information database 223 d of the hard disk 223 in step S 281 and classifies the error information 280 for each name 282 b of the analysis device 100 a from the acquired error information 280 in step S 282 . Subsequently, in step S 283 , the error information 280 is classified for each error code 284 from the error information 280 classified in step S 282 .
In this way, a plurality of groups is generated: e.g., a group (Group 7) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device A, and the error name is short sample; a group (Group 8) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device A, and the error name is whole blood aspiration motor stoppage abnormality; a group (Group 9) wherein a target period is from a previous graph creation date to a present graph creation date, the analysis device name is device B, and the error name is short sample; and the like.
Thereafter, in step S 284 , an abnormality occurrence rate is calculated for each of the groups generated in step S 283 by using the following formula (3).
Abnormality Occurrence Rate=(Number of Errors Received from Analysis Device 100 a )/(Total Number of Device Names 296 b being Connected to Management Device 200) (3)
Herein, the number of errors received from the analysis device 100 a corresponds to the number of error codes 284 contained in each of the groups.
Moreover, the total number of device names 296 b being connected to the management device 200 corresponds to the number of analysis devices 100 a having the same device name, being connected to the management device 200 .
For example, when the abnormality occurrence rate for each of the groups is calculated, in calculation of the abnormality occurrence rate of Groups 7 and 8, the total number of device names 296 b being connected to the management device 200 represents the number of analysis devices 100 a having the analysis device name of device A among the analysis devices 100 a being connected to the management device 200 . Moreover, in calculation of the abnormality occurrence rate of Group 9, the total number of device names 296 b being connected to the management device 200 represents the number of analysis devices 100 a having the analysis device name of device B among the analysis devices 100 a being connected to the management device 200 .
In step S 285 , the abnormality occurrence rate calculated in step S 284 is output as an accumulated bar graph for each device name 296 b . Furthermore, in step S 286 , the graph output in step S 285 is stored in a predetermined area of the error information aggregate result database 223 f.
FIG. 18 is an example of a graph output in step S 285 and displayed to the terminal equipment 300 of the call center 203 . On an upper portion of the graph, an aggregate period 461 and an analysis device name 462 are displayed. Reference numeral 463 is information representing the abnormality occurrence rate of a short sample error. Reference numeral 464 is information representing the abnormality occurrence rate of a blank error. Reference numeral 465 is information representing the abnormality occurrence rate of a rack operation abnormality error. Reference numeral 466 is information representing the abnormality occurrence rate of a subject ID reading error. Owing to such a configuration, since it is possible to identify an error showing a high occurrence frequency for each analysis device, it is possible to know which unit preferentially requires an improvement design in future device development, which becomes useful information in development of an efficient device capable of reducing a shutdown time of the analysis device 100 a.
Moreover, in the present embodiment, a description has been made for a configuration in which the engineer 205 of the customer support center 202 performs the update of the quality control error determination condition database 223 b . However, a configuration may be employed in which the user 107 of the analysis device 100 a performs the update of the quality control error determination condition database 223 b . For example, in response to a request sent from the analysis device 100 a to the management device 200 , an analysis device-side quality control error determination condition setting dialog 350 , as illustrated in FIG. 19 , for updating the quality control error determination condition database 223 b may be displayed on the display 102 a of the control device 102 .
The analysis device-side quality control error determination condition setting dialog 350 mainly includes a user determination condition setting grid 351 , an OK button 357 , and a Cancel button 358 .
The user determination condition setting grid 351 includes a material name 352 , a level 353 , a measurement item 354 , an abnormality determination rule 355 , and user determination availability 356 . The material name 352 is information representing a name of the quality control substance 106 . The level 353 is information representing a concentration, e.g., LOW, NORMAL, and the like, of the quality control substance 106 . The measurement item 354 is information representing a quality control measurement item. The abnormality determination rule 355 is information representing a determination item that makes a determination as to whether or not a notification to a user is required. The user determination availability 356 is a setting that is set by the user of the analysis device 100 a , and includes a user determination availability check box 356 a . The user determination availability check box 356 a is information representing that a determination as to the necessity of sending the notification to the user is to be performed when the box is checked (selected) while the determination as to the necessity of sending the notification to the user is not to be performed when the box is not checked. When the OK button 357 is pressed, the contents of the quality control error determination condition database 223 b are updated to the setting contents being displayed on the quality control error determination condition setting dialog 350 , and the quality control error determination condition setting dialog 350 is closed. When the Cancel button 358 is pressed, the contents of the quality control error determination condition database 223 b are not updated, and the quality control error determination condition setting dialog 350 is closed.
For example, the analysis device-side quality control error determination condition setting dialog 350 illustrated in FIG. 19 shows that for a material having settings wherein the material name 352 is quality control substance A, the level 353 is LOW, the measurement item 354 is RBC, and the abnormality determination rule 355 is action limit over or trend, when the management device 200 has received the quality control data 240 from the analysis device 100 a , the determination as to the necessity of the notification to the user is performed by the CPU 220 of the management device 200 in step S 202 . Meanwhile, for a material having settings wherein the material name 352 is quality control substance A, the level 353 is NORMAL, the measurement item 354 is HGB, and the abnormality determination rule 355 is action limit over, the determination as to the necessity of the notification to the user is not performed in step S 202 .
In addition, a description has been made for a configuration in which the analysis device-side quality control error determination condition setting dialog 350 in FIG. 19 selects the availability of each abnormality determination rule 355 . For example, when the quality control data 240 received from the analysis device 100 a have exceeded an average±an allowable percentage of the quality control data 240 obtained from the plurality of analysis devices 100 a , the action limit over 355 a determines that the notification to the user is required. However, a configuration may be employed in which the allowable percentage may be changed: that is, the settings of the abnormality determination rule 355 may be changed.
Furthermore, in the present embodiment, a description has been made for a configuration in which when the notification to the user has been determined to be necessary in the determination processing on the quality control data 240 received from the analysis device 100 a , the terminal equipment 300 of the call center 203 is determined as the notification destination in step S 222 . However, a configuration may be employed in which the analysis device 100 a is determined as the notification destination when the user determination availability 255 shows that the notification to the user is required, while the terminal equipment 300 of the call center 203 is determined as the notification destination when the external cooperative error determination availability 256 shows that the notification to the user is required.
Furthermore, in the present embodiment, a description has been made for a configuration in which the CPU 220 executes the graph creation processing of step S 231 when a predetermined period has been elapsed from the completion of the previous graph creation processing of step S 230 . However, a configuration may be employed in which the CPU 220 executes the graph creation processing of step S 231 when the engineer 205 of the customer support center 202 has instructed to execute the graph creation processing program 223 i. | A management system includes a plurality of analyzers; and a computer system connected to the analyzers via a network, wherein each of the analyzers comprises: a data transmitter for transmitting data produced by the analyzer to the computer system via the network, and wherein the computer system includes a memory under control of a processor, the memory storing instructions enabling the processor to carry out operations, comprising: (a) receiving a plurality of data transmitted from the data transmitters of the plurality of analyzers; (b) generating an aggregate result used for determining a determination condition for making a determination as to whether or not a notification to a user of the analyzer is required based on the plurality of received data; and (c) outputting the aggregate result. A computer system and a method of providing information are also disclosed. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a novel dicarboxylic acid derivative having antihypertensive activity and/or heart failure curing activity, and a process for preparing the same.
It has been known that atrial natriuretic peptide (ANP) secreted from atrial myocytes having strong diuretic, natriuretic and vasodilating activities and inhibiting activity on renin-angiotensin-aldosterone system is effective for curing hypertension and heart failure. However, ANP itself is a polypeptide and poorly absorbed in the digestive tracts, so that its administration route is limited to the parenteral route. On the other hand, it has been known that ANP is inactivated by neutral metalloendopeptidase, and the inhibitor of that enzyme increases the concentration of ANP in the blood and can also be used as a medicine for curing hypertension and/or heart failure.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a novel dicarboxylic acid derivative having excellent metalloendopeptidase inhibiting activity that is useful as an antihypertensive drug and/or a medicine for curing heart failure.
The present invention is concerned with a dicarboxylic acid derivative represented by the formula (I): ##STR2## wherein R represents hydrogen atom, a lower alkyl group, phenyl group or hydroxyl group; R 1 represents a straight or branched alkyl group having 1 to 10 carbon atoms or a lower alkyl group substituted by a group selected from aryl group, a sulfur- or nitrogen-containing heterocyclic monocyclic group and a cycloalkyl group having 4 to 8 carbon atoms; R 2 represents a substituted or unsubstituted aryl group, a cycloalkyl group having 4 to 8 carbon atoms or a sulfur-containing or nitrogen-containing heterocylcic group; X represents sulfur atom, oxygen atom or a substituted or unsubstituted imino group; Y 1 represents imino group, oxygen atom or sulfur atom and Y 2 represents nitrogen atom, or Y 1 represents a vinylene group and Y 2 represents a group: --CH═; m represents 0 to 3; and n represents 0 or 1, an ester thereof or pharmaceutically acceptable salts thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, the present invention is explained in detail.
As a specific example of the desired compound of the present invention, there may be mentioned compounds in which R 1 is a straight or branched alkyl group having 1 to 10 carbon atoms, a lower alkyl group substituted by phenyl group, a lower alkyl group substituted by thienyl group or a lower alkyl group substituted by cyclohexyl group; R 2 is phenyl group, a phenyl group substituted by a lower alkoxy group, cyclohexyl group, thienyl group or indolyl group; and X is sulfur atom, oxygen atom, imino group or an imino group substituted by a lower alkyl group. Among them, a pharmaceutically preferred compound is a compound in which R 1 is a straight or branched alkyl group having 1 to 10 carbon atoms, a lower alkyl group substituted by phenyl group or a lower alkyl group substituted by thienyl group; R 2 is phenyl group, a phenyl group substituted by a lower alkoxy group or indolyl group; X is imino group or an imino group substituted by a lower alkyl group; Y 1 is imino group, oxygen atom or sulfur atom; Y 2 is nitrogen atom; m is 2; and n is 0, and a further preferred compound is a compound in which R is hydrogen atom, R 1 is a straight or branched alkyl group having 1 to 10 carbon atoms or a lower alkyl group substituted by phenyl group; R 2 is phenyl group or indolyl group; X is imino group; Y 1 is oxygen atom or sulfur atom; Y 2 is nitrogen atom; m is 2; and n is 0.
In the desired compound (I) of the present invention, a free carboxylic acid has excellent pharmacological activity, and an ester thereof is a prodrug which is metabolized in vivo and hydrolyzed to be a free carboxylic acid exhibiting activity. Thus, as such an ester residue, there may be used any one which does not participate in the production of pharmaceutical effects when hydrolyzed in vivo, and is pharmaceutically acceptable. As a specific example of the ester compound, there may be mentioned, for example, mono C 1-8 alkyl ester, di C 1-8 alkyl ester, mono(phenyl lower alkyl) ester, di(phenyl lower alkyl) ester and mono C 1-8 alkyl-mono(phenyl lower alkyl) ester. Among them, a preferred ester compound is a mono or di C 1-8 alkyl ester compound, and particularly preferred is a mono- or diethyl ester compound. Further, as a pharmaceutically acceptable salt of the desired compound (I) of the present invention or an ester thereof, there may be mentioned, for example, an inorganic acid addition salt such as hydrobromide, hydrochloride, sulfate, phosphate and nitrate; and an organic acid addition salt such as methanesulfonate, p-toluenesulfonate, oxalate, fumarate, maleate, tartrate and citrate.
The desired compound (I) of the present invention includes 4 kinds of optically active isomers based on two asymmetric carbon atoms and a mixture thereof. Among them, those in which both of two asymmetric carbon atoms have S configurations (hereinafter referred to "(S--S) isomer") are pharmaceutically particularly preferred.
In the desired compound (I) of the present invention, the lower alkyl group and the lower alkoxy group mean an alkyl group having 1 to 6 carbon atoms and an alkoxy group having 1 to 6 carbon atoms, respectively.
The desired compound (I), an ester thereof or a salt thereof can be administered orally or parenterally, and can be used as a pharmaceutical preparation by mixing with an excipient suitable for oral or parenteral administration. The pharmaceutical preparation may be either a solid preparation such as a tablet, a capsule and a powder or a liquid preparation such as a solution, a suspension and an emulsion Further, in the case of parenteral administration, it may also be used in a form suitable for injection.
The dose varies depending on an administration method, age, body weight and state of a patient and a kind of a disease to be cured, but, in general, it may be preferably about 1 to 100 mg/kg, particularly about 3 to 30 mg/kg per day.
According to the present invention, the desired compound (I) can be prepared by: (1) carrying out condensation reaction of a carboxylic acid compound represented by the formula (II): ##STR3## wherein R 3 represents a protective group for carboxyl group; X 1 represents sulfur atom, oxygen atom or a substituted or unsubstituted imino group; and R 1 and R 2 each have the same meanings as defined above, a salt thereof or a reactive derivative of its free carboxyl group, and an amine compound represented by the formula (III): ##STR4## wherein R 4 represents a protective group for carboxy group; and R, Y 1 , Y 2 , m and n each have the same meanings as defined above, or a salt thereof, or
(2) carrying out condensation reaction of an acetic acid compound represented by the formula (IV): ##STR5## wherein Z 1 represents a reactive residue; and the other symbols each have the same meanings as defined above, and a compound represented by the formula (V): ##STR6## wherein X 2 represents thiol group, hydroxyl group or a substituted or unsubstituted amino group; and the other symbols each have the same meanings as defined above, or a salt thereof, then
(3) carrying out lower alkylation of said product when X 1 is an unsubstituted imino group or X 2 is an unsubstituted amino group, if desired, and
(4) removing the protective group(s) R 3 and/or R 4 , if further desired.
As the protective groups R 3 and R 4 for carboxyl group, there may be mentioned a lower alkyl ester, a halogen-substituted lower alkyl ester, a phenyl-lower alkyl ester and a phenacyl ester. As the reactive residue Z 1 , there may be suitably used a halogen atom, a lower alkylsulfonyloxy group and a lower alkylphenylsulfonyloxy group (e.g. p-toluenesulfonyloxy group).
As a salt of the carboxylic acid compound (II), an alkali metal salt and an alkaline earth metal salt may be suitably used, and as salts of the amine compound (III) and the compound (V), an inorganic salt such as a mineral acid salt and an organic acid salt may be suitably used.
The condensation reaction of the carboxylic acid compound (II) or a salt thereof and the amine compound (III) or a salt thereof may be carried out suitably in the presence of a dehydrating agent. As the dehydrating agent, any agent which can be used for synthesizing a peptide may be used, and there may be mentioned, for example, water-soluble carbodiimide such as 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide, and dicyclohexylcarbodiimide.
On the other hand, the condensation reaction of the reactive derivative in carboxyl group of the carboxylic acid compound (II) and the amine compound (III) or a salt thereof, and the condensation reaction of the acetic acid compound (IV) and the compound (V) or a salt thereof may be carried out suitably in the presence or absence of an acid acceptor. As the acid acceptor, there may be used suitably any of an organic base such as tri-lower alkylamine, N,N- di-lower alkylamine and pyridine; and an inorganic base such as an alkali metal hydroxide an alkali metal hydrogen carbonate, an alkali metal carbonate and an alkali metal hydride. As the reactive derivative in carboxyl group of the carboxylic acid compound (II), there may be used those conventionally used in synthesizing a peptide, for example, any of an acid halide, an active ester, mixed acid anhydride and azide.
These reactions are preferably carried out in the presence or absence of a suitable solvent under cooling or at room temperature, particularly at -30° C. to 30° C. The solvent is not particularly limited so long as it is inactive in the reactions, but may include, for example, dimethylformamide, tetrahydrofuran, dioxane, acetonitrile and hexamethylphosphoric triamide or a solvent mixture thereof.
In the starting compound (II) or (V), when X 1 is an unsubstituted imino group or X 2 is an unsubstituted amino group, the product obtained as described above may be further subjected to lower alkylation. The lower alkylation can be carried out according to a conventional method, for example, it can be carried out by reacting said product with a lower alkyl halide. The reaction with a lower alkyl halide can be carried out suitably in the presence of an acid acceptor in a solvent. As the lower alkyl halide, methyl iodide and ethyl iodide may be used suitably. As the acid acceptor and the solvent, there may be used the same ones described above. The reaction is preferably carried out under cooling or under heating, particularly at about room temperature.
The protective group(s) R 3 and/or R 4 can be removed from the product thus obtained by a conventional method such as catalytic hydrogenolysis and acidic hydrolysis depending on the kind of said protective group.
Among the above reactions, the reactions (1), (3) and (4) proceed without racemization, so that when an optically active starting compound is used, a corresponding optically active desired compound (I) can be obtained. Further, in the condensation reaction (2), nucleophilic substitution (SN 2 reaction) occurs on an asymmetric carbon atom. Since the reaction proceeds without racemization by selecting reaction conditions such as the kind of an acid acceptor suitably, an optically active desired compound having a desired configuration can be obtained by using an optically active starting compound previously having a suitable configuration. When the desired compound obtained is a racemic modification, it may be separated to the respective optically active isomers by a conventional method (e.g. chromatography).
The starting compounds (II) can be prepared by reacting the acetic acid compound (IV) with an acetic acid compound represented by the formula (VI): ##STR7## wherein R 5 represents a protective group for carboxyl group; and R 2 and X 2 each have the same meanings as defined above, in the presence of an acid acceptor (e.g. potassium carbonate) in a solvent (e.g. hexamethylphosphoric triamide), and then removing the protective group R 5 .
The amine compound (III) in which R is hydrogen atom, Y 1 is oxygen atom, Y 2 is nitrogen atom and n is 0 can be prepared by carrying out cyclization reaction of an amino acid compound represented by the formula (VII):
R.sup.6 --NH--(CH.sub.2).sub.m --COOH (VII)
wherein R 6 represents a protective group for amino group; and m has the same meaning as defined above, and an isocyanoacetic acid compound represented by the formula (VIII):
CN--CH.sub.2 --COOR.sup.4 (VIII)
wherein R 4 has the same meaning as defined above, in the presence of an acid acceptor (e.g. triethylamine) in a solvent (e.g. dimethylformamide), and then removing the protective group R 6 . Further, the compound (III) in which n is 1 may be prepared by reacting the product obtained above with diazomethane and then treating the product with silver benzoate.
The amine compound (III) in which Y 1 is sulfur atom or nitrogen atom and Y 2 is nitrogen atom can be prepared by treating an oxazole ring of the amine compound (III) in which Y 1 is oxygen atom and Y 2 is nitrogen atom in a solvent (e.g. methanol) with an acid (e.g. hydrochloric acid) to effect single ring-opening and closing the ring again by a sulfurizing agent (e.g. a dimer of p-methoxyphenylthionophosphine sulfide) or an iminating agent (e.g. ammonium acetate). Further, the starting compound (III) having a substituent (R) on a ring can be obtained by selecting an acylating agent, a sulfurizing agent or an iminating agent suitably when recyclization reaction is carried out after opening the oxazole ring. Moreover, the compound (III) in which Y 1 is sulfur atom, Y 2 is nitrogen atom, m is 0 and n is 1 may be prepared according to the method described in Beil., 27, 336, and the compound (III) in which Y 1 is vinylene group and Y 2 is a group: --CH═ may be prepared according to the method described in Beil., 14, 383.
The amine compound (V) can be prepared by carrying out condensation reaction of an acetic acid compound represented by the formula (IX): ##STR8## wherein X 3 represents a protected substituted or unsubstituted amino group or a protected thiol group, or a reactive derivative of its carboxyl group and the amine compound (III) by, for example, the method described in the reaction of the compounds (II) and (III), and then removing the protective group at X 3 .
Among the above reactions, the reactions of the acetic acid compound (IX) and the amine compound (III), and the acetic acid compound (IV) and the acetic acid compound (VI) can proceed without racemization as described in the above reaction (1) and reaction (2). Thus, by using an optically active compound as a starting material, an optically active compound (II) or (V) can be obtained. Further, when the compound obtained is a racemic modification, it may be separated to the respective optical isomers by a conventional method (e.g. chromatography).
EXAMPLES
The present invention is described in detail by referring to Examples.
EXAMPLE 1
(1) A mixture of 33 g of benzyl 2-bromo-4-phenylbutyrate, 22.1 g of (L)-phenylalanine tert-butyl ester, 13.8 g of potassium carbonate and 30 ml of hexamethylphosphoric triamide was stirred at room temperature overnight. Then, ethyl acetate was added to the mixture, and the insolubles were removed by filtration. The filtrate was washed and dried, and then the solvent was removed. The residue was purified by silica gel to obtain 16.6 g of N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)-(L)-phenylalanine tert-butyl ester and 9.9 g of N-((1R)-1-benzyloxycarbonyl-3-phenylpropyl)-(L)-phenylalanine tert-butyl ester as oily products, respectively.
(S--S) isomer
NMR CDCl 3 ) δ: 1.31 (s, 9H), 1.76˜2.06 (m, 3H), 2.51˜2.70 (m, 2H), 2.78˜2.97 (m, 2H), 3.30˜3.49 (m, 2H), 5.10 (s, 2H), 7.07˜7.28 (m, 10H), 7.34 (s, 5H).
(2) After 4.73 g of the above (S-S) isomer and 30 ml of trifluoroacetic acid were stirred under ice cooling for 10 minutes and further at room temperature for 50 minutes, the solvent was removed. A 10 % potassium carbonate aqueous solution was added to the residue to effect neutralization, and the crystals formed were collected by filtration to obtain 3.09 g of N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)-(L)-phenylalanine.
M.P.: 141° to 143.5° C.
(3) A mixture of 4.2 g of the product obtained, 3.27 g of 4-benzyloxycarbonyl-5-(2-aminoethyl)oxazole.monohydrobromide, 1.53 g of 1-hydroxybenzotriazole.monohydrate, 1.4 ml of triethylamine, 1.9 g of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide.hydrochloride and 30 ml of dimethylformamide was stirred at -20° C. for 1 hour and then at room temperature overnight. The solvent was removed, and then ethyl acetate was added to the residue. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel column chromatography (solvent: chloroform-ethyl acetate) to obtain 4.52 g of 4-benzyloxycarbonyl-5-(2-[N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl)oxazole as a colorless oily product.
NMR CDCl 3 ) δ: 1.68˜1.97 (m, 2H), 2.38˜2.76 (m, 3H), 2.97˜3.59 (m, 7H), 4.95, 5.06 (ABq, 2H), 5.33 (s, 2H), 7.02-7.42 (m, 20H), 7.67 (s, 1H).
EXAMPLES 2 TO 4
(1) The corresponding starting compounds (IV) and (VI) were treated in the same manner as in Example 1-(1) to obtain compounds shown in the following Table 1.
TABLE 1______________________________________ ##STR9##Ex- Absolute configura-am- tion of asymmetricple carbon atom substi- PhysicalNo. R.sup.1 R.sup.3 tuted by R.sup.1 group properties______________________________________2-(1)CH.sub.2 CH.sub.2 C.sub.6 H.sub.5 C.sub.2 H.sub.5 S State: oily product R State: oily product3-(1)(CH.sub.2).sub.7 CH.sub.3 Bzl S State: oily product R State: oily product4-(1)(CH.sub.2).sub.7 CH.sub.3 C.sub.2 H.sub.5 S State: oily product R State: oily product______________________________________ Note 1: Bzl represents benzyl group (hereinafter the same). Note 2: *represents an asymmetric carbon atom having an S configuration (hereinafter the same).
(2) The products having (S--S) configurations obtained in the above (1) were treated in the same manner as in Example 1-(2) to obtain (S--S) isomer compounds shown in the following Table 2.
TABLE 2______________________________________ ##STR10##Example No. R.sup.1 R.sup.3 Physical properties______________________________________2-(2) CH.sub.2 CH.sub.2 C.sub.6 H.sub.5 C.sub.2 H.sub.5 M.P.: 134 to 137° C.3-(2) (CH.sub.2).sub.7 CH.sub.3 Bzl M.P.: 129 to 131° C.4-(2) (CH.sub.2).sub.7 CH.sub.3 C.sub.2 H.sub.5 M.P.: 110 to 114° C.______________________________________
(3) The products obtained in the above (2) were treated in the same manner as in Example 1-(3) to obtain (S--S) isomer compounds shown in the following Table 3.
TABLE 3______________________________________ ##STR11##Ex-ampleNo. R.sup.1 R.sup.3 Y.sup.1 R.sup.4 Physical properties______________________________________2-(3) CH.sub.2 CH.sub.2 C.sub.6 H.sub.5 C.sub.2 H.sub.5 S C.sub.2 H.sub.5 State: syrup NMR (CDCl.sub.3) δ: 1.18 (t, 3H) 1.41 (t, 3H) 1.71˜1.88 (m, 2H) 2.49˜2.80 (m, 3H) 3.05˜3.63 (m, 5H) 3.93˜4.12 (m, 2H) 4.40 (q, 2H) 7.10˜7.36 (m, 10H) 8.60 (s, 1H)3-(3) (CH.sub.2).sub.7 CH.sub.3 Bzl O C.sub.2 H.sub.5 State: syrup NMR (CDCl.sub.3) δ: 0.78 (t, 3H) 1.16 (t, 3H) 1.15˜1.60 (m, 12H) 1.40˜1.54 (m, 2H) 2.65˜2.74 (m, 1H) 2.98˜3.17 (m, 2H) 3.19˜3.32 (m, 2H) 3.54˜3.68 (m, 2H) 3.93˜4.08 (m, 1H) 5.00 (q, 2H) 7.10˜7.39 (m, 10H) 7.76 (s, 1H)4-(3) (CH.sub.2).sub.7 CH.sub.3 C.sub.2 H.sub.5 O Bzl M.P. 58˜59° C.______________________________________
EXAMPLES 5 TO 14
The corresponding starting compounds (II) and (III) were treated in the same manner as in Example 1-(3) to obtain the desired compounds of (S-S) isomers shown in the following Tables 4 to 6.
TABLE 4______________________________________ ##STR12##Example No. R.sup.3 R.sup.4 Physical properties______________________________________5 Bzl C.sub.2 H.sub.5 State: syrup NMR (CDCl.sub.3) δ: 1.36 (t, 3H) 1.64 (br-s, 1H) 1.76˜1.96 (m, 2H) 2.42˜2.78 (m, 3H) 2.88˜3.32 (m, 5H) 3.41˜3.64 (m, 2H) 4.34 (q, 2H) 5.00 (q, 2H) 7.04˜7.37 (m, 15H) 7.67 (s, 1H)6 C.sub.2 H.sub.5 Bzl State: syrup NMR (CDCl.sub.3) δ: 1.17 (t, 3H) 1.69 (br-s, 1H) 1.68˜1.95 (m, 2H) 2.46˜2.76 (m, 3H) 3.03˜3.30 (m, 5H) 3.39˜3.60 (m, 2H) 4.02 (q, 2H) 5.34 (s, 2H) 7.10˜7.43 (m, 15H) 7.70 (s, 1H)7 C.sub.2 H.sub.5 C.sub.2 H.sub.5 State: syrup NMR (CDCl.sub.3) δ: 1.17 (t, 3H) 1.38 (t, 3H) 1.70 (br-s, 1H) 1.76˜1.96 (m, 2H) 2.47˜2.78 (m, 3H) 2.95˜3.30 (m, 5H) 3.43˜3.63 (m, 2H) 3.90˜4.11 (m, 2H) 4.37 (q, 2H) 7.12˜7.36 (m, 10H) 7.71 (s, 1H)______________________________________
TABLE 5______________________________________ ##STR13##Ex-ampleNo. R.sup.1 R.sup.3 R.sup.4 Physical properties______________________________________8 CH.sub.2 CH.sub.2 C.sub.6 H.sub.5 Bzl CH.sub.3 State: syrup NMR (CDCl.sub.3) δ: 1.7˜2.05 (m, 3H) 2.42˜2.69 (m, 2H) 2.84 (dd, 1H) 3.07 (dd, 1H) 3.19 (t, 1H) 3.36 (dd, 1H) 3.85 (s, 3H) 4.75 (d, 2H) 4.97, 5.07 (ABq, 2H) 7.03˜7.38 (m, 15H) 7.66 (t, 1H) 7.72 (s, 1H)9 CH.sub.2 CH.sub. 2 C.sub.6 H.sub.5 Bzl C(CH.sub.3).sub.3 State: syrup NMR (CDCl.sub.3) δ: 1.58 (s, 9H) 1.73˜1.95 (m, 2H) 2.42˜2.63 (m, 2H) 2.66˜2.79 (m, 1H) 3.02˜3.21 (m, 2H) 3.25˜3.36 (m, 1H) 3.39˜3.62 (m, 2H) 5.00 (q, 2H) 7.03˜7.37 (m, 15H) 7.64 (s, 1H)10 (CH.sub.2).sub.7 CH.sub.3 C.sub.2 H.sub.5 C.sub.2 H.sub.5 State: syrup NMR (CDCl.sub.3) δ: 0.87 (t, 3H) 1.16 (t, 3H) 1.20˜1.32 (m, 12H) 1.41 (t, 3H) 1.38˜1.55 (m, 2H) 2.68˜2.79 (m, 1H) 2.97˜3.16 (m, 3H) 3.22˜3.40 (m, 2H) 3.56˜3.72 (m, 2H) 4.01 (q, 2H) 4.39 (q, 2H) 7.16˜7.35 (m, 5H) 7.78 (s, 1H)______________________________________
TABLE 6______________________________________ ##STR14##Ex-ampleNo. R.sup.1 R.sup.3 Y.sup.1 R.sup.4 Physical properties______________________________________11 CH.sub.2 CH.sub.2 C.sub.6 H.sub.5 Bzl S C.sub.2 H.sub.5 State: syrup NMR (CDCl.sub.3) δ: 1.40 (t, 3H) 1.72˜1.98 (m, 2H) 2.41˜2.63 (m, 2H) 2.68˜2.80 (m, 1H) 3.00˜3.23 (m, 2H) 3.22˜3.33 (m, 1H) 3.41˜3.60 (m, 2H) 4.39 (q, 2H) 4.92˜5.10 (m, 2H) 7.03˜7.67 (m, 15H) 8.56 (s, 1H)12 CH.sub.2 CH.sub.2 C.sub.6 H.sub.5 C.sub.2 H.sub.5 S Bzl State: syrup NMR (CDCl.sub.3) δ: 1.78 (t, 3H) 1.73˜1.95 (m, 2H) 2.52˜2.78 (m, 3H) 3.03˜3.62 (m, 7H) 3.94˜4.12 (m, 2H) 5.38 (s, 2H) 7.09˜7.70 (m, 15H) 8.56 (s, 1H)13 (CH.sub.2).sub.7 CH.sub.3 Bzl O Bzl M.P. 58˜59° C.14 CH.sub.2 CH.sub.2 C.sub.6 H.sub.5 Bzl S Bzl State: syrup NMR (CDCl.sub.3) δ: 1.72˜1.98 (m, 2H) 2.39˜2.62 (m, 2H) 2.64˜2.78 (m, 1H) 2.97˜3.20 (m, 2H) 3.24˜3.33 (m, 1H) 3.34˜3.57 (m, 4H) 4.90˜5.09 (m, 2H) 5.37 (s, 2H) 7.01˜7.48 (m, 20H) 8.55 (s, 1H)______________________________________
EXAMPLE 15
1.8 g of 4-benzyloxycarbonyl-5-{2-[N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}oxazole was subjected to catalytic hydrogenolysis in 50 ml of dimethylformamide in the presence of 100 mg of palladium-black at 3 atmospheric pressure for 5 hours. After removal of the catalyst by filtration, the solvent was removed. The crystals obtained were recrystallized from methanol to obtain 1.1 g of 4-carboxy-5-{2-[N-((1S)-1-carboxy-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}oxazole.
M.P.: 179° to 181° C. (decomposed)
EXAMPLES 16 TO 22
The products obtained in Examples 3 to 6, 8, 9 and 13 were treated in the same manner as in Example 15 to obtain the desired products of (S--S) isomers shown in the following Tables 7 and 8.
TABLE 7______________________________________ ##STR15##Example No. R.sup.3 R.sup.4 Physical properties______________________________________16 C.sub.2 H.sub.5 H M.P.: 127˜129° C. Hydrochloride: 170˜171° C.17 H C.sub.2 H.sub.5 M.P.: 225˜227° C. (dec.)18 H CH.sub.3 M.P.: 221° C. (dec.)19 H C(CH.sub.3).sub.3 M.P.: 204° C. (dec.)______________________________________
TABLE 8______________________________________ ##STR16##Example No. R.sup.3 R.sup.4 Physical properties______________________________________20 H H M.P.: 170˜174° C.21 C.sub.2 H.sub.5 H M.P.: 126˜128° C.22 H C.sub.2 H.sub.5 M.P.: 165˜169° C.______________________________________
EXAMPLE 23
A mixture of 2.2 g of 4-benzyloxycarbonyl-5-{2-[N-((1S)-1-ethoxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}thiazole and 30 ml of a 25% hydrogen bromide-acetic acid solution was stirred at room temperature for one day. After removing the solvent, the mixture was neutralized with a 10% potassium carbonate aqueous solution. The crystals obtained were recrystallized from a methanol-isopropyl ether mixed solution to obtain 1.27 g of 4-carboxy-5-{2-[N-((1S)-1-ethoxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}thiazole.
M.P.: 121° to 124° C.
EXAMPLES 24 AND 25
The products obtained in Examples 11 and 14 were treated in the same manner as in Example 23 to obtain the desired compounds of (S--S) isomers shown in the following Table 9.
TABLE 9______________________________________ ##STR17##Example No. R.sup.3 R.sup.4 Physical properties______________________________________24 H C.sub.2 H.sub.5 M.P.: 211˜212° C.25 H H M.P.: 174° C. (dec.)______________________________________
EXAMPLES 26 TO 35
(1) A mixture of 5.91 g of ethyl (2R)-3-phenyl-2-p-toluenesulfonyloxy propionate, 15.7 g of (L)-phenylalanine benzyl ester, 2.91 g of di(isopropyl)ethylamine and 5 ml of hexamethylphosphoric triamide was stirred at 70° C. for 2 days, and then ethyl acetate was added thereto. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel column chromatography (solvent: hexane:ethyl acetate=9:1) to obtain 4.45 g (Yield: 69%) of N-((1S)-1-ethoxycarbonyl-2-phenylethyl)-(L)-phenylalanine benzyl ester as an oily product.
NMR (in CDCl 3 ) δ: 1.08 (t, 3H), 2.95 (t, 4H), 3.55˜3.69 (m, 2H), 3.99 (q, 2H), 5.01 (ABq, 2H), 7.08˜7.33 (m, 15H).
The corresponding starting compounds were treated in the same manner as described above to obtain compounds shown in the following Table 10.
TABLE 10__________________________________________________________________________ ##STR18##Example No. R.sup.1 R.sup.2 R.sup.3 R.sup.5 Physical properties__________________________________________________________________________27-(1) ##STR19## ##STR20## Bzl C(CH.sub.3).sub.3 State: oily product28-(1) CH.sub.2 CH(CH.sub.3).sub.2 " " " "29-(1) ##STR21## ##STR22## " " "30-(1) (CH.sub.2).sub.7 CH.sub.3 ##STR23## C(CH.sub.3).sub.3 Bzl "31-(1) ##STR24## " " " "32-(1) Isopentyl " Bzl C(CH.sub.3).sub.3 "33-(1) ##STR25## ##STR26## CH.sub.2 CH.sub.3 Bzl "34-(1) ##STR27## ##STR28## CH.sub.3 " M.P. = 87˜89° C.35-(1) " ##STR29## " " State: oily product__________________________________________________________________________
(2) The products obtained above were treated in the same manner as in Example 1-(2) or Example 15 to obtain compounds shown in the following Table 11.
TABLE 11__________________________________________________________________________ ##STR30##Example No. R.sup.1 R.sup.2 R.sup.3 Physical properties__________________________________________________________________________26-(2) ##STR31## ##STR32## CH.sub.2 CH.sub.3 M.P. = 150˜151° C.27-(2) ##STR33## " Bzl M.P. = 121˜123° C.28-(2) CH.sub.2 CH(CH.sub.3).sub.2 " " M.P. = 146˜148° C.29-(2) ##STR34## ##STR35## " M.P. = 126˜129° C.30-(2) (CH.sub.2).sub.7 CH.sub.3 ##STR36## C(CH.sub.3).sub.3 M.P. = 150˜152° C.31-(2) ##STR37## " " M.P. = 144˜146° C.32-(2) Isopentyl " Bzl M.P. = 146˜148° C.33-(2) ##STR38## ##STR39## CH.sub.2 CH.sub.3 Oily product34-(2) ##STR40## ##STR41## CH.sub.3 M.P. = 110˜112° C.35-(2) " ##STR42## " Oily product__________________________________________________________________________
(3) The products obtained above were treated in the same manner as in Example 1-(3) to obtain compounds shown in the following Tables 12 and 13.
TABLE 12__________________________________________________________________________ ##STR43##Example No. R.sup.1 R.sup.2 R.sup.3 Physical properties__________________________________________________________________________26-(3) ##STR44## ##STR45## CH.sub.2 CH.sub.3 State: Syrup NMR (in CDCl.sub.3) δ: 1.13 (t, 3H), 1.71 (s, 1H), 2.45˜ 2.62 (m, 2H), 2.74˜3.38 (m, 8H), 3.89˜4.17 (m, 2H), 5.39 (s, 2H), 6.36 (m, 1H), 7.11˜7.49 (m, 15H), 7.75 (s, 1H)27-(3) ##STR46## " Bzl State: Syrup NMR (in CDCl.sub.3) δ: 0.65˜ 1.83 (m, 15H), 2.67˜2.81 (m, 1H), 2.98˜3.18 (m, 2H), 3.18˜3.41 (m, 3H), 3.52˜ 3.71 (m, 2H), 4.91˜5.34 (m, 4H), 7.10˜7.42 (m, 15H), 7.74 (s, 1H)28-(3) CH.sub.2 CH(CH.sub.2).sub.3 " " M.P. 93˜95° C.29-(3) ##STR47## ##STR48## " State: Syrup NMR (in CDCl.sub.3) δ: 0.72˜ 1.04 (m, 2H), 1.06˜1.78 m, 11H), 1.78˜2.05 (m, 3H), 2.47˜2.79 (m, 2H), 3.12˜3.30 (m, 2H), 3.30˜ 3.72 (m, 2H), 5.13 (s, 2H), 5.32 (s, 2H), 7.07˜7.46 (m, 15H), 7.69 (s, 1H)30-(3) (CH.sub.2).sub.7 CH.sub.3 ##STR49## C(CH.sub.3).sub.3 State: Syrup NMR (in CDCl.sub.3) δ: 0.83˜ 0.86 (m, 3H), 1.11˜1.58 m, 14H), 1.36 (s, 9H), 2.70˜3.18 (m, 3H), 3.18˜ 3.39 (m, 3H), 3.42˜3.70 (m, 2H), 5.37 (s, 2H), 7.13˜7.43 (m, 10H), 7.76 (s, 1H)31-(3) ##STR50## " " State: Syrup NMR (in CDCl.sub.3) δ: 1.39 (s, 9H), 1.66˜1.92 (m, 2H), 1.93 (broad s, 1H), 2.46˜ 2.84 (m, 3H), 2.95˜3.28 (m, 7H), 5.34 (s, 2H), 7.11˜7.43 (m, 16H), 7.68 (s, 1H)32-(3) Isopentyl " Bzl M.P. 67˜69° C.__________________________________________________________________________
TABLE 13__________________________________________________________________________ ##STR51##Example No. R.sup.1 R.sup.2 R.sup.3 R.sup.4 Y.sup.1 Physical properties__________________________________________________________________________33-(3) ##STR52## ##STR53## CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.3 O State: Syrup NMR (in CDCl.sub.3) δ: 1.19 (t, 3H), 1.38 (t, 3H), 1.80˜1.97 (m, 3H), 2.47˜2.74 (m, 3H), 2.88˜3.27 (m, 6H), 3.43˜3.63 (m, 2H), 3.79 (s, 3H), 3.93˜4.17 (m, 2H), 4.36 (q, 2H), 6.72, 6.94 (ABq, 2H), 7.07˜ 7.31 (m, 7H), 7.71 (s, 1H)34-(3) ##STR54## ##STR55## CH.sub.3 Bzl " State: Syrup NMR (in CDCl.sub.3) δ: 1.97 (broad s, 1H), 2.40˜2.52 (m, 1H), 2.71˜2.95 (m, 5H), 3.16˜3.21 (m, 2H), 3.25 s, 3H), 3.28˜3.40 (m, 2H), 5.37 (s, 2H), 6.39˜6.44 (m, 1H), 7.02˜ 7.66 (m, 15H), 7.71 (s, 1H), 8.18 (broad s, 1H)35-(3) " ##STR56## " CH.sub.2 CH.sub.3 " State: Syrup NMR (in CDCl.sub.3) δ: 1.42 (t, 3H), 1.77 (broad s, 1H), 2.46˜2.59 (m, 2H), 2.76˜3.06 (m, 6H), 3.16˜3.42 (m, 2H), 3.54 (s, 3H), 3.80 (s, 3H), 4.39 (q, 2H), 6.38 (broad s, 1H0, 6.85, 7.07 (ABq, 2H), 7.15˜ 7.34 (m, 5H), 7.76 (s, 1H)__________________________________________________________________________
EXAMPLES 36 TO 37
The corresponding starting compounds were treated in the same manner as in Example 1-(3) to obtain compounds shown in the following Tables 14 and 15.
TABLE 14__________________________________________________________________________ ##STR57##Example No. R.sup.4 R Physical properties__________________________________________________________________________36 Bzl CH.sub.3 State: Syrup NMR (in CDCl.sub.3) δ: 1.62˜1.95 (m, 2H), 2.45˜3.60 (m, 10H), 2.38 (s, 3H), 4.94, 5.05 (ABq, 2H), 5.31 (s, 2H), 7.02˜7.39 (m, 20H)37 " ##STR58## State: Syrup NMR (in CDCl.sub.3) δ: 1.67˜1.83 (m, 2H), 1.90 (broad s, 1H), 2.32˜2.61 (m, 2H), 2.68˜2.79 (m, 1H), 3.00˜3.69 (m, 8H), 4.94, 5.04 (ABq, 2H), 5.37 (s, 2H), 6.93˜7.55 (m, 24H), 8.00˜8.05 (m, 2H)38 n-Oct H State: Syrup NMR (in CDCl.sub.3) δ: 0.03˜0.90 (m, 3H), 1.18˜1.46 (m, 10H), 1.63˜2.00 (m, 4H), 2.41˜2.65 (m, 8H), 2.67˜2.80 (m, 1H), 3.01˜3.15 (m, 1H), 3.16˜3.36 (m, 4H), 3.37˜3.67 (m, 2H), 4.24˜4.31 (m, 2H), 4.91˜5.10 (m, 2H), 7.03˜7.37 (m, 15H), 7.67 (s, 1H)39 n-Bu " State: Syrup NMR (in CDCl.sub.3) δ: 0.89˜0.97 (m, 2H), 1.32˜1.51 (m, 2H), 1.64˜2.00 (m, 4H), 2.41˜2.65 (m, 2H), 2.67˜2.80 (m, 1H), 3.01˜3.15 (m, 1H), 3.16˜3.36 (m, 4H), 3.37˜3.67 (m, 2H), 4.24˜4.31 (m, 2H), 4.91˜5.10 (m, 2H), 7.03˜7.37 (m, 15H), 7.67 (s, 1H)40 i-Bu " State: Syrup NMR (in CDCl.sub.3) δ: 1.72˜1.96 (m, 2H), 2.41˜2.62 (m, 2H), 2.64˜2.79 (m, 1H), 3.01˜3.11 (m, 1H), 3.12˜3.32 (m, 4H), 3.38˜3.63 (m, 2H), 4.01˜4.10 (m, 2H), 4.92˜5.10 (m, 2H), 7.03˜7.39 (m, 15H), 7.67 (s, 1H)41 i-Pr " State: Syrup NMR (in CDCl.sub.3) δ: 1.82˜2.05 (m, 2H), 2.51˜2.59 (m, 2H), 2.80˜3.00 (m, 1H), 3.08˜3.11 (m, 1H), 3.12˜3.25 (m, 2H), 3.26˜3.55 (m, 4H), 4.97˜5.11 (m, 2H), 5.15˜5.29 (m, 1H), 7.03˜7.38 (m, 15H), 7.66 (s, 1H)42 Bzl OH State: Syrup NMR (in CDCl.sub.3) δ: 1.70˜1.91 (m, 2H), 2.40˜2.61 (m, 2H), 2.68˜2.80 (m, 1H), 2.82˜2.95 (m, 2H), 2.98˜3.10 (m, 1H), 3.12˜3.24 (m, 1H), 3.36˜3.45 (m, 1H), 3.39˜3.52 (m, 2H), 4.90˜5.10 (m, 2H), 5.24 (s, 2H), 7.01˜7.37 (m, 20H), 8.38 (broad s, 1H)__________________________________________________________________________
TABLE 15__________________________________________________________________________ ##STR59##Example No. R.sup.1 R.sup.3 R.sup.4 Y.sup.1 m Physical properties__________________________________________________________________________43 ##STR60## t-Bu Bzl S 2 State: Syrup NMR (in CDCl.sub.3) δ: 1.39 (s, 9H), 1.63˜1.92 (m, 2H), 2.43˜2.70 (m, 2H), 2.78 (dd, 1H), 2.93˜ 3.10 (m, 2H), 3.22˜3.56 (m, 5H), 5.38 (s, 2H), 7.10˜7.48 (m, 16H), 8.58 (s, 1H)44 ##STR61## Et Et " " State: Syrup NMR (in CDCl.sub.3) δ: 1.14 (t, 3H), 1.47 (t, 3H), 1.50 (broad s, 1H), 2.40˜3.41 (m, 10H), 3.89˜ 4.09 (m, 2H), 4.46 (q, 2H), 6.43 (broad s, 1H), 7.11˜7.38 (m, 10H), 8.64 (s, 1H)45 ##STR62## CH.sub.3 CH.sub.3 O 1 State: Syrup NMR (in CDCl.sub.3) δ: 1.5˜2.0 (m, 4H), 2.5˜2.9 (m, 2H), 3.07˜3.47 (m, 2H), 3.42 (d, 2H), 3.75 (s, 3H), 3.93 (s, 3H), 6.93˜7.31 (m, 1H), 7.75 (s, 1H)46 " Bzl Bzl " 3 State: Syrup NMR (in CDCl.sub.3) δ: 1.63 (s, 1H), 1.72˜1.96 (m, 4H), 2.52˜2.70 (m, 2H), 2.75˜3.34 (m, 8H), 4.97, 5.07 (ABq, 2H), 5.3 (s, 2H), 7.01˜7.39 (m, 20H), 7.73 (s, 1H)47 " " " NH 2 State: Syrup NMR (in CDCl.sub.3) δ: 1.6˜2.2 (m, 2H), 2.4˜3.7 (m, 8H), 4.96, 5.06 (ABq, 2H), 5.32 (s, 2H), 7.00˜8.44 (m, 21H)__________________________________________________________________________
EXAMPLE 48
(1) A mixture of 2.56 g of (2S)-3-(2-thienyl)-2-(benzyloxycarbonylamino)propionic acid, 2.39 g of 4-benzyloxycarbonyl-5-(2-aminoethyl)oxazole.hydrobromide, 1.42 g of 1-hydroxybenzotriazole hydrate and 30 ml of dimethylformamide was cooled to -20° C., and 1.77 g of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide.hydrochloride was added thereto. After 10 minutes, 0.93 g of triethylamine was added to the mixture, and the temperature of the mixture was gradually returned to room temperature and the mixture was stirred overnight. The solvent was removed, and ethyl acetate was added to the residue. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel column chromatography (solvent: chloroform:ethyl acetate=19:1) to obtain 3.5 g of 4-benzyloxycarbonyl-5-{2-[N-((2S)-3-(2-thienyl)-2-(benzyloxycarbonylamino)propionyl)amino]ethyl}oxazole as syrup.
NMR (in CDCl 3 ) δ: 3.15˜3.28 (m, 4H), 3.46˜3.59 (m, 2H), 4.35 (m, 1H), 5.09 (s, 2H), 5.31 (s, 3H), 6.47 (br s, 1H), 6.75 (m, 1H), 6.83˜6.88 (m, 1H), 7.09˜7.12 (m, 1H), 7.32˜7.42 (m, 10H), 7.69 (s, 1H).
(2) A mixture of 2.67 g of the product obtained and 20 ml of a 25% hydrogen bromide-acetic acid solution was stirred at room temperature for 10 minutes. Then, the solvent was removed, and the residue was powdered by adding ethyl ether. A mixture of 1.67 g of the powder obtained, 1.67 g of (1R)-1-benzyloxycarbonyl-1-(p-toluenesulfonyloxy)-3-phenylpropane, 1.75 ml of triethylamine and 20 ml of hexamethylphosphoric triamide was stirred at 75° C. overnight, and then ethyl acetate was added thereto. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel column chromatography (solvent: chloroform:ethyl acetate =98:2) to obtain 2.1 g of 4-benzyloxycarbonyl-5-{2-[N-((2S)-3-(2-thienyl)-2-(N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)amino)propionyl)amino]ethyl}oxazole.
M.P.: 81°˜83° C.
EXAMPLES 49 TO 51
(1) The corresponding starting compounds were treated in the same manner as in Example 48-(1) to obtain the following compounds.
49-(1): 4-benzyloxycarbonyl-5-{2-(N-benzyloxycarbonyl-(L)-phenylalanyl)aminoethyl}oxazole
M.P.: 148°˜149° C.
50-(1): 3-benzyloxycarbonyl-1-(N-benzyloxycarbonyl-(L)-phenylalanyl)amino}benzene
M.P.: 141°˜143° C.
51-(1): 4-benzyloxycarbonylmethyl-2-((N-benzyloxycarbonyl-(L)-phenylalanyl)amino)thiazole
NMR (in CDCl 3 ) δ: 3.03˜3.38 (m, 2H), 3.69 (s, 2H), 4.73˜4.89 (m, 1H), 5.07˜5.09 (m, 2H), 5.14 (s, 2H), 5.55˜5.70 (m, 1H), 6.78 (s, 1H), 7.04˜7.41 (s, 1H).
(2) The compounds obtained in the above (1) and the corresponding starting compounds were treated in the same manner as in Example 48-(2), respectively, to obtain the following compounds.
49-(2): 4-benzyloxycarbonyl-5-{2-[N-((1S)-1-benzyloxycarbonyl-3-(2-thienyl)propyl)-(L)-phenylalanyl]aminoethyl}oxazole
State: syrup
NMR (in CDCl 3 ) δ: 1.66 (br s, 1H), 1.5˜1.9 (m, 2H), 2.31˜2.39 (m, 2H), 2.60 (dd, 1H), 3.13˜3.33 (m, 5H), 3.33˜3.49 (m, 2H), 5.02, 5.11 (ABq, 2H), 5.35 (s, 2H), 6.53 (m, 1H), 6.85 (m, 1H), 7.08 (m, 1H), 7.16˜7.52 (m, 16H), 7.69 (s, 1H).
50-(2): 3-benzyloxycarbonyl-1-{[N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]amino}benzene
State: syrup
NMR (in CDCl 3 ) δ: 1.60˜2.25 (m, 4H), 2.51˜3.02 (m, 2H), 3.13˜3.45 (m, 2H), 4.98, 5.08 (ABq, 2H), 5.32, 5.41 (ABq, 2H), 6.85˜7.44 (m, 24H), 7.7˜8.0 (m, 1H).
51-(2): 4-benzyloxycarbonylmethyl-2-{(N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl)amino}thiazole
State: syrup
NMR (in CDCl 3 ) δ: 1.85˜2.06 (m, 2H), 2.07˜2.29 (m, 2H), 2.53˜2.76 (m, 2H), 2.81˜3.00 (m, 1H), 3.44˜3.56 (m, 1H), 3.76 (s, 2H), 5.15˜5.17 (m, 4H), 6.80˜7.42 (m, 21H).
EXAMPLES 52 TO 68
The products obtained in Examples 26 to 32, 36 to 39, 41 to 43, 46, 47 and 49 were treated in the same manner as in Examples 15, respectively, to obtain compounds shown in the following Tables 16 to 18.
TABLE 16______________________________________ ##STR63##ExampleNo. R R.sup.3 R.sup.4 Physical properties______________________________________52 CH.sub.3 H H M.P. 174˜175° C. (dec.)53 ##STR64## " " M.P. 207˜209° C. (dec.)54 H t-Bu " M.P. 128˜209° C.55 " H n-Oct M.P. 191˜192° C.56 " " n-Bu M.P. 217˜218° C.57 " " i-Pr M.P. 212˜213° C.58 OH " H M.P. 105° C. (dec.)______________________________________
TABLE 17__________________________________________________________________________ ##STR65##Example No. R.sup.1 R.sup.2 Y.sup.1 m Physical properties__________________________________________________________________________59 ##STR66## ##STR67## NH 2 M.P. 178° C. (dec.)60 " " O 3 M.P. 179˜181° C.61 " ##STR68## " 2 M.P. 125° C. (dec.)62 CH.sub.2 CH(CH.sub.3).sub.2 ##STR69## " " M.P. 183˜185° C.63 ##STR70## " " " M.P. 187° C. (dec.)64 ##STR71## ##STR72## " " M.P. 110˜113° C. (dec.)65 CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 ##STR73## " " M.P. 124˜127° C.__________________________________________________________________________ (dec.)
TABLE 18______________________________________ ##STR74##Ex-ample PhysicalNo. R.sup.1 R.sup.3 Y.sup.1 properties______________________________________66 (CH.sub.2).sub.7 CH.sub.3 t-Bu O M.P. 136˜138° C.67 ##STR75## CH.sub.2 CH.sub.3 " M.P. 53˜56° C.68 ##STR76## t-Bu S M.P. 135˜136° C.______________________________________ (dec.)
EXAMPLE 69
A mixture of 2.6 g of the compound obtained in Example 1, 0.4 ml of methyl iodide, 0.83 g of potassium carbonate and 3 ml of hexamethylphosphoric triamide was stirred at room temperature overnight. Then, ethyl acetate was added to the mixture, and the insolubles were removed by filtration. The filtrate was washed and dried, and then the solvent was removed. The residue was purified by silica gel column chromatography (solvent: chloroform:ethyl acetate=95:5) to obtain 1.81 g (Yield: 68%) of 4-benzyloxycarbonyl-5-(2-[N-((1S)-1-benzyloxycarbonyl-3-phenylpropyl)-N-methyl-(L)-phenylalanyl]aminoethyl}oxazole as an oily product.
NMR (in CDCl 3 ) δ: 1.65 (s, 1H), 1.65˜1.97 (m, 2H), 2.35 (s, 3H), 2.35˜2.54 (m, 2H), 2.65˜2.82 (m, 1H), 3.00˜3.56 (m, 7H), 4.92˜5.17 (m, 2H), 5.32 (s, 2H), 6.99˜7.43 (m, 20H), 7.65 (s, 1H).
EXAMPLES 70 AND 71
The compounds obtained in Examples 50 and 69 were treated in the same manner as in Example 15 to obtain the following compounds.
70: 3-carboxy-1-{([N-((1S)-1-carboxy-3-phenylpropyl)-(L)-phenylalanyl]amino}benzene
M.P.: 201°˜202° C. (decomposed)
71: 4-carboxy-5-(2-(N-((1S)-1-carboxy-3-phenylpropyl)-N-methyl-(L)-phenylalanyl]aminoethyl}oxazole
M.P.: 104°˜106° C.
EXAMPLES 72 AND 73
The compounds obtained in Examples 49 and 51 were treated in the same manner as in Example 23 to obtain the following compounds.
72 4-carboxy-5-{2-(N-((1S)-1-carboxy-3-(2-thienyl)propyl)-(L)-phenylalanyl]aminoethyl}oxazole
M.P.: 125°˜12720 C. (decomposed)
73: 4-carboxymethyl-2-([N-((1S)-1-carboxy-3-phenylpropyl)-(L)-phenylalanyl]amino}thiazole
M.P.: 178° C. (decomposed)
EXAMPLE 74
0.35 g of the compound obtained in Example 35, 0.88 ml of 2N-NaOH and 20 ml of methanol were stirred overnight at room temperature, and then water was added thereto. Methanol was removed and the residue was extracted with ethyl ether. Then, the aqueous layer was neutralized with 1N-HCl and extracted with ethyl acetate. The extract was washed and dried, and then the solvent was removed. The residue was powdered by adding isopropyl ether to obtain 0.18 g of 4-carboxy-5-{2-[N-((1S)-1-carboxy-2-phenylethyl)-3-(4-methoxyphenyl)-(L)-alanyl]aminoethyl}oxazole.
M.P.: 103°˜106° C.
EXAMPLES 75 TO 80
The compounds obtained in Examples 26, 33 to 35 and 46 were treated in the same manner as in Example 74 to obtain compounds shown in the following Table 19.
TABLE 19__________________________________________________________________________ ##STR77##Example No. R.sup.1 R.sup.2 R.sup.7 Y.sup.1 m Physical properties__________________________________________________________________________75 ##STR78## ##STR79## H O 2 M.P. = 152˜154° C.76 ##STR80## ##STR81## " " " M.P. = 117˜119° C.77 ##STR82## ##STR83## " " " M.P. = 147° C. (dec.)78 " ##STR84## CH.sub.3 " " M.P. = 103˜106° C.79 " ##STR85## H S " M.P. = 188˜189° C.80 ##STR86## " " O 1 M.P. = 175˜178°__________________________________________________________________________ C.
EXAMPLE 81
(1) A mixture of 1.2 g of 1-tert-butoxycarbonyl-2-phenylethanethiol, 0.22 g of sodium hydride (60% oil) and 20 ml of dimethylformamide was stirred at room temperature for 30 minutes. Then, under ice-cooling, a solution of 1.7 g of benzyl 2-bromo-3-phenylbutyrate dissolved in 5 ml of dimethylformamide was added dropwise to the mixture, and the mixture was stirred at room temperature for 1 hour. Ethyl ether was added to the mixture, and the mixture was washed. The solvent was removed, and the residue was purified by silica gel chromatography (solvent: hexane:ethyl ether=95:5) to obtain 1.25 g (Yield: 51%) of 1-benzyloxycarbonyl-3-phenylpropyl-1-tert-butoxycarbonyl-2-phenylethyl sulfide as an oily product.
NMR (in CDCl 3 ) 6: 1.30 (m, 9H), 1.96˜2.24 (m, 2H), 2.59˜3.14 (m, 4H), 3.35˜3.66 (m, 2H), 5.12 (m, 2H), 7.06˜7.36 (m, 15H).
(2) A mixture of 1.47 g of the product obtained, 1.71 g of anisole and 10 ml of trifluoroacetic acid was stirred at room temperature for 1 hour, and then the solvent was removed. Toluene was added to the residue, and the solvent was removed again. Said operation was repeated twice. 0.86 g of the product obtained, 0.55 g of 1-hydroxybenzotriazole.hydrate, 0.69 g of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide.hydrochloride and 0.5 ml of triethylamine were mixed at -20° C., and then the mixture was stirred overnight while returning the temperature gradually to room temperature. The solvent was removed, and ethyl acetate was added to the residue. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel chromatography (solvent: hexane:ethyl acetate=5:1) to obtain 1.13 g (Yield: 54%) of 4-benzyloxycarbonyl-5-{[3-phenyl-2-((1S)-1-benzyloxycarbonyl- 3-phenylpropylthio)propionyl]aminoethyl}oxazole as an oily product.
NMR (in CDCl 3 ) δ: 1.89 (m, 1H), 2.12 (m, 1H), 2.60 (m, 2H), 2.82 (m, 1H), 2.99˜3.52 (m, 7H), 5.10 (m, 2H), 5.3 (m, 2H), 6.93˜7.41 (m, 20H), 7.65 (s, 1H).
(3) A mixture of 1.00 g of the product obtained, 2 g of palladium black and 50 ml of methanol was stirred under hydrogen atmosphere (3 atm.) overnight. The catalyst was removed by filtration, and then the solvent was removed to obtain 0.69 g (Yield: 95%) of 4-carboxy-5-{[3-phenyl-(2S)-2-((1S)-1-carboxy-3-phenylpropylthio)propionyl]aminoethyl}oxazole as an oily product.
NMR (DMSO-ds) δ: 1.75˜1.98 (m, 2H), 2.22˜2.39 (m, 1H), 2.50˜2.62 (m, 2H), 2.73˜2.89 (m, 2H), 3.01˜3.36 (m, 5H), 3.36˜3.66 (m, 1H), 7.15˜7.37 (m, 10H), 8.25, 8.26 (s, s, 1H).
REFERENCE EXAMPLE 1
(1) A mixture of 33.5 g of N-benzyloxycarbonyl-β-alanine, 15 g of methyl isocyanoacetate, 31.8 g of diethylphosphorylcyanide, 23 g of 1,8-diazabicyclo[5.4.0]undec-7-ene, 42 ml of triethylamine and 300 ml of dimethylformamide was stirred at room temperature overnight. Then, the solvent was removed, and ethyl acetate was added to the mixture. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel chromatography and crystallized from isopropyl ether, followed by recrystallization from an ethyl acetate-isopropyl ether mixed solution, to obtain 22.6 g of 4-methoxycarbonyl-5-{2-(benzyloxycarbonylamino)ethyl}oxazole.
M.P.: 68°˜70° C.
(2) 5 g of the product obtained and 50 ml of a 25% hydrogen bromide-acetic acid solution were stirred at room temperature for 15 minutes, and then the solvent was removed. The residue was crystallized from ethyl ether to obtain 4-methoxycarbonyl-5-(2-aminoethyl)oxazole monohydrobromide as crude crystals, which was used in the next reaction without purification.
REFERENCE EXAMPLE 2
(1) The corresponding starting compound was treated in the same manner as in Reference example 1-(1) to obtain the following compound.
4-benzyloxycarbonyl-5-(3-tert-butoxycarbonylamino)propyl}oxazole
M.P.: 124°˜126° C.
(2) The product obtained above was treated in the same manner as in Reference example 1-(2) to obtain 4-benzyloxycarbonyl-5-(3-Aminopropyl)oxazole.monohydrobromide.
REFERENCE EXAMPLES 3 TO 9
(1) The corresponding starting compounds were treated in the same manner as in Reference example 1-(1) to obtain compounds shown in the following Table 20.
TABLE 20______________________________________ ##STR87##Referenceexample No. R.sup.4 m Physical properties______________________________________3-(1) Bzl 1 M.P. 124˜126° C.4-(1) Bzl 2 M.P. 76˜79° C.5-(1) t-Bu " Oily product6-(1) n-Oct " M.P. 44˜46° C.7-(1) n-Bu " M.P. 43˜44° C.8-(1) i-Bu " Oily product9-(1) i-Pr " Oily product______________________________________
(2) The products obtained above were treated in the same manner as in Reference example 1-(2) to obtain compounds shown in the following Table 20-a.
TABLE 20-a______________________________________ ##STR88##Reference example No. R.sup.4 m______________________________________3-(2) Bzl 14-(2) Bzl 25-(2) t-Bu 26-(2) n-Oct 27-(2) n-Bu 28-(2) i-Bu 29-(2) i-Pr 2______________________________________
REFERENCE EXAMPLE 10
(1) A mixture of 30 g of 4-methoxycarbonyl-5-{2-benzyloxycarbonylamino)ethyl}oxazole, 75 ml of a 2N sodium hydroxide aqueous solution and 75 ml of methanol was stirred at room temperature for 3 hours. Methanol was removed, and then 1N hydrochloric acid was added dropwise to the residue under ice cooling. The crystals obtained were collected by filtration to obtain 25.8 g of 4-carboxy-5-{2-(benzyloxycarbonylamino)ethyl}oxazole, which was used in the next reaction without purification.
(2) A mixture of 2.9 g of the product obtained, 1.81 g of dicyclohexylamine, 2.33 g of ethyl iodide and 20 ml of dimethylformamide was stirred at room temperature overnight. The solvent was removed, and then 30 ml of ethyl acetate was added to the residue. The mixture was washed and died, and then the solvent was removed. The residue was purified by silica gel chromatography and crystallized from isopropyl ether, followed by recrystallization from an ethyl acetate-n-hexane mixed solution, to obtain 2.89 g of 4-ethoxycarbonyl-5-{2-(benzyloxycarbonylamino)ethyl}oxazole.
M.P : 46°˜48° C.
(3) 3.18 g of the product obtained was treated in the same manner as in Reference example 1-(2) to obtain 4-ethoxycarbonyl-5-(2-aminoethyl)oxazole.monohydrobromide as crude crystals, which was used in the next reaction without purification.
REFERENCE EXAMPLE 11
(1) A mixture of 36.5 g of 4-methoxycarbonyl-5-{2-(benzyloxycarbonylamino)ethyl}oxazole, 90 ml of concentrated hydrochloric acid and 270 ml of methanol was stirred at 55° C. for 6 hours. After removing the solvent, the residue was dissolved in tetrahydrofuran, and the solution was neutralized with 21 ml of triethylamine. Further, the solution was cooled to 0° C., and to the solution was added 450 ml of formic acid and was added dropwise 150 ml of acetic anhydride at the same temperature. The mixture was stirred at 10° C. for 3 hours, and ice water was added thereto. The solvent was removed, and then the residue was dissolved in ethyl acetate. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel chromatography to obtain 20 g of methyl 3-oxo-5-(benzyloxycarbonylamino)-2-(formylamino)pentanoate as a colorless oily product.
NMR (CDCl 3 ) δ: 2.86˜3.13 (m, 2H), 3.45˜3.53 (m, 2H), 3.79 (s, 3H), 5.09 (s, 2H), 5.29 (d, 1H), 5.1˜5.5 (br, 1H), 6.8˜7.0 (m, 1H), 7.34 (s, 5H), 8.22 (s, 1H).
(2) A mixture of 20 g of the product obtained, 12.5 g of 2,4-bis(4-methoxyphenyl)-1,3-dithia-2,4-diphosphetane-2,4-disulfide and 300 ml of toluene was refluxed for 30 minutes. After removing the solvent, the residue was purified by silica gel chromatography and crystallized from isopropyl ether, followed by recrystallization from an ethyl acetate-isopropyl ether mixed solution to obtain 10.5 g of 4-methoxycarbonyl-5-{2-(benzyloxycarbonylamino)ethyl}thiazole.
M.P.: 108°˜110° C.
(3) The product obtained was treated in the same manner as in Reference example 10-(1) to obtain 4-carboxy-5-{2-(benzyloxycarbonylamino)ethyl}thiazole as crude crystals, which was used in the next reaction without purification.
REFERENCE EXAMPLES 12 TO 16
(1) The corresponding compounds were treated in the same manner as in Reference example 11-(1) and (2) to obtain compounds shown in the following Table 21.
TABLE 21______________________________________ ##STR89##Referenceexample No. Y.sup.1 R.sup.4 R Physical properties______________________________________12-(1) S C.sub.2 H.sub.5 H M.P. 89˜91° C.13-(1) S Bzl H M.P. 99˜100° C.14-(1) O Bzl CH.sub.3 M.P. 88˜89° C.15-(1) O Bzl C.sub.6 H.sub.5 M.P. 83˜84° C.16-(1) O Bzl OH M.P. 111˜113° C.______________________________________
(2) The corresponding compounds were treated in the same manner as in Reference example 1-(2) to obtain compounds shown in the following Table 22.
TABLE 22______________________________________ ##STR90##Reference example No. Y.sup.1 R.sup.4______________________________________12-(2) S C.sub.2 H.sub.513-(2) S Bzl14-(2) O Bzl15-(2) O Bzl16-(2) O Bzl______________________________________
REFERENCE EXAMPLE 17
(1) The corresponding compounds were treated in the same manner as in Reference example 11-(1) and (2) to obtain 1-tert-butoxy-5-benzyloxycarbonyl-4-{2-tert-butoxycarbonylamino)ethyl}imidazole.
M.P.: 124°˜126° C.
(2) The product obtained above was treated in the same manner as in Reference example 1-(2) to obtain 5-benzylcarbonyl-4-(2-aminoethyl)imidazole.monohydrobromide.
REFERENCE EXAMPLE 18
(1) To a mixture of 2.9 g of 4-carboxy-5-{2-(benzyloxycarbonylamino)ethyl}oxazole, 4.9 g of pyridine, 6 ml of tert-butyl alcohol and 50 ml of chloroform was added dropwise 1.84 g of phosphoryl chloride at -10° C., and the mixture was stirred at the same temperature for 1 hour and further at room temperature overnight. The mixture was washed and dried, and then the solvent was removed. The residue was purified by silica gel chromatography to obtain 2.85 g of 4-tert-butoxycarbonyl-5-{2-(benzyloxycarbonylamino)ethyl}oxazole as a colorless oily product.
NMR (CDCl 3 ) δ: 1.58 (s, 9H), 3.22˜3.28 (m, 2H), 3.50˜3.59 (m, 2H), 5.08 (s, 2H), 7.33 (s, 5H), 7.74 (s, 1H).
(2) 3.45 g of the product obtained and 0.9 g of oxalic acid were treated in the same manner as in Reference example 1-(2). The crystals obtained were recrystallized from a tetrahydrofuran-isopropyl ether mixed solution to obtain 2.8 g of 4-tert-butoxycarbonyl-5-(2-aminoethyl)oxazole.monooxalate.
M.P.: 116°˜120° C.
The dicarboxylic acid derivative (I) which is the desired compound of the present invention, an ester thereof and a pharmaceutically acceptable salt thereof have excellent neutral metalloendopeptidase inhibiting activity, and exhibit excellent diuretic and vasodilating activities, and inhibiting activity on renin and aldosterone secretion based on the inhibiting effect of atrial natriuretic peptide (ANP) degradation. Moreover, the compounds of the present invention are low in toxicity and have high safety as a medicine. Thus, they can be used as a curing and/or prophylactic medicine for patients with hypertension, heart failure and renal insufficiency. Particularly for curing hypertension, angiotensin-converting enzyme inhibiting agents (ACE inhibiting agents) such as captopril and derapril hydrochloride have been clinically used at present. However, the desired product of the present invention, an ester thereof and pharmaceutically acceptable salts thereof have excellent characteristics in that they have effects also on low renin hypertension while the ACE inhibiting agents have relatively small effects thereon.
For example, when hypotensive activity is examined by using hypertension rats, in each group of rats orally administered with 30 mg/kg of 4-ethoxycarbonyl-5-{2-[N-((1S)-1-ethoxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}thiazole, 4-carboxy-5-{2-[N-((1S)-1-ethoxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}thiazole, 4-ethoxycarbonyl-5-{2-[N-((1S)-1-carboxy-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}thiazole or 4-carboxy-5-{2-[N-((1S)-1-ethoxycarbonyl-3-phenylpropyl)-(L)-phenylalanyl]aminoethyl}oxazole which is the desired compound of the present invention, significant hypotensive activity was observed as compared with that of the control group of rats to which purified water was orally administered.
Some known ANP degradation inhibitors have not only neutral metalloendopeptidase inhibiting activity but also angiotensin-converting enzyme inhibiting activity. However, the desired compound of the present invention have both characteristics of being weak in angiotensin-converting enzyme inhibiting activity and having neutral metalloendopeptidase inhibiting activity more selectively. | Disclosed are a dicarboxylic acid compound represented by the formula (I): ##STR1## wherein R represents hydrogen atom, a lower alkyl group, phenyl group or hydroxyl group; R 1 represents a straight or branched alkyl group having 1 to 10 carbon atoms or a lower alkyl group substituted by a group selected from aryl group, a sulfur- or nitrogen-containing heterocyclic monocyclic group and a cycloalkyl group having 4 to 8 carbon atoms; R 2 represents a substituted or unsubstituted aryl group, a cycloalkyl group having 4 to 8 carbon atoms or a sulfur-containing or nitrogen-containing heterocylcic group; X represents sulfur atom, oxygen atom or a substituted or unsubstituted imino group; Y 1 represents imino group, oxygen atom or sulfur atom and Y 2 represents nitrogen atom, or Y 1 represents a vinylene group and Y 2 represents a group: --CH═; m represents 0 to 3; and n represents 0 or 1, an ester thereof or pharmaceutically acceptable salts thereof, and a process for preparing the same. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention described herein relates to a process for forming surfactants for use in detergent compositions where a step in a process includes cooling the reaction mass, following the mixture of an alkaline component, the detergent acids and excess sulfating agent.
2. Discussion of the Art
The use of anionic surfactants particularly those where the anionic character is caused by a sulfonate or a sulfate group is well known in the detergency arts. Further, the sulfation or sulfonation of precursor materials such as alkylbenzene to form alkylbenzene sulfonic acid which is subsequently neutralized to the sulfonate is also well known in the art. For instance, U.S. Pat. No. 3,024,258, issued to Brooks et al, Mar. 6, 1962, discloses a process for sulfonating a reactant continuously and rapidly as well as for separating the resulting sulfonated reactant from the excess sulfonating agent and to the continuous neutralization of the resulting detergent acids. During the neutralization step the Brooks et al patent describes cycling the neutralized product through a heat exchanger to maintain the temperature in the range of from 85° F. to 140° F. The examples of Brooks et al indicate that the final product contains sodium sulfate in water in a ratio of from about 1:11. The Brooks et al patent is herein incorpated by reference.
Similarly, other patents describing sulfonation and sulfation processes are U.S. Pat. No. 3,259,645 issued July 5, 1966, U.S. Pat. No. 3,363,994 issued Jan. 16, 1968, U.S. Pat. No. 3,350,428 issued Oct. 31, 1967, and U.S. Pat. No. 3,427, 342 issued Feb. 11, 1969, all to Brooks et al which are herein incorporated by reference. Earlier patents describing sulfonation processes include U.S. Pat. No. 2,129,826, Reilly issued Sept. 13, 1938 and U.S. Pat. No. 2,039,989, issued to Gressner May 5, 1936, both of which are herein incorporated by reference.
In the process of forming anionic surfactants which have a sulfuric or sulfonic acid moiety it is necessary to react a precursor with a sulfating agent which is a material such as sulfur trioxide to form the organic sulfuric or sulfonic acid. Materials which supply a source of sulfur trioxide for the forming of such detergent acids are known as sulfating agents and the term embraces sulfonating agents as well. Sulfating agents include pure sulfur trioxide or sulfur trioxide diluted with a gas which is inert in the reaction, such as hydrogen chloride or sulfur dioxide. The most common sulfating agent, however, is oleum which is a mixture of sulfur trioxide dissolved or suspended in sulfuric acid. The method of formation of the detergent acids, also known as the acid mix, is not material to the present invention up to the point that an excess of the sulfating agent should be present in addition to that which is required to react the detergent precursor to the desired degree of sulfation.
The reason for using an excess of the sulfating agent is basically to ensure that the detergent precursor which is a relatively expensive material will be completely reacted. That is, for ecological, product performance and cost reasons, it is undesirable to leave unreacted alkylbenzene in the detergent product as it is relatively volatile and will in the instance of spray-dried formulations be driven off upon heating.
The step following the reaction of the detergent precursor and the sulfating agent is that of neutralizing the mixture containing the organic sulfuric or sulfonic acid. This mixture will also contain the excess sulfating agent, and water which is either introduced with the reactants or formed during the sulfation reaction. This mixture is then neutralized with an alkaline component such as sodium hydroxide or sodium carbonate or a similar material to form the sodium salt of the organic sulfuric or sulfonic acid. The introduction of the alkaline component, however, also neutralizes the excess sulfating agent to form sodium sulfate.
This second mixture referred to herein as the reaction mass then contains the sodium salt of the organic sulfuric or sulfonic acid, sodium sulfate, water, and small amounts of the excess alkaline component. As the sulfation reaction and the neutralization reaction are both highly exothermic it is necessary to quench the heat of reaction to avoid bringing the reaction mass to boil as well as to avoid undesirable secondary reactions which may take place. The most common method of quenching any exothermic reaction is to pass the product of the reaction through one or more heat exchangers where excess thermal energy is removed thus lowering the temperature of the product for further processing. It is noted, that the sulfation reaction mixture may be quenched through heat exchange prior to the neutralization reaction if desired although the present invention only relates to heat exchange following the neutralization step.
The most commonly used heat exchangers for the preparation of detergents are simply a large conduit through which the reaction mass passes and a series of smaller conduits within the larger conduit through which the cooling medium flows. In operation the cooling medium is of course maintained at a temperature below that of the reaction mass which swirls around the smaller conduits. The thermal energy then flows through the walls of the smaller conduits where the heat energy is transferred to the cooling medium and removed from the system. Thus, the reaction mass is cooled to a desirable temperature for further processing.
Known systems for the neutralization step have involved processing the reaction mass in diluted form in the presence of large volumes of water. The water is present in the reaction mass from the neutralization and from the alkaline component, e.g., a solution of caustic. Water may also have been added directly to the reaction mass to purposely dilute the heat generated by the reaction.
Obvious economic reasons dictate that the presence of a large volume of water in the reaction mass is undesirable. For instance, the water present in the reaction mass must be removed if the end product is to be solid such as a spray-dried granule. Moreover, the presence of the water in the reaction mass requires that storage or processing facilities have greater volume than that required for a reaction mass with lower water content. Conversely, lowered water content in the reaction mass allows greater throughput of the final product with existing equipment.
It is also observed, aside from the advantages listed above, that other processing goals can be achieved by lowering the water content of the reaction mass. For example, sodium sulfate in dry form is usually added to the reaction mass following the heat exchange operation to aid in the preparation of granular detergent compositions. If desired, however, in the present invention the sodium sulfate may be formed in situ during the neutralization step by using excess sulfating agent over that which is needed to accomplish sulfation of the organic precursor. The excess sulfating agent is then neutralized by the alkaline component to form sodium sulfate. In the case where oleum is used as the sulfating agent versus sodium sulfate to generate a source of sodium sulfate in the product a density and cost/availability advantage favor the use of oleum. Cost and availability is of course a readily apparent advantage while the density factor allows equivalent storage facilities to hold a greater weight of oleum as opposed to dry sodium sulfate.
An additional advantage to lowering the water content of the reaction mass resides in the difference of incorporating wet versus dry silicates into the detergent compositions. Most detergent products require the presence of alkali metal silicates to provide an anti-corrosion benefit to exposed washing machine surfaces as well as to provide non-gooey granules, e.g., granules which cake or do not flow freely under humid conditions.
The silicates, as stated above, may be added to the crutcher mix containing the reaction mass as a wet or dry material. If the water content of the crutcher mix is low, as is obtained in the present invention, then a slurry of wet silicate may be added to the crutcher mix. If the water content of the crutcher is already high from the aqueous reaction mass, then it is usually necessary to add dry silicate to reduce the crutcher water content to lower the drying load when forming the crutcher mix into granules. Drying load as used above is defined as the heat energy required to remove water in granules formation. It is also observed that not withstanding the use of costly energy for drying the crutcher mix, that a point can be reached where the crutcher mix is too wet to be dried by conventional spray-drying towers such as those described in U.S. Pat. Nos. 3,629,951 and 3,629,955, both issued to R. P. Davis et al on Dec. 28, 1971, which are herein incorporated by reference.
It is thus seen that reducing the water content of the reaction mass and subsequently that of the crutcher mix is highly desirable. To effectively reduce the water content of the reaction mass it is necessary that the sodium sulfate be supersatured in relation to the water. This is not undesirable as the sodium sulfate cannot be economically removed in a continuous detergent making operation and in any event the sodium sulfate is a very desirable ingredient, especially in its ability to act as a structurant to avoid gooey granules as previously stated in the discussion concerning the function of the silicate.
It has been observed, however, that when the reaction mass is passed through a heat exchanger with the sodium sulfate in a supersaturated condition that the heat exchanger immediately suffers a reduction in heat energy transfer capacity.
This loss of energy transfer capacity has been determined to be caused by the buildup of anhydrous sodium sulfate in the heat exchanger. Moreover, the loss of energy transfer capacity continues until the heat exchanger is completely plugged with the reaction mass. Thus, while it is extremely desirable to operate the detergent making process under conditions where the sodium sulfate is supersaturated in the reaction mass it has been impractical, if not effectively impossible, to do so.
The difficulty which the present invention alleviates is caused by the sodium sulfate which when supersaturated in the aqueous reaction mass precipitates on the surfaces of the smaller conduits in the heat exchanger and continues to precipitate until the entire heat exchanger is plugged with the precipitated sodium sulfate. At this point if there is but a single heat exchanger the neutralization reaction as well as the earlier sulfation reaction must be shutdown and the heat exchanger torn apart and cleaned or flushed with water to remove the precipitated sodium sulfate.
Alternatively, the sulfation reaction can be allowed to continue to proceed along with the neutralization reaction, however, additional capital expense is then necessary to provide a parallel series of heat exchangers through which the neutralized reaction mass is allowed to pass while the first heat exchanger has the sodium sulfate removed. Either alternative is quite costly and extremely undesirable.
A second alternative is to process the reaction mass with sufficient water present so that the sodium sulfate never becomes saturated in the reaction mass. However, such processing requires large amounts of water which, as previously discussed, is undesirable.
In view of the high degree of interest of operating heat exchangers at high capacity when removing heat from a neutralized detergent acid mix the following objects of the present invention are developed.
It is an object of the present invention to provide a method for rapidly and economically removing heat from a neutralized detergent acid mix.
It is a further object of the present invention to prepare an aqueous mixture of supersaturated sodium sulfate and the sodium salt of an organic sulfuric or sulfonic acid having as a processing step the cooling of the mixture in a heat exchanger while introducing a slurry of anhydrous sodium sulfate into the reaction mass to reduce the deposition of sodium sulfate in the heat exchanger.
Throughout the specification and claims, percentages and ratios are by weight and temperatures are in degrees Centrigrade unless otherwise indicated.
SUMMARY OF THE INVENTION
In the process of removing thermal energy from an aqueous mixture of sodium sulfate and the sodium salt of an organic sulfuric or sulfonic acid or mixtures thereof the steps of:
(a) reacting the organic sulfuric or sulfonic acid and excess sulfating agent with an alkaline component thereby forming a supersaturated solution with respect to the sodium sulfate; and,
(b) cooling the reaction mass formed in step (a) in a heat exchanger while introducing into the reaction mass a sufficient amount of an aqueous slurry of anhydrous sodium sulfate, to reduce the deposition of sodium sulfate on the surfaces of the heat exchanger.
DETAILED DESCRIPTION OF THE INVENTION
The present invention as stated above relates to a method of removing thermal energy from an aqueous mixture of sodium sulfate and the sodium salt of an organic sulfuric or sulfonic acid, while avoiding buildup of sodium sulfate in the heat exchanger.
In fact the present invention is advantageously utilized any time it is necessary to remove thermal energy from a supersaturated solution of sodium sulfate. Ordinarily sodium sulfate is prepared as a commercial product in the rayon making process where excess sulfuric acid is reacted with an alkaline component. Thus the present invention has utility outside of the field of detergent products and the nondetergent related aspects of the invention are employed advantageously.
For detergent products the presence of the desired level of the sodium sulfate in the end product is accomplished by over-using the sulfating agent which is present to add the anionic moiety to the detergent precursor and then neutralizing the excess sulfating agent.
For the purpose of this invention the term "detergent precursor" includes any material which following sulfation is capable of neutralization to form a surface active agent. Examples of such surface active agents are alkylbenzene sulfonates, alkyl ether sulfates, alkyl sulfates, olefin sulfonates, paraffin sulfonates, alpha-sulfocarboxylates, alpha-sulfocarboxylate alkylates, and mixtures of the foregoing. Such surfactants are listed for purposes of exemplification but the present invention is not limited to such surface active agents. Other materials which may be sulfated or sulfonated within the scope of the present invention, and embraced within the term of organic sulfuric or sulfonic acids, include toluene and benzene sulfonic acids as well as cumene sulfonic acids.
The term "sulfating agent" is interchangeable with "sulfonating agent", and examples of such materials are sulfuric acid, oleum, and chlorosulfonic acid, and sulfur trioxide. Oleum is defined as a material which is a mixture of sulfuric acid and sulfur trioxide. Oleum is the preferred sulfating agent of the present invention.
In practice the amount of the sulfating agent needed to completely sulfate the detergent precursor is greater than the actual amount of sulfating agent which is needed on a stoichiometric basis. Conveniently the actual amount of sulfating agent used is related to the spent acid strength which is defined by the following equation: ##EQU1## where (excess SO 3 ) is the sulfur trioxide introduced to the reaction over and above that used in the sulfation. This excess sulfur trioxide and the sulfuric acid present is subsequently neutralized to form sodium sulfate. The quantity (H 2 O) is the water introduced into the system or which is present during the sulfation process. The percentage spent acid strength is a measure of the available sulfur trioxide which may be used for sulfation or sulfonation. In other words, where the sulfur trioxide would react on a one-to-one mole basis with the detergent precursor to give a sulfated product, the presence of water in the system will lower the amount of sulfur trioxide available for the sulfation of the detergent precursor. Thus, it is desirable to minimize the amount of water present during the sulfation step. The spent acid strength, as more fully described later, is preferably from about 90% to about 103%.
The second chemical reaction carried out in following the present invention is the formation of the supersaturated solution of sodium sulfate. This reaction is accomplished by neutralizing the sulfated detergent precursor and the unreacted sulfating agent with an alkaline component. The alkaline component is any material which will function as a Lewis base, e.g., a material which will take up hydrogen ions to form water. The most common alkaline components utilized in the present invention will be sodium hydroxide or sodium carbonate. Other suitable materials, however, include potassium hydroxide, potassium carbonate, and partially neutralized salts such as bicarbonates and sesquicarbonates. The first aspect of the present invention set forth in detail is the sulfation system for forming the organic sulfuric or sulfonic acid from the detergent precursor.
The Sulfation System
Sulfation or sulfonation of various organic components, when carried out with oleum or sulfuric acid, may be done on a continuous scale such as in a dominant bath system or on a single batch basis. For the purposes of the present invention, the benefits may be obtained either as single batch reaction or on a continuous process.
A. Batch System
The batch process is an operation comprising adding the sulfating agent and the organic detergent precursor which is to be sulfated or sulfonated into a vat.
The initial reaction in the batch process proceeds rapidly to completeness because of the high concentration of the reactants. However, the final concentration of the sulfated organic product in the acid mix will be lower because of the poor mixing encountered in the batch process. The yield in a batch process can, however, be increased by thoroughly mixing the system by any conventional means.
The product obtained from the batch process comprises the sulfated reaction product as well as any excess sulfating agent and unreacted detergent precursor. The resultant acid mix described above is then further processed to remove the excess sulfating agent, or the acid mix may be neutralized with the excess sulfating agent present. Preferably, the acid mix does not have the excess sulfating agent removed from it prior to neutralization, so that the sodium sulfate will be present under conditions of super-saturation in the reaction mass. The reaction mass also known as paste is transported by conventional means to the heat exchanger.
B. Dominant Bath
The dominant bath is the most commonly used oleum or sulfuric acid sulfation process. The dominant bath provides for a continuous production of an acid mix. In contrast to the batch process, the dominant bath allows the preparation of an acid mix under much more controlled reaction conditions.
In the dominant bath process the reactants are injected into a recirculating stream of reaction products. The heat of reaction which is considerable in a sulfation or sulfonation process is thus dissipated into the recirculating acid mix which facilitates heat removal and mixing. In an ideal dominant bath the reactants are completely distributed throughout the system such that all parts of the bath have an identical composition with the mean reaction time equal to the volume of the system divided by the effluent flow rate. In this context effluent is defined as the acid mix which is removed from the system to be further processed, such as paste formation. In the dominant bath system the recirculation ratio will determine the degree of approach to the ideal system. The recirculation ratio is defined as being the volume of recirculated material divided by the volume of the effluent. Typical recirculation rates which will vary according to the material to be sulfated are from 15:1 to 40:1 with an average of 25:1. Thus, a recirculation ratio of 25:1 indicates that for every part of effluent, 25 parts of acid mix are recirculated through the system. The recirculation ratio also indicates the maximum amount of new reactants which may enter the system; thus the rate at which the effluent leaves the system is equal to the rate at which the new reactants enter the system.
In contrast to a batch system where the reaction is initially fast as the reactants are high in concentration with the rate decreasing as the reactants are consumed the dominant bath provides a system where the reactants are at their final concentration and hence the reaction is relatively slower. The longer reaction time for completion of the sulfation reaction is the most notable disadvantage of the dominant bath system. The foregoing disadvantage however, is greatly outweighed by the heat removal capacity in the dominant bath resulting in less charred material.
To avoid using a dominant bath with an unduly large volume or greatly increasing the recirculation ratio, it has been suggested to remove the effluent acid mix from the system before the sulfation reaction has been completed. The effluent which has been substantially reacted is then passed through a coil of sufficient length to allow the sulfation reaction to continue to completion despite the absence of mixing. The use of the coil is possible because the effluent has been substantially reacted in the dominant bath, thus requiring little or no heat transfer in the reaction coil. The length of the coil and the recirculation ratio can thus be varied so that the various sulfatable materials can achieve maximum completeness of the reaction with the shortest period of time in the dominant bath and in the coil.
If two components are to be sulfated which require different spent acid strengths for completeness and quality, series sulfation in the dominant bath may be employed. Series sulfation is a system in which one component is first sulfated as has been previously discussed, and then that acid mix is used as a diluent for the sulfation of a second material. A common practice is to sulfonate an alkylbenzene first and then combine the acid mix with a fatty alcohol or an ethoxylated alcohol prior to sulfating the latter materials.
The acid mix, following either of the procedures described above is then converted to the paste or reaction mass as indicated under the neutralization discussion, supra.
C. Film Sulfonation
Many detergent precursors can be sulfated by using film sulfation methods. Basically the process in a film reactor comprises introducing the detergent precursor at the top of a reaction vessel such that a thin film is formed on the walls of the vessel. The film is continuously exposed to a gaseous sulfating agent as the film moves along the surface of the reaction vessel. The sulfating agent may be sulfur trioxide or sulfur trioxide diluted with a gas which is inert in the process such as sulfur dioxide.
Examples of suitable detergent precursors which may be sulfated in the film process are ethoxylated alcohols, alpha-olefins and aliphatic carboxylic acids. Further film reactor techniques are described in U.S. Pat. Nos. 3,346,505; 3,309,392; 3,531,518; and 3,535,339 herein incorporated by reference.
D. Sulfating Agent
As was previously stated in this application the term "sulfating agent" is to be used in its generic sense indicating a material which is capable of sulfating or sulfonating another compound. The sulfating agents with which the present invention is primarily concerned are sulfuric acid, oleum, chlorosulfonic acid or sulfur trioxide. The practical use of sulfuric acid as a sulfating agent is limited to those situations where 100% sulfuric acid is used, as the spent acid strength is otherwise too low to ensure sulfation of the detergent precursor. Chlorosulfonic acid is normally employed in a batch reaction while sulfur trioxide diluted with an inert gas is employed in a film reactor.
Oleum, which is a mixture of sulfuric acid and sulfur trioxide, is the preferred sulfating agent in the present invention when the sulfation is carried out in a batch process or in a dominant bath system. The acid strength of the oleum used may be as high as 65%; however, the preferred range of oleum acid strengths is between 10% and 40%. Acid strength is defined as the percentage of a mixture of sulfur trioxide and sulfuric acid which is sulfur trioxide. Thus, a 10% acid strength is 10 parts sulfur trioxide and 90 parts sulfuric acid.
The choice of the oleum strength used is dependent upon such factors as the desired degree of completeness of sulfation in the dominant bath, the limitations on heat exchanger capacity wherein higher concentrations of oleum result in substantially higher reaction temperatures, the degree of charring which can be tolerated and the choice of the material to be sulfated.
The particular materials of interest in the instant invention are alkylbenzenes, fatty alcohols and ethoxylated alcohols, although other detergent precursors are utilized in the instant invention such as alpha-olefins, fatty acids, and fatty acid esters or other sulfatable organic compounds.
As used herein the term, "sulfatable compound", is the material which when reacted with the sulfating agent will form the organic sulfuric, or sulfonic acid.
An alkylbenzene which may include some branched chain material in the alkyl group will preferentially sulfonate with sulfuric acid or oleum in the para position with minor amounts of sulfonation at other positions on the benzene ring. The sulfonation of the alkylbenzene is a nonreversible reaction; however, the presence of water in the system may reduce the spent acid strength to a point at which the sulfonation reaction does not proceed. Below a spent acid strength of about 90% the sulfonation reaction will not proceed while at spent acid concentrations above 100%, secondary reactions which affect the color of the neutralized paste and odor become troublesome. Spent acid concentrations may be from 95% to 103%, preferably in the 98.0-101% range for the best completeness of alkylbenzene sulfonation with acceptable charring. The secondary reactions which are alluded to above can include oxidation, dehydration, and rearrangement of the alkyl radical of the alkylbenzene. The apparent acid strength of the oleum used with an alkylbenzene should be from about 100% to abou 122.5%, preferably about 102% to about 122.5%. Apparent acid strength is defined as the amount of sulfuric acid which can be formed from oleum if all the sulfur trioxide is converted to sulfuric acid. Thus, by convention, a mixture of 30 parts sulfur trioxide and 70 parts sulfuric acid has an apparent acid strength of 106.75%.
The sulfonation of an alkylbenzene is preferably carried out in a dominant bath with a temperature maintained between 29° C. and 65° C., preferably from 43° C. to 55° C., with a recirculation ratio of greater than 15:1 and preferably greater than 25:1. The weight ratio of alkylbenzene to sulfating agent is from about 1:8 to 7:1, preferably about 1:4 to 10:3. Alkyl chains on an alkylbenzene contain from about 9 to 15 carbon atoms, preferably between 11 and 12 carbon atoms.
The sulfation reaction of a fatty alcohol, preferably having 10 to 20 carbon atoms, proceeds rapidly but is reversible in the presence of water. Fatty alcohols while undergoing sulfation are also prone to side reactions resulting in the formation of alkenes, ethers, esters, and aldehydes. A high spent acid strength minimizes the reversible hydrolysis but increases the dehydration and oxidation reactions noted above.
The temperature range at which sulfation of an alcohol is best accomplished in a dominant bath system is between 29° C. and 65° C., and preferably from 38° C. to 52° C. with a recirculation ratio of greater than 15:1 and preferably greater than 25:1. The apparent acid strength used in sulfating a fatty alcohol should be from about 100% to about 122.5%, preferably about 102% to about 122.5%. The spent acid strength is preferably maintained in the range of from about 90% to about 103% and preferably from about 95% to about 101%. The weight ratio of sulfating agent to fatty alcohol is from about 3:1 to about 1:4, preferably about 2:1 to about 1:2. Preferably the fatty alcohol contains from about 8 to 24 carbon atoms with especially useful materials being of the tallow length.
The sulfation of an ethoxylated alcohol may be carried out by oleum or sulfuric acid in either a batch, the dominant bath process, or by film sulfation.
The apparent acid strength used in sulfating an ethoxylated alcohol should be from about 100% to about 122.5%, preferably about 102% to about 122.5%. The sulfation of the ethoxylated alcohol may take place between about 29° C. and about 65° C. and preferably from about 40° C. to about 55° C. The percentage of spent acid strength resulting from the preparation of an alkyl ether sulfuric acid should be maintained between about 90% and about 103%, and preferably from about 95% to about 101% with a recirculation ratio of greater than 15:1, preferably greater than 25:1. The weight ratio of sulfating agent to ethoxylated alcohol is from about 7:1 to about 1:10, preferably about 3:1 to about 1:3.
The ethoxylated alcohol preferably has an alkyl radical with from 8 to 24 carbon atoms and from 1 to 30 ethoxy groups. A preferred detergent precursor is the ethoxylated alcohol with an alkyl chain length average varying between 12 and 16 carbon atoms and the average degree of ethoxylation of said mixture varying between 1 and 4 moles of ethylene oxide, said mixture comprising:
(a) from about 0% to 10% by weight of said ethoxylated alcohol mixture of compounds containing 12 or 13 carbon atoms in the alkyl radical;
(b) from about 50% to 100% by weight of said ethoxylated alcohol mixture of compounds containing 14 or 15 carbon atoms in the alkyl radical;
(c) from about 0% to 45% by weight of said ethoxylated alcohol mixture of compounds containing 16 or 17 carbon atoms in the alkyl radical;
(d) from about 0% to 10% by weight of said ethoxylated alcohol mixture of compounds containing 18 or 19 carbon atoms in the alkyl radical;
(e) from about 0% to 30% by weight of said ethoxylated alcohol mixture of compounds having a degree of ethoxylation of zero;
(f) from about 45% to 95% by weight of said ethoxylated alcohol mixture of compounds having a degree of ethoxylation of from 1 to 4;
(g) from about 5% to 25% by weight of said ethoxylated alcohol mixture of compounds having a degree of ethoxylation of from 5 to 8; and
(h) from about 0% to 15% by weight of said ethoxylated alcohol mixture of compounds having a degree of ethoxylation greater than 8.
A desirable component in an acid mix containing an alkyl ether sulfuric acid or other organic sulfuric or sulfonic acid is a viscosity reducing aid such as benzoic acid. The use of benzoic acid to reduce viscosity is described in U.S. Pat. No. 3,957,671 issued May 18, 1976 to Sagel et al herein incorporated by reference. Preferably the weight ratio of the benzoic acid to the organic sulfuric or sulfonic acid is from about 1:1 to about 1:100.
Alpha-olefins having from 10 to 24 carbon atoms and fatty acids having from 8 to 20 carbon atoms and the esters of fatty acids with 1 to 14 carbon atoms in the alcohol radical may be converted to organic sulfuric or sulfonic acids and neutralized within the scope of the present invention. The acid mixes above, respectively, give upon sulfation alpha-olefin sulfonates, alpha-sulfocarboxylic acids, and esters thereof.
As used above, the esters of alpha-sulfocarboxylic acids are also known as alpha-sulfocarboxylate alkylates. An additional material which may be sulfonated and neutralized in the scope of the present invention are paraffin sulfonates having from 10 to 24 carbon atoms.
A preferred surfactant system and hence a preferred reaction mass comprises alkylbenzene sulfonate, alkyl sulfate, and alkyl ether sulfate in a respective weight ratio of about 0.5:1:2.0 to about 2.0:1:0.5. The weight ratio of the organic sulfuric or sulfonic acid to the water in the reaction mass is from about 2:1 to about 1:2, preferably about 10:16 to about 1:1.
E. Neutralization Step
Detergent compositions are ordinarily sold as solid materials and as such it is necessary to convert the organic sulfuric or sulfonic acid, which is a viscous liquid, into a fully or partially neutralized salt. The neutralization may be accomplished by suitable alkaline components as previously stated, which include sodium carbonate, sodium hydroxide, and the acid salts of carbonates such as bicarbonates and sesquicarbonates. The aforementioned components are merely those which are conveniently used, and in fact, any sodium containing Lewis base may be used. It is further noted that other non-sodium Lewis bases may be employed with the sodium containing Lewis base. It is preferred as stated above, that the reaction mass in the claimed process should contain the sodium sulfate at supersaturation following the neutralization step. This, or course, means that during the removal of thermal energy following neutralization that the sodium sulfate will be supersaturated within the heat exchanger(s). The pH of the reaction mass is conveniently from about 6 to about 12.
Subsequent to the neutralization process, the aqueous mixture containing the neutralized organic sulfuric or sulfonic acid, the sodium sulfate, small amounts of the alkaline component, will be passed through one or more heat exchangers to lower the temperature of the reaction mass also known as the paste.
It is also often desirable to recirculate a portion of the neutralized paste. The unneutralized acid mix is added to the recirculating paste stream to dilute the acid mix and further control the temperature upon neutralization. This operation is known as paste recirculation and avoids diluting the acid mix with components which are undesirable in the final product, e.g., water. The paste recirculation ratio is more preferably greater than 5:1, and most preferably greater than 10:1 of parts paste per part acid mix. The portion of the neutralized paste, which is not recycled, is drawn off for further processing into the detergent composition.
It was noted above that any of several conventional heat exchangers may be used with the present invention. Most commonly, however, the type of heat exchanger which will be used in the present invention, is a large conduit through which the aqueous mixture containing supersaturated sodium sulfate passes, preferably with turbulence to facilitate mixing. Inside the large conduit are one or more smaller conduits through which the cooling medium flows. Suitable heat exchangers as previously stated are manufactured by American Standard of Buffalo, N.Y. 14240. Such devices are discussed in detail in American Standard Bulletin 104-24 5M 7-72KC, herein incorporated by reference.
The most convenient cooling medium will of course be water at the required temperature. However, any cooling medium any be used provided that it can rapidly remove heat from the paste stream flowing through the larger conduit. It is preferred, but not necessary, that the flow rate of the cooling medium as it passes through the smaller conduit is sufficient to accomplish turbulent flow to minimize the amount of coolant which is required per given quantity of paste. This minimizes not only the amount of cooling medium which must be used, but also the amount of space which must be taken up within the larger conduit by the smaller conduits containing the cooling medium. The walls of the smaller conduit by convention are constructed to rapidly transfer heat from the reaction mass to the cooling medium. The heat exchanger will be run such that the cooling medium therein is maintained between about 5° C. and 100° C., preferably about 10° C. to about 70° C., more preferably between about 30° C. and about 65° C. As the object of utilizing the heat exchanger(s) is to remove thermal energy from the reaction mass, it is preferred that the temperature of the reaction mass, as it exists from the last heat exchanger in the series be in the range of about 100° C. to about 50° C., preferably about 95° C. to about 60° C.
F. Slurry Introduction
The present invention accomplishes the reduction of sodium sulfate precipitation in the heat exchanger by, surprisingly enough, increasing the amount of sodium sulfate within the heat exchanger. That is, it is not the amount of sodium sulfate which is present in the heat exchanger but rather the form of the sulfate which is important.
While not wishing to be bound by any particular theory, it is believed that the discovery of the property of controlled crystal growth accounts for the present invention. That is, as the sodium sulfate is supersaturated, almost any disturbance within the reaction mass will cause the sodium sulfate to precipitate out. Unfortunately, sodium sulfate in its anhydrous form plates out on the surfaces within the heat exchanger. Eventually if nothing is done to counteract the plating out, the system will become completely plugged with the sodium sulfate. It has been discovered, however, that if a slurry of anhydrous sodium sulfate is introduced into the aqueous mixture in the heat exchanger, that the system may be operated continuously without the need to shutdown the heat exchanger.
Thus, if a sufficient amount of a supersaturated anhydrous sodium sulfate slurry is introduced into the aqueous mixture the precipitation of sodium sulfate on heat exchanger surfaces is diminished. Preferably the weight ratio of the slurry to the aqueous mixture is from about 2:1 to about 1:200. The anhydrous sodium sulfate in the slurry preferably have a particle size of 0.01 micron to 100 microns, more preferably 0.03 micron to 20 microns. The anhydrous sodium sulfate is preferably present in a ratio to the water in the slurry of from about 160:100 to about 42:100. The slurry is introduced into the aqueous mixture by any convenient means. It is preferred that the slurry be introduced into the recirculation loop as previously described to give maximum effectiveness. The slurry is conveniently delivered to the heat exchanger through the means described in U.S. Pat. Nos. 2,825,543 and 2,987,380 issued Mar. 4, 1958 and June 6, 1961 to McCracken et al and Brumbaugh et al respectively, both of which are incorporated herein by reference.
It is believed that in the present system that by introducing the slurry of anhydrous sodium sulfate into the aqueous mixture that the precipitating anhydrous sodium will not deposit onto the conduit containing the cooling medium. Rather, the sulfate in the slurry seeds the precipitation of the sodium sulfate in the aqueous mixture and the precipitated sodium sulfate is carried out of the heat exchanger with the remainder of the reaction mass. The predominant salt which would otherwise precipitate is anhydrous sodium sulfate, thus the slurry accomplishes homogeneous seeding in the aqueous mixture. The positive effect of the present invention is two-fold. First, the aqueous mixture is run under conditions of supersaturation and second, the amount of sodium sulfate is further increased by the introduction of the sulfate in the slurry. An additional benefit to using the anhydrous sodium sulfate slurry is that it will function as a heat sink provided that the temperature of the slurry is less than that of the aqueous mixture.
To maintain the maximum efficiency of the present system, as well as to ensure that the maximum amount of sodium sulfate is in the end product, it is desirable that the weight ratio of the sodium sulfate to the water in the paste or reaction mass within the heat exchanger should be from about 100:60, to about 42:100, most preferably from about 40:30 to about 45:100. The water content is more fully defined as the total water free or bound within the system.
The following are examples of the present invention:
EXAMPLE I
A detergent acid mix is prepared with oleum having an acid strength of 106.75%. The acid mix with excess sulfuric acid present is then neutralized with aqueous sodium hydroxide solution to give a paste (reaction mass) comprising in parts:
7.0--sodium dodecyl benzene sulfonate
5.5--sodium hexadecyl triethoxy sulfate
5.5--sodium tallow sulfate
12.0--sodium sulfate
23.0--water
trace--free sulfur trioxide
trace--free caustic
The paste which is at a temperature of about 65° C. is then introduced into an American Standard SSCF two pass heat exchanger, model number 06800. The paste flows through the heat exchanger under conditions of turbulent flow.
An aqueous slurry of anhydrous sodium sulfate comprising 45 parts of the salt to 100 parts water is introduced into the aqueous mixture (paste) in a ratio of the slurry to the aqueous mixture of 1:10.
The cooling medium in the heat exchanger is water which enters the heat exchanger at about 29° C. and exits at about 34° C. The velocity of the water is such that turbulent flow occurs in the heat exchanger.
When operating under the conditions above the heat exchanger requires only routine maintenance. In contrast, an identical system operated at the same cooling medium temperature range without the benefit of the slurry introduction into the aqueous mixture will lose substantial heat transfer and paste flow capability in about 1/2 hour and will require a shutdown to remove the accumulated sodium sulfate within about 3 hours.
EXAMPLE II
Example I is repeated using as parts of paste to be cooled
17--sodium dodecyl benzene sulfonate or
17--sodium tallow alcohol sulfate
14--sodium sulfate
22--water
trace--free sulfur trioxide
trace--free caustic
Substantially similar results to those of Example I are obtained. Further, similar results are obtained when the above example is modified to a surfactant system containing 18 parts, 16 of which are sodium hexadecyl triethoxy sulfate and 2 parts tallow alcohol sulfate.
EXAMPLE III
Sulfuric acid which is 85% active (15% H 2 O) is completely neutralized with dry sodium hydroxide. The reaction mass is then passed through a heat exchanger as defined in Example I. A slurry of anhydrous sodium sulfate as defined in Example I is introduced into the heat exchanger to promote crystal growth on the anhydrous sodium sulfate. The cooling medium (water) in the heat exchanger is maintained at 38° C. and the reaction mass is cooled from 95° C. to 90° C. As a comparative example the same system without the slurry introduction becomes plugged with sodium sulfate. | This invention relates to a process for neutralizing detergent acid mixes containing unreacted sulfating agent such as sulfuric acid with an alkaline component such as sodium hydroxide. The neutralization process is highly exothermic and contains as a by-product large amounts of sodium sulfate. Due to the exothermic nature of the reaction it is necessary to use heat exchangers to regulate the temperature of the reaction mass following the addition of the alkaline component. When the sodium sulfate is supersaturated in the reaction mass, it has been observed that sulfate salts buildup upon the surfaces of the heat exchanger and eventually the system must be shut down to remove the buildup. This invention is therefore directed to a continuous neutralization and heat exchange process wherein the downtime required for removal of the sulfate salts from the heat exchanger surfaces is effectively eliminated. | 2 |
TECHNICAL FIELD
[0001] The invention relates to a method for operating a bale opener having a stripping element and a safety device for protecting people from intrusion into a hazardous zone of the stripping element and a bale opener, in accordance with the preamble of the independent claims.
PRIOR ART
[0002] It is known that with machines in general and also with textile machines, the moving parts on the machine, in particular the drive devices, must be secured by a safety device to prevent anyone from approaching too closely. Inasmuch as the drive parts are arranged in a stationary mount with the movable parts, a fixedly mounted cover is sufficient in general. This may be designed so that the machine is automatically shut down when opening the cover.
[0003] In practice, devices are present on textile machines, on so-called bale trimmers, to secure hazardous working elements. In the textile industry, in particular in spinning preparation, there are known machines for stripping fiber bales standing on the floor. The working elements used in this process, for example, cutting rollers, are situated in positions that change constantly during operation due to the nature of the system and they cannot be covered, so they constitute a high risk for the person operating the machine, among other things. Today, the work areas of the machines are therefore secured over a large area through appropriate equipment, for example, a number of light barriers.
[0004] In the case of power-operated textile machines, for example, it is known that for monitoring and securing hazardous areas that can be entered, one must provide for a transmitter and a receiver to be arranged spatially relative to one another, so that a signal is triggered by an interruption in the beam path between the transmitter and receiver and is used for direct interruption of the dangerous movement of the textile machine (cf. DE 4234606A1). In this regard, it is also known that an interruption device in the form of a light barrier safety device may be provided. In the case of a bale opener for textile fiber bales having portable removal elements and more than one hazardous region, the transmitter and receiver are arranged spatially relative to one another, so that the respective hazardous area is completely enclosed by the beam path between the transmitter and receiver in the working position of the removal element. Such a method of subdividing the enclosure of the beam of light has often proven to be cumbersome in operational practice. When setting up a new bale recipient, the opposing safety enclosure is often broken through unintentionally, so that the machine is shut down. It is then possible to correct the bale setup only by interrupting the entire operation. When limited space is available, problems arise in staking out hazardous areas.
[0005] With a known device in EP 0379465A, the problematical hazardous space is shielded by sensors and/or mechanical means. To do so, sensory protective means, which detect an area for monitoring at the side underneath and/or at the front underneath or directly beneath the stripping element of the bale opener, which changes its location. Due to a multitude of sensors, for example, infrared sensors, which are arranged more or less around the recipient, a type of protective curtain is implemented. This should be controlled in such a way that fiber bales are not detected but a person intruding into the area is detected. All the sensors are located on moving parts, in particular the tower and the recipient of the machine, i.e., there is a mechanical connection (coupling) between the sensors and the machine. One disadvantage is that the sensors must be moved in order to create protective areas that can change in position. In particular, the fact that the sensors and evaluation systems are mounted on the moving machines and/or machine parts, where they are exposed to substantial vibrations, which can lead to interference and dangerous failures of the safety system. Another disadvantage is that the ultrasonic sensors that are used are expensive and in particular are very susceptible with respect to air influences such as air stratification, wind, etc. Furthermore, the monitored area is small, i.e., not optimal, in particular with respect to its lateral coverage.
DESCRIPTION OF THE INVENTION
[0006] The invention is thus based on the object of creating a method for operating a bale opener and such a bale opener that avoids the disadvantages of the prior art.
[0007] The invention is also based on the object of creating a method for operating a bale opener and such a bale opener, which are less susceptible to interference, more reliable and less expensive than the methods and the systems offered in the prior art.
[0008] The invention is also based on the object of creating a method for operating a bale opener and such a bale opening, which can be used as collision monitoring in rotation of the stripping element.
[0009] These objects are achieved by a method and a bale opener corresponding to the preamble of the independent claims, which are characterized in that the safety equipment comprises at least one two-dimensional laser scanner, on which at least one monitoring area that is adjustable and variable over time is monitored.
[0010] These objects are also achieved first by a computer program product, which can be loaded directly into an internal memory of a bale opener and comprises software code segments, with which the process steps of the method according to the invention are carried out when the product is running on the bale opener.
[0011] Advantageous embodiments of the invention are the subject matter of the dependent claims.
[0012] Various monitoring regions that are independently adjustable and variable over time can be monitored redundantly on the two-dimensional laser scanner, for example, so that the two-dimensional laser scanner, for example, can monitor at least two monitoring regions, wherein one monitoring region extends to the floor and scans a region above the floor, this monitoring region becoming smaller with an increase in the depth of the stripping element. In another specific embodiment, the two-dimensional laser scanner monitors at least two monitoring regions redundantly in various safety fields, wherein the safety fields of the monitoring regions are switched among one another at certain times or at certain locations during operation.
[0013] This redundant design of the monitoring equipment with different safety fields and monitoring regions serves to improve the safety and robustness of the system and in particular this ensures that a failure or faulty behavior of the sensor can be detected easily. The bale opener is stopped as soon as an unforeseen event (for example, the movement of a person's arm, etc.) is detected in at least one monitoring region or the function of at least one laser scanner cannot be secured.
[0014] The present invention additionally has numerous advantages because the two-dimensional laser scanner can be used in rotation of the stripping element at the end of a group of bales as collision monitoring and also the lateral distance of the stripping element and/or of the bale opener can definitely be reduced.
[0015] The shape of the at least one monitoring region of the laser scanner can be adjusted advantageously. Machine parts or other objects can advantageously be masked out or avoided in this way.
[0016] Additional advantages of the invention can be found in the exemplary embodiment described and illustrated below.
BRIEF DESCRIPTION OF THE FIGURES
[0017] The invention will now be explained in greater detail on the basis of the accompanying figures, in which
[0018] FIG. 1 shows a schematic diagram of a bale opener,
[0019] FIG. 2 shows the configuration of a stripping tower with a laser scanner according to the invention, and
[0020] FIG. 3 a - c show a specific embodiment of the functioning of a laser scanner according to the invention.
[0021] Only features that are important for the invention are shown in the figures. The same reference numerals in different figures denote the same features.
MEANS OF CARRYING OUT THE INVENTION
[0022] FIG. 1 shows in a schematic diagram a bale opener 1 according to the invention. The bale opener 1 consists essentially of a stripping tower 2 and a stripping element 3 . The stripping element 3 is mounted on one side of the stripping tower 2 and is disposed so that it is freely cantilevered over the fiber bale 4 . The stripping tower 2 is equipped with a running gear 5 . The stripping tower 2 is moved along the fiber bale 4 on rails 6 with the help of the running gear 5 . Due to this movement, the stripping element 3 mounted on the stripping tower 2 is guided over the surface of the fiber bale 4 situated beneath it. The mounting of the stripping element 3 on the stripping tower 2 is designed to be adjustable in height, so that the fiber bales 4 can be stripped continuously. A stripping roller 7 having an axle 8 is arranged in the stripping element 3 . The stripping roller 7 removes fiber flocks from the fiber bale 4 . The fiber flocks are removed from the stripping roller 7 by means of a vacuum through the suction hood 9 and sent to the stripping tower 2 . A transport channel 10 which receives the fiber flocks from the suction hood 9 and sends them to a pneumatic fiber flock transport system 11 is arranged in the stripping tower 2 The transport channel 10 and thus also the suction hood 9 are under a certain vacuum which serves to provide pneumatic conveyance for the fiber flocks to the transport channel 10 . According to the invention, a two-dimensional laser scanner 12 is present on the stripping element on the front end. The laser scanner 12 scans its surroundings by emitting a laser pulse. If the laser pulse strikes an object, it is reflected to the receiver of the laser scanner 12 .
[0023] FIG. 2 shows a top view of the stripping element have the functioning of a laser scanner 12 . The laser scanner 12 monitors various monitoring regions 13 , which are independently adjustable and variable over time. In the example shown here according to FIG. 2 , three different safety fields are defined, forming three independent monitoring regions 13 1 , 13 2 , 13 3 . Two of these safety fields are adjusted, so that they remain above the floor but extend deeper than the stripping roller. This redundant monitoring serves to provide safety for the system according to the invention. Another safety field scans the floor continuously. The bale opener 1 is stopped as soon as at least one safety field of the first two has detected an object (for example, a person near the machine, etc.) or as soon as the aforementioned safety field three would no longer detect the floor because the laser scanner 12 , for example, has failed. Since the stripping element 3 is now lowered in the course of stripping the fiber bale, the monitoring region 13 1 , 13 2 of the first two safety fields must be reduced in size with an increase in depth of the stripping element 3 . Only in this way can reliable monitoring of the stripping element 3 be ensured.
[0024] For additional security, various field sets can now be defined, in which the defined monitoring regions 13 1 , 13 2 , 13 3 are inverted, for example, or altered in some other way. For example, each time the stripping roller 7 is stopped after one stripping pass or is stopped at other predefined points in time or at predefined locations of the stripping element 3 , the sensor 12 itself is also monitored as follows: one field set, in which the safety fields 1 and 2 must see the floor (i.e., an object, a person, etc.) and safety field 3 must not see the floor (i.e., no object) is used. If a condition does not correspond to the expected result, the machine is stopped and then is not ready to start. Next, the field set is switched back to normal operation (corresponding to the height of the stripping element) and there is also an analysis of whether this is correct.
[0025] At the same time, it is possible to define various field sets with monitoring regions 13 that can be adjusted in various ways and are variable over time. Between these field sets, it is possible to switch back and forth as desired. At the same time, the shape of the scanning field can be selected with the laser scanner 12 , so that the scanning field is defined as a rectangle, radially or freely by the user, for example. Machine parts or other objects such as machine casings, etc. can be masked out or bypassed advantageously in this way.
[0026] A much better area can advantageously be covered laterally. For example, a person with his arm resting on the bale can be detected promptly. Another advantage is obtained due to the fact that the two-dimensional laser scanner 12 can be used as a collision monitor by rotating the stripping element 3 . At the same time, the lateral distance of the stripping element 3 and/or the bale opener 1 from adjacent objects, walls, etc. can be reduced significantly because the scanning field can be maintained vertically downward.
[0027] Advantages of the method according to the invention include the fact that it is less expensive, more reliable and less susceptible to trouble than the approaches known from the prior art.
[0028] The invention also relates to a computer program product, which can be loaded directly into an internal memory of a bale opener and includes software code segments with which the process steps of the method according to the invention are carried out when the product is running on the bale opener.
LIST OF REFERENCE NUMERALS
[0029] 1 Bale opener
[0030] 2 Stripping tower
[0031] 3 Stripping element
[0032] 4 Fiber bale
[0033] 5 Running gear
[0034] 6 Rail
[0035] 7 Application roller
[0036] 8 Axle
[0037] 9 Suction hood
[0038] 10 Transport channel
[0039] 11 Transport system
[0040] 12 Sensor, laser scanner
[0041] 13 , 13 1 , 13 2 , 13 3 Monitoring region | The invention relates to a method for operating a bale opener ( 1 ) having a stripping element ( 3 ) and a safety device for protection against penetration into a hazardous zone of the stripping element ( 3 ), said safety device consisting of sensory safety means, wherein a monitoring region ( 13, 13 1 , 13 2 , 13 3 ) at the front beneath the stripping element is detected and wherein the stripping element ( 3 ) is mounted on a stripping tower ( 2 ). According to the invention the safety device is at least one two-dimensional laser scanner ( 12 ), on which at least one monitoring region ( 13, 13 1 , 13 2 , 13 3 ), which is adjustable and variable over time, is monitored. The invention also relates to a corresponding bale opener ( 1 ). | 3 |
FIELD OF DISCLOSURE
[0001] This disclosure relates to information systems, and in particular, to programming systems.
BACKGROUND
[0002] Existing programming systems rely on user data entry. These systems are also non-adaptive. Once an activity is programmed, it tends not to change in response to changed circumstances unless the user specifically causes it to change.
[0003] User interfaces for existing programming systems tend to copy the appearance of their paper-based forebears. As such, these user interfaces do not readily take advantage of the processing ability of a modern smart phone or similar mobile broadband devices.
SUMMARY
[0004] In one aspect, the invention features an apparatus for providing a user program to a user. Such an apparatus includes a mobile device configured to execute thereon a head end of an application for collecting user information and for providing a user program interface for delivery of user program information to the user, and a server in wireless data communication with the mobile device for providing user programming information thereto, the user programming being selected at least in part on the basis of the user information collected by the mobile device.
[0005] Embodiments of the apparatus include those in which the server includes a knowledge base for assessing the solicited user information and providing changes in program instructions to the mobile data in response to the user information.
[0006] Also among the embodiments of the apparatus are those in which the mobile device is configured to execute a programming interface for displaying a user program to the user. Among these are those in which the programming interface includes an activity map calibrated to represent a certain time interval.
[0007] The programming interface can also include an icon disposed at a location in the activity map, the location representing a time at which an activity corresponding to the icon is to occur. In some embodiments, the activity map includes a circular region. Others include an indicator on the activity map, the indicator being configured to change position on the activity map in response to passage of time.
[0008] In some embodiments, the icon is placed on the activity map at least in part in response to collected user information. In others, the location of the icon changes at least in part based on collected user information. In yet other embodiments, the icon disappears after the time at which the activity it represents has occurred.
[0009] In yet other embodiments, the mobile device is configured to execute an interface for collecting user information, the interface including an active corner region and an active side region, wherein the active corner region and the active side region each execute corresponding instructions in response to actuation by the user.
[0010] Additional embodiments include those in which the mobile device is configured to execute an interface for collecting user information, the interface including a plurality of active corner regions and a plurality of active side regions, each side region extending between two of the active corner regions, wherein the active corner regions and the active side regions each execute corresponding instructions in response to actuation by the user.
[0011] In another aspect, the invention features an apparatus for providing a user program to a user. Such an apparatus includes a server in wireless data communication with a mobile device for providing user programming information thereto, the user programming being selected at least in part on the basis of user information collected by the mobile device.
[0012] In yet another aspect, the invention features a computer-readable medium having encoded thereon software for providing a user program to a user. Such software includes instructions for providing, to a mobile device, user programming selected at least in part on the basis of user information collected by the mobile device.
[0013] In another aspect, the invention features a computer-implemented method for providing a user program to a user. Such a method includes establishing communication with a mobile device configured to execute thereon a head end of an application for collecting user information and for providing a user program interface for delivery of user program information to the user, and providing user programming information to the mobile device, the user programming being selected at least in part on the basis of the user information collected by the mobile device.
[0014] Among the practices of the method are those that also include providing a knowledge base for assessing the solicited user information, and providing changes in program instructions to the mobile data in response to the user information.
[0015] Yet other practices of the invention also include displaying a user program to the user. In some practices, displaying a user program includes displaying an activity map calibrated to represent a certain time interval.
[0016] In other practices, displaying a user program includes displaying an icon disposed at a location in the activity map, the location representing a time at which an activity corresponding to the icon is to occur.
[0017] Additional practices include those in which displaying a user program includes placing an icon on the activity map at least in part in response to collected user information, and those in which displaying a user program includes placing an icon on the activity map at a location based at least in part based on collected user information.
[0018] Other practices include in response to user actuation of an active corner region on the mobile device, executing first instructions, and in response to a user actuation of an active side region on the mobile device, executing second instructions.
[0019] Also among the practices of the invention are those that include, in response to user actuation of any one of plural corner regions, executing instructions corresponding to the actuated corner region, and in response to user actuation of any of a plurality of side regions, each of which extends between two of the active corner regions, executing user instructions corresponding to the actuated side region.
[0020] These and other practices of the invention will be apparent from the following detailed description and the accompanying drawings, in which:
DESCRIPTION OF THE FIGURES
[0021] FIG. 1 is a functional block diagram of an activity programming system;
[0022] FIG. 2 shows parts of a collection interface;
[0023] FIG. 3 shows an example of a collection interface having the parts shown in FIG. 2 ;
[0024] FIGS. 4-5 shows the collection interface of FIG. 3 after activating a region on a category strip thereof;
[0025] FIG. 6 shows the collection interface of FIG. 2 used to display a pre-defined list of symptoms;
[0026] FIGS. 7 and 8 show activity programming interfaces; and
[0027] FIG. 9 shows an activity programming interface optimized for a rectangular display area.
DETAILED DESCRIPTION
[0028] Activity programming includes providing a program of activities to be carried out at particular times, i.e. an “activity program,” in response to solicited information. One activity programming system 10 , shown in FIG. 1 , features a mobile device 12 on which executes a head-end 14 of an application, and a server 16 on which remotely executes a tail-end 18 of the application. The head-end 14 includes a collection interface 19 for collecting information from a user, and a user program interface 20 that provides an activity program, which may include instructions and reminders, to the user. Communication between the head-end 14 and the tail-end 18 takes place via the cloud 24 .
[0029] The tail-end 18 includes a monitor 26 that receives user information provided by the collection interface 19 and stores it in a user database 31 . In some embodiments, the tail-end 18 also retrieves information from the user database 31 for display on the mobile device 12 .
[0030] The tail-end 18 further includes a knowledge base 28 that functions as an expert system for evaluating the information provided by the user and making decisions based on that information, and a program changer 30 for providing a program of instructions, or “activity program,” to be carried out by the user, or alternatively, for providing changes to an activity program already provided earlier to the user's mobile device 12 .
[0031] An activity programming system 10 as described herein is particularly useful in the area of health care delivery. In this application, an activity program can include instructions to take certain medications at certain times, to take a blood pressure at certain times, to engage in particular exercises, and the like. Information solicited from the user might be information about current medical conditions, including quantitative information such as temperature and blood pressure or qualitative information, such as the presence of swelling and the like.
[0032] However, the activity programming system 10 described herein is also useful in other areas in which a user must perform certain activities that can change in response to changing circumstances.
[0033] A response center 32 fields inquiries from the user. These inquiries can be pre-recorded or pre-set inquiries made by activating selected areas of the collection interface 19 or user program interface 20 . These pre-recorded inquiries can be provided in a hierarchical fashion, so that selecting one inquiry will display additional inquiries related to the selected inquiry. In some cases, the response center 32 automatically responds to these inquiries. However, in other cases, the response center 32 will direct a query to a live human. For example, in a health care application, the user may be directed to trained medical practitioner communicate with the user, either directly, for example by a telephone call, or indirectly, for example by causing the activity program to change.
[0034] In response to certain data provided by the head-end 14 , the knowledge-base 28 may determine that a change is necessary to the activity program instructions provided by the program changer 30 . The program changer 30 then provides this information back to the head-end 14 for display on the mobile device 12 using the head-end's programming interface 20 .
[0035] To promote usability and to accommodate the constraints of space on a typical mobile device 12 , the collection interface 19 , shown in FIG. 2 , includes a main category strip 32 that features regions 34 , each of which is marked by an icon, text, or characters to identify a particular category. Stroking the finger over the category strip 32 causes the region 34 under the finger to momentarily enlarge relative to other regions. The entire category strip 32 can also be scrolled one way or the other to expose additional categories. A suitable gesture, such as a tap, on a particular region 34 exposes fields for soliciting information from the user for use in generating a user program. These fields are pertinent to the active category and are displayed in a working layer 38 . A subcategory strip 36 operates in essentially the same way as the main category strip 32 .
[0036] The collection interface 19 further includes menu buttons 40 , 42 , that, in response to selected gestures, expose various menus. Also included in the collection interface 19 is a dashboard 43 containing buttons 44 that, in response to a gesture, cause certain actions to occur.
[0037] FIG. 3 shows a representative collection interface 19 in which the dashboard 43 features buttons for various communication functions, such as for making telephone calls 46 or sending messages 48 , as well as four menu buttons 50 A-D. In the illustrated example, the main category strip 32 and subcategory strip 36 use sinographs for communication. However, it will be understood that the particular symbol used to convey meaning is not important, so long as it can be understood. The working layer 38 in this case shows a photograph of the user.
[0038] In some embodiments, the collection interface 19 can also collect information from the user database 31 . For systems used in health care, such information can include the user's compliance information and symptomatic history.
[0039] FIG. 4 shows the effect of drilling down by tapping the uppermost full region 52 in FIG. 3 . In response, the display shown in the working layer 38 has changed to show certain information about the user.
[0040] FIG. 5 shows the effect of drilling down by tapping the second full region 54 in FIG. 3 . In this case, the working layer 38 has changed to solicit information about the user's health. Information provided by the user, by tapping on a region 56 in the working layer 38 , is then provided to the tail-end 18 .
[0041] FIG. 6 shows another exemplary collection interface 19 for soliciting information in an embodiment specifically directed to health care. In this example, the collection interface 19 solicits information about any symptoms experienced by the user. The working layer 38 in this case provides a list of symptoms. By tapping on selected regions within the working layer 38 , the user causes relevant information to be transmitted to the tail-end 18 for storage in the user database 31 .
[0042] Referring to FIG. 7 , one embodiment of an activity programming interface 20 includes a circular activity map 50 that places activity icons 52 , 54 at positions that correspond to time. In the particular embodiment shown, angle represents time. Preferably, a clock 55 showing the actual time is placed within the circular activity map 50 .
[0043] The activity programming interface 20 further includes four menu buttons 57 , one at each of four corners of the display, and four hot edges 59 extending between pairs of menu buttons 57 and along the sides of the display. The menu buttons 57 and hot edges 59 can be used to access various options and functions, the details of which are application-specific.
[0044] The 360 degrees of the circular activity map 50 represent some convenient interval, such as 8 hours, 12 hours, or 24 hours. The interval is application-dependent and can depend on the number of activities and the intervals between them.
[0045] Different programmed activities are represented by activity icons 52 , 54 . These activity icons 52 , 54 are placed at locations within the activity map 50 that correspond to the times at which the activities they represent are to occur. For example, if a user is to take a particular medication at a particular time, the icon might be a picture of the pill, as is the case in FIG. 7 , which is disposed at a location corresponding to that angle.
[0046] Although the icons can be graphical representations of an activity, it is also possible for the icon to simply show a number or letter. In either case, the user merely taps on the icon to temporarily transform the programming interface into the state shown in FIG. 2 to see a description of the relevant activity.
[0047] The icon can be configured such that tapping the icon communicates completion of the activity back to the tail-end 18 . In response to failure to receive a completion signal, the tail-end 18 can also be configured to transmit an alarm signal to the head-end 14 to alert the user to his non-compliance and to reconfigure or otherwise change the activity icons 52 , 54 in response to such non-compliance.
[0048] The program interface further includes an indicator 56 whose position on the circular activity map 50 depends on time. In the illustrated embodiment, the indicator 56 is a radially-extending feature that extends at an angle that depends on time. The indicator 56 sweeps around the circular activity map 50 at a rate consistent with elapsed time. In doing so, the indicator 56 highlights particular activity icons 52 , 54 on the display.
[0049] In some embodiments, as shown in FIG. 7 , the indicator 56 is a radially-extending moving wedge that sweeps around the activity map 50 at a rate indicative of elapsed time. In this embodiment, the indicator 56 highlights a range of times corresponding to the angular extent of the moving wedge. This indicator 56 can thus be used to highlight particular activity icons, to hopefully remind the user to carry out the activity associated with the activity icon.
[0050] A variety of ways are provided to remind the user of an impending activity. In some embodiments, the color of the activity map 56 changes as the remaining time to an activity diminishes. For instance, a normally green activity map 56 might change to yellow when the remaining time falls below a threshold and then change to red when the remaining time falls below a second threshold. The thresholds can be constant across all kinds of activities, or they can be tailored to suit the nature of the activity. Or, one or more activity icons 52 , 54 can change appearance, for example, change color or intensity, to apprise the user of an impending activity.
[0051] In other embodiments, the activity map 56 includes a count-down timer 64 that indicates time remaining until the next activity is due. The count-down timer 64 can be present at all times, or it can be made to appear when the time remaining until the next activity has diminished to a third threshold.
[0052] FIG. 8 is an example of a user program interface 20 as described in connection with FIG. 7 but in which the icons 58 , 60 denote types of exercise rather than types of medication. In this embodiment, the indicator 62 is a radially-extending line rather than a radially-extending wedge.
[0053] FIG. 9 shows an alternative embodiment optimized for a display having a more rectangular aspect ratio. The illustrated display provides additional space for an auxiliary component 66 that can be used to provide an activity list or additional documentation concerning an activity.
[0054] Information for selection of and placement of icons 52 , 54 , 56 , 58 is communicated to the mobile device 12 from the program changer 30 via the cloud 24 and updated as necessary. For instance, as time progresses, new icons may appear and icons representing completed activities may disappear.
[0055] In addition, the activity programming system provides a way to dynamically modify the activity program in response to changing conditions. For example, in a health care delivery embodiment, the user may forget to take his medication at a prescribed time. Depending on the nature of the condition, the knowledge base 28 may instruct the program changer 30 to change the next time at which the medication should be taken. Or, if the monitoring center 26 recognizes an abrupt increase in blood pressure, the knowledge base 28 may instruct the program changer 30 to modify the time at which the next medication should be taken or to modify the dosage. In some cases, the activity programming system 10 will alert a doctor, who can then manually provide instructions for changing the activity program. | An apparatus for providing a user program to a user includes a mobile device configured to execute thereon a head end of an application for collecting user information and for providing a user program interface for delivery of user program information to the user, and a server in wireless data communication with the mobile device for providing user programming information thereto, the user programming being selected at least in part on the basis of the user information collected by said mobile device. | 6 |
BACKGROUND OF THE INVENTION
AND
PRIOR ART STATEMENT
The present invention relates generally to cleaning systems, and particularly to cleaning systems useful to clean large areas, such as baseball parks, football stadiums, picnic areas and zoos.
Standard practice heretofore in cleaning large areas such as baseball parks, football stadiums, picnic areas and zoos, has been to collect the refuse manually using rakes and brooms and eventually to place the refuse in receptacles for disposal. Attempts to automate the cleaning of large areas are exemplified by the following patents and article:
______________________________________U.S. PatentsPat. No. Inventor Date______________________________________2,471,326 W. C. Hoyt, Sr. May 24, 19492,850,162 E. Widmer Sept. 2, 19583,404,776 R. E. Shaddock Oct. 8, 19683,802,585 H. W. Churchman April 9, 1974______________________________________
Foreign Patents
British Pat. No. 852,853 published Nov. 2, 1960.
Italian Pat. No. 428,203 (with partial translation) granted Dec. 9, 1947.
Advertising Literature
Helix Product Data Bulletin No. 5101
The Hoyt Pat. No. 2,471,326 and the Helix Product Data Bulletin No. 5101 illustrate past devices useful in collecting leaves. Neither of these systems would be useful for collecting refuse from large areas such as baseball parks and the like since the hoses associated therewith are of limited extent. It is pointed out that the details of the compactor forming a part of the Helix leaf loader of Product Data Bulletin No. 5101 are illustrated in the Churchman Pat. No. 3,802,585.
The Widmer Pat. No. 2,850,162 shows a stationary system for collecting refuse, but there is no suggestion of applying this system in a mobile manner to clean large areas. To the same effect is the Italian Pat. No. 428,203.
Finally, the Shaddock Pat. No. 3,404,776 and the British Pat. No. 852,853 show portable systems for vacuum collecting of refuse, fundamentally from streets and the like. Neither of these systems though would be particularly useful in cleaning large areas in view of the limited extent of the hoses used to pick up the refuse.
SUMMARY OF THE INVENTION
The present invention provides an improved system for cleaning large areas such as baseball parks, football stadiums, picnic areas and zoos, and particularly utilizing long distance pickup of the refuse for conveying to a central collection point.
This is accomplished in the present invention, and it is an object of the present invention to accomplish these desired results, by providing a system for cleaning large areas including a portable chassis, a refuse compactor mounted on the chassis for packing refuse into a small volume therein, a blower mounted on the chassis and constructed and arranged to draw air and entrained refuse into an inlet for the blower and to blow the refuse from the blower into the compactor, a substantial length of flexible hose having one end thereof connected to the inlet to the blower and a pickup nozzle connected to the other end of the hose, the pickup nozzle having an inlet end with an opening therein substantially greater in area than the internal area of the hose, the blower creating a stream of air entering the inlet end of the nozzle and carrying refuse therewith and along the hose and through the blower and into the compactor thereby rapidly to clean refuse from large areas and to compact the refuse into a small volume in the compactor.
Another object of the invention is to provide in a system of the type set forth, a blower that shreds the refuse into pieces having a maximum dimension in the range from about two inches to about three inches with the compactor reducing the volume of the shredded refuse in the ratio of about 20 to 1.
Still another object of the invention is to provide a system of the type set forth wherein the substantial length of flexible hose has a length in the range from about 100 feet to about 400 feet or more and has an internal diameter in the range from about eight inches to about twelve inches, the flexible hose being formed of a lightweight molded plastic having a wall thickness of about one-sixteenth inch and being annularly corrugated to facilitate the bending and handling thereof.
Yet another object of the invention is to provide in a system of the type set forth a flexible hose formed in sections having lengths of about 20 feet, and further including hose clamps interconnecting adjacent hose sections and a hose clamp connecting one end of one of the hose sections to the inlet of the blower and another hose clamp connecting one end of another hose section to the pickup nozzle.
Still another object of the invention is to provide in a system of the type set forth a pickup nozzle wherein the plane defined by the inlet end thereof is disposed essentially parallel to the axis of the hose to which the nozzle is connected, and the area of the opening in the inlet end of the nozzle has a ratio to the area of the inlet end of the hose in the range from about 1.5 to 3.
Yet another object of the invention is to provide in a large area cleaning system of the type set forth a hose rack mounted on the chassis for carrying sections of hose therein.
A further object of the invention is to provide in a large area cleaning system of the type set forth a hose support member including a sleeve for slidingly receiving a hose therethrough, and a clamp for mounting the sleeve on the railing of an upper deck in a stadium or a ballpark to support the hose in an elevated position during the cleaning of the upper deck.
Further features of the invention pertain to the particular arrangement of the parts of the cleaning system, whereby the above outlined and additional operating features thereof are attained.
The invention, both as to its organization and method of operation, together with further features and advantages thereof will best be understood with reference to the following specification taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a large area cleaning system made in accordance with and embodying the principles of the present invention;
FIG. 2 is a side elevational view on an enlarged scale of the attachment plate used to interconnect the suction hose to the fan unit;
FIG. 3 is a view in longitudinal section through the attachment plate of FIG. 2 and the associated connected section of the suction hose;
FIG. 4 is an enlarged view of the pickup nozzle forming a part of the system of FIG. 1;
FIG. 5 is an enlarged view of the truck forming a part of the system of FIG. 1 with certain portions broken away to illustrate details of the compactor, and further illustrating a rack carried thereon to support sections of hose;
FIG. 6 is an end view of the hose carrying rack of FIG. 5;
FIG. 7 is a side elevational view showing a support for the hose on a balcony or upper deck in a baseball park or football stadium; and
FIG. 8 is an enlarged view with certain portions broken away of the hose support member illustrated in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
There is illustrated in FIG. 1 of the drawings a system for cleaning large areas such as baseball parks, football stadiums outdoor picnic areas, zoos and the like, comprising a truck 100 carrying a fan unit 105 and a compactor 110, a long flexible hose 120 having one end connected to the inlet of the fan unit 105 and carrying at the other end thereof a pickup nozzle 140, all made in accordance with and embodying the principles of the present invention.
The truck 100 includes the usual chassis 101 supported by four wheels 102 and carrying a cab 103 with the usual controls therein. The fan unit 105 is mounted directly behind the cab 103 and is connected by a duct 106 to the inlet to the compactor 110. The compactor 110 includes a generally rectangular housing 111 having a top wall 112, a pair of essentially parallel side walls 113, a front wall 114, and a hinged door 115 closing the rear of the housing 111. The duct 106 connects with an opening in the front wall 114 and blows refuse into a loading area 116 in the compactor 110. A side door 117 is provided for the loading area 116 for manual loading if required. Referring also to FIG. 5, there is shown diagrammatically an ejection blade assembly 118 and a packing blade 119. Further details of the construction and operation of the compactor 110 are set forth in the Churchman Pat. No. 3,802,585, and the disclosure thereof is incorporated herein by reference. Details of the fan unit 105 and the duct 106 are also set forth in the Helix Product Data Bulletin No. 5101 referred to above, and the disclosure thereof is incorporated herein by reference.
The flexible hose 120 is preferably formed of a plurality of sections 121. Each of the sections 121 has a length of 20 feet and may have a diameter of eight inches or ten inches or twelve inches, and in fact a diameter in the range from about eight inches to about twelve inches. The hose sections 121 are preferably formed of a resilient plastic having a thickness of about one-sixteenth inch and are provided with annular corrugations 122 (see FIG. 3 also). The lightweight molded plastic construction together with the corrugations 122 provide for ease of handling of the hose 120 even at lengths thereof as great as 400 feet. In addition, the hose can be folded and bent without breaking, even at operating temperatures as low as 40° F. below zero. The interior surfaces of the hose 120 are smooth and are readily cleaned prior to storage.
Adjacent sections 121 of the hose 120 are connected by split plastic couplers 123, the number of sections 121 being selected to provide the required overall length of the flexible hose 120. One end of the assembled hose 120 is connected to the fan unit 105 by means of an attachment plate 130 (see FIGS. 2 and 3). The fan unit 105 has an opening therein around which is disposed an essentially square attachment plate 130 having an aperture 131 in the center thereof registering with the opening into the fan unit 105. Surrounding the aperture 131 is an annular flange 132 that is welded to the plate 130 as at 133, the flange 132 extending outwardly and to the right as viewed in FIG. 3 for receiving the end of an adjacent hose section 121 thereon. An opening 134 is provided in each of the corners of the plate 130, each opening 134 receiving a bolt 135 therethrough, the bolts 135 cooperating to secure the attachment plate 130 to the fan unit 105. The adjacent end of the associated hose section 121 is secured to the flange 132 by means of a hose clamp 125.
The other end of the assembled hose 120 carries thereon the pickup nozzle 140, the details of construction of which are best illustrated in FIGS. 1 and 4. The pickup nozzle 140 includes an inlet end 141 that is disposed in a plane and has a generally circular opening therein that has a diameter of, for example, twenty inches. The nozzle 140 extends upwardly from the inlet end in a generally conical fashion and joins a transition section 142 which is of decreasing area in the direction away from the inlet end 141 and ends in a connection end 143 that is generally circular in shape and defines a plane that is normal to the plane defined by the inlet end 141. The external diameter of the connection end 143 is essentially equal to that of an associated connector pipe 145 that is secured thereto as by a weld 146. The connector pipe 145 has a free end 147 that is also essentially circular in shape and has an external diameter essentially equal to the internal diameter of the associated suction hose 120, i.e., a diameter in the range from about eight to twelve inches, and, for example, may be eight inches or ten inches or twelve inches in diameter. The adjacent end of the hose 120 is secured to the connector pipe 145 by a hose clamp 125 like the hose clamp 125 that secures the other end of the hose 120 to the attachment plate 130. There is secured to the connector pipe 145 a handle 150 that includes a right angle connecting portion 151 secured as by welding 152 to the connector pipe 145. The longitudinal axis of the handle 150 is parallel to the longitudinal axis of the connector pipe 145 and is spaced from the adjacent surface thereof to accommodate the hand of a user. Preferably the handle 150 is covered with a rubber or plastic grip for greater ease of operator convenience in cold and wet weather.
An example of a typical use of the large area cleaning system of the present invention is to clean up a football stadium after a professional football game. In a typical example of such a use, the system of the present invention was utilized to clean Soldier's Field at Chicago, Ill. after a professional football game attended by 57,000 people. After the game was completed and the spectators had departed, the truck 100 was driven onto the playing surface adjacent to one edge thereof with the attachment plate 130 disposed toward the stands. Workmen using brooms and rakes moved the refuse into windrows in the usual manner. The hose sections 120 were assembled, one end attached to the attachment plate 130 and the other end to the pickup nozzle 140. Using a substantial length of hose 120, the nozzle 140 was utilized to pick up the refuse from the windrows. The refuse typically included broken watermelons and other fruit and debris, fabric blankets, plastic and metal containers from a six ounce size up to a five gallon size, and general paper and cardboard refuse.
Collection of refuse was initiated by starting the fan unit 105 which generated a movement of air through the hose 120. The fan unit 105 is constructed and arranged so as to produce 10,000 linear feet of air movement per minute, this providing 9600 cubic feet of air movement per minute through a twelve inch diameter opening at the fan unit 105 under normal working conditions in accordance with the Air Moving And Conditioning Association Standards. 400 feet of hose 120 were coupled so as to be able to reach from the playing surface up to the farthest reach of the stands adjacent thereto. With the truck located in one position, a sector of the playing field and the adjacent viewing stands was cleared of debris. A stream of air was generated in the direction of the arrows 153 (see FIG. 4) entering the inlet end 141 of the pickup nozzle 140 and continuing in the direction of the arrows 154 (see FIG. 1) and 155 and into the fan unit 105.
The fan unit 105 includes a six-bladed fan which serves to shred the refuse into particles having a maximum diameter in the range from about two inches to about three inches. The stream of air with the entrained shredded refuse passes upwardly through the duct 106 and into the compactor 110. The compactor 110 is operated as described in Pat. No. 3,802,585 referred to above. More specifically (and referring to FIG. 5), the packing blade 119 oscillates in a horizontal manner and serves to pack refuse falling in front thereof into the upper space and against the ejection blade assembly 118. In the particular cleaning operation at Soldier's Field, the debris filled the compactor to about one-fourth of the capacity thereof, the ratio between the volume of the shredded refuse before compaction and after compaction being about 20 to 1.
After the first sector has been cleaned of refuse as described above, the truck 100 is moved to the next sector. This next sector is then cleaned both on the playing field and in the associated portion of the viewing stand. This process was continued until the entire playing surface and the associated stands had been cleaned of all refuse. This required about two hours and twenty minutes of elapsed time to clean Soldier's Field after a football game attended by 57,000 people. The truck 100 was then driven to a place of disposal, the rear door 115 opened upwardly, and the ejection blade assembly 118 and the packing blade 119 moved rearwardly simultaneously to eject the packed refuse therefrom.
During the cleaning operation in the stadium, it was found that the nozzle 140 was easily handled and could pick up all manner and types of debris as described above. Also the inlet end 141 of the nozzle was sufficiently small to get into restricted areas, yet was large enough to accept debris of large dimensions for transmission through the hose 120 and into the fan unit 105. The pickup nozzle 140 and the length of hose 120 was sufficiently light in construction that a single individual could operate and manipulate the same, whereby if needed, the entire refuse collecting operation could be accomplished by using a single operator.
Other compactors may be used in pace of the compactor 110 illustrated in Helix Product Data Bulletin No. 5101, and manufactured by the Prefection-Cobey Co., Division of Harsco Corp. For example, other suitable compactors are manufactured by Peabody Galion Corporation and PakMor, Inc. It is only necessary that the compactor has a size and shape such that it can enter into the baseball park or football stadium or other large area that is to be cleaned. All of the parts described herein are preferably formed of metal, except for those that have been designated as being formed of plastic.
There is illustrated in FIGS. 5 and 6 of the drawings a hose rack 170 that can be mounted on the truck 100, and specifically on top of the compactor 110 for holding a plurality of the sections 121 used in forming the elongated hose 120. The rack 170 is preferably formed of an angle iron framework using nuts and bolts. More specifically, there are provided bottom members 171 and top members 172 joined by side members 173 to provide an essentially rectangular array. Disposed between the bottom members 171 and the top members 172 are intermediate members 174, and disposed between the side members 173 are divider members 175. The various members mentioned cooperate to provide receptacles that each receive three of the hose sections 121. The members 171 through 175 extend rearwardly to the hinged door 115, and extending downwardly and rearwardly therefrom is a rear portion 180 including bottom members and top members 182 joined by side members 183 and having intermediate members 184 disposed therebetween. The rear portion 180 forms a rearward and downward continuation of the rack 170 as is best illustrated in FIG. 5. As illustrated, the rack 170 can accommodate twelve 20 foot sections 121 that can be connected to form a 240 foot suction hose 120.
In certain baseball parks and football stadiums, there is not only a lower or bottom tier to the seating arrangement, but there also are balconies or upper decks or upper tiers, sometimes two or more of such upper tiers being provided.
It is desirable to be able to clean such upper tiers using the system of the present invention, and all while the truck 100 is positioned upon the playing surface or adjacent to the playing surface at what is essentially ground level. There is illustrated in FIGS. 7 and 8 of the drawings a hose support member that is adapted to be mounted upon the rail of an upper tier designated by the numeral 60 in FIG. 7. The upper tier 60 includes stepped support surfaces 61 that support chairs 62, the forward portion of the upper tier 60 being provided with a protective rail 65. The rail 65 is arranged essentially horizontally and is supported by a series of spaced posts 66 that extend upwardly from the forwardmost support surface 61. In accordance with the present invention, a hose support member 160 is removably secured to the rail 65 to support an intermediate portion of the suction hose 120 while the associated upper tier 60 is being cleaned.
The hose support member 160 includes an elongated sleeve 161 which has the outer ends flared outwardly as at 162, the internal diameter of the sleeve 161 accepting the hose 120 therethrough and accommodating sliding movement thereof as is diagrammatically illustrated by the arrow 167. Fixedly secured to the sleeve 160 is a U-clamp 163 attached as by welding 164 to the sleeve 161. The legs of U-clamp 163 straddle the rail 65 and the outer ends of the legs of the U-clamp 163 receive a bolt 165 therethrough that carries on its upper threaded end a nut 166. Tightening of the nut 166 upon the bolt 165 serves to clamp the U-clamp 163 and the attached sleeve 161 in the desired operative position upon the rail 65. After cleaning of the associated section of the upper tier 60, the hose support member 160 can be moved to the next section of the upper tier 60 for supporting the hose 120 during the cleaning of the refuse therefrom.
While there have been described what are at present considered to be the preferred embodiments of the invention, it will be understood that various modifications may be made therein, and it is intended to cover in the appended claims all such modifications as fall within the true spirit and scope of the invention. | A system for cleaning large areas such as baseball parks and football stadiums and picnic areas and zoos, including a truck having a chassis, a refuse compactor mounted on the chassis for packing refuse into a small volume therein, a blower mounted on said chassis and constructed and arranged to draw air and entrained refuse into an inlet for the blower and to blow the refuse from the blower into the compactor, a substantial length of flexible hose having one end thereof connected to the inlet to the blower and a pickup nozzle connected to the other end of said hose, the pickup nozzle having an inlet end with an opening therein substantially greater in area than the internal area of the hose, the blower creating a stream of air entering the inlet end of the nozzle and carrying refuse therewith and along the hose and through the blower and into the compactor thereby rapidly to clean refuse from large areas and to compact the refuse into a small volume in the compactor. | 4 |
TECHNICAL FIELD
The present invention relates to a geological probing device comprising a hollow probing rod to be extended into the geological matter to be probed, and a measuring probe fitted to the probing rod, the measuring probe comprising at least one sensor for obtaining information (e.g. physical and chemical characteristics) about the matter (e.g. soil or rock).
Such probing devices can be implemented in Cone Penetration Test (CPT) equipment, and are primarily used in geotechnical investigations, but can also be used in geological investigations in general, on and off shore.
TECHNICAL BACKGROUND
A probing device of this kind is shown in U.S. Pat. No. 5,902,939. A drive mechanism is provided to push the probing rod into the soil, for example using hydraulic force. During operation, the probing rod is extended one section at a time, whereby each new section is linked to the sections of the probing rod already pushed down, for example by means of screw threads in the ends of each section. Preferably, the process of linking sections together can be performed without interrupting operation of the drive mechanism.
A measuring probe is fitted to the probing rod, preferably close to the tip of the rod, and can be adapted to measure friction, probe inclination, water pressure, etc, using one or several sensors. At the surface, processing and recording equipment is arranged to receive data from the probe.
When using probing devices of this kind, the data from the probe can be transmitted to the equipment at the surface using different techniques.
In the probing device mentioned above, the data is transmitted by means of a electrical or optical cable, running through the hollow probing rod. Such a cable complicates the process of linking rod sections during operation.
According to another known technique, the data is transmitted using acoustic signals, propagating through the material of the probing rod. A drawback with this solution is the transmitted signal's sensitivity to noise in the ground, caused by e.g. heavy equipment on the surface and the friction against the probing device itself. Also, the qualities of the soil has an important impact on the transmitted signal. Too much noise makes it difficult to process and analyze the acquired data.
A third solution is presented in EP 1065530, describing optical transmission of data. In this case, each section of the probing rod is provided with one or several optical guides located inside the hollow probing rod section. The optical guide section is in the form of a glass or plastic rod, or one or several optical fibers. When the rod sections are linked together, a continuous optical guide is formed, allowing transmission of optical signals from the probe to a receiver located at end of the probing rod, normally above the surface.
Although this solution eliminates the need for providing a cable into the rod, it complicates the linking of rod sections, as care has to be taken not to disrupt the optical guide. Also, the probing rod sections become more expensive, and also more sensitive to environment and treatment. Additionally, the process of receiving the optical signals is very delicate, and can easily be interrupted. Notably, the optical link will be interrupted each time a new rod section is linked to the probing rod. EP 1065530 attempts to solve such problems, including memory units, optical mirrors, camera based sensors, etc, resulting in a complex and costly probing device. It is considered that such an optical system is badly suited for the conditions present during soil probing.
SUMMARY DISCLOSURE OF THE INVENTION
Therefore, it is an object of the present invention to provide an improved geological probing device, alleviating the above mentioned problems.
More specifically, it is an object of the invention to provide an improved data transmission in a geological probing device.
These and other objects are accomplished by a geological probing device of the kind mentioned by way of introduction, wherein the measuring probe further comprises a microwave transmitter, arranged to transmit microwaves carrying data from said sensor, and wherein the hollow probing rod is adapted to act as a waveguide, guiding the microwaves to an upper orifice of said hollow probing rod.
According to the invention, the interior of the probing rod is thus employed as a waveguide, through which the microwaves can propagate from the probe to the upper orifice, located above or close to the surface. Conventional probing rods, typically made of steel, offer satisfactory wave guiding characteristics in the micro frequency range, and no particular preparation of the probing rod therefore needs to be performed.
It should be noted that the term “hollow” refers to the rod itself. In other words, the hollow space may well be filed with some material other than air, such as a suitable dielectric material, e.g. Teflon.
Compared to previously known techniques, the device according to the invention offers a reliable transmission of data under normal working conditions, and without substantial modifications of the probing rod. In fact, a conventional probing device can be adapted to the invention, by being provided with a microwave transmitter and a suitable interface(s).
Compared to acoustic transmission, the inventive device is less vulnerable to unpredictable sources of disturbance, such as characteristics of the geological matter and surroundings. Instead, the transmission of microwaves depends on factors inherently present in the device itself, such as the inner surface of the probing rod.
Compared to optical transmission, a micro wave based system is more robust, and signals will not be interrupted as easily. Although microwaves, like optical waves, cannot penetrate objects in their path, they are more easily reflected in e.g. the frame of a penetrometer, and can therefore often reach a receiver despite objects being placed in between.
The probing rod can be formed by a plurality of rod sections, arranged to be linked together one by one during extension thereof into the geological matter. This offers flexibility when extending the probing rod deep into the ground or sea bed. As mentioned, the microwaves will be spread and reflected when they leave the upper orifice of the rod, and a linking of an additional rod section will therefore only cause a minor disruption in signal reception.
Preferably, the device comprises a receiver at a location outside said upper orifice, adapted to receive the microwaves propagated through the probing rod. The receiver can comprise several receiving units, with different polarization, in order to further minimize disruptions of the signal caused e.g. when linking a new rod section, and to improve reception in general. The microwaves can have a frequency in the range 2-300 GHz, and preferably in the range 5-30 GHz. The most suitable frequency primarily depends on the characteristics of the probing rod (section shape, diameter) acting as a waveguide. In principle, a lower frequency wave requires a larger diameter waveguide. Further, some frequencies (e.g. the 5.6 GHz-band, the 24 GHz-band) are more convenient, as they do not require the end user to have permission from the national telecommunication authority, as long as the equipment is certified.
The geological matter can be soil, such as sand, clay, silt, and the probing rod can then be pushed into the soil using e.g. a hydraulic drive mechanism.
Alternatively, the geological matter can be rock, in which case the probing rod can be equipped with a suitable drilling point and be drilled into the rock.
The probing device can be used in all types of geological investigation, including geotechnical investigations on land, and off-shore investigations.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will be apparent from the preferred embodiments more clearly described with reference to the appended drawings.
FIG. 1 shows a penetrometer according to an embodiment of the invention.
FIG. 2 shows the probe of the penetrometer in FIG. 1 in more detail.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following description of a preferred embodiment is related to a penetrometer 1 uses hydraulic cylinders 2 to push a probing rod 3 consisting of several rod sections 4 into the ground 5 . The rod is typically made of steel, with standard diameter of for example 36 mm or 44 mm. The force from the cylinders 2 is transferred to the probing rod 3 by means of a clamp 6 (e.g. hydraulic or mechanical), arranged around one of the rod sections 4 a protruding above the surface of the ground. As this section is pushed further into the ground, a consecutive section 4 b is linked to the probing rod 3 , and the clamp 6 is released and then moved, in order to shift its point of application to this new rod section 4 b . This process forces the probing rod 2 further and further down into the ground 5 .
The first, leading section of the probing rod, shown in more detail in FIG. 2, is referred to as the probe 7 , and comprises five parts, 7 a-e . The first three parts are different sensors, namely a conical pressure sensor 7 a , a water filter for measuring 7 b , and a friction sleeve. Additionally, the probe 7 can be provided with an inclinometer 8 , arranged inside the friction sleeve. Transducers for generating electrical signals are schematically illustrated by 9 a-c in FIG. 2 .
The next part 7 d of the probe 7 is provided with an A/D-converter 10 , and a micro processor 11 , processing the data from the transducers 9 . The top part 7 e of the probe 7 comprises a microwave transmitter 12 , with an dipole antenna 13 and a power source 14 , such as a replaceable or rechargeable battery pack.
The measured data from the sensors, is digitized and multiplexed into one digital signal 18 , and then supplied to the transmitter 12 . In the illustrated example, the signal 18 is modulated by a carrier wave 15 , and carried through the battery pack 14 , avoiding the need for signal terminals between the probe parts 7 d and 7 e . The transmitter 12 encodes the signal into a microwave carried signal 19 which is then transmitted by the dipole 13 into the interior of the probing rod 3 .
Returning to FIG. 1, the probing rod 3 acts as a microwave guide, and guides the microwave signal 19 to the orifice 20 of the probing rod, located above ground. In the illustrated example, a microwave receiver 21 is arranged above this orifice 20 , and adapted to receive the microwave signal 19 propagating through the probing rod 3 . The receiver can be fixedly mounted on the frame of the penetrometer 1 , or on the hydraulic cylinders 2 . However, the receiver should be mounted so that it is located above the orifice 20 even during the linking of a new rod section to the probing rod. The receiver 21 can comprise circuitry 22 for decoding the microwave signal 19 and extracting the measuring data signal 18 .
The receiver 21 can in turn supply the signal 18 to be connected to equipment 23 for processing and logging the measured data. Such equipment 23 can be a data acquisitioning device of previously known type, and the receiver 21 can then be provided with circuitry (not shown) for supplying the equipment 23 with a signal it can interpret.
In an alternative embodiment, the receiver 21 can be arranged in contact with the orifice 20 , in order to improve the quality of the received signal. The receiver can be fitted onto the rod section 4 currently being pushed into the ground, and then moved when the next rod section is linked. Alternatively, the penetrometer 1 is arranged to push the probing rod by making contact with the upper end thereof, and the receiver can then be arranged in this part of the penetrometer.
To ensure that the probing rod is not filled with water, water tight or at least water resistant seals can be provided between the rod sections 4 . In some cases it can suffice to apply grease on the screw threads of the rod sections 4 , in other cases alternative linking means may have to be considered. In order to manage smaller amounts of water penetrating into the probing rod 3 , the dipole 13 can be arranged on a support 25 , ensuring that the dipole is located above the surface of any such water 26 . The dipole is then connected to the transmitter 12 by e.g. a coaxial cable 27 .
In a system tested by the applicant, the acoustic transmitter of a CPT probe of conventional type was replaced by a microwave transmitter according to the invention. Also, the microphone of the acoustic system was replaced by a microwave receiver. It is in fact one of the advantages of the present invention that it can be implemented in an existing system by a person skilled in the art.
The probe was pushed down into the ground using a 36 mm steel probing rod. The inner diameter of the rod was 16 mm, resulting in a cut-off frequency of around 11 GHz (the cut-off frequency of circular waveguide is inversely proportional to the radius). For this reason, a working frequency of 12.5 GHz was chosen. Depending on the dimensions and shape of the probing rod different frequencies in the microwave range can be preferred, and it is envisaged that different frequencies may be used in the future. Also, it may be convenient to choose a frequency that does not require the end user to acquire a permission from the authorities. Presently, examples of such frequencies are in the bands around 5.6 GHz, 24 GHz, 47 GHz and 76 GHz.
It should also be noted that it is not always advantageous to use the first node of the wave for transmission. As the damping may vary for different nodes, there is no linear relationship between damping and frequency.
The power of the transmitter was less than 10 mW, and it was powered by six standard batteries, normally used for driving an acoustic transmitter.
The working depth, i.e. the depth at which the system will provide satisfactory signal quality, is dependent primarily on the damping of the steel rod waveguide and the dynamics of the receiver. Due to corrosion and irregularities of the inner surface of the rod 3 , leading to impaired surface conductivity, damping in the tested frequency range is relatively high, in the order of several dB/m.
However, it is believed that the damping can be reduced using very simple measures, such as coating of the inner surface of the probing rod, for example with silver. Another important factor are the junctions between rod sections. They form a discontinuity in the waveguide, and may cause resonance and act as a filter, seriously impairing the performance of the waveguide. By redesigning the linking of the rod section, reduced damping may be obtained. Finally, it is possible that a significantly increased frequency (in the order of several hundred GHz) can improve the performance of the waveguide, as the effect of surface conductivity looses relative importance.
The bit rate capacity of the tested data transmission around 9600 baud, due to the conventional circuitry used in the probe and data acquisitioning device. However, it is estimated that transmission rates of at least 10 Mbit/s can be obtained, offering a significant improvement in data transmission capacity.
The invention has been described with reference to CPT probing. However, it should be noted that the invention is not limited to CPT probes, but on the contrary, any probe and any type of sensors can be used. Also, the invention is also applicable in equipment for drilling, e.g. in rock or seabeds. The diameter of the probing rod is then normally somewhat larger, e.g. 56 mm, 76 mm, and provided with a drilling head. Some kind of drilling machinery is used to rotate the drilling head. | Geological probing device comprising a hollow probing rod to be extended into the geological matter to be probed, and a measuring probe fitted to the probing rod, said measuring probe comprising sensors for obtaining information about the matter.
The measuring probe further comprises a microwave transmitter, arranged to transmit microwaves carrying data from said sensors, said hollow probing rod being adapted to act as a waveguide, guiding the microwaves to an upper orifice of said hollow probing rod.
Compared to previously known techniques, the device according to the invention offers a reliable transmission of data under normal working conditions, and without substantive modifications of the probing rod or other equipment. | 4 |
TECHNICAL FIELD
[0001] The invention pertains to a method for printing a surface, more particularly a plastic surface, by means of hot-stamping.
BACKGROUND
[0002] Surfaces of plastic parts are frequently decorated or printed with the aid of hot-transfer and hot-stamping methods. In contrast to the hot-transfer method, a foil coated with a monotone ink over its entire surface is used in the hot-stamping method. In this case, the printed image is produced by the contour of the stamping tool (e.g., a print wheel or a dot-matrix print head). Preprinted images, writings, logos, etc., are used in the hot-transfer method. In this case, the image with all its information is already preprinted on the foil.
[0003] Hot-transfer and hot-stamping methods require different temperatures and different stamping times, depending on the respective plastic material. In all hot-stamping/transfer methods, pre-applied pigments are transferred by a foil. Heat needs to be supplied in order to realize this transfer. The heat is used for activating the “separation layer” on the foil and the hot-melt adhesive for fixing the pigments on the substrate. This heat is generally transmitted through the foil by a heated hot-stamping tool.
[0004] A hot-transfer stamping tool usually consists of an aluminum carrier with a silicone coating that is adapted to respective process and serves for compensating the surface unevenness of the plastic part to be decorated. The inferior thermal conductivity of the silicone coating on the hot-stamping tool results in a high temperature gradient between the aluminum carrier and the outer silicon surface of the hot-stamping tool. Consequently, the recovery time for the silicon surface is insufficient, particularly when operating with short cycle times as it is the case, for example, in the manufacture of toothbrushes. This means that the aluminum carrier needs to have a higher temperature in order to reach the optimal working temperature. If the standstill times of the hot-stamping tool exceed 20 sec., an excessively high stamping tool temperature of approximately 260° C.-280° C. results. The high temperature results in the manufacture of rejects until the operating temperature is reached again. Any attempts to counteract the temperature on the hot-stamping tool would be unsuccessful because the system of the hot transfer press reacts quite sluggishly.
[0005] DE 34 40 131 C2 discloses a method for printing a substrate by means of hot-stamping. This method proposes to preheat a stamping foil to a temperature that lies slightly below the melting temperature of the pigments applied to the foil. Lettering can only be applied on a very thin substrate in this case because the metallic surface of the hot-stamping tool brings the information producing pigments in contact with the heated counterpressure element and the stamping foil through the substrate. It would be inconceivable to utilize such a method for surface decorating applications.
[0006] DE 101 48 975 A1 describes a method and a device for printing objects, in which a heated stamping tool presses a pigment layer arranged on a hot-stamping foil against a work piece surface to be printed such that the image adhering to the hot-stamping foil is transferred onto the surface of the work piece. After the image is transferred and the hot-stamping foil is removed from the stamping tool, the hot-stamping foil remains on the object to be printed for a certain period of time in order to ensure that the layer printed onto the object securely adheres thereto.
[0007] In DE 43 08 977 A1, a varicolored decor is printed on a plumbing fixture by means of a hot-stamping method. The plumbing fixture is heated to a temperature of at least 100° C. in order to ensure that the image to be transferred from the hot-stamping foil adequately adheres to the plumbing fixture.
[0008] It is desirable to lower the temperature of the hot-stamping tool such that its service life can be extended and the machine down-times can be reduced. This should simultaneously make it possible to lower the number of rejects produced due to the start-up of the machine. It should also be possible to improve the adhesion of an image being transferred with the same stamping tool temperature within a shorter stamping time, as well as to achieve a more secure adhesion of the decor or printed layer, respectively.
SUMMARY
[0009] In one aspect of the invention, a heating device is arranged above the work piece surface to be printed such that at least the entire surface to be decorated is homogenously heated. This makes it possible to lower the stamping tool temperature during the printing process because the heat required for separating and transferring the pigment layer to the work piece surface no longer has to be generated by the stamping tool alone. Therefore, the recovery time of the silicone surface on the hot-stamping tool can be shortened such that the cycle time can be increased and the costs for the manufacture of respective objects are reduced. Another advantage can be seen in that the stamping tool temperature no longer increases excessively during down-times because the stamping tool temperature is set lower to begin with. The temperature on the stamping surface lies between 140° C. and 240° C., preferably between 200° C. and 220° C. This means that the upper temperature range can be respectively lowered by 40° C. to 60° C. The reduction of the temperature on the hot-stamping tool results in the coated plastic foil being subjected to a lower thermal load and therefore less susceptible to wear. The surface temperature of the hot-stamping tool is adjusted higher or lower depending on the choice of temperature-sensitive plastic material for the work piece. The temperature on the stamping surface is then regulated accordingly. These temperatures should be adapted in such a way the stamping surface has the lowest temperatures possible and the work piece surface has the highest temperature possible, wherein the latter cannot cause any damages to the work piece surface to be printed.
[0010] It is possible to realize different absorption characteristics of the plastic surfaces to be printed during the stamping process by respectively adapting the heating power or the heating time accordingly. When stamping surfaces that require more heat for being heated to a certain temperature, it is either necessary to extend the heating time or to increase the heating power. This makes it possible to reach the same final temperature on different work piece surfaces within the same period of time such that the hot-stamping tool is not unnecessarily subjected to thermal loads. An optimal image is produced and an intensive adhesion is achieved due to the more homogenous temperatures on the stamping tool and on the work piece to be printed.
[0011] In some embodiments, the surface texture and the temperature of the work piece surface to be printed are determined by a sensor that forwards the data to an evaluation device in order to adapt the heating power or the heating time of the heating device in accordance with the evaluated data. This makes it possible to always reach the same temperatures on the work piece surfaces to be heated and printed within the same period of time. Naturally, this also makes it possible to increase the cycle times because the stamping tool no longer has to heat the surface to be printed for an extended period of time.
[0012] In some embodiments, the heating device consists of an infrared lamp. Infrared lamps allow a defined and reproducible heating of the surfaces to be printed by adjusting the time, the power, the distance from the work piece and the type of focusing accordingly. Infrared lamps of this type are also particularly inexpensive. In addition, it is very simple to decrease or increase the distance of the infrared lamp from the work piece surface in order to increase the thermal radiation on the surface to be printed. However, it would also be conceivable to utilize other heating devices such as, for example, fan heaters, laser lights, gas flames or other suitable heat sources for heating a work piece.
[0013] It can be advantageous that the surface to be printed is heated to a temperature between 30° C. and 250° C., wherein plastic surfaces are preferably heated to a temperature between 80° C. and 120° C. Depending on the surface to be printed and the work piece material, the surface temperatures on the work piece and on the stamping tool are adjusted in such a way that the lowest thermal load possible occurs on the hot-stamping tool. Excessively high temperatures on the work piece surface to be printed could lead to damages thereof. In some embodiments, the surface to be printed consists of a plastic toothbrush.
[0014] However, this method also makes it possible to print surfaces of different objects, e.g., housings of safety razors, household appliances, etc. The method can be carried out in a particularly advantageous fashion on polypropylene materials. In this respect, it is also possible to utilize any plastic material that can be printed by means of a corresponding printing foil.
[0015] An in-line measurement, i.e., the actual temperature of the surface to be printed can be continuously monitored while it is heated until the desired temperature is reached, is also possible. It can be advantageous to coat the hot-stamping tool with a silicone layer. This elastic coating makes it possible to compensate the unevenness of the surface to be printed, i.e., the silicone layer flatly adjoins the printing foil and uniformly presses the printing foil against the work piece surface to be printed. Consequently, the pigment layer is also applied onto a work piece surface that is uneven to a certain degree with a uniform pressure such that a consistent adhesion is achieved at all locations.
[0016] In some embodiments, the silicone layer has a thickness between 1 and 4 mm, preferably between 2 and 3 mm. These thicknesses make it possible for the silicone layer, i.e., the hot-stamping tool, to uniformly press the pigment layer against the work piece surface to be printed. Naturally, the surface of the hot-stamping tool needs to be largely adapted to the work piece surface to be printed in order to achieve a uniform contact pressure.
DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a block diagram of a hot-stamping device.
DETAILED DESCRIPTION
[0018] Referring to FIG. 1 , the hot-stamping device 1 is illustrated in the form of a block diagram in the only figure in order to better illustrate its basic design. The hot-stamping device 1 consists of a hot-stamping tool 3 that is fixed on a raising and lowering device 2 and comprises an aluminum base 5 that is in thermal contact with a heating block 4 . On its surface 8 that points downward in the figure, this aluminum base is provided with a thick silicone coating 6 that elastically yields under pressure and the exposed bottom surface of which forms the stamping surface 7 .
[0019] According to the FIG. 1 , a carrier foil 10 with a pigment layer 9 (illustrated with broken lines) arranged thereon is conveyed underneath the stamping surface 7 and tensioned by means of guide rollers 11 , 12 and a not-shown tensioning device. In the embodiment shown, the guide roller 11 is arranged to the left and the guide roller 12 is arranged to the right of the hot-stamping tool 3 , wherein both guide rollers are arranged at the same height such that the carrier foil 10 is conveyed horizontally within this region. The moving direction 14 of the raising and lowering device extends perpendicular to the carrier foil 10 such that essentially no transverse forces can act thereupon and possibly cause the carrier foil to be shifted laterally or even to be conveyed in an accelerated fashion in the transport direction 15 .
[0020] Relative to the transport direction 17 , the carrier foil 10 extends vertically upward upstream of the guide roller 11 and is wound on a not-shown reel at this location. The carrier foil 10 is also wound on a not-shown reel to the right of the guide roller 12 , wherein the pigment layer 9 no longer adheres to the carrier foil on this side because it was already printed onto the surface 18 of a work piece 16 during the printing process. In the region that lies underneath the carrier foil 10 and between the guide rollers 11 , 12 , work pieces 16 to be printed are equidistantly arranged on a conveyor belt that is not illustrated in the figure and transported parallel to the carrier foil 10 from the left to the right as indicated with arrows 17 .
[0021] The work pieces 16 are preferably manufactured of plastic and comprise the surface 18 to be printed, wherein the pigment layer 9 is already printed onto the work piece 16 illustrated to the right of the hot-stamping tool 3 . The surfaces 18 of the work pieces 16 are curved in the embodiment shown. However, this is inconsequential during the printing process because the hot-stamping tool 3 is provided with a relatively thick silicon coating 6 that flatly adjoins the surface 18 of the work piece 16 during the printing process due to its elastic deformation. This means that the silicone coating presses the carrier foil 10 very uniformly against the surface 18 of the work piece 16 , and that the pigment layer 9 is pressed against the entire surface 18 to be printed in an equally uniform fashion.
[0022] A counterpressure device 19 is arranged underneath the centrally positioned work piece 16 in the figure. When the hot-stamping tool 3 moves downward toward the work piece 16 , the counterpressure device is simultaneously displaced upward until it contacts the underside 20 of the work piece 16 and enables the hot-stamping tool 3 to exert its full stamping pressure upon the surface 18 of the work piece 16 , namely such that the work piece 16 is prevented from shifting upward or downward during this process. This means that the moving direction 21 of the counterpressure device 19 extends upward in the figure before the printing process and downward after the printing process. The lifting device 21 and the raising and lowering device 2 form an actuating unit and lie on a common axis, wherein said devices always operate in opposite directions. Only these measures ensure that the work piece 16 is aligned with the hot-stamping tool 3 and the counterpressure device 19 in order to centrally apply the compressive forces to the work piece.
[0023] FIG. 1 shows that a heating device 22 in the form of an infrared lamp is arranged above the surface 18 of the work piece 16 to the left of the stamping tool 3 , wherein said infrared lamp can preferably also be adjusted upward and downward as indicated with the arrows 23 . A sensor 24 arranged laterally adjacent to the heating device 22 serves for determining the type of work piece 16 and the texture of the surface 18 of the work piece 16 , as well as for subsequently transmitting corresponding electric signals to an electronic evaluation device 26 via the line 25 . The electronic evaluation device 26 then calculates the corresponding quantity of heat with the aid of a (not shown) microprocessor and controls the heating device 22 via the line 27 in such a way that its upward or downward movement is extended or shortened or its thermal radiation is increased. Naturally, it would also be conceivable to increase or decrease the speed and therefore the cycle time of the (not shown) conveyor belt in order to heat the surface 18 of the work piece 16 to the required temperature. Such an embodiment is particularly advantageous if different work pieces are situated on the conveyor belt and need to be alternately printed in random succession. The thermal radiation emitted by the heating device 22 is indicated with the reference symbol 29 .
[0024] The sensor 24 may consist of a pyrometer that allows an inline measurement, i.e., the temperature on the surface 18 of the work piece 16 to be printed is determined simultaneously with the thermal radiation emitted by the heating device 22 . Such an in-line measurement can be carried out with a pyrometer. The pyrometer needs to operate in a wavelength range that lies outside the wavelength range of the infrared lamp such that the temperature is measured directly on the surface 18 . The surface 18 is heated until a predetermined temperature is reached. Although the surfaces 18 to be printed may have different colors, measuring errors caused by color differences can be neglected because all these surfaces consist of the same material. The determination of the color can be eliminated in this case. These measurements would make it possible to document the ongoing production and to automatically counteract a reduction in the lamp power (lamp aging).
[0025] The hot-stamping device 1 operates as described below.
[0026] The hot-stamping tool 3 is initially heated to its predetermined temperature with the aid of the heating block 4 . As soon as the required temperature is reached (or even earlier), the heating device 22 is switched on and the first work piece 16 is heated to the required temperature on its surface 18 . As briefly described above, this is achieved with the aid of the sensor 24 and the evaluation device 26 . As soon as the temperature is reached, the conveyor belt is set in motion and the work pieces are transported in the direction 17 until a work piece is situated vertically underneath the stamping surface 7 . The carrier foil 10 is situated between the stamping surface 7 and the work piece surface 18 , wherein the pigment layer 9 of the carrier foil is arranged on the underside 28 that faces the surface 18 of the work piece 16 . The hot-stamping tool 3 as well as the counterpressure device 19 are now moved toward the work piece 16 such that the pigment layer 9 is homogenously pressed against the surface 18 of the work piece 16 by the elastic stamping surface 7 . Since the surface 18 of the work piece 16 is still sufficiently hot and the stamping surface 7 is heated to its working temperature, the pigment layer 9 is separated from the carrier foil 10 and adheres to the surface 18 of the work piece 16 . In this case, certain adhesives in the pigment layer 9 contribute to producing a rigid connection between the pigment layer 9 and the surface 18 of the work piece 16 . Naturally, particles of the pigment layer 9 are also fused into the surface 18 of the work piece 16 in order to produce an intimate connection between the pigment layer 9 and the surface 18 .
[0027] While a work piece 16 is transported underneath the hot-stamping tool 3 , a new work piece 16 is simultaneously conveyed underneath the heating device 22 and heated on its surface 18 by the heating device 22 in the instant in which the printing process takes place. The hot-stamping tool 3 and the counterpressure device 19 are now moved apart from one another and the conveyor belt conveys the printed work piece 16 toward the right in the conveying direction 15 such that it can be subsequently removed from the conveyor belt after a short cooling time.
[0028] The printed work piece 16 is now provided with the pigment layer 9 on its surface 18 . The carrier foil 10 is then once again incrementally moved toward the right in the figure in order to position a section of the carrier foil 10 containing a pigment layer 9 within the stamping region. The carrier foil 10 with the pigment layer 9 separated therefrom is wound up on a not-shown reel on the right side in the figure. After the corresponding heating process, the next work piece 16 is transported underneath the hot-stamping tool 3 and printed. This process is continued in a cyclic fashion, wherein the quantity of work pieces 16 that can be printed within a very short time is significantly increased in comparison with conventional arrangements, namely because the surface 18 is heated to the required temperature by the heating device 22 , and not by the stamping tool 3 , before the hot-stamping tool 3 presses the pigment layer 9 on the surface 18 of the work piece 16 . This means that an exchange of a hot-stamping tool 3 due to a thermal overload is no longer required. | A method for printing a plastic surface by means of hot-stamping with a metallic hot-stamping tool that can be heated and is coated with plastic is described. The plastic-coated outer surface of the hot-stamping tool forms the stamping surface. The stamping surface transfers a pigment layer applied onto the carrier foil to the work piece when the carrier foil is pressed against the surface of a work piece to be printed. The work piece surface to be printed is preheated before the printing process with the aid of a heating device, wherein the temperature of the stamping surface of the hot-stamping tool lies between 140° C. and 240° C.,. This extends the service life of the hot-stamping tools and the set-up times of the hot-stamping device are simultaneously reduced. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a method of treating fiber. More particularly, it relates to a method of treating fiber which comprises attaching a sublimable substance onto the fiber to increase the smoothness (or lubricity) and secondary processability thereof and furthermore to a method of treating fiber wherein the provision of smoothness (or lubricity) to fiber and a water-repellent, oil-repellent and stain-inhibiting treatment are performed at the same time.
Heretofore, in knitting or weaving fibers, or forming webs of nonwoven fabrics to produce various fiber products, the fibers have been treated with an oily lubricant, such as solid paraffin, Japan wax, carnauba wax, spindle oil, silicone oil, etc.
For example, in the production of knitted fabrics, spun knitting yarns have been provided with smoothness prior to the knitting by rubbing the surface of the yarn with solid lubricants, such as solid paraffin, Japan wax, carnauba wax, etc. in order to reduce the friction resistance between the yarns and knitting needles, and between adjacent yarns. In accordance with this method of treating yarns, however, the oily lubricant cannot be uniformly adhered to the yarns. Therefore, the tension is large and uneven, and may result in stoppage of the knitting machine. Furthermore, this method of treating yarns has the disadvantage that since the lubricant is a solid material and the yarn surface is rubbed with such solid materials, the fluff of the yarns first attaches onto the lubricant and then onto the yarns, producing unevenness in the diameter of the yarns and finally providing knitted fabrics which are non-uniform. Additionally, much labor is required to replace the used lubricant with a new one owing to the consumption thereof and in watching the condition of attachment of the fluff, and the treatment efficiency is poor because the yarn treatment is performed on individual yarns.
With weaving yarns, sizing has been applied to prevent the formation of fluff during the course of weaving and to increase the strength of the yarn. This sizing, however, decreases the smoothness of the yarn. Therefore, owing to friction between the yarn and the knitting stick during weaving, fluff is formed even in warp. This formation of fluff decreases the shedding properties and lowers the yarn workability. Furthermore, fabrics of uniform quality cannot be obtained.
In order to eliminate the disadvantages described hereinbefore, weaving yarns have been treated with a lubricant prepared by emulsifying waxes with a surface active agent, or they have been coated with a silicone-based lubricant by spraying. The wax type lubricant suffers from the disadvantage that it is oxidized in air and difficulties are encountered in completely removing the oxidized product by post-treatment as with the silicone-based lubricant.
The thus-treated fibers are processed by knitting, weaving, formation of webs, etc. to provide fiber products. After the formation of such fiber products, the lubricant used in the preceding stage is useless. The lubricant should be removed by the use of caustic soda or a surface active agent. For this operation, additional steps and equipment are undesirably required. Even by application of such additional operations, it is impossible to completely remove the lubricant. The residual lubricant causes trouble at subsequent operations, such as post-dyeing, etc. and makes it difficult to obtain a fiber product of high quality. In various resin treatments, for example, water-repellency, oil-repellency and stain-inhibiting finishing using a fluoride compound, the presence of residual lubricant markedly reduces the finishing efficiency and causes various difficulties.
It is an object of the present invention to provide a method of treating fiber which imparts lubricity (or smoothness) uniformly to the fiber with high workability.
Another object of the present invention is to provide a method of treating fiber wherein provision of a lubricity treatment and a treatment to impart water-repellency, oil-repellency, and stain-inhibiting properties by the use of a fluorine compound are preformed at the same time.
SUMMARY OF THE INVENTION
The present invention provides a method of imparting lubricity to fibers by applying a sublimable substance to said fibers. There is no limitation to methods of applying the sublimable substance to the fibers. Examples of such processes include (1) a method of applying the sublimable substance by heating it or by placing it under reduced pressure so that it sublimes and condenses on the fibers; (2) a method of applying the sublimable substance by applying a solution of the sublimable substance in a solvent to the fibers; and (3) a method of applying the sublimable substance by applying an emulsion or dispersion of the sublimable substance on the fibers.
In another embodiment, the present invention provides a method of treating fibers with a solution, emulsion or dispersion of a sublimable substance together with a fluorine compound. By application of heating after the formation of fiber products, a water-repellent, oil-repellent and stain-inhibiting finish can be applied to the fiber products.
One of the features of the invention is that the sublimable substance used as a lubricant can be removed by the sublimation of said substance without the application of additional procedures after the formation of the fiber products by weaving, knitting and formation of webs, and that there is no problem of the sublimable substance as a lubricant remaining in the fibers. Thus, the sublimable substance of the invention exerts no adverse influence on finishing operations, such as dyeing and applying a fluorine compound finish.
The invention also provides individual fibers and masses of fibers and yarns impregnated with a sublimable substance.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a graph depicting decreases in the residual ratio of four sublimable substances in yarn over a period of time.
DETAILED DESCRIPTION OF THE INVENTION
Fibers generally can be used in the present invention. Examples of such fibers include natural fibers such as cotton, flax, hemp, jute, wool, silk, etc.; synthetic fibers such as polyester fibers, acrylic fibers, nylon fibers, polyvinyl alcohol fibers, polyvinyl chloride fibers, polypropylene fibers, etc.; semi-synthetic fibers such as rayon fibers, acetate fibers, etc.; inorganic fibers such as glass fibers, rock wool fibers and asbestos fibers, etc., and mixtures thereof.
The fibers are spun, woven or knitted, or webs of fibers are bonded together to produce textile materials. Examples of such textile materials include yarn, thread, knitted fabric, woven fabric, cut pile fabric, fiber vlees, fleece, pile nap, carpet, nonwoven fabric, felt, etc. These textile materials may have any desired form.
Sublimable substances used in the present invention are sublimable substances which can provide lubricity to a fiber when condensed on or otherwise deposited thereon or attached thereto. Examples of sublimable substances which can be used in the present invention include alicyclic compounds, such as endo-trimethylenenorbornane, trimethylnorbornane, cyclododecane, adamantane and camphor. These sublimable substances can be used alone or in combination with each other.
In providing lubricity to spun knitting yarn, the spun knitting yarn can usually be treated when they are wound on a cone or beam. The yarn wound on the cone or beam is placed in an appropriate pot or evaporation chamber wherein a sublimable substance is evaporated by heating or under reduced pressure and uniformly deposited (condensed) onto the yarns. The treating temperature is appropriately determined according to the type of the sublimable substance and the spun knitting yarn to be treated. It is preferred to maintain the pot or evaporation chamber under reduced pressure. One of the major features of the present invention is that steam-setting of the yarn can be performed at the same time by introducing hot water or steam into the pot or evaporation chamber together with the sublimable substance.
The present invention is not limited to the above described method. For example, a method in which prior to the cone-winding, yarn is passed through a room containing the sublimable substance in vapor form so that it condenses on the yarn, can be employed.
In the method of the present invention, the amount of the sublimable substance which is deposited is about 0.02 to 5% by weight, preferably about 0.03 to 3% by weight, based on the weight of the yarn. Th sublimable substance of the present invention attains the object of the present invention when using smaller amounts than when using the conventional wax. The amount of the sublimable substance to be deposited can be controlled by adjusting the time of contact between the yarn and vaporized sublimable substance, the treating temperature or the like.
For yarn on which the sublimable substance is uniformly deposited, the frictional resistance between the yarn and knitting needle at the time of knitting is reduced and, therefore, the sliding properties of the yarn are improved. Furthermore, the frictional resistance between adjacent yarns is reduced and, therefore, withdrawal of the yarn can be easily performed. Thus, the tension at the time of knitting is made uniform and knitting ability is improved. Furthermore, since there is no unevenness in the strength and diameter of the yarn, end breakage does not occur and knitted fabrics having uniform properties are prepared.
On the thus-obtained knitted fabrics, a small amount of the sublimable substance remains. The sublimable substance is not needed after the knitting and it should be removed. The sublimable substance can be removed merely by allowing the knitted fabrics to stand because of its sublimable properties. Thus, another feature of the present invention is that the prior art processing operation to remove lubricant can be omitted.
As described in detail, the present invention uses gas to apply the lubricant to fibers, which is different from the conventional methods wherein a solid lubricant is used. In accordance with the method of the present invention, therefore, large amounts of yarns, including yarns wound on a cone or beam can be treated at the same time and the sublimable substance can be uniformly deposited even in the interior of wound yarns. Furthermore, the method of the present invention is advantageous over the conventional methods in that the replacement of the lubricant, the observation of fluff, and the removal of the lubricant, are not necessary. The method of the present invention is a power-saving method which needs no additional apparatus and has excellent workability.
In another method to deposit a sublimable substance on fibers, a dispersion of the sublimable substance is used. This composition can be obtained usually as an emulsion composition by mixing and stirring a sublimable substance, a surfactant and water at a temperature higher than the melting point of the sublimable substance. When the temperature of the emulsion composition is lower than the melting point of the sublimable substance, it is converted into a suspension composition. The term "dispersion composition" as used herein includes both the emulsion composition and the suspension composition.
The dispersion composition of the sublimable substance for use in the present invention is generally produced by first heating to melt a mixture of a sublimable substance and a surfactant to obtain Composition (A) and then gradually adding Composition (A) while stirring to water maintained at a temperature higher than the melting point of the sublimable substance, although the present invention is not limited thereto. Additionally, depending on the state in which the dispersion composition of the sublimable substance is used, a method can be employed in which Composition (A) is first prepared and prior to the use of the dispersion composition, Composition (A) is introduced into hot water maintained at a temperature higher than the melting point of the sublimable substance and is allowed to be emulsified therein.
Although the dispersion composition of the sublimable substance for use in the present invention is, as described above, generally produced at a temperature higher than the melting point of the sublimable substance, it can be produced at a temperature lower than the melting point of the sublimable substance depending on the sublimable substance and surfactant which are used, the stirring conditions, the composition ratio, and so forth.
Any surfactant can be used to produce the dispersion composition of the sublimable substance. Examples of surfactants which can be used include anionic surfactants and nonionic surfactants. Suitable examples of anionic surfactants include carboxylic acid salts, such as sodium stearate; sulfuric acid ester salts, such as sodium lauryl-alcohol sulfate, sulfonic acid salts, such as sodium dodecylbenzene sulfonate; and phosphoric acid salts, such as higher alcohol-phosphoric acid ester salt. They can be used alone or in combination with each other. Suitable examples of nonionic surfactants include polyhydric alcohol esters such as stearic acid monoglyceride and sorbitan stearate; and polyethylene glycol type of surfactants, such as nonylphenyl polyethylene glycol ether and stearic acid polyethylene glycol ester.
The amount of the surfactant added is usually about 0.1 to 40 parts by weight and preferably about 0.5 to 20 parts by weight per 100 parts by weight of the sublimable substance.
The amount of the sublimable substance added is usually about 0.1 to 100 parts by weight and preferably about 0.2 to 30 parts by weight per 100 parts by weight of water.
For the dispersion composition of the sublimable substance for use in the present invention, when the grain size of the sublimable substance is about 1 micron or less, the dispersion is stable over a long period of time. Where the grain size is relatively large, a stabilizer may be added, if necessary. Examples of stabilizers which can be used include hydrophilic polymeric compounds, such as CMC, PVA, methyl cellulose, starch, casein, sodium alginate and proteins; water-soluble compounds, such as methanol and ethylene glycol; and inorganic gelatinizers, such as bentonite and fine powder of silicic acid. These stabilizers can be used alone or in combination with each other.
In the dispersion composition of the sublimable substance, fine particles of the sublimable substance are uniformly dispersed in water in any desired proportion. This makes easy handling of the sublimable substance as a fluid and prevents the sublimation of the sublimable substance during the storage even though it is in a fine particle form.
Spun yarns can usually be treated when they are wound on a cone or beam. Cone- or beam-wound yarns are placed in an appropriate pot or evaporation chamber wherein the sublimable substance is evaporated, by heating or treating under reduced pressure the dispersion composition and is uniformly deposited on the yarns. Prior to the introduction of the dispersion composition of the sublimable substance into the pot or evaporation chamber, it is usually mixed with water (hot water) in a tank-like or tubular mixer so that a predetermined concentration is attained. In this case, a fluid main component consisting substantially of the sublimable substance and the surfactant can be mixed with hot water. This method is advantageous in that it permits reducing the amount of the treating composition to be stored and to be transferred. The temperature and pressure for use in the treatment can be suitably determined depending on the type of the sublimable substance and yarns used.
In the treatment of the present invention, the steam-setting of yarns can be performed at the same time by introducing hot water or steam along with the dispersion composition of the sublimable substance.
The application of the sublimable substance to yarn according to the present invention is not limited to the embodiment as described above. For example, a method of treatment can be employed in which before the yarn is wound on a cone, the yarn is passed through a room wherein the sublimable substance is evaporated and then deposited on the yarn.
In the method of treatment of the present invention, the amount of the sublimable substance attached to or deposited on yarns is usually about 0.005 to 5% by weight and preferably about 0.01 to 2% by weight based on the weight of the yarn. Thus, the present invention is advantageous over the conventional methods using wax in that the effect of providing high lubricity can be obtained using the sublimable substance in smaller amounts than the amount of wax of the prior art. The amount of the sublimable substance to be deposited can be adjusted by controlling the amount of the dispersion composition of the sublimable substance to be introduced, the sublimable substance content, the time of contact between the yarns and the vapor of the sublimable substance, the temperature, and so forth.
In knitting, weaving, etc of the yarn with the sublimable substance deposited thereon, the frictional resistance between the yarn and the knitting needle or the like is reduced, and furthermore the frictional resistance between adjacent yarns is reduced. Therefore, the sliding property of the yarn is improved and the yarn can be smoothly drawn. This leads to uniformity in the tension of the yarns and improvement in the efficiency of operation or productivity. Furthermore, since there is no unevenness in the strength and diameter of the yarns, no end breakage occurs and thus knitted and woven fabrics having uniform properties can be obtained.
A small amount of the sublimable substance remains deposited on the knitted and woven fabrics, which should be removed because it is not needed after the knitting or weaving. The removal of the residual sublimable substance can be performed merely by allowing the knitted, woven or like fabrics to stand because the deposited material is sublimable. Thus, the present invention has an important feature that the step of removing the lubricant, which is essential for the conventional methods, can be omitted.
In another embodiment, the sublimable substance is used in an amount of about 0.1 to 5 parts by weight, preferably about 0.2 to 3 parts by weight, per 100 parts by weight of water. The amount of the surfactant to be added to the sublimable substance may be the same as described hereinbefore.
In accordance with this embodiment, the dispersion composition of the sublimable substance is brought in contact with yarn. For this contact treatment, a soaking method, a spraying method, a touch roll method, and a slit method can be used. The slit method as used herein means a contact treating method in which the yarns are passed while introducing the dispersion composition in the form of a liquid into a slit. In accordance with the soaking method and spraying method, the yarns can be treated in the state that they are wound on a cone or beam.
The sublimable substance deposited on the yarns by the contact treating method is then dried.
In this embodiment, the amount of the sublimable substance to be deposited on the yarns is usually about 0.005 to 5% by weight and preferably about 0.01 to 2% by weight. Thus, when using smaller amounts of the sublimable substance than the conventional wax, high lubricity can be imparted to the yarns. The amount of the sublimable substance to be deposited is adjusted by controlling the sublimable substance content of the aqueous dispersion composition, the method of contacting the yarns with the aqueous dispersion composition, the time of contact, and so forth.
It is to be noted that a fiber processing method comprising attaching a sublimable substance to fibers in accordance with the method as described above, producing a fabric product using the fibers with the sublimable substance attached thereto, and treating the fabric product with a fluorine compound is included in the scope of the present invention.
The sublimable substance is deposited on the fibers either by a method in which the sublimable substance is placed in an appropriate pot or evaporation chamber and evaporated by heating or placing it under reduced pressure, or by a method in which the sublimable substance is converted into any desired form, such as an emulsion, a suspension, a solution and an aerosol, by the usual procedure and then brought in contact with the fibers by techniques, such as coating and soaking. In preparing such emulsions, mixtures of water and various surfactants are generally used. As solvents for use in preparing such solutions, those exerting no adverse influences on the fibers are selected, for example, acetone, methyl ethyl ketone, ethyl acetate, diethyl ether, methylene chloride, methyl chloroform, trichloroethylene, tetrachloroethylene, trichlorotrifluoroethane, tetrachlorodifluoroethane, etc.
When the fibers with the sublimable substance uniformly deposited thereon are knitted or woven, the frictional resistance between adjacent fibers and between the fibers and the knitting needle or mechanical parts is reduced, and thus the desired fabric product can be efficiently produced.
Although a small amount of the sublimable substance remains deposited on the fiber product, when being allowed to stand, it dissipates over a period of time. Thus, the step of removing the residual lubricant, which is essential for the conventional methods, can be omitted. Furthermore, when the fibers are sent to the subsequent operations while still containing the sublimable substance and are processed therein, the sublimable substance is evaporated and removed.
The treatment of textile materials with a textile treating fluorine compound can be carried out by the usual technique. The fluorine compound is applied onto the textile materials by a soaking method, a padding method, a spraying method, a coating method or the like, and then is dried and heat-treated.
Examples of fluorine compounds which can be used are the fluoro-organic compounds including polymerized fluoro- and fluoro-chloro-hydrocarbons, e.g. homopolymers of tetrafluoroethylene, and perfluoro alkyl group-containing acrylate or methacrylate, copolymers of such monomers and alkyl acrylate, maleic anhydride, styrene, butadiene or the like, and fluorine resins, such as fluorine-containing urethane compounds. Although the amount of the fluorine compound used in not critical, it is usually used in an amount of about 0.1 to 50% by weight based on the weight of the textile material. The treating conditions are suitably determined according to the type of the fiber to be treated, the processing equipment, the performance to be required, and so forth.
The treatment to provide lubricity to fibers and the water-repellent, oil-repellent and stain-preventing treatment can be performed at the same time with the results substantially satisfactory for each treatment. That is, a solution or dispersion of the sublimable substance and the fluorine compound in a solvent is used to treat the fibers. It is to be noted that this embodiment is included within the scope of the present invention.
In preparing the solution or emulsion of the sublimable substance and the fluorine compound as used in the above treatment, the same solvents as described hereinbefore can be used. Alternately, they can be used in the form of a suspension which is prepared by dispersing in water, or in the form of an emulsion which is prepared by adding a surfactant. This solution or dispersion is applied to the fibers by techniques such as coating and soaking and deposited thereon. This treatment reduced the frictional resistance between the fibers, thereby permitting smooth sliding of the fibers, and thus the desired knitted fabrics, weaved fabrics, nonwoven fabrics, carpets, and the like can be prepared.
Upon heat-treatment of the thus-obtained textile materials, the deposited sublimable substance is evaporated and removed. At the same time, this heat-treatment converts the fluorine compound into a tough film layer, thereby providing excellent water-repellent, oil-repellent and stain-preventing properties to the textile materials. Thus, by using a processing solution containing therein both the sublimable and fluorine compound as in this embodiment, the process of processing the fibers can be greatly simplified and furthermore the efficiency of working can be significantly increased.
In accordance with the method of the present invention, the sublimable substance is applied as a lubricant in the form of a solution, a dispersion in water, or a gas and even used in a small amount, can be uniformly applied to fibers. Furthermore, in view of the sublimation property of the sublimable substance, the step of removing the lubricant can be omitted. Moreover, since there is no residual lubricant on the fibers, the treatment using the fluorine compound can be efficiently carried out, and thus textile materials having excellent water-repellent, oil-repellent and stain-preventing properties can be obtained.
Hereinafter, the present invention will be explained in greater detail by reference to the following examples. In these examples, the component ratio is by weight unless otherwise indicated. The water-repellency and oil-repellency were measured as follows:
Water Repellency
For knitted fabrics and woven fabrics, the water-repellency was measured by the spray method as defined in JIS L 1092-1977.
In the case of nonwoven fabrics and carpets, one drop of a 30% aqueous solution of isopropyl alcohol was dropped on a test piece and the time taken for the droplet to disappear was measured to determine the level of the water-repellency.
Oil Repellency
The oil-repellency was measured according to the method as defined in AATCC 118-1972.
One drop of each of the reagents shown in Table 1 below was gently dropped on the surface of a test piece which was spread horizontally, and the state of penetration of the reagent after 3 minutes was examined to determine the oil-repellency.
TABLE 1______________________________________Rating Reagent______________________________________8 n-heptane7 n-octane6 n-decane5 n-dodecane4 n-tetradecane3 n-hexadecane2 mixed solution of nujol (65)/ n-hexadecane (35)1 nujol0 Penetration is below Rating (1)______________________________________
EXAMPLE 1
Fourteen hundred grams of cotton spun knitting yarns (combed yarns 40/1) which had been wound on cones were placed in a can member of NICUM type steam setter testing machine (produced by Nikku Industry Co., Ltd.), and the pressure in the can member was reduced to 12 mmHg. Then, heated water maintained at 150° C. and 140 g of endo-trimethylenenorbornane maintained at 90° C. were injected into the can member, and the can member was maintained at 50° C. for 10 minutes to attach the endo-trimethylenenorbornane to the yarns. After cooling the can member, the yarns were taken out thereof. The amount of the endo-trimethylenenorbornane attached to the yarns and the tension of the thus-processed yarns at the time of running were measured. The results are shown in Table 2 comparing with the conventional wax-treated yarns.
The tension at the time of running for rewinding was measured under the following conditions:
Testing Machine: TENSTER-D
Running Rate of Test Piece: 200 m/min
Disc Tension: 30 g washer
Full Scale: 25 g
EXAMPLE 2
Fourteen hundred grams of polyester/cotton (50:50) mixed knitting yarns (40/1) were placed in the same can member as used in Example 1. The pressure of the can member was reduced to 12 mmHg. Then, 140 grams of adamantane maintained at 200° C. and heated water maintained at 150° C. were injected into the can member, and the can member was maintained at 70° C. for 10 minutes. After cooling the can member, the yarns were taken out. The amount of the adamantane attached to the yarns and the tension of the thus-processed yarns at the time of running were measured. The results are shown in Table 2.
EXAMPLE 3
One kilogram of polyacrylic spun knitting yarns (32/2) which had been wound on cones were placed in an atmospheric pressure-steam chamber, and 100 grams of camphor was placed on the bottom of the steam chamber. By heating the steam chamber from the outside thereof to 150° C., the camphor was sublimated. After cooling the steam chamber, the yarns were taken out. The amount of the camphor deposited on the yarns was 0.5% by weight. The tension of the yarn at the time of running was measured, and the results are shown in Table 2.
EXAMPLE 4
One kilogram of rayon staple spun knitting yarns (30/1) were placed in the same atmospheric pressure-steam chamber as used in Example 3, and 50 grams of cyclododecane was placed on the bottom of the steam chamber. By heating the steam chamber from the outside thereof to 200° C., the cyclododecane was sublimated and deposited on the yarns. The amount of the cyclododecane deposited on the yarns was 0.05% by weight. The tension of the thus-processed yarn at the time of running was measured, and the results are shown in Table 2.
TABLE 2______________________________________Tension of Yarn at Running for Rewinding (gram) Example 1 2 3 4______________________________________Yarn not processed 12.7 11.2 15.2 10.6Yarn processed with 8.1 7.8 7.8 7.1Conventional Wax(Amount deposited on (0.2) (0.1) (1.0) (0.1)yarn; % by weight)Yarn processed by 2.5 3.5 4.9 5.1present invention(Amount deposited on (0.2) (0.1) (0.5) (0.05)yarn; % by weight)______________________________________
Reference Example
In the same manner as in Example 1, endo-trimethylenenorbornane, adamantane, camphor, and cyclododecane were each attached to cotton spun knitting yarns (combed yarn 40/1). For each of the thus-processed yarns, the amount of the sublimating substance was 1.0% by weight. These processed yarns were allowed to stand in a room at 30° C. and changes in the amount of the sublimable substance deposited with a lapse of time were measured. The results are shown in the Figure.
EXAMPLE 5
Fourteen hundred grams of polyester/cotton (50:50) mixed knitting yarns (40/S) which had been wound on cones were placed in a can member as used in Example 1, and the pressure of the can member was reduced to 12 mmHg. Then, a dispersion composition of a sublimable substance (an emulsion composition comprising 2 grams of endo-trimethylenenorbornane, 1 gram of polyoxyethylene oleate, and 100 milliliters of heated water) was heated to 150° C. and injected into the can member along with heated water maintained at 150° C. Thus, the yarns were treated with the dispersion composition for 20 minutes while maintaining the temperature in the can member at 70° C. After cooling, the yarns were taken out of the can member.
The amount of the endo-trimethylenenorbornane deposited on the yarns and the tension of the thus-processed yarn at running were measured. The results are shown in Table 3 below.
TABLE 3______________________________________ Tension of Yarn at Running for Rewinding (gram)*.sup.1______________________________________Yarn not processed 11.8Yarn processed with*.sup.2 6.3Conventional Wax(Amount deposited on (0.3)yarn: % by weight)Yarn processed by Present 2.8Invention(Amount deposited on Yarn: (0.2)% by weight)______________________________________ *.sup.1 Conditions are same as described in Table 2. *.sup.2 Yarns withdrawn from a spinning machine were transferred from cop (wound on wooden tubes) to cones and wound thereon, and in the course of this operation, the yarns were passed over a mixed wax of paraffin and Japan wax.
EXAMPLE 6
Fourteen hundred grams of cotton spun knitting yarns (40/s) which had been wound on cones were placed in a can member as used in Example 1, and the pressure of the can member was reduced to 12 mmHg. Then, a dispersion composition of a sublimable substance (an emulsion composition comprising 2 grams of endo-trimethylenenorbornane, 1 gram of polyoxyethylene oleate and 100 ml of heated water) was heated to 150° C. and injected into the foregoing can member which had been evacuated, wherein the dispersion composition was evaporated. Thus, the yarns were treated with the dispersion composition for 10 minutes while maintaining the temperature of the can member at 60° C. After cooling, the yarns were taken out of the can member.
The amount of the endo-trimethylenenorbornane deposited on the yarns and the tension of the thus-processed yarn at running were measured, and the results are shown in Table 4 below.
TABLE 4______________________________________ Tension of Yarn at Running for Rewinding (gram)*.sup.1______________________________________Yarn not processed 10.6Yarn processed with*.sup.2 7.5Conventional Wax(Amount deposited on (0.3)Yarn: % by weight)Yarn processed by 3.4Present Invention(Amount deposited on (0.2)Yarn: % by weight)______________________________________ *.sup.1,*.sup.2 Same as described in Table 3.
EXAMPLE 7
One kilogram of polyacrylic spun knitting yarns (30/S) which had been wound on cones were placed in a can member as used in Example 1, and the pressure of the can member was reduced to 30 mmHg. Then, a dispersion composition of a sublimable substance (prepared by emulsifying a mixture of 5 grams of endo-trimethylenenorbornane and 3 grams of polyoxyethylene cetyl ether in 100 ml of heated water) was heated to 150° C. and injected into the can member. While maintaining the temperature in the can member at 50° C., the yarns were treated with the dispersion composition for 20 minutes. After cooling, the yarns were taken out of the can member.
The amount of the endo-trimethylenenorbornane deposited on the yarns and the tension of the thus-processed yarn at running were measured. The results are shown in Table 5.
TABLE 5______________________________________ Tension of Yarn at Running for Rewinding (gram)*.sup.1______________________________________Yarn not processed 16.3Yarn processed with 7.6Conventional Wax*.sup.2(Amount deposited on (0.6)Yarn: % by weight)Yarn processed by Present 4.7Invention(Amount deposited on Yarns: (0.3)% by weight)______________________________________ *.sup.1,*.sup.2 Same as described in Table 3.
EXAMPLE 8
One hundred kilograms of reeled thread cotton spun knitting yarns (40S) were placed in an Obameyer dyeing machine, and boiled and scoured for 60 minutes in a bath of an aqueous solution which had been prepared by dissolving 3 kilograms of caustic soda (30% by weight) and 3 kilograms of soda ash in such a manner that the liquor ratio was 1:15. After washing with water, the yarns were bleached by boiling for 60 minutes in an aqueous solution of 5 kilograms of hydrogen peroxide (35% by weight) and 3 kilograms of sodium silicate.
Thereafter, the yarns were washed with water and dyed for 60 minutes in a bath comprising 2 kilograms of Michaleon Orange 2 RS (trade name), 20 grams per liter of soda ash and 50 grams per liter of Glauber's salt under the conditions of a liquor ratio of 1:15 and a temperature of 40° C. The yarns were then treated with a processing solution containing a sublimable substance (whose formulation is shown below) at ordinary temperature for 20 minutes in an Obameyer dyeing machine, dehydrated by the use of a centrifugal dehydrator and dried at 40° to 60° C. for 60 minutes. The tension of the thus-processed yarn at running was measured, and the results are shown in Table 6.
______________________________________Formulation of Processing Solution Parts by weight______________________________________Endo-trimethylenenorbornane 8Sodium Alkylbenzene Sulfonate 2Water 900(mixed using hot water maintained at 80° C.).______________________________________
COMPARATIVE EXAMPLE 1
The procedure of Example 8 was repeated except that a dispersion comprising 7 parts by weight of paraffin, 1 part by weight of carnauba wax, 2 parts by weight of sodium alkylbenzene sulfonate and 900 parts by weight of water was used as the processing solution. The results are shown in Table 6.
EXAMPLE 9
Ten kilograms of polyacryl spun knitting yarns (30S) were placed in a rotary pack dyeing machine and washed in a bath of 2 grams per liter of polyoxyethylene nonylphenyl ether under the conditions of a liquor ratio of 1:50 and a temperature of 60° C. for 20 minutes to thereby remove impurities. After washing with water, 200 grams of Sumi Acryl Red 5B (trade name) was added and boiled to dye the yarns.
After gradual cooling to 60° C., an emulsion prepared by emulsifying a mixture of 2 parts by weight of polyoxyethylene nonylphenyl ether and 1 part by weight of dimethyl laurylbenzyl ammonium chloride in 100 parts by weight of heated water was introduced into the foregoing dyeing machine, and the yarns were processed at 60° C. for 20 minutes. Thereafter, the yarns were taken out of the machine, dehydrated by the use of a centrifugal dehydrator, and dried at about 60° C. for 60 minutes. The tension of the thus-processed yarn at running was measured, and the results are shown in Table 6.
Comparative Example 2
The procedure of Example 9 was repeated except that the same paraffin-based processing solution as used in Comparative Example 1 was used as the processing solution. The results are shown in Table 6.
EXAMPLE 10
Ten kilograms of polyester/cotton (50:50) mixed knitting yarns (40/S) were placed in an Obameyer dyeing machine and scoured for 60 minutes in a boiling bath of an aqueous solution which had been prepared by dissolving a mixture of 500 grams of soda ash, 100 grams of caustic soda and 200 grams of sodium alkylbenzene sulfonate (50% by weight) in such a manner that the liquor ratio was 1:20. The yarns were washed with water and bleached in a boiling bath comprising 500 grams of hydrogen peroxide (35% by weight), 300 grams of sodium silicate and 20 grams of an ethylenediamine tetraacetate tetrasodium salt for 20 minutes. Then, after washing the yarns with water, 600 grams of Sumicaron Black S-B1 (trade name) was added and boiled at 130° C. for 60 minutes to thereby dye the polyester side of the yarns. The yarns were again washed with water and reduction-cleaned in a bath comprising 2 grams per liter of caustic soda and 2 grams per liter of concentrated hydrosulfide maintained at 80° C. for 20 minutes to thereby remove dyes attaching to the cotton side of the yarns and onto the surface of the polyester. After water-washing, the yarns were placed in an Obameyer dyeing machine and dyed at a liquor ratio of 1:20 for 90 minutes in a boiling aqueous solution which had been prepared by adding heated water to 600 grams of Chayazol Black B 600 (trade name) and 600 grams of sodium sulfide in an amount of 5 times that of the dye and then by reducing on heating. Thereafter, the yarns were washed with water and subjected to oxidation treatment in a bath (50° C.) containing 2 grams per liter of hydrogen peroxide (35% by weight) and 1 gram per liter of acetic acid (90%). Thus, the yarns dyed in a predetermined color were obtained.
Then, 7 parts by weight of endo-trimethylenenorbornane and 3 parts by weight of polyoxyethyleneoctyl phenol were mixed by heating and dispersed in 100 parts by weight of heated water to prepare a lubrication processing agent. The thus-obtained lubrication processing agent was introduced into the foregoing dyeing machine wherein the yarns were subjected to a lubrication processing at 40° C. for 10 minutes and then dehydrated and dried. The tension of the thus-processed yarn at running was measured, and the results are shown in Table 6. The sublimation fastness was measured, and the results are shown in Table 7.
COMPARATIVE EXAMPLE 3
The procedure of Example 10 was repeated except that the same paraffin-based processing solution as used in Comparative Example 1 was used as the processing solution. The results are shown in Table 6. The test results with respect to the sublimation fastness are shown in Table 7.
TABLE 6______________________________________Tension of Yarn at Running for Rewinding (gram)______________________________________Original Yarn 16.3 Original Yarn 11.8 Original Yarn 13.8Example 8 4.5 Example 9 2.5 Example 10 3.5Comparative 8.9 Comparative 8.6 Comparative 7.6Example 1 Example 2 Example 3______________________________________
Conditions for measurement of tension:
______________________________________Testing machine TENSTER-DRunning rate of test piece 200 m/minDisc tension 30 grams washerFullscale 25 grams______________________________________
TABLE 7______________________________________Sublimation Fastness (rating)Original yarn 4-5Example 10 4-5Comparative 2-3Example 3Sublimation fastness test:Testing machine Scorch testerTemperature 200° C.Time 90 seconds______________________________________
EXAMPLE 11
In this example, the sizing and lubrication processing of yarns for cotton fabrics were performed at the same time. In a sizing solution (40° C.) having the formulation as shown below was soaked 4.5 kilograms of cotton warp yarns (No. 40 count cotton yarn) for 2 minutes, and the yarns were dehydrated by the use of a dehydrator and dried at 40° to 60° C.
The physical properties of the thus-obtained yarns are shown in Table 8.
______________________________________Composition of Sizing Solution (parts by weight) No. 1 No. 2 No. 3______________________________________Corn Starch 80 80 80Polyvinyl Alcohol 30 30 30Paraffin (135° F.) -- 8 --Polyoxyethylene Lauryl -- 2 --EtherEndo-trimethylenenorbor- -- -- 8nanePolyoxymethylene Lauryl -- -- 2EtherWater 890 880 880______________________________________
TABLE 8______________________________________ Cohesion Sizing Cohesion Strength Elonga- strength Ratio Strength/Sample (gram) tion(%) (times) (%) Sizing Ratio______________________________________Original 139.6 2.5 719 -- --YarnNo. 1 262.3 1.8 2039 11.3 180.4No. 2 224.1 2.3 1480 10.2 145.1No. 3 258.6 2.0 1963 10.9 190.6______________________________________
Strength and elongation: Measured using a Shoper strong elongation testing machine.
Cohesion strength: Measured using a TM type cohesion strength testing machine.
Sizing ratio: Measured using a vacuum infrared dry measuring apparatus (desizing agent: Biotex S (trade name), iodo reaction indicator).
The friction test for the sized yarns was conducted by dry braid, and the results (number of cutting of yarns) are shown in Table 9.
TABLE 9______________________________________Number of Dry Braid Number of 500 to 700 to 900 to cutting of FormationSample 700 900 1,500 Warp Yarns of Fluff______________________________________No. 1 0 3 16 19 26No. 2 0 0 8 8 3No. 3 0 0 1 1 1______________________________________
EXAMPLE 12
Cotton warp yarns (No. 40 count cotton yarn) was soaked in a sizing solution containing 1.2% by weight of Poval (degree of polymerization, a partially saponified product) and 6.2% by weight of corn starch and having a viscosity (VIS CUP) of 20 seconds, which was maintained at 95° C., to thereby obtain the sized yarns having a sizing ratio of 6.5% by weight.
A lubrication processing solution was prepared by mixing 80 parts by weight of endo-trimethylenenorbornane and 20 parts by weight of polyoxyethylene octyl ether by heating, emulsifying or dispersing the resulting mixture in 500 parts by weight of heated water, and furthermore by adding thereto 400 parts by weight of water. The thus-obtained processing solution was sprayed on the foregoing warp and deposited thereon in an amount of 3% by weight.
The thus-obtained yarns for fabrics were woven and the number of cutting of warp was measured. The results are shown in Table 10 along with the results for silicone-processed yarns.
TABLE 10______________________________________ Yarns pro- cessed by Original Silicone-processed PresentYards Yarns Yarns* Invention______________________________________0 to 20 7 3 221 to 40 14 4 341 to 60 16 3 061 to 80 9 0 181 to 95 5 3 2Total 51 13 8______________________________________ *Warp with Shinetsu Silicone KM781 (produced by Shinetsu Chemical Industr Co., Ltd.; 30% emulsion) deposited thereon in an amount of 1%.
The thus-obtained fabric was soaked in a mixed solution of 0.1 gram of Seres Blue GN, 400 milliliters of isopropyl alcohol and 600 milliliters of water at ordinary temperature for 30 seconds to remove oily materials therefrom, and then it was washed with water and its degree of coloration was measured. The results are shown in Table 11.
TABLE 11______________________________________ Original Yarn processed Yarn processed by Yarn with silicone present invention______________________________________Degree of 3-4 1-2 3-4Coloration(rating)*______________________________________ *JIS Specification, gray scale.
It can be seen from Table 11 that when the fabrics produced from the yarns subjected to the present treatment are allowed to stand, the processing solution is sublimated and there is no residual processing solution on the fabrics.
EXAMPLE 13
One kilogram of polypropylene cotton was soaked in an aqueous dispersion containing 1% of adamantane and 0.05% of polyethylene glycol mono-p-nonylphenyl ether (adduction amount of ethylene oxide: 10 mol) maintained at 50° C., for 10 minutes. Then, the polypropylene cotton was taken out, dehydrated at a dehydration ratio of 50%, and allowed to dry. Using the thus-processed cotton, a nonwoven fabric carpet was produced.
On the surface of the thus-obtained nonwoven fabric carpet, an aqueous dispersion containing 5% of a fluorine resin emulsion (trade name: Asahi Guarde AG-800; produced by Asahi Glass Co., Ltd.) was sprayed in a coating amount of 250 g/m 2 and dried at 120° C. for 5 minutes. The water-repellency and oil-repellency of the nonwoven fabric carpet were as follows:
Water-repellency: Even after 5 minutes, no water droplets disappeared.
Oil-repellency: 6
Comparative Example 4
One kilogram of polypropylene cotton was soaked in an aqueous dispersion containing 1% of dimethyl polysiloxane type silicone oil and 0.05% of oleyl alcohol (adduction amount of ethylene oxide: 5 mol), maintained at 50° C., for 10 minutes, and thereafter was dehydrated and dried in the same manner as in Example 1. Using the thus-processed cotton, a nonwoven fabric carpet was produced.
The thus-obtained nonwoven carpet was then subjected to the same fluorine compound processing as in Example 13. The water-repellency and oil-repellency of the nonwoven fabric carpet were as follows:
Water-repellency: Within 1 second, water droplets disappeared.
Oil-repellency: 0
The nonwoven fabric carpets obtained in Example 13 and Comparative Example 4 were each bonded to a floor, and a treading test with shoes was performed for one month. Observation of the nonwoven fabric carpet with naked eye showed that the staining of the nonwoven fabric carpet of Comparative Example 4 was great and prominent, whereas for the nonwoven fabric carpet of Example 13, the staining was very limited.
EXAMPLE 14
Fourteen hundred grams of nylon spun knitting yarns which had been wound on cones were placed in a can member as used in Example 1, and the pressure of the can member was reduced to 12 mmHg. Then, heated water maintained at 150° C. and 140 g of endo-trimethylenenorbornane heated to 90° C. were injected into the can member. By maintaining the can member at 50° C. for 10 minutes, endo-trimethylenenorbornane was deposited on the yarns. After cooling, the yarns were taken out. The amount of the endo-trimethylenenorbornane deposited on the yarn was 0.2%.
The thus-processed yarns were knitted. The surface of the knitted fabrics thus obtained was soaked in an aqueous dispersion containing 3% of a fluorine resin emulsion (trade name: Asahi Guarde AG-710, produced by Asahi Glass Co., Ltd.), and it was then squeezed at a squeezing ratio of 90% using a Patting Mangle and dried at 100° C. Thereafter, the knitted fabrics were subjected to heat treatment at 170° C. for 1 minute. The water-repellency and oil-repellency of the knitted fabrics were as follows:
Water-repellency: Even after 100 minutes, no water droplets disappeared.
Oil-repellency: 7
Comparative Example 5
Fourteen hundred grams of nylon spun knitting yarns which had been wound on cones were soaked in an aqueous dispersion containing 5% of a coil-feeding lubricant consisting of spindle oil (2) and oleic acid (8) and 0.5% of oleyl alcohol (adduction amount of ethylene oxide: 5 mol), maintained at 50° C., for 10 minutes, dehydrated and dried. The amount of the lubricant deposited on the yarns was 0.2%.
The thus-processed yarns were knitted, and the fabrics thus obtained was subjected to the same fluorine compound processing as in Example 14. The water-repellency and oil-repellency of the fabrics were as follows:
Water-repellency: In 50 minutes, all water droplets disappeared.
Oil-repellency: 1
EXAMPLE 15
One kilogram of cotton spun yarns were soaked in a solution containing 1% of endo-trimethylenenorbornane, 3% of a solvent type fluorine resin (trade name: Asahi Guarde AG-650, produced by Asahi Glass Co., Ltd.) and 97% of 1,1,1-trichloroethane for 5 minutes, taken out, dehydrated at a dehydration ratio of 100%, allowed to dry, and then knitted. They showed good knitting properties.
Subsequently, the knitted fabrics were subjected to heat treatment at 130° C. for 5 minutes. The water repellency and oil-repellency of the knitted fabrics were as follows:
Water-repellency: Even after 100 minutes, no water droplets disappeared.
Oil-repellency: 6
COMPARATIVE EXAMPLE 6
One kilogram of cotton spun yarns were soaked in a solution containing 3% of solid paraffin, 1% of carnauba wax, 3% of a solvent type fluorine resin (trade name: Asahi Guarde AG-650; produced by Asahi Glass Co., Ltd.) and 97% of 1,1,1-trichloroethane for 5 minutes, and thereafter they were dehydrated, allowed to dry and then knitted in the same manner as in Example 1.
Thereafter, the knitted fabrics thus obtained were subjected to the same heat treatment as in Example 15. The water-repellency and oil-repellency of the knitted fabrics were as follows:
Water-repellency: Immediately, water droplets disappeared (0 second).
Oil-repellency: 1
EXAMPLE 16
One kilogram of polyester stretched yarns were soaked in an aqueous dispersion containing 2% of cyclododecane and 0.1% of lauryl alcohol (adduction amount of ethylene oxide: 6 mol %), maintained at 50° C., for 10 minutes, taken out thereof, dehydrated at a dehydration ratio of 80%, and allowed to dry. The thus-processed yarns were woven. The woven fabrics thus obtained were soaked in an aqueous dispersion containing 3% of a fluorine resin emulsion (trade name: Asahi Guarde AG-710; produced by Asahi Glass Co., Ltd.), squeezed at a squeezing ratio of 80% using a Patting Mangle, and dried at 100° C. for 3 minutes. Then, the woven fabrics were subjected to heat-treatment at 170° C. for 1 minute. The water-repellency and oil-repellency of the woven fabrics were as follows:
Water-repellency: Even after 100 minutes, no water droplets disappeared.
Oil-repellency: 7
COMPARATIVE EXAMPLE 7
One kilogram of polyester stretched yarns were soaked in an aqueous dispersion containing 2% of Japan wax and 0.2% of nonylphenol (adduction amount of ethylene oxide: 10 mol %), maintained at 50° C., for 10 minutes, taken out therefrom, dehydrated at a dehydration ratio of 80%, and allowed to dry. The thus-obtained fabrics were subjected to the same fluorine compound-processing as in Example 16. The water-repellency and oil-repellency of the fabrics were as follows:
Water-repellency: Immediately, water droplets disappeared (0 second).
Oil-repellency: 0
In the present invention, trimethylenenorbornane means 1,7,7-trimethylnorbornane (i.e. 1,7,7-trimethylbicyclo [2,2,1]heptane). Cationic surfactants can also be used. Suitable examples of cationic surfactants include lauryl trimethyl ammonium chloride, stearyl dimethyl benzyl ammonium chloride, polyethylene glycol stearyl amine, trimethyl octadecyl ammonium chloride, palmityl dimethyl benzyl ammonium chloride, lauryl pyridinium chloride, etc. | A method for imparting lubricity to fibers and masses of fibers such as yarn by applying a sublimable lubricating substance to said fibers in an amount sufficient to impart lubricity to said fibers. The preferred sublimable compounds are endo-trimethylenenorbornane, trimethylnorbornane, cyclododecane, adamantane and camphor. The invention also includes novel yarns containing an effective amount of a sublimable lubricating substance. | 3 |
FIELD OF THE INVENTION
[0001] Embodiments of the present invention are directed to micro-electro-mechanical system (MEMS) fabrication and, more particularly, to a protecting the media film of a MEMS probe memory device during the fabrication process.
BACKGROUND INFORMATION
[0002] Seek-scan probe (SSP) memories are a type of memory that uses non-volatile storage media as the data storage mechanism and offers significant advantages in both cost and performance over conventional charge-storage memories. Typical SSP memories include storage media made of materials that can be electrically switched between two or more states having different electrical characteristics such as resistance, polarization dipole direction, or some other characteristic.
[0003] SSP memories are written to by passing an electric current through the storage media or applying an electric field to the storage media. Passing a current through the storage media, or applying an electric field to the media, is typically accomplished by applying a voltage between a sharp probe tip on one side of the storage media and an electrode on the other side of the storage media. Current SSP memories use probe tips positioned on a free end of one or more MEMS probes. In an idle state each MEMS probe maintains the probe tip at a certain distance from the storage media, but before the electric field or current can be applied to the storage media the probe tip must usually be brought dose to, or in some cases in direct contact with, the storage media.
[0004] In order to fabricate an SSP memory device based on ferroelectric media, a high-quality media film must be deposited on virgin silicon wafers. These wafers must subsequently be subjected to many steps to create the mechanical and electrical functionality to enable the memory device. This processing may include multiple film depositions, lithography, etching, electroplating, and wafer bonding processes for example. These steps can cause significant damage to the media film by mechanical abrasion, chemical exposure, thermal treatment, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The foregoing and a better understanding of the present invention may become apparent from the following detailed description of arrangements and example embodiments and the claims when read in connection with the accompanying drawings, all forming a part of the disclosure of this invention. While the foregoing and following written and illustrated disclosure focuses on disclosing arrangements and example embodiments of the invention, it should be clearly understood that the same is by way of illustration and example only and the invention is not limited thereto.
[0006] FIGS. 1A-1C are diagrams showing an illustrative SSP memory device and its basic operation;
[0007] FIG. 2A-2B are diagrams showing a mover wafer including a protective layer added prior to processing to protect the media layer according to one embodiment;
[0008] FIGS. 3A-3D are diagrams illustrating the steps taken to fabricate drive and sense circuitry on the mover wafer using a carrier wafer;
[0009] FIGS. 4A-B are diagrams illustrating the steps taken to fabricate drive and sense circuitry on the mover wafer without a carrier wafer;
[0010] FIGS. 5A-5D are diagrams illustrating attachment of a cap assembly and releasing the mover from the mover wafer; and
[0011] FIG. 6 is a diagram illustrating the completed SSP memory device.
DETAILED DESCRIPTION
[0012] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0013] FIGS. 1A-1C illustrate tracking in a common SSP memory configuration. FIG. 1A illustrates an SSP memory configuration in which a cantilever probe is anchored to a substrate (the cantilever wafer), and can be actuated to contact or de-contact the storage media on a mover that carries a storage media and is positioned over the cantilever wafer. The data tracks are stored in the storage media in one of two ways, depending on how the media mover scans relative to the cantilever tips.
[0014] FIG. 1B illustrates axial scanning, where data is stored in the storage media in-line with the cantilever direction, such that the mover scans in the direction parallel to a longitudinal axis of the cantilever to read/write/erase (R/W/E) each data track.
[0015] FIG. 1C illustrates transverse scanning, where the media mover scans in a direction perpendicular to the longitudinal axis of the cantilever probe to R/W/E each data track; data is consequently stored in lines that are transverse to the cantilever's longitudinal axis. To maximize the amount of data that can be written in the storage media the data density should be very high. During the fabrication process the media is easily damaged and therefore according to embodiments, a protection layer is herein used to protect the media throughout the process.
[0016] FIG. 2A shows a mover wafer 200 including the media layer 202 . The media layer may comprise a dielectric layer, such as a layer of Lead Zirconate Titanate (PZT), for example. According to embodiments, a media protection layer is added over the media layer 202 . The protection layer comprises a germanium film 204 that is deposited on the media 202 , followed by a capping layer of silicon dioxide 206 . The Ge can be deposited by evaporation, sputtering, or chemical vapor deposition (CVD) for example. It is stable to high temperatures expected during mover processing (up to 400° C.) and can be removed selectively to the media film 202 once the mover process is completed.
[0017] The germanium-based protection layer 202 provides many advantages. First, the germanium film 202 can be deposited using a variety of gentle processes such as electron beam evaporation or chemical vapor deposition that does not damage the media 202 .
[0018] Second, the Ge may be removed by gentle chemical cleaning after mover processing. This can be done using hydrogen peroxide, or even hot water saturated with ozone or dissolved oxygen.
[0019] Third, since Ge is a semiconductor, it is extremely stable across the range of temperatures required for mover processing (up to 400 C), Since Ge can be etched relatively easily, a cap layer of silicon dioxide 206 is proposed for protecting the Ge throughout the wet cleaning steps in the mover process. The SiO 2 204 can be dry-etched selectively to Ge prior to Ge removal at the end of the process. The Ge—SiO 2 protection layer is also very resistant to abrasion or mechanical damage due to its high hardness.
[0020] Alternatives to the Ge—SiO 2 protection layer include polymers, metals, other semiconductors, glassy materials such as oxides or nitrides; however, these have various drawbacks. Fabricating the mover without using a protection layer exposes the media to extensive processes that may cause mechanical (abrasion) or chemical attack. Materials such as oxides and nitrides can be ruled out because they are typically etched using aggressive acids including Hydrofluoric acid (HF), which are not selective to the media film. Polymers normally cure or harden upon exposure to high temperature steps, and may be very difficult to remove. Metals are expected to diffuse into the media film at high temperatures, which may degrade or destroy the media properties.
[0021] The Ge—SiO 2 layer, 204 and 206 , is capable of surviving the entire mover process, which significantly simplifies the process compared to having different protection layers for different steps.
[0022] Still referring to FIGS. 2A and 2B , the Ge—SiO 2 protection layer, 204 and 206 is integrated into the SSP process as follows. First, the media film 202 is deposited on virgin silicon wafers 200 . The media film 202 may then be patterned (not shown), and the Ge layer 204 and SiO 2 protection layer 206 is deposited.
[0023] Referring now to FIGS. 3A-3D , the process of creating the mover is performed using a wafer support system. As shown in FIG. 3A , a carrier wafer 300 is bonded to the protective layer, 206 of the mover wafer 200 . In FIG. 3B , the mover wafer 200 may be thinned using known techniques. In FIG. 3C , mover drive/sense circuitry 302 is defined on the mover wafer 200 . In FIG. 3D , the carrier wafer 300 (shown in the previous Figures) is removed. This processing described above may include multiple film depositions, lithography, etching, electroplating, and wafer bonding processes for example. The media film 202 is protected according to embodiments from the potentially damaging steps processes by the protective layers 204 and 206 .
[0024] FIGS. 4A and 4B show an alternative method of forming the mover without the wafer support system where the wafer is simply thinned, as shown in 4 A, and thereafter the drive/sense circuitry 302 is defined directly on the thinned wafer 200 .
[0025] Referring to FIGS. 5A-5D , a Mover-Cap assembly 500 is attached. The cap wafer 500 and mover wafer 200 are bonded together. Bond rings 502 are defined on the bottom of the mover 200 on the protective layer 204 and 206 as shown in FIG. 5B . In FIG. 5C , the protection layer 202 and 204 is removed. Finally, the mover 504 is released by forming a suspension by deep reactive ion etching, for example. Contacts between the media electrode and bond metal may also be formed (not shown).
[0026] FIG. 6 show the completed Seek-scan probe (SSP) memory device wherein a cantilever wafer 600 including a plurality of MEMS probes 602 is attached to the mover wafer 500 and cap assembly 500 . The above process can significantly improve the yield of a probe-based memory device by ensuring the quality of the media 202 throughout the processing of the mover 504 . This can improve the manufacturability and reduce the cost, as well as reducing the time-to-market by simplifying the development cycle.
[0027] The above description of illustrated embodiments of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.
[0028] These modifications can be made to the invention in light of the above detailed description. The terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims. Rather, the scope of the invention is to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation. | A micro-electro-mechanical system (MEMS) seek-scan probe (SSP) memory device utilizes a protective layer over the delicate media layer to protect the media during harsh processing steps that may otherwise damage the media layer. The protective layer may comprise a layer of germanium and a layer of silicon dioxide. | 6 |
This application is a continuation of application Ser. No. 07/879,686, filed May 6, 1992, now abandoned.
FIELD OF THE INVENTION
The field of the present invention is increasing the number of copies (or amplifying) of a specific nucleic acid sequence or "target sequence." The target sequence may be present either alone or as a component, large or small, of an homogeneous or heterogeneous mixture of nucleic acids. The mixture of nucleic acids may be that found in a sample taken for diagnostic testing, environmental testing, for research studies, for the preparation of reagents or materials for other processes such as cloning, or for other purposes.
The selective amplification of specific nucleic acid sequences is of value in increasing the sensitivity of diagnostic and environmental assays, and other uses, while maintaining specificity, increasing the sensitivity, convenience, accuracy and reliability of a variety of research procedures, and providing ample supplies of specific oligonucleotides for various purposes.
The present invention is particularly suitable for use in environmental and diagnostic testing due to the convenience with which it may be practiced.
BACKGROUND OF THE INVENTION
The detection and/or quantitation of specific nucleic acid sequences is an increasingly important technique for identifying and classifying microorganisms, diagnosing infectious diseases, detecting and characterizing genetic abnormalities, identifying genetic changes associated with cancer, studying genetic susceptibility to disease, and measuring response to various types of treatment. Such procedures have also found expanding uses in detecting and quantitating microorganisms in foodstuffs, environmental samples, seed stocks, and other types of material where the presence of specific microorganisms may need to be monitored. Other applications are found in the forensic sciences, anthropology, archaeology, and biology where measurement of the relatedness of nucleic acid sequences has been used to identify criminal suspects, resolve paternity disputes, construct genealogical and phylogenetic trees, and aid in classifying a variety of life forms.
A common method for detecting and quantitating specific nucleic acid sequences is nucleic acid hybridization. This method is based on the ability of two nucleic acid strands which contain complementary or essentially complementary sequences to specifically associate, under appropriate conditions, to form a double-stranded structure. To detect and/or quantitate a specific nucleic acid sequence (known as the "target sequence"), a labelled oligonucleotide (known as a "probe") is prepared which contains sequences complementary to those of the target sequence. In a process commonly known as "screening," the probe is mixed with a sample suspected of containing the target sequence, and conditions suitable for hybrid formation are created. The probe hybridizes to the target sequence if it is present in the sample. The probe-target hybrids are then separated from the single-stranded probe in one of a variety of ways. The amount of label associated with the hybrids is then measured as an indication of the amount of target sequence in the sample.
The sensitivity of nucleic acid hybridization assays is limited primarily by the specific activity of the probe, the rate and extent of the hybridization reaction, the performance of the method for separating hybridized and unhybridized probe, and the sensitivity with which the label can be detected. Under the best conditions, direct hybridization methods such as those described above can detect about 1×10 5 to 1×10 6 target molecules. However, the most sensitive procedures may lack many of the features required for routine clinical and environmental testing such as speed, convenience, and economy. Furthermore, the sensitivities of even the most sensitive procedures may not be sufficient for many desired applications.
As a result of the interactions among the various components, and the component steps of this type of assay, there is almost always an inverse relationship between sensitivity and specificity. Thus, steps taken to increase the sensitivity of the assay (such as increasing the specific activity of the probe) may result in a higher percentage of false positive test results. The linkage between sensitivity and specificity has been a significant barrier to improving the sensitivity of hybridization assays. One solution to this problem would be to specifically increase the amount of target sequence present using an amplification procedure. Amplifying a unique portion of the target sequence without amplifying a significant portion of the information encoded in the remaining sequences of the sample could give an effective increase in sensitivity while at the same time not compromising specificity.
A method for specifically amplifying nucleic acid sequences termed the "polymerase chain reaction" or "PCR" has been described by Mullis, et al. (See U.S. Pat. Nos. 4,683,195, 4,683,202 and 4,800,159 and European patent applications 86302298.4, 86302299.2, and 87300203.4 and Methods in Enzymology, Volume 155, 1987, pp. 335-350). The PCR procedure uses repeated cycles of primer dependent nucleic acid synthesis occurring simultaneously using each strand of a complementary sequence as a template. In the PCR procedure, copies of both strands of a complementary sequence are synthesized. In order to make the PCR convenient, programmable thermal cycling instruments are required.
The PCR procedure has been coupled to RNA transcription by incorporating a promoter sequence into one of the primers used in the PCR reaction and then, after amplification by the PCR procedure for several cycles, using the double-stranded DNA as template for the transcription of single-stranded RNA. (See, e.g., Murakawa et al., DNA 7:287-295 (1988)).
Other methods for amplification of a specific nucleic acid sequence comprise a series of cycles of primer hybridization, extending steps and denaturing steps to provide an intermediate double stranded DNA molecule containing a promoter sequence through the use of a promoter sequence-containing primer. The double stranded DNA is used to produce multiple RNA copies of the target sequence. The resulting RNA copies can be used as target sequences to produce further copies and multiple cycles can be performed. (See, e.g., Burg, et al., WO 89/1050; Gingeras, et al., WO 88/10315 (sometimes called "transcription amplification system" or TAS); EPO Application No. 89313154 to Kacian and Fultz; EPO Application No. 88113948.9 to Davey and Malek; Malek, et al. WO91/02818).
Walker, et al., Proc. Natl. Acad. Sci. (USA) 89:392-396 (Jan. 1992), not admitted to be prior art, describes an oligonucleotide driven amplification method for use with a DNA template, using a restriction endonuclease to produce the initial target sequences and an enzyme to nick the DNA/DNA complex in order to enable an extension reaction and therefore amplification. Becker, et al., EPO Application No. 88306717.5, describes an amplification method in which a primer is hybridized to the target sequence and the resulting duplex is cleaved prior to the extension reaction and amplification; in the case where the primer extends past the region of hybridization, it requires cleavage prior to the extension and the primer must be blocked at its 3'-end to prevent any unwanted extension reactions from occurring prior to amplification. Kramer, et al., U.S. Pat. No. 4,786,600 describe a method of producing large numbers of copies of a probe sequence in an RNA target sequence using Qβ replicase. Urdea, WO 91/10746, describes a signal amplification method that incorporates a T7 promoter sequence.
Other methods of amplifying nucleic acid include the ligase chain reaction (LCR), described in European Patent Publication 320,308, in which at least four separate oligoprobes are used; two of the oligoprobes hybridize to opposite ends of the same target strand in appropriate orientation such that the third and fourth oligoprobes may hybridize with the first and second oligoprobes to form, upon ligation, connected probes that can be denatured and detected. Another method is that described in EPO Publication No. 0 427 073 A2, published May 15, 1991 and not admitted to be prior art, in which a palindromic probe able to form a hairpin and having a functional promoter region in the hairpin is hybridized to a target sequence, then ligated to a second oligonucleotide hybridized to the target sequence such that RNA transcripts may be made.
Still other methods include oligonucleotide synthesis and cloning.
SUMMARY OF THE INVENTION
The present invention is directed to synthesizing multiple copies of a target nucleic acid sequence without the need to modify reaction conditions such as temperature, pH, or ionic strength, and without the need to add multiple, different primers or promoters, nor enzymes other than polymerases, which may also have RNAse H activities.
The present invention may be used as a component of assays to detect and/or quantitate specific nucleic acid target sequences in clinical, environmental, forensic, and similar samples or to produce large numbers of copies of DNA and/or RNA of specific target sequence for a variety of uses. The present invention may also be used to produce multiple DNA or RNA copies of a nucleic acid target sequence for cloning or to generate probes or to produce RNA or DNA copies for sequencing.
The present method features incubating a mixture consisting essentially of a nucleic acid target sequence (DNA or RNA) with one or more oligonucleotides known as "promoter-primers" that have a "complexing" sequence (i.e., a primer) sufficiently complementary to the 3'-end of a target sequence to hybridize at or near the 3'-end of the target sequence. The promoter-primer also includes, located 5' to the complexing sequence, a promoter for an RNA polymerase.
By "at or near" is simply meant to indicate the 3'-end of the target itself, and not necessarily the whole RNA or DNA-molecule which is to be detected. For example, the "target" may be a small central portion of an RNA molecule within an otherwise large RNA molecule.
By "one or more" it is meant that the promoter-primers added to the reaction mixture are sufficiently similar that they are able to bind to approximately the same target sequence at approximately the same position (plus or minus about 10 bases, on the same strand) such that the amplification of the instant invention may go forward. This does not exclude providing other oligonucleotides to the mixture, for example "helper" oligonucleotides that aid hybridization of the promoter-primers.
By "consisting essentially of" as used above, it is meant that the mixture has all of the necessary reactants and reagents. However, such a mixture may also contain enzymes or other substituents that do not qualitatively affect the amplification of the invention, and the mixture may contain other promoter-primers for the same target sequence or "helper" oligonucleotides. A "helper" oligonucleotide is a nucleic acid sequence that assists complexing between the promoter-primer, or other complexing nucleic acid such as a probe, and the target sequence, and will be determined by the actual sequence at the 3'-end of the target sequence. Such helper oligonucleotides are used in a manner equivalent to hybridization helper oligonucleotides described by Hogan et al., U.S. Pat. No. 5,030,557, namely by aiding binding of the promoter-primer to its target nucleic acid even if that target nucleic acid has significant secondary structure. Despite the similarity in use of such helper oligonucleotides it is surprising that such helper oligonucleotides could be used in an amplification protocol without adverse effect on the efficiency of these procedures.
The promoter-primer and the target sequence are subjected to conditions whereby a promoter-primer/target sequence hybrid is formed and DNA synthesis can be initiated. It is believed that in this reaction, the 3'-end of the target sequence is extended in a DNA extension reaction from a location adjacent the hybridized complex between the complexing sequence and the target sequence. The promoter sequence is the template for this extension reaction, which produces a first DNA extension product and thereby a double stranded promoter sequence. The 3'-end of the promoter-primer may also serve as a primer, for a second DNA extension reaction, which reaction uses the target sequence as a template and results in a double stranded nucleic acid complex; the complex is a DNA/RNA complex if an RNA target sequence is used, and a DNA/DNA complex if a DNA target sequence is used.
The first DNA extension product is then used by an RNA polymerase that recognizes the promoter of the promoter-primer, to produce multiple RNA copies of the target sequence. Surprisingly, in the case of an RNA/DNA complex or RNA alone comprising the target sequence, a DNA-dependent RNA polymerase, such as T7 RNA polymerase, is able to "read" the RNA/DNA complex or RNA and produce single stranded RNA, and is therefore effective in the present invention.
In preferred embodiments, the promoter-primer has a modification that may comprise a modified nucleotide at or near its 3'-end that inhibits or prohibits nucleic acid extension in that direction. It is surprising that the invention may be performed with the 3'-end of the promoter-primer modified, and it is particularly surprising that using a mixture of a modified and an unmodified promoter-primer (or two differently modified promotor-primers) results in a higher efficiency amplification, and therefore a higher copy number, than use of an unmodified or modified promoter-primer alone. Methods for creating such useful modifications to prevent or decrease primer extension are known in the art.
Where the target sequence comprises DNA or RNA, a further aspect of the present invention includes generation of a 3'-end of the target sequence by chemical or enzymatic degradation or processing, so that extension of the 3'-end of the target sequence along the promoter region of the promoter-primer may proceed. Such generation may be performed by, for example, the action of RNase H on an RNA:DNA hybrid (e.g., a DNA promoter-primer and an RNA target hybrid), treatment with exonucleases, and digestion with specific restriction endonucleases (e.g., for a DNA target) or ribozymes (e.g., with an RNA or DNA target).
In other preferred embodiments, the present invention features inclusion of one or more "helper" oligonucleotides in the reaction composition.
In yet other preferred embodiments, the 5'-end of the target strand of nucleic acid may be defined so as to stop either the extension reaction or the transcription reaction. Methods to effect such definition are known in the art and may include complexing an appropriate sequence of nucleic acid (e.g., an oligonucleotide) to the 5'-end of the target sequence, or modification of the 5'-end of the target sequence.
The present invention also features a composition consisting essentially of a target sequence, a promoter-primer, an RNA polymerase, a DNA polymerase and/or a reverse transcriptase and reagent and buffer conditions sufficient to allow amplification. In another embodiment, the promoter-primer includes both modified and unmodified 3'-ends. The invention also features a composition including a mixture of modified and unmodified promoter-primers and/or a mixture of different promoter-primers suitable for use in this invention.
In one example of a typical assay featuring the present invention, a sample of target nucleic acid to be amplified is mixed with a buffer concentrate containing appropriate buffer, salts, magnesium, nucleotide triphosphates, one or more promoter-primers, dithiothreitol, and spermidine. The reaction is then optionally incubated near 100° C. to denature any secondary structure. (This step is unnecessary if the target is single-stranded RNA, and the promoter-primer is also single-stranded.) After cooling to room temperature, reverse transcriptase and RNA polymerase are added and the reaction is incubated for a time span from minutes to hours at a suitable constant temperature between, e.g., 37° C. to 42° C., at which the enzymes are active. The reaction can then be assayed by adding a probe solution, incubating 10-30 minutes at 60° C., adding a solution to selectively hydrolyze the unhybridized probe, incubating the reaction for 5-10 minutes at 60° C., and measuring the remaining chemiluminescence in a luminometer, as described by Arnold, et al., PCT US88/02746, corresponding to U.S. patent application Ser. No. 07/294,700, now abandoned. the disclosure of which is incorporated herein by reference, and is referred to as the "HPA" method. The products of the methods of the present invention may be used in many other assay systems, or for other uses, known to those skilled in the art.
The present invention further features a kit that incorporates the components of the invention and makes possible convenient performance of the invention. Such a kit may also include other materials that would make the invention a part of other procedures, and may also be adaptable for multi-well technology.
Definitions
As used herein, the following terms have the following meanings unless expressly stated to the contrary.
A. Nucleic Acid
"Nucleic acid" means either RNA or DNA, along with any nucleotide analogues or other molecules that may be present in the sequence and that do not prevent performance of the present invention.
B. Template
A "template" is a nucleic acid molecule that is able to be copied by a nucleic acid polymerase. A template may be either RNA or DNA, and may be any of single-stranded, double-stranded or partially double-stranded, depending on the polymerase. The synthesized copy is complementary to the template.
C. Primer
A "primer" is an oligonucleotide that is sufficiently complementary to a template so that it hybridizes (by hydrogen bonding or hybridization under hybridizing conditions, e.g., stringent conditions) with the template to give a primer/template complex suitable for initiation of synthesis by a DNA polymerase, such as a reverse transcriptase, and which is extended by the addition of covalently bonded bases linked to its 3' end that are complementary to the template. The result is a primer extension product. Virtually all DNA polymerases (including reverse transcriptases) that are known require complexing of an oligonucleotide to a single-stranded template ("priming") to initiate DNA synthesis. Under appropriate circumstances, a primer may be a part of a promoter-primer. Such primers are generally between 10 and 100 bases in length, preferably between 20 and 50 bases in length.
D. Promoter or Promoter Sequence
A "promoter" or "promoter sequence" is a specific nucleic acid sequence that is recognized by a DNA-dependent RNA polymerase ("transcriptase") as a signal to bind to a nucleic acid molecule and begin the transcription of RNA at a specific site. For binding, such transcriptases generally require that the promoter and its complement be double-stranded; the template portion need not be double-stranded. Individual DNA-dependent RNA polymerases recognize a variety of different promoter sequences that can vary markedly in their efficiency of promoting transcription. When an RNA polymerase binds to a promoter sequence to initiate transcription, that promoter sequence is not part of the sequence transcribed. Thus, the RNA transcripts produced thereby will not include the promoter sequence.
E. Promoter-primer
A promoter-primer comprises a promoter and a primer. It is an oligonucleotide that is sufficiently complementary to the 3'-end of a target nucleic acid sequence to complex at or near the 3'-end of that target nucleic acid sequence, which means that the promoter-primer complexes near enough to the end of the target sequence to allow amplification of enough of the target sequence that the requirements of the assay, testing, cloning or other use for the amplified nucleic acid are met. The promoter-primer is used as a template to create a complementary nucleic acid sequence extending from the 3'-end (also known as the 3' terminus) of a target nucleic acid sequence, to result in a generally double stranded promoter, subject to any denaturing or enzymatic activity that may disrupt the double strand.
A DNA- or RNA-dependent DNA polymerase also creates a complementary strand to the target nucleic acid molecule, using as a template the portion of the target sequence 5' to the complementary region of the promoter-primer.
The 3'-end of the promoter-primer may be modified, or blocked, so as to prohibit or inhibit an extension reaction from proceeding therefrom. A solution of promoter-primer comprising both modified and unmodified promoter-primer consists of essentially the same nucleic acid sequence for the purposes of the present invention. The modified promoter-primer does not contain a different promoter nor a different recognition sequence from the unmodified promoter-primer. This means that, within about 10 bases, the modified and unmodified promoter-primers are recognized by the same RNA polymerase, and recognize the same target sequence (although not necessarily at precisely the same position). In a preferred embodiment, the modified and unmodified or mixture of modified promoter-primers are identical except for the modification. The 3'-end of the promoter-primer can be blocked in a variety of ways well known to those skilled in the art. Such promoter-primers are generally between 40 and 100 bases in length, preferably between 40 and 60 bases.
F. Target Nucleic Acid Sequence, Target Sequence
A "target nucleic acid sequence," or "target sequence," has a desired nucleic acid sequence to be amplified, and may be either single-stranded or double-stranded and may include other sequences beside 5' or 3' of the sequences to be amplified which may or may not be amplified.
The target nucleic acid sequence includes the complexing sequences to which the promoter-primer hybridizes during performance of the present invention. Where the target nucleic acid sequence is originally single-stranded, the term refers to either the (+) or (-) strand, and will also refer to the sequence complementary to the target sequence. Where the target nucleic acid sequence is originally double-stranded, the term refers to both the (+) and (-) strands.
G. Plus (+) and Minus (-) Strand(s)
Discussions of nucleic acid synthesis are greatly simplified and clarified by adopting terms to name the two complementary strands of a nucleic acid duplex. Traditionally, the strand encoding the sequences used to produce proteins or structural RNAs was designated as the "plus" strand and its complement the "minus" strand. It is now known that in many cases, both strands are functional, and the assignment of the designation "plus" to one and "minus" to the other must then be arbitrary. Nevertheless, the terms are very useful for designating the sequence orientation of nucleic acids and will be employed herein for that purpose, with the "plus" strand denominating the original target sequence strand that is complexed with the promoter-primer.
H. DNA-Dependent DNA Polymerase
A "DNA-dependent DNA polymerase" is an enzyme that synthesizes a complementary DNA copy from a DNA template. Examples are DNA polymerase I from E. coli and bacteriophage T7 DNA polymerase. All known DNA-dependent DNA polymerases require a complementary primer to initiate synthesis. It is known that under suitable conditions certain DNA-dependent DNA polymerases may synthesize a complementary DNA copy from an RNA template.
I. DNA-Dependent RNA Polymerase (Transcriptase)
A "DNA-dependent RNA polymerase" or "transcriptase" is an enzyme that synthesizes multiple RNA copies from a double-stranded or partially-double stranded DNA molecule having a (usually double-stranded) promoter sequence. It should be noted that the present invention includes single stranded promoters, along with the RNA polymerases that recognize them. The RNA molecules ("transcripts") are synthesized in the 5'→3' direction of the RNA molecule, beginning at a specific position just downstream of the promoter. Examples of transcriptases are the DNA-dependent RNA polymerases from E. coli and bacteriophages T7, T3, and SP6. Under appropriate conditions, as shown herein, some transcriptases may use RNA or an RNA:DNA copolymer as a template.
J. RNA-Dependent DNA Polymerase (Reverse Transcriptase)
An "RNA-dependent DNA polymerase" or "reverse transcriptase" is an enzyme that synthesizes a complementary DNA copy from an RNA template. All known reverse transcriptases also have the ability to make a complementary DNA copy from a DNA template; thus, they are both RNA- and DNA-dependent DNA polymerases. A primer is required to initiate synthesis with either the RNA or DNA templates.
K. RNAse H
An "RNAse H" is an enzyme that degrades the RNA portion of an RNA:DNA duplex. RNAse H's may be endonucleases or exonucleases. Most reverse transcriptase enzymes normally contain an RNAse H activity in addition to their polymerase activity. However, other sources of the RNAse H are available without an associated polymerase activity. The degradation may result in separation of RNA from a RNA:DNA complex. Alternatively, the RNAse H may simply cut the RNA at various locations such that portions of the RNA melt off or permit enzymes to unwind portions of the RNA, or the RNA fragments generated may serve as primers for a DNA polymerase.
L. Hybridize, Complex
The terms "hybridize" and "complex" refer to the formation of duplexes between nucleotide sequences that are sufficiently complementary to form duplexes (or "complexes") via Watson-Crick base pairing. Where a promoter-primer or primer "hybridizes" with target (template), such complexes (or hybrids) are sufficiently stable to serve the priming function required by a DNA polymerase to initiate DNA synthesis.
M. Modified Primer or Promoter-Primer
The 3'-end of the primer or promoter-primer may be modified, or blocked, so as to prohibit or inhibit an extension reaction from proceeding therefrom. A primer or promoter-primer having both modified and unmodified members consists of essentially the same nucleic acid sequence for the purposes of the present invention. In other words, the modified primer or promoter-primer does not contain a different complexing sequence (primer) in terms of its specificity in that both the modified and unmodified oligonucleotide hybridizes in effectively the same position (plus or minus about ten bases) on the target nucleic acid sequence such that amplification of the target sequence is not prohibited. Also, the modified promoter-primer does not contain a different recognition sequence (promoter) from the unmodified promoter-primer. This means that, within about 10 bases, the modified and unmodified primers or promoter-primers are the same, are recognized by the same RNA polymerase, and recognize the same target sequence (although not necessarily at precisely the same position). In a preferred embodiment, the modified and unmodified primers or promoter-primers are identical except for the modification.
The 3'-end of the primer or promoter-primer can be modified in a variety of ways well known to those skilled in the art. Appropriate modifications to a promoter-primer can include addition of ribonucleotides, 3' deoxynucleotide residues, (e.g., cordycepin (CO, Glen Research)), 3'2'-dideoxy nucleotide residues, modified nucleotides such as phosphorothioates, and non-nucleotide linkages such as described in Arnold, et al., (PCT US 88/03173) corresponding to U.S. patent application Ser. No. 07/099,050, abandoned in favor of U.S. application No. 07/319,422. (RS) or alkane-diol modifications (Wilk et al. Nuc. Acids Res. 18:2065, 1990) (RP), or the modification may simply consist of a region 3' to the priming sequence that is uncomplementary to the target nucleic acid. Of course, other effective modifications are possible as well.
A mixture of modified and unmodified oligonucleotides may be used in an amplification reaction, and ratios of blocked to unblocked oligonucleotide from 2:1 to 1,000:1 have been successfully used. A mixture of oligonucleotides with different 3' modifications may also be used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an oligonucleotide (4) comprising a promoter-primer, (6)-(8), and a target nucleic acid (2), that has a defined 3'-end (9) and, thus, no additional sequences 3' to the target sequence, but which does have additional sequences 5' to the target sequence. The primer (8) portion of the oligonucleotide is sufficiently complementary to the 3' end (9) of the target nucleic acid (2) to form a promoter-primer/target sequence complex (11). The arrows, (10) and (12), show the direction of the extension reactions.
FIG. 2 depicts an RNA target sequence (14) having additional sequences (16), 3' to the complexing region (11) of the target sequence with an oligonucleotide (4) comprising a promoter-primer, (6)-(8).
FIG. 3 is a diagrammatic representation of an alkane diol modification or RP, on an oligonucleotide (zigzag line).
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a method, composition and kit for the amplification of specific nucleic acid target sequences. Such amplified target sequences are useful in assays for the detection and/or quantitation of specific nucleic acid target sequences or for the production of large numbers of copies of DNA and/or RNA of specific target sequences for a variety of uses.
Using FIG. 1 for illustration, the present invention features a method comprising treating a nucleic acid target sequence (2), which may be RNA or DNA, with an oligonucleotide (4) that comprises a promoter-primer that has a promoter (6) and a primer (8), wherein the primer (8) is sufficiently complementary to the 3'-end (9) portion of the target sequence to complex at or near the 3'-end (9) of the target sequence. The promoter-primer (4) consists essentially of only a single nucleic acid sequence, and no other promoter-primers need be introduced to the reaction mixture to achieve amplification. Promoters suitable for the promoter-primer of the present invention are nucleic acid sequences (produced naturally, synthetically or as a product of a restriction digest) that are specifically recognized by an RNA polymerase that binds to that sequence and initiates the process of transcription whereby RNA transcripts are produced. The promoter sequence may optionally include nucleotide bases extending beyond the actual recognition site for the RNA polymerase, which may impart added stability or susceptibility to degradation processes or increased transcription efficiency. Promoter sequences for which there is a known and available polymerase are particularly suitable. Such promoters include those recognized by RNA polymerases from bacteriophages T3, T7 or SP6, or from E. coli.
In some circumstances it may be desirable to introduce "helper" oligonucleotides into the mixture, which helper oligonucleotides assist the promoter-primer to complex with the target sequence.
The promoter-primer (4) and the target sequence (2) are subjected to conditions whereby a promoter-primer/target sequence complex (11) is formed and DNA synthesis may be initiated. Accordingly, the reaction mixture is incubated under conditions whereby a promoter-primer/target sequence complex is formed, including DNA priming and nucleic acid synthesizing conditions (including ribonucleotide triphosphates and deoxyribonucleotide triphosphates) for a period of time sufficient whereby multiple copies of the target sequence are produced. The reaction advantageously takes place under conditions suitable for maintaining the stability of reaction components such as the component enzymes and without requiring modification or manipulation of reaction conditions during the course of the amplification reaction. Accordingly, the reaction may take place under conditions that are substantially isothermal and include substantially constant ionic strength and pH. In other words, the reaction conditions may be effectively constant, which means that the temperature, pH and ionic concentration are not significantly, purposefully altered so as to affect the reaction conditions. The components of the reaction mixture may be combined stepwise or at once.
During performance of the reaction, the 3'-end (9) of the target sequence is extended by an appropriate DNA polymerase in an extension reaction using the promoter sequence of the promoter-primer as a template to give a DNA extension product (10) complementary to the promoter sequence. The 3'-end of the primer region of the promoter-primer is also extended in an extension reaction, using an appropriate reverse transcriptase, to form a complementary strand (12) to the target nucleic acid sequence. The resulting double stranded promoter is then used to bind the appropriate RNA polymerase, which then uses the resulting double stranded target nucleic acid sequence to produce multiple copies of single stranded RNA (which will be complementary to the (+) strand of the target sequence).
The DNA polymerase for extension of the promoter-primer must be an RNA-dependent DNA polymerase (i.e., a reverse transcriptase) when the target sequence is RNA. Concomitantly, where the target sequence comprises DNA, the DNA polymerase must be a DNA-dependent DNA polymerase. However, as all known reverse transcriptases also possess DNA-dependent DNA polymerase activity, it is not necessary to add a DNA-dependent DNA polymerase other than reverse transcriptase in order to perform the extension reaction, including where the promoter-primer is DNA and the target sequence is RNA. Suitable reverse transcriptases include AMV reverse transcriptase and MMLV reverse transcriptase.
The RNA polymerase required for the present invention may be a DNA-dependent RNA polymerase, such as the RNA polymerases from E. coli and bacteriophages T7, T3 and SP6; it is surprising that such a DNA-dependent RNA polymerase is effective when the target sequence is RNA.
In the case where the target sequence is DNA, the 3'-end of the target sequence must be defined, as in FIG. 1, to coincide approximately with the 5'-end of the primer of the primer-promoter (i.e., the target sequence must not have nucleotides extending 3' past the region complexed with the primer). Of course, such generation may also be practiced on an RNA target nucleic acid sequence. Generation of such a defined 3'-end of the nucleic acid target by chemical or enzymatic degradation or processing are known in the art.
As depicted in FIG. 2, the amplification may surprisingly be performed on an RNA target sequence 14 that has a strand of nucleotides 16 extending 3' past region 11 complexed with the primer.
It is a feature of the present invention that multiple copies of either DNA or RNA may be obtained.
In a preferred embodiment, the promoter-primer has a modification at its 3'-end to prevent or decrease extension from that end (along the target sequence). Methods of producing such modifications are known in the art. It is surprising that the amplification may be performed with the 3'-end so modified, and also surprising that using a mixture of modified and unmodified promoter-primer will result in higher efficiency amplification. For example, a ratio of about 150 modified promoter-primers to 1 unmodified promoter-primer has been found to greatly increase the efficiency and effectiveness of amplification. However, this ratio will change according to the reaction conditions and reagents, such as the promoter-primer and the target sequence.
In still a further aspect, the invention features a kit comprising some or all of the reagents, enzymes and promoter-primers necessary to perform the invention. The items comprising the kit may be supplied in separate vials or may be mixed together, where appropriate.
EXAMPLES
Preface
The following examples demonstrate the mechanism and utility of the present invention. They are not limiting and should not be considered as such.
The enzymes used in the following examples are avian myeloblastosis virus (AMV) reverse transcriptase, T7 RNA polymerase, Moloney murine leukemia virus (MMLV) reverse transcriptase, and Superscript (RNase H minus MMLV RT, "MMLV SC RT") from Bethesda Research Laboratories. Other enzymes containing similar activities and enzymes from other sources may be used. Other RNA polymerases with different promoter specificities may also be suitable for use.
Unless otherwise specified, the reaction conditions used in the following examples were 50 mM Tris-HCl, pH 7.6, 25 mM KCl 17.5 mM MgCl 2 , 5 mM dithiothreitol, 2 mM spermidine trihydrochloride, 6.5 mM rATP, 2.5 mM rCTP, 6.5 mM rGTP, 2.5 mM rUTP, 0.2 mM dATP, 0.2 mM dCTP, 0.2 mM dGTP, 0.2 mM dTTP, 0.3 μM promoter-primer, 600 units of MMLV reverse transcriptase and 400 units of T7 RNA polymerase, and specified amounts of template in 100 μl volumes. However, the best reaction conditions will vary according to the requirements of a given use and circumstances; given the present disclosure, such conditions will be apparent to one skilled in the art. The oligonucleotide sequences used are exemplary and are not limiting as other sequences have been employed for these and other target sequences.
Example 1
To demonstrate the invention using a target sequence with a defined 3'-end, a promoter-primer (Seq. ID No. 1) containing a sequence complementary to the 3' end of Ureaplasma urealyticum 5S rRNA, was incubated with RNA in the presence of T7 RNA polymerase and MMLV reverse transcriptase for four hours. Samples of the reaction were removed at certain timepoints and analyzed by hybridization with two probes of the same sense as the target RNA (Seq ID Nos. 2, 3) in the presence of helper probes (Seq ID Nos. 4, 5) as described in Hogan (U.S. Pat. No. 5,030,557, Means for Enhancing Nucleic Acid Hybridization).
______________________________________ RLUTime of incubation 1 fmole target 0.1 fmole target______________________________________ 15 min 5,389 307 30 min 10,360 778 60 min 40,622 5,588120 min 144,851 13,051180 min 192,618 16,249240 min 203,193 20,745______________________________________
Example 2
To demonstrate that the invention works with a target sequence containing nucleotides 3' to the promoter-primer binding site, a promoter-primer containing sequences complementary to 21 bases of Streptococcus pneumoniae 16S rRNA corresponding to bases 683-703 of the E. coli reference sequence, (Seq ID No. 6), was incubated with 1 fmole of (+) sense S. pneumoniae rRNA in the presence of the following enzymes. Ten μl of the reaction was assayed with acridinium ester labelled probes of both senses (Seq ID No. 7), with helper probes (Seq ID No. 8, 9), or their complements. In a separate experiment, part of the reaction was hydrolyzed with NaOH prior to hybridization.
______________________________________Enzymes (+) sense probe (-) sense probe______________________________________MMLV RT + T7 434,463 7,333MMLV SC RT + T7 2,617 3,579MMLV RT, no T7 2,614 1,733MMLV RT + T7, no primer 1,753 3,840MMLV RT + T7, no NaOH 615,299MMLV RT + T7, + NaOH 2,499______________________________________
The results show that the amplification of the present invention is dependent on reverse transcriptase, T7 RNA polymerase and RNase H activity, and that the predominant product produced is RNA complementary to the target RNA.
Example 3
To determine if extension of the 3' end of the promoter-primer was required for amplification, a promoter-primer was synthesized with 3' modifications using standard chemistry, as described by Arnold et al. (RS; PCT US 88/03173) or Wilk, et al., (RP; FIG. 3 in Nucleic Acids Res. 18:2065, 1990), or cordycepin (CO, Glen Research). The effect of these modifications on extension by reverse transcriptase was tested in the following experiment. A promoter-primer with a sequence complementary to S. pneumoniae 16S rRNA (Seq ID 6) was hybridized to target, then incubated in the presence of MMLV RT for 30 min. At the end of the extension reaction, the RNA and cDNA was denatured at 95° C. for two minutes, and assayed by hybridization protection assay with a probe the same sense as the rRNA (Seq ID No. 7) with helper probes (Seq ID Nos. 8, 9).
______________________________________Amount of target: RLUPrimer: 1 pmole 0 pmole______________________________________unmodified 756,996 5,0383' RSL 391,079 4,1323' RP 68,153 4,3653' CO 10,521 4,717______________________________________
The results indicated that the 3' modifications did alter extension by reverse transcriptase relative to the unmodified primer.
Example 4
To determine if extension of the 3' end was required for the amplification of a target sequence with a defined 3'-end, the promoter-primer complementary to the 3' end of Ureaplasma urealyticum 5S rRNA (Seq. ID 1), was modified at the 3' end with RS, and incubated with 1 fmole of target RNA, MMLV reverse transcriptase and T7 RNA polymerase. Hybridization with probes as described in Example 1 indicated that efficient extension of the promoter-primer was not required for amplification. Reverse transcriptase activity was required, as shown by the lack of amplification in the reaction containing only T7 RNA polymerase.
______________________________________ RLUEnzymes unmodified modified______________________________________MMLV RT + T7 11,189 12,443MMLV SC RT + T7 8,738 3,742T7 only 1,838 1,694No target 1,272 1,157______________________________________
Example 5
To test the effect of 3' modifications on amplification of a target containing sequences 3' to the promoter-primer binding site, a promoter-primer containing sequences complementary to S. pneumoniae 16S rRNA, (Seq ID No. 6), was synthesized with 3' RS, 3' RP, or 3' cordycepin modification. The modified and unmodified promoter-primers were incubated with S. pneumoniae rRNA, MMLV reverse transcriptase and T7 RNA polymerase at 37° C. for 4 hr. Ten μl of the reaction was assayed with a probe of the same sense as the target RNA.
______________________________________ RLUPrimer 1 fmol target 0.1 fmol target 0 target______________________________________unmodified 39,652 7,952 2,7853' RSL 227,639 15,732 3,1173' RP 556,708 589,168 3,3683' CO 509,262 30,004 3,219______________________________________
Surprisingly, the data show that modifications to the 3' end of the promoter-primer increased the signal observed with this amplification mechanism.
Example 6
The following experiment was performed to demonstrate the kinetics of accumulation of product with promoter-primers with unmodified or modified 3' ends. A promoter-primer containing sequences complementary to M. tuberculosis 23S rRNA was incubated with 1 fmole of M. tuberculosis rRNA in the presence of MMLV RT and T7 RNA polymerase. At the time points indicated, samples were removed and assayed with an acridinium ester labelled probe the same sense as the target RNA. Background RLU from target free reactions were subtracted from the data.
______________________________________Time Unmodified 3' RS 3' RP______________________________________ 0 min 0 0 015 min 2,266 430 4330 min 7,622 1,532 21460 min 9,349 9,584 1,403120 min 15,281 32,007 150,781180 min 24,528 38,086 590,033240 min 23,866 46,276 868,145______________________________________
The data show that the unmodified and 3' RS modified promoter-primers accumulate product in a linear manner, while the 3' RP promoter-primer appears to accumulate product in a more exponential fashion. This result was also unexpected, and implies a unique amplification mechanism that occurs at essentially constant temperature, pH and ionic strength.
Example 7
In this example, different promoter-primers were incubated with S. pneumoniae rRNA for 4 hours in the presence of 600 units of AMV reverse transcriptase and 400 units of T7 RNA polymerase. Ten μl of sample were assayed with an acridinium-ester labeled probe of the same sense as the target RNA.
______________________________________ 1 fmol target 0 fmol target______________________________________Unmodified 66,042 3,6073' RP 359,597 3,4113' CO 110,260 2,984______________________________________
The data show that the 3' modified promoter-primers result in higher signals than the unmodified version with AMV reverse transcriptase.
Example 8
The following experiment demonstrated that additives (DMSO and glycerol) increase the effectiveness (sensitivity) of the amplification system. Modified or unmodified promoter-primers (Seq ID No. 6) were added to S. pneumoniae rRNA in the presence of MMLV reverse transcriptase and T7 RNA polymerase and incubated at 37° C. for 4 hours. Ten μl of reaction were assayed with acridinium ester labelled probe of the same sense as the target RNA, and negative values were subtracted.
______________________________________Primer DMSO/gly 0.1 fmol 0.01 fmol______________________________________unmodified - 3,176 18 + 1,468 7633' CO - 5,168 668 + 46,915 3,0703' RP - 83,870 7,400 + 935,945 117,051______________________________________
The data show that the additives had little effect on the results with the unmodified promoter-primer, but increased signals significantly with the 3' modified promoter-primers, with the most marked effect with the 3' RP version.
Example 9
In this experiment, promoter-primers with a sequence complementary to the 23S rRNA of M. tuberculosis, (Seq ID No. 10) were synthesized with one (ribo) or two (diribo) 3' terminal deoxycytidines replaced with one or two 3' ribocytidine residues, or with a 3' terminal phosphorothioate (PS) deoxynucleotide. These modified promoter-primers were used to amplify M. tuberculosis rRNA in 50 mM Tris HCl pH 8, 20 mM MgCl 2 , 35 mM KCl, 4 mM each GTP, ATP, UTP, CTP and 1 mM each dTTP, dGTP, dCTP, dATP, 15 mM N-acetyl-cysteine, 10% glycerol, 10% DMSO, 600 units MMLV reverse transcriptase, and 400 units T7 RNA polymerase, at 42° C. for 4 hours. Five μl of each reaction was heated to 95° C. for 2 minutes and assayed with a probe of the same sense as the rRNA target (Seq ID #11), with helper probes ID 12 and 13.
______________________________________TmolTarget:Primer 3,000 300 30 3 0______________________________________Unmodified 11,162 1,508 931 779 8073' RP 1,901,532 1,494,050 513,419 14,243 6583' ribo 57,401 3,992 644 670 5893' diribo 34,265 11,459 1,445 666 584Unmodified 1,799 877 N.T. 7823' PS 266,755 12,567 1,617 656______________________________________
The results showed that promoter-primers with one or two ribonucleotides at the 3' end, or with a 3' phosphorothioate linkage, give better amplification in this system than unmodified promoter-primers.
EXAMPLE 10
Another method for altering the extension of promoter-primer by reverse transcriptase was to mix unmodified promoter-primer with blocked, cordycepin-modified promoter-primer. Use of a mixture of promoter-primers would significantly decrease the production of cDNA observed in a reverse transcription reaction, as observed for other 3' modifications. The following experiment used promoter-primers with sequence complementary to M. tuberculosis 16S rRNA (Seq ID. No. 14), either modified with cordycepin or unmodified. The promoter-primers were incubated with 3 tmol of M. tuberculosis rRNA, 300 units of MMLV reverse transcriptase and 200 units of T7 RNA polymerase, using the same conditions as example 9 except that 10 mM trimethyl ammonium chloride was present. After a 2 hour incubation at 42° C., twenty μl of the reaction was assayed with a probe of the same sense as the target RNA (Seq ID No. 15, with helpers Seq. ID No. 16, 17). The results are the average of 5 replicates.
______________________________________Target 3' CO Primer Unmodified Primer RLU______________________________________+ 15 pmol 0 pmol 1,879+ 14.9 pmol 0.1 pmol 191,988- 15 pmol 0 pmol 1,055______________________________________
As can be seen, a mixture of modified and unmodified promoter primer worked better than completely modified promoter primer. Varying the ratio (e.g., between 1:1 to 150:1) of modified to unmodified promoter-primer effectively increased the efficiency of amplification. The optimal ratio will change according to reaction conditions, including the reagents used, the target sequence, and the promoter-primer. Selecting appropriate conditions for a given amplification is within the skill of one skilled in the art without undue experimentation.
In a separate experiment, the signals obtained from the amplification were compared to known standards, and the degree of amplification calculated to be 2.6×10 5 fold.
EXAMPLE 11
In this example, reactions were performed as in Example 10, except that the promoter primers were unmodified or modified with RP or CO. Thirty tmol target was added to each reaction. As shown, a mixture of promoter primers with different 3' modifications result in significant amplification.
______________________________________Primer RLU______________________________________3' CO 3' RP Unmodified15 pmol -- 0.1 pmol 802,37413 pmol 2 pmol -- 440,854______________________________________
The amount of non-specific product generated was shown to be much lower with the modified primers, evidencing another advantage of the invention.
Example 12
The increase in the number of complementary copies of the target sequence with time requires reverse transcriptase and T7 RNA polymerase. When the promoter-primer hybridizes to the 3' end of a target, copying of the T7 promoter sequence results in a double-stranded DNA promoter that can be recognized by T7 RNA polymerase and utilized to make RNA copies of the target sequence. The results with the 3' modified promoter-primers implied that the T7 RNA polymerase was using RNA as a template for RNA synthesis. Synthetic oligonucleotides were made to test this hypothesis. The first oligonucleotide was a DNA promoter-primer, containing a 5' T7 promoter sequence linked to a 3' target binding sequence. Another oligonucleotide containing only the promoter sequence was also synthesized. The target sequence consisted of an RNA:DNA chimeric molecule containing 5' synthetic RNA target sequence with the DNA complement of the T7 promoter sequence attached to the 3' end.
In this experiment the 10 or 1 fmol of the RNA-DNA chimeric target was hybridized with the promoter-primer containing the T7 promoter and a target binding sequence, or the promoter sequence alone, leaving the RNA target strand single-stranded. The hybrids were incubated with or without T7 RNA polymerase and the products were hybridized with a probe of the same sense as the RNA target sequence.
______________________________________ RLU 10 fmol 1 fmolPromoter-primer +T7 -T7 +T7 -T7______________________________________Pro + target 146,060 2,490 16,532 2,721pro only 425,127 2,753 33,474 2,557______________________________________
Surprisingly, the data show that an RNA fragment can be used by T7 RNA polymerase as a template for RNA transcription.
Example 13
The following experiment showed that an RNA strand can be used to synthesize RNA in the presence of reverse transcriptase and T7 RNA polymerase. In this experiment, the RNA:DNA chimeric target was compared to a synthetic RNA fragment containing only the target sequence.
______________________________________Target T7 RT 10 fmole 1 fmole______________________________________RNA:DNA chimera + MMLV 1,369,888 264,864 + AMV 334,139 118,406 - - 5,066RNA target + MMLV 13,609 3,875 + AMV 26,318 4,824 - - 5,862______________________________________
The present embodiments of this invention 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, and all changes which come within the meaning and range of equivalency of the claims therefore are intended to be embraced therein.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 17(2) INFORMATION FOR SEQ ID NO: 1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 53(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 1:AATTTAATACGACTCACTATAGGGAGAGCGTAGCGATGACCTATTTTACTTGC53(2) INFORMATION FOR SEQ ID NO: 2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 30(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 2:CGAACACAGAAGTCAAGCACTCTAGAGCCG30(2) INFORMATION FOR SEQ ID NO: 3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 3:GTGATCATATCAGAGTGGAAATACCTGTTCCCATCC36(2) INFORMATION FOR SEQ ID NO: 4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 34(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 4:GTAGTGATCATATCAGAGTGGAAATACCTGTTCC34(2) INFORMATION FOR SEQ ID NO: 5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 26(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 5:GCAAGTAAAATAGGTCATCGCTACGC26(2) INFORMATION FOR SEQ ID NO: 6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 48(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 6:AATTTAATACGACTCACTATAGGGAGACTACGCATTTCACCGCTACAC48(2) INFORMATION FOR SEQ ID NO: 7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 7:GGCTTAACCATAGTAGGCTTTG22(2) INFORMATION FOR SEQ ID NO: 8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 39(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 8:GAGCGCAGGCGGTTAGATAAGTCTGAAGTTAAAGGCTGT39(2) INFORMATION FOR SEQ ID NO: 9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 9:GAAACTGTTTAACTTGAGTGCAAGAGGGGAGAGTGG36(2) INFORMATION FOR SEQ ID NO: 10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 47(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 10:AATTTAATACGACTCACTATAGGGAGACCAGGCCACTTCCGCTAACC47(2) INFORMATION FOR SEQ ID NO: 11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 11:GGAGGATATGTCTCAGCGCTACC23(2) INFORMATION FOR SEQ ID NO: 12:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 38(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 12:CGGCTGAGAGGCAGTACAGAAAGTGTCGTGGTTAGCGG38(2) INFORMATION FOR SEQ ID NO: 13:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 36(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 13:GGGTAACCGGGTAGGGGTTGTGTGTGCGGGGTTGTG36(2) INFORMATION FOR SEQ ID NO: 14:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 55(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 14:GAAATTAATACGACTCACTATAGGGAGACCACAGCCGTCACCCCACCAACAAGCT55(2) INFORMATION FOR SEQ ID NO: 15:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 15:GTCTTGTGGTGGAAAGCGCTTTAG24(2) INFORMATION FOR SEQ ID NO: 16:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 16:CCGGATAGGACCACGGGATGCAT23(2) INFORMATION FOR SEQ ID NO: 17:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) SEQUENCE DESCRIPTION: SEQ ID NO: 17:CGGTGTGGGATGACCCCGCG20__________________________________________________________________________ | A method, composition and kit for amplifying a target nucleic acid sequence under conditions of substantially constant temperature, ionic strength, and pH and using only a single promoter-primer. To effect the amplification, a supply of a single promoter-primer having a promoter and a primer complementary to the 3'-end of the target sequence, and a reverse transcriptase and an RNA polymerase are provided to a mixture including the target sequence; the amplification proceeds accordingly. The invention is useful for generating copies of a nucleic acid target sequence for purposes that include assays to quantitate specific nucleic acid sequences in clinical, environmental, forensic and similar samples, cloning and generating probes. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of pending application Ser. No. 08/761,211 filed Dec. 5, 1996, now U.S. Pat. No. 5,754,494.
FIELD OF THE INVENTION
The present invention is directed to landmine prodding instruments, in particular to instruments which introduce and then analyse acoustic waves which travel within a prod placed in contact with unknown objects, and thus characterize the nature of the material of the object.
BACKGROUND OF THE INVENTION
Despite a variety of mechanised means now available for detecting and clearing landmines, the current hand tool of choice is the hand prodder. Personnel exhibit greater confidence when traversing a minefield which has been hand-prodded by their compatriots than they do with fields cleared by other means.
The hand prodder typically comprises a 30 cm long pointed rod extending from a gripping handle. The probe is generally non-magnetic to avoid setting off magnetically-triggered mines. The user probes the ground ahead and excavates any hard objects which the probe contacts. As the ratio of rocks to landmines in a minefield may number 1000:1, excavation of every contact is labourious, but very necessary.
Thus, it would be a significant advance in the art should a user be able to discriminate between landmines and rocks upon contact and without excavation. Accordingly, applicant sought to provide a hand probe which could distinguish variations in the object's material characteristics.
As shown in FIG. 1, known apparatus for measuring the compressive characteristics of materials include the Split Hopkinson Pressure Bar apparatus ("SHPB"). The SHPB is typically used to apply rapid strain rates (100,000 mm/mm/second) to samples; compressing them for the measurement of mechanical properties. A sample is placed between the ends of two axially aligned elastic bars. Maintaining elastic conditions in the bar, the first "incident" bar is struck, rapidly compressing the sample between the incident bar and the second "transmitter" bar.
The act of striking the incident bar sends a high frequency elastic mechanical pulse or compression wave through the bar. Like an acoustic wave, it reflects from interfaces having differing characteristics. Dependent upon the samples material characteristics, a portion of the wave reflects from the incident bar/sample interface and travels back along the incident bar. The remainder of the wave passes through the sample. A lesser reflection occurs at the transmitter bar/sample interface. The residual portion of the wave continues as a compression wave along the transmitter bar.
Strain gauges located on both the incident and transmitter bars enable calculation of the strain in the bars. In the incident bar, the displacement of the bar's end is proportional to the sum of the strain in the bar which is calculated from time-shifted strain gauge data obtained for both the incident and reflected waves. The displacement of the transmitter bar end is proportional to the strain measured in the transmitter bar. The sum of the displacements of the ends of the incident and transmitter bars defines the compression of the sample.
Mechanical impedance ("MI") is a material's characteristic which relates to the material's effect on acoustic wave transmission and reflection. Not surprisingly, MI affects the nature of the reflected wave in the SHPB's incident bar. The effect of MI on the SHPB apparatus, for materials having differing MI values, is described for three particular cases as follows.
In a first case, following the basic rules of mechanics of materials, if the MI of the sample is the same as that of the bar, then there is no reflective interface and thus no wave reflection at all; the sample is elastically displaced exactly as is the bar itself. The displacement at the bar's end is directly proportional to the measured strain (ε).
If MI of the sample is very much greater than that of the bar, then the sample's MI is effectively infinity, and all of the incident wave is reflected. The incident and reflected waves are also in phase. The reflected wave is therefore also compressive and equal in magnitude to the incident wave. Thus the resultant bar end displacement is zero.
If the MI is zero (no sample at all, unconstrained bar end), the reflected wave is tensile, but of equal magnitude to the incident wave. The phase of the wave shifts 180° and is thus out of phase. In other words, the net stress cancels and the relative displacement at the bar end equals twice that for the first case (2×ε).
In tabular form, the above cases and the general case are shown as:
______________________________________ Strain Strain Proportional MI Incident Reflected DisplaceCase Sample ε.sub.i = ε.sub.r = (ε.sub.i -ε.sub.r)______________________________________1 = bar ε.sub.i 0 ε.sub.i2 ∞ ε.sub.i ε.sub.i 03 0 ε.sub.i -ε.sub.i 2 × ε.sub.iGeneral ? ε.sub.i ε.sub.r (ε.sub.i - ε.sub.r)______________________________________
Knowing the relative displacements of the bars, the displacement imposed on the sample is also known. From the Young's Modulus (E) and the displacement of a bar, the imposed stress is also known. The force imposed is equal to the product of the stress and bar's cross-sectional area. Thus the strain and stress functions as they apply to the sample may also be determined.
As the loading on the sample substantially equalizes after a very short time, it is known to make a simplifying assumption and merely apply the strain results for either one of the incident bar or the transmitter bar. In another arrangement, the striker is permitted to impact directly on the sample, and the transmitter bar results alone are used to define the sample characteristics.
The question is, can such an approach be successfully applied to materials as diverse as plastics, minerals and metals and enable one to sort out non-hazardous from the potentially hazardous prodder contacts.
SUMMARY OF THE INVENTION
The present invention provides a hand prodder having a rod which is fitted with means, preferably one or more piezoelectric crystals, for introducing an acoustic wave to the bar and for converting reflected waves into electric signals. A signal processor analyses the signals and establishes measurements representative of the acoustical characteristics of the object. The acoustical characteristics for the unknown object are compared with pre-determined characteristics for known objects for identifying the unknown object. Accordingly, the novel prodder provides the means for identifying the characteristics of unknown objects, and more preferably for distinguishing landmines from inert rocks.
The novel method comprises first positioning the rod into contact with an object and introducing a high frequency acoustic wave. The resultant incident elastic wave travels to the object where it is reflected back and is converted into an electric signal. A signal processor processes the signal and establishes values for the phase shift of the wave which is characteristic of the object. The values for phase shift for the object are compared to pre-determined values for phase shifts for contact of the rod with known materials. More particularly, values for phase shift are first determined for use of the rod without contacting an object. These non-contact or rod-alone phase shift values are mathematically combined with the phase shift values obtained for contact with an object, thereby providing a solution which identifies the phase shift due to the object and not due to the rod. The phase shift solution is compared to pre-determined solution levels which discriminated between inert rocks and potentially hazardous softer plastic or harder metallic objects. Preferably the result of the comparison is signalled visually or audibly to alert the user to contact of a rock (safe) or of an unidentified (unsafe) hazardous object.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a prior art materials testing apparatus known as the Split Hopkinson Pressure Bar;
FIG. 2 is a cross-sectional view of the hand prodder contacting a sub-surface object;
FIG. 3 is a cross-sectional view of the rod and piezoelectric crystal portion of the prodder, coupled to the signal processing module;
FIG. 4 is a flow chart of the digital signal processor and AID functions. The periods of active "wake-up" and "sleep" operations trace the flow chart steps;
FIG. 5 illustrates the raw piezoelectric signals for plastic, aluminum and rock;
FIG. 6 depicts the power chart (frequency-time-amplitude) for aluminium, after the processor conditioned the signal of FIG. 5 using Fast Fourier Transform;
FIG. 7 depicts the power chart for plastic;
FIG. 8 depicts the power chart for rock;
FIG. 9 is a map of the average transformed frequency-time-amplitude for a plurality of tests, illustrating distinct grouping of test results for metals (lower solid symbols), plastics (upper open symbols) and rock (line symbols);
FIGS. 10a and 10b illustrate the effect on the phase of an acoustic pulse for a rod contacting an infinite impedance object (same phase) and a zero impedance object (phase reversal) respectively;
FIGS. 11 and 12 are graphs which illustrate the theoretical pulse-echo signals, over time, which result from no contact and contact with an object respectively;
FIG. 13 is a graph illustrating the effect of mixing, over time, a baseline no contact signal with a signal generated from no contact demonstrating no phase shift;
FIGS. 14-16 is a graph illustrating the mixing, over time, the signals generated from a soft, medium and hard object respectively with a signal generated from no contact, phase shift being demonstrated by the negative values;
FIG. 17 is a graph illustrating the apportioning of the phase shift relative to the signal's amplitude (square symbol) and theoretical dc shift (cosine(phase)) as it relates to the particular echo;
FIG. 18 is a graph illustrating the comparison of the model phase shift and the cosine(phase) shift per echo;
FIG. 19 is a representation of the comparison of FIG. 18 after adding 20% noise (by amplitude);
FIGS. 20-22 are graphs illustrating the effect of adding 20% noise to the signals of FIGS. 14-16 respectively;
FIGS. 23-25 are actual mixed signals from contacts with plastic, rock and metal respectively.
FIG. 26 is a graph illustrating the non-normalized data for plastic (circular symbol), rock (square symbol), and metal (diamond symbol) at each echo and having a cosine-fitted curve through each;
FIG. 27 is a graph illustrating a rod no contact trace demonstrating the system droop rate and non-normalized contact data (diamond symbols) and the cosine-fitted curve;
FIG. 28 is a graph illustrating the no contact data of FIG. 27 and demonstrating the normalized contact data (diamond symbols) and the improved match to the cosine-fitted curve; and
FIG. 29 is a scatter graph illustrating the effect of rod loading on phase shift rate for plastic-like (soft), rock-like (medium), and metal-like (hard) objects versus load in grams.
The symbols in FIG. 29 correspond to materials as follows:
______________________________________Symbol ID Material______________________________________Solid diamond caa High density armour ceramic (Al.sub.2 O.sub.3);Large circle aba Brass;Large square ala Aluminium;Open diamond asa Steel;Small circle bcs Brass cartridge;Small plus raa Agate;Large X rpa,rqa Feldspar, quartz;Large plus rra,rsa Shale, sandstone;Large asterisk rfa Bloodstone, haematite;Small open square pla,pna,pua Polyethylene, nylon, polyurethane; andSmall solid square woa Wood (soft).______________________________________
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Having reference to FIGS. 2, 3, a hand-probing mine detector or prodder 1 is provided. The prodder comprises a rod 2 having a first end 3 flexibly supported by an annular rubber coupling 4 in a mounting nub 5. The nub 5 is screwed into a handle 6. The rod has a pointed second end 7 for sensing objects 8 buried in the ground 9. A protective sheath (not shown) fits over the rod's second and 7 and threads to the nub 5.
The rod 2 is 45 cm long and is formed of non-magnetic, austenitic stainless steel. Only 30 cm project from the rubber coupling 4. The rubber coupling 4 lessens the rigidity between the rod 2 and handle 6.
Best seen in FIG. 3, a piezoelectric crystal 10 is glued to the first, or driver end 3 of the rod 2. When an electric field is applied to the crystal 10, a mechanical strain will occur and drive mechanical energy into the rod's driver end 3. Conversely, when the crystal 10 is mechanically stressed, an electric charge is produced. A suitable crystal is a 15 mm long, 6.35 mm diameter poly-crystalline ceramic cylinder, model Sonex P-41 available from Hoechst CeramTec, Mansfield, Mass. The crystal 10 is electrically insulated from the rod 2 with a ceramic insulator 11.
Positive and negative electrical leads 12 from the crystal pass through the nub 5 for bi-directional electrical signal transmission between the crystal 10 and an electronics module 13. Shown in FIG. 1, the module 13 is installed within the prodder's handle and is powered with batteries 14, such as a 9 V or 2-1.5 V AA size batteries.
The electronics module 13 is capable of two modes: a driver mode and a signal processing mode. In the driver mode, an electrical signal is transmitted along leads 12 to the crystal 10 for generating a piezoelectric mechanical pulse. The pulse is introduced into the rod's driver end 3. In the signal processing mode, any electrical signals generated by the crystal 10 are transmitted along leads 3 for processing by the electronics module 13.
More specifically, the module 13 comprises a digital signal processing microcomputer 15, an EPROM 16 containing program instructions and digital storage means, an A/D converter 17, a signal input amplifier 18 and a driver output amplifier 19. An audio/visual binary output device 20 is provided.
A suitable signal processor is a model ADSP-2181 digital signal processing microcomputer by Analog Devices, Inc., Norwood, Mass. The ADSP-2181 contains a high speed serial port, 16 bit data processing capabilities and has both onboard program RAM and data memory RAM. For permitting battery powered operation, the ADSP-2181 features a power saving "sleep" mode. After downloading of program instructions from the EPROM, the ADSP-2181 will reduce its power consumption and await a suitable trigger before "waking-up" to begin signal processing.
Having reference to the flow chart in FIG. 4, when the prodder is activated, the EPROM 16 downloads the analysis program to the ADSP-2181 processor 15 and awaits a trigger. When triggered (ie. contact of the rod's sensing end with an object) the EPROM 16 signals the driver output amplifier 19 to generate an ultrasonic analog driver signal (20-200 kHz). The driver signal stimulates the crystal 10 to generate a mechanical pulse and send it as an acoustic incident elastic wave down the longitudinal axis of the rod 2. The incident elastic wave reflects from the object 8 at the rod's sensing end 7 and returns to the rod's driver end 3 as a reflected wave. The mechanical energy in the reflected wave stimulates the crystal 10 to generate electrical analog signals characteristic of the reflected wave. FIG. 5 illustrates typical reflected waves for plastic, aluminum and mineral (rock) objects 8.
Practically, the form of the reflected wave will have characteristics which fall between that which is received in response to either of the two boundary cases; one where there is no object; and secondly where the object is infinitely stiff.
The analog signals are processed through the signal input amplifier 18 and converted by the A/D converter 17 for analysis by the signal processor 15. A suitable A/D converter is available as model AD876 10 bit, 20 MSPS (million samples per second) CMOS converter, also from Analog Devices, Inc. The AD876 is also capable of a "sleep" mode.
The digital processor 15 stores signal and other data in its RAM memory, including the reflected wave signal. The characteristics of the reflected signal are dependant upon the material characteristics of the object 8. Different materials have different MI and frequency-dependent damping coefficients. Analysis of the reflections and damping rates demonstrated in the reflected data is instructive of the material characteristics of the object.
Accordingly, using one analytical technique, the stored data is conditioned using a stepping FFT and analyzed for frequency-time-amplitude information. A 256 point FFT from a 1024 sample is advanced in 128 sample steps which yields 7 time-slices of FF transformed data.
The characteristics distinctive of the material are generally located within the first 5-10 harmonics or bins of the transformed data. FIGS. 6,7,8 illustrate the transformed data for the signals of FIG. 5.
First, the effects of the peculiar characteristics of the rod are calibrated by causing the piezoelectric crystal to send a pulse along the rod when its sensing end is not contacting anything. This "dry-fire" provides a baseline reading which accounts for individual characteristics including the tapered point of the bar, wear, temperature, and accumulated debris. This resulting baseline power data is subtracted from the actual contact data.
Average signal frequency-time-amplitude or power data, contained within 5 frequency by 7 time slices of the FF transformed data, are compared against predetermined and stored average map values for known materials.
FIG. 9 illustrates mapped test results for a large number of samples of a variety of metals, plastic and rock, representing common conditions in landmine detection conditions. The three material types showed up as three distinct groupings with some overlap.
The processor 15 performs a comparison of a map of the transformed signal and mapped known groupings. The comparison is directed to differentiation between a first group A representing rock (excluding indistinct overlap areas), and a second group representing the plastics B', metals B" and the overlap areas. The signal processor signals the audio/visual output device 20 to signal one of two results: safe--definitely a rock, or bad/suspect--something other than a rock. Use of two distinctive audible tones and green/red LED lights serve this purpose.
Non-contact calibration can be done before each use to account for physical prodder variations. The extraction of the baseline rod characteristics heightens the sensitivity of the signal analysis, having removed a portion of the signal which is not attributable to the object. Similarly, the non-contact data can be compared against stored laboratory calibration to alert the user to performance variation beyond safe limits.
In an alternate analytical technique, some of the computing intensity required by the FFT technique can be simplified by substitution of a phase analysis technique. By mixing or multiplying non-contact wave data and the reflected wave data, the phase differences become apparent and the phase angle shifts determinable. As was the case with power data determined using FFT analysis and depicted in FIG. 9, phase angle shift analysis will result in phase shift angles which are indicative and distinctive of metals, rocks and plastics.
As introduced in the Background of the invention, at a rod-object interface, the pulse will be partially reflected and partially transmitted. As shown in FIG. 10a, if MI object >>MI rod ; then the object is very much stiffer than the rod, all of the pulse is reflected and remains in phase with the original pulse. If MI object =MI rod , the object stiffness matches that of the rod and there is no reflective interface and thus no reflection. Finally, as shown in FIG. 10b, if MI object ˜0(<<MI rod ), the object is very much more compliant than the rod, all of the pulse is reflected, but it's phase is inverted or is out of phase from the original pulse by 180° or π.
Basically, an acoustical pulse stream travels up and down the rod multiple times (pulse-echoes), interacting with the object and returning to the crystal to generate an electrical signal upon each return. A finite number of echoes are realized before the signal level is damped and drops below the noise level. Whatever the starting energy, there is an exponential decay of signal strength with time, even in the case of a non-contact. This is represented by a damping factor or relationship presented in equation (1).
|signal(f)|∞e.sup.-(df.sbsp.0.sup.t)( 1)
where f 0 is the initial frequency of the pulse (Hz); and
where df 0 is the damping factor for the pulse-echo stream.
The pulse-echoes are essentially sine-wave packets that can most easily be realized mathematically as a sine wave with time dependent phase steps (as a result of reflections at both the crystal end and the tapered end), convoluted with an envelope function that demarks the individual echoes, all multiplied by the above damping factor.
signal(t)=A.sub.0 e.sup.-df.sbsp.0.sup.t envelope(t)cos(2πf.sub.0 t+ψ.sub.i (t)) (2)
A 0 and df 0 are used to define the initial amplitude and the damping factor for a non-contact pulse-echo stream. The frequency of the pulse is f 0 (Hz or ω 0 =2πf 0 radians/s). The term ψ i (t) represents the phase shift due to the rod itself. The i subscript denotes the echo number (1 st , 2 nd , etc.). The signal(t) for an acoustic pulse-echo in a non-contact condition is shown in FIG. 11. Note the diminishing amplitude with each echo.
With a contact, the boundary condition at the rod's sensing end changes, and there is an additional phase shift term φ(t) on the pulse stream. The amplitude (A,) may also be affected, and the damping rate (df x ) will depend on the contact material and how much of the signal is transmitted into the object. Note that frequency can be represented as ω 0 =2πf 0 radians/s.
signal(t)=A.sub.x e.sup.-df.sbsp.x.sup.t envelope(t)cos(ω.sub.0 t+ψ.sub.i (t)+φ.sub.i (t)) (3)
Accordingly, equation 3 is mapped in FIG. 12 and demonstrates the signal(t) for an acoustic pulse-echo for a contact condition. Only a dramatic difference in either A x or df x or both would distinguish the signal from the non-contact case.
However, since there is at least a phase difference, the change can be made more evident by mathematical combination or mixing techniques. The non-contact pulse-echo stream contains all the phase, amplitude and damping information of the rod itself including the taper, the crystal, attachment, housing, imperfections in the rod, tip radius, temperature effects, etc. Adding the effect of an object contact to the rod's sensing end, merely adds the effect of the object's boundary condition. It is advantageous to isolate and review only the information which relates to the object.
Mixing comprises multiplying a stored, non-contact waveform with the sample (object contact) waveform and the result makes the phase differences apparent.
Having reference to FIGS. 13-16, a series of signals representing increasingly larger phase shifts per echo are depicted after having mixed them with a non-contact signal.
FIG. 13 represents the non-contact case, mixed with itself. As ψ i is unchanged and φ i =0, the mixed signal is simply the square of the original pulse-echo stream. The result is a signal with no negative component, representing a zero relative phase shift between echos; accordingly the mixed signal does not drop below zero.
FIGS. 14-16 illustrate signals for soft (plastic-like), medium (rock-like) and hard (metal-like) contacts. As shown in FIG. 14, the phase shift is represented by a small negative shift in the mixed signal. Referring to FIG. 15, as the MI of the object increases (gets harder), the mixed signal is pushed out of phase earlier as indicated by the rate at which the mixed signal goes negative. As shown in FIG. 16, at high values of MI, the rate at which the phase shifts is fast enough that the signal has time to be pushed back into phase (positive) before the signal is completely damped out.
Mathematically, the mixing of non-contact signals is represented by ##EQU1## There is a doubling of the signal frequency (cos(2ω 0 +2ψ i (t))+1), which is seen by the difference in density of the signal between FIGS. 11 and 13. Further, the damping rate is doubled. The cosine term varies from -1 to +1, thus the +1 term in the right hand term ensures a positive only signal.
With the introduction of an object with finite impedance and damping, the mixed solution is ##EQU2##
Equation (5) contains mixed amplitude, oscillatory and phase shift terms. The oscillatory part of the solution now contains a harmonic wave at twice the driver frequency (cos(2ω 0 t+2ψ i (t)+φ i (t))), plus a phase dependent term cos(φ i ) or dc shift. If φ i =0 (non-contact, FIG. 13), then the dc shift is cos(0)=1 as before. However, if there is a finite phase shift (φ i ≢0) due to the presence of an object, then the dc shift can take on any value between +1 and -1. This allows fully positive echoes (+1) through and into fully negative (-1) echoes.
For each echo, one can determine the dc shift level of the echo by integrating the signal(t) over the duration of the echo and dividing this by the duration (total time) as follows, ##EQU3## Where the i indicates the ith echo.
In order to extract the cos(φ i (t)) term, integration of the mixed x0 (t) term is required. The integration across an echo of the general mixed signal proceeds as follows, ##EQU4## The constants A x , A 0 and the 1/2 can immediately come outside the integral. Further, if one assumes that the damping during an echo is slow relative to the duration of the integral, then the exponential factor can be assumed roughly constant and also brought outside. This leaves ##EQU5## If the echo contains an integral number of wavelengths of frequency 2ω 0 , then the left term (cos(2ω 0 t+2ψ i (t)+φ i (t))) in the integrand will return zero. This leaves only the constant (over the echo) term of cos(φ i (t)). Thus, approximately, the integral, over the ith echo, evaluates to ##EQU6## Thus absolute dc is given by ##EQU7##
Substituting this result into equation (10) for the dc value of the echo, one can arrive at a proportional dc level for each echo. The proportional dc level is the dc level of the echo relative to that echo's amplitude (amplitude=1/2 of the peak-to-peak value). It is this proportional dc level that varies as the cos(φ i (t)). In fact, the φ i (t) can be determined for each mixed echo, ##EQU8##
In simpler but less rigorous terms, the cos(φ i (t)) term is related to the proportioning of the mixed signal above and below zero. The bounding examples are ##EQU9## A numerically stable and simple method for measuring the apportioning of the signal around zero is realized by integrating the positive and negative parts of the signal separately and then forming the sum and difference. The sum is simply the dc level times the echo duration. The difference is a measure of the signal size (though not simply related to the amplitude). ##EQU10## As shown in FIG. 17, this apportioning bears a resemblance to the term cos(φ i ), matching at the ends (±1) and zero, but does not follow it exactly.
In order to more closely evaluate the proportional dc, a means for determining the effective amplitude of an echo is required. The simplest means for measuring the amplitude of each purse is to find the maximum and minimum of each echo. The difference between each max-min pair is the peak-to-peak amplitude which is 2 times the amplitude. This method is sensitive to noise though, as a single spike could easily become the local maximum and minimum.
A noise tolerant method to calculate the amplitude, which involves the entire echo, is to shift out the dc, then square the result and integrate as follows: ##EQU11##
Having reference to FIGS. 18 and 19, the calculated value for the relative dc of the model is compared against the cosine of the actual phase shift introduced (3π/32) per echo.
With no noise (FIG. 18), the match of relative dc compared against cos(φ) is almost perfect. As shown in FIG. 19, even with the introduction of a 20% noise signal the tracking is still very good away from multiples of π(0,1,2, . . . ).
Applied to the signals depicted in FIGS. 14-16, the noise immunity of this method is demonstrated by adding 20% noise (by amplitude) to the signals and performing the same analysis. The result is shown in FIGS. 20-22, which continue to demonstrate the distinctive negative shift characteristic of the different materials.
EXAMPLE
Data recordings of numerous pulse-echo streams were made. The samples were digitized with 10 bits of resolution at approximately 10 times the pulse frequency. The samples were mixed with a non-contact signal and analysed as described above. Plastic, rock and metal were tested. The mixed signal results are shown in FIGS. 23-25. The phase shift versus echo number, for each of the three materials, is shown in FIG. 26. The curves for each material is fitted with a best-fit cosine function.
Following the testing of a large number of objects, it was found, not surprisingly, that plastics and light materials occupied regions of limited phase shift (Low MI), rocks generally could be classed as having a medium phase shift (Medium MI), and metals had the highest phase shift rate (High MI).
Roughly, for a retrofitted manual prodder rod, the phase shift rates per echo for the different types of materials were:
plastic-like materials 0.03-0.04 π
rock-like materials 0.055-0.09 π
metal-like materials 0.08-0.15 π(i.e. Aluminum--steel)
The overlap between rock-like and metal-like is in part due the inclusion of a piece of haematite (Fe 2 O 3 ) as a `rock`. At a further extreme, a piece of high density alumina showed a phase shift rate of 0.2 π, beyond that of steel. Accordingly, occasionally a metal-like rock would be classified as metal. This would be a fail-safe situation which can increase the false alarm rate, but does result in safety for the operator.
Therefore, despite occasional metal-like rocks which would be classified as metal, the discrimination illustrated is sufficient to distinguish between the majority of these materials.
Note that the theoretical relative dc values for a non-contact would experience no phase shift and should remain at a constant 1.0 for all echoes. The introduction of noise into the mathematical model disturbs the result near the reversal points, i.e. at 0, π, 2π, 3π, etc. Having reference to FIG. 27, it may be seen that a rod actually suffers a non-theoretical droop, representing a phase shift even in a non-contact instance. Thus the relative dc of a contact do not begin at +1 nor do they obtain a -1 at reversal. Using the non-contact droop, the contact results can be normalized and the scaling is restored to a theoretical +1 to -1 range, as shown in FIG. 28.
Further, the values for phase shift, at all frequencies, show a mild dependence upon the rod to contact application pressure. As shown in FIG. 29, a dimensionless solution for phase shift is presented for various materials over varying loads of 200-1200 grams. Generally, it is seen that phase shift is proportional to pressure. At a load of 600 grams, the interface between plastic-like and rock-like demonstrates a solution at about 2 and the interface between rock-like and metal-like is at a solution of about 8. At 200 grams the solution is about 1 and 6 respectively.
In use the digital processor stores reflected elastic wave data. The data may be that obtained from a non-contact "dry-fire" case, or from contact of the rod's sensing end with an object. Preferably non-contact calibration of the prodder rod's response alone is obtained both under ideal "factory" conditions and under field conditions, both of which involve sending an acoustic pulse along the rod when its sensing end is not contacting anything. Differences between factory and field non-contact data represent acoustical variations in the rod from new to used condition. Subtle variations are expected over time but large variations can advantageously serve to alert the user to mechanical failure such as separation of the crystal from the rod.
A field non-contact calibration can be initiated when upon powering the prodder on. The raw non-contact signals are analysed for phase shift and the resulting values are stored initially for factory case and subsequently for each field case. As stated, variations therebetween provide a basis for informing the user that the prodder has failed or is worn out.
Experimental testing for phase shift upon contact with known objects (FIG. 29) and mathematically mixing them with non-contact phase shift values provides thresholds or phase shift solution levels, for example: solution level 2 for a plastic/rock interface and level 8 for a rock/metal interface.
The solution may be conveniently be phrased in terms of the rate of change of the phase shift per echo or reflection. In FIG. 29, a solution of 2 represents the rate of change of the phase shift φ in units of 2*π/128 radians/echo.
As seen in FIG. 29, if a phase shift solution is below level 2, the signal processor can distinguish the and identify the material of the unknown object as being soft or plastic-like. If the phase shift solution is above level 8, then the signal processor can state the material is hard or metal-like.
The phase shift solution levels are stored. The experimentally determined solution levels are selected to ensure borderline cases (i.e. which "might" be a rock) are conservatively interpreted as potentially hazardous plastic or metal.
Accordingly, in operation, when an unknown object is contacted, a raw signal is stored. Values for the contact phase shift are determined. The raw phase shift values for the unknown object are mixed with the field calibration non-contact phase shift values for removal of rod effects and the phase shift is determined for obtaining a solution (rate of change of phase shift per echo). The solution is compared against the stored solution levels. Conservatively, using the above means and method, up to 50% of rocks may be deemed to be either plastic or metal. More importantly, plastic or metal (potential mines) are detected substantially 100% of the time.
In summary, the preferred operation comprises storing phase shift solution levels for known materials, obtaining a field calibration of a non-contact case and storing the phase shift values; obtaining contact data and storing the phase shift values; mixing the non-contact and contact phase shift values to obtain a solution; and comparing the solution against the stored solution levels for distinguishing safe rock-like objects from potentially hazardous plastic-like or metal-like objects.
As shown in FIG. 29, the reflected wave can be affected by the pressure of the contact with the object and thus the solution levels vary with load. Variable load can be compensated for by measuring load and applying additional signal processing to dynamically adjust the solution levels accordingly.
The solutions can be further improved by adjusting the solution levels after a field non-contact calibration, based on the variation in field and factory non-contact data.
It is further understood that alternate means exist for generating signals indicative of the reflected wave including the use of strain gauges or by providing a second piezoelectric crystal separate from the driver crystal.
Signal noise can be compensated for by producing a quick succession of pulses upon contact with the object and statistically averaging the results for the corresponding reflected waves for improving confidence in the solution. | A hand-held prodder capable of distinguishing inert rock from potentially hazardous landmines or other unknown objects. The prodder comprises a rod which is placed into contact with an unknown object. A high frequency acoustic wave is introduced into the rod and it is reflected back as an elastic wave. The wave is converted to a signal and is processed to determine values representative of the wave's phase shift, characteristic of the object. Different materials exhibit different acoustic characteristics and alter the wave's phase shift. The phase shift of the wave for an object contact is mixed with the phase shift of a wave for a non-contact for obtaining a solution which isolates the shift due to the object, less the rod's influence. By comparing the phase shift solution against pre-determined solution levels obtained from contact data for known materials, inert rocks are distinguishable from potentially hazardous plastic or metallic objects. Visual or audible signals inform the user whether a rock (safe) or an unidentified (unsafe) object was contacted. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to an electronic device, and more particularly to an electronic device for phase error detection.
[0003] 2. Description of the Related Art
[0004] Phase-locked loop (PLL) devices are applied in frequency generators, wireless receivers, communication devices and the like. A phase detector is an essential element in a PLL device as a stable, high accurate clock signal output is highly related to the accuracy of the phase error from the phase detector. Phase detectors range from very simple to complex in design. An XOR logic gate makes a passable phase detector. When the two compared signals are completely in phase, the two equal inputs to the XOR gate will output a constant level of zero. When a phase difference occurs, the XOR gate will output a “1” for the duration of the difference in phase between signals. Integration of the output signal results in an analog voltage proportional to the phase difference. A phase detector can also be made from an analog multiplier, sample and hold circuit, charge pump or a logic circuit consisting of flip-flops. These phase detectors have more desirable properties such as better accuracy at small phase differences or ability to phase lock to signals with large frequency mismatches. Although a complex phase detector generates a high accuracy phase error signal, the complex design causes unexpected errors, thus, a simple phase detector capable of performing high accuracy phase error detection method is desirable.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention provides a vernier phase error detection method comprising providing a first signal having a first cycle T 1 , wherein
[0000]
T
1
=
1
N
T
;
[0000] providing a second signal having a second cycle T 2 , wherein
[0000]
T
2
=
1
M
T
;
[0000] aligning a rising edge of the second signal with a rising edge of the first signal; when a second data sampled by the second signal is different from a first data sampled by the first signal at Xth second cycle, a phase error Ø is evaluated by the following equation:
[0000]
Ø
=
(
N
2
-
X
)
*
T
1.
[0006] The invention provides a vernier phase detector comprising an alignment unit, a first sampler, a second sampler and a processing unit. The alignment unit aligns a rising edge of a first clock signal with a rising of a second clock signal. The first sampler is controlled by the first clock signal for sampling a data signal. The second sampler is controlled by the second clock signal for sampling the data signal. The processing unit determines a phase error signal between the first clock signal and the data signal, wherein when a first data sampled by the first sampler is different from a second data sampled by the second sampler, the processing unit determining the phase error signal based on the first clock signal and the second clock signal.
[0007] The invention provides a PLL device, comprising a phase detector, a charge pump circuit, a loop filter, a voltage controlled oscillator and a feedback divider. The phase detector comprises an alignment unit, a first sampler, a second sampler and a processing unit. The alignment unit aligns a rising edge of a first clock signal with a rising of a second clock signal. The first sampler is controlled by the first clock signal for sampling a data signal. The second sampler is controlled by the second clock signal for sampling the data signal. The processing unit determines a phase error signal between the first clock signal and the data signal, wherein when a first data sampled by the first sampler is different from a second data sampled by the second sampler, the processing unit determining the phase error signal based on the first clock signal and the second clock signal. The charge pump circuit outputs a current based on the phase error signal, and the loop filter then transfers the current into a voltage. The voltage controlled oscillator outputs an output signal based on the voltage. The feedback divider receives the output signal to generate the first clock signal, wherein the output signal is multiple of the first clock signal.
[0008] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0010] FIG. 1 is a schematic diagram of an embodiment of a phase detection method of the invention.
[0011] FIG. 2 is a schematic diagram of another embodiment of a phase detection method of the invention.
[0012] FIG. 3 is a block diagram of an embodiment of a vernier phase error detector of the invention.
[0013] FIG. 4 is a block diagram of an embodiment of a PLL device of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
[0015] FIG. 1 is a schematic diagram of an embodiment of a vernier phase detection method of the invention. T D represents the period of the data signal. T 1 is the period of the first clock CLK 1 . T 2 is the period of the second clock CLK 2 . In this embodiment, T D is equal to T 1 , and T 1 is slightly different from T 2 . If the data signal is sampled at the center of each high and low level when the first clock CLK 1 and the second clock CLK 2 are aligned with each other, the data signal is locked to the first clock CLK 1 or the second clock CLK 2 . If the data signal is not sampled at the center of each high and low level when the first clock CLK 1 and the second clock CLK 2 are aligned with each other, the data signal is not locked to the first clock CLK 1 . A phase error between the data signal and the first clock CKL 1 can be detected.
[0016] With reference to FIG. 1 , T 2 is slightly longer than T 1 , so after a clock cycle, the sampling edge of the second clock CLK 2 slightly lags that of the first clock CLK 1 . The phase deviation caused by the lag is represented by Δ. After another clock cycle, the second clock CLK 2 further lags the first clock CLK 1 by 2Δ, and so on. In this embodiment, when the second clock CLK 2 lags the first clock by 13Δ, the first clock CLK 1 and the second clock CLK 2 are realigned. It can be found that T 1 /T 2 =13/14.
[0017] If the data signal is locked to the first clock CLK 1 as shown in FIG. 1 , the sampling edge of the first clock CLK 1 is at the center of the high or low level when the alignment between the first clock CLK 1 and the second clock CLK 2 occurs. In this situation, the same data value (0 or 1) is sampled by the first clock CLK 1 and the second clock CLK 2 until the phase deviation reaches 7Δ. That is, a data value transition occurs when the phase deviation increases from 6Δ to 7Δ. This is because the phase deviation of 6.5Δ is about T D /2, the second clock CLK 2 starts to sample the next value of the data signal by crossing the transition.
[0018] FIG. 2A , FIG. 2B , and FIG. 2C show the shifts of sampling edges for each clock cycle. With reference to FIG. 2A , during the clock cycle 0 , the first clock CLK 1 and the second clock CLK 2 are aligned at the center of D 0 . This is a lock status. During the clock cycle 1 , the second clock CLK 2 deviates from the first clock CLK 1 by Δ. During the clock cycle 2 , the second clock CLK 2 deviates from the first clock CLK 1 by 2Δ, and so on. During the clock cycle 7 , the second clock CLK 2 has crossed the transition edge of D 0 and D 1 , so the second clock CLK 2 samples D 1 instead of D 0 . If D 0 has a different value from D 1 during the clock cycle 7 , the first clock CLK 1 and the second clock CLK 2 will have different sampled values.
[0019] With reference to FIG. 2B , during the clock cycle 0 , the first clock CLK 1 and the second clock CLK 2 are not aligned at the center of D 0 . This is not a lock status. During the clock cycle 1 , the second clock CLK 2 deviates from the first clock CLK 1 by Δ. During the clock cycle 2 , the second clock CLK 2 deviates from the first clock CLK 1 by 2Δ, and so on. During the clock cycle 3 , the second clock CLK 2 has crossed the transition edge of D 0 and D 1 , so the second clock CLK 2 samples D 1 instead of D 0 . If D 0 has a different value from D 1 during the clock cycle 3 , the first clock CLK 1 and the second clock CLK 2 will have different sampled values.
[0020] It can be found from FIG. 2A and FIG. 2B that by detecting the number of clock cycles when the second clock CLK 2 crosses the data transition edge, one can know whether the data signal is in a lock status. If the data signal is in a lock status, the detected number of clock cycles is corresponding to T D /2. If the data signal is not in a lock status, the detected number of clock cycles is not corresponding to T D /2. The phases of the first clock CLK 1 and the second clock CLK 2 can be further adjusted to make the data signal locked by the first clock CLK 1 or the second clock CLK 2 . For example, in FIG. 2B , if the first clock and the second clock are shifted left by 4Δ, then D 0 can be sampled at the center when the first clock CLK 1 and the second clock CLK 2 are aligned.
[0021] However, T D need not be the same as T 1 . With reference to FIG. 2C , during the clock cycle 0 , the first clock CLK 1 and the second clock CLK 2 are aligned at the center of D 0 . This is a lock status. It is noted that the period of first clock CLK 1 or the second clock CLK 2 is different from that of the data signal, so that during the clock cycle 1 , both the first clock CLK 1 and the second clock CLK 2 are not at the center of D 0 , and the second clock CLK 2 deviates from the first clock CLK 1 by Δ. During the clock cycle 2 , the second clock CLK 2 deviates from the first clock CLK 1 by 2Δ, and so on. During the clock cycle M, the second clock CLK 2 has crossed the transition edge of D 0 and D 1 , so the second clock CLK 2 samples D 1 instead of D 0 . If D 0 has a different value from D 1 during the clock cycle M, the first clock CLK 1 and the second clock CLK 2 will have different sampled values. In this embodiment, during the clock cycle N, the first clock CLK 1 and the second clock CLK 2 are realigned at the center of D 1 .
[0022] FIG. 5 is a diagram showing the relationship between the data signal, the first clock CLK 1 and the second clock CLK 2 . For each clock cycle, the first clock CLK 1 gets a further phase shift T D /P with respect to the rising edge of the data signal, where P is a natural number. Similarly, for each clock cycle, the second clock CLK 2 gets a further phase shift T D /Q with respect to the rising edge of the data signal, where Q is a natural number. That is, for each clock cycle, the second clock CLK 2 gets a further phase shift T D /Q−T D /P with respect to the first clock CLK 1 . Every P first clock cycles (or every Q second clock cycles), the first clock CLK 1 and the second clock CLK 2 are realigned. If the realignment occurs at the center of the high level or low level of the data signal, it is a lock status. It is preferred that P and Q are relatively prime. One convenient embodiment is Q=P+1 or P−1. However, even if P and Q are not relatively prime, the first clock CLK 1 and the second clock CLK 2 will eventually be realigned. The realignments can be detected to determine whether a lock status is reached.
[0023] FIG. 3 is a block diagram of an embodiment of a vernier phase error detector. The vernier phase error detector 30 comprises a first sampler 31 , a second sampler 32 , an aligning unit 33 , and a processing unit 36 . The aligning unit 33 outputs the first clock CLK 1 and the second clock CLK 2 to sample the data signal. The aligning unit 33 also determines the time when the first clock CLK 1 and the second clock CLK 2 are aligned. The processing unit 36 determines a phase error according to the first sampled value (sampled by the first clock CLK 1 ), the second sampled value (sampled by the second clock CLK 2 ), and the alignments of the first clock CLK 1 and the second clock CLK 2 . The vernier phase error detector 30 can further comprise a first buffer for storing the first sampled value and a second buffer for storing the second sampled value.
[0024] FIG. 4 is a block diagram of an embodiment of a PLL device of the invention. The PLL comprises a phase error detector 41 , a charge pump circuit 42 , a loop filter 43 , a voltage-controlled oscillator 44 and a feedback divider 45 . The phase error detector 41 is described in FIG. 3 , for brevity, description of like structures are omitted. The charge pump circuit 42 converts a phase error signal from the phase error detector 41 into a charge current for charging or discharging the loop filter 43 . The loop filter 43 limits the rate of charge of a capacitor therein to generate a voltage corresponding to the phase error signal, and the voltage-controlled oscillator 44 then generates an output signal based on the voltage. The feedback divider 45 receives the output signal to generate a first clock signal CLK 1 , wherein the frequency of the output signal is multiple of the frequency of the first clock signal. In this embodiment, the frequency of the output signal is also a multiple of the frequency of the second clock. In another embodiment, the second clock signal is also generated by the feedback divider 45 .
[0025] While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | A vernier phase error detection method is provided. The method comprises providing a first signal having a first cycle T 1, wherein T 1 =1/N T; providing a second signal having a second cycle T 2, wherein T 2 =1/M T; aligning a rising edge of the second signal with a rising edge of the first signal; when a second data sampled by the second signal is different from a first data sampled by the first signal at the Xth second cycle, a phase error Ø is evaluated by the following equation: Ø=(N/2−X)*T 1. | 7 |
FIELD OF THE INVENTION
The present invention relates to frequency acquisition in general and to frequency acquisition in the presence of high power adjacent channels, in particular.
BACKGROUND OF THE INVENTION
Reference is now made to FIGS. 1A and 1B. FIG. 1A is a schematic illustration of frequency versus power, describing the initial stage of a initial frequency synchronization procedure, known in the art. The present example describes a closed loop automatic frequency control (AFC) mechanism.
FIG. 1B is a schematic illustration of frequency versus power, describing the final stage of the initial frequency synchronization procedure of FIG. 1 A.
Arrow 14 represents the frequency of a mobile unit which detects and attempts to lock and synchronize with the carrier frequency 10 of a base unit transmitter having a value of F BASE , which is located near by. In the present example the mobile unit further detects a carrier frequency 12 provided by a neighbor transmitter, having a value of F NEIGHBOR . The value of the mobile unit F MOBILE is located between the values of the base unit frequency F BASE and the neighbor mobile transmitter frequency F NEIGHBOR .
In the present example the mobile unit 14 detects the signals provided by base 10 and the neighbor 12 wherein the received power of the neighbor 12 is higher than the received power of the base unit 10 .
According to conventional initial synchronization procedures, the mobile unit frequency is synchronized with the frequency having the highest received power, which in the present example is the neighbor frequency 12 .
It will be noted that often the received frequencies are filtered so as to exclude undesired signals. Such a filter is represented by arc 16 . These techniques often fail when the power of the undesired signal is significantly high.
Accordingly the synchronization mechanism of the mobile unit sets synchronization path towards the neighbor frequency F NEIGHBOR and starts progressing its frequency 14 towards F NEIGHBOR . Finally the synchronization mechanism allows the frequency of the mobile unit 14 to acquire and synchronize with the frequency of the neighbor unit 12 . This is shown in FIG. 1B by aligning line 12 and arrow 14 . As can be seen, at this stage the frequency 10 of the base transmitter is filtered out by the filter 16 .
A conventional synchronization mechanism provides frequency shifts within a limited range, determined by its structure, such as VCO voltage and the like. It will be appreciated by those skilled in the art that the F NEIGHBOR can be located outside this range. in such a case, F MOBILE , might get stuck at the boundary frequency value which is closest to F NEIGHBOR .
It will be appreciated by those skilled in the art that such situations, where the frequency of the mobile unit 14 is synchronized with the frequency of neighbor unit 12 instead of the frequency of the base unit 10 , is not acceptable.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide a novel method for performing accurate initial frequency acquisition in the presence of high power adjacent channels.
It is a further object of the present invention to provide a novel device for performing accurate initial frequency acquisition in the presence of high power adjacent channels.
In accordance with the present invention there is thus provided a method for acquiring frequency of a desired channel having a carrier frequency F MAIN , for a dynamic receiver frequency F MOBILE , from a starting frequency F START , in the presence of high power adjacent interfering channels.
The starting frequency F START is shifted from F MAIN by not more than a predetermined frequency gap ΔF. The method includes the steps of:
determining a first frequency boundary and a second frequency boundary;
detecting channels within a filtering bandwidth;
selecting a dominant channel from the detected channels;
progressing the dynamic receiver frequency F MOBILE towards the carrier frequency of the dominant channel;
detecting when the step of progressing has exceeded one of the first frequency boundary and the second frequency boundary;
restarting the step of detecting channels, from the other of the one of the first frequency boundary and the second frequency boundary; and
repeating from the step of detecting channels.
According to another aspect of the present invention, one of the first frequency boundary and the second frequency boundary is F START −ΔF, while the other is F START +ΔF.
The method of the invention can also include the step of determining a frequency advance direction. The frequency advance direction can be fixed at the beginning of each frequency acquisition cycle, wherein the frequency acquisition cycle is determined from the point where F MOBILE shifts from F START until the point where F MOBILE returns to F START .
The step of progressing can be performed in a frequency step F STEP . The value of the frequency step F STEP can be infinitesimal with comparison to the predetermined frequency gap ΔF, or adjustable. Accordingly, the method can further include the step of adjusting the frequency step F STEP after each step of detecting channels.
In accordance with another aspect of the present invention, there is provided a device for acquiring frequency of a desired channel having a carrier frequency F MAIN , for a dynamic receiver frequency F MOBILE , from a starting frequency F START , in the presence of high power adjacent interfering channels.
The device is connected to an antenna via a receiver and to a reference frequency F REFERENCE source. The device includes controllable frequency generating means for generating an internal frequency F INTERNAL , frequency shift means connected to the controllable frequency generating means, and to the receiver, for shifting received frequency F RECEIVED , of a received channel, according to the internal frequency F INTERNAL .
The device also includes a frequency shift detector, connected to the frequency shift means, for detecting a frequency difference between the internal frequency F INTERNAL and the received frequency F RECEIVED , with respect to the reference frequency F REFERENCE , thereby producing a frequency shift value F SHIFT .
The device further includes loop filtering means, connected to the frequency shift detector, for filtering the frequency shift value F SHIFT , thereby producing a filtered frequency shift value F SHIFT-FILTERED , and controlling means, connected to the controllable frequency generating means and to the loop filtering means, for determining a frequency step F STEP from the filtered frequency shift value F SHIFT-FILTERED .
The controlling means provide the frequency shift value F SHIFT to the controllable frequency generating means. The controllable frequency generating means adjust the internal frequency F INTERNAL according to the frequency shift value F SHIFT , and the controlling means control the controllable frequency generating means to generate frequency in a range from a first frequency boundary F FIRST and a second frequency boundary F SECOND .
According to one aspect of the invention, the controlling means set the frequency shift value F SHIFT to be F SECOND −F INTERNAL , when |F INTERNAL −F START |>|F INTERNAL −F FIRST | while the controlling means set the frequency shift value F SHIFT to be F FIRST −F INTERNAL , when |F INTERNAL −F START |>|F INTERNAL −F SECOND |.
According to another aspect of the invention, the device further includes frequency filtering means, connected between the frequency shift detector and frequency shift means.
The controlling means reset the loop filtering means when setting the frequency shift value F SHIFT to be F SECOND −F INTERNAL or F FIRST −F INTERNAL .
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:
FIG. 1A is a schematic illustration of frequency versus power, describing the initial stage of a conventional initial frequency synchronization procedure;
FIG. 1B is a schematic illustration of frequency power, describing the final stage of the initial frequency synchronization procedure of FIG. 1 A.
FIG. 2A is a schematic illustration of frequency versus power, describing the initial stage of a frequency synchronization procedure, operative in accordance with the present invention;
FIG. 2B is a schematic illustration of frequency versus power, describing the secondary stage of a frequency synchronization procedure, operative in accordance with the present invention;
FIG. 2C is a schematic illustration of frequency versus powers describing the third stage of a frequency synchronization procedure, operative in accordance with the present invention;
FIG. 2D is a schematic illustration of frequency versus power, describing the final stage of a frequency synchronization procedure, operative in accordance with the present invention;
FIG. 2E is a schematic illustration of frequency versus power, describing the third stage of a frequency synchronization procedure, operative in accordance with another aspect of the present invention;
FIG. 2F is a schematic illustration of frequency versus power, describing the final stage of a frequency synchronization procedure, operative in accordance with another aspect of the present invention;
FIG. 3 is a schematic illustration of a device for synchronizing frequencies, constructed and operative in accordance with another preferred embodiment of the invention;
FIG. 4 is a schematic illustration of a method for operating the device of FIG. 3, operative in accordance with a further embodiment of the invention;
FIG. 5A is a schematic illustration of a method for operating the device of FIG. 3, operative in accordance with yet another embodiment of the invention; and
FIG. 5B is a schematic illustration in detail of a step of the method of FIG. 5 A.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention overcomes the disadvantages of the prior art by providing a frequency detect and fold mechanism. Accordingly, when the frequency shift exceeds a boundary value, then a predetermined frequency shift is enforced.
Reference is now made to FIGS. 2A, 2 B, 2 C and 2 D. FIG. 2A is a schematic illustration of frequency versus power, describing the initial stage of a frequency synchronization procedure, operative in accordance with the present invention. FIG. 2B is a schematic illustration of frequency versus power, describing the secondary stage of a frequency synchronization procedure, operative in accordance with the present invention. FIG. 2C is a schematic illustration of frequency versus power, describing the third stage of a frequency synchronization procedure, operative in accordance with the present invention. FIG. 2D is a schematic illustration of frequency versus power, describing the final stage of a frequency synchronization procedure, operative in accordance with the present invention.
The schematic illustration provided by FIG. 2A describes the frequency 100 of a base station, having a value F BASE , a frequency 104 of a mobile unit, having an initial value F 0 MOBILE , and a frequency 102 of a neighbor transmitter, having the value of F 0 NEIGHBOR , wherein
F BASE °F MOBILE <F NEIGHBOR .
In conventional communication standards, such as AMPS, NAMPS, JTACS, NTACS, USDC-TDMA and the like, the initial value of F 0 MOBILE of the mobile unit frequency 104 can be shifted from the value F BASE of the base station frequency 100 , by no more than a predetermined frequency gap ΔF. Another condition set by these standards is that any neighbor transmitter will transmit in a frequency F NEIGHBOR , which is considerably shifted from F BASE . Accordingly |F BASE −F NEIGHBOR |>2ΔF.
The method of the present invention generally searches the received spectrum within a frequency range of [F 0 MOBILE −ΔF, F 0 MOBILE +ΔF], for stabilized frequency values.
According to the invention, at the initial stage (i.e., at frequency F 0 MOBILE ) the mobile unit detects all of the signals of transmitters in its vicinity and detects the frequency of the signal with the highest received power, which in the present example is the neighbor transmitted frequency 102 . Accordingly, the mobile unit commences shifting its frequency 104 from the value of F 0 MOBILE , towards the value F NEIGHBOR of neighbor transmitter frequency 102 .
The present invention makes use of the above limitations, of conventional communication standards, which outline that the initial value F 0 MOBILE of the mobile unit frequency 104 has to be within a frequency gap of ΔF from the value F BASE , of the base transmitter frequency 100 .
Accordingly, any shift from the initial stage F 0 MOBILE , cannot exceed the value of ΔF. After the frequency 104 of the mobile unit has progressed towards the neighbor transmitter frequency 102 value F NEIGHBOR , by a frequency shift 110 , having a value of ΔF, to the value F 1 MOBILE , then, according to the invention, any further progress in this direction would result in a detection error and hence, should not be pursued.
At this stage, the present invention determines a reversed path 112 for frequency 104 (FIG. 2C) for shifting frequency 104 from the value of F 1 MOBILE to the value of F 2 MOBILE wherein the shift value of this reverse path 112 , is a frequency gap which is twice the value of ΔF.
At the final stage (FIG. 2D) the spectrum is searched, thereby detecting the base frequency 100 as the dominant signal. Accordingly, the mobile unit 104 commences shifting its frequency towards base frequency 100 , from the value of F 2 MOBILE to F BASE . This shift is shown by path 114 . According to the present example, no direction is enforced for path 114 .
It will be noted that applying a filter, such as filter 106 , improves the performance of an initial synchronization process, according to the invention. As illustrated in FIG. 2C, as long as the filter size is less than |F BASE −F NEIGHBOR |×2, (provided that the filter is generally symmetrical), wherein F NEIGHBOR is not a high power signal, then, F NEIGHBOR would not be detected as a major signal by the receiver of the mobile unit, in the original direction of progress.
Reference is now made to FIG. 3 which is a schematic illustration of a device for synchronizing frequencies, generally referenced 200 , constructed and operative in accordance with another preferred embodiment of the invention.
Device 200 includes a frequency shift unit 202 , an inter-mediate frequency (I.F.) filter 204 connected to the frequency shift unit 202 , a frequency shift detector 206 connected to the I.F. filter 204 , a loop filter 208 connected to the frequency shift detector 206 , a non-linear controller 210 connected to the loop filter 208 , and a voltage control oscillator (VCO) 212 , connected to the non-linear controller 210 and to the frequency shift unit 202 . It will be noted that VCO 212 can be replaced with any type of controlled oscillator. The frequency shift unit 202 is further connected to an antenna 220 . The frequency shift detector 206 is further connected to a host 222 . The host 222 provides a reference frequency value to the frequency shift detector 206 .
The antenna 220 detects frequency signals of neighbor transmitters wherein one of these detected frequency signals is transmitted by a base station. The antenna 220 provides these received frequency signals to the frequency shift unit 202 . The VCO 212 generates a signal having a frequency and provides it to frequency shift unit 202 .
Frequency shift unit 202 shifts frequencies, received from antenna 220 , according to the frequency provided by the VCO and provides the results to the I.F. filter 204 . The I.F. filter 204 filters some of these frequencies and provides the remaining ones to the frequency shift detector 206 . The frequency shift detector 206 attempts to detect the frequency shift of each of these shifted frequencies from the reference frequency value, provided by the host 222 .
Accordingly, the frequency shift detector 206 determines a frequency shift value and provides it to the loop filter 208 . The loop filter 208 includes the history of the frequency shifts performed by device 200 and accordingly determines a frequency shift direction and provides it with the frequency shift value to the non-linear controller 210 .
The non-linear controller 210 detects if the overall shift, up until this stage has exceeded the value of ΔF. If so, then the non-linear controller 210 provides VCO 212 with the command to generate a reversed frequency shift such as the one according to path 112 (FIG. 2 C). If not, then the non-linear control 210 provides the VCO 212 with a frequency shift value and a frequency shift direction for further shifting the frequency towards the most dominant received frequency. Then the VCO 212 provides a new shift frequency to the frequency shift unit 202 and the process is repeated from the beginning.
It will be noted that when using a slow loop filter, such as software implemented loop filter, it would be difficult for such a loop filter to process a considerable shift such as the one defined by path 112 , since such shifts are compared to frequency behavior history contained therein.
According to a further aspect of the invention, when the non-linear controller 210 determines a 2ΔF shift, it also sends a clear command back to the loop filter 208 , thereby erasing the frequency history contained in the memory of loop filter 208 . This operation enables the loop filter 208 to further process considerable frequency shifts.
It will be noted that the terms base, mobile and neighbor are presented as a matter of convenience only. The present invention is applicable for any type of initial frequency acquisition in the presence of a high power adjacent channels, wherein the base of the above example is assigned to a main transmitter, the mobile of the above example is assigned to a receiver and the neighbor of the above example is assigned to an adjacent interfering transmitter.
It will be noted that each of the main transmitter, the adjacent transmitter and the receiver may be implemented for a mobile unit, a base unit and the like.
Reference is now made to FIG. 4 which is a schematic illustration of a method for operating the device 200 of FIG. 3, operative in accordance with a further embodiment of the invention.
In step 300 , the device 200 stores the value F 0 of the internal initial frequency F. F 0 is used to determine, later on, the total amount of shift from the initial frequency. It will be noted that for this purpose, the device 200 can store and accumulate the values of the later frequency shifts, instead.
In step 302 , the device 200 detects incoming frequency signals.
In step 304 , the device 200 filters the incoming frequency signals, thereby obtaining selected frequencies.
In step 306 , the device 200 determines a target frequency value F TARGET , from the selected frequencies. In the present example (FIG. 2 A), the device 200 (FIG. 3) selects the right side signal 102 (F NEIGHBOR ), as the target frequency F TARGET .
In step 308 , the device 200 progresses the internal frequency F towards the target frequency F TARGET by a predetermined frequency step F STEP . It will be noted that F STEP can be determined using a range of considerations, such as speed, accuracy and the like. In general, F STEP is determined to be significantly smaller than ΔF, thereby yielding higher accuracy. It will further be noted that F STEP can be infinitesimal thereby yielding an analog like behavior.
In step 310 , the device 200 detects if the internal frequency F was shifted beyond a gap of ΔF. If so, then the device 200 proceeds to step 312 . Otherwise, the device 200 proceeds to step 314 .
In step 312 , the device 200 reverses F by 2ΔF. In the present example (FIG. 2 C), reverse path 112 , describes such a reverse shift, from the value of F 1 MOBILE to the value of F 2 MOBILE . Then, the device 200 repeats the steps of the above method, from step 302 .
It will be noted that at this stage, signal 102 appears to be outside of the filtering bandwidth of filter 106 , thereby leaving the base station frequency signal 100 , the strongest, at the output of filter 106 . Accordingly, the device 200 determines F BASE as F TARGET .
In step 314 , the device 200 detects if the internal frequency F is synchronized with the target frequency F TARGET . If so, then the device 200 has completed the initial frequency acquisition procedure and accordingly, locks the frequency F (step 316 ). Otherwise, the device 200 repeats the steps of the above method, from step 302 .
The method of FIG. 4 overcomes a situation where there exists interfering neighbor frequencies such as F NEIGHBOR (reference numeral 102 ) on one side of the spectrum.
In a situation where there exist interfering neighbor frequencies on both sides of the base frequency F BASE , the present invention provides a slightly different solution, as will be disclosed hereinbelow.
Reference is now made to FIGS. 2E and 2F. FIG. 2E is a schematic illustration of frequency versus power, describing a stage of a frequency synchronization procedure, operative in accordance with another aspect of the present invention. FIG. 2F is a schematic illustration of frequency versus power, describing a final stage of a frequency synchronization procedure, operative in accordance with another aspect of the present invention.
According to the present example, there exists an additional neighbor frequency 120 having a value of F* NEIGHBOR , on the left side of the base frequency 100 F BASE . When the mobile frequency completes the 2ΔF frequency shift 112 , additional neighbor frequency 120 falls within the filtering bandwidth of filter 106 , together with base frequency 100 .
It will be noted that if, at the output of filter 106 , the signal of the additional neighbor frequency 120 appears to be stronger than the signal of the base frequency 100 , then, according to the method of FIG. 3, the mobile frequency 104 would be drawn towards the additional neighbor frequency 120 .
According to another aspect of the present invention, the initial direction set forth in the second stage (i.e., the direction of frequency shift 110 , (FIG. 2 B)), is stored. In the present example, this direction is from left to right.
Then, after the mobile frequency completes the 2ΔF frequency shift 112 , the acquisition mechanism continues searching in that initial direction, only. It will be noted that such forced search direction provides an accurate acquisition of the desired base frequency, in one or less search cycle.
In a more detailed form, at the final stage (FIG. 2F) the spectrum is searched again in the direction set forth in the initial stage (i.e., the direction of shift 110 ), thereby detecting the base frequency 100 as the dominant signal. Accordingly, a path 122 is set towards base frequency 100 , for shifting mobile frequency 104 from the value of F 2 MOBILE to F BASE .
It will be noted that the present invention provides a search shift step which can be calibrated at each search stage. For example, on the one hand, in the presence of a powerful additional neighbor 120 , frequency shift 122 may include a large number of infinitesimal frequency shift steps. Otherwise, frequency shift 122 may include a small number of larger frequency shift steps.
Reference is now made to FIGS. 5A and 5B. FIG. 5A is a schematic illustration of a method for operating the device 200 of FIG. 3, operative in accordance with yet another embodiment of the invention. FIG. 5B is a schematic illustration in detail of step 406 of the method of FIG. 5 A.
In step 400 , the device 200 stores the value F 0 of the internal initial frequency F.
In step 402 , the device 200 detects incoming frequency signals.
In step 404 , the device 200 filters the incoming frequency signals, thereby obtaining selected frequencies.
In step 406 , the device 200 determines frequency step F STEP and a frequency advance direction, in a way which is described in detail in FIG. 5 B.
In step 418 , if the detection performed according to step 402 is the first detection in the current acquisition cycle, then the device 200 proceeds to step 420 . Otherwise, the device 200 proceeds to step 408 .
In step 420 , the device 200 determines an initial advance direction which will be constant during the present acquisition cycle, and proceeds to step 408 .
In step 408 , the device 200 progresses the internal frequency F by frequency step F STEP , in the advance direction.
In step 410 , the device 200 detects if the internal frequency F was shifted beyond a gap of ΔF. If so, then the device 200 proceeds to step 412 . Otherwise, the device 200 proceeds to step 414 .
In step 412 , the device 200 reverses F by 2ΔF. In the present example (FIG. 2 E), reverse path 112 , describes such a reverse shift, from the value of F 1 MOBILE to F 2 MOBILE . Then, the device 200 repeats the steps of the above method, from step 402 .
It will be noted that at this stage, additional neighbor frequency signal 120 falls within the filtering bandwidth of filter 106 , which poses a problem if additional neighbor frequency signal 120 appears stronger than the base station signal 100 , at the output of filter 106 .
Referring now to FIG. 5B, the device 200 determines a target frequency value F TARGET from the selected frequencies (step 430 ). In the present example, when the mobile frequency is at a value of F 0 MOBILE (FIG. 2 A), the device 200 (FIG. 3) selects the right side signal 102 (F NEIGHBOR ), as the target frequency F TARGET . Alternatively, when the mobile frequency is at a value of F 2 MOBILE (FIG. 2 E), the device 200 (FIG. 3) selects the left side signal 120 (F* NEIGHBOR ), as the target frequency F TARGET .
In step 432 , if the detection performed according to step 402 is the first detection in the current acquisition cycle, then, the device 200 proceeds to step 440 . Otherwise, the device 200 proceeds to step 434 .
In step 434 , the device 200 determines an advance direction from the mobile frequency value F and the target frequency value F TARGET .
In step 436 , if the advance direction determined in step 434 is equal to the initial advance direction, determined in step 420 , then the device 200 proceeds to step 440 . Otherwise, the device 200 proceeds to step 438 . It will be noted that a situation where these directions are not equal occurs, for example, when a neighbor signal, such as the one of additional neighbor frequency 120 , appears to be stronger than the signal of the base frequency 100 , at the output of the filter 106 .
In step 440 , the device 200 determines the frequency step F STEP according to the position of F and F TARGET . In the present example, F STEP ≦|F-F TARGET |.
In step 438 , the device 200 determines the advance direction to be the initial advance direction.
In step 442 , the device 200 determines the frequency step F STEP relatively small. It will be noted that, according to the present example, the size of F STEP is smaller, compared to the size of ΔF.
Referring back to FIG. 5A, wherein if the device 200 detects if the internal frequency F is synchronized with the target frequency F TARGET (step 414 ), then the device 200 proceeds to step 416 and locks F. Otherwise, the device 200 repeats the steps of the above method, from step 402 .
Hence, the method of FIGS. 5A and 5B overcomes a situation where there exist interfering neighbor frequencies such as F NEIGHBOR (reference numeral 102 ) and F* NEIGHBOR (reference numeral 120 ) on either side of the F BASE .
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the claims which follow. | Method for acquiring frequency of a desired channel having a carrier frequency F MAIN , for a dynamic receiver frequency F MOBILE , from a starting frequency F START , in the presence of high power adjacent interfering channels, wherein the starting frequency F START is shifted from F MAIN by not more than a predetermined frequency gap ΔF, the method includes the steps of determining a first frequency boundary and a second frequency boundary, detecting channels within a filtering bandwidth, selecting a dominant channel from the detected channels, progressing the dynamic receiver frequency F MOBILE towards the carrier frequency of the dominant channel, detecting when the step of progressing has exceeded one of the first frequency boundary and the second frequency boundary, restarting the step of detecting channels, from the other of the one of the first frequency boundary and the second frequency boundary, and repeating from the step of detecting channels. | 7 |
FIELD OF THE INVENTION
The present invention relates to lamps, and in particular to a head mount lamp seat comprises a pivotal unit, a movable unit and a rotary unit; wherein the movable unit is rotatably connected to one end of the pivotal unit; and another end of the pivotal unit is rotatably connected to the rotary unit. A lamp is installed to the rotary unit. The rotary unit is rotatable horizontally with respect to another end of the movable unit.
BACKGROUND OF THE INVENTION
Referring to FIG. 9 , a conventional head mount lamp seat is illustrated. The prior art has a pivotal unit 81 and a retaining strip 14 . A lamp 82 is fixed to a cap 91 . The cap 91 is worn by people. In the prior art, the lamp 82 is only adjustable within a small range to a fourth position P 4 . It cannot be adjusted rightwards or leftwards or rearwards. Thereby the use of the prior art head mount lamp seat is limited.
SUMMARY OF THE INVENTION
Accordingly, the primary object of the present invention is to provide a head mount lamp seat which comprises a pivotal unit, a movable unit and a rotary unit; wherein the movable unit is rotatably connected to one end of the pivotal unit; and another end of the pivotal unit is rotatably connected to the rotary unit; a lamp is installed to the rotary unit; the rotary unit is rotatable horizontally with respect to the another end of the movable unit.
The various objects and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the present invention.
FIG. 2 is a schematic view about the first embodiment of the present invention.
FIG. 3 is a schematic view about the second embodiment of the present invention.
FIG. 4 is a first schematic view showing the operation of FIG. 2 .
FIG. 5 is a second schematic view about the operation of FIG. 2 .
FIG. 6 is a third schematic view about the operation of FIG. 2 .
FIG. 7 is a fourth schematic view about the operation of FIG. 2 .
FIG. 8 is a schematic view of the third embodiment of the present invention.
FIG. 9 is a schematic view of a prior art structure.
DETAILED DESCRIPTION OF THE INVENTION
In order that those skilled in the art can further understand the present invention, a description will be described in the following in details. However, these descriptions and the appended drawings are only used to cause those skilled in the art to understand the objects, features, and characteristics of the present invention, but not to be used to confine the scope and spirit of the present invention defined in the appended claims.
With reference to FIGS. 1 , 2 and 3 , the head mount lamp seat of the present invention is illustrated. The present invention has the following elements.
A pivotal unit 10 has the following elements.
A pivotal element 11 is included. In this the present invention, preferably, the pivotal unit 10 is a pair of pivotal ear portion. A connecting seat 12 serves for fixing the pivotal element 11 and for connecting a cap 91 or a head mount 92 (referring to FIG. 8 ). The connecting seat 12 is formed with a pair of connecting ears 13 . A retaining strip 14 passes through the connecting ears 13 so that the pivotal unit 10 can retain the cap 91 or the head mount 92 rapidly.
A movable unit 20 includes the following element:
A connecting sheet 21 has two ends. A first movably portion 22 is installed at one end of the rod 21 .
The first movably portion 22 has an approximate round shape. The first movably portion 22 is pivotally installed to the pivotal element 11 so that the movable unit 20 is pivoted to the pivotal unit 10 by the pivotal element 11 .
A first retaining unit 40 is installed to the first movably portion 22 . The first retaining unit 40 has the following elements.
A spring 41 is included. Two first teeth disks 42 are installed to two ends of the spring 41 . Each first teeth disk 42 has a first teeth portion 421 facing toward the spring 41 . Two second teeth disks 43 are installed at outer sides of the two first teeth disks 43 . Each second teeth disk 43 has a second teeth portion 431 facing toward the first teeth disk 42 . A stud 44 passes through the pivotal element 11 , the spring 41 , the two first teeth disks 42 and the two second teeth disks 43 . A nut 45 screws with the stud 44 so as to compress the pivotal element 11 , spring 41 , two first teeth disks 43 and two second teeth disks 43 . Thereby the first teeth disks 42 are engaged to the second teeth disks 43 .
A second movable portion 23 is installed at another end of the connecting sheet 21 . The second movable portion 23 has an approximate round shape. A second retaining unit 40 is installed to the second movable portion 23 . The structure of second retaining unit 40 is identical to the first retaining unit 40 .
A rotary unit 30 is included. The second movable portion 23 serves to make the movable unit 20 to swing along the rotary unit 30 . The rotary unit 30 has the following elements.
A body is included.
A pivotal portion 31 is included. In this embodiment, the pivotal portion is a pair of pivotal ears. Thereby the rotary unit 30 can be installed to the second movable portion 23 .
A rotary teeth surface 32 protrudes from the body and has an axial hole 321 .
A sliding path 33 is a concave path in the body and arranged approximately around the rotary teeth surface 32 .
A retaining seat 34 serves for connecting a lamp 94 .
A fixed teeth surface 35 is corresponding to the rotary teeth surface 32 . The fixed teeth surface 35 is installed below the retaining seat 34 and around the axial hole 321 . Thereby the retaining seat 34 is rotatable continuously or step by step with respect to the rotary teeth surface 32 .
An auxiliary unit 36 is installed below the retaining seat 34 with respect to the sliding path 33 .
Referring to FIG. 4 , the movable unit 20 swings to a first position P 1 around the pivotal element 11 of the pivotal unit 10 by the first movably portion 22 thereof. The pivotal portion 31 of the rotary unit 30 is rotatable around 360 degrees around the second movable portion 23 of the movable unit 20 . The headlight 94 at the first position can illuminate from the front end to the rear end (the rotation range can be greater than that illustrated in the drawings).
Referring to FIG. 5 , the movable unit 20 swings to a second position P 2 from the first position P 1 , the pivotal portion 31 of the rotary unit 30 is rotatable around 360 degrees around the second movable portion 23 of the movable unit 20 . Thereby by adjusting the movable unit 20 , the headlight 94 can move forwards so as to illuminate farther places. In the second position P 2 , the headlight 94 can illuminate from the front end to the rear end (the rotation range can be greater than that illustrated in the drawings).
Referring to FIG. 6 , when the movable unit 20 swings to a third position P 3 from the second position P 2 , the pivotal portion 31 of the rotary unit 30 is rotatable through 360 degrees around the second movable portion 23 of the movable unit 20 . In the third position P 3 , the headlight 94 is placed at a near place. In the second position P 3 , the headlight 94 can illuminate from the front end to the rear end (the rotation range can be greater than that illustrated in the drawings).
Referring to FIG. 7 , when the movable unit 20 swings to any position around the first movably portion 22 on the pivotal element 11 of the pivotal unit 10 , the fixed teeth surface 35 and the auxiliary unit 36 are rotatable horizontally. The headlamp 94 is driven to rotate horizontally through 360 degrees on the pivotal unit 10 . The illumination range is from left to right, from near side to far side.
Thereby as shown in FIGS. 3 and 8 , the rotary seat 34 is transversally fixed to the cap 91 , which can be adjusted to have will illumination range as a ball surface.
The present invention is 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 present 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 head mount lamp seat comprises a pivotal unit, a movable unit and a rotary unit; wherein the movable unit is rotatably connected to one end of the pivotal unit; and another end of the pivotal unit is rotatably connected to the rotary unit; and a lamp is installed to the rotary unit. The rotary unit is rotatable horizontally with respect to the another end of the movable unit. | 5 |
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/290,823, filed May 14, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to biopharmaceutical and nutritional products obtained from human milk and mammary gland secretions. More particularly, the present invention relates to methods of isolating, storing, transferring, processing, packaging and delivering pharmaceutical and nutritional formulations comprising cells and tissues of human milk, fractionated human milk components and specifically reunited components of human milk. One embodiment of the present invention relates to improving the nutrition of low birth weight infants. Another embodiment of the present invention relates to a novel type of immunoglobulin useful in treating disorders, such as, for example, cancer, immune disorders, gastrointestinal disorders, nutritional disorders and metabolic disorders.
BACKGROUND OF THE INVENTION
[0003] The lack of a standardized source of human milk, available for research purposes, has seriously hampered scientific investigation of human milk as well as the majority of the nearly 4,000 unique, species-specific milks. Accordingly, it would be desirable to provide a standardized source of human milk that can be modified to reflect the various stages of lactation and various immune responses.
[0004] Although the presence of immunoglobulins in human milk has been acknowledged for a number of years, the specific role and function of each of the human milk immunoglobulins and their subclasses has been poorly understood. For the patient of any age suffering from an immune disorder, the worldwide gamma globulin shortage is impacting care to such a degree that some patients are unable to obtain treatment. Purified immunoglobulins from human milk hold the potential for a solution for this worldwide shortage. Accordingly, it would be desirable to provide formulations comprising higher levels of immunoglobulins isolated from human milk, as well as methods to deliver these formulations to patients.
[0005] It has been known for a long time by physicians, scientists and nutritionists that the best food or nutrition supplied to an infant is its own mother's milk, i.e., fresh human milk. Recent research has indicated that “species-specific” milk plays a significant role in disease prevention and the severity of disease when the infant does become ill. Until recently, the reasons behind the superiority of species-specific milk were not well understood, nor were the various components and the roles they play in development and disease prevention. It is recognized, however, that many situations arise wherein the infant cannot obtain its mother's milk and as a result a suitable replacement is desired. Artificial baby milks, predominantly based on cow's milk, have been prepared and used to nourish an infant but there is increasing evidence that infants fed artificial baby milks suffer long-term ill consequences. It has been suggested that the exposure of an infant to any foreign proteins, such as the bovine protein, during the first few days of life will increase the infant's chance of becoming afflicted with juvenile diabetes. Other ill effects include allergies, lowered immunity, gastrointestinal disorders, respiratory disease and other associated etiology. Although much effort has been made to improve synthetic infant milk formulas, attempting to make them more closely simulate mother's milk, the presence of living organisms and other “species-specific” cells that act in a way to trigger other disease preventing mechanisms in the infant, these efforts have proven futile.
[0006] According to Jenness and Sloan, human milk contains three major groups of constituents that carry strong “species-specific” and “organ-specific” missions: (1) constituents specific to both organ and species, including proteins and lipids; (2) constituents specific to organ but not species, including lactose; and (3) constituents specific to species but not to organ, including albumin and some immunoglobulins.
[0007] Human milk is not a uniform body fluid; instead, it is a secretion from the mammary gland of constantly changing composition. In nature, the composition of human milk changes not only from day to day, but also throughout the course of a single day. While the reasons and outcome of these changes are not fully understood, it is intuitive to believe that these changes benefit the species and that substantial advantages may be gained for the infant who is provided an opportunity to reap the benefits of a modified formulation of 100% human milk. Accordingly, it would be desirable to provide formulations comprising human milk proteins as nutritional supplements and therapeutics for patients in need of gamma globulin therapy.
SUMMARY OF THE INVENTION
[0008] Compositions containing 100% human milk proteins, including the so-called host resistance factors (HRF) of human milk, as well as other nutrients, living cells, and components are useful when employed to enhance and improve outcomes for babies and children who are not able to obtain human milk from their mothers (or cannot obtain enough mother's milk or mother's milk in the formulation needed due to immunodeficiency of the mother) as well as other patients (including adults) suffering from immune disorders, nutritional disorders and other diseases and dietary challenges.
[0009] The sequential administration of many of the human milk constituents provides substantial value to the recipient because of metabolic and catabolic processes. It is at the core of the present invention to utilize such human milk constituents, in their processed form, in such a sequential fashion as to provoke the same type of chain reaction in the body. With this concept, the pairing of the processed milk tissue with the sequential and differentiated delivery methods, patients may enjoy a new type of preventative and therapeutic medicine. Because human milk immunoglobulins are specifically targeted to many diseases of the newborn, as well as the protective functions of the mucus membranes of the newborn's body, and contain higher levels of IgA, IgD, IgM and IgE, the term “panoglobulin” or “lactapanoglobulin” has been coined for this newly identified formulation. In addition to fighting immune disorders with a human-milk origin panaglobulin, patients preparing for surgery, chemotherapy, radiation or other “currently accepted, but destructive” therapies, may enjoy preliminary therapies that may mitigate the ill effects of their upcoming procedure. In the same fashion, the constantly changing nature of species-specific milk allows for the inclusion of the mammary gland as a laboratory of sorts, seeking not to simply initiate and artificially replicate structures like antibodies and proteins, but instead, to produce a bonafide human-produced fluid that can be isolated, processed and delivered for a highly targeted use against disease.
[0010] One embodiment of the present invention provides a nutritional formulation of isolated human milk containing protective human milk proteins or host resistance factors of human milk suitable for infant consumption which can be directly administered to an infant.
[0011] Another embodiment of the present invention provides a method of isolating human milk comprising the steps of collecting a sample of human milk from a donor in a collection device, storing the sample of milk obtained from the donor, and processing the milk sample by conducting a nutritional analysis on the milk sample; fortifying the sample with heat-resistant nutrients, pasteurizing the sample; fortifying the pasteurized sample with heat-sensitive nutrients and testing the sample to ensure successful pasteurization.
[0012] Yet another embodiment of the present invention provides a system for delivering human milk to an infant. The system contains a feeding tube treated to minimize adherence of milk fat to the interior of the feeding tube; a heated sheath surrounding the feeding tube and an enteral pump removably mounted to a motorized platform.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention and the methods of obtaining and using the present invention will be described in detail after setting forth preliminary definitions.
[0000] Definitions
[0014] The following definitions are provided to facilitate understanding of certain terms used in the present invention.
[0015] As used herein, “human milk” means any stage of human milk production including the production of breast secretions not associated with lactation. These stages include, but are not limited to, colostrums, transitional milk and mature milk.
[0016] As used herein, “species-specific milk” means any milk that would be processed or formulated to provide an advantage of any kind to its own offspring.
[0017] As used herein, “second-best species-specific milk” means any milk that would be processed or formulated to provide a “close second” to its own species-specific milk resulting in better outcomes than using the standard bovine or soy based milk replacer.
[0018] The present invention describes a method that includes multiple steps and processes to harvest or isolate, store, transfer, process, package and deliver a variety of pharmaceutical and nutritional formulations containing cells and tissues comprising 100% human milk tissue, fractionated human milk tissue components and specifically reunited compounds, as well as novel methods and procedures to affect levels of such fractionated human milk tissue components, isolate them from raw human milk and deliver them through various methods including (but not limited to) ingestion, inhalation, intra-nasal administration, eye drops, ear drops, enema, douche, lavage, transdermally, rectally, intravenously, intramuscularly injection, direct injection, direct topical application, ng tube and jg tube.
[0019] Additionally, these formulations may be delivered through any of these methods, but when delivered, the present invention describes a sequence of delivery by which certain components or compounds will catabolize to create optimum conditions for the sequential delivery of an additional compound. For instance, if the formulation is nutritionally focused, the present invention provides a formulation that is specifically delivered in the morning, with a different formulation delivered in the afternoon and evening.
[0020] Little is understood at this time, as to why the formulation of mammalian milk evolves throughout the day. The present invention is directed to a method by which this differentiation is preferred and would create an improved outcome for the patient. Additionally, by any method, there may be an advantage to the “priming” of the patient by the delivery of certain processed human milk components, thereby eliciting a response in the patient's body that will improve outcomes when the next treatment in the sequence is followed. This sequential treatment concept would not be limited to the method of delivery. Instead, the present invention relates to the possibility that multiple delivery methods may actually trigger multiple advantageous responses in the patient, increasing the patients' chance of an improved outcome by coaxing the patient's system into active collaboration with the treatment method. This method simulates the natural processes of the mammalian immune system, which cannot be described as any one “silver bullet” but a series of complex communications between multiple cell structures and the offending pathogen.
[0021] The present invention relates to use of the disclosed methods and formulations from all mammalian species and is not limited to human beings. Additionally, the present invention encompasses all breast fluids as a potential source for harvesting milk and immune cells, as the mammary gland is a lymphoid organ, capable of producing immunoglobulins with or without accompanying lactation.
EXAMPLES
[0022] The following examples are intended to illustrate various embodiments of the present invention and are not to be construed as limiting the scope of the invention.
Example 1
Gamma Globulin Formulations
[0023] At the center of this invention, is the intent to solve the worldwide shortage of gamma globulin. The current source of gamma globulin is blood serum, and specifically IgG from human blood. The present invention discloses a prophetic inclination, based upon a 15-year study of human milk, that a new form of gammaglobulin referred to herein as “panaglobulin,” “mammaglobulin” or “lactopanaglobulin” may replace the current gamma globulin. Because higher levels of IgA and IgM are present in human milk and colostrums, and a more diverse form of IgG as well, panaglobulins may provide protection beyond the scope of current gamma globulin therapy. Manipulation of the levels of immunoglobulins and their subclasses will result in formulations that are targeted at specific diseases or organ systems, making it possible to attack disease using nature's pharmaceutical laboratory, the mammary gland. Furthermore, milk donors who have weaned their babies or have initiated lactation without pregnancy could feasibly become human labs, becoming exposed through any method to mild strains of disease and producing the appropriate antibody in their milk. Since the breast is reactive to new exposures of pathogens, an array of new immunities can be produced to combat such diseases. Whether these types of donors could produce enough milk to become a primary source remains to be seen, but at least these donors could provide a human lab for biosynthesizing disease specific antibodies that could be replicated later using other methods.
[0024] Colostrum contains high levels of immunoglobulins, a vital defense mechanism that protects the newly born. sIgA provides immediate protection to the infant by lining the gastrointestinal system and providing a first defense against dangerous pathogens like E. coli and other devastating disease organisms. The invention discloses concentrated, processed sIgA for use as a prevention or therapeutic for gut disorders in patients of all ages. Potency levels will depend upon the severity of the disease, the general health of the patient and the cost of the processing.
[0025] Colostrum also contains IgG1, G2, G3, G4, IgM, IgD and trace amounts of other human origin immunoglobulins. All of these immunoglobulins function in a myriad of ways, targeting specific organs and disease states. Because the mammary gland is a lymphoid organ, it is capable of synthesizing immunoglobulins, especially the four IgG subclasses, making it possible to achieve a higher level of IgG subclasses in breast fluid than is present in human blood serum. This capability of the mammary gland is not limited to lactation, with measurable quantities of IgG present in breast ductal fluid from non-lactating women. Expressing ductal fluid may provide protective advantages to the donor, specifically the cleansing of the breast ductal system, as disclosed in a prior patent application by the inventor. This invention envisions breast fluid from non-lactating women as a potential source of human immunoglobulins. Current research cites a wide variety of volume and constituents present in colostrums, transitional milk and mature milk but little information exists for the constituents present in the breast ductal fluid of non-lactating women. The present invention is directed to the ability to influence the volume and constituents of breast ductal fluid through dietary and pharmaceutical manipulation.
[0026] For nutritional and pharmaceutical applications, other valuable proteins contained in human milk include alpha-lactalbumin, beta-lactoglobulin, lactoferrin, serum albumin, lysozyme, and other proteins as well. Human milk has a higher proportion of alpha-lactalbumin and the host resistance factors or anti-microbial proteins of human milk, which include lactoferrin, lysozyme and secretory IgA, and account for 75% of the protein in human colostrum as compared with 39% in mature human milk. Additional human milk cells that provide substantial disease resistance in the newly born include lymphocytes, macrophages, and secretory IgA. Lactoferrin is present in relatively high amounts in human milk as is lysozyme and bifidus-stimulating factors. A major objective of this invention is to provide techniques and routines for improving the diet and feeding of infants, particularly very-low-birth-weight infants. By varying the levels of many of these species-specific milk constituents, the invention will result in a myriad of formulations specially suited to a wide variety of medical conditions.
Example 2
Collection of Donor Milk
[0027] U.S. Pat. No. 4,772,262, which is hereby incorporated by reference in its entirety, is directed to technology for milk removal. As disclosed in that patent, milk yields increase due to the sensory stimulus provided by the patented breast pump equipment. When milk yield increases, the formulation of milk including many of the valuable immunoglobulins also increase along with living cells, such as macrophages and lymphocytes. Lipids also increase and the mother's body responds to the stimulus by producing higher levels of prolactin that will trigger continuing milk supply and the secretion of additional nutrients into her milk.
Example 3
Storage of Donor Milk
[0028] Previous methods of collecting donor milk failed to recognize the importance of stimulation to the mammary gland as well as collection chambers designed for the anaerobic collection and transfer of donor milk. The invention describes such a method as part of its unique collection, storage and transfer system. Additionally, the preservation of milk components and nutrients is paramount to the success of the invention wherein harvesting of milk cells specific to the species will result in pharmaceutical and nutritional improvements in outcomes for the newly born or immune compromised patient. For that reason, it is important that the container in which the donor milk is stored, will preserve and protect these vital milk constituents from harm due to ultraviolet light and other damaging light rays. A UV coating or additive, applied to the collection bottle during the molding process or afterwards as an exterior coating or sheath will ensure that light degradation does not occur.
[0029] Finally, the design of the donor milk collection bottle should make it easy to draw off a sample of the donor milk without compromising the integrity of the milk sample. A proprietary design allows for a twist-turn valve to open and release a small amount of donor milk through a one-way valve into a test vial. The one-way valve prevents any bacteria or other pathogen from contaminating the milk sample. Additionally, a “tear down” design will allow frozen milk to be processed immediately, without the necessity of waiting for the milk to thaw. The tear down feature will provide an easy pull-tab that will strip the container from the frozen block of donor milk. The pull-tab will feature a tag on which a bar code is attached, so that during the tear down process, a “lot” numbering system will track the pooled milk back to their original donors.
Example 4
Transfer of Donor Milk
[0030] Novel designs for refrigerated transfer units utilizing alternative forms of energy and equipped with temperature indicator recorders ensure that the milk has been maintained under safe conditions. A programmable chip that records temperature variations as well as handling conditions (rough treatment can compromise milk quality by breaking cell walls), prevents the opening of the transfer case upon arrival at the processing plant. The milk is automatically rejected for quality issues and quarantined for further scrutiny. The transfer unit will contain a programmable chip that stores the contents, origin of contents, date shipped, date received, lot numbers and any other information required for quality control, regulatory or other reasons.
Example 5
Hospital Based Testing and Processing of “Mothers Own” Milk
[0031] The invention discloses a total quality control system that encompasses both routine and novel procedures and tests. For mothers wishing to provide their own milk for use specifically with their own baby, onsight testing will be done at the hospital. Standard donor screening will be done in accordance with current recommendations and accepted practices. In the present day, no routine testing is done in this case, and frequently the lack of testing causes consternation and concern in the physician with the end result being that babies are being routinely deprived of their mothers' milk. Upon questioning the areas of concern, several neonatologists indicated a concern for the presence of street drugs, disease pathogens and contaminants. To answer this concern, the invention includes a series of quick tests, designed to screen for the presence of the most common pathogens, drugs and contaminants. In order to provide the most efficient form of testing, a series of pumped milk is pooled, mixed and tested. A report is provided to the neonatologist and also placed in the infant's chart. The mothers' milk, intended for her own baby, is housed in the milk laboratory,.under optimum storage conditions. Again, a temperature indicator on each container of milk ensures that milk has not been exposed to adverse conditions that may cause degradation or contamination. The temperature indicator is attached to a disposable cap that covers the container. In the event of adverse circumstances, the temperature indicator activates a locking mechanism and the milk is quarantined until further analysis can be done.
Example 6
Onsight (Hospital Based) Delivery Methods for Mothers Own Milk
[0032] Of special concern in high risk neonatal units, is the loss of milk fat through feeding tubes used to feed very-low-birth-weight, sick or pre-term infants. A special design for extruded tubing employs a method during the manufacturing process, that will eliminate the problem of fat sticking to the inside of the tubing. After extrusion, a heat treatment is applied to the inside of the tubing, via a “pull-through” rod. A heated element, coupled with an anti-static element, of sorts, eliminate the static charge while smoothing the “tackiness” of the interior tubing wall. Coupled with a heated sheath, used during the tube feeding to keep the flow of milk warm, the fat loss can be substantially decreased. A gentle rocking motion, created by a motorized platform on which the enteral pump sits, provides constant agitation and prevents the pumped milk from separating. Additional design features prevent the fat from clinging to the inside of the enteral syringe, in which the pumped milk is contained. A Teflon coating, or alternatively a silicone interior bag or collapsible bag made from a food safe polyvinyl may create additional solutions to this problem. Techniques associated with sequential feeding methods may also mitigate the problems associated with single feed method. By utilizing sequential feeds, the “foremilk” formulation (simulating the composition of the first milk a baby receives during a direct feeding from the breast), is administered. Low in fat, but high in volume, this feed usually takes more time than the higher fat “hindmilk” feed. The hindmilk feed can be then administered from a push syringe specially designed to conserve a large amount of the fat that normally would have stayed in the long tubing associated with the earlier feed.
Example 7
Plant Processing Methods
[0033] In the practices of this invention the human milk proteins, including the so-called host resistance factors (HRF) of human milk, are prepared by chemically fractionating the same using standard techniques, such as the Cohn method, from pooled donor milk. This method will form the basis for the extraction of the immunoglobulins for the ultimate purpose of purification and processing into nutritional, IV and injectable forms. The present invention discloses a completely closed system for processing.
[0034] Under this system, there is no opportunity for contamination. When the donor milk is received at the processing center, a representative sample from each donor lot is tested and cultured. The remaining samples in the lot are transferred to the freezer to hold until the cultures are read. From the strip-down phase to the spray drying of the final product, all processing occurs within a sealed system. After the lot has been cleared for processing, the frozen containers of milk are placed in an anaerobic chamber where the strip down of the bottle occurs. A filter prevents particles of stripped down plastic bottles from entering the processing system. The frozen chunks of donor milk are thawed, using a slow, continuous heat with a mild churning action. Once thawed, a nutritional analysis is performed to determine specific nutritional levels of the pooled donor milk. Depending upon the desired human milk formulation, the system automatically adjusts the formulation, using validated sources from human milk origin, if augmentation above the levels of the donor milk is desired. Fortification at this point is limited to nutrients that are not adversely affected by heat. As the fortification is being done, the milk is gently churned. The pasteurization process takes place, again, in the same closed system, using the Holder Method of 62.5 C for 20 minutes of 56 C for 30 minutes. After pasteurization, the milk is cooled. Second stage fortification occurs at this point, with the addition of previously processed immunoglobulins, as well as selected, 100% screened human milk cells. After processing, final testing is done to determine that the pasteurization process has been successful.
[0035] The formulations and methods of the present invention may be embodied in other specific forms without departing from the teachings or essential characteristics of the invention. The described embodiments are therefore to be considered in all respects as illustrative and not restrictive. The scope of the present invention is defined in the following claims, rather than the previous description, and all changes that come within the meaning and range of equivalency of the claims are therefore to be embraced therein. | Methods of isolating, treating, storing and processing human milk, as well as nutritional formulations of human milk comprising protective human milk proteins. | 0 |
BACKGROUND AND SUMMARY
The present invention relates to a control system for docking a marine vessel.
Today's marine vessels are often equipped with a plurality of propulsion units, for example three, for driving the vessel. If every propulsion unit is associated to a separate control lever the handling of the vessel can be unnecessarily complicated. As many users of marine vessels are not experienced helmspersons, a simplified control system is desirable.
WO 2007/105995 describes a control system for a set of propulsion units where a centrally arranged propulsion unit of the set is controlled as a slave based on control signals provided by at least one of the remaining propulsion units of the set. Thereby, the number of control levers are decreased, for example from three to two, thus the control system for the vessel is simplified.
However, there is always a desire to even further simplify the handling of a marine vessel, for example by means of introducing further improvements to the control system for controlling a set of marine propulsion units.
It is desirable to achieve a control system for a set of marine propulsion units and a marine vessel with such a control system that is further simplified.
The inventor has realized that the thrust that can be applied from each propulsion unit is limited due to the propeller cavitation effect, resulting in reduction of the total thrust generated on the vessel. The invention is based on the inventor's realization that the cavitation typically occurs on the propulsion unit with reverse gear engaged, and that in a triple propulsion unit installation the normally idle center propulsion unit can be used to increase the reverse thrust and thereby limit the RPM of propulsion units in reverse, so that the cavitation effect is limited, and simultaneously allow for higher forward thrust on the third propulsion unit, thus increasing the total thrust for the vessel.
According to a first aspect of the inventive concept, a marine propulsion control system for controlling a set of propulsion units carried by a hull of a vessel, wherein the set of propulsion units comprise a first propulsion unit, a second propulsion unit and a third propulsion unit, wherein the second propulsion unit is provided as a center propulsion unit between the first and third propulsion unit, the marine propulsion control system comprising a control unit configured to receive an input command from a steering control instrument for operating the vessel, determine a desired delivered thrust, gear selection and steering angle for the first, second and third propulsion unit respectively, based on the input command, and provide a set of control commands for controlling the desired delivered thrust, gear selection and steering angle for the first, second and third propulsion unit, wherein if the input command indicates a sway command the first propulsion unit is set to have a forward gear selection and the third propulsion unit is set to have a reverse gear selection, each with a selected thrust level, and if the thrust level for at least one of the first and the third propulsion unit exceeds a predetermined thrust level the second propulsion unit is set to have a reverse gear selection with a thrust level depending on the selected thrust level of at least one of the first and the third propulsion unit.
In the context of this application a vessel should interpreted as any type of vessel, such as larger commercial ships, smaller vessel such as leisure boats and other types of water vehicles or vessels.
Furthermore, in the context of this application “gear selection” should be interpreted as selection of rotation direction of the propeller, i.e. forwards or rearwards rotation direction.
Through the system described, the propulsion units can be controlled individually. Thereby the propulsion units may for example be switched independently between a forward propulsion state and a reverse propulsion state and steered independently of one another.
By allowing the second propulsion unit to assist the first or third propulsion unit in creating a reverse thrust on the vessel, the total thrust of the vessel can be increased with 80-100 percent. Thereby, an operator of the vessel has more thrust to control the vessel, thus allowing the operator to act later and with more effect which means facilitated handling of the vessel.
Many inexperienced operators compare operating a marine vessel to operating a land vehicle, e.g. a car, and one of the hardest things to learn is how the marine vessel drifts due to inertial effects, wind and currents, which require the operators to plan their movements long in advance. When increased thrust to control the vessel is provided, the operator can reduce the time-span of the vessel's planned movements. This is a great advantage for an inexperienced operator.
In one embodiment the steering angle of the second propulsion unit is substantially the same as the steering angle of the third propulsion unit.
The first propulsion unit can be either a starboard or a port propulsion unit. Consequently, the third propulsion unit can be either a port or a starboard propulsion unit. The vessel will sway in the same direction as the position of the propulsion unit that is set with a reverse gear selection relative a thought center line. Thus, if the first propulsion unit is a port propulsion unit and the first propulsion unit is set in a reverse gear selection, the vessel will sway in a port direction.
Preferably, the first and third propulsion units' steering angles are substantially inverted relative a longitudinal axis. In the context of this application a longitudinal axis should be interpreted as an axis extending from the vessel's bow to the vessel's stern.
In one embodiment of the invention the first and third propulsion unit angles are set to an outwards angle. Thereby a component force in the lateral axis achieving a sway movement of the vessel is provided.
In another embodiment the first and third propulsion unit angles are set to a substantially maximum outwards angle. Thereby, the component force in the lateral axis achieving a sway movement of the vessel may be substantially maximized.
Further, if the first and third propulsion units are substantially inverted relative the longitudinal axis, and their thrust level are substantially equal, the force component in a forward/reverse direction will be zero, thus only a sway movement of the vessel will be achieved.
According to another embodiment, the marine propulsion control system further comprises three independent Engine Control Unit for providing an interface between the control unit and the first, second and third propulsion unit respectively. Thereby, the control unit does not have to comprise an interface for communicating with each of the first, second and third propulsion unit. Moreover, existing ECUs in a marine vessel can be utilized. According to yet another embodiment of the inventive concept, the three independent ECUs are electrically connected to the control unit.
According to another embodiment, the predefined level of the thrust level for one of the first or third propulsion unit corresponds to a level less than where a reverse propulsion direction of the first or third propulsion unit causes cavitation. Thereby, the cavitation effect typically occurring in the propulsion unit with a reverse gear selection can be alleviated through that the second propulsion unit assists the propulsion unit with a reverse gear selection by also creating a reversely directed thrust. By avoiding cavitation effects the total thrust of the vessel can be increased further.
According to yet another embodiment, the marine propulsion control system further comprises a steering control instrument for providing the control unit with an input command. Thereby, the operator can easily provide input commands to the control unit, so that the control unit can control the propulsion units in a direction desired by the operator.
Preferably, the inventive control system forms part of a marine vessel, further comprising a first propulsion unit, a second propulsion unit, a third propulsion unit, wherein the second propulsion unit is provided as a center propulsion unit between the first and second propulsion unit, each propulsion unit are carried by a hull.
By providing a vessel with a marine propulsion control system allowing the second propulsion unit to assist the first or third propulsion unit in creating a reverse thrust on the vessel, the total thrust of the vessel can be increased. Thereby, an operator of the vessel has more thrust to control the vessel, thus allowing the operator to act later and with more effect which implies facilitated handling of the vessel.
According to a second aspect of the present inventive concept, there is provided a method for controlling a set of propulsion units carried by a hull of a vessel, wherein the set of propulsion units comprise a first propulsion unit, a second propulsion unit and a third propulsion unit, wherein the second propulsion unit is provided as a center propulsion unit between the first and second propulsion unit, the method comprising receiving an input command from a steering control instrument operating the vessel, determining a desired delivered thrust, gear selection and steering angle for the first, second and third propulsion unit respectively, based on the input command, and providing a set of control commands for controlling the desired delivered thrust, gear selection and steering angle for the first, second and third propulsion unit, and setting the second propulsion unit to have a reverse gear selection with a thrust level if the input command indicates a sway command and the first propulsion unit is set to have a forward gear selection and the third propulsion unit is set to have a reverse gear selection, each with a thrust level, and if the thrust level for one of the first or the third propulsion unit exceeds a predetermined thrust level.
The effects of a method as described above are largely analogous to the effects of a marine propulsion control system and a vessel as described above. By providing a method for allowing the second propulsion unit to assist the first or third propulsion unit in creating a reverse thrust on the vessel, the total thrust of the vessel can be increased substantially. Thereby, an operator of the vessel has more thrust to control the vessel, thus allowing the operator to act later and with more effect which implies facilitated handling of the vessel.
According to another embodiment, the method further comprises providing the predefined thrust level for one of the first or the third propulsion unit so that it corresponds to a level less than where a reverse propulsion direction of the first or third propulsion unit causes cavitation. Thereby, the cavitation effect typically occurring in the propulsion unit with a reverse gear selection can be alleviated through that the second propulsion unit assists the propulsion unit with a reverse gear selection by also creating a reversely directed thrust. By avoiding cavitation effects the total thrust of the vessel can be increased further, which in turn means facilitated handling.
According to a third aspect of the present invention there is provided a computer program product comprising a computer readable medium having stored thereon computer program means for causing a control unit to control a set of propulsion units carried by a hull of a vessel, wherein said set of propulsion units comprise a first propulsion unit, a second propulsion unit and a third propulsion unit, wherein said second propulsion unit is provided as a center propulsion unit between said first and second propulsion unit, wherein the computer program product comprises code for receiving an input command from a steering control instrument operating the vessel, code for determining a desired delivered thrust, gear selection and steering angle for said first, second and third propulsion unit respectively, based on the input command, code for providing a set of control commands for controlling the desired delivered thrust, gear selection and steering angle for said first, second and third propulsion unit, and code for setting said second propulsion unit to have a reverse gear selection with a thrust level if said input command indicates a sway command and the first propulsion unit is set to have a forward gear selection and the third propulsion unit is set to have a reverse gear selection, each with a thrust level, and if the thrust level for one of said first or said third propulsion unit exceeds a predetermined thrust level.
The control unit is preferably a micro processor or similar device, and the computer readable medium may be one of a removable nonvolatile random access memory, a hard disk drive, a floppy disk, a CD-ROM, a DVD-ROM, a USB memory, an SD memory card, or a similar computer readable medium known in the art. The effects of a the computer product implementation of the invention for controlling a set of propulsion units by a control unit as described above are largely analogous to the effects of a marine propulsion control system, vessel and method as described above.
Furthermore, a code for controlling a set of marine propulsion units allows a user to upgrade an existing marine propulsion control system that allows separate individual control of the steering angle, thrust level and gear selection of the set or propulsion units. With abovementioned code, the upgrade could be done carried out with merely software alterations, vastly reducing the costs for a vessel owner to upgrade the marine propulsion control system.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention will in the following be described in more detail with reference to the enclosed drawings, wherein:
FIG. 1 schematically illustrates a perspective-view of a marine vessel comprising a marine propulsion control system configured to control three propulsion units,
FIG. 2 illustrates a scheme of a control system for a set of marine propulsion units,
FIG. 3 a schematically illustrates a top-view of a marine vessel comprising a marine propulsion control system configured to control three propulsion units,
FIG. 3 b schematically illustrates a top-view of a marine vessel comprising a marine propulsion control system configured to control three propulsion units,
FIG. 4 schematically illustrates a top-view of a marine vessel comprising a marine propulsion control system configured to control five propulsion units,
FIG. 5 is a line chart illustrating the thrust level of three propulsion units depending on an input command, and
FIG. 6 is a flow-chart illustrating a method for controlling a set of propulsion units.
DETAILED DESCRIPTION
The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The inventive concept may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements.
In the description below a control system for a set of marine propulsion units wherein the input means is a joystick, is mainly discussed. It should however be noted that this by no means should limit the scope of the application which is equally applicable on a control system where the input means is a stick, a set of buttons, a touch screen or equivalent.
Moreover, a control system for a set of marine propulsion units comprising three propulsion units is mainly discussed. It should however be noted that this by no means should limit the scope of the application, which is equally applicable on a set of marine propulsion units comprising five, seven or any other odd numbers above two.
Furthermore, a control system for a set of marine propulsion units, comprising three Engine Control Units (ECU), is mainly discussed. It should however be noted that this by no means should limit the scope of the inventive concept, which is equally applicable on a control system where a control unit internally comprise the functionality of the ECU.
FIG. 1 shows a simplified top view of a marine vessel 1 in which the marine propulsion control system 9 according to an embodiment of the inventive concept can be used. Generally, the control system according to an embodiment of the inventive concept may be used in any type of vessel, such as larger commercial ships, smaller vessel such as leisure boats and other types of water vehicles or vessels. The invention is particularly useful for small leisure boats, but it is nevertheless not limited to such type of water vehicle only.
As further schematically illustrated in FIG. 1 , the vessel 1 may be designed with a hull 2 having a bow 3 , a stern 4 and being divided into two symmetrical portions by a thought centre line running from the bow 3 to the stern 4 . In the stern 4 , three propulsion units 6 , 7 and 8 may be mounted. More precisely, the vessel 1 may be provided with a first propulsion unit 6 arranged at the port side, a second propulsion unit 7 arranged in the centre and a third propulsion unit 8 arranged at the starboard side. The propulsion units 6 , 7 and 8 may be pivotally arranged in relation to the hull 2 for generating a driving thrust in a desired direction of a generally conventional kind. The propulsion units may alternatively be inboard propulsion units, mounted under the boat on the hull 2 or mounted on the stern 4 as so called sterndrives. That is, the propulsion units 6 , 7 and 8 may be outboard propulsion units or inboard propulsion units.
The control of the propulsion units are performed by a marine propulsion control system 9 as further illustrated in FIG. 2 .
FIG. 2 is a scheme diagram showing the scheme of a marine propulsion control system 9 according to one embodiment. The control system includes a control unit 10 , steering control instruments such as a joystick 14 , a steering wheel 13 and/or a thrust regulator 15 , and a first 16 , second 17 and third 18 Engine Control Unit (ECU). The first 16 , second 17 and third 18 ECU are adapted to control a first 6 , second 7 and third 8 propulsion unit, respectively.
In one implementation, each propulsion unit 6 , 7 , 8 may include a gear selector, a steering actuator, and a steering angle detecting section. The gear selector may change gear selection for each propulsion unit between a forward propulsion position, a reverse propulsion position, and a neutral position. Alternatively, two gear selectors are provided. One for each group of propulsion units positioned on the starboard side of the thought centre line and one for the group of propulsion units positioned on the port side of the thought centre line.
The steering actuator may turn the propulsion unit about a steering axis and thereby altering the steering angle thrust direction. The steering actuator may include a hydraulic cylinder or an electrical motor. The steering angle detecting section may detect an actual steering angle propulsion unit. If the steering actuator is a hydraulic cylinder, then the steering angle detecting section may be a stroke sensor for the hydraulic cylinder. However, the steering angle detecting section may be any means for measuring or calculating the steering angle.
The control unit 10 contains means for mapping an input signal from the steering control instruments into a reference value angle for respective propulsion unit 6 , 7 , 8 where the steering actuators are arranged to move the propulsion units such that they assume the reference value angle. The mapping may be of simple type such that a steering angle is obtained from the steering control instruments and that the steering actuator uses this input command as the reference value angle. The mapping may also be more complex such that the reference value angles are calculated in dependence of the driving situation including speed, desired trim angle, whether docking is performed such that sway of the vessel is desired and so forth.
The ECUs may control operations of the associated propulsion units, through controlling the gear selection, delivered thrust and the steering angle. The controlled operations may be based on the input commands from the steering wheel 13 , joystick 14 and thrust regulator 15 . The ECUs may be connected to the control unit 10 through a communication line. In another embodiment, the ECU is capable of communicating with the control unit 10 wirelessly.
In another embodiment of the invention, the three mentioned ECUs form an integral part of the control unit 10 .
Through the system described, the propulsion units 6 , 7 , 8 can be controlled individually. Thereby the propulsion units may be e.g. switched independently between a forward propulsion state and a reverse propulsion state and steered independently of one another.
The thrust regulator 15 comprises port throttle lever 19 a , and a starboard throttle lever 19 b arranged to generate a desired delivered thrust by the propulsion units contributing to the thrust on the port and starboard side respectively. When a throttle lever 19 a , 19 b is tilted forward/backwards a detection signal is transmitted to the control unit 10 comprising the desired gear selection, i.e. forward/backward, and a thrust level associated with the angle that the throttle lever 19 a , 19 b is tilted with relative a neutral position.
The port throttle lever 19 a is primarily intended for the first propulsion unit and the starboard throttle lever 19 b for the third propulsion unit. If the first 6 and third 8 propulsion units have the same gear selection, i.e. forward or backward, the second 7 propulsion unit will also have said same gear selection. However, if one of the first 6 and the third 8 propulsion unit is set to have a forward gear selection and the other of the first 6 and the third 8 propulsion unit is set to have a reverse gear selection, each with a selected thrust level, and if the thrust level for at least one of the first 6 and the third 8 propulsion unit exceeds a predetermined thrust level, then the second 7 propulsion unit is set to have a reverse gear selection with a thrust level depending on the selected thrust level of at least one of the first 6 and the third 8 propulsion unit.
Gear selectors and throttle lever units are previously known as such, and for this reason they are not described in detail here. Based on received information from the steering control instruments 13 , 14 , 15 the control unit 10 is arranged to control the propulsion units 6 , 7 , 8 in a suitable manner to propel the vessel 1 with a requested direction and thrust.
The joystick 14 may be adapted to primarily be used to control the vessel in low speed. The joystick 14 may supply the control unit 10 with input commands comprising any combinations of a translational movements, such as sway or surge, and yaw movements. Thus, a user may through the joystick 14 supply the control unit with an input command comprising e.g. port sway and clockwise yaw.
The joystick 14 may be tilted in at least four directions; forward, rearward, leftward, and rightward. Thus, the direction may be operated so as to issue input commands in at least forward or reverse surge, left or right sway movement of the vessel 1 . Moreover, the joystick 14 may also be rotatable operated so as to issue an operating instruction for achieving a yaw movement of the vessel 1 . In one embodiment this is accomplished by rotating the joystick about a central vertical axis. When the joystick is altered from its neutral position a detection signal is transmitted to the control unit 10 .
For example, when an operator tilts the joystick to the port side and rotates it clockwise the propulsion units are controlled such that the hull 2 moves in a sway movement translational to the port side with a clockwise rotation. As described above, there are only four basic combinations of sway and yaw movements.
In one embodiment the control unit 10 comprises computing means such as a CPU or other processing device, and storing means such as a semiconductor storage section, e.g., a RAM or a ROM, or such a storage device as a hard disk or a flash memory. The storage section can store settings and programs or schemes for interpreting input commands and generation control commands for controlling the propulsion units.
The control unit 10 controls a forward/reverse propulsion direction, a desired thrust, i.e. propulsion force, and a desired steering angle of each of the propulsion units individually in accordance with input commands from the steering control instruments 13 , 14 , and 15 .
The desired thrust of the propulsion units correspond to a target propulsion unit rotational speed. Thus, controlling the thrust often means controlling a propeller rotational speed.
In one implementation the thrust regulator 15 includes a single starboard input command and a single port input command for each function that is under control by the thrust regulator. As have been explained above, these functions may include port and starboard throttle levers and port and starboard gear selectors.
FIG. 3 a and FIG. 3 b illustrates two opposing sway movements, where the set of propulsion units in FIG. 3 a are controlled by the control unit 10 to achieve a port sway movement and in FIG. 3 b to perform a port sway movement. In one embodiment, an operator has tilted the joystick 14 to the starboard/port and thereby generated an input command to the control unit 10 .
In both FIG. 3 a and FIG. 3 b the second propulsion unit 7 has a reverse gear selection, thus assisting the third 8 or first 6 propulsion unit with the reverse thrust respectively. As earlier discussed, the second 7 propulsion unit will always assist the propulsion unit 6 , 8 that has a reverse gear selection, since the propulsion unit with reverse gear selection has the most tendency for cavitation effect.
Each of the propulsion units' thrust can be divided into force components in a forward/backward and port/starboard direction respectively. In both FIG. 3 a and FIG. 3 b the force component in the forward backward direction becomes zero, thus the vessel 1 will not surge either forwardly or backwardly. In FIG. 3 a the force component in the port/starboard direction is directed to the starboard direction, thus the vessel will sway in a starboard direction. In FIG. 3 b the force component in the port/starboard direction is directed to the port direction, thus the vessel will sway in a port direction.
In FIG. 4 the exact same principal is illustrated, however the set of propulsion units in FIG. 4 comprise five propulsion units, more specifically a fourth 31 and fifth 32 propulsion units are introduced arranged between said first 6 and second 7 propulsion unit and between said second 7 and third 8 propulsion unit, respectively. Other than that, there are no differences from what is illustrated in and described to FIG. 3 a . Thus, the vessel 1 shown in FIG. 4 will also sway in a starboard direction.
By assisting the propulsion unit with the reverse gear selected the vessel's 1 total thrust can be maximized through avoiding cavitation. The principle is illustrated in FIG. 5 , which is a line chart showing the propulsion units' 6, 7, 8 rpm on the y-axis based on the amount the joystick 14 is tilted to the starboard side.
FIG. 5 is illustrating the scenario discussed in relation to FIG. 3 a , when the vessel 1 makes a starboard sway movement. In the line chart's origin of coordinates the joystick 14 is in its neutral position, thus all propulsion units are idle. As the joystick 14 is tilted to the starboard, the RPM of the first 6 and third 8 propulsion units are increased as displayed with lines 26 a and 28 respectively. The first propulsion unit 6 has a forward gear selection and the third propulsion unit has a backward gear selection. Since the forward gear selection is generally more efficient than a backward gear selection, the rpm of the first propulsion unit 6 does not have to be as high as for the third propulsion unit 8 . As the joystick is tilted with an amount above X-i, the second 7 propulsion units goes from being idle to assisting the third propulsion unit 8 with the reverse thrust, as illustrated by line 27 . By assisting the third propulsion unit 8 , the rpm of the first propulsion unit 6 can be increased compared to if only the second propulsion unit 7 would have been idle, which is illustrated by the dotted line 26 b . Moreover, at one point, indicated as X2 the third propulsion unit set with a reverse gear selection, will show tendency for cavitation. However, this point is further out on the x-axis, thus the total thrust of the vessel 1 is increased.
In measurements done by the inventor, the total thrust of the vessel 1 may possibly be increased with approximately 80-100 percent, depending on the type of engine and propeller used. Generally, the largest increases are with smaller engines, such as V6 engines compared to e.g. V8 engines. Moreover, the concept increases potential total thrust both in vessels 1 with outboard engines and inboard engines. The largest effect has however been measured in vessels with outboard engines, which typically use single propeller mountings, as opposed to inboard propulsion units that often use duoprop systems.
FIG. 6 is a block diagram showing the method for controlling the set of propulsion units 6 , 7 , 8 as described above wherein the method comprises receiving an input command S1 from a steering control instrument, such as the steering wheel 13 , joystick 14 and/or thrust regulator 15 operating the vessel. Further the method comprises determining a desired delivered thrust, gear selection and steering angle S2 for the first 6 , second 7 and third 8 propulsion unit respectively, based on the input command, and thirdly providing a set of control commands for controlling the desired delivered thrust, gear selection and steering angle S3 for the first 6 , second 7 and third 8 propulsion unit. Further the method comprises setting the second propulsion unit 7 to have a reverse gear selection with a thrust level S4 if the input command indicates a sway command and the first propulsion unit is set to have a forward gear selection and the third propulsion unit is set to have a reverse gear selection, each with a thrust level, and if the thrust level for one of the first 6 or the third 8 propulsion unit exceeds a predetermined thrust level.
While the present invention has been described with reference to a number of preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
In the drawings and specification, there have been disclosed preferred embodiments and examples 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, the scope of the invention being set forth in the following claims. | In a marine propulsion control system for controlling a set of propulsion units carried by a hull of a vessel, cavitation typically occurs on the propulsion unit with reverse gear engaged, and in a triple propulsion unit installation the normally idle center propulsion unit can be used to increase the reverse thrust and thereby limit the RPM of propulsion units in reverse, so that the cavitation effect is limited, and simultaneously allow for higher forward thrust on the third propulsion unit, thus increasing the total thrust for the vessel. | 1 |
STATEMENT OF GOVERNMENT INTEREST
[0001] This invention was made with Government support under Contract No.: W911NF-10-1-0324 awarded by Army Research Office (ARO). The Government has certain rights in this invention.
BACKGROUND
[0002] The present invention relates to quantum information processing, and more specifically, to systems and methods for a frequency arrangements for implementation of surface code on superconducting lattices.
[0003] Quantum information processing holds potential for solving certain categories of mathematical problems that are intractable with conventional machine computation. Building a useful quantum computer requires the implementation of a quantum error correcting code on a system consisting of several million physical qubits. Recently, the surface code has emerged as an architecture for a quantum computer due to its high tolerance to errors on the physical qubits. The surface code has a fault-tolerant threshold of about 1%. In this architecture each physical qubit is coupled to it nearest neighbor forming a two dimensional grid with half the qubits being used to store the quantum information and the other half being used for the error correction.
[0004] Superconducting qubits have made considerable progress recently in experimental demonstration of the requirements for implementing a surface code quantum computer. Recently single and two qubit gates have been shown to have gate errors approaching the fault-tolerant threshold and high-fidelity measurements are becoming feasible.
SUMMARY
[0005] Exemplary embodiments include a device lattice arrangement, including a plurality of devices, a plurality of physical connections for the plurality of devices, wherein each of the plurality of devices are coupled to at least two of the plurality of physical connections, a plurality of identity labels associated with individual devices of the plurality of devices and an arrangement of identity labels such that pairs of devices of the plurality of devices connected by some number of the plurality of connections have different identity labels.
[0006] Further exemplary embodiments include a superconducting qubit surface code system, including a first plurality of superconducting qubits, a second plurality of superconducting qubits and a plurality of resonators coupling the first and second plurality of superconducting qubits, wherein the each of the plurality of first and second plurality of superconducting qubits includes an identity label.
[0007] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with the advantages and the features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The forgoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0009] FIG. 1 illustrates an example of a skew-square lattice arrangement;
[0010] FIG. 2 illustrates an example a distorted square lattice representing the lattice for a surface code;
[0011] FIG. 3 illustrates an example of a snub-square lattice;
[0012] FIG. 4 illustrates an example of a full lattice arrangement;
[0013] FIG. 5 illustrates an example of a connection-wise equivalent of the lattice of FIG. 4 ;
[0014] FIG. 6 illustrates an example of a physical lattice of qubits and physical connections; and
[0015] FIG. 7 illustrates a flowchart of a method for arranging a lattice of superconducting qubits in accordance with exemplary embodiments.
DETAILED DESCRIPTION
[0016] In exemplary embodiments, the systems and methods described herein arrange a lattice of superconducting qubits on a skew symmetric lattice so that a universal quantum computer with the surface code can be implemented. In this way a reduced number of identifiers is realized (i.e., about five identifiers). To realize a surface code with superconducting qubits, a “skew-square” (or Pythagorean) lattice of resonators can be implemented as in FIG. 1 , which illustrates a skew square lattice arrangement 100 . Each qubit 105 is coupled to two physical connections (e.g., resonators 110 , 115 ). The resonators 110 , 115 can be resonant cavities in the case of superconducting qubit technology. The skew-square lattice arrangement 100 has the benefit in that a single qubit only couples to at most two resonators. For example, as shown in FIG. 1 , one qubit 105 couples to two resonators 110 , 115 . In exemplary embodiments, the systems and methods described herein implement a surface code mapping with fewer “ancilla” qubits than previously implemented (i.e., one ancilla qubit per data qubit) and show that with this arrangement fewer different unique labels are implemented (e.g., up to about nine different unique labels). The systems and methods described herein implement arrangements for the surface code and include respective frequencies.
[0017] In exemplary embodiments, the systems and methods described herein arrange superconducting qubits for the implementation of a universal quantum computer using the surface code on a skew symmetric lattice. For a surface code quantum computer, each data qubit is controllably coupled to its four neighboring ancilla qubits in order to perform a series of four controlled NOT (CNOT) gates which implement a step in the error correction procedure.
[0018] The surface code is a two-dimensional grid with each qubit coupling to its four neighbors and so on. In order to implement the surface code, controllers for surface code systems address two qubits at once and perform a two-qubit entangling gate (for example the CNOT gate). On this two-dimensional grid, at least at least five different unique labels are required for the CNOT gates to be realized without cross-talk. For example, with superconducting qubits, the unique labels can be realized with different frequencies or tunable interactions. In superconducting qubits the interactions between the qubits are generally performed by a quantum bus (e.g., a co-planner resonator or 3D waveguide cavity). By implementing a quantum bus, physical design can be realized in which every qubit is only coupled to at most two quantum buses. It has been shown that the surface code could be implemented on a skew symmetric lattice with many of the qubits acting only as ancilla qubits to simulate the effect of the fourfold connectivity implemented by the surface code.
[0019] In exemplary embodiments, the systems and methods described herein implement a surface code in which the lattice can be modified to reduce the number of identifiers and labels, while maintaining the advantages of the known surface code. The systems and methods described herein enable an efficient mapping of the surface code onto the “snub-square” lattice. As such, half the qubits are implemented as data qubits and half the qubits are implemented as measurement “ancillas.” One mapping has been shown to achieve only ⅕ of the qubits for data. FIG. 2 illustrates a surface code lattice mapping 200 , which is a simple square lattice of data qubits that has been deformed into a tiling of trapezoids. The example in FIG. 2 is a distorted square lattice representing the lattice for the surface code. In the example, the qubits 205 , 210 , 215 , 220 are spread out on the intersections of lattice points. Surface code measurements can be thought of as taking place in a middle point 230 of the resulting trapezoid shapes, measuring the X or Z parity of the four surrounding qubits 205 , 210 , 215 , 220 .
[0020] The ancillas/measurements are done on the interior of each resulting trapezoid shape defined by the qubits 205 , 210 , 215 , 220 . FIG. 3 illustrates an example of a “snub-square” lattice arrangement 300 . For illustrative purposes, the same four qubits as in FIG. 2 are illustrated. Resulting trapezoid shapes are no longer shown. Instead, ancilla qubits 335 , 340 are shown. The ancilla qubit 340 is connected to the four data qubits 205 , 210 , 215 , 220 whose parity the ancilla qubit, 340 measures. Similarly, ancilla qubit 335 measures the parities of the qubits on the vertices of next trapezoid to the right, consisting of qubits 205 , 220 and two more not labeled here. Each of the ancilla qubits 335 measure X parities, and each of the ancilla qubits e 340 measure Z parities, or vice versa.
[0021] FIG. 4 illustrates an example of a full lattice arrangement 400 . For illustrative purposes, each of the data qubits 205 , 210 , 215 , 220 and each ancilla qubit 335 , 340 are shown. In addition, physical connections 450 , 455 (e.g., resonators) are shown. Each qubit 205 , 210 , 215 , 220 , 335 , 340 is coupled to the closest two physical connections 450 , 455 . Connectivity though the physical connections 450 , 455 can implement all the required measurement connections of the overlaid snub-square lattice.
[0022] As such, the layout of the physical connections 450 , 455 and qubits 205 , 210 , 215 , 220 , 335 , 340 in the example in FIG. 4 , includes the connectivity of the snub-square lattice 300 of FIG. 3 . The layout has each qubit connected to only two physical connections. The layout 400 is a lattice with the p4g wallpaper group symmetry. A wallpaper group (or plane symmetry group or plane crystallographic group) is a mathematical classification of a two-dimensional repetitive pattern, based on the symmetries in the pattern.
[0023] FIG. 5 illustrates connection-wise equivalent layout 500 to that of FIG. 4 . The various snub-squares have been stretched into squares, and the resonators have been expanded to fill their squares, representing the fact that they couple to all surrounding qubits. The qubits (not shown) are at the corners of each square, data qubits spread out on various alternating squares, and the remaining corners are the ancilla/measurement qubits.
[0024] The layout 400 can optionally be deformed into the existing skew-square layout without changing its basic connectivity properties. The skew-square layout has the additional advantage that the physical distance between qubits directly across a physical connection can be increased.
[0025] In exemplary embodiments, there are many possible combinations of layouts of the previous figures (depending on various constraints explained below) of the layout such that each qubit has an “identity label” that differs from every other qubit to which it may need to be connected by a CNOT in carrying out the surface code. Additionally, these other qubits also have different labels than one another, which allow addressability of both qubits involved in a CNOT, while isolating them from other qubits. This labeling scheme is general enough to support various gate control schemes, as well as gates other than the CNOT. Because the physical connections in our layout connect some qubits which need not be connected in the surface code (see FIG. 4 ), the exemplary embodiments described herein have that the qubits connected by physical connections also have distinct labels. FIG. 5 shows how the snub-square lattice can be stretched into a traditional square lattice. The squares are stretched versions of the resonators from FIG. 4 . Data qubits are located at the upper-right and lower-left corners of a first set of alternating squares and ancilla qubits are located at the remaining corners (the qubits are not shown). The lattice could be physically arranged this way as well, but the example in FIG. 5 illustrates the isomorphism to the simple square arrangement of the surface code. The labels can then be written down as simple tables of numbers, corresponding to the grid points in FIG. 5 .
[0026] In exemplary embodiments, the systems and methods described herein can arrange the surface code connections to be addressable as above as described in the previous example, having five labels. In this way, each row repeats the pattern 123451234512345, and each consecutive row shifts the starting number by 2. In other exemplary embodiments, if the data qubits 205 , 210 , 215 are to have different labels from the ancilla qubits 335 , 340 then eight labels can be implemented. The first row has the pattern 1A2B1A2B1A2B, the next row is C3D4C3D4C3D4, the next is 2B1A2B1A2B1A (the first row shifted by two places), the next row is D4C3D4C3D4C3 (the second row shifted by two places) and then the pattern repeats. Numbers correspond to data qubits and letters to ancilla qubits. In further exemplary embodiments, if isolation and addressability is implemented, such that every qubit connected through two physical connections has a distinct label, then nine labels can be implemented. In exemplary embodiments, the pattern 123456789123456789 is implemented on the first row, then shifted by three on the next row, and so on, which allows for every qubit to have the addressability to have two-qubit gates performed between it and every qubit to which is connected by a physical connection.
[0027] In exemplary embodiments, another implementation of nine labels is illustrated in FIG. 6 . FIG. 6 illustrates a physical lattice of qubits 205 , 210 , 215 , 220 , 335 , 340 and physical connections 450 , 455 as in FIG. 4 , but with the snub square overly removed for clarity. In the example of FIG. 6 , there are nine different types of qubits, noting that there are different shapes to the data qubits 205 , 210 , 215 , 220 . The red and green qubits are the ancillas, while the blue qubits are the data. The large shaded square 605 shows the extent of a unit cell of the lattice (the area after which it repeats).
[0028] In the example, the data qubits 205 , 210 , 215 , 220 and the ancilla qubits 335 , 340 have different labels, and enough addressability so that every data qubit can have two-qubit gates applied between it and every data qubit to which it is joined by a physical connection 450 , 455 , as well as the gates required for the surface code connecting data qubits to ancilla qubits.
[0029] For example, certain labels can be different frequencies in the case of superconducting qubits. Additionally, the physical connections 450 , 455 may need to be isolated from one another, being cavities of different frequencies, for example. Two cavity labels are sufficient, and have been indicated by the two types of physical connections 450 , 455 throughout the examples herein.
[0030] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one more other features, integers, steps, operations, element components, and/or groups thereof.
[0031] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
[0032] The flow diagrams depicted herein are just one example. There may be many variations to this diagram or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
[0033] While the preferred embodiment to the invention had been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described. | A device lattice arrangement including a plurality of devices, a plurality of physical connections for the plurality of devices, wherein each of the plurality of devices are coupled to at least two of the plurality of physical connections, a plurality of identity labels associated with individual devices of the plurality of devices and an arrangement of identity labels such that pairs of devices of the plurality of devices connected by some number of the plurality of connections have different identity labels. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS AND PATENTS
[0001] The present application is related to co-pending, and commonly-assigned U.S. patent application Ser. No. 10/821,123, Attorney Docket No. 65744/P018US/10404217, entitled “Systems And Methods Providing ASICS For Use In Multiple Applications,” filed Apr. 8, 2004 and U.S. patent application Ser. No. 10/821,198, Attorney Docket No. 65744/P021US/10404749, entitled “System And Method For Enhancing Gray Scale Output On A Color Display,” filed Apr. 8, 2004; the disclosures of which are all hereby incorporated herein by reference herein.
TECHNICAL FIELD
[0002] The embodiments of this disclosure are directed to medical diagnostic and/or treatment systems and more particularly to systems and methods for the ubiquitous processing of medical signals originating from medical equipment at diverse locations.
BACKGROUND OF THE INVENTION
[0003] Similar to the development of PCs in computing and cellular telephones in mobile communication, system miniaturization can bring high performance to medical diagnostic equipment. Even sophisticated imaging devices, such as obtained by portable ultrasound transducers, are available at the point-of-care.
[0004] For ubiquitous imaging, it is necessary that the imaging system transducer be easily moved from patient to patient and thus it must have a high degree of portability. Such systems however, typically have limited network connectivity and storage and generally lack the capability of accessing patient files or other relevant medical information that reside within a hospital information system.
[0005] As any new technology or application evolves, new operational issues and demands from users arise. Some of these issues are: image quality, user interface, display size, battery power, packaging, system size and weight, transducer size and weight, image analysis and connectivity. When images are involved high performance (i.e., sharp images, detailed analysis, etc.) is demanded. The requirement of high performance, however, typically increases the complexity of system design and is generally in conflict with the requirement of smaller system size necessary for mobility.
[0006] One way to reduce the system size and weight is through elimination of system features and imaging functions. However, by doing so this will also result in possible undesirable reduction of clinically efficacy.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention is directed to a system and method in which real-time ubiquitous imaging is feasible in local areas, such as inside a clinic, hospital room or doctor office. This is achieved by designing a wireless network having a central processing server with, for example, distributed broadband acquisition and video bus capability. Remote access is possible using store-and-forward image transfer over a wide area network. With these capabilities, a physician can use a handheld transducer (such as an ultrasound transducer) as a basic tool to facilitate diagnostic decisions similar to the way a stethoscope is used today.
[0008] In one embodiment, a handheld ultrasound imaging system is constructed similar in size to a cellular handset. The imaging system has wireless connectivity, using, for example, a low cost CMOS process for implementing imaging functions with signal processors. This enables medically relevant information to be accessible by the handheld ultrasound device and also allows images acquired from the handheld device to be transferred and retrieved from a number of locations while the signals are processed from a location common to all of those locations.
[0009] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated 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 of the present invention. It should also be realized that such equivalent constructions do not depart from the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its 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 present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
[0011] FIG. 1 shows a block diagram of one embodiment of a multi-room system where processing of data from many rooms is performed centrally;
[0012] FIG. 2A shows a portable transducer device;
[0013] FIG. 2B shows a monitor;
[0014] FIGS. 3 and 4 show diagnostics performed remotely by different specialist; and
[0015] FIG. 5 shows one embodiment of a flow chart of system operation.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 shows one embodiment 10 of a ubiquitous system having a high performance back-end processing server, such as a central control and processor 16 . Processor 16 is used in conjunction with transducer devices, such as devices 21 , which can move from room to room or from office to office as one or more physicians ( 101 - 104 ) moves about. Signals 13 to and from each device 21 are transmitted, for example, via antenna 22 (room 1 ) to trans/receiver 12 - 1 and to/from trans receiver 12 - 1 and server 16 via antenna 15 and transmission path 14 - 1 . Transmission path 14 - 1 can be wireless or wireline or a combination thereof. Also, receiver (radio access point) 12 - 1 can serve a plurality of rooms or locations or could serve a particular room, as shown by ( 12 - 1 , 12 - 2 , 12 - 3 , 12 - 01 , 12 - 02 ).
[0017] The processing power of process 16 (which acts as a server) is designed to be capable of simultaneously processing data received from multiple radio access points. In return, if desired, processed signals, usually containing images are communicated back to the proper room for display. For example, display 23 in room 1 shows image 18 - 1 taken from the patient by Dr. 101 in room 1 , while display 23 in room 3 shows image 18 - 3 taken by Dr. 102 in room 3 . Similarly, Dr. 103 in office 1 can view images taken from office 1 via display 23 at office 1 .
[0018] This operation may be accomplished by implementing multiple ASICs and multiplexing switches in parallel in server 16 which can be interfaced to an acquisition bus and to video bus as will be discussed. The bandwidth of these buses is designed to be broad enough to support the simultaneous processing of image data received from the various radios of multiple devices 21 . The bandwidth also preferably supports sending data to multiple monitors 11 concurrently. Memory 17 operates in conjunction with server 16 to match data from a particular room with data flowing to that room and with other stored data as necessary.
[0019] The user interface for image controls is preferably easily accessible by the user to facilitate roaming between rooms. This can be done by making the transducer independent of the monitor as will be discussed with respect to FIGS. 2A and 2B .
[0020] Each radio access point ( 12 - 1 , 12 - 2 , 12 - 3 , 12 - 01 , 12 - 02 ) can be implemented by any radio having sufficient bandwidth. For example, a 7.5 GHz ultra wide band (UWB) radio band, spanning from 3.1 GHz to 10.6 GHz, broadband personal area network applications. This 7.5 GHz band contains 13 bands to support multi-user application as described in the 802.15.3 Ga proposal. Each UWB radio band could support a data rate of 110 Mb/sec at a range of 10 meters. There are also a total of 300 MHz in 12 bands available from 802.11a UNII band and three 22 MHz bands available for 802.11a and 802.11b ISM band. 802.11a, g, b are developed for wireless local are network applications. They cover more range than the UWB; however, they have lower data rates and consume more power. For short distance communication, UWB is specified to consume 100 MW for 110 Mbps rate at 10 meters whereas the WLAN 802.11a and 802.11.8 radios typically consume 1 to 2 watts and cover a range of 30-100 meters at 54 Mbps. Since the handheld scanhead is battery-powered, power consumption is an important design factor to the usability of handheld ultrasound. Technologies useful in providing power efficient and portable medical diagnostic equipment are shown and described in U.S. Pat. No. 5,722,412 dated Mar. 3, 1998 and U.S. Pat. No. 6,471,651 dated Oct. 29, 2003, each commonly assigned to the assignee of the present application, the disclosures of which are hereby incorporated herein by reference.
[0021] The recent release of third generation mobile services 3G provides much greater bandwidth to cellular handsets. The CDMA 1× EVDO allows a rate of 2.4 Mbps downlink and greater than 384 kbps uplink for data transfer. Availability of 3G enables E-mail, World Wide Web and other Internet based services through mobile handsets. However, the bandwidth of 3G radio is not yet broad enough for implementation of the radio access point to support the real-time imaging applications. 3G radio, however, could be found useful in a variety of tele-ultrasound applications based on the store-and-forward method discussed herein.
[0022] Let us now assume that UWB radio is chosen for implementation of radio access points, such as 12 - 1 , in the wireless ultrasound network shown in FIG. 1 . A single UWB radio access point may cover a range of 10 meters at a rate of 110 Mbps. Additional access points may be placed at different distances to ensure overlapped radio coverage of all scanning rooms of interest. In the embodiment shown, each room has a unique access point, but rooms can share access points. Physicians may scan patients in any room using a handheld ultrasound device 21 . The device need not contain a monitor if a monitor 23 is also installed (or available) in that scanning room. Many physicians may scan patients in different rooms simultaneously by time-sharing back-end processor 16 , assuming proper bandwidth is available in the wireless network.
[0023] Since the image file system is located centrally, all images are buffered in processor 16 and can easily be archived, for example in memory 17 , or forwarded to various locations via communications) link 19 , which could be the Internet or any other transmission system. The system of a preferred embodiment is always on and ready and thus a physician may start scanning a patient immediately after the handheld transducer's power is turned on and may do so in any scanning room. The physician may have access to medically relevant information available in the network, such as patient history, lab reports, pharmaceutical, insurance information and medical resources for assisting in making a diagnosis at the point-of-care. This information can be obtained via communication link 19 or from one or more memory 17 .
[0024] FIG. 2A shows one embodiment 21 of a handheld transducer containing imaging electronics integrated with transducer 201 inside a package approximately 6.5″×2.75″×1.25″ in size. In the embodiment shown in FIG. 2A , the electronics are partitioned into four processing blocks; transmit/receive (Tx/Rx) 202 , digital beam former (DBF) 203 , digital signal processor (DSP) 204 and radio 205 . Power is in the form of battery 206 .
[0025] Pulser circuits, high voltage multiplexor circuits, low noise time gain control amplifiers are integrated into Tx/Rx 202 . Multiple A/D converters, digital beamforming circuits and control logic are integrated in DBF 203 . DSP 204 comprises circuits utilized for echo and flow signal processing and include analytic signal detection and compression, multi-rate filtering, and moving target detection capabilities. In a preferred embodiment, DBF 203 , DSP 204 and BE 205 would be implemented using digital CMOS ASICS and mixed-signal technologies and Tx/Rx 202 would be implemented based on high-voltage and bipolar technology. The total weight of the scanhead module in one embodiment is 11.4 ounces. Excluding the housing, transducer 21 , in one embodiment, weighs about 7.9 ounces. The peak power consumption is approximately 9.2 watts. Average power consumption with power management is approximately 5.15 watts.
[0026] Note that while a wireless transducer is shown, the transducer could be hardwired to the common processor or to a relay point and then the communication could be wireless to the processor.
[0027] FIG. 2B shows display 23 having screen 220 for display of data including image data, a power source, such as battery 221 , and input 222 for receipt of data to be displayed. Input 222 can be hard wired or a wireless input or a combination of both. The input can come from the output of device 21 , for example from antenna 22 , or from processor 16 ( FIG. 1 ). When data comes from device 21 , BE 205 is preferably provided for processing the data for proper display. Image processing, scan conversion and video processing are implemented in BE 205 , which supports many image manipulation functions. In addition, a general purpose embedded microprocessor may be integrated in BE 205 for user interface control, image analysis and measurement. According to embodiments, when the data comes from processor 16 , the “backend” processing is accomplished in processor 16 and need not be repeated at display 23 .
[0028] For video streaming, a substantial amount of data bandwidth is needed and it has been found that the bandwidth required for transmitting the “un-compressed” color VGA video in real time may exceed 200 Mbps. Video stream techniques are now well-known and can be employed in this system.
[0029] In order to integrate wireless technology and ultrasound, one important task is to analyze the required data rates at different stages in the ultrasound image formation process to determine a system partition so that the available radio bandwidth may be most efficiently utilized. Such a determination according to one embodiment begins with an examination of data rates required for acquiring a sequence of ultrasound image frames at three different bus locations with respect to transducer 21 , as shown in FIG. 2A . These locations are RF bus 210 , acquisition bus 211 and video bus 232 ( FIG. 2B .)
[0030] RF bus 210 : Significant radio bandwidth is required over link 210 . For example, if the beamformed RF signals from transducer 201 are sampled at 20 MHz and digitized into 16 bits, then the required data transfer rate may exceed 320 Mbps. Currently (UWB) appears to be the only broadband radio link that supports this rate. However, the covering range for UWB radio at this rate is only about 4 meters.
[0031] Acquisition bus 211 : Only moderate radio bandwidth is required at link 211 . Thus, since the beamformed RF signal is filtered, decimated and detected in DSP processor 204 , the bandwidth is greatly reduced at this point. For example, assuming there are 128×512 pixels in one image frame and eight bits per pixel, to transmit 30 frames/sec of image data prior to scan conversion, the data rate is about 16 Mbps. This is about a factor of ten reduction in data rate as compared to that at link 210 .
[0032] Video bus 232 : the data rate increases again at link 232 ( FIG. 2B ) after the image lines are scanconverted into video frames. The data rate may reach 85,221 Mbps depending upon the color image frame format. Clearly, partitioning the system at link 211 requires the least overall bandwidth for interconnection between transducer 21 and video processing.
[0033] Establishing a point-to-point communication from device 21 using partitioning at link 211 sets up a basic imaging system with a single transducer. More than one scanhead may simultaneously access central processor 16 (or display 23 ) provided that the radio bandwidth and processing power for backend process are available.
[0034] Returning for a moment to FIG. 1 . It has been discussed that readings using an ultrasound device or from any other type of device and taken from different rooms or from different offices can be transmitted either directly or through an intermediary transport system to central control processor 16 . Central control and processor 16 can then perform analysis image enhancement and any other type of processing required. This processing could, for example, include comparing the presently obtained data to previously obtained data from memory 17 or from an external source via the internet or otherwise. This data then can be sent back, either hard wired or wireless via path 19 or via the transmission path from antenna 15 to the appropriate display 23 in the room in which the data is being taken from the patient. Thus, data from room 1 would of course would be returned to display 23 in room 1 , while data from office 2 would be returned to display 23 in office 2 . The data, as its being obtained and sent from a location, can be tagged so that processor 16 knows from where the data is coming and to where it is to be returned. At the same time, or at a different time, the data that is brought into processor 16 from the various different offices and rooms can also be transmitted to different experts, either in the same facility or remotely anywhere in the world. This transmission could be, for example, via output 19 which can be the inland, wireless, or wireline transmission.
[0035] For example, assume that a sonogram of a gall bladder is being taken from a patient in, for example, room 2 of FIG. 1 . This information could be received by processor 16 analyzed therein and transmitted to gall bladder expert 301 at location 30 , as shown in FIG. 3 . The gall bladder expert, using equipment in his or her office, would then review the data, compare it to other data, and send back analysis and even a treatment course, if desired. This can all be done in real time, if desired. Expert 301 may use keyboard 34 , and computer 32 .
[0036] If for example, the sonogram or any other instrument were being used by a physician say in office 1 to look at the heart of a patient, then processor 16 could determine that this is a heart issue and send the information to heart expert 401 at location 40 and the heart expert then could respond as discussed above.
[0037] FIG. 5 shows one embodiment of flow chart 50 for controlling the ubiquitous system. This control could occur via processor 16 . Process 501 determines if a new signal is arriving from a patient. If its not a new signal, processing continues via process 510 . If it is a new signal process 502 determines the identity of the sending unit, or process 503 determines the identity and location of the patient. This information can be provided by keyboard, spoken message or otherwise from an examining attendant with respect to the patient.
[0038] Process 504 determines, if desired, the signal type, i.e. whether it is sound, MRI, Xray, etc. that is being received. Process 505 , if desired, determines the image area, i.e. heart, kidney, gall bladder, thyroid, etc. This determination can be made either by the attending physician or by spoken word, key input or by processor 16 analyzing the data to determine what area is being scanned.
[0039] The signal is then processed by process 510 as discussed above with respect to backend processing and additional processing can be utilized, if desired.
[0040] Process 511 performs diagnostic operations on the data and could also optionally retrieve previous records, normal records for comparison, or any other type of records. Process 512 determines whether to send the signal to the patient's room and if that option is selected then the signal is sent to display 23 in the patient's room for real time viewing by the attending physician.
[0041] Process 513 is an optional process to determine if the signal should be sent to an expert. If it should be sent to an expert then the proper expert is selected. This selection can be done automatically by signal comparison or otherwise or by a code that is selected by the attending physician. Process 516 and process 517 selects and sends the signal to the specialty expert.
[0042] The specialty expert was discussed with respect to FIGS. 3 and 4 and many such experts can be available and utilized across different areas or within a single area. Process 515 is utilized when a single expert is utilized for different types of signals and the expert can further direct the signal or diagnose the situation in real time him or herself.
[0043] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the invention as defined by 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 will readily appreciate from the disclosure, 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 corresponding embodiments described herein 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. | The present invention is directed to a system and method in which real-time ubiquitous imaging is feasible in local areas, such as inside a clinic, hospital room or doctor office. This is achieved by designing a wireless network having a central processing server with, for example, distributed broadband acquisition and video bus capability. Remote access is possible using store-and-forward image transfer over a wide area network. With these capabilities, a physician can use a handheld transducer (such as an ultrasound transducer) as a basic tool to facilitate diagnostic decisions similar to the way a stethoscope is used today. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 13/531,615, filed on Jun. 25, 2012, which is a continuation of U.S. patent application Ser. No. 12/146,839, filed on Jun. 26, 2008, which claims the benefit of the filing dates of U.S. Provisional Application Nos. 60/946,336, filed on Jun. 26, 2007, and 61/037,892, filed on Mar. 19, 2008, the disclosures of which are hereby incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] Embodiments of the present invention generally relate to a method for sharing multi-media content among users in a global computer network. More specifically, embodiments of the present invention relate to a method for managing an interactive computer network involving user-submitted multi-media content in a competitively structured format.
[0004] 2. Description of the Related Art
[0005] Social interaction on computer networks has increased in popularity since the time when computers users first communicated with one another over a telecommunication connection. What started with electronic messages exchanged on the dial-in bulletin board systems (“BBS”) in the early 1980's has blossomed into a variety of “online communities,” such as, for example, chat rooms, on-line forums, web logs (“blogs”), as well as specialty web sites that are dedicated to particular subjects, e.g., digital photographs. As data transfer rates continue to increase in step with the improvements in high speed data transfer technology, so too does the demand for computer networks that provide individuals with more interactive and creative features.
[0006] Some computer networks have tried to incorporate these features. Some are setup in a manner that provides the user with tools and functions that facilitate communication between the users. They permit individuals to meet, talk, share ideas, and become acquainted without the users ever leaving the comfort of their own home. Typically these computer networks allocate storage space so that users can create, store and share information. This space is hosted by the computer network and available to anyone in the public domain with access to the Internet. Even more advanced computer networks permit users to identify individuals with distinct labels, such as, “friends,” “buddies,” and “links,” among others. These labels help the user to organize their contacts, whether personal friends, relatives, or individuals in which they share a common interest, into a “social network.” Such social networks simplify communication because the user can choose the individuals to whom they communicate regularly. But, computer networks that simply offer the user an scheme to organize those individuals to whom they send messages, chat, and share personal information, does not meet the needs of the users that wish to use their social network for higher-level interaction that involves complex data and information, like audio, videos, and images.
[0007] Thus, there is a need for an improved interactive portal that permits users to share such content in a social network setting and that utilizes this content in a manner to increase the interaction between the users of the portal.
SUMMARY
[0008] Embodiments of the present invention relate to a method for managing an interactive computer network involving user-submitted multi-media content in a competitively structured format. In one embodiment of the present invention, a method for sharing multi-media content among a plurality of users in a computer network comprises creating a plurality of user accounts, each of said user accounts corresponding to one of the plurality of users, and having a plurality of interactive features including a first feature that permits the user to upload the multi-media content to the computer network; forming a user network including one or more of the plurality of user accounts in communication with one or more other user accounts and to the uploaded multi-media content via the computer network; categorizing the uploaded multi-media content in accordance with the subject matter of the uploaded multi-media content; organizing the uploaded multi-media content in a competitive format; and establishing a hierarchy for the uploaded multi-media content within the competitive format as a function of a competitive measurement system; wherein the competitive measurement system includes a rating measure assigned to the uploaded multi-media content by the users via the computer network.
[0009] In another embodiment of the present invention, a method of facilitating an online contest within a computer network comprises creating a plurality of user accounts, each of the user accounts corresponding to one of the plurality of users, and having a plurality of interactive features including a first feature that permits the user to upload the multi-media content to the computer network; providing a user interface for the users to access the first interactive feature, the user interface including an embedded multi-media player adapted for viewing the uploaded multi-media content; categorizing the uploaded multi-media content in accordance with the subject matter of the uploaded multi-media content; organizing the uploaded multi-media content in a competitive format having a plurality of competitive rounds based on the quantity of multi-media content being organized; and applying a competitive measurement system to advance particular uploaded multimedia through the plurality of competitive rounds; wherein the competitive measurement system includes a rating measure assigned to the uploaded multi-media content by the users via the computer network.
[0010] In yet another embodiment of the present invention, a computer readable medium comprising a computer program having executable code, the computer program for enabling an interactive multi-media network, the computer program comprises a first set of instructions for creating a plurality of user accounts, each of the user accounts corresponding to one of the users and having a plurality of interactive features including a first feature that permits the user to upload the multi-media content to the computer network; a second set of instructions for forming a user network including one or more of the user accounts in communication with one or more other user accounts and to the uploaded multi-media content via the computer network; a third set of instructions for categorizing the uploaded multi-media content in accordance with a genre selected by the user based on the subject matter of the uploaded multi-media content; a fourth set of instructions for organizing the uploaded multi-media content in a competitive format in a manner consistent with the genre; and a fifth set of instructions for establishing a hierarchy for the uploaded multi-media content within the competitive format as a function of a competitive measurement system, wherein the competitive measurement system includes a rating measure assigned to the uploaded multi-media content by the users after viewing the uploaded multi-media content via the computer network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So the manner in which the above recited features of the present invention can be understood in detail, a more particular description of embodiments of the present invention, briefly summarized above, may be had by reference to embodiments, several of which are illustrated in the appended drawings. It is to be noted, however, the appended drawings illustrate only typical embodiments of embodiments encompassed within the scope of the present invention, and, therefore, are not to be considered limiting, for the present invention may admit to other equally effective embodiments, wherein:
[0012] FIG. 1 illustrates a schematic diagram of the components in an example of an interactive portal that is made in accordance with the concepts of the present invention;
[0013] FIG. 2 illustrates a block diagram of a database used in the embodiments of the interactive portal, such as the interactive portal of FIG. 1 ;
[0014] FIG. 3 illustrates an example of a user interface that is presented to the user of the interactive portal;
[0015] FIG. 4 illustrates a flow chart that describes a method for organizing the shared content in accordance with feedback provided by the users of the interactive portal;
[0016] FIG. 5 is a screenshot of the graphical user interface (GUI) of FIG. 3 illustrating an example of the home link of the interactive portal;
[0017] FIG. 6 is a screenshot of the GUI of FIG. 3 illustrating an example of the challenger link of the interactive portal;
[0018] FIG. 7 is a screenshot of the GUI of FIG. 3 illustrating an example of the challenger home link of the interactive portal;
[0019] FIG. 8 is a screenshot of the GUI of FIG. 3 further illustrating another example of the challenger home link of the interactive portal;
[0020] FIG. 9 is a screenshot of the GUI of FIG. 3 illustrating an example of the search function of the interactive portal;
[0021] FIG. 10 is a screenshot of the GUI of FIG. 3 for gathering feedback from the user on the shared content for use in the method for organizing the shared content based on this feedback, such as the method of FIG. 4 ;
[0022] FIG. 11 is a screenshot of the GUI of FIG. 3 illustrating an example of the category link of the interactive portal;
[0023] FIG. 12 is a screenshot of the GUI of FIG. 3 illustrating an example of the winners club link of the interactive portal; and
[0024] FIG. 13 is a screenshot of the GUI of FIG. 3 illustrating an example of the video off link of the interactive portal.
[0025] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include,” “including,” and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.
DETAILED DESCRIPTION
[0026] Embodiments of the present invention generally relate to a method for sharing multi-media content among users in a global computer network. More specifically, embodiments of the present invention relate to a method for managing an interactive computer network involving user-submitted multi-media content in a competitively structured format.
[0027] Systems that are designed in accordance with the present invention are configured in a manner that permits the users to communicate with other users via electronic mechanisms (e.g., email, chat, text messages) in the context of a social network setting. These systems, however, permit the users to share digital content with the other users of the system. This includes video content, audio content, and image content that is typically not supported by the computer networks discussed in the Background section above. More particularly, a feature of the systems described herein organize the shared content so as to cause the users that provide the shared content to receive rewards, e.g., monetary rewards, and/or other distinctions. More details and an example of the method employed by the embodiments of these systems to select and arrange the shared content will be discussed in more detail below in connection with FIG. 4 below. Before continuing with that discussion, however, a general discussion of the architecture of the system as discussed in connection with FIG. 1 , follows immediately below.
[0028] Referring now to the drawings, FIG. 1 illustrates the general architecture of an example of an interactive portal 100 that operates in accordance with concepts of the present invention. Interactive portal 100 is described herein as an online computer network that connects users in a social network environment. More particularly, interactive portal 100 of FIG. 1 includes a computer network 103 with content 106 that is accessible to users 109 , e.g., users 109 A-F, via a user interface 112 . The interface is presented to users 109 on computing machines 115 that are connected to computer network 103 . Examples of content that content 106 can be include, but are not limited to, multi-media content (e.g., data, music, video, and images), software content (e.g., downloadable/ executable programs), and Internet content (e.g., websites), among others. In many embodiments, content 106 also includes shared content 118 that includes, but is not limited to, video data, audio data, image data, and other digital data that users 109 can upload onto computer network 103 via user interface 112 . As discussed in more detail below, the data that is shared by users 109 may include, for example, music videos, audio recordings, comedy routines, short films, blooper videos, and other homemade digital recordings and pictures that are created, captured, or otherwise acquired by users 109 .
[0029] It will be understood by those having ordinary skill in the art that certain concepts and implementations of interactive portal 100 described herein may be conveniently implemented using one or more computing machine 115 that are programmed according to the teachings of the present specification, as will be apparent to those of ordinary skill in the computer art. For example, various aspects of a method for sharing multi-media content using an interactive interface described herein, may be implemented as machine-executable instructions (i.e., software coding), such as program modules executed by one or more machines.
[0030] Typically a program module may include routines, programs, objects, components, date structures, etc. that perform specific tasks. Appropriate machine-executable instructions can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those of ordinary skill in the software art. Such executable software may be a computer program product that employs a machine-readable medium. Example computer programs include, but are not limited to, an operating system, a browser application, a micro-browser application, a proxy application, a business application, a server application, an email application, an online service application, an interactive television client application, an ISP client application, a gateway application, a tunneling application, and any combinations thereof. A computer-readable medium may be any medium that is capable of storing and/or encoding a sequence of instructions for execution by a machine (e.g., a computing device) and that causes the machine to perform any one of the methodologies and/or embodiments described herein. Examples of a computer-readable medium include, but are not limited to, a magnetic disk (e.g., a conventional floppy disk, a hard drive disk), an optical disk (e.g., a compact disk “CD,” such as readable, writeable, and/or re-writeable CD; a digital video disk “DVD,” such as a readable, writeable, and/or rewriteable DVD), a magneto-optical disk, a read-only memory “ROM” device, a random access memory “RAM” device, a magnetic card, an optical card, a solid-state memory device (e.g., a flash memory), an EPROM, and EEPROM, and any combinations thereof. A computer-readable medium, as used herein, is intended to include a single medium as well as a collection of physically separate media, such as, for example, a collection of compact disks or one more hard disk drives in combination with a computer memory.
[0031] User interface 112 , for example, may conform to a set of machine-executable instructions that is implemented on computing machines 115 and that facilitate the interaction of users 109 via computer network 103 . These instructions may include instructions and/or program modules that permit users 109 to upload, download stream, modify, and /or manipulate shared content 118 . In one embodiment of interactive portal 100 , user interface 112 provides a graphical user interface (GUI) that has graphical icons, visual indicators, and other graphical elements that correspond to the various features, functions, and operations of interactive portal 100 . An example of interactive portal 100 includes such machine-executable instructions so as to cause users 109 to access content 106 , including shared content 118 , of interactive portal 100 via a web browser or similar browser-type applications. These are well-known in the art. Another embodiment of interactive portal 100 includes machine-executable instructions for user interface 112 that are implemented as embedded software on computing machines 115 . This interface may have icons, access bars, access panels, and/or other selectable feature. Often, the embedded software permits users 109 to connect to the content 106 of interactive portal 100 without the use of a Web browser. Still other examples of interactive portal 100 include machine-executable instructions for user interface 112 that permit users 109 to access content 106 via content delivery services, e.g., cable services, satellite services, fiber optic, DSL, and other digital and/or high speed data transmission technologies. An example of a user interface that is suited for use as user interface 112 of the embodiments of interactive portal 100 will be discussed in more detail in connection with FIG. 3 below.
[0032] Computing machines 118 that are used by users 109 will be generally recognized in the art. Examples of machines for use as computing machines 118 include, but are not limited to, a general purpose computer; a special purpose computer; a computer workstation; a terminal computer; a notebook/laptop computer; a server computer; a handheld device (e.g., tablet computer, a personal digital assistant “PDA,” a mobile telephone, etc.); a web appliance; a network router; a network switch; a network bridge; a set-top box “STB;” video tape recorder “VTR;” a digital video recorder “DVR;” a digital video disc “DVD” device (e.g., a DVD recorder, a DVD reader); any machine, component, tool, equipment capable of executing a sequence of instructions that specify an action to be taken by that machine, and any combinations thereof. In one example, a computing device may include and/or be included in, a kiosk. In another example, a computing device includes a mobile device. In yet another example, a computing device includes a device configured for display of video and/or audio content accessed over a network.
[0033] In the present example of interactive portal 100 , users 109 access the interactive portal via computing machines 109 , each in the form of a computer system 121 within which a set of instructions for causing the computing device to perform any one or more of the aspects and/or methodologies of the present disclosure may be executed. It should be noted that although computer system 121 itself and its' components may be shown as singular entities, each component and computer system 121 may include any number of components configured to perform one or more certain functionalities. For example, multiple computer systems 121 may combine to perform any one or more of the aspects and/or methodologies of the present disclosure. Additionally any one aspect and/or methodology of the present disclosure may be dispersed across any number of computer network 105 or across any number of computer system components.
[0034] Computer system 121 includes a processor 124 and a memory 127 that communicate with each other, and with other components, via a bus 130 . Bus 130 may include any of several types of bus structures including, but not limited to, a memory bus, a memory controller, a peripheral bus, a local bus, and any combinations thereof, using any of a variety of bus architectures. Memory 127 may include various components (e.g.; machine readable media) including, but not limited to, a random access memory component (e.g., a static RAM “SRAM,” a dynamic RAN “DRAM,” etc.) a read only component, and any combinations thereof. In one example, a basic input/output system 133 (BIOS), including basic routines that help to transfer information between elements within computer system 121 , such as during start-up, may be stored in memory 127 . Memory 127 may also include (e.g., stored on one or more machine-readable media) instructions 136 (e.g., software) embodying any one or more of the aspects and/or methodologies of the present disclosure. In another example, memory 127 may further include any number of program modules including, but not limited to, an operating system, one or more application programs, other program modules, program data, and any combinations thereof.
[0035] Computer system 121 may also include a storage device 139 . Examples of a storage device (e.g., storage device 139 ) include, but are not limited to, a hard disk drive for reading from and/or writing to a hard disk, a magnetic disk drive for reading from and/or writing to a removable magnetic disk, an optical disk drive for reading from and/or writing to an optical media (e.g., a CD, a DVD, etc.), a solid-state memory device, and any combinations thereof. Storage device 139 may be connected to bus 130 by an appropriate interface (not shown). Example interfaces include, but are not limited to, SCSI, advanced technology attachment (ATA), serial ATA, universal serial bus (USB), IEEE 1394 (FIREWIRE), and any combinations thereof. In one example, storage device 139 may be removably interfaced with computer system 121 (e.g., via an external port connector (not shown)). Particularly, storage device 139 and an associated machine-readable medium 142 may provide nonvolatile and/or volatile storage of machine-readable instructions, data structures, program modules, and/or data for computer system 121 . In one example, software 136 may reside, completely or partially, within machine-readable medium 142 . In another example, software 136 may reside, completely or partially, within processor 124 .
[0036] Computer system 121 may also include an input device 145 . In one example, user 109 of computer system 121 may enter commands and/or other information into computer system 121 via input device 145 . For example, user 109 may utilize a computing device with an input device, such as input device 145 to enter information corresponding to the personal information that is solicited by one or more screens of user interface 112 of interactive portal 100 of FIG. 1 . Examples of an input device 145 include, but are not limited to, an alpha-numeric input device (e.g., a keyboard), a pointing device, a joystick, a gamepad, an audio input device (e.g., a microphone, a voice response system, etc.), a cursor control device (e.g., a mouse), a touchpad, an optical scanner, a video capture device (e.g., a still camera, a video camera), a touchscreen, and any combinations thereof. Still other examples of an input device include a storage device 148 (e.g., a removable disk drive, a flash drive, etc.). Input device 145 may be interfaced to bus 130 via any of a variety of interfaces (not shown) including, but not limited to, a serial interface, a parallel interface, a game port, a USB interface, a FIREWIRE interface, a direct interface to bus 130 , and any combinations thereof.
[0037] Computer system 121 may further include a video display adapter 152 for communicating a displayable image to a display device, such as display device 155 . For example, video display adapter 152 may be utilized to display an interface for accessing one or more content items over a network to display device 155 . Examples of a display device include, but are not limited to, a liquid crystal display (LCD), a cathode ray tube (CRT), a plasma display, and any combinations thereof. In addition to a display device, a computer system 121 may include one or more other peripheral output devices including, but not limited to, an audio speaker, a printer, and any combinations thereof. Such peripheral output devices may be connected to bus 130 via a peripheral interface 158 . Examples of a peripheral interface include, but are not limited to, a serial port, a USB connection, a FIREWIRE connection, a parallel connection, and any combinations thereof.
[0038] A digitizer (not shown) and an accompanying pen/ stylus, if needed, may be included in order to digitally capture freehand input. A pen digitizer may be separately configured or coextensive with a display area of display device 155 . Accordingly, a digitizer may be integrated with display device 155 , or may exist as a separate device overlaying or otherwise appended to display device 155 .
[0039] Users 112 may also input commands and/or other information to computer system 121 via a network interface device 161 . A network interface device, such as network interface device 161 may be utilized for connecting computer system 121 to one or more of a variety of networks, such as computer network 103 , and one or more remote computing devices 164 , and/or machines 121 , connected thereto. Examples of a network interface device include, but are not limited to, a network interface card, a modem, and any combination thereof.
[0040] Computer network 103 is a network that may include one or more network elements configured to communicate data (e.g., direct data, deliver data). Examples of a network element include, but are not limited to, a router, a server, a switch, a proxy server, an adapter, an intermediate node, a wired data pathway, a wireless data pathway, and any combinations thereof. Examples of a network or network segment include, but are not limited to, a wide area network (e.g., the Internet, an enterprise network), a local area network (e.g., a network associated with an office, a building, a campus or other relatively small geographic space), a telephone network, a direct connection between two computing devices, and any combinations thereof.
[0041] These networks may employ a wired and/or a wireless mode of communication. Various communication protocols (e.g., HTTP, WAP, TCP/IP) and/or encryption protocols (e.g., UDP) may be utilized in connecting and/or for communication over a network, such as computer network 103 . In general, any network topology may be used. Information (e.g., data, software 136 , etc.) may be communicated to and/or from computer system 121 via network interface device 161 . In yet another example, storage device 139 may be connected to bus 130 via network interface device 161 . In still another example, input device 180 may be connected to bus 150 via network interface device 161 .
[0042] Computer network 103 in interactive portal 100 of FIG. 1 may include a server apparatus 167 that is connected to computing machines 115 via a global computer network 170 , e.g., the Internet. The term “Internet” generally refers to any collection of distinct networks working together to appear as a single network to users 109 . The term refers to the so-called world wide “network of networks” (e.g., the World Wide Web (“WWW”), where each network is connected to each other using the Internet Protocol (IP) and other similar protocols. Internet 170 provides file transfer, remote log in, electronic mail, news and other services. Thus, as used herein, the term “Internet,” refers to any computer network. Server apparatus 167 is connected to Internet 170 through a router 173 and a 176 , e.g. switch 176 A-B. It is known in the relevant art(s) that routers (e.g., router 173 ) forward packets between networks. Router 173 forwards information packets between server apparatus 167 and computing devices 121 over Internet 170 . A load balancer 179 balances the traffic load across multiple mirrored servers 182 , 185 , 188 , and a firewall 191 provides protection from unauthorized access to server apparatus 167 . Switch 176 A may act as a gatekeeper to and from Internet 170 . Switch 176 B allows the components of server apparatus 167 to be interconnected in a LAN or WAN configuration. This permits data to be transferred to and from the various components of server apparatus 167 . It is noted that the components that appear in server apparatus 167 refer to an exemplary combination of those components that would need to be assembled to create the infrastructure in order to provide the tools and services contemplated by interactive portal 100 , as well as some other embodiments of interactive portal 100 made in accordance with concepts of the present disclosure. It will be readily appreciated by those having ordinary skill in the art that all of the components that are found “inside” of server apparatus 167 may be connected and may communicate via a wide or local area network (respectively, WAN or LAN).
[0043] Server apparatus 167 includes an application server 182 or a plurality of application servers 182 , as well as databases 194 , 197 . Examples of applications servers that application server 182 can be include a multi-media server 182 A, web application server 182 B, a computer server 182 C, and a messaging server 182 D, among others. Multi-media content server 182 A stores the digital content and provides it to other components of server apparatus 167 , and to computing machines 112 , as desired. This content may be configured separately from web application server 182 B so as to increase the scalability of server apparatus 167 . In an alternative configuration, web application server 182 B and multi-media content server 182 A are configured together.
[0044] Examples of content formats that can be managed by multi-media content server 182 A include, but are not limited to, Graphical Interchange Format (“GIF”), Joint Photographics Experts (“JPEG”), Portable Network Graphics (“PNG”), Tagged Image File (“TIFF”), Audio Video Interleave (“AVI”), Waveform (“WAV”), Audio Interchange File Format (“AIFF”), Au File Format (“AU”), Windows Media Audio (“WMA”), WavePack (“WV”), Free Lossless Audio Code (“FLAC”), Monkey's Audio (“APE”), True Audio (“TTA”), Apple Lossless (“AL”), MPEG-1 Audio Layer 3 (“MP3”), Advanced Audio Coding (“AAC”), Extensible Music Format (“XMF”), 3GP and its derivatives, Advanced Systems Format (“ASF”), DVR-MS, Moving Picture Experts Group (“MPEG”) and its derivatives, IFF, Matroska Multimedia Container (“MKV”), MOV, OGG, Ogg Media File (“OGM”), RealMedia, Media Player Classic (“MPC”), RAW, Global System for Mobile Communications (“GSM”), Dialogic ADPCM (“VOX”), DCT, Adaptive Transform Acoustic Coding (“ATAC”), RealAudio (“RA”) and its derivatives, DVF, BMP and Bitmap, Portable Pixmap File Format (“PPM”), Portable Greymap File Format (“PGM”), Portable Bitmap File Format (“PBM”), Portable Anymap (“PNM”), Scalable Vector Graphics (“SVG”), Shockwave Flash (“SWF”), Portable Document Format (“PDF”), encapsulated PostScript, Windows Metafile, and other formats that are used to otherwise electronically store and/or transmit data. Of course, this is not an exhaustive list, but, rather, examples of formats that the multimedia content servers that are used for multi-media server 182 A in embodiments of interactive portal 100 .
[0045] Messaging server 182 D is configured to store and distribute electronic communications to and from computing machines 112 . Examples of electronic communications include, but are not limited to, electronic mail and electronic messages (“email”), text messages, and chat messages, among others. Although shown as a single server in server apparatus 167 , messaging server 182 D may include a number of servers that are each configured to exchange one or more of the types of electronic messages mentioned previously. For example, messaging server 182 D may include an email server (not shown) that is configured to send and receive the electronic communications, as well as it acts as a repository for electronic communications received from Internet 170 . Generally, servers of the type used as messaging server 182 D (and the email server, if necessary) include a storage area, a set of user definable rules, a list of users, and a series of communication modules that are consistent with the type of electronic communication.
[0046] Web application server 182 D and computer server 182 C serve as the application layer of the present example of interactive porta 1100 . More specifically, web application server 182 B is a system that sends out web pages in response to Hypertext Transfer Protocol (HTTP) request from remote browsers (i.e., users 115 ). That is, web application server 182 B provides user interface 102 to users 109 of interactive portal 100 in the form of Web pages.
[0047] Computer server 182 C may include a central processing unit (“CPU”), a random access memory (“RAM”) for temporary storage of information, and a read-only memory (“ROM”) for permanent storage of information. Computer server 182 C is generally controlled and coordinated by an operating system that is itself a set of machine executable instructions, similar to software 136 discussed above. This operating system controls allocation of system resources and performs tasks such as processing, scheduling, memory management, networking and/or services, among other things. For example, the operating system resident in system memory and executed by the CPU coordinates the operation of the other elements of server apparatus 167 .
[0048] Second switch 176 B may include inter-process communications protocols 140 A (“IPCP”). These are sets of rules for marshalling and unmarshalling parameters and results. This is the activity that takes place at the point where the control path in the calling and called process enters or leaves the IPCP domain. The IPCP is essentially a set of rules for encoding and decoding information transmitted between multiple processes.
[0049] Firewall 191 is configured to shield application servers 182 , databases 194 , 197 , from Internet 170 . It is a dedicated gateway machine with special security precaution software that is designed to protect the loosely administered network elements from hidden invasion. Firewalls for use as firewall 191 are generally well-known in the art therefore, no additional description is necessary.
[0050] Databases 194 , 197 store software, descriptive data, digital content, system data, and any other data item required by the other components of server apparatus 167 . Databases used as databases 194 , 197 are provided as, for example, a database management system (“DBMS”), an object-oriented database management system (“ODBMS”), a relational database management system (e.g., DB2, ACCESS, etc.), a file system, and/or another conventional database package. In alternative examples, each of database 194 , 197 are implemented using object-oriented technology or via text files that are accessed with a Structured Query Language (SQL) or other tools known to those having ordinary skill in the art.
[0051] In view of the foregoing discussion of server apparatus 167 , it will be readily appreciated by those having ordinary skill in the art that computer network 103 as described herein will include one or more of the components discussed above. The type, quantity, and selection of such components may depend, however, on the type of architecture that is required to implement the various embodiments of the interactive portal 100 . It may further depend on the architecture that is desired. For example, embodiments of interactive portal 100 are configured in accordance with architecture that permits users 109 to view, upload, download, stream, modify, or manipulate content 106 , and, in particular, shared content 118 . They are also configured to permit users 115 to communicate, to exchange data, and to implement the other features of interactive portal 100 as described herein. Examples of architecture that is suited for use with the features in the embodiments of the interactive portals includes, but is not limited to, client-server architecture, peer-to-peer architecture, and file transfer protocol (“FTP”) architecture, among others. Examples of peer-to-peer architectures that might be used include, but are not limited to, pure peer-to-peer networks, friend-to-friend networks, and darknet networks, among others. Whereas such broad concepts of architecture, software and the like currently exist in the art, a detailed explanation of the relevant architecture and such concepts is not needed.
[0052] Referring now to FIG. 2 , and also FIG. 1 , a block diagram of an example of a database 200 that is compatible with one or more embodiments of interactive portal 100 is illustrated. Database 200 includes data categories 203 , e.g., 203 A-C, that are further organized into data groups 206 , e.g., user data 209 , profile data 212 , location data 215 , zip code data 218 , format data 221 , genra date 224 , length data 227 , feedback data 230 , among others. Databases that are used as database 200 are generally used to manage, organize, and categorize the information that is collected from the users of the interactive portal. These are implemented on, for example, database 194 , 197 of FIG. 1 , as a DBMS, an ODBMS, a relational database management system (e.g., DB2, ACCESS, etc.) or another conventional database packages.
[0053] Although only specific examples of data categories 203 (and data groups 206 ) are shown in the embodiment of database 200 in FIG. 2 , it will be appreciated by those having ordinary skill in the art that any number of categories and groups are available for use in database 200 . Thus, the illustration of database 200 , and the discussion herein should not limit in anyway the scope and spirit of the present disclosure. Rather, database 200 is described herein as one example of the way the information in the interactive portals is implemented in accordance with concepts of the present invention.
[0054] Information found in database 200 is identified in accordance with each individual user. It may be linked together into cohesive units, such as, for example, user accounts, corporate accounts, and other types accounts that the information in database 200 to the users of the interactive portal. In the present example, data groups 206 are configured in a manner that organizes the information into individual user accounts. These include information that is entered by the users via the user interface or other collection method, e.g., via telephone.
[0055] Data groups 206 include several categories of information, including, but not limited to, descriptive data, shared content data, rating data, as well as other data items. Generally, descriptive data refers to information that describes the user or characteristics of the user. It may also include elements that describe attributes of the user, such as, for example, gender, marital status, occupation, and the like. The descriptive data can be further grouped into user data 209 , profile data 212 , location data 215 , and zip code data 218 , each of which include any number of data elements.
[0056] Content data refers to data that describes the content that is shared by users of the interactive portal. It may also include data elements that describe attributes of the content, such as, for example, format, category, length, rating data, and the like. The content data can be further grouped into format data 221 , genre data 229 , length data 227 , feedback data 230 , each of which include any number of data elements.
[0057] Other data items relate to operating components of the exemplary system. Such other data items include favorite content 233 , messages 236 , bulletin board 239 , as well as preference data. Preference data refers to data that describes the preferences that the users of the interactive portal have with respect to one another, and with respect to their individual account settings. The data fields that are used to capture descriptive data can also be used to capture preference data, as well. In one example, in the descriptive context someone might “have a specific zip code;” while in the preference context that person might “prefer to meet people in that zip code.” Most preference data in this example when presented in the user interface (e.g., GUI) is presented in hypertext markup language (“HTML”). So, embodiments of the interactive portal can include search functions that permit user to type any search terms they desire into a search box so as to search the descriptive data and get the results.
[0058] Referring now to FIG. 3 , a schematic diagram of an example of a user interface 300 that allows users to access the features of the interactive portal and is designed to allow a user to navigate the content of embodiments of the interactive portal, such as interactive portal 100 of FIG. 1 , is illustrated. It may include, for example, a screen 303 , e.g., screens 303 A-F that includes an interactive area 306 that has a multi-media area 309 , a challenge area 312 , and a navigation area 315 that are each configured to present to the user information, data, and other content that is found on the interactive portal.
[0059] Generally, multi-media area 309 of user interface 300 has a multi-media player 315 that is configured to display, play, and otherwise present the shared content in a manner that is visually and audibly accessible to the user. In accordance with embodiments of the present invention, the multi-media player 315 may be an embedded player, such that it may be embedded on any accessible webpage or interactive portal. For example, the multi-media player 315 may be embedded on an individual's personal home webpage not associated with the interactive network described herein. When embedded on such individual's home webpage, any features and embodiments disclosed herein would be available via the multi-media player 315 , whereby the multi-media player acts 315 as an embedded portal to the interactive network described herein.
[0060] Challenge area 312 includes category links 321 , e.g., category links 321 A-F, that are each associated with a content list 324 that includes shared content 327 that is stored on the interactive portal. Navigation area 315 has a number of navigation links 330 that permit the user to navigate to other ones of screen 303 of user interface 300 with an input device, e.g., by “pointing and clicking on the appropriate link.”
[0061] In the present example, navigation links 330 include, 1) a home link 333 ; 2) a challenges link 336 that displays a search feature 339 that uses a search criteria 342 to retrieve user information that is stored on the interactive portal; 3) a challenger link 345 that provides a challenger information region 348 , a challenger picture region 351 , and a content upload region 353 , that are used to establish the user accounts, or “challenger accounts,” for the users of the interactive portal; 4) and a challenger home link 355 that displays a features region 358 that is accessible to those users of the interactive portal with a challenger account. Features region 358 includes a file structure region 361 that displays file folders 364 that correspond to one or more features of the challenger account in a hierarchical order, an icon region 367 that displays selectable icons 370 that correspond to one or more of the features of the challenger account, and a display region 373 that acts as the display for these features in response to either the file folders 361 and/or selectable icons 370 .
[0062] Navigation links 330 also include 5) a winners club link 373 that displays a category region 376 with categories 379 and a winners region 382 with winning content 385 that is selected from among the shared content in particular ones of categories 379 in accordance with a competitive format (not shown), as well as 6) a video off link 388 that displays regional competition region 391 with regions 394 A-D, and overall competition area 397 that includes regional content 397 , e.g. 397 A-D from each of regions 394 A-D. Details of the features of screens 303 of user interface 300 , will be discussed below, and in connection with the exemplary screens illustrated in the screen shots of FIGS. 5-12 below.
[0063] While navigation area 315 is shown having a particular arrangement of navigation links 330 , those skilled in the art will readily appreciate that other arrangements may be used to suit a particular user interface design. For example, the types of links that are suited for use in embodiments of user interface 300 may include, but are not limited to, a link that permits the user to search for content on the interactive portal or on the WWW; a link that permits the user to purchase merchandise, e.g., clothing, digital video disks (DVD); a link that provides information and/or permits the user to communicate criticism, suggestions, questions, and general commentary about their experience on the interactive portal; a link that permits the user to explore business endeavors, e.g., advertisements, on the interactive portal; a link the provides the user with information about the rules, analysis and organization of the shared content, as well as many other links that are not detailed herein but that fall within the scope and spirit of the present invention.
[0064] With continued reference to FIG. 3 , screens that are used as screen 303 of user interface 300 are linked together so that the user can navigate from one screen to another. This enables users to move amongst the various screens using any suitable input device, e.g., a mouse, touch screen, etc. This can be achieved in a manner similar to the way Web sites are navigated on the World Wide Web (WWW). In one example, user interface 300 employs one or more uniform resource identifiers (URI), and the protocols, software, and rules that are associated with systems that use URI-type identifiers, to link the screens of user interface 300 .
[0065] Players that are used as multi-media player 318 are generally adaptable to audio, video, and image content. It may be desirable, for example, that players that are selected for player 318 are suited to handle each type of content, as well as the range of formats that is available for each type of content. For example, players that are suited for player 318 are adapted for a variety of video formats, including, but are not limited to AIFF, WAV, XMF, 3gp, ASF, AVI, DVR-MS, MPEG, IFF, MKV, MPEG-TS, MP4, MOV, OGG, RealMedia, as well as similar format that are used to electronically capture, store, and/or transmit video files. The players are also compatible with audio content formats that include, but are not limited to, MP3, WMA, WAV, OGG, MPC, FLAC, AIFF, RAW, AU, GSM, VOX, DCT, ACC, M 4 A, MP 4 , ATRAC, RA, RAM, DSS MSV, DVF, as well as similar format that are used to electronically capture, store, and/or transmit audio files. Players for player 318 are also compatible with image formats including, but not limited to, JPEG, TIFF, RAW, PNG, GIF, BMP, PPM, PGM, PBM, PNM, SVG, SWF, PDF, encapsulated PostScript, Windows Metafile, and any other format that is used to electronically capture, store, and/or transmit image files. Although it may be desirable that the player selected for player 318 is compatible with every type and format of the multi-media content, alternative embodiments of user interface 300 may include more than one player that are selected, respectively, because they are adaptable to one or more of the types of content.
[0066] Typical category links that are used for category links 321 A-F are based on the characteristics of the content found in content list 324 . This content as it relates to shared content 327 . Exemplary characteristics include subject matter (or “genre”), length, and language, among others. But, this is not an exhaustive list. Rather other characteristics can be selected and assigned to shared content 327 , as desired. For purposes of the embodiment of user interface 300 of FIG. 3 , shared content 345 is organized in accordance with its genre. Examples of the genre that can be used in embodiments of the interactive portal include, but are not limited to, “short films,” “comedy,” “pesky pets,” “garage bands,” “family video,” and agony of defeat.” It is contemplated, however, that the genre is amenable to other descriptive indicators of the subject matter. Such indicators may be selected by the interactive portal, i.e., by the administrators or designers of the interactive portals. Or, the users of the portal may create their own genre, as desired.
[0067] Content list 324 may be instantiated in a number of ways. One exemplary content list for content list 324 is a list of shared content 327 . Another is displayed as one or more images taken that are part of, or taken from, shared content 327 (e.g., “thumbnails”). Each of these can be readily implemented by those having ordinary skill in the art. In one example, shared content 327 that is uploaded to the interactive portal is assigned a genre. This may occur automatically, or, alternatively, it may require that the user input or select the proper information that corresponds to the genre of their uploaded content.
[0068] Once the genre is assigned to the shared content, it may be found in content list 324 under category link 321 that corresponds to that genre. Thus, a music video that features a rock band would be assigned to the genre “garage bands.” When a user selects a particular one of category links 321 in challenge area 312 , e.g., by “pointing and clicking on it,” user interface 300 may display on screen 303 the content list with shared content that is assigned to that genre, if any, associated with that category link. Then, the user can select from the resultant list a particular one of the shared content for viewing.
[0069] It would be customary, though not imperative, that the screen associated with home link 333 in navigation links 330 is the primary screen, i.e., the “home page,” of embodiments of the interactive portal. As discussed in connection with FIG. 5 below, home link 333 is typically associated with the first Web page presented to a user of the interactive portal. In accordance with embodiments of the present invention, the home link 333 is the portion of the interactive portal that provides the user with general content, advertisements, links, and other information that has to do with the interactive portal.
[0070] Users that want to search for other users on the interactive portal may enter search criteria 342 , via an input device (e.g., a keyboard), into search feature 339 . Search criteria that search criteria 342 of challenges link 336 can be include, but are not limited to, name, age, email address, account ID, country, state, zip code, age, and gender, among others. Use of the search criteria in search feature 339 to retrieve information will be generally understood by those having ordinary skill in the art. Search feature may utilize, for example, algorithms that are configured interact with the portions of the interactive portal e.g databases 194 , 197 ( FIG. 1 ), where the relevant information is stored to retrieve that information that corresponds to the particular search criteria.
[0071] Challenger information region 348 , a challenger picture region 351 , and content upload region 353 that are used to set up the challenger accounts is each configured to receive data, e.g., from an input device. This data includes, but is not limited to, text, images, video, and audio, among others. In one embodiment of the interactive portal 194 and 197 , the information is stored on the interactive portal, i.e., in databases discussed in connection with FIG. 1 above.
[0072] As illustrated in FIG. 3 challenger information region 348 may be configured for information about the user, e.g., email address, passwords, address (e.g., country, state, zip code), gender, birth data, first name, last name, school, work, other general data and commentary about the user, and the like. Challenger picture region 351 and content upload region 353 are configured to permit the user to upload, save and/or store their shared content (e.g., images, video, and audio) in one or more of the formats discussed above.
[0073] File folders 364 and selectable icons 370 of features region 358 typically correspond to applications that are available to users that have challenger accounts. For example, some of the file folders and/or selectable icons found in the features region typically correspond to applications that permit the user to communicate (and manage communications) with other users of the interactive portals that have challenger accounts. This may be done via email, instant message, text message, and similar types of electronic messaging applications. The file folders and/or selectable icons may also correspond to applications that have planning and other functionality, like calendars, datebooks, journals, and other similar type of applications that are suited to maintain chronological order of important events, dates, and other information in daily, weekly, and/or annual order, as desired. Still other options that may be available in the feature region may include applications that permit the user to modify certain aspects of their challenger account. These aspects may include, for example, personal information, server and folder information, login information, message composition, message viewing, message location, message filters, as well as other display options and applications. Suitable applications that are used in the features region include, but are not limited to, email, address book, notes, calendar, and account management applications. It is contemplated that a user can select from among the file folders 364 and/or selectable icons 370 with an input device, e.g., by “pointing and clicking on it.” When the user selects one of these features, it causes display region 373 to display menu choices, options, and other selections that the user can navigate to further implement the chosen application, e.g., by “pointing and clicking on them.” An example of some of these options will be discussed in FIGS. 7-8 below.
[0074] A feature of some embodiments of the interactive portals discussed herein is the way the portal organizes particular ones of the shared content. In the present example, winning content 385 that is found in winners region 382 is identified using a number of competitive analysis methods. Generally, the analysis methods that are used by the interactive portal include algorithms, software, and other automatedly implemented methods. These are configured to identify particular ones of the shared content from among other ones of the shared content based on feedback provided by the users of the interactive portal. In many embodiments, the shared content is from the same genre. Feedback that is suited for use in the analysis methods can take many different forms. Examples include, but are not limited to, points, scores, commentary, votes, ratings, letter grades, total number of views, and any combination thereof. In one exemplary embodiment of the present invention, a plurality of multi-media content is eligible for a particular level of competitive analysis. In such an example, users of the interactive portal may choose which of plurality of multi-media content is most enjoyable and/or deserving of winning a competition. When a user chooses which multi-media content should win, the user designates a “point” to that multi-media content.
[0075] Where the user rating system is based on “points,” as exemplified above, then the analysis method to identify the winning content from among two or more shared content of the same genre determines which of the shared content received the highest cumulative point total for a predetermined period of time. Exemplary time periods include, daily, weekly, monthly, annually, bi-monthly, bi-annually, or the like. An example of a method for identifying shared content is discussed in more detail in connection with FIG. 4 below.
[0076] Regional content 397 A-D in overall competition area 397 that is displayed via video off link 388 is also selected in accordance with the competitive formats discussed above, and in more detail below. To provide one or more of the regional content, however, the analysis method may compare shared content from different genre. For example, the regional content that is found in overall competition area 397 can be selected by comparing the cumulative point totals of the winning content for each genre over a given period of time. Then, an overall winner (not shown) is selected from among the regional content that is found in overall competition area 397 . Thus, it is possible that the overall winner is selected from among regional content that are all from different genre.
[0077] FIG. 4 illustrates an example of a method 400 that is used to organize the shared content of the interactive portal in accordance with concepts of the present invention. Method 400 includes, at step 405 , selecting a time period for gathering data. Then, at step 410 , method 400 includes gathering feedback from the users on the shared content. This includes, for example, gathering points, votes, and other indicators that users select via the user interface after they view particular ones of the shared content.
[0078] Next, at step 415 , method 400 includes determining whether the time period has been met. If it is, then the method moves to step 420 , where method 400 includes analyzing the feedback to identify which of the shared content received the highest cumulative point total.
[0079] The steps of method 400 can be applied, in whole, or, in part, to analyze the feedback that users provide for particular ones of the shared content. In a one embodiment of the interactive portal, examples of method 400 are applied in a manner that identifies the winning content that is found in the winners region, as discussed above. It can also be used to determine the overall winner from among the regional winners, as well as, for the purpose of identifying a particular one of the shared content from other shared content that is found on the interactive portal. In accordance with embodiments of the present invention, any competitive format is contemplated within embodiments of the present invention. For example, head-to-head, bracket, open popularity forum, and the like, are suitable competitive formats for embodiments of the present invention.
[0080] It is noted that the processing and decision block that are illustrated in FIG. 4 represent steps performed by functionally equivalent circuits such as a digital signal processor circuit or an application specific integrated circuit (ASIC). The flow diagram does not depict the syntax of any particular programming language. Rather, the flow diagram illustrates the functional information one having ordinary skill in the art requires to fabricate circuits or to generate computer software to perform the processing required of the particular machine. It should also be note that many routine program elements, such as initialization of loops and variables and the use of temporary variables are not shown. The particular sequence of steps described is illustrative only and can be varied without departing from the scope, spirit, and concepts of the present disclosure.
[0081] Generally speaking, the time period that is selected identifies the period during which the interactive portal will consider the feedback that the users of the interactive portal provide in connection with the shared content. It may be based on a time increment, e.g., minutes, hours, days, etc. While the actual value of the time increment can be selected at random, it may be desirable that the time increment is selected based on the desired length of a contest, or other event, that is used to grant rewards to the users that uploaded the winning content or the overall winner.
[0082] The algorithms used to gather the feedback from the users will be generally recognized in the art. They may respond to actions from the users. In one example, the algorithm may register the numerical value or the other indicator that is assigned to the users' selection, e.g., “by pointing and clicking on a menu item.”
[0083] Similarly the instructions that are used to analyze the feedback may operate on the registered values in order to organize, and/or to identify, particular ones of the shared content and their corresponding user. Such instructions will often operate in a manner that access the various user information that may be saved in the databases of the computer network.
[0084] Referring to FIGS. 5-12 , these figures are used hereinbelow to illustrate various features of the user interface that are available on some exemplary embodiments of the interactive portal. Generally, the screens illustrated by the screen shots of FIGS. 5-12 are examples only, and, for purposes of the descriptions that follow below, illustrate examples of user interface 500 , 600 , 700 , of the interactive portal in accordance with embodiments of the present invention. Such interactive portals may run on any suitable machine, e.g., a computing device (such as computer system 121 of FIG. 1 .) As discussed in more detail below, user interface 500 , 600 , 700 , include interactive features that greatly simplify the actions the user must take in navigating the content of the interactive portal.
[0085] With continued reference to FIG. 5 , the screen shot of user interface 500 includes a screen 503 that has an interactive area 506 that is configured to display a multi-media area 509 , a challenge area 512 , and/or a navigation area 515 . While interactive area 506 , and user interface 500 in general, is shown having particular arrangement of areas 509 , 512 , and 515 , those skilled in the art will readily appreciate that other arrangements may be used to suit a particular user interface design. Using the layout of interactive area 506 shown, when the user wishes to view other screens of the interactive portal, they may select one or more of the links that are found in interactive area 410 so as to be transported (electronically) to one or more different screens, such as the screens discussed in FIGS. 6-12 below.
[0086] Assuming, for this illustration only, that interactive area 506 of user interface 500 of FIG. 5 is the home page and displays only content of the interactive portal that is of a general nature, then the user can select from amongst the links that are found in areas 509 , 512 , and 515 , to explore other areas of the interactive portal. The user, for example, may select one of the links from challenge area 512 and from navigation area, e.g., “by pointing and clicking on it.”
[0087] FIG. 6 illustrates a screen shot of an example of user interface 600 that permits users to enter data, e.g., personal data, content data, etc. User interface 600 may be associated with the challenger link, discussed above. It may be desirable that this information is stored on one of the databases use on the computer network. In the present example, user interface 600 can enter descriptive data (e.g., e-mail address, country, state, zip code, gender, etc.) in the challenge information region and to upload shared content to the interactive portal in the content upload region. Some screens that are used for user interface 600 may also include a video search feature, as well as a multi-media player that is used to view shared content on the interactive portal.
[0088] FIGS. 7-8 illustrate screen shots of an example of user interface 700 , 800 that allows the user to view and manage the various applications that may be available via their challenger account. The screens of user interface 700 , 800 may be linked to the challenger home link, discussed above, as well as to each other. When the user wishes to activate one of the applications, they can select a file folder from the file folder region or, alternatively, from amongst the selectable icons in the icon region, e.g., by “pointing and clicking on it.” Then, the features of the application that correspond to the file folder and/or selectable icon will be displayed in the display region. In the example of user interface 700 that is illustrated in FIG. 7 , the features of the “inbox” application are seen. Similarly, in the example of user interface 800 that is illustrated in FIG. 8 , the features of the “options” for the email application are seen.
[0089] FIG. 9 illustrates a screen shot of an example of user interface 900 that permits the user to search for other users, shared content, and other information. This screen often corresponds to the challenger link, described above. In the screen shown in FIG. 9 , the user can enter one or more search criteria, e.g., name, challenger and/or user id, country, state, zip code, age, gender, e-mail address, and other criteria that is associated with the information and data stored by the interactive portal. The user can then activate the search by selecting the “search” icon, e.g., by “pointing and clicking on it.”
[0090] FIG. 10 illustrates a screen shot of an example of user interface 1000 that permits the user to view (or hear) particular ones of the shared content. It also allows the users to provide feedback on the shared content. In the present example, the user can add comments, thoughts, and messages about the shared content. Some embodiments of the interactive portal may transmit this commentary to the user associated with the shared content via email, text message, or in a manner that is consistent with the concepts discussed herein. The user can also provide feedback by selecting the rating they feel is appropriate. In the present illustration of user interface 1000 , the ratings that can be applied to the shared content include, from the lowest value to the highest value, “sorry try again,” “rookie,” “not too shabby,” “worthy,” and “challenger.” It is noted that although the ratings that are seen on the screen of FIG. 10 are textual, they can be used in the competitive analysis methods that are contemplated by the disclosure herein. For instance, each of the ratings that are found in user interface 1000 may be assigned numerical values that are then utilized by the analysis methods. Alternatively, it is further contemplated that one of the competitive methods may be constructed (e.g., via machine-executable instructions, software) so as to be able to utilize the textual message.
[0091] FIG. 11 illustrates a screen shot of an example of user interface 1100 that provides the user with a list of the categories (e.g., genre) of the shared content that is available on the interactive portal. This screen typically corresponds to the challenges link, discussed above. Further, in certain implementations of the interactive portals described herein, these categories will correspond to the subject matter of the shared content, as described above. As can be seen in FIG. 11 , the list may include images, or “thumbnails,” that relate to particular ones of the shared content that is associated with that category. Or, in alternative embodiments of the interactive portal, the list may simply show a list of the categories that have shared content available for the user. Of course, the actual appearance of the categories is flexible, in that, the screen that is used for user interface 1100 can present the categories in a manner that is suitable for the user to select from among the available categories of the shared content.
[0092] FIG. 12 illustrates a screenshot of an example of user interface 1200 that displays particular ones of the shared content that is selected in accordance with the competitive analysis methods that are discussed above. This screen is often associated with the winners' club link, described in detail above. In the present example, the winning content that is found in the winners region are organized so as to display monthly winners that correspond to the various categories of the shared content. Similarly, FIG. 13 illustrates a screenshot of an example of user interface 1300 that displays particular ones of the shared content that are also selected in accordance with the competitive analysis methods that are discussed above. In this example of user interface 1300 , it is seen that the overall winners region is organized to display the regional content, as desired.
[0093] In view of the foregoing discussion of the winners region and the overall winners region, it is noted that various embodiments of the interactive portal may use a variety of schemes, monikers, and other identifies to elaborate on the contest that may be administered via the interactive portal. For example, winning content that is identified over a given time period can also be paired against each other to identify which of the regional content has received the most favorable feedback (e.g., the highest cumulative point total). Consider, for instance, a first video in category A received 100 points in a given monthly time period, and a second video in category B received 150 points during the same monthly time period. In context of the winning content that is displayed via, e.g., the winners' club link, the first video and the second video may both appear as winning content in the winners region. However, for purposes of the regional content that is displayed via, e.g., the video off link, the second video will be identified when compared to the first video.
[0094] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. | In one embodiment of the present invention, a method for sharing multi-media content among a plurality of users in a computer network comprises creating a plurality of user accounts, each of said user accounts corresponding to one of the plurality of users, and having a plurality of interactive features including a first feature that permits the user to upload the multi-media content to the computer network; forming a user network including one or more of the plurality of user accounts in communication with one or more other user accounts and to the uploaded multi-media content via the computer network; categorizing the uploaded multi-media content in accordance with the subject matter of the uploaded multi-media content; organizing the uploaded multimedia content in a competitive format; and establishing a hierarchy for the uploaded multi-media content within the competitive format as a function of a competitive measurement system. | 6 |
The application claims benefit of Provisional Application No. 60/655,725, filed Feb. 24, 2005.
The present invention relates to a snap-type locking device for releasable and principally external keeping together of two parts and comprising at least one grip part, at least one movable arm and at least one spring, said at least one movable arm being turnably attached to said at least one grip part as well as, directly or indirectly, to a first part of said two parts.
PRIOR ART
U.S. Pat. No. 2,829,912 discloses draw bolts for luggage. Each draw bolt or locking device has a grip part, a movable arm and springs. The springs are not arranged to urge the grip part in a direction away from the luggage, and therefore unintentional locking or sticking may occur in the unlocked position.
SUMMARY OF THE INVENTION
A first object of the invention is to provide a snap-type locking device that is convenient to lock and unlock and convenient to use also in the unlocked state in such a way that the lock not unintentionally gets stuck in the locked or semi-locked position. A second object of the invention is to provide a snap-type locking device having fewer components included than in locks of known types. A third object of the invention is to provide a snap-type locking device that is simple and therefore cost-effective to produce.
Hence, the invention embodies a snap-type locking device for releasable and principally external keeping together of two parts and comprising at least one grip part, at least one movable arm and at least one spring, said at least one movable arm being turnably attached to said at least one grip part as well as, directly or indirectly, to a first part of said two parts. Said at least one spring abuts against said at least one grip part in order to urge the same in a direction away from said two parts.
Said at least one spring may abut against a first side, facing said two parts, of said at least one grip part.
Said at least one movable arm may be turnable around a first axis of rotation in relation to said at least one grip part and turnable around a second axis of rotation in relation to said first part. Said at least one movable arm may be turnably or fixedly attached to at least one fixed arm, which in turn is turnably or fixedly attached to said first part. Said at least one fixed arm may be a part of the locking device. Said at least one fixed arm may be a part of said first part. Said at least one fixed arm may be integral with said first part.
Said at least one spring may comprise at least one anchoring spring leg, which extends from a second axis of rotation, around which said at least one movable arm may be arranged to turn in relation to said first part, and into a recess, slot or the like in said first part, and/or in an additional part attached to said first part, in order to, in this way, prevent said at least one spring in its entirety from being turned around said second axis of rotation.
Said at least one spring may be equipped with at least two urging spring legs, which extend at an angle in relation to each other from said second axis of rotation into abutment against a first side, facing said two parts, of said at least one grip part in such a way that at least a first urging spring leg of said at least two urging spring legs can bring said at least one grip part to turn in a first direction around said second axis of rotation and at least a second urging spring leg of said at least two urging spring legs can bring said at least one grip part to turn in a second direction around said second axis of rotation, said second direction being counter-directed to said first direction and a state of equilibrium occurring when the locking device is in the unlocked position. In said state of equilibrium, said at least one grip part may be positioned in a free position at a distance from said two parts. A main extension plane of said at least one grip part may, in the unlocked position, extend principally parallel to a main extension plane of said at least one grip part in the locked position.
Each one of two movable arms may be turnably attached to said at least one grip part as well as, directly or indirectly, to said first part, wherein the arms may constitute a unit together with a first spindle, coinciding with a first axis of rotation, and a second spindle, coinciding with said second axis of rotation, in order to move together, wherein each one of the spindles may extend between and unite the arms, wherein said first spindle, in the unlocked position, may abut against at least one of said at least a first and a second urging spring legs.
Said at least one spring may abut against a first side, facing said two parts, of said at least one grip part of a spring side of a plane that intersects a main extension plane of said at least one grip part under a principally right angle and that simultaneously passes through, and principally parallel to, a second axis of rotation, around which said at least one movable arm may be arranged to turn in said first part and vice versa, wherein at least a first arm leg of said at least one movable arm, in the unlocked position, may abut against at least one fold on said first side of an arm side of said plane, wherein said spring side and said arm side may be different sides of said plane.
At least a second arm leg of said at least one movable arm may, in the unlocked position, abut against said at least one spring, wherein said at least one grip part may be positioned in a free position at a distance from said two parts. Said main extension plane of said at least one grip part may, in the unlocked position, extend principally parallel to said main extension plane of said at least one grip part in the locked position.
Said at least one movable arm may be turnable around a first axis of rotation in relation to said at least one grip part and may be formed in such a way that it simultaneously constitutes a first spindle, at least partly coinciding with said first axis of rotation, and a second spindle, at least partly coinciding with said second axis of rotation, wherein a first end of said at least one movable arm may be mounted in a bearing in a recess suitable therefor in a first flange of said at least one grip part, a second end of said at least one movable arm may be mounted in a bearing in a recess suitable therefor in a second flange of said at least one grip part and a portion of said at least one movable arm occurring therebetween may be mounted in a bearing in a recess suitable therefor in said first part, and/or in an additional part attached to said first part.
LIST OF DRAWINGS
FIG. 1 shows, in a side view from the left, a first embodiment of a locking device according to the invention and in the locked state.
FIG. 2 shows, in a front view, the locking device of FIG. 1 .
FIG. 3 shows, in a partly sectioned side view from the left, the locking device of FIG. 1 in the unlocked state.
FIG. 4 shows, in a partly sectioned side view from the left, the locking device of FIG. 1 in a semi-locked state.
FIG. 5 shows, in a partly sectioned side view from the left, the locking device of FIG. 1 in the locked state.
FIG. 6 shows, in a sectioned perspective view from the right, a second embodiment of a locking device according to the invention and in the locked state.
FIG. 7 shows, in a sectioned side view from the right, the locking device of FIG. 6 in the locked state.
FIGS. 8 and 9 show, in sectioned perspective views from the right, the locking device of FIG. 6 in the locked state.
FIGS. 10 and 11 show, in sectioned perspective views from the right, the locking device of FIG. 6 in the unlocked state.
FIG. 12 shows, in a perspective view from the left, the locking device of FIG. 6 in the unlocked state.
FIG. 13 shows, in a sectioned perspective view from the left, the locking device of FIG. 6 in the unlocked state.
FIG. 14 shows, in a perspective view from the left, the locking device of FIG. 6 in the locked state.
FIG. 15 shows, in a perspective view from the right and from above, a part of the locking device of FIG. 6 .
FIG. 16 shows, in a perspective view from the right and from below, the part according to FIG. 15 .
FIG. 17 shows, in a perspective view from the right, parts of the locking device of FIG. 6 .
DESCRIPTION OF EMBODIMENTS
A first embodiment of the locking device has an appearance and a function in accordance with the FIGS. 1-5 . The locking device is mounted on a first part 1 , for instance a bottom part 1 of a case, and comprises a grip part 11 , two movable arms 12 and two springs 14 . Said grip part 11 is turnably attached to each one of the movable arms 12 (and vice versa), each one of which in turn is turnably attached to one and the same fixed arm 13 , which is attached to the first part 1 . Said springs 14 hold, in the unlocked state, the grip part 11 at a certain distance from not only the first part 1 but also a second part 2 , such as, for instance, a lid part 2 of a case.
The movable arms 12 are turnable around a first axis of rotation 16 , which coincides with a spindle 16 , in relation to the grip part 11 and turnable around a second axis of rotation 17 , which coincides with a spindle 17 , in relation to the fixed arm 13 and thereby simultaneously to the first part 1 . Two urging spring legs 14 a , 14 b of each spring 14 , i.e., totally four urging spring legs, extend in pairs at an angle in relation to each other from said second axis of rotation 17 into abutment against a first side 11 a of the grip part 11 , i.e., the side of the grip part 11 that is facing the first and second parts 1 , 2 . A first urging spring leg 14 a of said two urging spring legs 14 a , 14 b of each spring 14 brings the grip part 11 to turn in a first direction around said second axis of rotation 17 and a second urging spring leg 14 b of said two urging spring legs 14 a , 14 b of each spring 14 brings the grip part 11 to turn in a second direction around said second axis of rotation 17 , said second direction being counter-directed to said first direction and contributing to the fact that a state of equilibrium occurs when the locking device is in the unlocked position.
The mutually principally parallel arms 12 constitute a unit together with the mutually principally parallel first and second spindles 16 , 17 and move together with them. Each one of the spindles 16 , 17 extends, at a distance from each other, between and unites the arms 12 and meets the arms 12 at principally right angles. In the unlocked position, the spindle 16 abuts, by the spring action described above from occurring spring legs, against a 14 b of the urging spring legs 14 a , 14 b of each pair, i.e. of each spring 14 , which acts as an anchorage for the entire locking device in the unlocked state. In this anchored position, a main extension plane of the grip part 11 extends principally parallel to a main extension plane of the grip part 11 in the locked position of the locking device.
Rotation of each one of the occurring springs 14 around the spindle 17 , in connection with the operation of the locking device and/or upon storage, can be avoided by the fact that each spring 14 also comprises an anchoring spring leg 14 c , which extends from the spindle 17 and into a recess in said first part 1 .
Each spring 14 is ingeniously manufactured in one piece from a wire of metal or the like, which has been formed to, in a first end, show the spring leg 14 a in abutment against the side 11 a of the grip part 11 in order to, therefrom, extend towards the spindle 17 and around the same at least one turn in order to further extend down into the recess in the first part 1 and there form a loop included in the anchoring spring leg 14 c and extend back to the spindle 17 and around the same at least one turn in order to further extend at an angle in relation to the spring leg 14 a in the direction of the side 11 a of the grip part 11 in order to be terminated in the form of the spring leg 14 b in abutment against the side 11 a . The two springs 14 are mounted in each end of the spindle 17 and the angle between the two urging spring legs 14 a , 14 b of each spring 14 , as well as the anchoring spring leg 14 c of the same spring 14 , is in one and the same plane, which is principally perpendicular to the direction of extension of each one of the spindles 16 , 17 .
A second embodiment of the locking device has a geometry and a function in accordance with the FIGS. 6-17 , FIGS. 15 and 16 of which only show the grip part 11 and FIG. 17 only shows the other parts. Here, only one movable arm 12 is present, which is formed in such a way that it alone gives the same possibilities of operation as two arms and two spindles together according to the first embodiment of the invention. Thus, the movable arm 12 is turnable around a first axis of rotation 16 in relation to the grip part 11 and is formed in such a way that it simultaneously constitutes a first spindle 16 , at least partly coinciding with said first axis of rotation 16 , and a second spindle 17 , at least partly coinciding with said second axis of rotation 17 . A first end of said movable arm 12 is mounted in a bearing in a recess suitable therefor in a first flange 20 in the grip part 11 while a second end of said movable arm 12 is mounted in a bearing in a recess suitable therefor in a second flange 21 in the grip part 11 . A portion of said movable arm 12 occurring therebetween is mounted in a bearing in a recess suitable therefor in an arm or a projection 13 attached to said first part 1 .
Only one spring 14 is present, which abuts against said first side 11 a of a spring side of a plane that intersects a main extension plane of the grip part 11 under a principally right angle and that simultaneously passes through, and principally parallel to, said second axis of rotation 17 . A first arm leg 1 2 a of said movable arm 12 abuts, in the unlocked position, against at least one fold 18 on said first side 11 a of an arm side of said plane, said spring side and said arm side being different sides of said plane. A second arm leg 12 b of said movable arm 12 abuts, in the unlocked position, against said spring 14 , said grip part 11 being in a free position at a distance from said two parts 1 , 2 . In this anchored position, a main extension plane of the grip part 11 extends principally parallel to a main extension plane of the grip part 11 in the locked position of the locking device.
Each spring 14 is ingeniously manufactured in one piece from a wire of metal or the like, which has been formed to, in a first end, start from a dedicated groove 19 in said projection 13 attached to said first part 1 in order to, therefrom, extend out of this groove 19 and towards the spindle 17 and around the same in order to further extend in the direction of the side 11 a of the grip part 11 into abutment against the side 11 a in order to further extend along the side 11 a in a direction that is principally parallel in relation to the principal direction of extension of the spindle 17 in order to, therefrom, again extend towards the spindle 17 and around the same in order to further extend in the direction of said groove 19 in said projection 13 in order to, in said groove 19 , be terminated in the form of a second end. The part of the spring 14 that is between the spindle 17 and the grip part 11 may be regarded as an urging spring leg 14 a , while the parts of the spring lo 14 that are between the spindle 17 and the groove 19 in said projection 13 may be regarded as anchoring spring legs 14 c , which accordingly prevent rotation of the entire spring 14 around the spindle 17 .
Upon closure including subsequent locking, a front/upper part of the grip part 11 can be forced over a fold 15 present on the second part 2 , see FIG. 4 , and then the locking device can be brought to lock together the second part 2 and the first part 1 by snap action by the fact that a rear/lower part of the grip part 11 is pressed against the first part 1 , see FIG. 5 . Said front/upper part of the grip part 11 is provided with a third flange 22 particularly adapted for the purpose, the main extension plane of which forms principally the same angle with the main extension plane of the grip part 11 as does a main extension plane of a particularly adapted recess 23 in said fold 15 in the unlocked as well as the locked state of the locking device. From, for instance, FIG. 7 , it is seen that the angle, which may vary between close to 0° and close to 90°, in the present case is approx. 45°. Upon unlocking, said rear/lower part of the grip part 11 can instead be retreated from the first part 1 , see FIG. 4 , after which said front/upper part of the grip part 11 can be removed from the fold 15 present on the second part 2 , see FIG. 3 .
The locking device is particularly suitable for a tool case of plastic provided with two locking devices, but a number of other application areas are feasible such as, for instance, most known types of cases, boxes, drawers, fittings and various forms of building elements etc. The number of locking devices of each application object may vary and, for instance, a case is conceivable having one or more locking devices. Distances between occurring locking devices and their placement on the case or the like may also vary.
The parts included in the locking device are preferably manufactured from metal but any other expedient material is feasible, for instance, various forms of plastic. Also combinations of different materials are feasible, such as, for instance, a grip part 11 of plastic and a movable arm 12 and a spring 14 of metal. Also combinations of different materials in one and the same part is feasible.
The invention is not limited to the embodiments shown here but may be varied within the scope of the subsequent claims. | The present invention relates to a snap-type locking device for releasable and principally external keeping together of two parts and comprising at least one grip part at least one grip part, at least one movable arm and at least one spring, said at least one movable arm being turnably attached to said at least one grip part as well as, directly or indirectly, to a first part of said two parts. Said at least one spring abuts said at least one grip part in order to urge the same in a direction away from said two parts. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of producing a semiconductor device using sidewall spacers to obtain alignment of overlying device features. The present invention in particular relates to a method of producing a field-effect transistor using sidewall spacers on a semiconductor substrate for adjusting the position of an active region with respect to a gate electrode without realigning steps during the production process.
[0003] 2. Description of the Related Art
[0004] The manufacturing process of integrated circuits involves the fabrication of numerous insulated gate field-effect transistors, such as metal-oxide semiconductor field-effect transistors (MOSFETs). In order to increase integration density and improve device performance, for instance, with respect to signal processing time and power consumption, feature sizes of the transistor structures are steadily decreasing. Most importantly, not only the gate length but also the length of the active region of the fabricated transistors needs to be reduced to comply with these requirements in order to reduce parasitic source and drain capacitances.
[0005] Conventionally, device features are defined and delineated by lithographic techniques, in particular photolithography, preferably using a high numerical aperture lens and a deep ultraviolet (DUV) light source. Current DUV lithography reaches its resolution limit at a feature size of approximately 0.2 μm. Together with emerging gate length trim techniques, it is possible to reach device features in the sub-100 nm region. Such feature definition by lithography requires a plurality of process steps, each usually involving a resist mask technique. Overlay alignment of subsequent resist masks using special alignment features on the semiconductor substrate requires exact positioning of a mechanical stage supporting the substrate. Desirably, the overlay accuracy is considerably higher than the smallest feature size, preferably, at least one order of magnitude.
[0006] However, mechanical alignment of the various resist mask layers necessary for production of a field-effect transistor (FET) structure having a gate length of approximately 0.1 μm is very difficult to achieve due to the mechanical nature of the overlay alignment process.
[0007] To comply with the general requirements of mass production of semiconductor devices, any new technology must conserve the current standards of efficiency, reliability, and cost of already existing methods or provide improvements in this respect.
[0008] As mentioned above, the formation of the active region relative to the gate electrode is a critical step in the manufacturing process of a field-effect transistor. The gate length dimension, i.e., the lateral extension of the gate electrode between the source region and drain region of the field-effect transistor, is commonly known as critical dimension of the gate. This critical dimension is desirably reduced to sizes approaching or even exceeding the resolution limit of the optical imaging systems used for patterning the device features. In a field-effect transistor such as a MOSFET, the gate is used to control an underlying channel formed in the semiconductor substrate between source region and drain region. Channel, source region, and drain region are formed in, on, or over a semiconductor substrate which is doped inversely to the drain and source regions. The gate electrode is separated from the channel, the source region, and the drain region, by a thin insulating layer, generally by an oxide layer. Additionally, device insulation features are necessary to ensure electrical isolation between neighboring field-effect transistors in integrated circuits.
[0009] During operation of such a MOSFET, a voltage is supplied to the gate electrode in order to create an electric field between the gate electrode and the source and drain regions affecting conductivity in the channel region of the substrate. Besides the desired transistor current control function, the gate electrode, the gate insulation layer, and the regions underlying the gate insulation layer, also act as a capacitor generating a parasitic capacitance. The amount of this parasitic capacitance depends on the feature size of the gate electrode. Most commonly in integrated circuit applications, the transistors are operated in a switching mode with clock frequencies currently as high as 400 to 500 MHz. In this operation mode, the gate capacitor has to be continuously charged and discharged, which significantly affects signal performance and power consumption of the device.
[0010] Moreover, the electric field between the source region and the drain region generates an additional parasitic capacitance. The amount of this additional parasitic capacitance depends on the sizes of the source region and of the drain region. This additional parasitic capacitance also significantly affects signal performance and power consumption of the semiconductor device. Decreasing sizes of the source region and of the drain region will reduce the additional parasitic capacitance. Decreasing source and drain regions, however, require difficult aligning steps during the photolithography for patterning the gate electrode, and, thus, lead to a deterioration of device characteristics due to an unavoidable misalignment of the gate electrode with respect to the source and drain regions because of the mechanical nature of the alignment step.
[0011] Due to the limitations of standard photolithography including mechanical alignment used to pattern and position the gate electrode within the active transistor region in which the drain and source have to be formed, advanced techniques for trimming the gate electrode will neither be translated into a decreasing size of the active region and, thus, into reduced source and drain regions, nor into reduced source and drain capacitances nor into an increased circuit-density.
[0012] As the dimensions of the transistor significantly influence its electrical characteristics, when decreasing device dimensions it is important to provide a method of reliably and reproducibly forming and positioning device features and device insulation features in order to minimize variations in the electrical characteristics of integrated circuits.
[0013] With reference to FIGS. 1 a - 1 c , an illustrative example of forming a field-effect transistor according to a typical prior art process will be described. It is to be noted that FIGS. 1 a - 1 c , as well as the following drawings in this application, are merely schematic depictions of the various stages in manufacturing the illustrative device under consideration. The skilled person will readily appreciate that the dimensions shown in the figures are not true to scale and that different portions or layers are not separated by sharp boundaries as portrayed in the drawings but may instead comprise continuous transitions. Furthermore, various process steps as described below may be performed differently depending on particular design requirements. Moreover, in this description, only the relevant steps and portions of the device necessary for the understanding of the present invention are considered.
[0014] [0014]FIG. 1 a shows a schematic cross-section of a field-effect transistor at a specific stage of a typical prior art manufacturing process. Within a silicon substrate 1 , shallow trenches 2 , e.g., made of silicon dioxide, are formed and define a transistor active region 3 in which a channel, a drain region and a source region will be formed. A gate insulation layer 4 is formed above the substrate 1 . The gate insulation layer 4 may be formed by a variety of techniques, e.g., thermal growth, chemical vapor deposition (CVD), etc., and it may be comprised of a variety of materials, e.g., an oxide, an oxynitride, silicon dioxide, etc.
[0015] [0015]FIG. 1 b shows a schematic cross-section of the field-effect transistor of FIG. 1 a after formation of a layer of gate electrode material 5 above the gate insulation layer 4 . The layer of gate electrode material 5 may be formed from a variety of materials, e.g., polysilicon, a metal, etc., and it may be formed by a variety of techniques, e.g., CVD, low pressure chemical vapor deposition (LPCVD), sputter deposition, etc. Over the layer of gate electrode material 5 , a resist feature 6 is formed. The process steps involved in patterning a layer of resist (not shown) for producing the resist feature 6 are of common knowledge to the skilled person. These steps include the formation of the layer of resist by a spin-coating process, and the employment of short exposure wavelengths, such as wavelengths in the DUV range, while performing the required photolithography steps. Since these procedures are commonly known, the description thereof will be omitted.
[0016] [0016]FIG. 1 c shows a schematic cross-section of the field-effect transistor of FIG. 1 b after conventional etching of the layer of gate electrode material 5 and after removing all remaining parts of resist feature 6 . As a result of these process steps, a gate electrode 7 is obtained. Lightly doped drain (LDD) regions 10 are then formed in the active region 3 by a shallow ion implantation with a low dose before the formation of sidewall spacers 8 . Next, the sidewall spacers 8 are formed adjacent the gate electrode 7 . Thereafter, source and drain regions 9 are formed by a deep ion implantation with a high dose. The implanted ions are electrically activated by rapid thermal annealing (RTA). In order to form the sidewall spacers 8 adjacent to the gate electrode 7 , silicon dioxide (SiO 2 ) was blanket deposited and subsequently anisotropically etched. According to the conventional fabrication process as described above, drain and source regions 9 are limited by lightly doped drain and source regions 10 , which connect to a channel 11 . The transverse dimension of the gate electrode 7 defines a critical dimension 12 , and the transverse dimension of the active region 3 defines a length dimension 13 .
[0017] Since the source and drain regions 9 are defined by overlay alignment, i.e., mechanical alignment, in the various lithographic steps while forming the gate electrode, it is extremely difficult to decrease the length dimension 13 due to the mechanical nature of the alignment procedure. Therefore, advanced techniques for a desired down-sizing of the gate electrode 7 will not necessarily allow a corresponding scaling of the drain and source regions, and, thus, may not be translated into an increased circuit density or into reduced source and drain capacitances.
[0018] In view of the above-mentioned problems, a need exists for an improved method for forming the source region, the drain region, and the gate electrode of field-effect transistors on semiconductor substrates and to precisely align the gate electrode within the active region.
SUMMARY OF THE INVENTION
[0019] The present invention provides methods of forming a field-effect transistor in an integrated circuit using self-aligning technology on the basis of a gate electrode and sidewall spacer masking procedure both for forming the device isolation features and the source and drain regions.
[0020] According to a first embodiment of the invention there is provided a method of forming a field-effect transistor in an integrated circuit comprising the steps of providing a semiconductor substrate having a surface, forming a gate electrode over the surface, the gate electrode having a gate width and sidewalls along its width direction, forming first sidewall spacers having a first lateral extension along the sidewalls of the gate electrode, removing portions of the semiconductor substrate adjacent the first sidewall spacers, using the first sidewall spacers as a masking material for defining trenches and an active region, and forming device insulation features at the trenches.
[0021] According to a second embodiment of the invention there is provided a method of forming a field-effect transistor in an integrated circuit comprising the steps of providing a semiconductor substrate having a surface, forming a thin insulating layer over the surface, forming a gate electrode over the thin insulating layer, the gate electrode having a gate length direction and sidewalls along a gate width direction, forming a gate cover layer over the gate electrode and first sidewall spacers along the sidewalls of the gate electrode, the first sidewall spacers having a first lateral extension, masking and etching the gate cover layer and the first sidewall spacers so as to remove the first sidewall spacers along the gate length direction while maintaining the first sidewall spacers along the gate width direction, removing material of the semiconductor substrate adjacent the first sidewall spacers and the gate electrode, using the first sidewall spacers and the gate cover layer as a masking material for defining trenches and an active region, growing a thin thermal oxide film in the trenches for the benefit of trench corner rounding, filling the trenches with insulating material, polishing the insulating material back until the gate cover layer is exposed, etching the insulating material isotropically back, removing the gate cover layer and the first sidewall spacers, forming second sidewall spacers along the sidewalls of the gate electrode, the second sidewall spacers having a second lateral extension which is less than the first lateral extension, and forming source and drain regions in the active region.
[0022] The present invention as outlined above enables one to fabricate a transistor device having reduced device dimensions, wherein the active region, as well as device insulation features, are aligned with respect to the gate electrode without any overlay steps. With the production method provided by this invention, the active region of a field-effect transistor may be tuned to minimum desired dimensions regardless of lithographic restrictions. Consequently, a drastically increasing circuit density and decreasing parasitic capacitances can be reached.
[0023] This invention will enable a significant reduction of field-effect transistor dimensions in integrated circuits and, therefore, a significant cost reduction in manufacturing in semiconductor industries can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Further advantages and objects of the present invention will become more apparent with the following detailed description when taken with reference to the accompanying drawings in which:
[0025] [0025]FIGS. 1 a - 1 c are schematic cross-sectional views of a semiconductor substrate in different process steps during production of a field-effect transistor according to the prior art;
[0026] [0026]FIG. 2 a is a schematic cross-sectional view of a semiconductor substrate after gate electrode formation, gate cover layer formation, and sidewall spacer formation during production of a field-effect transistor according to this invention;
[0027] [0027]FIG. 2 b is a schematic top view of the semiconductor substrate after forming a mask over said gate cover layer and said sidewall spacers during production of the field-effect transistor according to this invention;
[0028] [0028]FIG. 2 c is a schematic cross-sectional view of the semiconductor substrate after active region formation and mask removal during production of the field-effect transistor according to this invention;
[0029] [0029]FIG. 2 d is a schematic cross-sectional view of the semiconductor substrate after thermal oxide layer formation during production of the field-effect transistor according to this invention;
[0030] [0030]FIG. 2 e is a schematic cross-sectional view of the semiconductor substrate after trench filling with insulating material during production of the field-effect transistor according to this invention;
[0031] [0031]FIG. 2 f is a schematic cross-sectional view of the semiconductor substrate after polishing during production of the field-effect transistor according to this invention;
[0032] [0032]FIG. 2 g is a schematic cross-sectional view of the semiconductor substrate after isotropic etching the insulating material during production of the field-effect transistor according to this invention;
[0033] [0033]FIG. 2 h is a schematic cross-sectional view of the semiconductor substrate after sidewall spacer removal and gate cover layer removal during production of the field-effect transistor according to this invention; and
[0034] [0034]FIG. 2 i is a schematic cross-sectional view of the semiconductor substrate after completion of the field-effect transistor according to this invention.
[0035] While the present invention is described with reference to the embodiment as illustrated in the following detailed description as well as in the drawings, it should be understood that the following detailed description as well as the drawings are not intended to limit the present invention to the particular embodiment disclosed, but rather the described embodiment merely exemplifies the various aspects of the present invention, the scope of which is defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0036] Further advantages and objects of the present invention will become more apparent with the following detailed description and the appended claims. Furthermore, it is to be noted that although the present invention is described with reference to the embodiments as illustrated in the following detailed description, it should be noted that the following detailed description is not intended to limit the present invention to the particular embodiments disclosed, but rather the described embodiment merely exemplifies the various aspects of the present invention, the scope of which is defined by the appended claims.
[0037] With reference to FIGS. 2 a - 2 i , an illustrative example of forming a field-effect transistor according to one embodiment of the present invention will be described. FIG. 2 a shows a schematic cross-section of a field-effect transistor at a specific stage of a manufacturing process according to the present invention. The structure shown in FIG. 2 a includes a gate insulation layer 102 , comprised of, for example, silicon dioxide (SiO 2 ), formed over a semiconductor substrate 101 , comprised of Si, Ge, or the like, a gate electrode 103 having a gate length 105 and formed above the gate insulation layer 102 , a gate cover layer 104 positioned over the gate electrode 103 , and a sidewall spacer 106 formed around the sidewalls of the gate electrode 103 and the gate cover layer 104 . The sidewall spacer 106 and the gate cover layer 104 may preferably be comprised of a material such as silicon nitride (SiN) that can selectively be etched with respect to the semiconductor material of the substrate.
[0038] The process steps involved in patterning a resist (not shown) for producing the gate electrode 103 , the gate cover layer 104 , and the sidewall spacers 106 are of common knowledge to the skilled person, and usually include the employment of short exposure wavelengths, such as wavelengths in the DUV range, while performing the required photolithography steps. According to the anisotropic etching necessary for formation of the sidewall spacers 106 , due to a relation of sidewall height to spacer thickness at the bottom, depending on the slope of the sidewall spacers 106 , their lateral extension can be determined by the thickness of the gate cover layer 104 . Hence, by increasing the sidewall height, substantially thicker sidewall spacers 106 can be formed, employing a standard anisotropic etch process for sidewall spacer formation, which otherwise is commonly known, so that the detailed description thereof will be omitted.
[0039] [0039]FIG. 2 b shows a schematic top view of the field-effect transistor of FIG. 2 a after deposition of a mask 107 over the gate cover layer 104 , over the sidewall spacers 106 , and over the thin gate insulation layer 102 . The deposition of this mask 107 is made such that both end caps 108 of the gate cover layer 104 , and, therefore, both end caps of the gate electrode 103 , and all remaining parts of the sidewall spacers 106 around the end caps 108 , are exposed. All the exposed parts have to be selectively removed until the thin gate insulation layer 102 is exposed (not shown) resulting in two opposing sidewall spacers 106 in both directions of the gate length 105 .
[0040] [0040]FIG. 2 c shows a schematic cross-section of the field-effect transistor of FIG. 2 b after conventional etching all parts of the thin gate insulation layer 102 , as well as the substrate 101 , which are not covered with the gate cover layer 104 or the sidewall spacers 106 , and thereby forming trenches 109 . These trenches 109 are needed for shallow trench isolations (STIs), as described below.
[0041] [0041]FIG. 2 d shows a schematic cross-section of the field-effect transistor of FIG. 2 c after growing a thin thermal oxide layer 110 , which is of benefit to trench corner rounding.
[0042] [0042]FIG. 2 e shows a schematic cross-section of the field-effect transistor of FIG. 2 d after an insulating material layer 111 , comprised of, for example, silicon dioxide (SiO 2 ), is formed over the field-effect transistor depicted in FIG. 2 d . This covering step, including overfilling, is needed for a secure filling of the trenches 109 for the shallow trench isolations (STIs) with necessary insulating material.
[0043] [0043]FIG. 2 f shows a schematic cross-section of the field-effect transistor of FIG. 2 e after polishing said insulation layer 111 to a plane level 112 . This polishing process is executed until just a top part of the gate cover layer 104 is exposed.
[0044] [0044]FIG. 2 g shows a schematic cross-section of the field-effect transistor of FIG. 2 f after isotropically etching the insulation layer 111 . This etching process results in completed shallow trench isolations (STIs) 113 with a top surface 114 that is located above the gate insulation layer 102 for the benefit of a reduced probability of shorts to the drain and source regions to be formed. Such shorts may occur due to the relatively small overlap of the end caps 108 with the shallow trench isolations 113 . Preferably, the top surface 114 is located above the gate insulation by at least an amount that ensures compensation for oxide consumption of the shallow trench isolation 113 during subsequent process steps.
[0045] [0045]FIG. 2 h shows a schematic cross-section of the field-effect transistor of FIG. 2 g after removing the gate cover layer 104 and the sidewall spacers 106 . The shallow trench isolations (STIs) 113 define an active region 115 with a length dimension 116 in the substrate 101 . The length dimension 116 is defined by the length dimension 105 of the gate electrode and the bottom thickness of the sidewall spacers 106 . That is, both the length and the location of the active region are determined by well-controllable deposition and etching processes without the necessity of any additional (mechanical) aligning steps. This will hereinafter also be referred to as self-aligned. Moreover, since the length and the location of the active region with respect to the gate electrode are related to the gate length, a down-scaling of the gate length may also be translated in a corresponding down-scaling of the active region. Furthermore, for a given gate length, the length dimension of the active region may be controlled by adjusting the thickness of the sidewall spacers so that a length of the drain and source regions may be controlled in accordance to design requirements irrespective from the channel length (gate length).
[0046] Finally, FIG. 2 i shows a schematic cross-section of the field-effect transistor of FIG. 2 h after conventional device processing is performed to complete the field-effect transistor. Lightly doped drain (LDD) and source regions 119 were formed in the active region 115 by a shallow ion implantation with a low dose. The implanted ions are diffused by rapid thermal annealing (RTA) so as to partially extend in the area below the thin gate oxide layer 102 . Silicon dioxide (SiO 2 ), or other similar material, was blanket deposited and subsequently anisotropically etched in order to form sidewall spacers 117 adjacent to the gate electrode 103 and to the lightly doped drain and source regions 119 . Thereafter, source and drain regions 118 are completed by a deep ion implantation with a high dose. The source and drain regions 118 are limited by the lightly doped drain and source regions 119 , which connect to a channel 120 .
[0047] After the formation of the gate electrode 103 , the gate insulation layer 102 , the active region 115 , and the shallow trench isolations (STIs) 113 , manufacturing of the field-effect transistor is continued by commonly known standard techniques. Since these techniques are known to the skilled person, the production steps for these standard techniques are not described in this description.
[0048] The present invention provides a method of forming a field-effect transistor in an integrated circuit, wherein the source region and the drain region are self-aligned with respect to the gate electrode, i.e., the gate electrode is substantially centrally positioned within the active region without the need of a separate aligning step. Additionally, the transistor length, particularly the source length and the drain length, can be reduced, regardless of the critical dimension of the gate electrode. Hence, the source and drain lengths may be optimized in conformity with design requirements so as to significantly reduce the parasitic capacitances as well as the circuit-density. Therefore, the overall product performance is improved and the production costs are reduced.
[0049] Due to the self-alignment technique of the shallow trench isolations (STIs) 113 and of the active region 115 relative to the gate electrode 103 as described above, the length dimension 116 of the active region 115 may be tuned to minimum desired dimensions without lithographic processing and therefore without lithographic restrictions. Thus, the production of field-effect transistors according to the present invention requires less masks as compared to conventional processing for the benefit lower production cost.
[0050] According to a modification of the above-described embodiment of the present invention, the first sidewall spacers 106 are formed without the gate cover layer 104 over the gate electrode 103 . In order to achieve sidewall spacers 106 of sufficient bottom thickness for defining the active region 115 , the process for depositing the spacer material and/or the anisotropic etch process for forming the sidewall spacers 106 is accordingly adjusted to lead to spacer flanks of a shallower slope so as to achieve a greater thickness to height ratio of the sidewall spacers 106 . Since anisotropic etching and depositing of material layers are well-controllable within a range of few nm to several μm, any desired bottom thickness is adjustable so that corresponding drain and source lengths may be manufactured.
[0051] According to another modification of the above-described embodiment of the present invention, the sidewall spacers 106 are not removed after the formation of the active region 115 . In this case, the sidewall spacers 106 are trimmed, e.g., by an etch process, yielding sidewall spacers 117 having a shorter lateral extension than the sidewall spacers 106 . Afterwards, the lightly doped drain and source regions 119 will be formed in the active region 115 under said sidewall spacers 117 by diffusion of ions or by oblique ion implantation with a low dose. Thereafter, source and drain regions 118 are formed by a deep ion implantation with a high dose. The remaining production steps according to the above-mentioned embodiment describing the drawings remain the same.
[0052] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below. | This invention provides methods of forming a field-effect transistor in an integrated circuit using self-aligning technology on the basis of a sidewall spacer masking procedure, both for defining the device isolation features and the source and drain regions. The active region is defined after patterning the gate electrode by means of deposition and etch processes instead of overlay alignment technique. Thus, the present invention enables an increase of the integration density of semiconductor devices, a minimization of the parasitic capacitances in field-effect transistor devices, and a quicker manufacturing process. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to apparatus for cutting elongated material into shorter lengths and the means for uniformly removing the cut material. More particularly, the invention provides a means for overcoming centrifugal and adhesive forces that tend to prevent the staple from freely falling from the cutter reel.
Cutters as described by Keith in U.S. Pat. No. 3,485,120 are broadly used for cutting tow into staple length fibers. These cutters include a rotatable reel having outwardly facing cutter blades against which the tow is wound and a fixed pressure roller pressing upon the tow wound around the reel resulting in cutting of the innermost layers of tow by the cutter blades. As cutting progresses a wad of cut staple fibers is forced inwardly between adjacent pairs of blades. Unfortunately, centrifugal forces and interfiber adhesion resist removal of wads of cut fibers by gravitational forces. Thus the wads of cut fibers continue to rotate with the reel and continue to increase in size until either the cutter jams or until chips of cohered staple break off from the wads and fall into the collection hopper. These chips are heavily entangled, difficult to open, and cause subsequent difficulties in mill processing.
Cook in U.S. Pat. No. 3,733,945 recognizes the problems of jamming the cutter and lack of staple openness using cutters described by Keith and as a solution to these problems Cook discloses mounting at least one fixed jet so that it jets air downwardly upon the proximity of the doffing point of the cut fiber through aligned apertures in the cutting reel which rotate past the jet. This assists the gravitational forces in overcoming the effect of centrifugal and fiber-to-fiber forces allowing the cut fiber to fall freely downward. However, Cook's arrangement has disadvantages associated with discontinuous passage of air from the fixed jet through apertures in the reel crossing through the air jet stream. Cook's arrangement is essentially that of a siren and as a consequence produces very high noise levels.
Potter U.S. Pat. No. 4,120,222 is a modification of the known reel type cutter wherein the jet-producing orifices rotate with the reel and by not interrupting jet-air flow, as with Cook, a negligible increase in noise level results, regardless of orifice size or operating speed of the reel.
While the reel-type cutters of the prior art provide a staple exhibiting fairly uniform openness with substantially no fiber chips, a further means has been discovered to assist gravitational forces and injected air to overcome the centrifugal and adhesive forces permitting the cut staple product to fall more freely in smaller tufts.
SUMMARY OF THE INVENTION
In an apparatus for cutting filamentary material into predetermined lengths comprising a cutting assembly including a plurality of knife edges secured to a reel having an upper and a lower mounting member and having means adapted to receive successive wrappings of filamentary material to be cut in contact with said plurality of knife edges and means for forcing said material between adjacent knife edges to a doffing point thereby severing said filamentary material into lengths of controlled dimensions, the improvement comprising: a cone attached at its base to said upper mounting member; a plurality of outwardly directed vanes attached to said cone, each pair of said vanes spanning a doffing point; a plate spanning each pair of vanes, said plate extending in an inwardly curved direction from said upper mounting member near said blades to said cone; and an orifice supplied with pressurized fluid in said plate directed toward the proximity of the doffing point of the severed material.
The entire assembly--cone, vanes and curved plate--is coated with a nonstick, low friction material, e.g., matte chrome plate, "Teflon"-S nonstick finish (Du Pont's registered trademark for its nonstick finishes), and the like.
The apparatus includes a shell positioned below the reel which contains spaced plates and baffles fixed at different levels around the inner periphery of the shell. In a preferred embodiment the cone and the vanes extend downwardly into the shell within the plates and baffles. In another preferred embodiment the shell containing the plates and baffles is used in conjunction with the cutter reel without the cone and the vanes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of the cutting apparatus similar to the Keith apparatus illustrating the relationship between the various elements thereof and showing a preferred cutting reel configuration;
FIG. 2 is a view taken along 2--2 of FIG. 1 showing the relationship between the cutting reel, the pressure applicator and the material being severed;
FIG. 3 is an enlarged, fragmentary detail view showing the relationship between the blades, the material being cut, and the pressure applicator at the point of cutting; and
FIG. 4 is an enlarged detailed partially sectioned elevation view of the reel and drive shown in FIG. 1.
FIG. 5 is a partial side elevation view similar to FIG. 1, without the cone-vane assembly 100.
FIG. 6 is a perspective view of the shell partially cut away to show the arrangement of the plates and baffles fixed at different levels around the shell.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, the embodiment chosen for purposes of illustration is a cutting apparatus 10 that includes as its major components a drive shaft 12 mounted on a base 14 by means of bearings 12a and 12b and connected to a cutting reel designated generally 18. The shaft 12 is driven by a motor (not shown) via belt 16 engaging pulley 16a attached to shaft 12. Referring to FIG. 4, the cutting reel 18 is seen to comprise a bottom ring 29 attached to and spaced from a top plate 26 by spaced connector posts 32 which are secured in position by any of a number of well known expedients as, for example, brazing. A guiding ring 24 for the material being cut extends circumferentially around top plate 26 and is attached to the peripheral edge of plate 26. As an alternative the ring 24 could be made integral with plate 26. Rectangular cutter blades 28 are inserted through slots in top plate 26 down into grooves in the top of ring 29. When in place, each cutter blade 28 has its cutting edge 30 facing radially outwardly, and its back edge supported in U-groove 31 of a connector post 32 and its top end extending into annular space 38 above plate 26. A cover plate 22 is bolted to top plate 26 (bolts not shown). Fitted between cover plate 22 and tow guiding ring 24 is retaining ring 36 which has a stepped lower surface to provide space 38 into which the top of cutter blade 28 extends. Spaced fasteners 40 are attached to the upper surface of retaining ring 36 and have slide bolts 43 which extend into corresponding holes in the edge of cover plate 22 holding the retaining ring 36 securely in position. Thus, the combination of the cover plate 22, top plate 26, guiding ring 24 and retaining ring 36 form what may be generally referred to as the upper mounting member of the cutting reel 18 while ring 29 will be considered the lower mounting member of the reel. An intermediate hub 20 is used between the reel and drive shaft 12 and these portions are fastened to the upper mounting member by a bolt 35 threaded into the bottom of shaft 12.
Passageways are formed so as to continuously communicate from the top of shaft 12 to orifices 34 formed through top plate 26 near its outer extremities. A rotary union 80 is attached to the top of shaft 12. Fixed piping (not shown) leads high pressure air to rotary union 80 through inlet opening 82 in the rotary union whereby compressed air may be fed to the passageways during rotary operation of the cutter. It is feasible to provide a rotary union around a shaft directly driven by a motor at its end, but the installation is much simpler when the motor is off-set and the rotary union is mounted on the end of the shaft. An axial passageway 84 is provided through most of shaft 12 leading from the inlet 82 and stopping short of the hole receiving bolt 35. At least one transverse passageway 86 is formed through hub 20 and shaft 12 intersecting with the end of passageway 84. The ends of passageway 86 are closed by plugs 88. Next, a pair of passageways 90 is formed vertically through cover plate 22 and hub 20 intersecting at the upper end with passageway 86 and at the lower end with annular chamber 92 formed between cover plate 22 and top plate 26. Channels 94 are machined into the bottom of cover plate 22 and extend from chamber 92 to annular distribution ring 96 also formed in the bottom of cover plate 22 in an area over orifices 34 to form a manifold in communication with each orifice 34, the manifold being in communication with high pressure air through hollow shaft 12. Sealing lip 95, preferably fitted with a gasket, is left around the outside edge to prevent air leakage. Hole 33 provides ready passage of bolt 35. The number of channels 94 is not critical, but a preferred embodiment has three with a total cross-sectional flow-area equal to or greater than that of passage 84.
As best shown in FIGS. 1 and 2, a pressure applicator 42 of the rotatable type such as a wheel or roller is mounted on a shaft 44 secured to a bifurcated bracket 46 which in turn is supported on a movable slide 48 fitted into machined ways 50 secured to the base 14. Regulated movement of the slide 48 is accomplished by a lead screw 52 rotatably secured in a pillow block 54 fixed in position relative to machined ways 50 and thus to the base 14. One end 56 of lead screw 52 is threaded into an appendage 58 integral with or otherwise fixed on the surface of the movable slide 48 so that rotation of screw 52 will cause slide 48 to move relative to machined ways 50 and base 14. This structure, a lead screw actuated slide and ways assembly well known in the art, provides for movement of pressure roll 42 relative to cutting reel 18 and minute adjustment of the space between it and cutting edges 30.
A plurality of finger guides 60 or others well known in the art extend outwardly from a plate 62 secured at right angles to the base 14. For operation at high speeds guides 60 may be rolling guides. The finger guides 60 shape the incoming filamentary tow 64 into a flattened tape or band. From the finger guides 60 the filamentary material or tow passes through rounded edge guides 66 which are pivotally mounted on an elongated rod 68 secured, as are finger guides 60, to plate 62. Guides 66 serve to control the width of the flattened tape band 64 so that it will wind snugly between ring 29 and guiding ring 24 of the cutting reel 18. In addition to flattening the incoming tow 64, the finger guides 60 also serve as a friction brake to place the tow under a controlled amount of tension as it is fed into the cutting reel 18.
The cutter is substantially that disclosed by Cook in U.S. Pat. No. 3,733,945 and by Potter in U.S. Pat. No. 4,120,222, the operation of which is described in detail at column 4, lines 7-47 of the Cook patent. The details of the method of cutting are shown in FIG. 3 wherein a filamentary tow 64' is under maximum tension in the outer wrap and under substantially zero tension at 64". The problem is that cut fibers 64'" collect in between the knife blades 28 compacting the cut fibers until gravitational forces plus the urging of the air from orifice 34 overcome the combined effect of fiber to fiber adhesive forces and centrifugal force. The point where the combined forces are overcome is called the doffing point.
The improvement of this invention is a modification of the known cutter reels that provides a compartmentalized assembly 100 attached to the upper mounting member of the cutter reel that extends downward into a stationary shell 101 containing opposed baffles 108, 110 and plates 109. The assembly 100 includes a cone 102 attached at its base to top plate 26 and a plurality of outwardly directed vanes 104 attached to the cone. The vanes are angled outward from the cone so that for each pair of vanes their maximum separation occurs near the doff point of the cutter reel, i.e., approximately below orifice 34. The vanes are also tapered inward from the base of the cone toward its apex. A plate 106 spans each pair of vanes 104 and extends in an inwardly curved direction from the upper mounting member 26 near blades 28 to the cone 102. Thus a compartment which is open at the bottom is formed by the combination of cone 102, each pair of vanes 104 and an included top plate 106 which curves inward and downward toward the apex of the cone. The entire spreading cone assembly, i.e., cone 102, vanes 104, and curved plates 106, is coated with "Teflon"-S nonstick finish to provide anti-frictional surface characteristics. The curve plate 106 of each compartment is fitted with air orifice 34 by which compressed air may be directed into the compartment to assist in forcing the cut product downward.
This invention retains cut fibers in a highly parallized orientation with minimum fiber-to-fiber entanglement and provides an additional assist to overcoming gravitational and adhesive forces by use of the curved plate 106 which, as the cut product is compressed inward past knives 28 into a compartment, provides a downward force vector that assists gravitational forces and injected air to permit the cut product to fall more freely and in smaller tufts.
As best shown in FIGS. 1 and 6 opposed baffle plates 108, 110 and splitter plates 109 which are affixed at different levels on the stationary shell 101 surrounding the vane assembly 100 provide a further means to more easily open the cut product. Staple tufts exiting a compartment of vane assembly 100 are further opened by the splitter plate 109 which cuts the tuft surface, retaining yarn above the plate while the inclined primary baffle 108, located directly below the splitter plate, forces all product below the splitter plate to flow down the vane. This operation occurs two or more times per revolution of the cutter reel. As product flows downward, the vanes lose their grip on the product because they become shorter as they approach the cone apex. Product blooms out as the vanes become shorter and falls free in small tufts from the vane compartments. Any residual material entangled with product still in the vane compartments is broken loose as centrifugal force throws the tufts outwardly into the secondary angled baffles 110. The splitter plates 109 and baffles 108 are fastened to shell 101 and arranged in groups of three, e.g., one splitter plate 109, one primary baffle 108 and one secondary baffle 110, around the inner surface of the shell (FIG. 6) and act to split, separate, and promote flow down from each cutting compartment.
While the preferred embodiment discloses the cone and vane assembly 100 used in conjunction with the shell 101 containing the baffle plates, satisfactory results can be achieved when the shell 101 containing the plates and baffles is used in comjunction with the cutter reel without the cone and vane assembly 100 as shown in FIG. 5. | A modification to a reel type staple cutter that includes a compartmentalized assembly located below the cutter reel, each compartment forms an isolated cutting zone which reduces the opportunity for falling tufts of cut staple to mix and intermingle to form clumps which are difficult to open. The curved top plate of each compartment provides a downward force vector which assists gravitational forces and injected air to overcome centrifugal and adhesive forces tending to prevent staple from falling. Plates and baffles attached to a stationary shell located beneath the cutter reel split the cut fibers into discrete tufts despite the cohesive nature of the product and promote flow down and from each compartment. | 8 |
FIELD OF THE INVENTION
[0001] The present invention is related to a method for the functionalization of particulate and powdered products such as for example carbon black, glass fibres, carbon fibres and in particular carbon nanotubes. The present invention is also related to a plasma reactor able to functionalize these products.
STATE OF THE ART
[0002] Particulate and powdered substrates are often used as additives for reinforced polymer-based composites. In particular fibres, powders and nanoparticles are able to improve the physical properties of polymer-based composites.
[0003] Among the variety of particles, carbon nanotubes (CNTs) are particularly promising due to their unique mechanical and physical properties. However, the use of carbon nanotubes in polymer-based composites is now still limited due to the nonreactive nature of their surface and the agglomeration of CNTs into micron-size structures (as bundles, spheres etc.) during their growth. To overcome these problems, a functionalization (modification) of CNTs by changing their surface composition via the introduction of other elements or groups of elements (functional groups) has proved to be efficient.
[0004] Functionalization of carbon nanotubes can improve their solubility and processability and will allow to combine the unique properties of the carbon nanotubes with those of other types of materials. New chemical bonds created during the functionalization process might be used to tailor the interaction of the nanotubes with solvents or polymer matrices.
[0005] Functionalization of carbon nanotubes usually begins with the introduction of O-containing groups (mainly carboxylic groups), which further gives an access to a large number of functional exploitations by transformation of the carboxylic functions and provides anchor groups for further modification.
[0006] The introduction of O-containing groups in the structure of the CNTs can be realized via liquid-phase and gas-phase methods.
[0007] Liquid-phase oxidative treatment of carbon nanotubes is usually performed using boiling nitric acid, sulfuric acid, or a mixture of both. A so-called “piranha” solution (sulfuric acid-hydrogen peroxide mixture) can also be used. These methods have a low efficiency of functionalization, create defects in the structure of the CNTs, decrease their length, dramatically increase the density of the material and produce considerable amounts of toxic acidic waste.
[0008] Gas-phase oxidative processes are based on the treatment of the carbon nanotubes with oxygen, ozone or air at elevated temperatures. The main disadvantages of this type of functionalization are high-process temperatures leading to the creation of defects in the nanotube structure. Furthermore, this type of process requests a preliminary purification to remove the traces of metal catalysts which can catalyze the reaction of CNTs with O 2 or O 3 .
[0009] Gas-phase functionalization can also be realized by using mechano-chemical treatment via ball milling of nanotubes under different reactive atmospheres such as H 2 O, NH 3 and/or Cl 2 . Nevertheless mechano-chemical functionalization also results in the considerable densification of CNTs and the formation of structural defects.
[0010] In contradistinction to the methods mentioned above, the functionalization method based on plasma treatment is a low-temperature process which is very effective, non-polluting and which can provide a wide range of functional groups. Thus, for industrial applications a plasma functionalization process should be preferred to other methods mentioned previously.
[0011] A plasma is a partially or entirely ionized gas or vapour comprising elements in various excitation states. This includes all molecules which are not in a fundamental state. Such plasma can be created and maintained by electromagnetic fields. Due to the exposure of the electromagnetic field, active species of plasma such as ions and free radicals are formed by collisions between molecules from the gas phase and free electrons. The resulting plasma consists of ions, free electrons, free radicals, species in an excited state, photons and neutral stable species. Free radicals react with the surface of treated materials differently depending on the gas nature and the surface chemistry of the material.
[0012] Depending on gas pressure, the plasma can be atmospheric or low-pressure. The pressure range below approximately 10 3 Pa is designated as low-pressure plasma. One of the most important advantages of low-pressure plasma is that reactions requiring elevated temperatures at atmospheric pressure typically take place near ambient temperature under low-pressure plasma conditions. This phenomenon is due to the fact that despite low gas temperatures, high electron temperatures are realized in low-pressure plasma due to the increased free path length. Another advantage of low-pressure plasma is that treatment occurs under vacuum, i.e. in a precisely controlled environment. Due to this fact, the low-pressure plasma treatment has higher repeatability in comparison with atmospheric plasma process. Due to these advantages, low-pressure plasmas have found wide applications in materials processing (M. A. Lieberman, A. J. “Principles of plasma discharges and materials processing”, New York, Wiley, 1994). Low-pressure plasma can be formed by applying a direct current (DC), low frequency (50 Hz), radio frequency (RF) (40 kHz, 13.56 MHz) or microwave (GHz) electric field over a pair or a series of electrodes.
[0013] Radio frequency (RF) plasma devices generally use 13.56 MHz electromagnetic waves since this frequency band is dedicated to the research and does not affect telecommunications.
[0014] Plasma treatments can be achieved under various gas pressures in various reactors. In case of powders such as carbon black, graphite or carbon nanotubes, a uniform treatment of each particle is desirable but difficult to obtain. This is mainly due to particle size distributions and to the agglomeration of the particles.
[0015] In the prior art, vibrating and fluidized-bed reactors have been developed to functionalize carbon nanotubes (CNTs) with O-containing groups via plasma treatment by using high frequency electric fields. The disadvantage of a fluidized-bed reactor working continuously lies in the fact that the residence time of each particle treated in the reactor is in fact unknown and uncontrollable.
[0016] The document WO 2010/081747A discloses a fluidized-bed reactor of a particular shape, comprising a section enlargement in the reactor, where the plasma treatment of the powder occurs.
AIMS OF THE INVENTION
[0017] The present invention aims to provide a plasma reactor and a method which does not have the drawbacks of the prior art.
[0018] The present invention aims in particular to propose a method allowing the powder to fall by gravity through the reaction zone containing active species created by the plasma at low pressure, which guarantees a specific residence time and a controlled treatment.
[0019] Finally the present invention discloses polymer-based composites reinforced with carbon nanotubes functionalized according to the method of the invention and in the reactor of the invention.
SUMMARY OF THE INVENTION
[0020] The present invention discloses a continuous method for the functionalization of a pulverulent product in a plasma reactor comprising the steps of:
generating a plasma in a vertical reactor; bringing the particles in contact with said plasma by letting said particles fall by gravity from top to bottom trough said reactor.
[0023] Preferred embodiments of the present invention disclose at least one or an appropriate combination of the following features:
the continuous method comprises the steps of introducing said pulverulent product into the plasma reactor via an inlet lock chamber and recovering a functionalized pulverulent product in an outlet lock chamber without discontinuation of any of the steps; the pulverulent product comprises carbon nanotubes; the pressure of the plasma is lower than 10 Pa, preferably lower than 1 Pa, and most preferably lower than 0.8 Pa; the molecules for the generation of the plasma are introduced on the top of the plasma reactor; the vertical reactor has a constant cross section; the plasma is generated by a frequency of 13.56 MHz and a power between 100 and 1000 Watt, preferably between 200 and 600 Watt; contemplated molecules for the generation of the plasma are argon (Ar), helium (He), nitrogen (N 2 ), oxygen (O 2 ), hydrogen (H 2 ), water (H 2 O), ammonia (NH 3 ), tetrafluoromethane (CF 4 ), allylamine (C 3 H 5 NH 2 ), acrylic acid (C 3 H 4 O 2 ), isoprene (C 5 H 8 ), hexamethyldisiloxane (C 6 H 18 OSi 2 ), isoprene (C 5 H 8 ), methanol (CH 3 OH) and ethanol (C 2 H 5 OH), and in particular the molecules are selected from the groups consisting of inert gases such as argon (Ar), helium (He); nitrogen-containing gases such as molecular nitrogen (N 2 ), ammonia (NH 3 ); oxygen-containing gases such as oxygen (O 2 ), ozone (O 3 ), carbon monoxide (CO), carbon dioxide (CO 2 ); alkanes such as, for example, ethane (C 2 H 6 ), hexane (C 6 H 14 ); alkenes such as, for example, ethylene (C 2 H 4 ); alkynes such as, for example, acetylene (C 2 H 2 ); monomers such as, for example, methyl methacrylate (C 5 H 8 O 2 ); carboxylic acids with the formula R—COOH, where R is some monovalent functional group and R can be saturated, for example propanoic acid (C 3 H 6 O 2 ), or unsaturated, for example acrylic acid (C 3 H 4 O 2 );
[0031] amines such as alkylamines, for example methylamine (CH 5 N), heptylamine (C 7 H 17 N), butylamine (C 4 H 11 N), propylamine (C 3 H 9 N), 1,3-diaminopropane or allylamines such as allylamine (C 3 H 7 N); amides such as, for example, dimethylformamide (C 3 H 7 NO), alcohols such as methanol (CH 3 OH), ethanol (C 2 H 5 OH), allyl alcohol (C 3 H 5 OH), isopropyl alcohol (C 3 H 7 OH), 1-propanol (C 3 H 7 OH), propargyl alcohol (C 3 H 3 OH), furfuryl alcohol (C 5 H S O 2 H), isobutanol (C 4 H 9 OH); silanes and their derivatives; siloxanes and their derivatives such as hexamethyldisiloxane (C 6 H 18 OSi 2 ); halogens and their derivatives, such as fluorocarbons, for example as tetrafluoromethane (CE); terpenes and terpenoids such as isoprene (C 5 H 8 ) and its derivatives.
[0032] The present invention further discloses an installation for the functionalization of a pulverulent product by means of the method according to the invention comprising:
a plasma reactor placed in a vertical position; a first device in connection with the reactor for admitting a gaseous precursor of active species into the reactor;
[0035] a second device in connection with the plasma reactor for charging the reactor with a pulverulent product;
a third device in connection with the plasma reactor for withdrawing the pulverulent product from the reactor wherein the second device and the third device include one or more lock chamber(s) isolated by one or more valve(s) from the plasma reactor; a fourth device surrounding at least a part of the reactor supplying electromagnetic waves for the generation of the plasma; a fifth device in connection with the plasma reactor for the generation of low-pressure in the plasma reactor.
[0039] Preferred embodiments of the installation according to the invention disclose at least one or an appropriate combination of the following features:
the second device includes a distributor of the pulverulent product; the fourth device is an antenna, preferably solenoid coil-shaped; the second device includes a hopper in connection with a lock chamber; the first device comprises a flow mass controller.
[0044] The present invention further discloses polymer-based composites comprising carbon nanotubes which are functionalized according to the method and the installation of the invention.
SHORT DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 represents the scheme of the plasma functionalization setup of the present invention.
[0046] FIG. 2 represents the TEM images of the structure of pristine CNTs (A) and CNTs after plasma treatment under O 2 (B) and allylamine (C) atmosphere.
[0047] FIG. 3 represents typical X-ray photoelectron spectra of CNTs before (A) and after (B) functionalization under N 2 atmosphere with the characteristic peaks of C, N and O.
[0048] FIG. 4 represents the influence of power of Radio Frequency Electro-Magnetic (RF EM) field on the concentration of nitrogen attached on the CNTs surface after plasma treatment under N 2 atmosphere (based on XPS measurements).
[0049] FIG. 5 represents the influence of the number of passages through the plasma on nitrogen and oxygen concentration in the CNTs after N 2 plasma treatment (based on XPS measurements).
[0050] FIG. 6 represents the influence of the number of the antenna's coils on nitrogen concentration in the CNTs after plasma treatment under N 2 atmosphere (based on XPS measurements).
[0051] FIG. 7 presents typical scanning electron microscopy images of non-carbon materials tested in plasma functionalization setup of the present invention: ferrite (A, B), fumed silica (C, D), silicate glass (E, F), cloisite (G, H).
DETAILED DESCRIPTION OF THE INVENTION
[0052] A large-scale method for the functionalization of powders, and in particular carbon nanotubes, together with a specific reactor type was developed.
[0053] The method is based on the treatment of the powders under plasma conditions and in particular under radio frequency (RF) plasma conditions in the presence of different gases.
[0054] Depending on the nature of the gas used, this method results in the particular case of carbon nanotubes in the replacement of a part of carbon atoms by other atoms or groups of atoms, and/or in the attachment of other atoms or groups of atoms to the carbon atoms of CNTs, or in the deposition of a layer of various substances on the surface of CNTs.
[0055] The variation of the process conditions allows to vary the nature and the concentration of elements or compounds introduced in or deposited on the structure of the CNT surface or other powders. The main advantages of the method according to the invention are:
cold surface treatment (there is no heating of the setup and the pulverulent product); possibility to vary the nature and the concentration of the elements introduced; high yield of the process in comparison with other existing methods of functionalization;
[0059] Setup Description
[0060] FIG. 1 presents the scheme of setup for the plasma functionalization. The developed setup consists in a RF power supply 1 with a matching box 2 which is connected with an antenna 3 . The antenna has several solenoid coils and is placed around a vertical quartz reactor 4 . The expression “vertical reactor” or “vertical position” should be understood as “substantially vertical”, comprising positions slightly deviating from a right angle of 90°.
[0061] The reactor is connected at the top with a powder insertion (feeding) system 5 with feeding means, for example an endless screw 6 and a gas inlet 7 , and at the bottom with a product recovering system 8 . The gas line consists in a gas inlet system 7 , a flow mass controller 9 and a gas balloon (in the case of gaseous precursors) or container with a liquid (in the case of precursor in liquid state) 10 . In a particular embodiment, both the gas inlet and the pumping system are situated on the top of the reactor.
[0062] The pressure inside the vertical reactor is controlled by one or more turbo pumping system(s) ( 11 , 13 ) and a shielding system 12 avoids the propagation of electromagnetic waves outside the reactor zone.
[0063] The treated powder is delivered from the insertion system on the top of the reactor by a suitable feeding system, for example an endless screw, and is transferred through the reactor where it is submitted to the plasma treatment while falling by gravity forces to the bottom of the reactor where it is collected.
[0064] Since the reactor operates under specific low pressure conditions, the (vacuum) outlet 8 and the inlet 5 lock chambers are necessary for the introduction and the recovery of the plasma treated powders to maintain a low pressure inside the reactor. Double lock chambers in a parallel position ( 5 , 8 ) such as represented in FIG. 1 are preferred configurations allowing a continuous functionalization process without interruption of the powder supply and recovery.
[0065] Operating Conditions
[0066] The RF plasma is generated by a frequency of 13.56 MHz and the available power ranges between 100-1000 W. The process gas pressure in the reactor during the treatment is in the range of 10 −2 and 10 Pa.
[0067] The functionalization can be performed in presence of various substances, for example inert gases such as argon (Ar), helium (He); nitrogen-containing gases such as molecular nitrogen (N 2 ), ammonia (NH 3 ); oxygen-containing gases such as oxygen (O 2 ), ozone (O 3 ), carbon monoxide (CO), carbon dioxide (CO 2 ); alkanes such as, for example, ethane (C 2 H 6 ), hexane (C 6 H 14 ); alkenes such as, for example, ethylene (C 2 H 4 ); alkynes such as, for example, acetylene (C 2 H2); monomers such as, for example, methyl methacrylate (C 5 H 8 O 2 ); carboxylic acids with the formula R—COOH, where R is some monovalent functional group and R can be saturated, for example propanoic acid (C 3 H 6 O 2 ), or unsaturated, for example acrylic acid (C 3 H 4 O 2 ); amines such as alkylamines, for example methylamine (CH 5 N), heptylamine (C 7 H 17 N), butylamine (C 4 H 11 N), propylamine (C 3 H 9 N), 1,3-diaminopropane or allylamines such as allylamine (C 3 H 7 N); amides such as, for example dimethylformamide (C 3 H 7 NO); alcohols such as methanol (CH 3 OH), ethanol (C 2 H 5 OH), allyl alcohol (C 3 H 5 OH), isopropyl alcohol (C 3 H 7 OH), 1-propanol (C 3 H 7 OH), propargyl alcohol (C 3 H 3 OH), furfuryl alcohol (C 5 H S O 2 H), isobutanol (C 4 H 9 OH); silanes and their derivatives; siloxanes and their derivatives such as hexamethyldisiloxane (C6H180Si2); halogens and their derivatives, such as fluorocarbons, for example as tetrafluoromethane (CF4), terpenes and terpenoids such as isoprene (C5H8) and its derivatives.
[0068] The method and the installation are suitable for any pulverulent material. Non-limitative examples of powders submitted to functionalization can be single-wall (SWCNTs) or multi-wall carbon nanotubes (MWCNTs), carbon fibres, carbon black, graphite, glass fibres, metal oxides ex: ferrite, fumed silica, silicate glass, nanoclays.
[0069] Characterization Methods
[0070] The structure of the particles after functionalization was characterized by transmission electron microscopy (TEM). The concentration of inserted elements has been estimated by X-ray photoelectron spectroscopy (XPS).
[0071] In the particular case of carbon nanotubes, unique electrical and mechanical properties of polymer-based composites containing these nanotubes are obtained via the structure and the morphology of their aggregates. The preservation of the structure of CNTs and their aggregates during functionalization is therefore one of the important tasks. The structure of CNTs before and after plasma functionalization was investigated with TEM. Typical TEM images of pristine and plasma treated nanotubes presented in FIG. 2 demonstrate that the plasma functionalization process does not change the structure of the nanotubes, acting mainly on the extreme surface of CNTs.
[0072] XPS spectra of CNTs after plasma functionalization proved the introduction/attachment of the elements (Oor/and N) in the nanotubes. The estimation of atomic concentrations of carbon and introduced elements is based on the measurements of the area of their characteristic peaks. The changes in typical XPS spectra of CNTs after functionalization are presented in FIG. 3 .
[0073] The nature of the elements introduced during plasma functionalization can vary by using different gases. The concentration of elements can vary by changing the following parameters:
RF power; length of the antenna (amount of solenoid loops or distance between them); process gas pressure; number of passages of the material through the plasma.
[0078] The results presented in FIG. 4 demonstrate that the increase of the power from 100 up to 300 watt results in the increase of nitrogen concentration in CNTs from 3 to 9 atomic %.
[0079] The increase of the number of passages through the plasma zone also results in the increase of the concentration of the introduced elements ( FIG. 5 ). A bigger concentration of introduced elements can also be achieved by increasing the number of solenoid loops in the antenna ( FIG. 6 ). So, the increase of the number of coils from 4 to 8 leads to the approximately twofold increase of nitrogen concentration.
EXAMPLES
Example 1
[0080] 5 . 0 g of multi-wall carbon nanotubes were placed in the reservoir of the insertion system via an inlet lock chamber, the system was hermetically closed and the setup was pumped by a turbo pump up to a pressure of 5.10 −3 Pa. An N 2 gas was inserted into the system via the top of the vertical reactor tube with a pressure of about 0.99 Pa. The RF plasma was generated by a frequency of 13.56 MHz with a power of 300 W and an antenna with 4 solenoid coils on a quartz reactor. CNTs were transferred from the reservoir to the center of the reactor on the top using the insertion system with an endless screw with the speed 0.4 rotation/sec approximately. CNTs passed through the plasma zone driven by the gravity force.
[0081] After passing the plasma zone, CNTs were collected in the recovery system tank via an outlet lock chamber. The whole system is arranged to coordinate the closure and the opening of the lock chambers so that the low pressure can be maintained while a continuous supply and recovery of CNTs is possible. The concentration of N, O and C was estimated by XPS method. The structure of CNTs was investigated by transmission electron microscopy. The composition of the CNTs sample after functionalization is the following: 93.7 at. % of C, 2.9 at. % of N, 3.4 at. % of O. The composition of the CNTs sample before functionalization was: 99.1 at. % of C, 0.9 at. % of O.
Example 2
[0082] The same operating conditions as in Example 1 were chosen, but an NH 3 gas was used instead of N 2 , with the same pressure (0.99 Pa). The composition of CNT sample after functionalization based on XPS measurements was the following: 96.8 at. % of C, 1.0 at. % of N, 2.2 at. % of O.
Example 3
[0083] The same operating conditions as in Example 1 were chosen, but an C 3 H 5 NH 2 gas was used instead of N 2 , with the same pressure (0.99 Pa). The composition of CNT sample after functionalization based on XPS measurements was the following: 95.7 at. % of C, 1.8 at. % of N, 2.5 at. % of O.
Example 4
[0084] The same operating conditions as in Example 1 were chosen, but an H 2 gas was used instead of N 2 , with the same pressure (0.99 Pa). The composition of CNT sample after functionalization based on XPS measurements was the following: 98.5 at. % of C, and 1.5 at. % of O.
Example 5
[0085] The same operating conditions as in Example 1 were chosen, but an H 2 O gas was used instead of N 2 , with the same pressure (0.99 Pa). The composition of the CNT sample after functionalization based on XPS measurements was the following: 97.2 at. % of C, and 2.8 at. % of O.
Example 6
[0086] The same operating conditions as in Example 1 were chosen, but an 0 2 gas was used instead of N 2 , with the same pressure (0.99 Pa). The composition of the CNT sample after functionalization based on XPS measurements was the following: 96.5 at. % of C, and 3.5 at% of O.
Example 7
[0087] The same operating conditions as in Example 1 were chosen, but a C 3 H 4 O 2 gas was used instead of N 2 , with the same pressure (0.99 Pa). The composition of the CNT sample after functionalization based on XPS measurements was the following: 97.6 at. % of C, and 2.4 at. % of O.
Example 8
[0088] The same operating conditions as in Example 1 were chosen, but the sample was passed through the plasma zone 5 times instead of one. The composition of the CNT sample after functionalization based on XPS measurements was the following: 87.4 at. % of C, 6.2 at. % of N, 6.4 at. % of O.
Example 9
[0089] The same operating conditions as in Example 1 were chosen, but the antenna with 8 solenoid coils was used instead of a 4-coils antenna. The composition of the CNT sample after functionalization based on XPS measurements was the following: 91.2 at. % of C, 5.6 at. % of N, 3.2 at. % of O.
Example 10
[0090] The same operating conditions as in Example 1 were chosen, but the antenna with 8 solenoid coils was used instead of a 4-coils antenna and the sample was passed through the plasma zone 5 times instead of one. The composition of the CNT sample after functionalization based on XPS measurements was the following: 81.3 at. % of C, 13.4 at. % of N, 5.3 at. % of O.
Example 11
[0091] The same operating conditions as in Example 1 were chosen, but the power of 100 W was used instead of 300 W. The composition of the CNT sample after functionalization based on XPS measurements was the following: 94.7 at. % of C, 1.2 at. % of N, 4.1 at. % of O.
Example 12
[0092] The same operating conditions as in Example 1 were chosen, but the power of 200 W was used instead of 300 W. The composition of the CNT sample after functionalization based on XPS measurements was the following: 89.8 at. % of C, 5.9 at. % of N, 4.3 at. % of O.
Example 13
[0093] The same operating conditions as in Example 1 were chosen, but the N 2 pressure of 0.48 Pa was used instead of 0.99 Pa. The composition of the CNT sample after functionalization based on XPS measurements was the following: 88.1 at. % of C, 8.7 at. % of N, 3.2 at. % of O.
Example 14
[0094] The same operating conditions as in Example 1 were chosen, but the N 2 pressure of 0.48 Pa was used instead of 0.99 Pa and the power of 100 W was used instead of 300 W. The composition of the CNT sample after functionalization based on XPS measurements was the following: 93.5 at. % of C, 3.1 at. % of N, 3.4 at. % of O.
Example 15
[0095] The same operating conditions as in Example 1 were chosen, but the N 2 pressure of 0.48 Pa was used instead of 0.99 Pa and the power of 200 W was used instead of 300 W. The composition of the CNT sample after functionalization based on XPS measurements was the following: 93.7 at. % of C, 3.7 at. % of N, 2.6 at. % of O.
Example 16
[0096] The same operating conditions as in Example 1 were chosen, but 5.0 g of carbon black (KETJENBLACK EC600JD, AKZO NOBEL) were used instead of multi-wall carbon nanotubes. The composition of the sample after functionalization based on XPS measurements was the following: 93.5 at. % of C, 4.1 at. % of N, 2.4 at. % of O. The composition of the sample before the plasma treatment was: 97.4 at. % of C, 2.6 at. % of O.
Example 17
[0097] The same operating conditions as in Example 1 were chosen, but 5.0 g of graphite (Expandable graphite GHL PX 98, HUNTSMAN) were used instead of multi-wall carbon nanotubes. The composition of the sample after functionalization based on XPS measurements was the following: 95.2 at. % of C, 1.6 at. % of N, 3.2 at. % of O. The composition of the sample before the treatment was: 99.1 at. % of C, 0.9 at. % of O.
Example 18
[0098] The same operating conditions as in Example 1 were chosen, but 5.0 g of glass fibers were used instead of multi-wall carbon nanotubes. The composition of the sample after functionalization based on XPS measurements was the following: 44.2 at. % of C, 16.1 at. % of N, 39.7 at. % of O. The composition of the sample before the treatment was: 73.4 at. % of C, 26.6 at. % of O. No presence of Si was detected because of the presence of polymer sizing on the surface of glass fibers.
Example 19
[0099] The same operating conditions as in Example 1 were chosen, but 5.0 g of ferrite powder (Fe 2 O 3 ), consisting of irregular shape particles with size 0.2-50 μm ( FIG. 7A , B), were used instead of multi-wall carbon nanotubes, the antenna with 8 solenoid coils was used instead of a 4-coils antenna, the N 2 pressure of 2.0 Pa was used instead of 0.99 Pa and the sample was passed through the plasma zone 5 times instead of one. The composition of the sample after functionalization based on XPS measurements was the following: 2.9 at. % of N, 67.4 at. % of O, 29.7 at. % of Fe. The composition of the sample before the treatment was: 69.1 at. % of O, 30.9 at. % of Fe.
Example 20
[0100] The same operating conditions as in Example 1 were chosen, but 5.0 g of fumed silica powder (SiO 2 ), consisting of agglomerates with size 1-20 μm of particles with size <100nm ( FIG. 7C , D), were used instead of multi-wall carbon nanotubes, the antenna with 8 solenoid coils was used instead of a 4-coils antenna, C 3 H 5 NH 2 was used instead of N 2 with the pressure of 2.0 Pa, and the sample was passed through the plasma zone 5 times instead of one. The composition of the sample after functionalization based on XPS measurements was the following: 1.9 at. % of N, 65.7 at. % of O, 32.4 at. % of Si. The composition of the sample before the treatment was: 67.1 at. % of O, 32.9 at. % of Si.
Example 21
[0101] The same operating conditions as in Example 1 were chosen, but 5.0 g of silicate glass powder (with approximate formula Na 2 OCa0.6SiO 2 ), consisting of spherical particles with size 0.1-50 μm ( FIG. 7E , F), were used instead of multi-wall carbon nanotubes, the antenna with 8 solenoid coils was used instead of a 4-coils antenna, the N 2 pressure of 2.0 Pa was used instead of 0.99 Pa and the sample was passed through the plasma zone 5 times instead of one. The composition of the sample after functionalization based on XPS measurements was the following: 0.8 at. % of N, 62.2 at. % of O, 25.5 at. % of Si, 9.9 at. % of Na, 1.6 at. % of Ca. The composition of the sample before the treatment was: 63.2 at. % of O, 26.4 at. % of Si, 8.8 at. % of Na, 1.6 at. % of Ca.
Example 22
[0102] The same operating conditions as in Example 1 were chosen, but 5.0 g of silicate glass powder (with approximate formula Na 2 OCa0.6SiO 2 ) were used instead of multi-wall carbon nanotubes, the antenna with 8 solenoid coils was used instead of a 4-coils antenna, allylamine (C 3 H 5 NH 2 ) with pressure of 2.0 Pa were used instead of nitrogen and the sample was passed through the plasma zone 5 times instead of one. The composition of the sample after functionalization based on XPS measurements was the following: 12.1 at. % of N, 56.2 at. % of O, 23.7 at. % of Si, 6.6 at. % of Na, 1.4 at. % of Ca. The composition of the sample before the treatment was: 63.2 at. % of O, 26.4 at. % of Si, 8.8 at. % of Na, 1.6 at. % of Ca.
Example 23
[0103] The same operating conditions as in Example 1 were chosen, but 5.0 g of nanoclay Cloisite 20A powder (with approximate formula M x (Al 4-x Mg)Si 8 O 28 (OH) 4 , where M can be Na + , Ca 2+ or NH 4 + ), consisting of irregular shape agglomerates of flakes-like /particles with aggregates size 1-20 μm ( FIG. 7H , G), were used instead of multi-wall carbon nanotubes, the antenna with 8 solenoid coils was used instead of a 4-coils antenna, N 2 pressure of 2.0 Pa was used instead of 0.99 Pa and the sample was passed through the plasma zone 5 times instead of one. The composition of the sample after functionalization based on XPS measurements was the following: 8.5 at. % of N, 56.8 at. % of O, 21.8 at. % of Si, 9.5 at. % of Al, 3.4 at. % of Mg. The composition of the sample before the treatment was: 62.0 at. % of O, 23.7 at. % of Si, 10.6 at. % of Al, 3.7 at. % of Mg.
[0104] Table 1 summarizes the correlation between the nature of the gas, the reaction parameters and the concentration of the elements which 1t0091/ZIOZ OM are introduced in the powder structure.
[0000]
TABLE 1
The relationship between the plasma treatment parameters and
the nature and the concentration of the introduced elements
Antenna
Sample
Pressure,
(number of
Power
Number of
number
Type of powder
Gas
[Pa]
coils)
[W]
passages
Element composition, [atomic %]
1
MWCNT
—
—
—
—
—
99.1 (C), 0.0 (N), 0.9 (O)
1
MWCNT
N 2
0.99
4
300
1
93.8 (C), 2.9 (N), 3.4 (O)
2
MWCNT
NH 3
0.99
4
300
1
96.8 (C), 1.0 (N), 2.2 (O)
3
MWCNT
C 3 H 5 NH 2
0.99
4
300
1
95.7 (C), 1.8 (N), 2.5 (N)
4
MWCNT
H 2
0.99
4
300
1
98.5 (C), 0.0 (N), 1.5 (O)
5
MWCNT
H 2 O
0.99
4
300
1
97.2 (C), 0.0 (N), 2.8 (O)
6
MWCNT
O 2
0.99
4
300
1
96.5 (C), 0.0 (N), 3.5 (O)
7
MWCNT
C 3 H 4 O 2
0.99
4
300
1
97.6 (C), 0.0 (N), 2.4 (O)
8
MWCNT
N 2
0.99
4
300
5
87.4 (C), 6.2 (N), 6.4 (O)
9
MWCNT
N 2
0.99
8
300
1
91.2 (C), 5.6 (N), 3.2 (O)
10
MWCNT
N 2
0.99
8
300
5
81.3 (C), 13.4 (N), 5.3 (O)
11
MWCNT
N 2
0.99
4
100
1
94.7 (C), 1.2 (N), 4.1 (O)
12
MWCNT
N 2
0.99
4
200
1
89.8 (C), 5.9 (N), 4.3 (O)
13
MWCNT
N 2
0.48
4
300
1
88.1 (C), 8.7 (N), 3.2 (O)
14
MWCNT
N 2
0.48
4
100
1
93.5 (C), 3.1 (N), 3.4 (O)
15
MWCNT
N 2
0.48
4
200
1
93.7 (C), 3.7 (N), 2.6 (O)
16
carbon black
—
—
—
—
—
97.4 (C), 0.0 (N), 2.6 (O)
16
carbon black
N 2
0.99
4
300
1
93.5 (C), 4.1 (N), 2.4 (O)
17
graphite
—
—
—
—
—
99.1 (C), 0.0 (N), 0.9 (O)
17
graphite
N 2
0.99
4
300
1
95.2 (C), 1.6 (N), 3.2 (O)
18
glass fibers
—
—
—
—
—
73.4 (C), 0.0 (N), 26.6 (O)
18
glass fibers
N 2
0.99
4
300
1
44.2 (C), 16.1 (N), 39.7 (O)
19
ferrite
—
—
—
—
—
0.0 (N), 69.1 (O), 30.9 (Fe)
19
ferrite
N 2
2.00
8
300
5
2.9 (N), 67.4 (O), 29.7 (Fe)
20
fumed silica
—
—
—
—
—
0.0 (N), 67.1 (O), 32.9 (Si)
20
fumed silica
C 3 H 5 NH 2
2.00
8
300
5
1.9 (N), 65.7 (O), 32.4 (Si)
21
silicate glass
—
—
—
—
—
0.0 (N), 63.2 (O), 26.4 (Si),
8.8 (Na), 1.6 (Ca)
21
silicate glass
N 2
2.00
8
300
5
0.8 (N), 62.2 (O), 25.5 (Si),
9.9 (Na), 1.6 (Ca)
22
silicate glass
C 3 H 5 NH 2
2.00
8
300
5
12.1 (N), 56.2 (O), 23.7 (Si),
6.6 (Na), 1.4 (Ca)
23
cloisite
—
—
—
—
—
0.0 (N), 62.0 (O), 23.7 (Si)
10.6 (Al), 3.7 (Mg)
23
cloisite
N 2
2.00
8
300
5
8.5 (N), 56.8 (O), 21.8 (Si)
9.5 (Al), 3.4 (Mg) | The present invention is related to a continuous method for the functionalization of a pulverulent product in a plasma reactor comprising the steps of:—generating a plasma in a vertical reactor;—bringing the pulverulent product in contact with said plasma by letting said particles fall by gravity from top to bottom trough said reactor. The present invention also discloses an instalation for performing the functionalization method. | 2 |
This application is a division of Ser. No. 09/315,411 filed on May 20, 1999.
FIELD OF THE INVENTION
The field of this invention relates to suspending one tubular in another, especially hanging liners which are to be cemented.
BACKGROUND OF THE INVENTION
In completing wellbores, frequently a liner is inserted into casing and suspended from the casing by a liner hanger. Various designs of liner hangers are known and generally involve a gripping mechanism, such as slips, and a sealing mechanism, such as a packer which can be of a variety of designs. The objective is to suspend the liner during a cementing procedure and set the packer for sealing between the liner and the casing. Liner hanger assemblies are expensive and provide some uncertainty as to their operation downhole.
Some of the objects of the present invention are to accomplish the functions of the known liner hangers by alternative means, thus eliminating the traditionally known liner hanger altogether while accomplishing its functional purposes at the same time in a single trip into the well. Another objective of the present invention is to provide alternate techniques which can be used to suspend one tubular in another while facilitating a cementing operation and still providing a technique for sealing the tubulars together. Various fishing tools are known which can be used to support a liner being inserted into a larger tubular. One such device is made by Baker Oil Tools and known as a “Tri-State Type B Casing and Tubing Spear,” Product No. 126-09. In addition to known spears which can support a tubing string for lowering into a wellbore, techniques have been developed for expansion of tubulars downhole. Some of the techniques known in the prior art for expansion of tubulars downhole are illustrated in U.S. Pat. Nos. 4,976,322; 5,083,608; 5,119,661; 5,348,095; 5,366,012; and 5,667,011.
SUMMARY OF THE INVENTION
A method for securing and sealing one tubular to another downhole facilitates cementing prior to sealing and allows for suspension of one tubular in the other by virtue of pipe expansion techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 are a sectional elevation, showing a first embodiment of the method to suspend, cement and seal one tubular to another downhole, using pipe expansion techniques.
FIGS. 5-11 a are another embodiment creating longitudinal passages for passage of the cementing material prior to sealing the tubulars together.
FIGS. 12-15 illustrate yet another embodiment incorporating a sliding sleeve valve for facilitating the cementing step.
FIGS. 16-19 illustrate the use of a grapple technique to suspend the tubular inside a bigger tubular, leaving spaces between the grappling members for passage of cement prior to sealing between the tubulars.
FIGS. 20-26 illustrate an alternative embodiment involving a sequential flaring of the inner tubular from the bottom up.
FIGS. 27-30 illustrate an alternative embodiment involving fabrication of the tubular to be inserted to its finished dimension, followed by collapsing it for insertion followed by sequential expansion of it for completion of the operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a tubular 10 is supported in casing 12 , using known techniques such as a spear made by Baker Oil Tools, as previously described. That spear or other gripping device is attached to a running string 14 . Also located on the running string 14 above the spear is a hydraulic or other type of stroking mechanism which will allow relative movement of a swage assembly 16 which moves in tandem with a portion of the running string 14 when the piston/cylinder combination (not shown) is actuated, bringing the swage 16 down toward the upper end 18 of the tubular 10 . As shown in FIG. 1 during run-in, the tubular 10 easily fits through the casing 12 . The tubular 10 also comprises one or more openings 20 to allow the cement to pass through, as will be explained below. Comparing FIG. 2 to FIG. 1, the tubular 10 has been expanded radially at its upper end 18 so that a segment 22 is in contact with the casing 12 . Segment 22 does not include the openings 20 ; thus, an annular space 24 exists around the outside of the tubular 10 and inside of the casing 12 . While in the position shown in FIG. 2, cementing can occur. This procedure involves pumping cement through the tubular 10 down to its lower end where it can come up and around into the annulus 24 through the openings 20 so that the exterior of the tubular 10 can be fully surrounded with cement up to and including a portion of the casing 12 . Before the cement sets, the piston/cylinder mechanism (not shown) is further actuated so that the swage assembly 16 moves further downwardly, as shown in FIG. 3 . Segment 22 has now grown in FIG. 3 so that it encompasses the openings 20 . In essence, segment 22 which is now against the casing 12 also includes the openings 20 , thereby sealing them off. The seal can be accomplished by the mere physical expansion of segment 22 against the casing 12 . Alternatively, a ring seal 26 can be placed below the openings 20 so as to seal the cemented annulus 24 away from the openings 20 . Optionally, the ring seal 26 can be a rounded ring that circumscribes each of the openings 20 . Additionally, a secondary ring seal similar to 26 can be placed around the segment 22 above the openings 20 . As shown in FIG. 3, the assembly is now fully set against the casing 12 . The openings 20 are sealed and the tubular 10 is fully supported in the casing 12 by the extended segment 22 . Referring to FIG. 4, the swage assembly 16 , as well as the piston/cylinder assembly (not shown) and the spear which was used to support the tubular 10 , are removed with the running string 14 so that what remains is the tubular 10 fully cemented and supported in the casing 12 . The entire operation has been accomplished in a single trip. Further completion operations in the wellbore are now possible. Currently, this embodiment is preferred.
FIGS. 5-12 illustrate an alternative embodiment. Here again, the tubular 28 is supported in a like manner as shown in FIGS. 1-4, except that the swage assembly 30 has a different configuration. The swage assembly 30 has a lower end 32 which is best seen in cross-section in FIG. 8 . Lower end 32 has a square or rectangular shape which, when forced against the tubular 28 , leaves certain passages 34 between itself and the casing 36 . Now referring to FIG. 7, it can be seen that when the lower end 32 is brought inside the upper end 38 of the tubular 28 , the passages 34 allow communication to annulus 40 so that cementing can take place with the pumped cement going back up the annulus 40 through the passages 34 . Referring to FIG. 8, it can be seen that the tubular 28 has four locations 42 which are in contact with the casing 36 . This longitudinal surface location in contact with the casing 36 provides full support for the tubular 28 during the cementing step. Thus, while the locations 42 press against the inside wall of the casing 36 to support the tubular 28 , the cementing procedure can be undertaken in a known manner. At the conclusion of the cementing operation, an upper end 44 of the swage assembly 30 is brought down into the upper end 38 of the tubular 28 . The profile of the upper end 44 is seen in FIG. 10 . It has four locations 46 which protrude outwardly. Each of the locations 46 encounters a mid-point 48 (see FIG. 8) of the upper end 38 of the tubular 28 . Thus, when the upper end 44 of the swage assembly 30 is brought down into the tubular 28 , it reconfigures the shape of the upper end 38 of the tubular 28 from the square pattern shown in FIG. 8 to the round pattern shown in FIG. 11 a . FIG. 11 shows the running assembly and the swage assembly 30 removed, and the well now ready for the balance of the completion operations. The operation has been accomplished in a single trip into the wellbore. Accordingly, the principal difference in the embodiment shown in FIGS. 1-4 and that shown in FIGS. 5-12 is that the first embodiment employed holes or openings to facilitate the flow of cement, while the second embodiment provides passages for the cement with a twostep expansion of the upper end 38 of the tubular 28 . The first step creates the passages 34 using the lower end 32 of the swage assembly 30 . It also secures the tubular 28 to the casing 36 at locations 42 . After cementing, the upper end 44 of the swage assembly 30 basically finishes the expansion of the upper end 38 of the tubular 28 into a round shape shown in FIG. 11 a . At that point, the tubular 28 is fully supported in the casing 36 . Seals, as previously described, can optionally be placed between the tubular 28 and the casing 36 without departing from the spirit of the invention.
Another embodiment is illustrated in FIGS. 12-15. This embodiment has similarities to the embodiment shown in FIGS. 1-4. One difference is that there is now a sliding sleeve valve 48 which is shown in the open position exposing openings 50 . As shown in FIG. 12, a swage assembly 52 fully expands the upper end 54 of the tubular 56 against the casing 58 , just short of openings 50 . This is seen in FIG. 13 . At this point, the tubular 56 is fully supported in the casing 58 . Since the openings 50 are exposed with the sliding sleeve valve 48 , cementing can now take place. At the conclusion of the cementing step, the sliding sleeve valve 48 is actuated in a known manner to close it off, as shown in FIG. 14 . Optionally, seals can be used between tubular 56 and casing 58 . The running assembly, including the swage assembly 52 , is then removed from the tubular 56 and the casing 58 , as shown in FIG. 15 . Again, the procedure is accomplished in a single trip. Completion operations can now continue in the wellbore.
FIGS. 16-19 illustrate another technique. The initial support of the tubular 60 to the casing 62 is accomplished by forcing a grapple member 64 down into an annular space 66 such that its teeth 68 ratchet down over teeth 70 , thus forcing teeth 72 , which are on the opposite side of the grappling member 64 from teeth 68 , to fully engage the inner wall 74 of the casing 62 . This position is shown in FIG. 17, where the teeth 68 and 70 have engaged, thus supporting the tubular 60 in the casing 62 by forcing the teeth 72 to dig into the inner wall 74 of the casing 62 . The grapple members 64 are elongated structures that are placed in a spaced relationship as shown in FIG. 17 A. The spaces 76 are shown between the grapple members 64 . Thus, passages 76 provide the avenue for cement to come up around annulus 78 toward the upper end 80 of the tubular 60 . At the conclusion of the cementing, the swage assembly 82 is brought down into the upper end 80 of the tubular 60 to flare it outwardly into sealing contact with the inside wall 74 of the casing 62 , as shown in FIG. 18 . Again, a seal can be used optionally between the upper end 80 and the casing 62 to seal in addition to the forcing of the upper end 80 against the inner wall 74 , shown in FIG. 18 . The running assembly as well as the swage assembly 82 is shown fully removed in FIG. 19 and further downhole completion operations can be concluded. All the steps are accomplished in a single trip.
FIGS. 20-25 illustrate yet another alternative of the present invention. In this situation, the swage assembly 84 has an upper end 86 and a lower end 88 . In the run-in position shown in FIG. 20, the upper end 86 is located below a flared out portion 90 of the tubular 92 . Located above the upper end 86 is a sleeve 94 which is preferably made of a softer material than the tubular 92 , such as aluminum, for example. The outside diameter of the flared out segment 90 is still less than the inside diameter 96 of the casing 98 . Ultimately, the flared out portion 90 is to be expanded, as shown in FIG. 21, into contact with the inside wall of the casing 98 . Since that distance representing that expansion cannot physically be accomplished by the upper end 96 because of its placement below the flared out portion 90 , the sleeve 94 is employed to transfer the radially expanding force to make initial contact with the inner wall of casing 98 . The upper end 86 of the swage assembly 84 has the shape shown in FIG. 22 so that several sections 100 of the tubular 92 will be forced against the casing 98 , leaving longitudinal gaps 102 for passage of cement. In the position shown in FIGS. 21 and 22, the passages 102 are in position and the sections 100 which have been forced against the casing 98 fully support the tubular 92 . At the conclusion of the cementing operation, the lower segment 88 comes into contact with sleeve 94 . The shape of lower end 88 is such so as to fully round out the flared out portion 90 by engaging mid-points 104 of the flared out portion 90 (see FIG. 22) such that the passages 102 are eliminated as the sleeve 94 and the flared out portion 90 are in tandem pressed in a manner to fully round them, leaving the flared out portion 90 rigidly against the inside wall of the casing 98 . This is shown in FIG. 23 . FIG. 25 illustrates the removal of the swage assembly 84 and the tubular 92 fully engaged and cemented to the casing 98 so that further completion operations can take place. FIGS. 24 and 26 fully illustrate the flared out portion 90 pushed hard against the casing 98 . Again, in this embodiment as in all the others, auxiliary sealing devices can be used between the tubular 92 and the casing 98 and the process is done in a single trip.
Referring now to FIGS. 27-30, yet another embodiment is illustrated. Again, the similarities in the running in procedure will not be repeated because they are identical to the previously described embodiments. In this situation, the tubular 106 is initially formed with a flared out section 108 . The diameter of the outer surface 110 is initially produced to be the finished diameter desired for support of the tubular 106 in a casing 112 (see FIG. 28) in which it is to be inserted. However, prior to the insertion into the casing 112 and as shown in FIG. 28, the flared out section 108 is corrugated to reduce its outside diameter so that it can run through the inside diameter of the casing 112 . The manner of corrugation or other diameter-reducing technique can be any one of a variety of different ways so long as the overall profile is such that it will pass through the casing 112 . Using a swage assembly of the type previously described, which is in a shape conforming to the corrugations illustrated in FIG. 28 but tapered to a somewhat larger dimension, the shape shown in FIG. 29 is attained. The shape in FIG. 29 is similar to that in FIG. 28 except that the overall dimensions have been increased to the point that there are locations 114 in contact with the casing 112 . These longitudinal contacts in several locations, as shown in FIG. 29, fully support the tubular 106 in the casing 112 and leave passages 116 for the flow of cement. The swage assembly can be akin to that used in FIGS. 5-11 in the sense that the corrugated shape now in contact with the casing 112 shown in FIGS. 29 at locations 114 can be made into a round shape at the conclusion of the cementing operation. Thus, a second portion of the swage assembly as previously described is used to contact the flared out portion 108 in the areas where it is still bent, defining passages 11 6 , to push those radially outwardly until a perfect full 360° contact is achieved between the flared out section 108 and the casing 112 , as shown in FIG. 30 . This is all done in a single trip.
Those skilled in the art can readily appreciate that various embodiments have been disclosed which allow a tubular, such as 10 , to be suspended in a running assembly. The running assembly is of a known design and has the capability not only of supporting the tubular for run-in but also to actuate a swage assembly of the type shown, for example, in FIG. 1 as item 16 . What is common to all these techniques is that the tubular is first made to be supported by the casing due to a physical expansion technique. The cementing takes place next and the cementing passages are then closed off. Since it is important to allow passages for the flow of cement, the apparatus of the present invention, in its various embodiments, provides a technique which allows this to happen with the tubular supported while subsequently closing them off. The technique can work with a swage assembly which is moved downwardly into the top end of the tubular or in another embodiment, such as shown in FIGS. 20-26, the swage assembly is moved upwardly, out of the top end of the tubular. The creation of passages for the cement, such as 34 in FIG. 8, 76 in FIG. 17A, or 102 in FIG. 22, can be accomplished in a variety of ways. The nature of the initial contact used to support the tubular in the casing can vary without departing from the spirit of the invention. Thus, although four locations are illustrated for the initial support contact in FIG. 8, a different number of such locations can be used without departing from the spirit of the invention. Different materials can be used to encase the liner up and into the casing from which it is suspended, including cement, blast furnace slag, or other materials, all without departing from the spirit of the invention. Known techniques are used for operating the sliding sleeve valve shown in FIGS. 12-15, which selectively exposes the openings 50 . Other types of known valve assemblies are also within the spirit of the invention. Despite the variations, the technique winds up being a one-trip operation.
Those skilled in the art will now appreciate that what has been disclosed is a method which can completely replace known liner hangers and allows for sealing and suspension of tubulars in larger tubulars, with the flexibility of cementing or otherwise encasing the inserted tubular into the larger tubular.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit of the invention. | A method for securing and sealing one tubular to another downhole facilitates cementing prior to sealing and allows for suspension of one tubular in the other by virtue of pipe expansion techniques. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Japanese Patent Application No. 2009-278120, filed on Dec. 8, 2009. The entire disclosure of Japanese Patent Application No. 2009-278120 is hereby incorporated herein by reference.
BACKGROUND
1. Field of the Invention
The present invention relates to an electronic device. More specifically, the present invention relates to an electronic device that allows connection with an external device.
2. Background Information
Japanese Patent Application No. 2006-202234 discloses a USB switching device that controls the switching of a USB communication path. This USB switching device switches between a digital still camera (DSC)-printer connection state and a DSC-storage device connection state, on the basis of a switching signal from a storage device.
SUMMARY
It has been discovered that if the user tries to make a USB connection between a DSC and an external device, e.g., a printer or a storage device, using the device disclosed in Japanese Patent Application No. 2006-202234 above, the operation remains problematic.
In view of the state of the known technology, one object of the present invention is to provide an electronic device in which connection to an external device can be accomplished by a relatively simple operation.
In order to achieve the above object of the present invention, an electronic device is provided comprising a plurality of memory components, a connector, a receiver, and a communication component. The connector is configured to operatively connect the electronic device to a first external device. The first external device is capable of individually recognizing the plurality of memory components one at a time or simultaneously recognizing only a few of the plurality of memory components. The receiver is configured to receive a select instruction that specifies which of the memory components will be recognized by the first external device. The communication component is configured to automatically communicate with the first external device to permit the first external device to automatically recognize at least one of the memory components as a predefined memory component. The communication component is further configured to communicate with the first external device when the receiver receives the select instruction to permit the first external device to recognize at least one memory component according to the select instruction.
These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system including a digital video camera and an external device;
FIG. 2 is a block diagram illustrating the configuration of the digital video camera;
FIG. 3 is a sequence diagram illustrating the flow of initial communication;
FIG. 4 is a flowchart illustrating the startup operation of application software;
FIG. 5 is a flowchart illustrating the decision operation of a memory medium;
FIG. 6A is a diagram of a screen displayed on a liquid crystal monitor during initial communication, and FIG. 6B is a diagram of a screen displayed on a liquid crystal monitor after completion of initial communication;
FIG. 7 is a diagram of a medium selection screen;
FIG. 8 is a flowchart illustrating the startup operation of application software pertaining to a modification example;
FIG. 9 is a flowchart illustrating the decision operation of a memory medium pertaining to a modification example;
FIG. 10 is a flowchart illustrating the startup operation of application software pertaining to another modification example;
FIG. 11 is a flowchart illustrating the decision operation of a memory medium pertaining to another modification example;
FIG. 12 is a diagram of a medium selection screen pertaining to a modification example; and
FIG. 13 is a diagram of a medium selection screen pertaining to a modification example.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Embodiment 1
Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
An example of applying the present invention to a digital video camera will now be described through reference to the drawings.
1-1. Overview
The digital video camera 100 pertaining to this embodiment has a USB (universal serial bus) 290 . The digital video camera 100 can be connected via the USB 290 to various kinds of external device, such as a personal computer or a DVD (digital versatile disc) recorder.
The user can connect the digital video camera 100 with a personal computer, a DVD recorder, or another such external device by a relatively simple operation.
1-2. Configuration
1-2-1. Configuration of Entire System
As shown in FIG. 1 , the digital video camera 100 pertaining to this embodiment is connected via the USB 290 to an external device to configure an entire system. With this system, the external device can access a HDD (hard disk drive) 320 and/or a memory card 240 within the digital video camera 100 .
1-2-2. Configuration of Digital Video Camera
The electrical configuration of the digital video camera 100 pertaining to this embodiment will be described through reference to FIG. 2 . FIG. 2 is a block diagram illustrating the configuration of the digital video camera 100 . The digital video camera 100 uses a CCD image sensor 180 to capture an image of a subject formed by an optical system composed of a zoom lens 110 , etc. The image data produced by the CCD image sensor 180 is subjected to various processing by an image processor 190 and stored in the HDD 320 and/or the memory card 240 . The image data stored in the HDD 320 and/or the memory card 240 can be displayed on a liquid crystal monitor 270 . The configuration of the digital video camera 100 will now be described in detail.
The optical system of the digital video camera 100 includes the zoom lens 110 , an Optical Image Stabilizer (OIS) 140 , and a focus lens 170 . The zoom lens 110 can enlarge or reduce a subject image by moving along the optical axis of the optical system. The focus lens 170 adjusts the focus of the subject image by moving along the optical axis of the optical system.
The OIS 140 has an internal correction lens that can move within a plane perpendicular to the optical axis. The OIS 140 stabilizes the subject image by driving the correction lens in a direction that cancels out shake of the digital video camera 100 .
A zoom motor 130 drives the zoom lens 110 . The zoom motor 130 may be a pulse motor, a DC motor, a linear motor, a servo motor, or the like. The zoom motor 130 may drive the zoom lens 110 via a cam mechanism, a ball screw, or another such mechanism. A detector 120 detects the position where the zoom lens 110 is located on the optical axis. The detector 120 outputs a signal related to the position of the zoom lens by means of a brush or other such switch according to the amount of movement of the zoom lens 110 in the optical axis direction.
An OIS actuator 150 drives and moves the correcting lens inside the OIS 140 within a plane that is perpendicular to the optical axis. The OIS actuator 150 can be a plane coil, an ultrasonic motor, or the like. A detector 160 detects the amount of movement of the correcting lens inside the OIS 140 .
The CCD image sensor 180 produces image data by capturing a subject image formed by the optical system composed of the zoom lens 110 , etc. The CCD image sensor 180 performs exposure, transfer, electronic shuttering, and various other such operations.
The image processor 190 subjects the image data produced by the CCD image sensor 180 to various processing and thereby produce image data for display on the liquid crystal monitor 270 , or produces image data to be re-stored in the HDD 320 and/or the memory card 240 . For example, the image processor 190 subjects the image data produced by the CCD image sensor 180 to gamma correction, white balance correction, scratch correction, and various other such processing. The image processor 190 also compresses the image data produced by the CCD image sensor 180 , using a compression format that conforms to the MPEG2 standard, the H.246 standard, or the like. The image processor 190 can be a DSP, a microprocessor, or the like.
A controller 210 is a control unit that controls the entire digital video camera 100 . The controller 210 can be a semiconductor element or the like. The controller 210 may be constituted by hardware alone, or a combination of hardware and software. In this embodiment, the controller 210 is a microprocessor. The controller 210 reads and executes control programs held in an internal memory 280 , and thereby operates as a communication component 210 a , a determination component 210 b , a data controlling component 210 c , etc., to control, for example, the liquid crystal monitor 270 and other devices in the digital video camera 100 . The operation of the communication component 210 a , the determination component 210 b , and the data controlling component 210 c will be described in detail below.
A memory 200 functions as a working memory for the image processor 190 and the controller 210 . The memory 200 is a DRAM, a ferroelectric memory, or the like, for example.
The liquid crystal monitor 270 is able to display an image corresponding to the image data produced by the CCD image sensor 180 , an image corresponding to the image data read out from the HDD 320 and/or the memory card 240 , etc. In another embodiment, an organic EL display, a plasma display, or another such display capable of displaying images can be used in place of the liquid crystal monitor 270 .
A gyro sensor 220 has a piezoelectric element or another such vibrating material. The gyro sensor 220 obtains angular velocity information by converting the Coriolis force exerted on the vibrating material, which is vibrated at a specific frequency, into voltage. The controller 210 obtains angular velocity information from the gyro sensor 220 . The controller 210 corrects any effect of shaking of the user's hand by driving the correcting lens inside the OIS 140 in the direction of canceling out the shake indicated by the angular velocity information.
The memory card 240 can be inserted into and removed from a card slot 230 . The card slot 230 can be mechanically and electrically connected to the memory card 240 . The memory card 240 includes an internal flash memory, ferroelectric memory, etc. The memory card 240 is a storage medium that records video data and so forth captured by the digital video camera 100 .
The internal memory 280 can be a flash memory, ferroelectric memory, or the like. The internal memory 280 holds control programs and so forth for controlling the entire digital video camera 100 .
A manipulation member 250 is an operating interface that receives image capture commands and other various commands from the user. A zoom lever 260 receives zoom ratio change commands from the user.
The USB 290 is an interface for connecting the digital video camera 100 with a personal computer or other such external device. For example, the USB 290 and the USB of a personal computer or other such external device can be connected via a USB cable. The digital video camera 100 can send and receive data to and from an external device, and can receive power supply from an external device, via the USB 290 .
An AC adapter connection terminal 300 is an interface for connecting the digital video camera 100 to an AC adapter. The digital video camera 100 can receive power supply from an AC adapter via the AC adapter connection terminal 300 .
A battery 310 is a chargeable battery for supplying power to the digital video camera 100 .
The HDD 320 is a storage medium that is incorporated into the main body of the digital video camera 100 . The HDD 320 is a storage medium that records video data and/or the like captured by the digital video camera 100 .
1-2-3. Correspondence to Elements of the Embodiments
The memory card 240 and the HDD 320 are examples of memory components of the present invention. A DVD recorder is one example of a first external device. A personal computer is an example of a second external device. The USB 290 is one example of a connector. The manipulation member 250 is one example of a receiver. The communication component 210 a of the controller 210 is an example of a communication component. The determination component 210 b of the controller 210 is one example of a determination component. The data controlling component 210 c of the controller 210 is one example of a data controlling component 210 c . The liquid crystal monitor 270 is one example of a display component. The CCD image sensor 180 is one example of an imaging element.
1-3. Operation
The various operations of the digital video camera 100 pertaining to this embodiment will be described through reference to the drawings.
1-3-1. Initial Communication Between External Device and Digital Video Camera
The initial communication between the digital video camera 100 and a personal computer, DVD recorder, or other such external device will be described through reference to FIG. 3 . FIG. 3 is a sequence diagram illustrating the flow of the initial communication.
The user can connect the digital video camera 100 to an external device via the USB 290 . Once an external device is connected to the USB 290 , the communication component 210 a of the digital video camera 100 notifies the external device that a USB connection has been made (S 100 ).
Upon receipt of a notification that a USB connection has been made, the external device requests device information about the digital video camera 100 from the communication component 210 a (S 110 ). The device information here is information related to the name of the device, the number and types of storage media included in the device, and so on.
Upon receipt of the request for device information, the communication component 210 a responds to the external device with the requested device information (S 120 ). Upon receipt of this response, the external device notifies the communication component 210 a that the device information has been properly received, that is, that the digital video camera 100 has been properly recognized (S 130 ).
After the notification of the proper receipt of device information, the external device requests detailed information about one or more of all the storage media included in the digital video camera 100 from the communication component 210 a (S 140 ). The detailed information about a storage medium here is information related to the capacity of the storage medium, the number of blocks of the storage medium, and so on. A personal computer requests detailed information about all the storage media included in the digital video camera 100 . A DVD recorder, on the other hand, requests detailed information about only a predetermined storage medium (default storage medium) out of all the storage media included in the digital video camera 100 .
Upon receipt of a request for detailed information about a storage medium or media, the communication component 210 a responds to the external device with the requested detailed information (S 150 ). As a result, a personal computer becomes in a state in which it recognizes all the storage media included in the digital video camera 100 . On the other hand, a DVD recorder becomes in a state in which it recognizes only a predetermined storage medium out of all the storage media included in the digital video camera 100 .
With the above operation, the initial communication between the external device and the digital video camera 100 is completed. This completion of initial communication establishes communication between the digital video camera 100 and the external device via the USB 290 . More specifically, completion of initial communication establishes communication between the digital video camera 100 and a personal computer in a state in which both of the two storage media (the memory card 240 and the HDD 320 ) of the digital video camera 100 are recognized. Meanwhile, completion of initial communication establishes communication between the digital video camera 100 and a DVD recorder in a state in which one of the two storage media (the memory card 240 and the HDD 320 ) of the digital video camera 100 is recognized.
This initial communication is automatically begun once an external device is connected to the USB 290 . Therefore, the above-mentioned communication is automatically established once the user connects an external device to the USB 290 of the digital video camera 100 .
The operation after completion of initial communication will now be described.
1-3-2. Startup Operation of Application Software in External Device
The operation of the external device after the completion of initial communication between the external device and the digital video camera 100 will be described through reference to FIG. 4 . FIG. 4 is a flowchart illustrating the startup operation of application software in an external device. The external device is in a state in which it is connected to the digital video camera 100 via the USB 290 . Here, a personal computer and a DVD recorder will be used as examples of external devices.
First, the operation of the personal computer will be described. Application software and resident software corresponding to the digital video camera 100 have been installed in this personal computer ahead of time. Resident software is software that causes the personal computer to execute processing for monitoring the connection of a device to the personal computer. Resident software is automatically started up once a device is connected to the personal computer. Application software is software that causes the personal computer to execute processing such as the editing of moving pictures and/or still pictures outputted from the digital video camera 100 to the personal computer.
The resident software (more precisely, the controller of the personal computer that executes resident software, the same shall apply hereinafter) executes initial communication with the device connected to the personal computer (S 200 ). If the device connected to the personal computer is the digital video camera 100 , the initial communication shown in FIG. 3 is executed.
Upon completion of this initial communication (S 200 ), the resident software in the personal computer determines whether or not the device connected to the personal computer is a target device (S 210 ). The “target device” here is a device that has been recognized ahead of time by the resident software to be a device to which the resident software can start up the application software. The resident software recognizes the digital video camera 100 as a target device ahead of time.
If the device is determined not to be a target device, the resident software ends the operation.
On the other hand, if the device is determined to be a target device, the resident software sends the digital video camera 100 a medium selection screen switch-off command (S 220 ). The “medium selection screen switch-off command” here is a command to switch off the medium selection screen (discussed below) from the liquid crystal monitor 270 . Upon sending of a medium selection screen switch-off command to the digital video camera 100 , the resident software starts up the application software (S 230 ).
Next, the operation of the DVD recorder will be described. The controller of the DVD recorder automatically executes the initial communication shown in FIG. 3 once the digital video camera 100 is connected to the DVD recorder. Upon completion of the initial communication (S 300 ), the DVD recorder immediately starts up the application software (S 310 ). This application software is software that causes the DVD recorder to execute moving picture and/or still picture recording, reproduction, or other such processing.
1-3-3. Operation of Determining Storage Media of Digital Video Camera
The operation of the digital video camera 100 after completion of initial communication between the external device and the digital video camera 100 will be described through reference to FIG. 5 . FIG. 5 is a flowchart illustrating the decision operation of the storage media of the digital video camera 100 . The processing in FIG. 5 performed by the digital video camera 100 is executed in parallel with the processing in FIG. 4 performed by the external device. The decision operation of the storage media of the digital video camera 100 is automatically executed once an external device is connected to the USB 290 .
Upon completion of the initial communication (S 400 ) shown in FIG. 3 , the determination component 210 b of the controller 210 determines whether or not a medium selection screen switch-off command has been received from the external device (S 410 ). During initial communication, the controller 210 displays the screen of FIG. 6A on the liquid crystal monitor 270 . After completion of the initial communication, the controller 210 instructs the liquid crystal monitor 270 to display the screen illustrated in FIG. 6B . The screen displays the medium selection screen illustrated in FIGS. 7 , 12 and 13 , which is generated when the controller 210 received information from the internal memory 280 .
If it is determined that a medium selection screen switch-off command has been received, the controller 210 executes step S 420 . If a medium selection screen (discussed below) is being displayed on the liquid crystal monitor 270 , the controller 210 controls the liquid crystal monitor 270 so as to switch off the medium selection screen (S 420 ). On the other hand, if a medium selection screen is not being displayed on the liquid crystal monitor 270 , the controller 210 does nothing (S 420 ). The liquid crystal monitor 270 displays the screen of FIG. 6B at the point when step S 420 comes to an end.
Meanwhile, if it is determined that no medium selection screen switch-off command has been received, the controller 210 controls the liquid crystal monitor 270 so that the medium selection screen of FIG. 7 is displayed (S 430 ). The medium selection screen is a screen that allows the user to input a select instruction and thereby allows the user to select which of the two storage media (the memory card 240 and the HDD 320 ) of the digital video camera 100 is to be recognized by the external device. The select instruction is an instruction with which the user shows the digital video camera 100 which of the plurality of memory components are to be recognized by the external device. In other words, the medium selection screen prompts the user to select either the memory card 240 or the HDD 320 as the storage medium to be recognized by the external device. That is, the medium selection screen asks the user to select either the memory card 240 or the HDD 320 as the storage medium that the external device is to recognize.
After step S 430 , the controller 210 determines whether or not the user has selected a storage medium on the medium selection screen (S 440 ). The user can select a storage medium on the medium selection screen by manipulating the manipulation member 250 . The manipulation member 250 is a member that receives the select instruction from the user. The manipulation member 250 may be a button, or may be a touch panel provided to the liquid crystal monitor 270 . In short, the manipulation member 250 may be any interface with which the controller 210 can be made to recognize the selection of a storage medium by the user. If it is determined that no storage medium has been selected, the controller 210 again performs the determination of step S 410 . On the other hand, if it is determined that a storage medium has been selected, the controller 210 determines which storage medium was selected by the user (S 450 ).
If it is determined that the HDD 320 was selected, the digital video camera 100 and the external device again perform the initial communication of FIG. 3 (S 460 ). At that time, if the DVD recorder is connected to the USB 290 , the communication component 210 a sends the DVD recorder detailed information about the HDD 320 in step S 150 , which is included in the initial communication. Therefore, when the initial communication (S 460 ) is complete, the DVD recorder becomes in a state in which the HDD 320 of the digital video camera 100 has been mounted (recognized) (S 470 ).
On the other hand, if it is determined that the memory card 240 was selected, the digital video camera 100 and the external device again perform the initial communication of FIG. 3 (S 480 ). At that time, if the DVD recorder is connected to the USB 290 , the communication component 210 a sends the DVD recorder detailed information about the memory card 240 in step S 150 , which is included in the initial communication. Therefore, when the initial communication (S 480 ) is complete, the DVD recorder becomes in a state in which the memory card 240 of the digital video camera 100 has been mounted (recognized) (S 490 ).
The digital video camera 100 receives a medium selection screen switch-off command only when the digital video camera 100 is connected to a personal computer. That is, a medium selection screen switch-off command is a signal that causes the digital video camera 100 to recognize the type of external device (whether it is a personal computer or a DVD recorder) connected to the digital video camera 100 . Therefore, the above-mentioned step S 410 is a step of determining the type of external device connected to the digital video camera 100 .
1-4. Data Controlling Component
The external device such as, for example, a personal computer or a DVD recorder, can read data from the memory card 240 and/or the HDD 320 , whichever the external device is currently recognizing. The data controlling component 210 c stores the image data recorded by the user in the memory card 240 and/or the HDD 320 . The data controlling component 210 send the external device the data (including the image data) stored in the memory card 240 and/or the HDD 320 according to a command sent from the external device.
1-5. Features of Digital Video Camera
Once a DVD recorder is connected to the digital video camera 100 , the digital video camera 100 automatically executes initial communication and causes the DVD recorder to recognize the default storage medium. The DVD recorder is a type of external device capable of simultaneously recognizing only some of the plurality of storage media of the digital video camera 100 . Therefore, communication between the DVD recorder and the digital video camera 100 can be established in plug-and-play fashion, without requiring the user to go through a complicated operation.
Also, once a DVD recorder is connected to the digital video camera 100 , the digital video camera 100 automatically displays a medium selection screen on the liquid crystal monitor 270 upon completion of the initial communication. The medium selection screen is a screen that receives an instruction from the user with which the storage medium to be recognized by the DVD recorder is selected from among the two storage media (the memory card 240 and the HDD 320 ) of the digital video camera 100 . When the digital video camera 100 is instructed via the medium selection screen to change the storage medium, it executes initial communication again, and causes the DVD recorder to recognize the storage medium indicated by this instruction. Consequently, the user can easily have the DVD recorder recognize a storage medium other than the default storage medium.
Also, once a DVD recorder is connected to the digital video camera 100 , the digital video camera 100 automatically executes initial communication to cause the DVD recorder to recognize the default storage medium, and automatically causes the liquid crystal monitor 270 to display the medium selection screen after completion of initial communication. Consequently, if the usage frequency of the default storage medium by the user is generally greater than the usage frequency of other storage media, in most cases the storage medium desired by the user will be recognized by the DVD recorder in plug-and-play fashion. Furthermore, if necessary, the user can select a storage medium other than the default storage medium with the medium selection screen. The default storage medium may be set to one with a storage capacity that is greater than that of other storage media, or may be set to one with a data read speed that is greater than that of other storage media, or may be set to one determined to be suitable on the basis of survey results, or can be set to any other storage medium.
Also, the medium selection screen is displayed on the liquid crystal monitor 270 , which allows the user to visually understand the choices of the storage medium to be recognized by the external device. As a result, changing the storage medium to be recognized by the external device can be accomplished easily and intuitively.
Also, once a personal computer is connected to the digital video camera 100 , the digital video camera 100 automatically executes initial communication. A personal computer is a type of external device capable of simultaneously recognizing all of the plurality of storage media included in the digital video camera 100 . As a result, regardless of whether the user connects a personal computer or a DVD recorder to the digital video camera 100 , communication between the digital video camera 100 and the external device can be automatically established in plug-and-play fashion. Consequently, the user can start communication between the digital video camera 100 and the external device automatically, merely by connecting the two, without going to the trouble of making a selection, etc.
Also, once a DVD recorder is connected to the digital video camera 100 , the digital video camera 100 automatically displays a medium selection screen on the liquid crystal monitor 270 , but when a personal computer is connected to the digital video camera 100 , either a medium selection screen is not displayed on the liquid crystal monitor 270 , or, if a medium selection screen is already being displayed on the liquid crystal monitor 270 , it is switched off. The digital video camera 100 executes the different processing according to the type of external device which is connected to the digital video camera 100 , so that the user does not need to do any unnecessary operations.
Other Embodiments
Embodiment 1 was described above as an embodiment of the present invention, but the present invention is not limited to or by these. Other embodiments of the present invention will be described in this section.
In Embodiment 1, a digital video camera was used as an example of an electronic device pertaining to the present invention, but the present invention can also be applied to other electronic devices having a plurality of storage media.
Also, in Embodiment 1, a hard disk drive and a memory card were given as examples of a plurality of storage media (or memory components), but the present invention is not necessarily limited to these examples. The present invention can be applied to an electronic device equipped with a flash memory, a hard disk drive, and a memory card, an electronic device equipped with two memory cards, or other various electronic devices having a plurality of media. In other words, in Embodiment 1 there were two storage media that the DVD recorder could recognize, and there was one default storage medium. In other embodiments, however, there may be three or more storage media that the DVD recorder can recognize. In this case, there may be two or more default storage media.
Also, in Embodiment 1 a medium selection screen switch-off command was sent from the personal computer to the digital video camera 100 , but the present invention is not necessarily limited to such a situation. For instance, instead of a medium selection screen switch-off command, any command can be sent that can notify to the effect that an external device is able to simultaneously recognize all of the storage media of the digital video camera 100 .
Also, in Embodiment 1 the USB 290 was given as an example of a connector, but the present invention is not necessarily limited to this. Any connector that allows bidirectional communication between the digital video camera 100 and an external device may be used.
Also, in Embodiment 1 a medium selection screen was automatically displayed on the liquid crystal monitor 270 once the DVD recorder was connected to the USB 290 , but a medium selection screen does not necessarily have to be displayed in plug-and-play fashion. For example, the user may use the manipulation member 250 to direct that a medium selection screen be displayed at the desired timing.
Also, in Embodiment 1 a medium selection screen switch-off command was sent from the personal computer to the digital video camera 100 in order for the digital video camera 100 to recognize the type of external device connected to the digital video camera 100 . However, the digital video camera 100 can recognize the type of external device connected to the digital video camera 100 in some other way.
For example, as shown in FIG. 8 , both the personal computer and the DVD recorder may send the digital video camera 100 signals that allow the respective types to be identified. In this case, the processing of FIG. 5 can be modified to the processing of FIG. 9 , for example. More specifically, in step S 410 , the processing is ended when a specific signal has been sent from the personal computer and the processing moves to step S 430 when a specific signal has been sent from the DVD recorder. If a determination of “no” is made in step S 440 , the processing returns to step S 440 , rather than going to step S 410 .
Alternatively, as shown in FIG. 10 , only the DVD recorder may send a specific signal to the digital video camera 100 . In this case, the processing of FIG. 5 can be modified to the processing of FIG. 11 , for example. More specifically, if a determination of “no” is made in step S 410 , step S 410 is repeated. Furthermore, if a determination of “no” is made in step S 440 , the processing returns to step S 440 , rather than going to step S 410 .
As described above, if a specific signal is sent from the personal computer and/or the recorder, the determination component 210 b is able to determine the type of external device connected to the digital video camera 100 .
Also, the medium selection screen is not limited to the example shown in FIG. 7 , and may instead be as shown in FIG. 12 or 13 , for example. That is, the medium selection screen need not be a screen on which all of the storage media included in the digital video camera 100 are given as options as shown in FIG. 7 , and may instead be a screen on which the currently selected storage medium option is omitted as shown in FIGS. 12 and 13 , and only options for the storage media not currently selected are given.
The screen in FIG. 12 is a screen that receives an instruction to change the storage medium to be recognized by the DVD recorder from the HDD 320 to the memory card 240 when the HDD 320 has been connected to the USB 290 . If the user wants to select the HDD 320 , he or she can make the selection to do nothing, but if the user wants to select the memory card 240 , he or she can make the selection to press the icon for the memory card 240 . Similarly, the screen in FIG. 13 is a screen that receives an instruction to change the storage medium to be recognized by the DVD recorder from the memory card 240 to the HDD 320 when the memory card 240 has been connected to the USB 290 . If the user wants to select the memory card 240 , he or she can make the selection to do nothing, but if the user wants to select the HDD 320 , he or she can make the selection to press the icon for the HDD 320 . That is, the medium selection screens shown in FIGS. 12 and 13 are screens that allow the user to select which of the two storage media (the memory card 240 and the HDD 320 ) of the digital video camera 100 is to be recognized by the external device.
Also, in Embodiment 1, a DVD recorder was given as an example of an external device (first external device) of a type capable of simultaneously recognizing only some of the plurality of storage media of the digital video camera 100 , and a personal computer was given as an example of an external device (second external device) of a type capable of simultaneously recognizing all of the plurality of storage media of the digital video camera 100 . However, the present invention is not limited to or by these examples. For instance, when USB connection is assumed, any device equipped with an OS (operating system) that can simultaneously recognize a plurality of logical units can be used as the second external device. Meanwhile, a device in which such an OS is not installed, and which is designed to be able to recognize only one logical unit at a time, can be used as the first external device.
INDUSTRIAL APPLICABILITY
The present invention can be applied to a digital video camera, a digital still camera, or other such electronic devices.
GENERAL INTERPRETATION OF TERMS
In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms “including,” “having,” and their derivatives. Also, the terms “part,” “section,” “portion,” “member,” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiments, the following directional terms “forward”, “rearward”, “above”, “downward”, “vertical”, “horizontal”, “below” and “transverse” as well as any other similar directional terms refer to those directions of an electronic device. Accordingly, these terms, as utilized to describe the above embodiments should be interpreted relative to an electronic device.
Moreover, the term “configured” as used herein to describe a component, section, or part of a device includes hardware and/or software that is constructed and/or programmed to carry out the desired function.
While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. Thus, the scope of the invention is not limited to the disclosed embodiments. | An electronic device comprises a plurality of memory components, a connector, a receiver, and a communication component. The connector is configured to operatively connect the electronic device to an external device. The external device is capable of individually recognizing the memory components one at a time or simultaneously recognizing only a few of the memory components. The receiver is configured to receive a select instruction that specifies which of the memory components will be recognized by the external device. The communication component is configured to automatically communicate with the external device to permit the external device to automatically recognize at least one of the memory components as a predefined memory component. The communication component is further configured to communicate with the external device when the receiver receives the select instruction to permit the external device to recognize at least one memory components according to the select instruction. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a photoreceptor for electrophotography that contains amorphous silicon.
2. Prior Art
The life of a photoreceptor for use in electrophotography is known to be chiefly governed by such factors as the deterioration of its electrical properties, the occurrence of flaws on its surface, and the changes (especially the thermal change) in the properties of the materials of which the photoreceptor is made. Photoreceptors made of amorphous silicon based materials have recently been the subject of intensive studies by many researchers because it is anticipated that such materials will be completely free from the restraints of the various factors that have governed the life of conventional photoreceptors. In other words, since amorphous silicon materials retain stable electrical characteristic over cyclic use, have high hardness, and are thermally stable, they have the potential to provide an extremely long-lived photoreceptor.
Beside its potential for extending the life of photoreceptors, amorphous silicon has a high photosensitivity in the range of longer wavelength than conventional materials and its sensitivity can be further extended into the range of still longer wavelength by selecting an appropriate formulation. Therefore, photoreceptors made of amorphous silicon can be used with printers that employ small and low-cost semiconductor lasers as light sources.
In spite of these advantages that increase its potential for use as the material of a photoreceptor, amorphous silicon has its own problems in practice in terms of dark resistance, photosensitivity at long wavelengths, mechanical strength properties (in particular, ductility), time-dependent stability, and dependency of image quality on environmental factors (i.e., temperature and humidity).
Amorphous silicon materials have high hardness (their Vickers hardness is on the order of 10 3 ) but if they are brought into contact with less hard materials (e.g. the edge of copying paper and the cleaning blade in a copying machine), the area of contact will fail to produce an image and remain as white dots. It is also known that a photoreceptor made of amorphous silicon experiences a reduced resolution (i.e., dilation) if it is cyclically used for fairly long period in a copying machine (or printer). This is probably due to the deposition of foreign matter on the surface of the photoreceptor and/or to the change in the proterties of the photoreceptor. The phenomenon of dilation can also materialize for reasons associated with the structure of the photoreceptor (e.g. use of an inappropriate surface layer) and if this is the case, the phenomenon will occur in the initial period of use, that is, within a few cycles to several tens of cycles of operation.
The applicants of the present invention previously resolved the aforementioned problems by proposing an amorphous silicon photoreceptor having two amorphous silicon surface layers containing different concentrations of nitrogen atoms as disclosed in U.S. Ser. No. 061,964 filed on June 15, 1987.
However, the above photoreceptor, if the overall film thickness of the surface layers is set so as to satisfy the resistance to printing which is required according to the various conditions in a copying machine or a printer used, it has been difficult to satisfy the requirements for the residual potential and the sensitivity to a short wavelength light (in the vicinity of 500 nm). That is, the residual potential is proportional to the concentration of nitrogen atoms in the surface layers, while the absorption coefficient of the surface layer for the short wavelength light is inversely proportional to the concentration of nitrogen atoms. Accordingly, when the concentration of nitrogen atoms is lowered to reduce the residual potential, there occurs a problem that the sensitivity to light is reduced due to absorption by the surface layers.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a photoreceptor for electrophotography which has an excellent resistance performance to printing, low residual potential and high light sensitivity over the entire range of the visible light region.
Another object of the present invention is to provide a photoreceptor for electrophotography which can provide an initial image of high quality and has an excellent stability against the passage of the time.
Another object of the present invention is to provide a photoreceptor for electrophotography which has a high dark resistance and an excellent electrification capacity.
Another object of the present invention is to provide a photoreceptor for electrophotography which has a small dependence of the properties thereof on the environment in which the photoreceptor is used.
Another object of the present invention is to provide a photoreceptor for electrophotography which can provide stable and high initial picture quality in any environment where the photoreceptor is used, and will not be deteriorated even for repetitive use.
The above objects of the present invention can be achieved by the following structural features. The photoreceptor according to this invention includes: a photoconductive layer comprising an amorphous silicon base, a first surface layer, a second surface layer and a third surface layer laminated sequentially on a substrate in this order. Each of the first, second and third surface layers includes amorphous silicon as a principal ingredient and is doped with nitrogen atoms and the film thicknesses d 1 , d 2 , and d 3 of the first, second and third surface layers satisfy the conditions d 2 >d 1 and d 2 >d 3 . Further, the nitrogen concentrations c 1 , c 2 and c 3 of the first, second and third surface layers satisfy the relation c 3 >c 2 >c 1 .
In addition, the above objects of the present invention can be accomplished more effectively by adding 0.01-100 ppm atoms of a group III element to the photoconductive layer of the photoreceptor. The effect of the present invention can be made more conspicuous by providing between the substrate and the photoconductive layer a charge injection blocking layer of amorphous silicon which is added with 1-5,000 ppm atoms of a group III or a group V element.
Moreover, in the photoreceptor of the present invention, a charge capturing layer of amorphous silicon which contains 0.1-5,000 ppm atoms of a group III or a group V element may be provided between the photoconductive layer and the first surface layer to accomplish this invention more effectively.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the construction of the photoreceptor according to the present invention; and
FIG. 2 is an explanatory diagram showing the schematic construction of the electrophotographic apparatus using the photoreceptor of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of this invention will be described with reference to the accompanying drawings.
FIG. 1 is a schematic diagram illustrating the typical structure of the photoreceptor of the present invention. The photoreceptor comprises a substrate 1, a charge injection blocking layer 2, a photoconductive layer 3, a charge capturing layer 4, and first, second and third surface layers 5, 6 and 7, respectively. The charge injection blocking layer 2 comprises amorphous silicon which is added with 1-5,000 ppm atoms of a group III or a group V element. The preferable quantity of the additive is in the range of 5-1,000 ppm. The photoconductive layer 3 is amorphous silicon which is added with 0.01-100 ppm atoms of a group III or a group V element. The preferable quantity of the additive is in the range of 0.05-50 ppm. The charge capturing layer 4 comprises amorphous silicon which is added with 0.1-5,000 ppm atoms of a group III or a group V element. The preferable quantity of the additive is in the range of 1-1,000 ppm. The surface layers 5, 6 and 7 comprise amorphous silicon which is added with nitrogen atoms, and when their film thicknesses are represented by d 1 , d 2 and d 3 , and their nitrogen atom concentrations are represented by c 1 , c 2 and c 3 , respectively, they satisfy the following relations: d 2 >d l , d 2 >d 3 and c 3 >c 2 >c 1 .
As for the substrate 1, depending upon the need, appropriate choice may be made from among metals such as aluminum, nickel, chrome and stainless steel, and a plastic sheet, glass, and paper having an electrically conductive film.
Each of the layers 2 to 7 is a layer having amorphous silicon as the main body, and may be formed by means of the glow discharge decomposition method, sputtering method, ion plating method, vacuum deposition method or the like. With the glow discharge decomposition method as an example, the method of manufacture proceeds as follows. First, as the raw material gas, the mixture of the main raw material gas containing silicon atoms and a raw material gas containing required additive atoms is used. In this case, a carrier gas such as a hydrogen gas or an inert gas may be added to the above mixture. The film formation is carried out in the following conditions: frequency of 0-5 GHz, internal reactor pressure of 10- 5 -10 Torr (0.001-1,330 Pa), discharge power of 10-3,000 W, and the substrate temperature of 30°-300° C. The film thickness of the each layer can be set appropriately by adjusting the discharge time. In addition, silanes, especially SiH 4 and/or Si 2 H 6 are used as the main raw material gas.
The charge injection blocking layer 2 comprises amorphous silicon which is added with a group III or group V element. The film thickness is preferably in the range of 0.01-10 μm. The decision as to the choice of a group III or group V element is made by the sign of the charge on the photoreceptor. In forming the film, diborane (B 2 H 6 ) is typically used as a raw material gas containing a group III element, and phosphine (PH 3 ) is typically used as a raw material gas containing a group V element. To the charge injection blocking layer having amorphous silicon as the main body, other elements, in addition to a group III or group V element, may also be added for various purposes.
The photoconductive layer 3 comprises amorphous silicon which is added with a group III element. The film thickness is preferably in the range of 1-100 μm. Diborane is typically used as the raw material gas containing the group III element. To the photoconductive layer having amorphous silicon as the main body, other elements may be further added in addition to the group III element for various purposes. Further, the photoconductive layer may be formed by a charge generating layer and a charge transporting layer.
The charge capturing layer 4 comprises amorphous silicon which is added with a group III element or a group V element. The film thickness is preferably in the range of 0.01-10 μm. The selection of a group III element or a group V element for use is determined by the sign of the charge on the photoreceptor. Diborane is typically used as the raw material gas containing a group III element, and phosphine is typically used as a raw material gas containing a group V element. To the charge capturing layer having amorphous silicon as the main body, other elements, in addition to the group III or group V element, may also be added for various purposes.
Each of the surface layers 5, 6 and 7 comprises amorphous silicon which is added with nitrogen atoms. As the raw material gas containing nitrogen atom in the film formation, any simple substrance or compound having nitrogen atom as a component may be employed as long as it is usable in vapor phase. As examples, N 2 gas or a gas of hydrogenated nitrogen compounds such as NH 3 , N 2 H 4 and HN 3 may be used. The raw material gas containing nitrogen atom to be used for various surface layers may be identical or may be different. In addition, other elements may also be added to the respective surface layers for various purposes.
In the present invention, when the nitrogen atom concentrations of the surface layers 5, 6 and 7 are represented by c 1 , c 2 and c 3 , and their film thicknesses are represented by d 1 , d 2 and d 3 , respectively, these quantities have to satisfy the relations c 3 >c 2 >c 1 , d 2 >d 1 and d 2 >d 3 .
The nitrogen atom concentration in the first surface layer 5 is preferably in the range of 0.1-1.0 in terms of the atom number ratio to silicon. In addition, the film thickness thereof is preferably in the range of 0.01-0.1 μm.
The nitrogen atom concentration in the second surface layer 6 is preferably in the range of 0.1-1.0 in terms of the atom number ratio to silicon. The film thickness thereof is preferably in the range of 0.05-1 μm.
The nitrogen atom concentration in the third surface layer 7 is preferably in the range of 0.5-1.3 in terms of the atom number ratio to silicon. Further, the film thickness thereof is preferably in the range of 0.01-0.1 μm.
The photoreceptor of the present invention may be used in any electrophotographic process. However, it can be used more effectively in an electrophotographic process which is operated under the condition that at least the surface of the photoreceptor is heated at 35°-50° C. because when the photoreceptor is used under the above heat-condition, a stable and high-quality initial image can be obtained in any environment, and it will not be deteriorated in image quality by repetitive use.
Such an electrophotographic process will be described with reference to FIG. 2.
FIG. 2 shows a schematic construction of an electrophotographic device using a photoreceptor of the present invention. Reference numeral 8 represents a photoreceptor according to the present invention; 9, electrifying means for uniformly electrifying the photoreceptor in a dark place; 10, latent image forming means for forming a latent image in the photoreceptor by exposing the photoreceptor to an optical image corresponding to an original image; 11, developing means for developing the latent image into a visible image with toner powder; 12, transfer means for transferring the developed image onto a transfer member; 13, fixing means for fixing the transferred image; 14, cleaning means; 15, a transfer paper; and 16, photoreceptor heating means comprising a rotary shaft and a quartz lamp mounted therein.
The means for heating the photoreceptor may be provided at an arbitrary position. Although the photoreceptor heating means 16 is provided within the rotary shaft for rotating photoreceptor 8 the as shown in FIG. 2, it may be provided at a neighboring position to the peripheral surface of the photoreceptor, like developing means, electrifying means, transfer means and the like. When provided on the substrate side, the photoreceptor heating means 16 may be disposed at an arbitrary position. In this case, it is preferably designed so as to be a planar heater for heating the photoreceptor, which is closely and uniformly contacted with the inner side of the photoreceptor.
As the photoreceptor heating means, a heating lamp, for example, a quartz lamp formed by providing nichrome wires within quartz glass or a planar heater obtained by arranging nichrome wires within flexible rubber having a heat-resistance such as silicon rubber, may be used. In addition, a hot air blowing type heater, a heater utilizing radiative heat such as infrared rays, a heater utilizing the heat generated at the fixing unit and the like, may also be used. As power supply means to the above photoreceptor heating means, an arbitrary device may be used. In the case where the heating means is provided at the inside of a photoreceptor supporting member, it is preferable to employ a device which supplies a power through a slip ring thereto because the photoreceptor is rotated.
EMBODIMENT
The present invention will be described concretely with examples and comparative examples.
Using a capacity-coupled type plasma CVD apparatus which can form an amorphous silicon film on a cylindrical aluminum substrate, the mixture of silane (SiH 4 ) gas, hydrogen (H 2 ) gas and diborane (B 2 H 6 ) gas are decomposed by glow discharge to form a charge injection blocking layer having thickness of about 4.3 μm on the cylindrical aluminum substrate. The manufacturing conditions for the above process were as follows:
______________________________________Flow rate of 100% silane gas 180 cm.sup.3 /min,Flow rate of 100% hydrogen gas 90 cm.sup.3 /min,Flow rate of diborane gas diluted 90 cm.sup.3 /min,with 20 ppm hydrogenInternal pressure of reactor 1.0 Torr,Discharge power 200 W,Discharge time 60 min,Discharge frequency 13.56 MHz,Substrate temperature 250°C.______________________________________
(It is to be noted that the discharge frequency and the substrate temperature in the manufacturing conditions for each layer in the embodiment and the comparative examples to be described below were fixed to the values listed above.)
After forming a charge injection blocking layer, the inside of the reactor was thoroughly evacuated, and then the mixture of silane gas, hydrogen gas and diborane gas is introduced into the reactor to be decomposed by glow discharge, so that a photoconductive layer having a thickness of about 15 μm was formed on top of the charge injection blocking layer. The manufacturing conditions for the above process were as follows:
______________________________________Flow rate of 100% silane gas 180 cm.sup.3 /min,Flow rate of 100% hydrogen gas 162 cm.sup.3 /min,Flow rate of diborane gas diluted 18 cm.sup.3 /min,with 20 ppm hydrogenInternal pressure of reactor 1.0 Torr,Discharge power 200 W,Discharge time 210 min.______________________________________
After the formation of the photoconductive layer, the inside of the reactor was evacuated thoroughly, and by introducing the mixture of silane gas, hydrogen gas and diborane gas and decomposing the mixture by glow discharge, a charge capturing layer having a thickness of about 0.9 μm was formed on the photoconductive layer. The manufacturing conditions for the above process were as follows.
______________________________________Flow rate of 100% silane gas 180 cm.sup.3 /min,Flow rate of 100% hydrogen gas 90 cm.sup.3 /min,Flow rate of diborane gas diluted 90 cm.sup.3 /min,with 20 ppm hydrogenInternal pressure of reactor 1.0 Torr,Discharge power 200 W,Discharge time 12 min.______________________________________
After the formation of the charge capturing layer, the inside of the reactor was evacuated thoroughly, and by introducing the mixture of silane gas, hydrogen gas and ammonia (NH 3 ) gas in the reactor and decomposing the mixture by glow discharge, a first surface layer having a thickness of about 0.05 μm was formed on top of the charge capturing layer. The manufacturing conditions for the above process were as follows:
______________________________________Flow rate of 100% silane gas 26 cm.sup.3 /min,Flow rate of 100% hydrogen gas 180 cm.sup.3 /min,Flow rate of 100% ammonia gas 30 cm.sup.3 /min,Internal pressure of reactor 0.5 Torr,Discharge power 50 W,Discharge time 6 min.______________________________________
After the formation of the first surface layer, by introducing the mixture of silane gas, hydrogen gas and ammonia gas and decomposing the mixture by glow discharge, a second surface layer having a thickness of about 0.25 μm was formed on top of the first surface layer. The manufacturing conditions for the above process were as follows:
______________________________________Flow rate of 100% silane gas 24 cm.sup.3 /min,Flow rate of 100% hydrogen gas 180 cm.sup.3 /min,Flow rate of 100% ammonia gas 36 cm.sup.3 /min,Internal pressure of reactor 0.5 Torr,Discharge power 50 W,Discharge time 40 min.______________________________________
After for formation of the second surface layer, the mixture of silane gas, hydrogen gas and ammonia gas was introduced and the mixture was decomposed by glow discharge, to form a third surface layer having a thickness of about 0.1 μm on top of the second surface layer. The manufacturing conditions for the above process were as follows.
______________________________________Flow rate of 100% silane gas 15 cm.sup.3 /min,Flow rate of 100% hydrogen gas 180 cm.sup.3 /min,Flow rate of 100% ammonia gas 43 cm.sup.3 /min,Internal pressure of reactor 0.5 Torr,Discharge power 50 W,Discharge time 20 min.______________________________________
As described above, there was obtained a photoreceptor having a charge injection blocking layer, a photoconductive layer, a charge capturing layer, a first surface layer, a second surface layer and a third surface layer on an aluminum substrate. The residual potential of the photoreceptor thus formed body was 45 V, and the sensitivity which is represented as the reciprocal of the light-exposure amount for half attenuation was 0.13 cm 2 /erg for light of 450 nm.
Using this photoreceptor, an image quality evaluation test was carried out in a copying machine. A drum heating unit inside the copying machine was operated so as to heat the drum surface to a temperature of 45° C. on. This photoreceptor was able to produce a sharp image even after a copying test of about one hundred thousand printings, and there were observed no image fading or defect in image quality caused by flaws or the like on the photoreceptor.
COMPARATIVE EXAMPLE 1
By using the same apparatus, conditions and method as described in the Embodiment, a charge injection blocking layer, a photoconductive layer and charge capturing layer were successively formed on an aluminum substrate in this order.
After the formation of the charge capturing layer, the inside of the reactor was evacuated thoroughly, and then a first surface layer about 0.05 μm in thickness was formed under the same conditions to those of the first surface layer in the Embodiment.
After the formation of the first surface layer, a second surface layer was formed under the same conditions to those of the second surface layer in the Embodiment. However, the discharge time was changed to 16 min and the film thickness was chosen to be 0.1 μm.
After the formation of the second surface layer, a third surface layer about 0.1 μm in thickness was formed under the same conditions to those of the third surface layer in the Embodiment.
In the above manner, a photoreceptor having a charge injection blocking layer, a photoconductive layer, a charge capturing layer, a first surface layer, a second surface layer and a third surface layer on an aluminum substrate was obtained. The residual potential of the photoreceptor was 40 V, and the sensitivity represented as the reciprocal of the light-exposure amount for half attenuation was 0.17 cm 2 /erg for light of 450 nm. Using this photoreceptor, an image quality evaluation test was carried out in the copying machine. The drum heating unit inside the copying machine was operated so as to heat the surface of the drum to a temperature of 45° C. After about fifty thousand sheets copying test, flaws corresponding to contact scars by the paper peeling finger provided in the copying machine began to the printed in this photoreceptor.
COMPARATIVE EXAMPLE 2
Using the same apparatus, conditions and method as described in the Embodiment, a charge injection blocking layer, a photoconductive layer and a charge capturing layer were successively formed on top of an aluminum substrate in this order.
After the formation of the charge injection blocking layer, the inside of the reactor was evacuated thoroughly, and a lower surface layer was formed under the same conditions as in the first surface layer in the Embodiment. However, the discharge time was set to be 25 min and the film thickness was chosen to be about 0.2 μm.
After the formation of the lower surface layer, an upper surface layer about 0.1 μm in thickness was formed under the same conditions as the third surface layer of the Embodiment.
As described above, a photoreceptor having a charge injection blocking layer, a photoconductive layer, a charge capturing layer, a lower surface layer and an upper surface layer on top of an aluminum substrate was obtained. The residual potential of this photoreceptor was 35 V, but the sensitivity was 0.05 cm 2 /erg for a radiation of 450 nm, revealing disensitization.
COMPARATIVE EXAMPLE 3
Using the same apparatus, conditions and method as described in the Embodiment, a charge injection blocking layer, a photoconductive layer and a charge capturing layer were successively formed on an aluminum substrate in this order.
After the formation of the charge capturing layer, the inside of the reactor was evacuated thoroughly, and a lower surface layer about 0.05 μm in thickness was formed under the same conditions as those of the first surface layer in the Embodiment.
After the formation of the lower surface layer, an upper surface layer was formed under the same conditions as those of the third surface layer in the Embodiment. However, the discharge time was changed to 40 min and the film thickness was set to about 0.2 μm.
In the above manner, a photoreceptor having a charge injection blocking layer, a photoconductive layer, a charge capturing layer, a lower surface layer and an upper surface layer on an aluminum substrate was obtained. The sensitivity of the photoreceptor was about 0.20 cm 2 /erg for light of 450 nm, and its residual potential has a high value of 80 V.
As described above, the photoreceptor according to the present invention provided an initial images of high quality and has an excellent stability independent on the lapse of time and a high resistance to printing. Further, the photoreceptor possesses a high light sensitivity over the entire visible ray region, the low residual voltage and a high dark resistance. In addition, the electrifying capability thereof is excellent. Still further, it possesses an excellent property having the low dependence of the characteristics on the environment at which it is used. Accordingly, copied images obtained have excellent resolution and gradation reproducibility, and can show a high density of image without fogging in both of the initial period and after repeated operation for a long time.
Moreover, the photoreceptor according to this invention can be effectively used, especially in an electrophotographic process which is operated under a condition that at least the surface of the photoreceptor is heated at a temperature in the range of 35°-50° C. That is, when used under conditions where the surface of the photoreceptor is heated at a temperature in the above temperature range, it gives a stable and high quality initial images, and will not be deteriorated in the image quality even after repeated operation, under any environment at which the photoreceptor is used. | A photoreceptor for electrophotography, comprising: a photoconductive layer substantially composed of amorphous silicon, and first, second and third surface layers substantially composed of amorphous silicon added with nitrogen atom, those layers being formed on a support. The thickness d 1 , d 2 and d 3 of the first, second and third surface layers satisfies the following relation: d 2 >d 1 and d 2 >d 3 , and the nitrogen concentrations c 1 , c 2 and c 3 of said first, second and third surface layers satisfy the following relation: c 3 >c 2 >c 1 . | 6 |
This application is a continuation of application Ser. No. 07/933,137 filed Aug. 21, 1992, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to fuel nozzles for gas turbines. More specifically, the present invention relates to a fuel nozzle assembly, along with a method of making and repairing same, suitable for use with liquid or gaseous fuels and having the capability for steam injection for NOx control.
Gas turbines include one or more combustors adapted to produce a hot gas by burning a fuel in compressed air. A fuel nozzle assembly is employed to introduce the fuel into the combustor. To provide maximum flexibility to the user, such fuel nozzles are often of the dual fuel type--that is, they have the capability of burning either a liquid or a gaseous fuel, or both simultaneously.
Unfortunately, combustion in gas turbine combustors results in the formation of oxides of nitrogen (NOx) in the combusted gas that is considered an environmental pollutant. One method of minimizing the formation of NOx involves injecting steam, via the fuel nozzle, into the combustor along with the fuel. However, such steam injection can not be readily accomplished in a traditional dual fuel nozzle so that the flexibility of a dual fuel nozzle is lost. Another problem with steam injection via conventional fuel nozzles is that it is difficult to introduce the steam symmetrically around the longitudinal center line of the combustor so as to prevent non-uniformities in the combustion gas.
A further drawback of traditional fuel nozzles is that they are subject to deterioration of the nozzle cap due burning and erosion from exposure to the hot combustion gases. If oil fuel is being burned, such nozzles are also subject to coking at the fuel outlet port. Consequently, replacement of the nozzle is a frequent occurrence. This presents a maintenance problem for the user.
It is therefore desirable to provide a fuel nozzle for a gas turbine capable of burning gaseous or liquid fuel, or both simultaneously, along with injecting steam. It would also be desirable to provide a method of replacing the nozzle cap portion of such a fuel nozzle.
SUMMARY OF THE INVENTION
Accordingly, it is the general object of the current invention to provide a fuel nozzle assembly for a gas turbine capable of burning gaseous or liquid fuel, or both simultaneously, along with injecting steam, and to provide a method of making and repairing such a fuel nozzle.
Briefly, this object, as well as other objects of the current invention, is accomplished in a gas turbine having (i) a compressor for producing compressed air, (ii) a combustor for heating the compressed air by burning fuel therein, thereby producing a heated Compressed gas; (iii) a fuel nozzle assembly for introducing fuel into the combustor, and (iv) a turbine for expanding the heated compressed gas produced by the combustor. The fuel nozzle assembly has (i) first and second fluid inlet ports, (ii) first, second and third fluid outlet ports, (iii) a first annular conduit placing the first fluid inlet port in flow communication with the first fluid outlet port, (iv) a second annular conduit placing the second fluid inlet port in flow communication with the second fluid outlet port, the second conduit enclosed by the first conduit, and (v) a centrally disposed chamber enclosed by the first and second annular conduits, the third fluid outlet port disposed in the chamber.
According to one embodiment of the current invention, the first fluid inlet and outlet ports are gaseous fuel inlet and outlet port, the second fluid inlet and outlet ports are steam inlet and outlet ports and the fuel nozzle assembly further comprises a liquid fuel nozzle disposed in the chamber, the liquid fuel nozzle being in flow communication with the third fluid outlet port.
The invention also concerns a method of making a fuel nozzle for a gas turbine, comprising the steps of (i) forming a nozzle body having first and second fluid inlet ports, (ii) forming a nozzle cap having first, second and third fluid outlet ports, (iii) affixing a first end of an inner sleeve to the nozzle cap, (iv) placing middle and outer sleeves around the inner sleeve so that the middle and outer sleeve are free to slide axially thereon, (v) affixing a second end of the inner sleeve to the nozzle body, thereby forming a centrally disposed chamber in which the third fluid outlet port is disposed, (vi) affixing a first end of the middle sleeve to the nozzle cap and a second end of the middle sleeve to the nozzle body, thereby forming a first annular chamber enclosing the central chamber and placing the first and second fluid inlet and outlet ports in flow communication, and (vii) affixing a first end of the outer sleeve to the nozzle cap and a second end of the outer sleeve to the nozzle body, thereby forming a second annular chamber enclosing the first annular chamber and placing the second fluid inlet and outlet ports in flow communication.
The invention further concerns a method of replacing a nozzle cap in a gas turbine fuel nozzle having a nozzle body connected to the nozzle cap by inner, outer and middle sleeves substantially concentrically arranged and attached to the nozzle body and cap, comprising the steps of (i) detaching the outer sleeve from the nozzle cap, (ii) separating the outer sleeve into first and second portions, (iii) sliding the outer sleeve portion axially, thereby exposing the middle sleeve, (iv) cutting through the inner and middle sleeves, thereby separating the nozzle cap from the nozzle body, (iv) affixing a replacement nozzle cap to the inner and middle sleeves, and
(v) rejoining the first and second outer sleeve portions and reattaching the outer sleeve to the nozzle cap.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a gas turbine.
FIG. 2 is a longitudinal cross-section through the fuel nozzle shown in FIG. 1.
FIG. 3 is a cross-section taken through line III--III shown in FIG. 2.
FIG. 4 is a cross-section taken through line IV--IV shown in FIG. 2.
FIGS. 5-7 show the fuel nozzle of FIG. 2 in various stages of assembly.
FIG. 8 shows the body of the fuel nozzle of FIG. 2 after the front section of the fuel nozzle has been cut away to allow replacement of the nozzle cap.
FIGS. 9 and 10 show various stages of the replacement of the fuel nozzle cap on the fuel nozzle body of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is shown in FIG. 1 a schematic diagram of a gas turbine 1. The gas turbine 1 is comprised of a compressor 2 that is driven by a turbine 4 via a shaft 5. Ambient air 7 is drawn into the compressor 2 and compressed. The compressed air 8 produced by the compressor 2 is directed to a combustor 3 in which a fuel 9 is burned. The fuel 9 may be a liquid, such as no. 2 distillate oil, or a gas, such as natural gas, and is introduced into the combustor 3 by a fuel nozzle assembly 11. The hot compressed gas 12 produced by the combustor 3 is directed to the turbine 4 where it is expanded, thereby producing shaft horsepower for driving the compressor 2, as well as a load, such as an electric generator 6. The expanded gas 3 produced by the turbine 4 is exhausted, either to the atmosphere directly or, in a combined cycle plant, to a heat recovery steam generator and then to atmosphere.
As shown in FIG. 2, the fuel nozzle assembly 11 is mounted in a cylinder 53 (shown in phantom in FIG. 2), that encloses the combustors 3, and extends into the front end of the combustor. As shown in FIGS. 2 and 3, the fuel nozzle 11 of the current invention has a gas fuel inlet port 16. Gas fuel flows from the inlet port 16 to a manifold 20 formed in the nozzle body 14. The manifold 20 distributes the gas fuel to a series of passages 22 that then directs it to an annular conduit 18. From the annular conduit 18, the gas fuel discharges via outlet ports 28 formed in the face 29 of a nozzle cap 15, after which it is burned in the compressed air.
As previously discussed, a fluid 10, such as steam, is injected into the combustor 3 via the fuel nozzle assembly 11 in order to minimize the formation of NOx. Accordingly, the fuel nozzle assembly 11 also has a steam inlet port 17. Steam flows from the inlet port 17 to a manifold 21 formed in the nozzle body 14. The manifold 21 distributes the steam to a series of passages 23 that then direct it to an annular conduit 19. The steam annular conduit 19 is encircled by, and substantially concentric with, the gaseous fuel annular conduit 18. From the annular conduit 19, the steam discharges via outlet ports 31 formed in the face 29 of the nozzle cap 15, after which it enters the combustion gas to reduce NOx formation.
The fuel nozzle assembly 11 also has a centrally disposed oil fuel nozzle 38, which may be of the conventional type. Oil fuel enters an inlet port 37 at the base of the oil nozzle and exits through an outlet port 30 formed in the front face 29 of the nozzle cap 15, after which it is burned in the compressed air. Thus, according to the current invention, the fuel nozzle assembly 11 is capable of burning gaseous or liquid fuel, or both simultaneously, as well as injecting steam into the combustor 3. This greatly increases the flexibility of the fuel nozzle assembly according to the current invention.
As previously discussed, oil fuel nozzles are subject to coking at the outlet port 30. According to the current invention, coking is prevented by supplying cooling air, drawn from the compressor discharge air 8, to the outlet port 30. This is accomplished by radially extending cooling air passages 40 arranged around the nozzle body 14. The inlets 39 of these passages 40 are in flow communication with the compressed air flowing within the combustor cylinder 53. From the inlets 39, the passages 40 direct the cooling air to a central cavity 32 that is encircled by, and concentric with, the gas and steam annular conduits 18 and 19, respectively, and in which the oil nozzle 38 is disposed. The cooling air flows along the annular space between the inner sleeve 33 and the oil nozzle 38 and then exits the nozzle via the oil fuel outlet port 30. By washing over the tip of the oil nozzle 38 and flowing through the oil fuel outlet port 30, the cooling air prevents coking.
As shown in FIG. 2, the annular gas fuel conduit 18 is formed between an outer sleeve 24, 26 and a middle sleeve 25, with the middle and outer sleeves being concentrically arranged. The outer sleeve is comprised of front 26 and rear 24 portions joined by a weld 44. The rear end of the outer sleeve rear portion 24 is attached to the fuel nozzle body 14 by a weld 47. The front end of the outer sleeve front portion 26 is attached to an outer ring 27, projecting rearward from the nozzle cap 15, by a weld 46. A flange 52 is formed on the outer sleeve rear portion 24 for installing a swirl plate (not shown) onto the nozzle assembly to aid in mixing the fuel and compressed air.
The middle sleeve 25 is comprised of front and rear portions joined by an expansion bellows 36. The expansion bellows reduces the stress on the middle sleeve 25 due to differential thermal expansion in the fuel nozzle assembly 11. The rear end of the middle sleeve 25 is attached to the fuel nozzle body 14 by a weld 49. The front end of the middle sleeve 25 is attached to a middle ring 41, projecting rearward from the nozzle cap 15, by a weld 45.
As also shown in FIG. 2, the annular steam conduit 19 is formed between the middle sleeve 25 and the inner sleeve 33, also concentrically arranged. Like the middle sleeve 25, the inner sleeve 33 is comprised of front and rear portions joined by an expansion bellows 35. The rear end of the inner sleeve 25 is attached to the fuel nozzle body 14 by a weld 43. The front end of the inner sleeve 33 is attached to an inner ring 34, projecting rearward from the nozzle cap 15, by a weld 42. The inner sleeve 25 forms the central cavity 32 in which the oil nozzle 38 is disposed.
As shown in FIG. 4, the gas fuel and steam outlet ports 28 and 31, respectively, are circumferentially arranged around concentric circles on the face of the nozzle cap 15. The ports are arranged in a staggered relationship, thereby minimizing the space required for the ports. In addition, the nozzle cap 15 has scallops 51 cut out around each steam outlet port 31, thereby allowing use of larger diameter gas fuel and steam outlet ports than would otherwise be possible.
According to the current invention, uniformity in the combustion gas with respect to the longitudinal center line of the combustor 3 is achieved by utilizing concentric annular conduits to supply steam and gas fuel to outlet ports that are arranged around concentric circles.
The novel arrangement of the fuel nozzle assembly according to the current invention, in which inner and outer annular chambers enclose a central cylindrical chamber, each concentric with the others, is made possible by a novel assembly method. First, the nozzle body 14, shown in FIG. 5, is cast, although other fabrication techniques could also be utilized. Next, the nozzle cap 15 is attached to the inner sleeve 33 via a weld 42, as shown in FIG. 6. The middle sleeve 25 and the front portion 26 of the outer sleeve are then slipped over the inner sleeve 33 so that they are free to slide along the assembly, as shown in FIG. 7. With the middle sleeve 25 slid forward, weld 43 is formed to attach the inner sleeve 33 and nozzle cap 15 to the nozzle body 14.
In the next step, the middle sleeve 25 is slid rearward into its final position, as shown in FIG. 2, and its front and rear ends are attached to the nozzle body 14 and nozzle cap middle ring 41 by welds 45 and 49, respectively. The forward portion 26 of the outer sleeve is then slid forward into its final position, as shown in FIG. 2, and attached to the nozzle cap outer ring 27 by weld 46. Lastly, the rear portion of the outer sleeve 24 is slid over the assembly and attached to the nozzle body 14 via weld 47 and to the front portion 26 of the outer sleeve 26 via weld 44.
According to the current invention, a novel method is provided for replacing the nozzle cap 15, which, as previously discussed is a source of frequent maintenance. After removing the oil fuel nozzle 38, the weld 44 joining the forward and rear portions 26 and 24, respectively, of the outer sleeve is broken. Next, forward portion 26 of the outer sleeve is separated from the nozzle cap 15 by cutting through the weld 46 attaching the outer sleeve forward portion to the nozzle cap outer ring 27. The outer sleeve forward portion 26 can then be slid rearward, exposing the middle sleeve 25. The middle 25 and inner 33 sleeves are then cut along a line 50, shown in FIG. 2, that passes through the weld 42 attaching the inner sleeve to the nozzle cap inner ring 34. The result is a partial nozzle assembly, shown in FIG. 8, to which a new nozzle cap 15 can now be attached. Note that since the middle sleeve 25 was cut at a location rearward of the weld 45 joining it to the nozzle-cap middle ring 41, in order to provide access to the inner sleeve weld 42, only a portion 25' of the original middle sleeve 25 remains.
Prior to installing the new nozzle cap 15, a new middle sleeve portion 25'', shown in FIG. 9, that is of sufficient length to restore the middle sleeve to its original length, is slid on to the nozzle cap middle ring 41. Next, as shown in FIG. 9, the inner sleeve 33 is attached to the nozzle cap inner ring 34 by weld 42. The new middle sleeve portion 25'' is then slid rearward and attached to the remaining portion 25' of the original middle sleeve by a weld 48 and to the nozzle cap middle ring 41 by a weld 45, as shown in FIG. 10. Lastly, the outer sleeve forward portion 26 is slid into position and attached to the outer sleeve rear portion 24 and to the outer ring 27 of the new nozzle cap 15 by welds 44 and 46, respectively, shown in FIG. 2.
Although the current invention has been described with reference to a fuel nozzle assembly having the capability of burning oil or gas fuel and using steam injection, the invention is also applicable for introducing other fluids into the combustor--for example, the central chamber 32 could house a nozzle for naphtha or pulverized coal fuel or for a water spray to further reduce NOx. Accordingly, 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 fuel nozzle assembly is provided having the capability of burning either gaseous or liquid fuel, or both simultaneously, along with steam injection. The nozzle has a nozzle body that is attached to a nozzle cap by inner, outer and middle sleeves. The sleeves form inner and outer concentric annular conduits between themselves for directing the flow of gaseous fuel and steam from the fuel and steam inlet ports to the outlet ports. In addition, the inner sleeve forms a central chamber in which an oil fuel nozzle is disposed. Radial passages in the nozzle body allow cooling air to flow over the oil nozzle and through the oil outlet port, thereby preventing coking at the nozzle tip. The fuel nozzle assembly is originally built, and the nozzle cap is replaced, by sliding the sleeves forward and aft on the assembly so as to gain access to the next innermost sleeve. | 5 |
FIELD OF THE INVENTION
This invention relates to a light emitting material, and in particular to a material suitable for use in an optoelectronic device which may emit light in the yellow to blue region of the spectrum and which may be employed as part of an integrated circuit. The invention relates in particular to such a material suitable for use in a device that may be formed as an integral part of an integrated circuit.
BACKGROUND OF THE INVENTION
A wide variety of optoelectronic devices are known for emitting light and which may be used in various devices such as calculator displays, flat screen television screens and many other applications. Among various well known existing devices are light emitting diodes (LEDs), laser diodes, liquid crystals and electroluminescent devices.
A light emitting diode is a semiconductor device, in particular it is a p-n junction diode, that emits light as a result of direct radiative recombination of excess electron-hole pairs. In a semiconductor such as GaAs a significant amount of light can be emitted following injection of excess minority carriers. The useful light obtainable from such a device is dependent on various factors including the optical quality of the crystal surfaces. The colour of the light emitted is a property of the material used as the semiconductor since the energy of the emitted light is determined by the band-gap energy. Such devices are advantageous in that they can be made very small and if desired can be formed as part of an integrated circuit using convention circuit fabrication technologies. A disadvantage however is that the range of colours available from such devices are limited by the number of suitable materials available. The majority of suitable semiconductors, such as GaAs, emit useful light only in the red end of the spectrum.
Another known optoelectronic method of generating light is by utilising the property of electroluminescence. This is the emission of light by certain phosphorescent materials under the influence of an applied electric field. Again, however, with known materials there are problems with constructing a device that emits light at shorter wavelengths toward the blue end of the spectrum. This problem is compounded when attempting to find such a material that will emit blue light and which can be integrated into a circuit directly.
PRIOR ART
Many studies have been made of the properties of various semiconductor materials in the search for suitable materials for emitting blue light in optoelectronic devices. For example a blue light emitting diode was disclosed by K. Akimoto et al: Japan J. Appl. Phys. 28 (1989) L2001. This LED comprises a substrate made of GaAs (100), a n-type ZnSe:Ga layer and a p-type ZnSe:O layer. In such a construction the ZnSe layer emits the blue light and the device as a whole is capable of emitting blue light at a peak wavelength of 400 nm. However this can only be achieved at a liquid nitrogen temperature of 77K and almost no emission is provided at room temperature. Clearly this is unsuitable for any practical application.
U.S. Pat. No. 5,198,690 to Kitagawa et al suggests the use of a II-IV compound semiconductor using zinc as an essential composite element. Kitagawa et al propose a wide range of materials such as ZnS, ZnTe, ZnSe, ZnCdS, ZnCdTe, ZnSTe, ZnSeTe, ZnBeS, ZnBeSe, ZnHgTe, ZnHgS, ZnMgTe and ZnBeTe. However although Kitagawa et al disclose a large number of examples in all the examples the light emitting layer is chosen from ZnSe, ZnS or a solid solution of ZnSSe. ZnS and ZnSSe are also disclosed as blue light emitting materials in U.S. Pat. No. 5,057,183 to Tomomura et al. Other materials such as CdS, HgS, MgS, CaS, ZnCdS, ZnHgS, CaHgS, ZnSSe, CdSSe, ZnSTe and CdSTe are suggested but not tried by Tomomura et al. U.S. Pat. No. 5,278,856 to Migita et al discloses ZnS x Se 1-x as a light emitting material, and also discloses ZnS 1-x Te x grown on GaPAs, ZnSe and InP substrates. In Migita et al, however, the active luminescent layer is sandwiched between two cladding layers of p-type and n-type semiconductor materials respectively. Furthermore in Migita et al the source of the luminescence is believed to be a direct band to band transition mechanism, and as a consequence of this Migita et al proposes a relatively high concentration of Te, in particular 0.12<x<0.42.
SUMMARY OF THE INVENTION
According to the present invention there is provided a photoluminescent material comprising an active luminescent layer of ZnS 1-x Te x (0<x<1) deposited directly on a substrate selected from the group consisting of GaAs or Si, said active layer being deposited by molecular beam epitaxy.
One of the advantages of ZnS 1-x Te x as an active material is that by varying the value of x the alloy layer can be lattice matched to the substrate. Silicon is a particularly preferred substrate material since extremely high-quality large-area substrates are available at low cost. More importantly perhaps, forming the device by depositing the active layer directly on a silicon substrate allows a light emitting device capable of emitting blue light to be incorporated directly into an integrated circuit. Preferably therefore the active luminescent layer is deposited on a Si substrate. Furthermore the present applicants have discovered that the luminescence comes from recombination of excitons trapped by Te isoelectronic traps. This means that in fact strong luminescence can be obtained with low Te concentrations, and indeed the luminescence efficiency will in fact decrease significantly with increasing Te concentration after x=0.10. Preferably therefore 0.01≦x≦0.07 and in particular it is preferred that x=approximately 0.03.
When Si is used as the substrate care has to be taken to minimise the problems that can occur at the interfacial region. In particular the Si substrate should be cleaned before deposition occurs, such cleaning comprising a degreasing step followed by chemical etch. It may also be desirable to passivate the surface of the substrate by oxidation before it is ready for use, the oxide layer being removed before the active layer is deposited.
Methods may also be used to minimise structural problems at the interfacial layer. These methods may include forming a buffer layer of smooth Si then growing a monolayer of an elemental layer such as Zn, Se or As upon which the active layer is then deposited.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the relationship between band gap energy and luminescence peak position as a function of Te composition x, and
FIG. 2 shows the room temperature photoluminescence spectra of ZnS 1-x Te x for x=0.01, x=0.064, x=0.3 and x=0.707 when grown on GaAs, and
FIG. 3 shows the room temperature photoluminescence spectra of ZnS 1-x Te x for x=0.01 and x=0.03 when grown on Si.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In preferred embodiments of the present invention the active photoluminescent layer is formed on the semiconductor substrate by molecular beam epitaxy (MBE) using a VG V80H system. Semi-insulating GaAs (001) substrates with 2+0.1° off toward the <011> direction, and Si (001) substrates were used. When using Si as a substrate pre-growth treatment is important for achieving high-quality epilayers. Before loading into the MBE chamber the Si wafers were cleaned using the standard RCA method (W. Kern and D. A. Puotinen, RCA Rev. 31(1970) 187) which starts with a degreasing step followed by a wet chemical etch. The substrates were then passivated with a thin oxide layer. After loading into the MBE chamber the substrates were first outgassed at 450° C. and then heated to 800° C. to remove the oxide layer.
ZnS 1-x Te x alloy layers were grown using ZnS and ZnTe sources contained in separate effusion cells. Te composition was controlled by adjusting the cell temperatures. The optimal growth temperature was found to depend strongly on the desired Te composition of the alloy. As Te composition increases from x=0 to x=1 the optimal growth temperature increases from 160° C. to 300° C.
The Te composition of the thus formed ZnS 1-x Te x layers was determined using energy dispersive X-ray spectrometry carried out in an EDAX DX-4 system. The measurements were done using a 15 KeV electron beam. The calibration and normalization of the measured data were performed using MBE-grown ZnS and ZnTe layers as standard references. The Te composition was determined to an accuracy of within 0.01.
The transmission spectra of the alloys were obtained at room temperature on samples with the GaAs substrate removed by chemical etching. The band gap energy was estimated from the absorption edge of these spectra. Photoluminescence measurements were performed at room temperature using either a frequency-doubled output (wavelength=395 nm, pulse width=200 fs) of a regeneratively amplified mode-locked Ti-sapphire operating at 1 kHz, or a 200 Watt Hg lamp with suitable UV filters.
The structural characterization on a set of ZnS 1-x Te x epilayers with 0<x<1 has been performed using high resolution X-ray diffraction (HRXRD). ZnS 1-x Te x alloys are found to be lattice matched to GaAs at about x=0.27, and to Si at about x=0.03. The details of their structural characteristics are reported by the present inventors in the Proceedings of the 1994 Materials Research Society Spring Meeting, San Francisco.
The band energy gap determined from optical transmission measurements is plotted as a function of Te composition x in FIG. 1. A strong bowing effect is clearly visible with the largest bowing occurring at about 70% Te composition.
The photoluminescence (PL) spectra obtained from four samples of ZnS 1-x Te x grown on GaAs substrates are shown in FIG. 2, and the corresponding results from two samples grown on Si substrates are shown in FIG. 3. Two general features may be observed. Firstly the width of the PL peak is broader than those previously observed with ZnS and ZnTe compounds. This broadening increases as Te composition decreases. Secondly the integrated luminescence intensity of an ZnS 1-x Te x alloy is much greater than for ZnS and ZnTe compounds, and this also increases as Te composition decreases. The broadening of the PL peak is attributed to efficient hole capture and exciton "self trapping" at Te sites. The fact that isoelectronic trapping only occurs at low Te levels is believed to arise from the large difference in the electronegativity of Te compared to S. The observation that broadening and integrated intensity decrease with increasing Te concentration indicates that the effective density of the isoelectronic centres decreases as Te concentration increases.
The peak position of the photoluminescence spectrum for each ZnSTe layer is defined as the wavelength (which can be converted into the energy gap) of the highest luminescence intensity in the spectrum. As shown in FIG. 2 there are four spectra corresponding to the four samples with differing Te concentrations. Each curve has some peaks and troughs due to interference effects, but these can easily be removed and a smooth curve obtained from which a peak may be extracted. FIG. 1 plots these peak values against Te composition. By comparison of the luminescence data with the corresponding transmission data it will be seen that the photoluminescence peaks are Stokes shifted from the bandgap energy as determined from the transmission measurements. Where photoluminescence results from band to band transitions the Stokes shift is small, but in the present case there is a large Stokes shift due to the fact that the source of luminescence is Te isoelectronic traps.
Growth of good quality III-V and II-VI layers on silicon substrates is usually hampered by the formation of anti-domains near the interface between the polar (III-V and II-VI) and non-polar (Si) semiconductors. In order to achieve the best possible growth a particular Te composition was chosen so that the resulting alloy is lattice matched to the Si substrate to ensure pseudomorphic growth. As has been mentioned previously such lattice matching to Si may be achieved when x=0.03 approximately. By fine tuning of the Te concentration it is possible to grow epitaxial layers lattice matched on silicon to within 0.2%.
It is also possible to buffer the otherwise abrupt polar non-polar transition by growing a monolayer of elemental species on the Si substrate to avoid the formation of such anti-domains. Zn, Se and As are possible materials. Observations suggest however that there will remain a disordered interfacial region for the first few monolayers of the epitaxial layer before a smooth epitaxial layer is achieved. High quality ZnSTe layers can be obtained if a smooth Si buffer layer is first grown followed by the growth of a monolayer of elemental species such as Zn, Se or As on which the active layer is then grown.
Despite the problems associated with the low structural quality of the Si/ZnS 1-x Te x interface the intensity of room temperature PL from samples grown on Si was as strong as those grown on GaAs substrates. PL spectra of ZnS 1-x Te x epilayers grown on Si substrates exhibit the general features associated with Te isoelectronic hole traps such as large broadening of the luminescence lineshape and the large Stokes shift from the band edge, similar to the observations of the samples grown on GaAs. The structural defects near the interface with the Si substrate do not appear to affect the PL properties of the epitaxial layer.
The quantum efficiency of PL from ZnS- 1-x Te x layers are significantly higher than for known ZnSe and ZnS layers. PL from samples in accordance with the present invention could be clearly seen with the naked eye under normal room light conditions when the layers were illuminated by 5 mW of unfocused UV light from a Hg lamp. Under illumination by bright sunlight with proper UV filtering luminescence can also be seen with the naked eye.
The room temperature Pl efficiency was measured by the following method. A 200 Watt Hg lamp was used as the excitation source. The light beam from the lamp was sent through a combination of three filters, firstly a piece of plain glass to remove the ozone-generating UV, then a UG-11 filter to remove visible radiation except for the red and infra-red regions of the spectrum, and finally an interference band pass filter (10 nm in half-width) centered at 365 nm. The light was then incident on the sample surface at an angle of incidence of approximately 45°. The incident beam as focused onto a 2×3 mm 2 spot and its total power was 5 mW as measured by a Newport Model 835 Picowatt Digital Power Meter with an attenuated 835-Uv detector.
The luminescence from the sample was so strong that the same power meter was sufficiently sensitive to measure the luminescence. To do so the detector surface was placed in a plane containing the sample surface normal direction and was perpendicular to the incident direction of the excitation beam so as to avoid specular reflection of the excitation beam. A Si wafer with similar surface morphology as the samples was used to measure the intensity of the scattered light and this was found to be insignificant as compared with the intensity of the luminescence. A filter was placed in front of the detector to remove further scattered UV radiation.
A cos[theta] dependence of the measured luminescence intensity was found as the detector was moved in the vertical plane where [theta] was the angle between the direction from the spot to the detector and the surface normal direction. The luminescence intensity was then measured as a function of the distance r between the spot and the detector at [theta]=0 and was found to decrease with 1/r 2 . The total luminescence through the whole hemisphere was then calculated, taking into account the spectral response of the power meter and the reflectance of the sample at 365 nm. The measured efficiencies of the samples ranged from 2 to 4% with layers of about 1.5 microns thickness. The efficiency will depend on the thickness of the layer and the quality of the sample as well as the wavelength used to excite the layer.
In summary the present invention provides a luminescent material that may be grown by molecular beam epitaxy on a GaAs or Si substrate. Other possible materials upon which the layer may be deposited include ZnSe and InP. The material shows a strong enhancement in photoluminescence efficiency, a large Stokes shift from the band edge, a broadening in the luminescence peak and a strong bowing of the band gap energy as a function of Te composition. The relatively high PL efficiency and the fact that the layers can be grown directly on Si make ZnS 1-x Te x a good material for use in the manufacture of optoelectronic devices such as light emitting diodes and thin film electroluminescence devices. Furthermore since the photoluminescence efficiency is high it is even possible to observe photoluminescence by photoexcitation under strong sunlight and the materials of the present invention could also be applied to the construction of a UV detector. | A novel photoluminescent material is disclosed comprising an active layer of ZnS 1-x Te x deposited directly onto a substrate by molecular beam epitaxy. The emitted light is primarily in the blue end of the spectrum. The substrate may be GaAs or more preferably Si. Depositing the material directly onto Si allows the material to be used to manufacture integrated semiconductor light emitting devices. High efficiency may be obtained at low concentrations of Te (0.01≦x≦0.07) which allow good lattice matching of the active layer to an Si substrate. | 2 |
[0001] The present invention relates to a self-heatable container.
FIELD OF THE INVENTION
[0002] The field of the invention is that of the preparation of containers intended to contain food products, especially beverages, soups and the like, which can be consumed at a temperature greater than room temperature and in any place, particularly when specific heating means are not available.
BACKGROUND OF THE INVENTION
[0003] Several types of self-heatable containers provided with incorporated means for the local generation of heat in order to increase the temperature of a beverage up to a certain value are known. Among the mentioned types are that described in patent WO 03/064283 and other similar patents.
[0004] The models of containers provided with incorporated heating means which have been disclosed have certain drawbacks, such as their complex structure demanding complicated and therefore expensive manufacturing processes. In addition, some types described in patents have a questionable suitability, given the technical difficulty in maintaining the constitutive parts thereof hermetically joined.
[0005] In other cases, the functional and shape design of the proposed containers is scarcely suitable for the intended purpose.
[0006] Therefore, it is desirable to have a container provided with its own heating means, which has a suitable structure and is easy to use and which reaches temperature levels suitable for the type of product contained relatively quickly.
BRIEF DESCRIPTION OF THE INVENTION
[0007] The invention relates to a container with a simple structure (with a minimum of component parts) and reasonably simple construction, essentially formed by a body containing the product, conventionally closed, and by an incorporated heating device which works by the likewise known principle of the exothermic reaction of two chemical products which are contacted prior to the consumption of the beverage of interest. This process takes place with safety and efficiency as a result of the design of the parts forming the container and the associated device thereof.
[0008] To facilitate the explanation, several drawings are attached to the present description, in which a case of embodiment of a self-heatable container, according to the principles of the claims, has been depicted by way of an illustrative and non-limiting example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an exploded view of the components forming essential container parts of the new container, depicted in the relative position of their coupling.
[0010] FIG. 2 is a view of a housing which can be operated to cause the heating process of the container and with two associated elements.
[0011] FIG. 3 shows the housing and its associated elements coupled to one of the containers forming the new container, which, in turn, is associated with another of the containers.
[0012] FIG. 4 shows the operation of the device causing the heating of one of the containers and the latter, in turn, that of the beverage contained in the other container of the container.
[0013] FIG. 5 indicates the normal position of the container with its content heated and ready for its consumption.
[0014] FIGS. 6 and 7 are sectional details of the functional housing included in the container.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Constitution of the container. The body 1 contains the product, such as a beverage, soup or the like, intended for its consumption, optionally, once heated by the incorporated means.
[0016] Said body 1 can have any regular shape, such as a cylindrical shape, according to the attached drawings, and is made of a metallic material of a suitable thickness. In its upper part it has a flange 2 intended to receive a discoid lid 3 provided with conventional opening means and fixed by a peripheral crimp 4 .
[0017] In its lower part, the body 1 has an area 5 with an optionally decreasing diameter and followed by a cylindrical area 6 with a smaller diameter provided with a flange 7 at its end for placing a closing lid 8 , similar to lid 3 , finally fixed by a hermetic crimp 24 .
[0018] The container 9 consists of a cylindrical body having in its mouth a projecting flange 9 ′, therefore said component 9 is supported in the lower flange 7 of the first container 1 .
[0019] The component 10 in the form of a housing is a cylindrical body of a small height with respect to its diameter, made of a plastic material which, in its cylindrical side part 11 , has a considerable resistance, whereas its base 12 , of a reduced thickness, is flexible in its central part, defining a dome in the inner face of which there is the projection 13 . The latter has the form of a prism with a square section, with cuts 14 in its faces like acute angles determining the formation of four fingers with an L-shaped or right-angled section.
[0020] A thin disc-shaped seal 15 of aluminum or similar material, easily piercable when appropriate, hermetically closes the housing as a result of a peripheral rim 16 . Such housing incorporates in the outer face of its base a disc 17 of a porous material acting as a filter.
[0021] The disc 17 is of a flexible, porous and air-permeable and also moisture-absorbing material.
[0022] After the housing 10 and its associated elements are placed, the lower lid 8 is arranged, which is fixed by the aforementioned double crimp 24 , which gathers together in a completely leak-tight manner the lid 8 , the filter 17 , the flange 9 ′ of the container 9 and the lower flange 2 of the body 1 , while at the same time it holds the housing 10 such that it is completely locked.
[0023] The assembly of the self-heatable container which is described from its components can be stated as follows:
[0024] A certain amount of water is placed in the housing 10 , and it is hermetically closed by means of the seal 15 , the inner face of which is supported exactly on the central projection 13 and its fingers with a right-angled section. The filter disc 17 is likewise incorporated to it.
[0025] Separately, a certain amount of a product 20 such as calcium oxide which, upon contact with water, will give rise to an exothermic reaction, is placed in the container 9 . The container 9 with its content introduced in the mouth of the cylindrical lower part 6 of the body 1 , according to FIG. 3 .
[0026] Then the housing 10 and its annexes are introduced in the joint mouth of the components 1 and 9 , according to the mentioned FIG. 3 , after which the lid 8 is fixed, followed by the already mentioned double crimp 24 which assures the hermetic closing of this end part of the container, i.e., the associated edges of the lid 8 , the filter 17 , the housing 10 and the container 9 . The latter is absolutely locked with respect to the body 1 .
[0027] Inverting the position of the body 1 , passing to the position of FIG. 5 , the desired amount of the food product (beverage or the like), the consumption of which will optionally take place after heating, is poured through the upper mouth of such body. The product bathes the upper and side part of the container 9 and likewise occupies the lower part 19 located between the body 1 and the actual container 9 , according to the mentioned FIG. 5 . Finally the upper lid 3 , which is fixed by a conventional peripheral crimp, is placed.
[0028] In most cases and according to the type of product contained, a sterilization of the finished container (with its heating module incorporated) then takes place in an autoclave at a temperature and pressure suitable for the characteristics of the product. The sterilization is possible given the simplified configuration and the metallic nature of the new container, and the latter is ready for its final conditioning, which occurs with the placement of a preferably tubular and laminar label 18 .
[0029] It can likewise be emphasized that the lower lid 8 , fixed by the safety crimp 24 , closes and holds all the components of the heating module associated with the container 9 .
[0030] Use. The consumption of the beverage contained in the body 1 takes place, with regard to its prior heating, by partially extracting the lower lid 8 , retained by the crimp 24 , which leaves the filter 17 and, behind it, the dome or (flexible) central part 12 of the housing exposed. This central part is pressed, whereby the projection 13 moves forward in an axial direction and, like a striker, causes the tearing of the seal 15 and the passage of the water contained in the housing into the container 9 . The water contacts the calcium oxide 20 contained in the mentioned container, initiating the exothermic chemical reaction which gives rise to a considerable increase of the temperature of the actual container 9 .
[0031] The container with its content is shaken for 10 seconds to facilitate the mixture of the reagents and is again inverted, leaving it face up ( FIG. 5 ). In less than 30 seconds the heating is noted due to the exothermic chemical reaction, which gives rise to a considerable increase of the temperature of the surface of the container 9 and, as a result, of the product.
[0032] Finally, the user, in less than 3 minutes, can open the mouth of the container by separating the upper lid 3 and have access to the heated beverage.
[0033] The wall of the body metallic 1 is obviously also heated with the previous operation, normally at a high temperature which can be, for example, of the order of 65-70° C., since the container is designed so that the temperature of the content rises from 38 to 40° C. with respect to the environment. To that end and to prevent the inconvenience and risk of burning for the user when holding the body 1 of the container, the label 18 is made of a heat-insulating material, such as polystyrene.
[0034] As a result of the chemical reaction occurring inside the container 9 , a condensation of the moisture contained in the hot air can occur upon contacting a cold surface (for example, the surface of a table on which the container is placed).
[0035] In the event that the container is not inverted after the activation of the reaction, the content will not be suitably heated and some amount of vapor may appear, which will be partly absorbed by the filter disc 17 .
[0036] Two important details must be emphasized in the design of the housing 10 . In the first place, the openings 21 existing in the crown 22 determine air passages between the outside and the inside of the container 9 and assure that the reaction always occurs at atmospheric pressure, whereas the ribs 23 reduce to a minimum the amount of calcium hydroxide in powder form, resulting from the reaction, which could be deposited on the filter disc 17 .
[0037] It is recommendable to use a protective element for the user's lips, by means of the use of an incorporable and separable ring made of an insulating material, which does not form part of the object of the present patent. | The invention comprises an outer metallic body containing a product for consumption after heating and a second container which holds a reagent and receives a heating module formed by a housing which holds another reagent and is closed by a seal piercable by the pressure from the fingers before consumption of the product. Useful for preparation of packaged products which can be rapidly heated using an integrated heating module. | 1 |
BACKGROUND OF THE INVENTION
[0001] Technical Field
[0002] The present invention relates to a flow cell for both batch and continuous simultaneous electrochemical and electron paramagnetic resonance spectroscopic measurements, and methods of using the flow cell.
[0003] Description of the Related Art
[0004] The “background” description provided herein is for the purpose of generally presenting the context of the disclosure, Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description which may not otherwise qualify as prior art at the time of filing, are neither expressly or impliedly admitted as prior art against the present invention,
[0005] New U.S. FDA guidelines on Metabolites in Safety Testing (MIST) have led pharmaceutical companies to reassess the timing of drug metabolite studies within the development process. To facilitate effective decision making, information on metabolite identity, quantity, pharmacological, and toxicological effects is now often required at earlier stages. Oxidation is a primary route of drug metabolism, and can result in the production of reactive species that may lead to adverse effects. Studies have shown that electrochemical (EC) oxidation can be used to produce species that correspond to biological oxidative metabolites,
[0006] Electron paramagnetic resonance (EPR) spectroscopy yields incontrovertible evidence of the presence of paramagnetic intermediates (e.g. radicals) formed in oxidation processes. In addition, EPR spectroscopy sheds light on the molecular structure near the unpaired electron. Therefore, this technique may be employed to identify the paramagnetic species and help researchers elucidate the oxidation mechanism that leads biological oxidative metabolites.
[0007] A simultaneous EC-EPR technique was developed more than fifty years ago to identify paramagnetic intermediates in EC reactions (D. H. Geske, A. H. Maki, Journal of the American Chemical Society, 1960, 82, p. 2671; J. D. Wadhawan, R. G. Compton Encyclopedia of Electrochemistry, 2003, vol. 2, Wiley VCH, Germany, p. 171—each incorporated herein by reference in its entirety). A variety of EC-EPR cells have been designed to facilitate this technique (R. N. Bagchi, A. M. Bond, F. Scholz, Electroanalysis, 1.989, 1, p. 1—incorporated herein by reference in its entirety). However, these cells are either expensive or difficult to use, and the electrodes in these cells are made of platinum or silver precious metals. In addition, these cells are designed for batch monitoring and hence are incompatible with continuous measurements.
[0008] In view of the foregoing, the objective of the present disclosure is to provide an economical flow cell for batch and continuous simultaneous EC and EPR measurements.
BRIEF SUMMARY OF THE INVENTION
[0009] According to a first aspect, the present disclosure relates to a flow cell comprising: (i) a first tube with a hollow interior, a top portion and a bottom portion, (ii) a second tube forming a conduit with an inlet and an outlet, where the second tube is positioned in the hollow interior of the first tube, (iii) a first electrode with a first end positioned in the conduit, and (iv) a second electrode with a first end positioned in the conduit, where the first end of the second electrode opposes the first end of the first electrode and leaves a gap therebetween, where the bottom portion of the first tube is removably connected to a first tube assembly, the top portion of the first tube is removably connected to a second tube assembly, the inlet of the conduit is fluidly connected to at least one solution comprising an analyte, the outlet of the conduit is fluidly connected to a waste receptacle, and a second end of the first electrode is electrically connected to a measurement device and a second end of the second electrode is electrically connected to a voltage source.
[0010] In one embodiment, the first tube and the second tube are arranged to form concentric cylinders.
[0011] In one embodiment, the voltage source is a potentiostat.
[0012] In one embodiment, the first tube assembly comprises: (i) a third tube with a hollow interior and a top portion, which is removably connected to the bottom portion of the first tube, (ii) a fourth tube with a hollow interior and an exterior, where the fourth tube is positioned in the hollow interior of the third tube and the second end of the first electrode is located in the hollow interior of the fourth tube, (iii) an electro-conductive material positioned in the hollow interior of the fourth tube, where a second end of the first electrode engages the electro-conductive material, (iv) at least one inlet flow channel positioned in the hollow interior of the third tube, where the at least one inlet flow channel connects the inlet of the conduit with at least one solution comprising an analyte, (v) a wire with a first end and a second end, where the first end of the wire is positioned in the hollow interior of the fourth tube, opposing the second end of the first electrode and engages the electro-conductive material, and (vi) a first seal positioned circumferentially about the first electrode that seals the hollow interior of the fourth tube from the conduit, where the inlet flow channel and the exterior of the fourth tube secured in the hollow interior of the third tube.
[0013] In another embodiment, the second tube assembly comprises; (i) a fifth tube with a hollow interior and a bottom portion, which is removably connected to the top portion of the first tube, (ii) a sixth tube with a hollow interior and an exterior, where at least a portion of the sixth tube is positioned in the hollow interior of the fifth tube and the second electrode extends through the hollow interior of the sixth tube, (iii) an outlet flow channel positioned in the hollow interior of the fifth tube, where the outlet flow channel connects the outlet of the conduit with the waste receptacle, and (iv) a second seal positioned circumferentially about the second electrode that seals the hollow interior of the sixth tube from the conduit, where the interior of the fifth tube, the outlet flow channel and the exterior of the sixth tube are irreversibly attached to one another.
[0014] In one embodiment, the first electrode has a diameter ranging from 0.13-1.40 mm.
[0015] In one embodiment, the first tube and the second tube comprise quartz.
[0016] In one embodiment, the first tube has an inner diameter and the second tube has an inner diameter, where a ratio of the inner diameter of the first tube to the inner diameter of the second tube ranges from 2:1 to 12:1.
[0017] In one embodiment, the third tube and the fourth tube comprise quartz.
[0018] In one embodiment, the third tube has an inner diameter and the fourth tube has an inner diameter, where a ratio of the inner diameter of the third tube to the inner diameter of the fourth tube ranges from 2:1 to 12:1.
[0019] In one embodiment, the exterior of the fourth tube and the inlet flow channel are secured by epoxy in the interior of the third tube.
[0020] In one embodiment, there are two inlet flow channels each fluidly connected to a different solution.
[0021] In one embodiment, the electro-conductive material is positioned the fourth tube proximal to the conduit.
[0022] In one embodiment, the electro-conductive material is in a form of a paste or a liquid.
[0023] In one embodiment, the wire comprises copper.
[0024] In one embodiment, the fifth tube and the sixth tube comprise quartz.
[0025] In one embodiment, the fifth tube has an inner diameter and the sixth tube has an inner diameter, where a ratio of the inner diameter of the fifth tube to the inner diameter of the sixth tube ranges from 5:3 to 14:1.
[0026] In one embodiment, the inner diameter of the fifth tube is larger than an outer diameter of the first tube by 10-40%.
[0027] According to a second aspect, the disclosure relates to a method for monitoring formation of radical species with the flow cell of the first aspect. The method comprises: (i) flowing the at least one solution comprising the analyte into the conduit, (ii) positioning the flow cell within a EPR spectrometer comprising a probehead comprising a cavity, where the gap is positioned within the cavity, (iii) applying a voltage to the second end of the second electrode to form a solution comprising radical species, (iv) measuring the electrical potential at the first end of the first electrode, and (v) monitoring the formation of radical species with the EPR spectrometer.
[0028] In one embodiment, the method further comprises continuously removing the solution comprising radical species after the monitoring, where the flowing, the applying and the monitoring are performed continuously.
[0029] The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0031] FIG. 1 is a schematic of an embodiment of the first tube assembly of the flow cell.
[0032] FIG. 2 is a schematic of another embodiment of the first tube assembly of the flow cell.
[0033] FIG. 3 is a schematic of an embodiment that shows an arrangement of the second tube within the first tube.
[0034] FIG. 4 is a schematic of an embodiment of the second tube assembly of the flow cell.
[0035] FIG. 5 is a schematic of an embodiment of the assembled flow cell.
[0036] FIG. 6 is an overlay of electron paramagnetic resonance spectra obtained during the oxidation of Ketoconazole (200 mg/L,) in 0.1 M sulfuric acid at +0.6 V accumulation potential with a flow ON-OFF-ON from bottom to top using a working electrode (graphite pencil lead) and a Ag/AgCl auxiliary electrode in a two-electrode electrochemical cell system.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0037] Embodiments of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown.
[0038] A flow cell having removable tube assemblies for simultaneous electrochemical and electron paramagnetic resonance (EPR) spectroscopic measurements is shown in FIG. 5 . The flow cell has: (i) a first tube 11 with a hollow interior, a top portion and a bottom portion, (ii) a second tube 9 forming a conduit with an inlet which is fluidly connected to a solution and an outlet which is fluidly connected to a waste receptacle, and the second tube is positioned in the hollow interior of the first tube, (iii) a first end of a first electrode 1 positioned in the conduit, and (iv) a first end of a second electrode 13 positioned in the conduit such that the first end of the second electrode opposes the first end of the first electrode and leaves a gap 19 therebetween, while a second end of the first electrode is electrically connected to a measurement device and a second end of the second electrode is electrically connected to a voltage source. The flow cell is arranged in a two-electrode configuration that allows for the reduction or oxidation of a compound that is placed within the flow cell when a voltage is applied to the second electrode, such as from a battery or preferably a potentiostat. The flow cell can also be placed within a cavity of an EPR spectrometer to analyze free radicals.
[0039] The first tube may be made of a material comprising fused quartz which may be electrically fused quartz, flame fused quartz, or preferably, synthetic fused silica. In a preferred embodiment, the first tube is made of synthetic fused silica. An inner diameter of the first tube may range from 1-6 mm, preferably 2-5 mm, more preferably 2-4 mm. A thickness of a wall of the first tube may range from 0.1-1 mm, preferably 0.4-0.9 mm, more preferably 0.5-0.8 mm. An outer diameter of the first tube may range from 1.2-8 mm, preferably 2.2-7 mm, preferably 2.2-6 mm. A height of the first tube may range from 30-80 mm, preferably 40-70 mm, more preferably 40-50 mm.
[0040] The second tube may be made of the aforementioned materials for the first tube. Preferably, the second tube is made of synthetic fused silica. A diameter of the conduit, which is also an inner diameter of the second tube, may range from 0.5-1.5 mm, preferably 0.8-1.2 mm, more preferably about 1 mm. A thickness of a wall of the second tube may range from 0.1-1 mm, preferably 0.3-0.7 mm, more preferably 0.3-0.5 mm. An outer diameter of the second tube may range from 0.7-3.5 mm, preferably 0.7-2.6 mm, preferably 0.7-2.5 mm. A height of the conduit, which is also a height of the second tube, may range from 30-70 mm, preferably 40-60 mm, more preferably 40-45 mm.
[0041] A ratio of the inner diameter of the first be to the inner diameter of the second tube ranges from 2:1 to 12:1, preferably 2:1 to 7:1, more preferably 2:1 to 4:1.
[0042] In a preferred embodiment, the first and second tubes form concentric cylinders such that a longitudinal centerline of the first tube overlaps with a longitudinal centerline of the second tube. This arrangement may be achieved by employing at least one concentric member 10 positioned circumferentially about an exterior of the second tube and in the interior of the first tube. The concentric member may be a gasket, or preferably an O-ring. Preferably, there are two O-rings, one positioned on a lower end of the second tube, and one positioned on an upper end of the second tube so as to leave the gap unobstructed for EPR. analysis. A distance between the first end of the first electrode and the first end of the second electrode, and hence the size of the gap, ranges from 0.1-0.5 cm, preferably 0.1-0.4 cm, more preferably 0.2-0.4 cm. A shortest vertical distance measured between the centers of the O-rings ranges from 0.5-4 cm, preferably 1-3.5 cm, more preferably 1-3 cm. The gasket may be preferably made of a chemical-resistant material, such as Viton® or Teflon®, which can withstand organic solvents and corrosive chemicals such as acids and bases.
[0043] The first end of first electrode is positioned within the interior of the second tube, preferably in a middle portion of the second tube, and the second end of the first electrode is located in the interior of the fourth tube. In a preferred embodiment, the first electrode is a working electrode, which may be made from at least on material, including but not limited to base metals, such as copper, precious metals, such as gold, silver or platinum, and allotropes of carbon. Preferably, the first electrode is made from graphite, an allotrope of carbon. In a preferred embodiment, the first electrode is a black graphite pencil lead. In this regard, the graphite pencil lead is typically classified in terms of hardness grades. Hardness grades are associated on a hardness scale with the letter H or B or a combination of both, H B. Graphite pencil lead of grades B, H or preferably HB, may be used. A length of the pencil lead may range from 20-50 mm, preferably 25-50 mm, more preferably 30-50 mm. A diameter of the pencil lead may range from 0.13-1.40 mm, preferably 0.3-1 mm, more preferably 0.5-0.7 mm.
[0044] The first end of the second electrode is positioned within the interior of the second tube, opposing the first end of the first electrode, and preferably in a middle position of the second tube, more preferably at 40-50% of the height of the second tube. The second end of the second electrode is connected to a voltage source. The second electrode may be a reference electrode which is made from silver and silver chloride, for example, or other suitable materials, such as mercury and mercury(I) chloride, copper and copper(II) sulfate, depending on the application.
[0045] The bottom portion of the first tube is removably connected to a first tube assembly (embodiments of the first tube assembly are shown in FIGS. 1 and 2 ) while the top portion of the first tube is removably connected to a second tube assembly ( FIG. 3 ). Specifically, the bottom portion of the first tube is removably connected to a top portion of a third tube 6 . In a preferred embodiment, the tubes are connected by a straight tube connector 12 which has two opposing ends. More preferably, the tube connector has an inner diameter larger than the outer diameters of the first and third tubes. For example, the inner diameter of the tube connecter may range from 1.5-10 mm, preferably 2.5-8 mm, preferably 2.5-7 mm. In one embodiment, the first and third tubes are inserted into the opposing ends of the tube connector, The tube connector may be made of a material comprising polypropylene, polyethylene, polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE). In a preferred embodiment, the tube connector is in the form of flexible tubing (e.g. Tygon tubing)
[0046] Embodiments of the first tube assembly are shown in FIGS. 1 and 2 . The first tube assembly comprises a third tube 6 with a hollow interior and a top portion, and a fourth tube 3 with a hollow interior and is positioned in the hollow interior of the third tube, In a preferred embodiment, the third tube and the fourth tube form concentric cylinders.
[0047] The third tube may be made of a material comprising glass or fused quartz which may be electrically fused quartz, flame fused quartz, or preferably, synthetic fused silica. In a preferred embodiment, the third tube is made of synthetic fused silica. The dimensions of the third tube may be the same as the dimensions of the first tube.
[0048] The fourth tube may be made of the aforementioned materials for the third tube. Preferably, the fourth tube is made of synthetic fused silica. An inner diameter of the fourth tube may range from 0.5-1.5 mm, preferably 0.8-1.2 mm, more preferably about 1 mm. A thickness of a wall of the fourth tube may range from 0.1-1 mm, preferably 0.3-0.7 mm, more preferably 0.3-0.5 mm. An outer diameter of the fourth tube may range from 0.7-3.5 mm, preferably 0.5-3.0 mm, preferably 0.5-2.5 mm. A height of the fourth tube may range from 30-80 mm, preferably 40-70 mm, more preferably 40-50 mm.
[0049] A ratio of the inner diameter of the third tube to the inner diameter of the fourth tube ranges from 2:1 to 12:1, preferably 2:1 to 7:1, more preferably 2:1 to 4:1.
[0050] The first electrode extends from the second tube, through a first seal 2 and the second end of the first electrode is located in an upper portion of the interior of the fourth tube.
[0051] The first seal is positioned circumferentially about the first electrode and in the upper portion of the fourth tube, closing off the aperture at the top of the fourth tube and prevents a liquid flow from the conduit into fourth tube. The first seal may be made from a number of suitable materials, including but are not limited to, plastic, rubber, or thread seal tape, commonly referred to as “Teflon® tape”. Thread seal tape is typically a polytetrafluoroethylene (PTFE) film common for use in sealing pipe threads and tubes. In another embodiment, the first seal is a glue.
[0052] An electro-conductive material 4 is deposited within the upper portion of the interior of the fourth tube. The electro-conductive material carries the potential from the first electrode to a wire 5 . The electro-conductive material may be of any suitable form, such as in the form of either a conducting paste or a conducting liquid. The electro-conductive material may also be made from a number of various materials, including a carbon paste or liquid mercury. The height of the electro-conductive material in the fourth tube may range from 1-15 mm, preferably 3-10 mm, more preferably 3-8 mm. The second end of the first electrode engages, or is preferably buried in, the electro-conductive material, A depth of the first electrode in the electro-conductive material ranges from 0.1-2 mm, preferably 0.1-1.5 mm, more preferably 0.5-1 mm.
[0053] The wire 5 originates from outside the fourth tube, extends through the hollow interior into the upper portion of the fourth tube to engage the electro-conductive material. In a preferred embodiment, the first end of the wire is buried in the electro-conductive material at a depth ranging from 0.1-2 mm, preferably 0.1-1.5 mm, more preferably 0.5-1 mm. The wire communicates the potential from the first electrode that is carried by the electro-conductive material to a measurement device. The wire may be made from a number of various metals, including but are not limited to copper, aluminum and gold. In a preferred embodiment, the wire is made of copper. A diameter of the wire may range from 0.1-1.40 mm, preferably 0.3-1 mm, more preferably 0.5-0.7 mm, As the wire is engaged with the electro-conductive material, various electrochemical measurements can be taken and determined, such as values of potential or current that act upon the first electrode. Non-limiting examples of a measurement device include a potentiostat, an ammeter, a voltmeter or a multi-meter.
[0054] There is at least one inlet flow channel 7 positioned in the hollow interior of the third tube. There may be one ( FIG. 1 ), or preferably, two inlet flow channels ( FIG. 2 ). The inlet flow channel connects the inlet of the conduit and fills the gap with at least one solution comprising an analyte and each flow channel may connect to a different solution. Each different solution may comprise a different analyte or the same analyte at varying concentrations. The flow channel may take a form of a tubing, preferably a flexible tubing. An outlet of the flow channel is positioned in the hollow interior of the third tube, preferably near the top portion of the third tube, and an inlet of the flow channel is connected to a syringe containing the solution, a vessel containing the solution or a pump which pumps the solution from a vessel into the flow cell. The flow channel has an external diameter ranging from 0.1-2 mm, preferably 0.3-1.5 mm, more preferably 0.5-1 mm. An internal diameter of the flow channel ranges from 0.05-0.8 mm, preferably 0.1-0.5 mm, more preferably 0.1-0.3 mm. The flow channel may be made of a material compatible with the solution. Non-limiting examples of such material include polypropylene, polyethylene, polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE). Preferably, the inlet flow channel is made of PTFE.
[0055] The solution may be an electrolyte solution comprising an analyte, which refers to the substance to be analyzed or tested. The electrolyte may be a buffer, an acid, or a base in an aqueous or non-aqueous solution. Non-limiting examples of electrolytes include a solution of sulfuric acid, a solution of sodium hydroxide and a solution of potassium hydroxide. Preferably, the electrolyte is a solution of sulfuric acid with a concentration ranging from 0.05-0.5 M, preferably 0.5-0.3 M, more preferably 0.05-0.2 M. As used herein, the term “analyte” refers to the compound of interest that will be analyzed by an EPR spectrometer and an electrochemical process. Non-limiting examples of the analyte include carotenoids and therapeutic pharmaceutical compounds such as Ketoconazole, a common drug for the treatment of fungal infections of the mouth, skin, and urinary tract. A concentration of the analyte may range from 0.05-0.5 mM, preferably 0.1-0.4 mM, more preferably 0.1-0.3 mM. In one embodiment with two inlet flow channels, a first inlet flow channel may be fluidly connected to the electrolyte while a second flow channel may be fluidly connected to a concentrated solution of an analyte.
[0056] The inlet flow channel and the exterior of the fourth tube are irreversibly attached to one another in the interior of the third tube, and are preferably secured by an epoxy glue 8 , which also seals a bottom aperture of the third tube to prevent leakage of the solution from the flow cell. The inlet flow channel and the exterior of the fourth tube may be secured by a super glue and/or a sealant.
[0057] The second tube assembly comprises a fifth tube 17 with a hollow interior and a sixth tube 15 with a hollow interior, where at least a portion of the sixth tube is positioned in the hollow interior of the fifth tube. In a preferred embodiment, the sixth tube is positioned in an upper portion of the fifth tube. In another preferred embodiment, a longitudinal centerline of the fifth tube overlaps with a longitudinal centerline of the sixth tube.
[0058] The fifth tube may be made of a material comprising polypropylene, polyethylene, polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), glass or fused quartz which may be electrically fused quartz, flame fused quartz, or preferably, synthetic fused silica. In a preferred embodiment, the fifth tube is made of polyethylene. The dimensions of the fifth tube may be the same as the dimensions for the first tube. In a preferred embodiment, the inner diameter of the fifth tube ranges from 1.5-10 mm, preferably 2.5-8 mm, preferably 2.5-7 mm. More preferably, the inner diameter of the fifth tube is larger than an outer diameter of the first tube by 0.1-2 mm, preferably 0.1-1.5 mm, more preferably 0.1-1 mm so that the hollow interior of the fifth tube can accommodate an upper portion of the first tube, preferably in a removable manner. The inner diameter of the fifth tube may be larger than an outer diameter of the first tube by 10-40%, preferably 10-30%, more preferably 10-20% relative to the outer diameter of the first tube. In another embodiment, the top exterior portion of the first tube has male screw threads that are compatible with female screw threads on the interior bottom portion of fifth tube. In another embodiment, the first and fifth tubes are connected by a straight tube connector with two opposing ends. More preferably, the tube connector has an inner diameter larger than the outer diameters of the first and fifth tube. For example, the inner diameter of the tube connecter may range from 1.5-11 mm; preferably 2.5-9 mm, preferably 2.5-8 mm. In one embodiment, the first and fifth tubes are inserted into the opposing ends of the tube connector. The tube connector may be made of a material comprising polypropylene, polyethylene, polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE). In a preferred embodiment, the tube connector is in the form of flexible tubing (e.g. Tygon tubing).
[0059] The sixth tube may be a capillary glass tube or made of the aforementioned materials for the fourth tube. The dimensions of the sixth tube may be the same as the dimensions of the fourth tube. In a preferred embodiment, the length of the sixth tube is 10-40 mm, preferably 10-30 mm, more preferably 10-20 mm.
[0060] A ratio of the inner diameter of the fifth tube to the inner diameter of the sixth tube ranges from 5:3 to 14:1, preferably 5:3 to 7:1, more preferably 5:3 to 4:1.
[0061] The second end of the second electrode extends through an upper portion of the sixth tube, through a second seal 14 and is connected to a voltage source. The second seal is positioned circumferentially about the second electrode and in an upper p on of the sixth tube, closing off the aperture at the top of the sixth tube to prevent leakage of the solution from the conduit into the sixth tube. The second seal may be made from the same material as the first seal.
[0062] There is an outlet flow channel 18 positioned in the hollow interior of the fifth tube. The outlet flow channel connects the outlet of the conduit to a waste receptacle. The flow channel may take a form of a tubing, preferably a flexible tubing. An inlet of the outlet flow channel is positioned in the hollow interior of the fifth tube, preferably near the top portion of the fifth tube, and an outlet of the outlet flow channel terminates in a waste receptacle such as a beaker, a flask or a carboy. The flow channel has an external diameter ranging from 0.1-2 mm, preferably preferably 0.3-1.5 mm, more preferably 0.5-1 mm. An internal diameter of the flow channel ranges from 0.05-0.8 mm, preferably 0.1-0.5 mm, more preferably 0.1-0.3 mm. The flow channel may be made of a material compatible with the solution. The outlet flow channel may be made of the same material as the inlet flow channel. Preferably, the outlet flow channel is made of PTFE.
[0063] The outlet flow channel and the exterior of the sixth tube are irreversibly attached to one another in the interior of the fifth tube, and are preferably secured by an epoxy glue 16 , which also seals a top aperture of the fifth tube to prevent leakage of the solution from the flow cell. The outlet flow channel and the exterior of the sixth tube may also be secure by a super glue.
[0064] According to the second aspect, this disclosure relates to a method of employing the flow cell in batch and continuous EC-EPR studies. The method may be performed at a temperature ranging from 4-60° C., preferably 4-40° C., more preferably 4-30° C. The method comprises flowing at least one solution comprising an analyte into the conduit to fill the gap. In a batch experiment, the volume of the solution ranges from 10-200 preferably 20-150 μL, more preferably 40-120 μL. The solution may be introduced from the inlet flow channel into the conduit from a syringe or a vessel. In one embodiment, the inlet flow channel is connected directly to the reaction vessel and the solution flows into conduit by gravity, The flow may be controlled by a valve, such as a stopcock. An outlet of the outlet flow channel is sealed to prevent the solution from leaking from the assembled flow cell. The outlet may be sealed by a stopper and/or a pinch clamp.
[0065] In a continuous monitoring embodiment, a solution comprising radical species is removed after the monitoring and the conduit is re-filled with a fresh solution comprising the analyte. A pump, which is fluidly connected to a reaction vessel containing the solution, may be employed to feed the solution into the conduit. The flow rate of the solution may range from 0.05-2 ml/min, preferably 0.1-1.5 ml/min, more preferably 0.1-0.5 min. Non-limiting examples of the pump include a peristaltic pump, a piston pump and a syringe pump. In a continuous monitoring embodiment, the outlet of the outlet flow channel is left open so that the solution comprising radical species can be collected in a waste receptacle such as a beaker, a flask or a carboy.
[0066] The flow cell is positioned within an EPR spectrometer comprising a probehead comprising a cavity. Preferably, the gap is positioned within the cavity such that the center of the gap coincides with the center of the cavity
[0067] A voltage is applied to the second end of the second electrode to form the solution comprising radical species. The applied voltage may range from 0.4-1 V, preferably 0.5-0.8 V, more preferably 0.55-0.65 V. When voltage is applied to the second electrode, the generated potential enters the solution and initiates a reduction or an oxidation of the analyte at the first electrode. The voltage may be applied for a period of time to result in an accumulation potential, which acts upon the first electrode. The voltage may be applied for a duration ranging from 30-300 seconds, preferably 50-200 seconds, more preferably 60-120 seconds. A rest period ranging from 2-60 s, preferably 2-40 s, more preferably 2-30 s may ensue. The electro-conductive material communicates the accumulation potential to the wire. The measurement device, in communication with the wire, measures the potential and current acting upon the first electrode. In a preferred embodiment, the measurement device and the voltage source are the same device, being a potentiostat.
[0068] After the voltage is applied, the solution is monitored for the presence of radical species. The operations of the EPR spectrometer and the relevant spectrum processing software are well known to those skilled in the art. A spectrum may be obtained intervals ranging from 60-300 seconds, preferably 60-180 seconds, more preferably 60-120 seconds in the presence of the accumulation potential. In another embodiment, a spectrum is obtained in the absence of an applied voltage.
[0069] The present embodiments are being described with reference to specific example embodiments and are included to illustrate but not limit the scope of the disclosure or the claims.
EXAMPLE
[0070] A pharmaceutical drug, Ketoconazole (200 mg/L), was mixed with a 0.1 M sulfuric acid electrolyte solution and oxidized at an accumulation potential of +0.6 V. The first electrode was a graphite pencil lead and the reference electrode was a Ag/AgCl electrode. FIG. 6 shows an overlay of electron paramagnetic resonance (EPR) spectra obtained when the voltage was turned on (second spectrum from the bottom), then turned off (third spectrum from the bottom), and then turned on again (fourth spectrum from the bottom). When a sample of Ketoconazole was oxidized to form radicals comprising unpaired electrons, the radicals generated EPR signals that were in a range of 333 milliTeslas (mT) and 338 mT. The electrolyte solution contained Mn (II) as a reference and the satellite peaks of Mn (II) are seen in FIG. 6 .
[0071] Thus, the foregoing discussion discloses and describes merely exemplary embodiments of the present invention. As will be understood by those skilled in the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting the scope of the invention, as well as other claims. The disclosure, including any readily discernible variants of the teachings herein, defines, in part, the scope of the foregoing claim terminology such that no inventive subject matter is dedicated to the public. | A flow cell and a method for batch and continuous simultaneous electrochemical (EC) and electron paramagnetic resonance (EPR) measurements. The flow cell includes first and second tubes with hollow interiors and the first tube is removably connected to first and second tube assemblies. The interior of the second tube contains first ends of first and second electrodes and a solution comprising an analyte. When a voltage is applied to the second electrode, the analyte undergoes a reduction or an oxidation process to generate radicals, which in turn, give rise to EPR signals. | 6 |
FIELD OF THE INVENTION
The present invention relates to a process for iron ore pellets production and more specifically to a process in which an equipment for reducing the size of the solid iron ore particles is used.
BACKGROUND OF THE INVENTION
As it is known, pelletizing is an agglomeration process whereby the fine iron ore particles are converted into spherical bodies with size ranging from 8 to 18 mm. These spherical bodies having an appropriate physical, chemical and metallurgical properties for use in steel mill's reduction reactors.
The quality of the product yielded by the pelletizing process has direct relation with the material size fed to the process, and it is suitable that at least 50% of the raw material charged to the process have a size less than 0.40 mm (325 mesh) and a specific surface of 1200 cm 2 /g. Usually, the ore fines employed in pelleting have a granulometry 100% less than 0.149 mm (100 mesh), however only 30 to 45% being less than 0.044 mm (325 mesh). Therefore, in order to adapt the granulometric characteristics and specific surface of the ore fines to the pelleting process requirements it becomes necessary to submit the ore fines to a crushing stage to reduce the particles size.
In the conventional pelletizing process the reducing of size (crushing and grinding) of the ore fines is achieved by grinding in a tubular mill wherein steel balls or truncated steel cones (cylpebs) are usually employed to help with the grinding operation or as a grinding medium. This grinding operation is a heavy burden on the overall production cost of pellets due to the significant consumption of energy and grinding media.
There are several options available to the grinding operation. It can be performed in or wet or dry, open or closed operations.
In the wet grinding process iron ore and water are mixed together and both are added to the mill in adjusted proportions performing a diluted grounded ore pulp. A large amount of water that is added to the grinding operation is removed by subsequent thickening, homogenizing and filtering stages.
On the other hand, dry grinding operation requires the prior drying of the ore fines, however disregards the water draining step that is necessary when the wet process is employed.
Grinding in an open operation consists in passing the material through the mill only once, while in the closed operation the hydrocyclones employed for wet grinding or the air classifiers used in the dry grinding process perform the granulometric classification at the discharge of the mill.
Finally, in the closed mills a fraction of sufficiently fine material below 0.44 mm (325 mesh) goes on to the next stages of the pelletizing process while the coarser fraction returns to the mill as the circulating load of the grinding process.
SUMMARY OF THE INVENTION
Some years ago, a new crushing technique was tested by the ore mining processing industry. The technology is based on the employment of high pressure to obtain the reduction in the ore particles size. The principle of high pressure crushing was introduced to industrial applications through the machine called roller press in which high pressures, above 50 MPa is applied to two rollers unto which is fed the material to be crushed.
In a roller press the crushing and grinding is achieved through the transfer of pressure between the particles of a bed or layer of material without using any external means of action, such as grinding elements, or coatings in the mill onto the individual particles of the material to be ground. Due to the high pressure as applied, the material which has been processed in a roller press is compacted into a shape of agglomerates called flocks.
Industrial roller presses, such as those which are employed by the cement industry, copper and diamond mines among others, are usually designed with rollers of 1.6 meters in width and 1.4 to 2.2 meters of diameter.
The peripheral velocity of the rollers is from 0.7 to 2.0 m/s and the hydraulic power applied to the rolls ranges of 100 kN per linear roller centimeter, or meters of diameter. The capacity of an industrial roller press may attain up to 1000 tons/h, depending on the dimensions of the equipment, operating conditions and the specific characteristics of the material to be crushed.
The main advantage of the roller press over conventional crushing equipment, such as ball mills and rock crushers are: a significant reduction in electric power of approximately 20 to 30% due to the greater efficiency of energy transfer from the rollers surface to the particles at the beginning and afterwards between the particles; a significant reduction in the operating cost due to (i) the elimination of grinding devices replacement, (ii) preventing fissures and cracks on the ore particles, (iii) consequently reduction of electric power needed for the subsequent stages of comminution, (iv) and the promotion of a greater degree of reactivity of the ore, specially during the interaction with liquids, for example in the leaching process of gold, and the interaction with gases as in the combustion process of coal or in the reduction of ores. Therefore, this provides for a low costs of investment and the improvement of maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in accordance with the attached drawings which are not to be considered as limitations of the present invention.
FIG. 1 is a schematic viewing of the conventional grinding process of iron ore fines carried out in a ball mill;
FIG. 2 is a schematic viewing of a process for the iron ore pellets production, comprising a pre-comminution of the iron ore fines in a roller press;
FIG. 3 schematically represents, a process for the iron ore pellets production comprising the post-comminution of the ore fines in a roller press;
FIGS. 4 and 4a, schematically represent two arrangements for a process for the iron ore pellets production with the total comminution of the fines in a roller press;
FIG. 5 represents a block diagram of the stages in the production process of iron ore pellets having a crushing stage prior to the wet grinding in the ball mill;
FIG. 6 represents a block diagram of the stages in the production process of iron ore pellets having the crushing stage prior to the dry grinding in the ball mill;
FIG. 7 represents a block diagram of the stages in the production process of iron ore pellets in which the crushing stage is performed after the wet grinding in the ball mill;
FIG. 8 represents a block diagram of the stages in the production process of iron ore pellets in which the crushing stage is performed after the dry grinding in the ball mill;
FIG. 9 represents a block diagram of the stages in the production process of iron ore pellets having a series of crushing stage with a total comminution.
DETAILED DESCRIPTION OF THE INVENTION
According to the drawings, the present invention comprises a process for the iron ore pellets production in which the pellets are obtained from a comminuted material prepared using a roller press equipment.
FIG. 1 shows the raw material feeding 1 to be pelletized having a high specific surface of about from 450 cm 2 /g to 1800 cm 2 /g which is not dependent from the particularities of the conventional iron ore production process, being it carried out through a dry or wet, open or closed circuit.
FIG. 2 illustrates an iron ore pellets production process of the present invention wherein the raw material feeding 1 for pelletizing is done in a roller press 5. The material is submitted to roller press 5 at a pre-comminution stage before the pelleting and after that it is immediately submitted to the other stages of conventional grinding in ball mills 2, 3, 4 or 2a, and 4a. According to this arrangement, the feeding 1 for the ore fines to be transformed in pellets is submitted to a single pass through the roller press 5 resulting in the increase of the specific surface from approximately 450 cm 2 /g to about 1800 cm 2 /g. Then the material is crushed and fed into the conventional wet circuit of the ball mill 2a and 4a, or the dry 2, 3 and 4, where the specific surface is increased approximately to 1800 cm 2 /g.
FIG. 3 represents an iron ore pellet production process in which the comminution stage of the pelletizing material in the roller press 5 is performed by crushing the material after the conventional grinding in the ball mills 2, 3, 4 or 2a and 4a. In this case, the iron ore fines feeding 1 has a high specific surface raised from approximately 450 cm 2 /g to 1400 cm 2 /g in the conventional wet grinding mill 2a and 4a or the dry grinding mills 2, 3, and 4.
In the case of wet grinding 2a and 4a, the ground product is submitted to thickening stage 6, homogenizing stage 7 and filtering stage 8. Following the filtered material is crushed in the roller press 5 only once until the specific surface reaches 1800 cm 2 /g. However, in the case of dry grinding 2, 3 and 4, the ground product with a specific surface of 1400 cm 2 /g is submitted to one single passage through the roller press 5 omitting stages 6, 7 and 8, leading to a material with a specific surface of approximately 1800 cm 2 /g. This arrangement initially implies in the production of a coarser ground material 1 in comparison with the conventional process, since a supplementary comminution shall occur from the processing of this pre-molded material in the roller press 5.
FIG. 4 represents the total comminution of the material to be pelletized wherein the ore fines feeding 1 has the specific surface raised from approximately 450 cm 2 /g to about 1800 cm 2 /g by the successive passages through the roller press 5. In this arrangement, the conventional wet or dry grinding process 2, 3 and 4, or 2a and 4a in ball mills is completely substituted by a process with with the single passage through roller press 5. The advantage of this embodiment is that it enables the elimination of the thickening stage 6, homogenization stage 7 and filtering stage 8 which are required in the conventional pelletizing process by the ball mill wet grinding.
In the embodiment shown in FIG. 4A, the conventional wet or dry grinding process in ball mills 2, 3, 4 or 2a, 4a is completely substituted by the crushing stage in a number (n) of roller presses 5, 5a, . . . , 5n with one single pass through each press.
FIGS. 5 to 9 show the block diagrams of the tests that have been performed on the variation of arrangements provided in the pelletizing process in which was included at least one crushing stage in roller press 5 which arranged along a pilot plant for the pelletizing process in accordance with the arrangements illustrated in FIGS. 1 to 4a. This pilot plant is provided with at least roller presses 5, ball mills 2 and 2a, hydrocyclones 11, dryer 12, a thickener 6a, homogenizing tank 7a, a vacuum rotating filter 8a, mixer, pelletizing disk 9 and a pilot furnace 10 for firing the iron ore pellets. The operating productivity of the set of comminution operation was measured for each test.
The quality characteristics of the raw and fired pellets produced during the various tests were evaluated in adequately chemical and physical laboratory for performing pelleting tests.
To evaluate the process with the pre-comminution stage for the iron ore fines in the roller press 5 followed by the supplementary conventional grinding in the ball mill as illustrated in FIG. 2, three tests were performed with different materials. Two under wet grinding as illustrated in FIG. 5 and one dry grinding as shown in the diagram of FIG. 6. The results of these tests have ascertained that the pre-comminution stage of the fines in the roller press 5 in combination of a supplementary grinding operation in a congenital ball mill produced raw and fired pellets of satisfactory quality and the increasing in the operating productivity ranged 20 to 33%.
For the ore fines post-comminution stage in a roller press 5 after the conventional grinding in ball mills as illustrated in FIG. 3, three tests were performed with different materials. Two with wet grinding shown in the diagram of the FIG. 7 and one with dry grinding as illustrated in the diagram of the FIG. 8. The results of these tests have indicated that the iron ore fines grinding in a ball mill up to a coarser granulometry than that obtained with the conventional process in combination with the post-comminution state via the passage of the pre-ground material through roller presses, it can also be achieved satisfactory quality indices of the processed products. These tests have shown an expressive increase in the operating productivity, between 20 and 36%.
For ore fines comminution circuits through successive passages in roller presses 5, 5a, . . . , 5n as illustrated in FIGS. 4 and 4a, three tests were performed with different materials as can be seen in FIG. 9. In each one the material was submitted to a determined number of passages through the recirculation by the roller press 5 until the material reached the desired specific surface. Also, in these tests were obtained results that have shown good quality indices for the raw and fired pellets obtained from successively crushed iron ore fines. The gain in productivity reached in these tests was 26 to 30%.
Therefore, it is possible to conclude that the introduction of roller press equipment in the pelletizing process according to one of the proposed arrangements, FIGS. 2, 3 and 4, afford a considerable increase to the process productivity in the yield of raw or fired pellets at the rate that a portion of the iron ore fines comminution operation 5 is no longer being executed in the conventional ball mills.
In spite of the description and illustrations above be related to a preferred embodiment of the present invention, it is to be understood that changes is possible without any deviations from the scope of the invention. | The present invention concerns a process for iron ore pellets production comprising at least one iron ore crushing stage in a roller press for the production of iron ore pellets. The crushing stage(s) can be done prior or after grinding, or still defined by successive passages of the material through the foregoing crushing stage. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 100 23 011.3 filed May 11, 2000, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a device which forms an integral part of a carding machine and which processes fiber material, particularly cotton, chemical fibers or the like. The carding machine includes a main carding cylinder followed by a doffer and a pull-off (withdrawing) device for the fiber material.
In a known apparatus, as disclosed, for example, in German Offenlegungsschrift (application published without examination) No. 23 64 262, two doffers are provided which take the fiber material off the main carding cylinder. The two doffers are disposed with respect to the carding cylinder and with respect to one another in such a manner that each doffer cooperates with both the carding cylinder and with the other, adjacent doffer and further, a web stripping device cooperates with one of the doffers. The two doffers rotate in opposite directions with respect to the main carding cylinder. An increased production rate is intended by the provision of the two doffers and their arrangement with respect to the carding cylinder and to one another. It is a condition of such a prior art arrangement that the carding cylinder process a fiber quantity which is approximately twice the usual amount handled by a carding cylinder. For such an increased fiber amount the cylinder clothing must be coarser to increase its processing capacity. This disadvantageously reduces the carding quality to a significant extent.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved fiber processing device of the above-outlined type from which the discussed disadvantages are eliminated and with which a fiber web of increased specific weight may be obtained without adversely affecting the carding quality.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the carding machine includes a main carding cylinder and a doffer to which fiber material is transferred from the main carding cylinder and a fiber removing device positioned downstream of the doffer as viewed in an advancing direction of the fiber material through the carding machine. A gathering device including at least one gathering roll is disposed downstream of the doffer for effecting a negative draft on the fiber material between the doffer and the gathering roll.
The fiber gathering device, including at least one fiber gathering (fiber accumulating) roll, results in a negative draft of the fiber material: The gathering rolls accumulate and densify the fiber material, whereby an increased specific weight (quantity per surface or length) of the fiber web is obtained. The fiber web or sliver of increased specific weight is advantageously adapted for further processing, for example, into articles of hygiene.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a travelling flats-type carding machine including a gathering device according to the invention.
FIG. 2 is a schematic side elevational view of a gathering roll disposed between a doffer and a stripping roll.
FIG. 3 is a schematic view of two gathering rolls with rpm-controlled drives.
FIG. 4 is a schematic side elevational view of a sliver draw unit following a sliver forming device.
FIG. 5 is a schematic side elevational view of a calender assembly following a sliver forming device.
FIG. 6 shows two crushing rolls and a transverse fiber web pull-off device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a carding machine CM which may be a high-performance DK 903 model manufactured by Trüftzschler GmbH & Co. KG, Mönchengladbach, Germany. The carding machine CM has a feed roll 1 , a feed table 2 cooperating with the feed roll 1 , licker-ins 3 a , 3 b , 3 c , a main carding cylinder 4 , a doffer 5 , a stripping roll 6 , crushing rolls 7 , 8 , a web guiding element 9 , a sliver trumpet 10 , calender rolls 11 , 12 , a traveling flats assembly 13 having slowly circulating flat bars 14 (whose speed is between 0.05 and 0.4 m/min) and stationary carding elements 15 a , 15 b . The doffer 5 is rotated by a symbolically shown drive 5 a . The directions of rotation of the rolls are shown by curved arrows drawn therein. The width of the rolls is between 1 and 1.5 m. The fiber processing direction, that is, the travel direction of the fiber material through the carding machine is indicated at A, while B designates the sliver discharged by the calender rolls 11 , 12 . The carding machine CM serves particularly for the processing of cotton and/or chemical fibers.
The carding machine CM may be supplied with fiber material by an upstream-connected fiber feeder 30 which may be a DIRECTFEED DFK model, manufactured by Trützschler GmbH & Co. KG.
According to the invention two gathering rolls 18 and 19 are disposed between the doffer 5 and the stripping roll 6 . The first gathering roll 18 cooperates upstream with the doffer 5 and downstream with the second gathering roll 19 . The doffer 5 and the second gathering roll 19 rotate co directionally, while the first gathering roll 18 rotates in the opposite direction. The circumferential speed of the first gathering roll 18 is less than that of the doffer 5 , whereas the circumferential speed of the second gathering roll 19 is less than that of the first gathering roll 18 . In this manner the fiber material is slowed down and accumulated. The circumferential speed of the doffer 5 may be, for example, 5 m/sec and that of the stripping roll 6 may be 8 m/sec. The circumferential speed of the first and second gathering rolls 18 and 19 may be, for example, 125 m/min and, respectively, 105 m/min at the most. The exit speed of the weight-enhanced sliver B discharged by the calender rolls 11 , 12 may be approximately 20 m/min or more. Also referring to FIG. 2, the clothing teeth 5 b of the doffer 5 are oriented rearwardly with respect to its direction of rotation. The clothing teeth 6 b of the stripping roll 6 are essentially radially oriented. The clothing teeth 18 b of the first gathering roll 18 are oriented rearwardly relative to its rotary direction whereas the clothing teeth of the second gathering roll 19 are oriented rearwardly with respect to its direction of rotation. By virtue of the gathering device 17 according to the invention, comprising the two gathering rolls 18 and 19 illustrated in FIG. 1, a negative draft, that is, an accumulation of the fiber material is effected at the first gathering roll 18 with respect to the doffer 5 in a ratio of approximately 1:3 to 1:5 and at the second gathering roll 19 with respect to the doffer 5 in a ratio of approximately 1:3 to 1:6. In this manner a heavy sliver B may be made, having a sliver weight of, for example, 80-150 g/m.
As shown in FIG. 2, between the doffer 5 and the stripping roll 6 a single gathering roll 18 is provided which cooperates with the doffer 5 and the stripping roll 6 .
As shown in FIG. 3, the gathering rolls 18 and 19 are driven by respective rpm-regulated motors 24 and 25 which may be a.c. servomotors and which are coupled to an electronic control and regulating device 26 . Such a control system may set the negative draft (accumulation) of the fiber material to the desired extent.
As shown in FIG. 4, the calender rolls 11 , 12 at the output of the carding machine are followed by a regulated draw unit 20 with which irregularities in the sliver B may be evened, particularly as concerns sliver thickness and structure. The intake roll pair 20 a and the mid roll pair 20 b are driven by an rpm-regulated electric motor 21 and the output roll pair 20 c is driven by an rpm-regulated electric motor 22 . The motors 21 and 22 are connected to an electronic control and regulating device 23 .
Turning to FIG. 5, the calender rolls 11 , 12 of the carding machine are followed by a reinforcing device 27 having two calender rolls 27 a and 27 b which serve for reinforcing the fiber web or the sliver B by pressure or profiling. By virtue of this arrangement structural changes are compensated for which may appear in the course of the gathering process and at the same time, the fiber web or sliver B is improved for further processing. The reinforcing device 27 is followed by a processing device 29 which may be an automatic apparatus for making sanitary napkins. To achieve a high output speed and output quantity, advantageously the speed of the sliver B exiting the carding machine and the speed of the sliver C entering the after-connected processing machine 29 are adapted to one another. In such a case no intermediate storage arrangement for the sliver is required. The adaptation is effected by a non-illustrated electronic control and regulating device which is connected with the rpm-regulated drive motors of the carding machine and the processing machine 29 .
It is noted that in a carding machine for practicing the invention instead of the traveling flats assembly 13 exclusively stationary carding elements, and instead of the fiber web guiding elements 9 a transverse fiber web pull-off unit 31 as shown in FIG. 6 may be used.
In case an intermediate storage arrangement is required, the sliver B may be deposited in a non-illustrated coiler can.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A carding machine includes a main carding cylinder and a doffer to which fiber material is transferred from the main carding cylinder and a fiber removing device positioned downstream of the doffer as viewed in an advancing direction of the fiber material through the carding machine. A gathering device including at least one gathering roll is disposed downstream of the doffer for effecting a negative draft on the fiber material between the doffer and the gathering roll. | 3 |
INCORPORATION BY REFERENCE
Priority is claimed to Japanese Patent Application No. 2012-023127, filed Feb. 6, 2012, and International Patent Application No. PCT/JP2013/051474, the entire content of each of which is incorporated herein by reference.
BACKGROUND
1. Technical Field
The present invention relates to a particle beam irradiation apparatus for irradiating an irradiated body with a particle beam.
2. Description of the Related Art
As a particle beam irradiation apparatus which is used for radiation therapy for a tumor or the like, a particle beam irradiation apparatus described in, for example, the related art is known. The particle beam irradiation apparatus is provided with scanning means (an electromagnet) for performing particle beam scanning, electric current supply means (a power supply) for supplying an electric current to the scanning means, and scanning control means (a command value transmission section) for controlling the particle beam scanning by the scanning means by sending an electric current command value to the electric current supply means. In the particle beam irradiation apparatus, the scanning control means sends the electric current command value to the electric current supply means on the basis of a treatment plan planned beforehand, whereby the electric current supply to the scanning means by the electric current supply means is changed, and thus scanning control of the particle beam along the treatment plan is performed.
SUMMARY
Therefore, according to an embodiment of the present invention, there is provided a particle beam irradiation apparatus including: a scanning unit configured to scan a particle beam; an electric current supply unit configured to supply an electric current to the scanning unit; and a scanning control unit configured to control the scanning unit by sending an electric current command value to the electric current supply unit, wherein a period of an operation clock of the scanning control unit and a period of an operation clock of the electric current supply unit are the same.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an embodiment of a particle beam irradiation apparatus according to the present invention.
FIG. 2 is a diagram for describing scanning irradiation by a particle beam.
FIG. 3 is a diagram for describing a signal that a scanning controller transmits to a scanner power supply.
FIG. 4 is a diagram showing an operation clock of the scanning controller and an operation clock of the scanner power supply.
FIG. 5 is a diagram for describing variation in clock delay time.
DETAILED DESCRIPTION
Incidentally, in radiation beam therapy, if misalignment occurs between particle beam scanning in a prior treatment plan and actual particle beam scanning, an excessive or deficient irradiation dose occurs according to the site of a tumor, and thus a problem such as an insufficient treatment effect being obtained occurs. For this reason, in a particle beam irradiation apparatus, improvement in the accuracy of the scanning control of a particle beam is strongly desired.
Therefore, it is desirable to provide a particle beam irradiation apparatus in which it is possible to perform high-precision scanning control of a particle beam.
The inventors of the present invention have found, as a result of repeating an extensive investigation, that there is variation in the delay time after a scanning control unit sends an electric current command value to an electric current supply unit and before a scanning unit supplied with an electric current from the electric current supply unit actually performs particle beam scanning. Such variation in delay time contributes to a decrease in the accuracy of the scanning control.
As a result of repeating a further investigation, the inventors of the present invention have found that variation in delay time is caused by a difference between an operation clock of the scanning control unit and an operation clock of the electric current supply unit. Specifically, the inventors have found that variation which is caused by a difference between the operation clock of the scanning control unit and the operation clock of the electric current supply unit, of the delay time after the scanning control unit transmits an electric current command value and before the scanning unit actually performs the particle beam scanning, is a cause of variation in the entire delay time.
FIG. 5 is a diagram for describing variation in clock delay time. In FIG. 5 , transmission timings of an electric current command value in a transmission-side operation clock are shown as s0 to s2. Further, reception timings of the electric current command value in a reception-side operation clock are shown as r0 to r2. As shown in FIG. 5 , in a case where the period of the transmission-side operation clock and the period of the reception-side operation clock are different from each other, delay time between the transmission timing of the electric current command value by the scanning control unit and the reception timing of the electric current command value by the electric current supply unit occurs with variation.
According to the particle beam irradiation apparatus related to the embodiment of the present invention, the period of the operation clock of the scanning control unit and the period of the operation clock of the electric current supply unit are the same, and thus it is possible to make delay time between the operation clocks of the scanning control unit and the electric current supply unit constant, and thus it is possible to avoid occurrence of variation in the delay time after the scanning control unit transmits the electric current command value and before the scanning unit actually performs the particle beam scanning. For this reason, according to the particle beam irradiation apparatus described above, it is possible to avoid a situation where due to variation in delay time, the particle beam is irradiated for a longer time than a treatment plan at a certain irradiation position and the particle beam is irradiated for a shorter time than the treatment plan at the other irradiation position. Therefore, according to the particle beam irradiation apparatus described above, it is possible to perform the high-precision scanning control of the particle beam which accurately controls the irradiation time at each irradiation position on the basis of the treatment plan.
In the particle beam irradiation apparatus described above, according to an embodiment of the present invention, a configuration is also acceptable in which the scanning control unit has a transmission section configured to transmit an operation clock signal to the electric current supply unit and the electric current supply unit has a receiving section configured to receive the operation clock signal transmitted from the transmission section.
According to the particle beam irradiation apparatus described above, by transmitting the operation clock signal from the transmission section of the scanning control unit to the receiving section of the electric current supply unit, it is possible to drive the electric current supply unit by the operation clock having the same period as the operation clock of the scanning control unit. Therefore, in the particle beam irradiation apparatus described above, it is not necessary to separately provide an operation clock signal transmission section for matching the periods of the operation clock of the scanning control unit and the operation clock of the electric current supply unit, and thus it is possible to attain simplification of an apparatus configuration.
In the particle beam irradiation apparatus described above, the particle beam irradiation apparatus may further include position measuring unit configured to measure a position of the particle beam scanned by the scanning unit, and the scanning control unit may determine whether or not there is an abnormality in a scanning by the scanning unit, on the basis of a comparison result between a plan position of the particle beam corresponding to the electric current command value and a measurement position of the particle beam measured by the position measuring unit.
According to the particle beam irradiation apparatus described above, it is possible to make the delay time almost constant by suppressing variation in the delay time, and thus it becomes possible to obtain, by calculation, the influence of the delay time on the position of the particle beam, and it is possible to exactly compare the plan position of the particle beam with the actual measurement position. Therefore, according to the particle beam irradiation apparatus described above, it is possible to properly determine whether or not there is an abnormality in the scanning control of the particle beam, on the basis of a comparison result between a plan position of the particle beam and a measurement position of the particle beam.
According to the embodiment of the present invention, it is possible to perform high-precision scanning control of the particle beam.
Hereinafter, a preferred embodiment of a particle beam irradiation apparatus according to the present invention will be described in detail with reference to the drawings.
As shown in FIGS. 1 and 2 , a charged particle beam therapy apparatus (a particle beam irradiation apparatus) 1 according to the above embodiment is for performing radiation therapy by irradiating a charged particle beam R with respect to a tumor (an irradiated body) 51 of a patient 50 on a treatment table 100 . As the charged particle beam R, a proton beam, a heavy particle (heavy ion) beam, or the like can be given.
The charged particle beam therapy apparatus 1 performs continuous irradiation or intermittent irradiation of the charged particle beam R by a scanning method. Specifically, the charged particle beam therapy apparatus 1 performs continuous irradiation (raster scanning or line scanning) or intermittent irradiation (spot scanning) while virtually dividing the tumor 51 into a plurality of layers in a depth direction and performing scanning of the charged particle beam R along a scanning pattern L set to each layer.
The charged particle beam therapy apparatus 1 is provided with an accelerator 2 which accelerates charged particles and emits the charged particle beam R, a transport line 3 which transports the charged particle beam R emitted from the accelerator 2 , an irradiation section 4 which irradiates the charged particle beam R transported by the transport line 3 , toward the tumor of the patient, and a position measurement monitor (a position measuring unit) 5 for measuring an irradiation position of the charged particle beam R which is irradiated from the irradiation section 4 .
The accelerator 2 emits the charged particle beam R by accelerating particles with an electric charge. As the accelerator 2 , for example, a cyclotron, a synchrotron, a synchrocyclotron, or a linear accelerator can be used.
The charged particle beam R emitted from the accelerator 2 is transported to the irradiation section 4 by the transport line 3 . A traveling direction of the charged particle beam R transported from the transport line 3 into the irradiation section 4 is indicated by an arrow A.
The irradiation section 4 performs the irradiation of the charged particle beam R toward the tumor 51 in the body of the patient 50 on the treatment table 100 . The irradiation section 4 is provided with a scanning electromagnet (a scanning unit) 6 for performing the scanning of the charged particle beam R. In the scanning electromagnet 6 , the scanning of the charged particle beam. R is performed by a change in magnetic field. The scanning electromagnet 6 has a first scanning electromagnet 6 A which performs the scanning of the charged particle beam R in an X direction perpendicular to the traveling direction A, and a second scanning electromagnet 6 B which performs the scanning of the charged particle beam R in the traveling direction A and a Y direction perpendicular to the X direction.
The scanning electromagnet 6 is supplied with an electric current from a scanner power supply (an electric current supply unit) 7 disposed outside the irradiation section 4 . The scanner power supply 7 changes an electric current which is supplied to the scanning electromagnet 6 , according to an electric current command value from a scanning controller 10 (described later). The scanner power supply 7 has a first power supply (an X power supply) 7 A which supplies an electric current to the first scanning electromagnet 6 A, and a second power supply (a Y power supply) 7 B which supplies an electric current to the second scanning electromagnet 6 B.
The position measurement monitor 5 measures the irradiation position of the charged particle beam R (a position in an X-Y plane perpendicular to the travel direction A of the charged particle beam R) scanned by the scanning electromagnet 6 . The position measurement monitor 5 is provided with a lattice-shaped wire grid made of a large number of wires extending in the X direction or the Y direction and measures the irradiation position of the charged particle beam R by detecting electric charges generated by the contact of the charged particle beam R with the wire grid.
Next, irradiation control of the charged particle beam R in the charged particle beam therapy apparatus 1 will be described. The charged particle beam therapy apparatus 1 has a treatment planning section 8 , an irradiation control section 9 , the scanning controller (a scanning control unit) 10 , and a beam control section 11 .
In the treatment planning section 8 , a treatment plan for treating the tumor 51 of the patient 50 is created. The treatment planning section 8 creates the treatment plan on the basis of various types of data input thereto. In the treatment plan, the scanning pattern L of the charged particle beam R of each layer obtained by virtually dividing the tumor 51 into a plurality of layers in the depth direction is included. In the scanning pattern L, scanning position information of the charged particle beam R for each predetermined time is included.
The irradiation control section 9 controls the irradiation of the charged particle beam R on the basis of the treatment plan created by the treatment planning section 8 . The irradiation control section 9 transmits information about the treatment plan obtained from the treatment planning section 8 to the scanning controller 10 .
Further, the irradiation control section 9 transmits an emission preparation signal to the beam control section 11 on the basis of a demand signal from the scanning controller 10 . The beam control section 11 starts emission preparation of the charged particle beam R by controlling the accelerator 2 in a case of receiving the emission preparation signal. The beam control section 11 transmits an emission preparation completion signal to the irradiation control section 9 and the scanning controller 10 in a case where the emission preparation of the charged particle beam R is completed.
As shown in FIGS. 1 and 3 , the scanning controller 10 performs the scanning control of the charged particle beam R on the basis of treatment plan information transmitted from the irradiation control section 9 . The scanning controller 10 transmits the electric current command value according to the treatment plan to the scanner power supply 7 . The scanning controller 10 indirectly controls the scanning of the charged particle beam R by the scanning electromagnet 6 by changing the electric current supply from the scanner power supply 7 to the scanning electromagnet 6 by the electric current command value.
The scanning controller 10 transmits a first electric current command value (an X electric current command value) for performing the scanning of the charged particle beam R in the X direction to the first power supply 7 A. Similarly, the scanning controller 10 transmits a second electric current command value (a Y electric current command value) for performing the scanning of the charged particle beam R in the Y direction to the second power supply 7 B.
Further, the scanning controller 10 is driven with an internal basis clock thereof as an operation clock. The scanning controller 10 has a transmission section 12 which transmits its own operation clock signal to the scanner power supply 7 . The transmission section 12 transmits the operation clock signal to the scanner power supply 7 in order to make the period of an operation clock of the scanner power supply 7 equal to the period of an operation clock of the scanning controller 10 .
On the other hand, the X power supply 7 A and the Y power supply 75 of the scanner power supply 7 respectively have receiving sections 13 A and 133 which receive the operation clock signal. In the X power supply 7 A and the Y power supply 7 B, the receiving sections 13 A and 13 B receive the operation clock signal transmitted from the transmission section 12 and the supply of an electric current to the scanning electromagnet 6 is performed by an operation clock having the same period as the operation clock of the scanning controller 10 . Specifically, operation clocks of the operation clock signals received by the receiving sections 13 A and 13 B are used as the operation clocks of the X power supply 7 A and the Y power supply 7 B. Alternately, the operation clocks of the X power supply 7 A and the Y power supply 7 B are synchronized with the operation clocks of the operation clock signals received by the receiving sections 13 A and 13 B. In addition, the expression, the same period, is not limited to the periods being strictly the same, and an error less than or equal to 10 μs is allowed.
Further, the scanning controller 10 obtains information about a measurement position of the charged particle beam R from the position measurement monitor 5 . The scanning controller 10 performs the comparison of a plan position of the charged particle beam R according to the treatment plan (a plan position of the charged particle beam R corresponding to the electric current command value) with the measurement position of the charged particle beam R obtained from the position measurement monitor 5 .
The scanning controller 10 determines whether or not there is an abnormality in the scanning control of the charged particle beam R, on the basis of a comparison result between the plan position and the measurement position of the charged particle beam R. Specifically, the scanning controller 10 determines whether or not there is an abnormality in the scanning control, by determining whether or not a difference between the measurement position of the charged particle beam R and the plan position of the charged particle beam R is within an allowable range.
The scanning controller 10 stops the irradiation of the charged particle beam R by transmitting an irradiation stop signal to the beam control section 11 in a case where it is determined that there is an abnormality in the scanning control.
According to the charged particle beam therapy apparatus 1 related to the embodiment described above, since the period of the operation clock of the scanning controller 10 and the period of the operation clock of the scanner power supply 7 are the same, variation in delay time due to a difference in the operation clock is not generated, and it is possible to obtain a constant delay time after the scanning controller 10 transmits the electric current command value and before the scanning unit actually performs particle beam scanning.
Here, FIG. 4 is a diagram showing the operation clock of the scanning controller 10 and the operation clock of the scanner power supply 7 . In FIG. 4 , transmission timings of the electric current command value in the operation clock of the scanning controller 10 are shown as s0 to s2. Further, reception timings of the electric current command value in the operation clock of the scanner power supply 7 are shown as r0 to r2. In addition, the delay time between the transmission timing s0 and the reception timing r0 is shown as t0, the delay time between the transmission timing s1 and the reception timing r1 is shown as t1, and the delay time between the transmission timing s2 and the reception timing r2 is shown as t2.
As shown in FIG. 4 , in the charged particle beam therapy apparatus 1 according to the embodiment, since the period of the operation clock of the scanning controller 10 and the period of the operation clock of the scanner power supply 7 are the same, it is possible to make the delay times t0 to t2 between the operation clocks of the scanning controller 10 and the scanner power supply 7 constant, and thus it is possible to avoid the generation of variation in the delay time after the scanning controller 10 transmits the electric current command value and before the scanning electromagnet 6 actually performs the particle beam scanning. For this reason, according to the charged particle beam therapy apparatus 1 , it is possible to avoid a situation where due to variation in delay time, the particle beam is irradiated for a longer time than the treatment plan at a certain irradiation position and the particle beam is irradiated for a shorter time than the treatment plan at the other irradiation position. Therefore, according to the charged particle beam therapy apparatus 1 , it is possible to perform the high-precision scanning control of the particle beam which accurately controls the irradiation time at each irradiation position on the basis of the treatment plan.
Further, in the charged particle beam therapy apparatus 1 , by transmitting the operation clock signal from the scanning controller 10 to the scanner power supply 7 , it is possible to drive the scanner power supply 7 by the operation clock having the same period as the operation clock of the scanning controller 10 . Therefore, according to the charged particle beam therapy apparatus 1 , it is not necessary to separately provide an operation clock signal transmission section for matching the periods of the operation clock of the scanning controller 10 and the operation clock of the scanner power supply 7 , and therefore, it is possible to attain simplification of an apparatus configuration.
In addition, in the charged particle beam therapy apparatus 1 , since it is possible to make the delay time almost constant by suppressing variation in the delay time after the scanning controller 10 transmits the electric current command value and before the scanning electromagnet 6 actually performs the scanning of the charged particle beam R, it becomes possible to obtain, by calculation, the influence of the delay time on the irradiation position of the charged particle beam R. Therefore, according to the charged particle beam therapy apparatus 1 , since it is possible to exactly compare the plan position of the charged particle beam R with the actual measurement position, it is possible to determine whether or not the charged particle beam R deviates from the plan position beyond the allowable range, and it is possible to properly determine whether or not there is an abnormality in the scanning control of the charged particle beam R.
The present invention is not limited to the embodiment described above. In the embodiment described above, the charged particle beam therapy apparatus 1 which irradiates a proton beam, a heavy particle (heavy ion) beam, or the like has been described. However, the present invention can also be applied to a particle beam irradiation apparatus which irradiates other particle beams.
Further, a configuration is also acceptable in which the transmission section which transmits the operation clock is provided separately from the scanning controller and the scanner power supply and both the scanning controller and the scanner power supply have the receiving sections.
The embodiment of the present invention is applicable to a particle beam irradiation apparatus in which it is possible to perform the high-precision scanning control of a particle beam.
It should be understood that the invention is not limited to the above-described embodiment, but may be modified into various forms on the basis of the spirit of the invention. Additionally, the modifications are included in the scope of the invention. | A particle beam irradiation apparatus including: a scanning unit configured to scan a particle beam; an electric current supply unit configured to supply an electric current to the scanning unit; and a scanning control unit configured to control the scanning unit by sending an electric current command value to the electric current supply unit, wherein a period of an operation clock of the scanning control unit and a period of an operation clock of the electric current supply unit are the same. | 6 |
FIELD OF THE INVENTION
[0001] This invention is in the field of rocking equipment and in particular a device that may be applied to baby strollers, cribs and other wheeled objects that rock the stroller, crib or other object, for example, to comfort a baby and assist it to fall asleep.
BACKGROUND OF THE INVENTION
[0002] Many patents have revealed a wide range of methods and devices to assist babies to fall asleep. Examples of such inventions are Australian Patent No. 2131483 and U.S. Pat. No. 6,519,792 issued to Chen both of which patents are bulky and less portable than the present invention. U.S. Pat. No. 5,002,144 issued to McMahon attempts to provide an orbital movement rather than the simpler to and fro movement.
[0003] This innovation is another and unique device that combines novelty, versatility to fit a wide range of styles, kinds, and manufactures of baby strollers, cribs and other wheeled objects.
SUMMARY OF THE INVENTION
[0004] It is to be understood that both the foregoing general description and the following detailed description present embodiments of the invention and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention and, together with the description, serve to explain the principles and operations of the invention but not to limit the invention to these descriptions only.
[0005] This invention comprises a motor with apparatus comprising a series of connected links to change the circular motion of the motor to a linear motion and from the linear motion to a continuous oscillation to and fro which motion is transferred to an arc shaped rocker cradle. A wheel of the stroller or other object sits in the rocker cradle of this invention and the stroller or other object is thereby rocked gently to and fro.
[0006] The power could be supplied from mains electricity or from batteries and a timer device could enable the rocking to switch off after a chosen amount of time. The rocking cradle is easily transferable and transportable and is made to fit virtually any size wheel used for strollers, cribs and other wheeled objects without special adaptor devices.
[0007] There could be a gear to make the rocking faster and slower while the motor rotates at a constant speed. There could be a physical stopper at both ends of the rocking cradle to prevent the stroller or crib wheel from exiting from the rocking cradle unintentionally.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain by way of example only, the principles of the invention:
[0009] FIG. 1 is a schematic depiction of a wheel resting on a rocking cradle.
[0010] FIG. 2 is a schematic depiction of FIG. 1 from the end view.
[0011] FIG. 3 is a schematic depiction of the motor, the device for changing rotary motion to a rocking motion and a rocking cradle.
[0012] FIG. 4 is a schematic depiction of FIG. 3 from a different angle.
[0013] FIG. 5 is a schematic depiction of the rocking cradle.
[0014] FIG. 6 is a schematic depiction of FIG. 5 from the sectional view.
[0015] FIG. 7 is a schematic depiction of the motor and the device for changing rotary motion to rocking motion.
[0016] FIG. 8 is a schematic depiction of the motor stand and slit.
[0017] FIG. 9 is a schematic depiction of the disc drive.
[0018] FIG. 10 is a schematic depiction of the bearing in the disc drive.
[0019] FIG. 11 is a schematic depiction of the connector rod.
[0020] FIG. 12 is a schematic depiction of the sliding groove and rocking rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] As will be appreciated the present invention is capable of other and different embodiments than those discussed above and described in more detail below, and its several details are capable of modifications in various aspects, all without departing from the spirit of the invention. Accordingly, the drawings and description of the embodiments set forth below are to be regarded as illustrative in nature and not restrictive.
[0022] FIG. 1 shows the rocking machine 100 with the motor housing 102 containing a motor, motion transformer and batteries or mains electricity connection. There is a control switch 104 with positions for off, on-slow and on-fast. The rocking cradle 106 rocks to and fro making the stroller or crib wheel 108 , sitting in the rocking cradle 106 , roll back and forth.
[0023] FIG. 2 shows the rocking machine 100 from the end view showing the motor housing 102 and the rocking cradle 106 . In the rocking cradle 106 is a stroller or a crib wheel 108 that is attached to the stroller or crib via the stroller or crib leg 110 .
[0024] FIG. 3 shows the motor 120 with its axle 122 that turns when the motor is switched on. The motor 120 is held firmly in place with the aid of the motor stand 123 and slit 128 as described in more detail in relation to FIG. 8 . The motor 120 is attached to the motor stand 123 by means of bolts 124 . After the rotational motion of the motor has been converted to linear motion, the connector pin slides back and forth in the slit 128 thereby creating a back and forth arc motion in the rocking arm 130 resulting in a rocking motion in the rocking cradle 106 .
[0025] FIG. 4 shows the motor 120 from another angle. The motor 120 turns the axle 122 that in turn, turns the disc drive 132 . The disc drive 132 has an a-centric hole containing a bearing 134 . When the disc drive 132 is turned, one side of the connector rod 136 moves a circular path together with the disc drive 132 . The connecting rod 136 is connected at one end to the bearing 134 . The bearing allows the one end of the connecting rod 136 to move in a circular motion as the disc drive 132 revolves.
[0026] At the distal end of the connecting rod 136 is a pin that slides in a slit in the motor stand and slit 123 . The slit is not visible in FIG. 4 but can be seen in FIG. 8 . The continuation of force transfer that results in the rocking movement of the rocking cradle 106 is described in later Figures.
[0027] FIG. 5 shows a rocking cradle 106 in which rests a leg or wheel FIG. 1 108 of a stroller, a crib or other item that is desired to be rocked. The nut FIG. 7 162 is connected into the rocking arm housing 140 and when the nut FIG. 7 162 turns to and fro, the rocking cradle 106 rocks in synchronization.
[0028] FIG. 6 shows the sectional view of the rocking cradle 106 and rocking arm housing 140 is on the inside of the rocking cradle 106 so that the outer surface 142 of the rocking cradle 106 that touches the floor is a smooth arc shape to enable a smooth rocking movement of the rocking cradle 106 .
[0029] FIG. 7 shows the motor and attached apparatus in greater detail. There is a motor 120 with electrical terminals 119 and a motor encasement 121 that is held in place by being attached to the motor stand and slit 123 . The disc drive 132 is turned by the revolutionary movement of the motor 120 . The bearing 134 is situated a-centrically in the disc drive 132 causing the connecting rod 136 to move in a circular motion at the end attached to the bearing 134 . The distal end of the connecting rod 136 is pulled and pushed in a linear movement back and forth in a slit FIG. 8 154 in the motor stand and slit 123 . The resulting linear movement is converted to a rocking movement by the connecting rod 136 being connected at one end to a bearing 139 that slides in the groove 160 of the sliding groove 126 . The sliding groove 126 has a rod 161 attached at one end of the sliding groove 126 that turns in a bearing 164 in the motor encasement 121 . The distal end of the rod 161 is a nut 162 that fits into the rocking arm housing FIG. 5 140 thereby causing the rocking cradle 106 to rock to and fro.
[0030] FIG. 8 shows the motor stand and slit 123 . The circular cut out 150 holds the distal end of the motor FIG. 3 120 which spins the axle FIG. 3 122 of the motor FIG. 3 120 . The holes 152 are used to firmly attach the motor FIG. 3 120 to the motor stand and slit 123 .
[0031] There is a slit 154 in which a connector pin slides up and down.
[0032] FIG. 9 shows the disc drive 132 . The central axle housing 122 that is turned by the motor FIG. 3 120 and in turn, turns the disc drive 132 . The disc drive 132 has in it an a-centric hole 133 into which is firmly fitted a bearing FIG. 4 and FIG. 10 134 .
[0033] FIG. 10 shows the bearing 134 that is fixed into the hole FIG. 9 133 of the disc drive FIG. 4 132 . This bearing 134 enables the pin that fits into the center of the bearing 134 to turn in the bearing 134 as the disc drive 132 turns.
[0034] FIG. 11 shows the connecting rod 136 that has a pin 137 at one end of the connecting rod 136 and a pin 138 at the distal end. The pins 137 and 138 are situate on opposite ends and opposite sides of the connecting rod 136 . The connecting rod 136 enables the circular motion of the motor to convert to linear motion. This motion conversion occurs when pin 137 is attached to the bearing FIG. 4 134 and makes a circular motion as the disc drive FIG. 4 132 turns and the pin 138 is held in the slit FIG. 8 154 . The pin 138 is thereby pulled and pushed up and down the slit FIG. 8 154 as the disc drive FIG. 4 132 revolves.
[0035] FIG. 12 shows a sliding groove and rocking rod 126 that converts the linear motion of pin FIG. 11 138 into a rocking motion in the sliding groove and rocking rod 126 . The pin FIG. 11 138 is connected to a sliding bearing FIG. 4 139 that slides up and down the indented groove 160 . The sliding groove and rocking rod 126 is attached by the rod 161 to a bearing in the motor encasement FIG. 7 121 to enable the rod 161 to turn on its axis in the said bearing. The result of the sliding bearing FIG. 4 139 being pulled and pushed in the groove 160 is a back and forth arc movement of the sliding groove and rocking rod 126 . The rocking rod 161 is has at its distal end a nut 162 that attaches to the rocking arm housing FIG. 5 140 thereby causing the rocking cradle 106 to rock to and fro. | A motor with apparatus comprising a series of connected links to change the circular motion of the motor to a linear motion and from the linear motion to a continuous oscillation to and fro which motion is transferred to an arc shaped rocker cradle. A wheel of the stroller or other object sits in the rocker cradle and the stroller or other object is thereby rocked to and fro. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a reset circuit which is used in, for example, bit lines or data bus lines of memory devices of an integrated circuit device.
2. Description of the Prior Art
Reset circuits for resetting the state of a first and second circuit systems to an original state, and the operations of said reset circuits, are illustrated in FIGS. 1, 2, 3A and 3B. In FIG. 1, the first circuit system and the second circuit system are represented by the data bus line 1 and the data bus line 2, respectively, which are connected through the flip-flop 4 consisting of the FETs (field effect transistors) Q 5 , Q 6 , Q 7 and which Q 8 and has its two input and output terminals connected to the data bus lines 1 and 2, respectively. The reset circuit 3 comprises the FETs Q 1 , Q 2 and Q 3 , the gates of which are connected to a common terminal to which the clock signal φ 1 is supplied. The FET Q 9 is connected to the FETs Q 7 and Q 8 which are included in the flip-flop 4. The clock signal φ 2 which causes the flip-flop 4 to switch on and off is supplied to the gate of the FET Q 9 .
The reset operation in the system shown in FIG. 1 is explained with reference to the waveforms illustrated in FIG. 2. It is presumed that the operation to read-out information from the memory through the data bus lines 1 and 2 is completed. At this moment, the voltage of the power source EL is V DD , the voltage V(1) of the first circuit 1 is "0" and the voltage V(2) of the second circuit 2 is "V DD -V TH ", where V DD is the drain supply direct current voltage of the FETs Q 1 and Q 2 , V Th6 is the threshold voltage of the FET Q 6 . The reset operation is achieved if this condition is changed into the condition in which the potentials of the first circuit 1 and the second circuit 2 have the same value. In order to achieve the reset operation, at first, the clock signal φ 1 having the value of V DD is supplied to the gates of the FETs Q 1 , Q 2 and Q 3 . Thus, the FET Q 1 in an OFF state is caused to become in an ON state, and the first circuit 1 is charged from the power source EL, and accordingly the potential V(1) of the first circuit 1 rises to potential P. At the same time, the FET Q 3 , which is in an OFF state is caused to become in an ON state, and the charge is caused to move from the second circuit 2 to the first circuit 1, and accordingly the potential V(2) of the second circuit 2 falls to potential P. Thus, the FET Q 2 which is in an OFF state is caused to become in an ON state because of the lowering of the potential of the second circuit 2, and the charging commences of the both circuits 1 and 2 from the power source EL from the reset circuit 3. Accordingly, the potentials of the first circuit 1 and the second circuit 2 which were at the level P start together to rise up to the potential "V DD -V TH6 " so that the reset operation is completed assuming that V TH1 =V TH2 =V TH .
The problem of the system shown in FIG. 1 under the condition when the threshold voltages of the FETs Q 1 , Q 2 and Q 3 are the same value V TH is as follows. That is, after the instant t 3 at which the first and the second circuits are reset to the potential "V DD -V TH ", if the potential of the first circuit 1 rises up to the value "V DD -V TH +α" as illustrated in the portion A of FIG. 2 because of some noise effect, due, for example to an electrostatic coupling with a neighbouring electirc circuits, while the potential of the second circuit 2 remains the value "V DD -V TH ", it is possible that an erroneous judgement is incurred in the next reading-out of the memory. The cause of such an erroneous judgement is explained as follows. In order to read-out the memory cell storing information "0", the judgement of the potential of the first circuit 1 with reference to the potential of the second circuit 2 by means of flip-flop 4 is effected by lowering the potential of the first circuit to which said memory cell is connected and supplying the clock signal φ 2 to the gate of the FET Q 9 . If the potential of the first circuit was "V DD -V TH +α" and the potential of the first circuit is then caused to fall to the value approximately "V DD -V TH " by the above-mentioned potential lowering, such potential of approximately "V DD -V TH " of the first circuit is not substantially lower than the potential "V DD -V TH " of the second circuit 2. Therefore, the erroneous judgement that the information stored in the above-mentioned memory cell is not "0" but "1" is incurred. The above-described reset circuit is disclosed in, for example, U.S. Pat. No. 3,678,473.
In other words, when the potential of the first circuit 1 is higher by β than that of the second circuit 2 and if a low voltage which is smaller than β is applied to the first circuit 1 to reduce the potential of the first circuit 1 and is amplified by the flip-flop 4 consisting of the FETs Q 5 through Q 8 , the flip-flop 4 causes the potential of the first circuit 1 to become "1", i.e., "HIGH", and the potential of the second circuit 2 to become "0", i.e., "LOW". Contrary to this, when no unequality of the potential exists between the first circuit 1 and the second circuit 2 and if a low voltage is applied to the first circuit 1 to reduce the potential of the first circuit 1 and is amplified by the flip-flop 4, the flip-flop 4 causes the potential of the first circuit to become "0", i.e., "LOW", and the potential of the second circuit 2 to become "1", i.e., "HIGH", so that a correct amplification takes place.
Since, in general, very low voltage signals are supplied from a memory cell to a bit line and from a bit line to a data bus line in a memory circuit, the erroneous operation described above can occur when an unequality of the potential exists between the first circuit 1 and the second circuit 2.
In order to avoid the above-mentioned erroneous judgement, the systems as shown in FIGS. 3A and 3B have been proposed. In the system shown in FIG. 3A, the gate signal φ 3 for the FET Q 3 is selected higher than the gate signal φ 1 ' for the FETs Q 1 and Q 2 . In the system shown in FIG. 3B, a FET Q 4 is connected between the first circuit 1 and the second circuit 2 in parallel with the FET Q 3 . A gate signal φ 3 ' which is higher than the gate signal φ 1 is supplied to the gate of the FET Q 4 . Thus, in the systems shown in FIGS. 3A and 3B, it is possible to avoid the erroneous judgement which occurs in FIG. 1.
However, the systems shown in FIGS. 3A and 3B are not the best solutions of the problem, because in the systems shown in FIGS. 3A and 3B it is necessary to provide the gate signals φ 3 and φ 3 ', to make the gate signals φ 3 and φ 3 ' higher than the gate signals φ 1 and φ 1 ', to provide electric conductors to supply the gate signals φ 3 , φ 3 ' to the gates of the FETs Q 3 and Q 4 , and to acquire a predetermined space for locating the FET Q 4 .
The present invention is proposed for the purpose of providing a solution to the above explained problems.
SUMMARY OF THE INVENTION
It is the principal object of the present invention to provide a reset circuit for resetting the state of two circuit systems to the original state, in which the erroneous operation, because of a noise effect due to, for example, an electrostatic coupling with the neighbouring electric circuits, is avoided without addition of either a supplemental FET or a supplemental signal source.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, which is presented for the purpose of illustrating both the background of the present invention as described hereinbefore and an embodiment of a reset circuit to which the present invention is applied as described hereinafter, shows a reset circuit for resetting the state of two circuit systems to the original state.
FIG. 2 shows the waveforms appearing in the circuit shown in FIG. 1.
FIGS. 3A and 3B, which also illustrate the background of the present invention as described hereinbefore, show reset circuits for resetting the state of two circuit systems to the original state.
FIG. 4 shows an example of the integrated circuit type memory device in which the reset circuits are applied in accordance with the present invention.
FIG. 5 shows another system in which the reset circuit is applied in accordance with the present invention.
FIG. 6 shows the wave forms appearing in the circuit shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the device shown in FIG. 1, the first and the second circuit are represented by the data bus lines 1 and 2, respectively, which connected together through the flip-flop 4 consisting of the FETs Q 5 , Q 6 , Q 7 and Q 8 . The reset circuit 3 comprises the FETs Q 1 , Q 2 and Q 3 the gates of which are connected together to form a common terminal to which the clock signal φ 1 is supplied. The FET Q 9 is connected to the FETs Q 7 and Q 8 which are the constituents of the flip-flop 4. The clock signal φ 2 which causes the flip-flop 4 to switch on and off is supplied to the gate of the FET Q 9 .
With regard to the threshold voltages of the FETs Q 1 , Q 2 and Q 3 , the threshold voltage of the FETs Q 1 and Q 2 are selected higher than that of the FET Q 3 . The ordinary value of the threshold voltage of an integrated circuit type FET is between 1.2 and 1.3 volts, and the variation of the value of said threshold voltage due to the condition of the FET manufacturing process is approximately tens of milli-volts. In the present invention, however, the threshold voltage V TH of the FETs Q 1 and Q 2 are selected, for example, between 2.2 and 2.8 volts, and the threshold voltage V TH of the FET Q 3 is selected, for example, between 1.2 and 1.3 volts. Thus, there exists a difference of, for example, 1 volt to 1.5 volts between the threshold voltage of the FETs Q 1 and Q 2 and that of the FET Q 3 . The value of the threshold voltage is easily controlled by using the ion implantation method.
The operation of the device shown in FIG. 1 in accordance with the present invention is illustrated in FIG. 2. Since the threshold voltage of the FET Q 1 and Q 2 is selected higher than that of the FET Q 3 , the FET Q 3 maintains its ON state even after the FETs Q 1 and Q 2 are caused to become in an OFF state in a reset operation. Thus, the charge in the first circuit 1 is allowed to move to the second circuit 2 through the conductive state FET Q 3 , even when the potential of first circuit 1 is enhanced up to "V DD -V TH +α" because of a noise voltage. Accordingly, the potentials of the first and the second circuit are rendered equal, unlike the case of the above explained prior art where the potential of the first circuit 1 is kept by voltage α higher than that of the second circuit 2. Therefore, in accordance with the present invention, no erroneous judgement, as explained above in connection with the prior art, is incurred and no modified circuits, as shown in FIGS. 3A and 3B, are necessary.
It should be noted that, after rising up to the value V DD , the gate signal φ 1 is maintained at said value V DD until it is caused to return to zero level immediately before the next reading-out.
A storing of an information into a memory cell is effected by a cutting-off of the memory cell from the first circuit 1 prior to the returning to "HIGH" of the reset clock signal φ 1 . (No storing of an information into a memory cell is effected by a turning-off of the reset clock signal φ 1 .)
In FIG. 4 an integrated circuit type memory device including the reset circuits in accordance with the present invention is illustrated. The memory unit 12 comprises the memory cells 71, 72, the dummy cells 91, 92 and the sense amplifier circuit 10. The memory cells 71, 72 are controlled by the word decoder 6 and the dummy cells 91, 92 are controlled by the dummy word decoder 8. The memory cells 71, 72 and the dummy cells 91, 92 are connected respectively to the bit lines 111 and 112. The memory unit 12 is connected to the read-out amplifier circuit 13 which is connected to the output logic circuit 14 which produces output information at the output terminal 15. The reset circuits 32 and 31 are provided corresponding to the sense amplifier circuit 10 and the read-out amplifier circuit 13, respectively.
In FIG. 5 an input circuit for a differential amplifier to which the reset circuit 33 in accordance with the present invention is illustrated. The signals S1 and S2 which are to be differentially amplified are supplied to the input circuits 101 and 201 of the differential amplifier 16 through the FETs Q 51 and Q 52 . The reset FETs Q 1 and Q 2 and the short-circuit FET Q 3 of the reset circuit 33 are connected to the input circuits 101 and 201. In accordance with the present invention the value of the threshold voltage V TH of the FETs Q 1 and Q 2 is selected higher than that of the FET Q 3 . The phase of the gate signal φ 1 supplied to the gates of the FETs Q 51 and Q 52 is opposite to that of the gate signal φ 1 supplied to the gates of the FETs Q 1 , Q 2 and Q 3 .
The operation of the system shown in FIG. 5 is illustrated in FIG. 6. Due to the supply of the gate signal φ 1 during the period from t 0 to t 1 , the reset of the first and the second circuits 101 and 201 is effected, and accordingly, the potentials V(101) and V(201) of the first and the second circuits 101 and 201 are rendered equal. This is because, even if there exists a noise voltage in the first and the second circuits 101 and 201, the potentials of the first and the second circuits 101 and 201 are equalized due to the transfer of the charge through the FET Q 3 which is in an ON state. After the gate signal φ 1 is supplied to the gates of the FETs Q 51 and Q 52 at the moment t 1 , the difference of the potentials V(101) and V(201) of the first and the second circuits 101 and 201 is amplified to produce an output signal T at the output terminal 17 during the period from t 1 to t 2 . Accordingly, since the potentials V(101) and V(201) are equal for the period from t 0 to t 1 and are maintained equal even if there exists a noise voltage in one of the first and second circuits 101 and 201, no erroneous operation of the differential amplifier circuit for the period from t 1 to t 2 takes place. | A reset circuit used for resetting, for example a memory device after a reading-out from a memory is effected, comprises fist and second reset transistors, for connecting first and second circuits to a common voltage source, and a short-circuit transistor, having a lower threshold voltage than the threshold voltage of said first and second reset transistors, for connecting said first and second circuits when said short circuit transistor receives the same input signal as supplied to said first and second reset transistors. | 6 |
FIELD OF INVENTION
[0001] This invention relates to electronic devices for aiding people with low vision.
BACKGROUND OF THE INVENTION
[0002] Low vision is a general term used to describe lowered visual acuity, and a specific legal term in Canada and the United States used to designate someone with vision of 20/70 or less in the better eye with correction. It can be a result of either congenital or acquired factors. An example of the former is Leber's congenital amaurosis and of the latter age related macular degeneration.
[0003] Some people with low vision can use their residual vision—their remaining sight—to complete daily tasks without relying on alternative methods. The role of a low vision specialist is to maximize the functional level of a patient's vision by optical or non-optical means. Primarily, this is by use of magnification in the form of telescopic systems for distance vision and optical or electronic magnification for near tasks.
[0004] Visually impaired patients may benefit from high-tech aids such as OCR scanners that can, in conjunction with text-to-speech software, read the contents of books and documents aloud via computer. Vendors also build closed-circuit televisions that electronically magnify paper, and even change its colour contract, for visually impaired users.
[0005] The vast majority of patients with low vision can be helped to function at a higher level with the use of low vision devices. Low vision specialists recommend appropriate low vision devices and counsel patients on how better to deal with their reduced vision in general. See, for example, Computer Resources for People With Disabilities: A Guide to Assistive Technologies Tools and Resources for People of All Ages , Alliance for Technology Access, Hunter House, Inc. Publishers, 2004; and In Sight: Guide to Design with Low Vision in Mind , Lucienne Roberts, Rotovision 2004 which are incorporated herein by reference.
[0006] The use of a CCTV or video magnifier is a simple way providing access to classrooms and public events to people with low vision. In the classroom setting, for example, printed material and objects displayed at the front of the room can be captured by a camera and the magnified image is displayed on a television screen or computer monitor. There are a large number of different types of models to choose from and they vary widely in the features offered.
[0007] For example, U.S. Pat. No. 6,731,326 to Bettinardi (which is incorporated herein by reference) describes a method of displaying information captured from a camera on a monitor. The camera captures an image and then allows the user to select a smaller portion for full, magnified, display. The '326 patent also provides a method of allowing the user to pan the image and zoom in on a desired area. The user, however, must recapture information as he moves from portion to portion of the image. This takes additional time as well as requiring significant resources from the processor controlling the display.
[0008] Of the commercially available distance cameras, a problem arises where a user wishes to toggle through various areas in the camera's line of sight. Continuing with the classroom example; a user may wish to pan and zoom such as where a chalkboard contains a large amount of written information. Previous devices required a user to recapture information when a user desired to scroll back, perhaps to review some previous information. The need to recapture the image of the chalkboard creates a cumbersome interface, as well as wasting computer resources.
SUMMARY OF INVENTION
[0009] In a first embodiment, the invention includes an image display method utilizing an image capture device, a display in communication with the image capture device and an image memory in communication with the image capture device and display. The user defines an area of interest, either manually or through software developed to implement the invention, and then captures a plurality of images, or areas of focus, each image comprising at least a portion of the area of interest. The method stores the plurality of images in the image memory and establishes a location parameter associated with each image (to designate where the area of focus is located within the area of interest). The images are shown on the display, usually as a full image allowing the user to cycle through the images according to the location parameter associated with each image.
[0010] The user can further manipulate or alter each image or area of focus; such as changing magnification levels, orientation (rotation) and navigation. In some instances, such as when an area of focus is captured from a stored image of the area of interest rather than directly from the image capture device, the method provides the missing pixels in the magnified view using known interpolation techniques.
[0011] Although many location techniques are contemplated, one embodiment of the invention establishes the location parameter for each image using a Cartesian coordinate system whose increments are automatically determined by the resident software. Alternate embodiments, however, allow a user to manually determine location parameters.
[0012] The method also allows a user to display a live image of an area (such as the field of view or the areas of focus). The plurality of images are stored independently in image memory but can also be stored in an array for organization and efficient recall. All images in image memory can be stored to permanent (mass) memory without disrupting the user's access.
[0013] The invention also includes a device for implementing the previously describe method. The device includes a processor module, an image capture device communicatively coupled to the processor module, a monitor communicatively coupled to the processor module; and an image memory communicatively couple to the processor module. The image capture device is adapted to define an area of interest as well as to capture a plurality of images comprising an area of focus; the processor, however is also capable of capturing the areas of focus from a stored image of the area of interest. The processor module is also adapted to establish a location parameter to each are of focus regardless of how it is captured. The image memory is adapted to store the plurality of images captured by the image capture device or processor. The monitor displays each image, usually as a full image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
[0015] FIG. 1 is a block diagram of an illustrative architecture for employing the inventive method.
[0016] FIG. 2 illustrates how an area of interest is divided into multiple areas of focus.
[0017] FIG. 3 illustrates an enlarged area of focus selected from the area of interest and displayed on a screen.
[0018] FIG. 4 is a block diagram illustrating directional navigation of the areas of focus.
[0019] FIG. 5 illustrates an illustrative interface for displaying a menu of captured areas of focus.
[0020] FIG. 6 is a block diagram illustrating one embodiment of the invention.
[0021] FIG. 7 is a block diagram illustrating an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention.
[0023] The instant invention, hereinafter “the invention,” includes a method of displaying graphic and textual information on an electronic screen to enhance visibility for persons with low vision or who are otherwise visually impaired. The invention employs the use of multiple, communicatively coupled hardware devices under the control of instructions from software designed to implement the invention. A general embodiment, shown in FIG. 1 , uses image capture device 10 , monitor 20 , processing unit 30 and image memory 40 . An alternate embodiment also includes user input device 35 and mass memory 45 .
[0024] Image capture device 10 is commonly a distance camera, specifically designed for use by persons with low vision, but can be any imaging device capable of capturing an image of textual or graphic information. In a preferred embodiment, capture device 10 is coupled to the invention in a closed-circuit. The signal from capture device 10 is therefore transmitted to a predetermined number of users. The users are directly linked to image capture device 10 , although the link may include point-to-point wireless connections. An example of an embodiment employing a single capture device and multiple monitors is a classroom specifically equipped to accommodate a number of users with low vision. In this embodiment, wherein a single image capture device is shared, successive areas of focus are captured from an image of the entire area of interest.
[0025] Monitor 20 is any device that can display signals generated by image capture device 10 and processor 30 . While monitor 30 is most commonly a computer display (i.e. LCD, CRT), it can also include a portable device such as a PDA, or other wireless device, and a dedicated viewing device.
[0026] Processor 30 is any logic unit capable of running the software for implementing the invention. Processor 30 is connected to capture device 10 , monitor 20 , input device(s) 35 , image memory 40 and mass memory 45 through bus 12 . Processor 30 performs selected operations under the instructions of the corresponding operation program (the “software”). The software, in an illustrative embodiment, is stored in and selected from mass memory 45 .
[0027] Image memory 40 is, in an illustrative embodiment, a temporary storage location where images captured by image capture device 10 are stored. The images, representing the area of interest or multiple areas of focus, are stored in image memory prior to being saved in mass memory 45 , altered (i.e. magnified or rotated) by processor 30 or displayed by monitor 20 . Accordingly, a user can easily return to the original image saved in image memory 40 after the image is otherwise altered. Image memory 40 can be volatile (memory which is lost if power is disrupted) or nonvolatile memory.
[0028] Mass memory 45 is any device capable of storing, usually large amounts, information in a persistent and machine readable form. Examples of devices suitable for mass media 45 include, but are not limited to hard disks, floppy disks, drum memory, magentic tape, flash memory, optical disks, megneto-optical disks and holographic memory. Mass memory 45 does not include random access memory (RAM) or volatile memory.
[0029] In an illustrative embodiment, the invention permits a user to capture an area of interest, such as a blackboard or whiteboard in a classroom, through image capture device 10 for viewing on monitor 20 . The captured image can be magnified for easier viewing by the user. Moreover, the user can capture multiple images for magnification and viewing without losing previously captured images. Continuing with the example of a classroom setting, the user positions image capture device 10 to focus on the area of interest; namely the chalkboard, containing textual and graphic information, at the front of the room. The user can then capture specific subregions of the area of interest, or areas of focus, for viewing.
[0030] Referring now to FIG. 2 , the user may decide to divide the chalkboard (area of interest 50 ) into quadrants (areas of focus 60 ). The user decides to capture quadrant I ( 60 a ), II ( 60 b ), III ( 60 c ) and IV ( 60 d ) successively. In this example, each area of focus (quadrant) is saved in image memory 40 independently for quick and easy recall by the user. The user can therefore bring up each area of focus for viewing, including magnification and navigation, without losing the remaining areas of focus. This frees the user from having to “re-capture” information. The user can easily cycle through images of the areas of focus saved in image memory.
[0031] In one embodiment, processor 30 establishes boundary parameters for area of interest 50 , using methods such as a Cartesian coordinate system. The boundary parameter is used to assign location values to points in the plane of the area interest, i.e. x-coordinates and y-coordinates. Coordinates are established by defining two perpendicular axis and assigning a unit length to each. The unit length assigned to each axis, as well as the points defining the x and y coordinates, are preferably determined by processor 30 but can also be defined by the user. The area of interest can be defined in numerous ways. The user can define the area of interest by adjusting the focus of image capture device 10 , or using a graphic interface to highlight, or crop, an image displayed on monitor 20 .
[0032] The invention also provides an embodiment wherein processor 30 electronically determines and captures multiple areas of focus after area of interest 50 has been defined by the user. In this example, processor 30 uses the boundary parameter to establish the multiple areas of focus, the size of which can be user defined (i.e. quadrants) or set by default. Each area of focus can be captured from an image of the entire area of focus or by a motorized device attached to the image capture device. An example of a suitable motorized device is described in U.S. Pat. No. 6,964,412 to Reed et al, which is incorporated herein by reference.
[0033] The area of interest can be stored in image memory 40 or saved to mass memory 45 prior to being displayed on monitor 20 . The area of interest can further be magnified, navigated or otherwise manipulated by processor 30 for direct viewing on monitor 20 .
[0034] Once the area of interest has been defined, and assigned boundary parameter values in some embodiments, areas of focus 60 can be captured. Area of focus 60 can be a subregion of area of interest 50 but in some cases, as discussed above, is the entire area of interest. In all cases, area of focus 60 comprises at least a portion of area of interest 50 . It is also possible for an area of focus to comprise all or some of another area of focus.
[0035] When area of focus 60 is established, processor 30 assigns an identification value to identify its location within the area of interest. In keeping with the illustrative embodiment above, the area of focus is assigned a location value based on the Cartesian coordinates corresponding to its location relative to the x and y axis of area of interest 50 . It is also possible, however, to assign other values based on parameters such as order-captured, quadrant, size, etc. Area of focus 60 is then displayed as a full image on monitor 20 , as shown in FIG. 3 . The area of focus can be further magnified, navigated or otherwise manipulated by processor 30 during viewing on monitor 20 . It is also possible to save such an altered (manipulated) area of focus as displayed in either image memory 40 or mass memory 45 .
[0036] FIG. 4 illustrates one advantage of assigning a location value to each area of focus. Here it can be seen that providing a spatial identity to each area of focus makes it easier for a user to navigate individual areas of focus, 60 a through 60 d , relative to the entire area of interest 50 . The user can be provided with directional navigation input options 70 , i.e. “left,” “right,” “up” and “down”, rather than (or in addition to) providing the user with common functions such as “next page” and “previous page.”
[0037] The invention provides the user with the ability to capture images of multiple areas of focus in temporary (image memory) and/or permanent memory (mass memory). Moreover the user can toggle between the plurality of images of the areas of focus in memory and/or a live image (passing directly from the camera to the monitor) without losing instant access to the saved images. Previously, the user was required to recapture the image after changing views. The interface also allows the user to remove unwanted images from image memory while keeping remaining images in the toggle cycle.
[0038] It is also possible, using the invention, to save images in image memory to mass memory without removing them from the toggle cycle. Images can be saved in mass memory as either individual images or in an array for convenient recall. Individual areas of focus can further be removed from the toggle cycle without disturbing the integrity or location parameter associated with the remaining images. Once an area of focus has been removed from the toggle cycle, processor 30 alters the toggle cycle to allow navigation to the next logical image when the user cycles through to where the deleted image would have otherwise been viewed.
[0039] By defining an area of focus, the user can zoom in on and navigate the textual and graphic information contained therein. The area of focus (or interest) is defined by adjusting the magnification of the camera or an image in image memory. Menus and/or key combinations switch views of consecutive areas of focus (left, right, up or down) as defined by the location parameter associated with each area of focus. This can be accomplished by accessing images in image memory or by providing live views of the area of focus and moving the camera with an associated motorized apparatus providing a smooth pan in the desired direction. Panning stops when reaching the boundary of the relevant area of focus or the area of interest.
[0040] In an alternate embodiment, the invention allows the user to alter the magnification of any area of interest 50 , or area of focus 60 and automatically adjusts the values for the remaining areas in turn. For example, the user establishes area of interest 50 , again a chalkboard, and captures the image thereof at 8× magnification. Processor 30 then establishes four areas of focus which are also captured at 8× magnification and displayed as full images. If the user then increases the magnification of area of focus 50 to 9×, processor 30 automatically adjusts the magnification level of the four established areas of focus to 9× magnification as well. Similarly, if the user increases or decreases the magnification of a particular area of focus, processor 30 automatically adjusts the magnification level of the remaining three areas of focus as well as the area of interest accordingly. This saves the user from having to continually adjust the magnification level for the successive views.
[0041] Once a plurality of areas of focus have been captured and stored, it may be beneficial to establish a catalog or a menu of areas of focus for viewing ( FIG. 5 ). This menu 80 can be kept in text form or thumbnail images 82 of the respective views. The user can then easily move between the different areas of focus without having to recapture or reload the images. It is also possible to establish an area of focus containing a live view of a preferred area 84 , or any subset thereof. From this interface it is possible to save the corresponding image to mass memory ( 86 ) or delete/close the image ( 88 ). Additional functionality is also added by coupling the stored images with optical character recognition (OCR) software 90 to allow text elements in the area of focus to be saved in files usable by word processors, or to be converted to a predetermined format 92 (i.e. .pdf) from the interface.
[0042] An alternate embodiment of the invention is shown in FIG. 6 . In step 1 , the user zooms in on the viewing; thereby establishing the parameters of the area of interest. The user then zooms in on the area of interest to a desired magnification level, one that is comfortable for them to see the content within the area of interest, in step 2 . In step 3 , the processor automatically calculates the number of areas of focus needed to capture the information within the area of interest at the desired magnification level. For example, if the user does not zoom in after establishing the parameters of the area of interest, the number of areas of focus needed to capture the information is one (1). If, however, the user zooms into a magnification level of 8×, then additional areas of focus will be required. The number of areas of focus corresponding to an increase in magnification is the square of the magnification value. Therefore, if the area of interest is viewed at a magnification level of 8× then the number of areas of focus required is sixty four (64).
[0043] Once the necessary number of required areas of focus is calculated, each area of focus is displayed as a live image on the monitor (Step 4 ). In yet another embodiment, each area of focus is captured from an image of the entire area of focus or by a motorized device attached to the image capture device (discussed supra).
[0044] The user can navigate through the areas of focus using simple controls such as up, down, left and right. If the user moves to an area of focus which touches the boundary of the area of interest, subsequent commands to cycle in the direction of the outer parameter are ignored, as this would take the user outside the area of interest. Instead, the processor determines the next logical area of interest for display.
[0045] The user may determine that some areas of focus contain no useful information while they are in the process of navigation. In this case, the user can exclude unwanted areas of focus from the navigation cycle. Once an area of focus is marked for exclusion, it is skipped in the navigation cycle. When the user comes to a place in the navigation cycle where an area of focus has been removed, the processor determines the next logical area of interest for display.
[0046] In yet another embodiment, shown in FIG. 7 , the areas of focus can be reestablished responsive to the user changing the magnification of any area of interest. For example, the user establishes an area of interest and selects a magnification level of 4×. The processor then determines that four (4) areas of magnification are required and displays them on the monitor. In step 1 of this embodiment, the areas of focus are shown at the original level of magnification. In step 2 the user changes the magnification level of one of the areas of focus to 8×. The processor, in step 3 , reestablishes the number of areas of focus necessary to cover the area of interest (which is 64 , the square of the magnification level 8). The new areas of focus are then displayed at the new magnification level (8×) in step 4 . The user can also elect to exclude previously removed areas of focus from the new segmentation.
[0047] It will be seen that the advantages set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0048] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall there between. Now that the invention has been described, | A method is provided for displaying information from a distance on a monitor. By defining an image plane, the inventive system displays an area of focus of the plane on the monitor while storing the image in short-term memory. When the user selects a subsequent area of focus it is stored in short-term memory also, along with the first area of focus. The user is allowed to toggle between the stored images without having to recapture previously viewed information by retaining subsequent areas of focus in short-term memory. The user can discard, or delete, unwanted areas of focus or choose to move them to permanent memory. It is also possible to organize multiple areas of focus into groups or albums or save them individually. | 7 |
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